Aircraft Service Manual
Jabiru Aircraft
Pty Ltd
JTM001-1
J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants
REVISION
1
Dated: Nov 2011
Issued By: SW
Page: 72 of 233
6.
Remove flap from wing so it does not crush the fuselage when lowering down.
7.
Unbolt aileron control cables (2) from rear of control stick horn inside cabin.
8.
Remove pin and clamp block from aileron control cable clamps at rear of seat
– 1 each seat.
9.
Loosen hose clamps from fuel lines & breather tubes between the wing & fuselage.
10.
Disconnect fuel gauge sender electrical wires (where equipped).
11.
With one person supporting wing tip, unbolt top wing strut bolt and lower wing strut to the ground.
12.
Lower wing tip to towards the ground making sure you do not crush the underside of the wing on
the fuselage wing root. Rest the wing tip on a saw-horse or other suitable stand.
13.
Unbolt and remove front wing attachment bolt.
14.
Unbolt and remove rear wing attachment bolt.
Note: It may be necessary to rock the wing slightly while pulling attaching bolt, or carefully use
a long drift punch to drive out attaching bolt.
15.
Carefully remove wing by moving it out to clear the aileron cable from the fuselage.
16.
Place wing on cushioned structure to avoid damage to wing strut attachment.
17.
Unbolt lower wing strut bolt and remove wing strut.
18.
Repeat Steps above to remove other wing.
7.3.3 REPAIR
All repairs must be referred to Jabiru Aircraft Pty Ltd or our approved local agent.
7.3.4 INSTALLATION
1.
Fit the lower strut attaching bolt, leaving the top end of the strut on the ground.
WARNING
Do Not Tighten nut or metal fatigue may result. Washer must be free to rotate.
2.
Fit wing to fuselage, leaving wing tip on the saw-horse and routing aileron cable through hole in
fuselage wing root.
3.
Install front and rear wing attaching bolts/nuts.
4.
Put top wing strut attaching bolt in your pocket.
5.
Lift wing tip and install wing strut to wing strut attachment with bolt from pocket. Install nut.
WARNING
Do Not Tighten nut or metal fatigue may result. Washer must be free to rotate.
6.
Connect all fuel lines to wing. Connect wires to fuel gauge sender (where equipped)
WARNING
Ensure no fuel or breather lines are kinked.
7.
Put about 10lts of fuel in each tank & check for any leaks.
8.
Attach flap to wing ensuring all bushes are in place.
9.
Install bolt/nut in flap control rod.
10.
Install bolt/nut in aileron control cable on main control stick horn.
11.
Install clamp block and pin in aileron control cable clamp at rear of seat.
12.
On RH wing, reconnect Pitot tube.
13.
Replace wing strut fairings
– top and bottom.
14.
Replace wing root fairings.
15.
Perform a fuel flow test. Disconnect the fuel line from the mechanical fuel pump in the engine
compartment. Have a second person catch any fuel that flows out of the line in a container with
accurate volume marks. Turn electric fuel pump on and pump fuel through the lines into
container. Ensure there is about 1 litre per minute flow rate. *
NOTE: After carrying out the fuel flow test, check that both wing tanks are feeding fuel by
blocking fuel from both wing tanks, pumping about a litre out of the header tank, then allowing
fuel to flow from the left wing. The wing tank will gravity feed to the header tank, and it should re-
fill within approximately 1-2 minutes. This must be repeated for the right wing. If a wing is not
flowing correctly, check lines for kinks, blockages & airlocks.
