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Jabiru j120, Technical Manual

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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: 205 of 233 

 

 

Figure 180 

– Hall Effect Sensor Inst. (For Tach with Jabiru Logo on Face) 

15.8  ANALOGUE ENGINE GAUGES 

15.8.1  DESCRIPTION 

  The Oil Pressure, Oil Temperature, Voltage, Exhaust Gas Temperature (EGT, where equipped), hour 

meter (where equipped) and Cylinder Head Temperature (CHT) Gauges are electronic instruments. 

  With  the  exception  of  the  CHT  gauge  the  instruments  require  power  to  operate  which  is  supplied 

from the main bus bar. 

  The  CHT gauge  does  not  require  power 

– it connects only to a thermocouple which is fitted to the 

exhaust-side spark plug of the hottest cylinder of the engine. 

15.8.2  GAUGE REMOVAL & INSTALLATION 

 

  Remove the instrument panel fascia as detailed above. 

  Disconnect the instrument. 

  Undo the fasteners and remove the instrument from the fascia. 

  For installation, reverse removal steps above. 

 

Table 20 

– Trouble Shooting – Engine Gauges 

Trouble 

Probable Cause 

Remedy 

Instrument fails to 

operate 

Circuit breaker(s) open 

Check master and avionics 

circuit breakers.  Re-set if 

necessary. 

Summary of Contents for j120

Page 1: ...r applicable Service Bulletins and have them implemented as soon as possible Manuals are also updated periodically with the latest revisions available from the web site Failure to maintain the engine...

Page 2: ...TIONS 19 3 GROUND HANDLING STORAGE 27 3 1 TOWING 27 3 2 JACKING 27 3 3 HOISTING 28 3 4 LEVELLING 28 3 5 PARKING 28 3 6 TIE DOWN 28 3 7 STORAGE 29 4 INSPECTION SERVICING 31 4 1 BASIC INSPECTION PROCEDU...

Page 3: ...200 WINGS 77 7 6 J230 WINGS 78 7 7 J250 J450 WINGS 80 7 8 WING STRUTS 81 7 9 LANDING LIGHT S 82 7 10 LANDING LIGHT ADJUSTMENT NIGHT VFR MODELS 82 7 11 DYNON PITOT 84 7 12 WING INSPECTION WINDOW 85 7 1...

Page 4: ...FLAP 135 10 8 FLAP RIGGING AS PER TEMPLATE 136 11 ELEVATOR CONTROL SYSTEM 137 11 1 ELEVATOR CONTROL SYSTEM 137 11 2 CONTROL COLUMN 139 11 3 ELEVATOR 139 11 4 ELEVATOR CONTROL CABLES 141 11 5 RIGGING 1...

Page 5: ...16 1 ELECTRICAL POWER SUPPLY SYSTEM 208 16 2 MINOR ELECTRICAL EQUIPMENT 211 16 3 BATTERY SYSTEM 212 16 4 ELECTRICAL LOAD ANALYSIS ELA 213 16 5 RADIO INSTALLATION 213 16 6 TRANSPONDER 215 18 PAINTING...

Page 6: ...pty Right Indications 52 Figure 21 Fuel Gauge Calibration Decal Parts 53 Figure 22 20L Indication on Sender Decal to Match 53 Figure 23 EMS Fuel Calibration Screens 54 Figure 24 Fuel Line Clamps 55 Fi...

Page 7: ...Assy 103 Figure 69 Nose Leg Assy Long Trail J160 Family 103 Figure 70 Fabricated Nose Wheel Yoke Assy 104 Figure 71 Machined Nose Leg Housing 105 Figure 72 Brake Master Cylinder Lever Assy Type 1 107...

Page 8: ...ype 2 141 Figure 115 Elevator Travel Limits 142 Figure 116 Trim Lever Assy Type 1 144 Figure 117 Trim Lever Assy Type 2 144 Figure 118 Elevator Trim Handle Assy Type 3 145 Figure 119 Trim Controls At...

Page 9: ...Figure 164 Single Line Fuel Tap 186 Figure 165 Fuel Gauge Electric Sender Installation 188 Figure 166 Fuel Gauge Electric Sender Assembly 188 Figure 167 Fuel Gauge Sight Glass 188 Figure 168 Instrumen...

Page 10: ...e 94 Table 11 Trouble shooting Nose Leg 101 Table 12 Trouble Shooting Brakes 111 Table 13 Trouble Shooting Fuel System 179 Table 14 Trouble Shooting Fuel Gauge 187 Table 15 Trouble Shooting Pitot Stat...

Page 11: ...0 D Factory Built Light Sport Aircraft J250 J450 Kit built aircraft Model MTOW kg Category J120 C 500 LSA Experimental LSA All other J120 variants 500 Experimental J160 C 540 Primary J160 D 540 LSA Ex...

Page 12: ...afety directions issued by the manufacturer The aircraft has been maintained in accordance with the manufacturer s requirements and The continuing airworthiness functions are performed by the manufact...

Page 13: ...atic changes in the performance of the aircraft and may cause unexpected engine stoppage loss of control or have other detrimental effects on the aircraft which may lead to injury or death Jabiru Airc...

Page 14: ...raft Australia web site www jabiru net au Maintenance must only be carried out by an approved person Depending on the country and the category of the aircraft this may be a Licensed Aircraft Maintenan...

Page 15: ...craft is to be weighed Other tools as required to maintain the engine and propeller refer to the applicable manuals for these products Specialist tools such as the torque wrench and scales are require...

Page 16: ...ed in the Experimental category may be maintained exclusively by the owner builder or by authorised aircraft maintainers CAUTION It is the operator s responsibility to ensure that the kit built aircra...

Page 17: ...ts on oil free cadmium plated threads For Engine Bolt Torque Values see Engine Instruction Maintenance Manual The above values are recommended for all installation procedures contained in this Manual...

Page 18: ...Nov 2011 Issued By SW Page 18 of 233 2 15 ENGINES The engines used in Jabiru Aircraft are not discussed within this manual For details of installation maintenance and overhaul refer to the engine man...

Page 19: ...aft is equipped with appropriate fuel tank sealant and fittings Refer to Service Letter JSL007 the Pilot Operating Handbook or Flight Manual for details CAUTION CASA certified models may not use fuel...

Page 20: ...Capacity 65 litres 65 litres Oil Capacity 2 3 litres 2 3 litres Engine Model Jabiru 2200B Jabiru 2200A Propeller Pitch Jabiru 42 pitch 1067mm Sensenich 43 pitch 1092mm or Sensenich 46 pitch 1168mm Ja...

Page 21: ...il Capacity 2 3 litres 2 3 litres 2 3 litres Engine Model Jabiru 2200C Jabiru 2200B Jabiru 2200B Jabiru 2200A Propeller Pitch Jabiru 42 pitch 1067mm Jabiru 42 pitch 1067mm Sensenich 43 pitch 1092mm or...

Page 22: ...5 litres Oil Capacity 2 3 litres 2 3 litres 2 3 litres Engine Model Jabiru 2200B Jabiru 2200 Jabiru 2200 Propeller Pitch Jabiru 42 pitch 1067mm or Sensenich 43 pitch 1092mm or Sensenich 46 pitch 1168m...

Page 23: ...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 23 of 233 Figure 4 J170 D General Arrangement...

Page 24: ...t 700kg 544kg category limitation 700kg Fuel Capacity 135 litres 135 litres Oil Capacity 3 5 litres 3 5 litres Engine Model Jabiru 3300A Jabiru 3300A Propeller Pitch Jabiru 53 pitch 1346mm Jabiru 53 p...

Page 25: ...s 3 5 litres Engine Model Jabiru 3300A Jabiru 3300A Jabiru 3300A Propeller Pitch Jabiru 53 pitch 1346mm or Jabiru 55 pitch 1397mm or Sensenich 53 pitch 1346mm or Sensenich 55 pitch 1397mm or Sensenich...

Page 26: ...t 700kg 544kg category limitation 700kg Fuel Capacity 135 litres 135 litres Oil Capacity 3 5 litres 3 5 litres Engine Model Jabiru 3300A Jabiru 3300A Propeller Pitch Jabiru 53 pitch 1346mm Jabiru 53 p...

Page 27: ...cked may be blocked using a vent cap This is to prevent fuel leaking onto the wing while the aircraft is jacked CAUTION Where a vent cap is used ensure that it is large and highly visible to ensure it...

Page 28: ...ored in hangars wherever possible to minimise degradation caused by the elements and pests Parking precautions depend principally on local conditions As a general precaution check the wheels and tie t...

Page 29: ...vent moisture accumulation For indefinite storage drain fuel tank ensure carburettor bowl is empty by running engine with fuel valve off until it stops or by draining bowl CAUTION Do not store MOGAS o...

Page 30: ...rocedures for returning the aircraft to service are as follows 1 Remove aircraft from blocks and check tyres for proper inflation 2 Check battery and install 3 Check carburettor air filter and service...

Page 31: ...equired 4 2 MANDATORY INSPECTIONS LIFED ITEMS 4 2 1 AIRFRAME At intervals of 5000 hours the Jabiru all models airframe must be subject to an overall condition inspection by Jabiru Aircraft or an aircr...

Page 32: ...viced or otherwise completed At each 200 hours inspection the 100 hours items are completed in addition to the items marked under Each 200 Hours An inspection conducted Annually would likewise include...

Page 33: ...structure 9 Starter solenoid and electrical connections 10 Coils and electrical connections 11 Carburettor heat system 12 Firewall 13 Exhaust System Including Muffler 14 Fuel pressure warning light s...

Page 34: ...s 6 Main gear struts clamps bolts nuts 7 Main gear bolts Check life replace at 1000hrs TIS 8 Tyres tubes 9 Brake fluid hoses linings discs brake assemblies master cylinder 10 Rod ends condition freedo...

Page 35: ...n Monoxide Detector where equipped 20 Emergency Beacon where equipped 21 Landing Taxi Light Alignment N VFR only Aircraft Control Systems In addition to the items listed below always check for correct...

Page 36: ...xcessive wear safety proper operation proper adjustment correct travel cracked fittings security of hinges defective bearings cleanliness corrosion deformation sealing and tension METAL PARTS Check fo...

Page 37: ...mine that any discrepancies or abnormalities have been corrected 4 7 PROPELLER 100 HOURLY As all possible circumstances cannot be listed here the following is provided as guidance only A critical trai...

Page 38: ...all electrical wiring is secure Check for rubbing and damage to insulation or fittings Visually inspect for corrosion on fittings and any evidence of heat caused by a degraded connection or other iss...

Page 39: ...ts While the bowl is removed inspect the float level and check for any foreign objects in any of the jets Check the electronic fuel boost pump functions and produces a sufficient flow rate Inspect fue...

Page 40: ...spongy response on the brake lever Check that discs are straight not excessively corroded and not worn outside of limits Check for brake fluid leaks chafing or other damage to brake hoses Ensure that...

Page 41: ...ctly and indexed correctly on the cables Check all hardware is in good condition and is secure Move all controls through their full travel ensuring full and free movement with no binding Check control...

Page 42: ...nt weight transfer and consequentially C of G errors In addition door must be shut flaps in the UP position and any items not part of the standard equipment of the aircraft removed 7 Using a string li...

Page 43: ...0 J230 J430 J250 J450 Variants REVISION 1 Dated Nov 2011 Issued By SW Page 43 of 233 NOTE The CG datum point for the J120 C is an imaginary line 1403mm forward of the right wing leading edge Most CG c...

Page 44: ...eedom of movement Using a spring balance with graduations of no more than 300g measure the friction required to move the cable Repeat this step to give a minimum of 5 friction measurements in each dir...

Page 45: ...ar point where the rearmost edge of the aircraft is aligned with the front of the non hinged side of the control This is the critical point where a control jam becomes possible Any control which has a...

Page 46: ...ld close the control clearance Measure the control clearance while this load is applied Remove the load from the control and re measure the control clearance Controls are to be tested this way at ever...

Page 47: ...leron and wing Control at the point of overlap Measure the control clearance in this position while pressing on the control in the middle of the hinge Repeat the measurement when unloaded Interference...

Page 48: ...the aircraft If no marks are found further inspection and or rectification is unnecessary However if such marks are found compete the following steps Mark the extents of the control surface travel wh...

Page 49: ...the positions where they will be in normal operation Mark a reference centreline for the aircraft on the floor Use a plumb bob from the tip of the spinner and from the tip of the ventral fin to mark p...

Page 50: ...a circle around the point where the centreline of the axle hits the ground The toe of the wheel is used to compensate for this so that the wheel doesn t try and pull in or out on the leg as the plane...

Page 51: ...d By SW Page 51 of 233 aircraft forwards to allow the undercarriage legs to set to the new angles Alternatively the wheel may be re assembled with flock etc left to cure and then re checked once the r...

Page 52: ...to each tank this is the unusable fuel Check the indication of the fuel gauge The fuel gauge needle must be pointing at the E or below If it is not then the gauge unit will need to be removed and adju...

Page 53: ...Aircraft Pty Ltd JTM001 1 J120 J160 J170 J200 J400 J230 J430 J250 J450 Variants REVISION 1 Dated Nov 2011 Issued By SW Page 53 of 233 Figure 21 Fuel Gauge Calibration Decal Parts Figure 22 20L Indica...

Page 54: ...EMS main page and pressing MORE SETUP MORE FUEL You are presented with the screen shown Figure 23 left Press SEL and then enter a tank size of 65 Then press NEXT Then press START You will be presented...

Page 55: ...ton below an EMS main page and pressing MORE SETUP MORE FUEL You are presented with the screen shown Figure 25 The menu reflects the number of fuel tanks selected in the Global Parameters Setup If you...

Page 56: ...VISION 1 Dated Nov 2011 Issued By SW Page 56 of 233 WARNING Before removing clamps on the fuel line make sure all fuel lines are connected On removal of clamps check that the fuel lines are not damage...

Page 57: ...CES The exterior surfaces under normal conditions require a minimum of polishing and buffing CAUTION DO NOT polish or buff the aircraft within the first 2 weeks after delivery from the factory as surf...

Page 58: ...e protected against moisture Caustic cleaning solutions should not be used Recommended cleaning procedure is lightly spray with degreasing fluid after sealing coils and starter motor WIPE clean with b...

Page 59: ...illed those longer than 25 mm should NOT be repaired the windshield must be replaced 6 2 2 CLEANING Refer to Section 5 6 2 3 WAXING Waxing will fill in minor scratches in clear plastic and help protec...

Page 60: ...ing Hole should be approximately 1 16 inch in diameter depending on length of crack and thickness of material A slightly dull unfluted drill should be used 6 2 7 REMOVAL As the windscreen and windows...

Page 61: ...nd all edges of the door Apart from excluding wind and water the weather strip is important in minimising exhaust fume entry to the cabin It should be maintained in good condition and fit at all times...

Page 62: ...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 62 of 233 Figure 27 J160 Type Door Hinge Assy Figure 28 J160 T...

Page 63: ...al 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 63 of 233 Figure 29 J120 Type Door Assembly Figure 30 J200 Type Do...

Page 64: ...abiru Aircraft Pty Ltd JTM001 1 J120 J160 J170 J200 J400 J230 J430 J250 J450 Variants REVISION 1 Dated Nov 2011 Issued By SW Page 64 of 233 Figure 31 J160 Type Rear Door Assy Figure 32 J160 Type Door...

Page 65: ...d into the door and an acrylic window is bonded in place during assembly 6 5 2 REMOVAL AND INSTALLATION Removal of doors is achieved by removing the hinge bolts or removing the machined screws that at...

Page 66: ...a simple spring type This is complemented by a catch at the top front quadrant of each door An assembly drawing of the latch mechanism is provided as Figure 37 below 6 6 2 REMOVAL AND INSTALLATION Dis...

Page 67: ...ual 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 67 of 233 Figure 35 J200 Type Front Door Assembly Figure 36 J200...

Page 68: ...pans incorporate crushable foam which is essential in providing shock absorption in crash conditions The seat backs are also essential to restrain baggage in crash conditions 6 7 2 REMOVAL AND INSTALL...

Page 69: ...and resulting in a severe aft centre of gravity condition The curtain should be in place for all flights WARNING Do not stow items behind the sound curtain 6 10 SAFETY PROVISIONS 6 10 1 SEATBELTS Air...

Page 70: ...n type with a single main spar The wing is a moulded structure with solid foam core that is bonded to the fibreglass skin and spar The forward wing attachment is an extension of the forward sub spar T...

Page 71: ...ap to wing ensuring all bushes are in place 7 Install bolt nut in flap control rod 8 Install bolt nut in aileron control cable on main control stick horn 9 Install clamp block and pin in aileron contr...

Page 72: ...gue 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 attachi...

Page 73: ...abiru Aircraft Pty Ltd JTM001 1 J120 J160 J170 J200 J400 J230 J430 J250 J450 Variants REVISION 1 Dated Nov 2011 Issued By SW Page 73 of 233 Figure 38 J160 Wing Assembly Sheet 1 Ser X Figure 39 J160 Wi...

Page 74: ...iru Aircraft Pty Ltd JTM001 1 J120 J160 J170 J200 J400 J230 J430 J250 J450 Variants REVISION 1 Dated Nov 2011 Issued By SW Page 74 of 233 Figure 40 J160 Wing Assembly Sheet 1 Ser XIV Figure 41 J160 Wi...

Page 75: ...om the attachments to the main spar Both attachments are through stainless steel threaded bushes bonded into the attachment blocks The wing internal structure is sealed and only needs to be accessed f...

Page 76: ...120 J160 J170 J200 J400 J230 J430 J250 J450 Variants REVISION 1 Dated Nov 2011 Issued By SW Page 76 of 233 7 4 4 INSTALLATION Refer to Section 7 3 for installation details Figure 43 J170 Friese Ailero...

Page 77: ...re contained in a reinforced Wing End Plug and bond to the wing skins The Wing End Plug distributes load from the attachments to the main spar Both attachments are through stainless steel threaded bus...

Page 78: ...ttachments are contained in a reinforced Wing End Plug and bond to the wing skins The Wing End Plug distributes load from the attachments to the main spar Both attachments are through stainless steel...

Page 79: ...biru Aircraft Pty Ltd JTM001 1 J120 J160 J170 J200 J400 J230 J430 J250 J450 Variants REVISION 1 Dated Nov 2011 Issued By SW Page 79 of 233 Figure 47 J230 Wing Assembly Sheet 2 Ser 13 Figure 48 J230 Wi...

Page 80: ...bonded into the attachment blocks The wing internal structure is sealed and only needs to be accessed for repairs The J250 family wings are different to the modular wing families discussed above While...

Page 81: ...The strut consists of a streamlined tube bolted to two end fittings which attach to the fuselage and wing WARNING Do Not Tighten Strut Attachment Bolts Metal fatigue may result Bolt must be free to r...

Page 82: ...housing chaffing on the strut 7 10 LANDING LIGHT ADJUSTMENT NIGHT VFR MODELS The alignment of lights for aircraft carrying out Night VFR operations must be checked as a part of the 100 hourly inspecti...

Page 83: ...Aircraft Pty Ltd JTM001 1 J120 J160 J170 J200 J400 J230 J430 J250 J450 Variants REVISION 1 Dated Nov 2011 Issued By SW Page 83 of 233 Figure 52 Night VFR Lighting Aim Diagram Figure 53 Night VFR Land...

Page 84: ...the optional Dynon instrumentation system a special pitot head can be used which allows the measurement of the angle of attack of the aircraft in flight CAUTION This probe incorporates water drain hol...

Page 85: ...small acrylic window in the underside of the wing to allow inspection of the outboard aileron clamp In some models this window is a simple rectangular piece of clear acrylic screwed to the wing using...

Page 86: ...AND REPAIR The fin is an integral part of the fuselage structure and cannot be removed All repairs must be referred to Jabiru Aircraft Pty Ltd or our approved local agent 7 14 HORIZONTAL STABILISER Th...

Page 87: ...atching the paint etc WARNING When making a wing stand ensure that it is strong and stiff enough to support the aircraft with minimal distortion 2 Remove all unnecessary equipment from the aircraft 3...

Page 88: ...Remove the bolt on the outside of the fairing 2 Remove the machine screws on the inboard side of the fairing 3 In some models the fairing is in two pieces the large outboard section and the small inb...

Page 89: ...8 5 2 MAIN WHEEL REMOVAL 1 Jack aircraft as outlined in Section 8 2 above 2 Remove the upper leg fuselage fairing and the wheel spat if equipped as detailed above 3 Remove outboard brake pad plates 4...

Page 90: ...s during assembly Uneven or improper torque of through bolt nuts can cause failure of bolts with resultant wheel failure 9 Insert through bolts through brake disc and position disc on the inner wheel...

Page 91: ...ce 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 91 of 233 Figure 58 Main Wheel to Leg Assy Figure 59 Main W...

Page 92: ...ection 8 3 2 Remove wheel in accordance with Section 8 5 3 Allow the brake calliper s to hang on the brake line ensuring that the line is not being kinked distorted or otherwise damaged If the leg mus...

Page 93: ...mbly to take the load off the brake line 4 Cut the zip ties holding the brake line to the undercarriage leg 5 Un bolt the stub axle from the composite leg and remove 6 Remove bolt nut from top inboard...

Page 94: ...ossible for this leg type to have internal damage which does not show to the surface In this case the best indicator of the damage is that the damaged leg will have lost stiffness compared to the othe...

Page 95: ...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 95 of 233 Figure 61 Main Undercarriage Type 1 Figure 62 Main Underca...

Page 96: ...mbly consists of a cast Aluminium split rim tube and tyre The smaller half of the split rim is common with the main wheel assemblies while the larger half with integral bearing carriers is specific to...

Page 97: ...automotive wheel rim lubricant to the tyre bead faces on the inside of the wheel rims Note that if this step is skipped disassembly of the wheel in future will be made much more difficult 3 Position t...

Page 98: ...pedals to the nose leg assembly The systems are shown in Section 12 For some models a soft link is fitted between the nose leg and the rudder pedals to absorb vibrations Details of this assembly are...

Page 99: ...ity an Aluminium housing is used Nose wheel steering is achieved by connecting the rudder pedal assembly to the nose wheel steering link by push rods The nosewheel is centred by springs Some models in...

Page 100: ...a sanding block to remove a small amount of material from the top of the Ertalyte bush to allow a proper fit 3 If no smaller adjustments remain then the Ertalyte bushes must be replaced 8 13 5 NOSE G...

Page 101: ...jaws are used to avoid damaging the nose leg yoke 4 Remove the nut from the bolt on the top of the spring shaft 5 Fit an extension to the nose leg as shown in Figure 66 right and use it as a lever to...

Page 102: ...SW Page 102 of 233 Trouble Probable Cause Remedy Nose wheel shimmy Nose strut bolts loose Tighten bolts Loose or worn steering link Tighten replace defective parts Nose wheel out of balance Refer Sect...

Page 103: ...anual 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 103 of 233 Figure 68 Nose Leg Assy Figure 69 Nose Leg Assy Long...

Page 104: ...n 8 12 and the nose leg removed Section 8 13 To remove remove the bolts holding the housing to the firewall If required the aluminium housing can be disassembled by removing the assembly cap screws No...

Page 105: ...l residual thread retaining compound If new hardware is being used thoroughly clean all threads using aerosol tool cleaner or similar Apply a bead of Loctite 620 to each screw and to each female threa...

Page 106: ...mbly from the console and unbolt the master cylinder retaining bolts 6 Plug or cap hydraulic fittings and hoses to prevent the entry of foreign material 7 Reverse the preceding steps to install brake...

Page 107: ...rcraft Pty Ltd JTM001 1 J120 J160 J170 J200 J400 J230 J430 J250 J450 Variants REVISION 1 Dated Nov 2011 Issued By SW Page 107 of 233 Figure 72 Brake Master Cylinder Lever Assy Type 1 Figure 73 Brake M...

Page 108: ...container to collect the brake fluid draining from the system The brake disc is removed after the wheel is removed and disassembled 8 19 3 WHEEL BRAKE INSPECTION AND REPAIR 1 Clean all parts except br...

Page 109: ...e 6 Realign the lining of the pad plate and install and set rivets in the remaining holes 7 Replace the brake pad and refix with through bolts and springs To replace inboard lining 1 On aircraft with...

Page 110: ...s rubbing and the other free or if the pads are sitting at an angle to the disc it is necessary to adjust the caliper mounting plate The caliper mounting plate can be adjusted by carefully bending it...

Page 111: ...linder Restriction in hydraulic lines or in master cylinder Drain brake line clear with compressed air If cleaning lines fails the master cylinder may be faulty and should be repaired or replaced Brak...

Page 112: ...Aircraft Pty Ltd JTM001 1 J120 J160 J170 J200 J400 J230 J430 J250 J450 Variants REVISION 1 Dated Nov 2011 Issued By SW Page 112 of 233 Figure 75 Single Calliper Detail Non Quick Change Figure 76 Singl...

Page 113: ...ron control system is comprised of a control column and two enclosed push pull cables fitted with spherical bearings Due to space constraints not all different variations are shown herein When orderin...

Page 114: ...abiru Aircraft Pty Ltd JTM001 1 J120 J160 J170 J200 J400 J230 J430 J250 J450 Variants REVISION 1 Dated Nov 2011 Issued By SW Page 114 of 233 Figure 78 Aileron System Schematic Type 2 Figure 79 Aileron...

Page 115: ...t remove the aileron drive yoke from the rear end of the control column 4 Draw the column forwards and out of the centre console note that it may be necessary to partially or fully remove the instrume...

Page 116: ...ual 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 116 of 233 Figure 81 Control Column Assy Type 2 Figure 82 Control...

Page 117: ...spections given below are a part of a normal 100 hourly however Repair of control cables is limited to the installation of new parts The Figures below show various pictures of the cable clamps and cab...

Page 118: ...dder Cable Figure 85 Clamp Installations Elevator Aileron Figure 86 Trim Cable Clamp Installation Primary Control Cable Clamp note square corner of clamp Rudder cable clamp properly installed Note sea...

Page 119: ...on procedure is the opposite of removal procedure outlined above Ensure the cable clamps used match the cables and are properly installed WARNING Failure to properly install control cables may result...

Page 120: ...ileron and the wing Section 4 17 refers Repairs must be referred to Jabiru Aircraft Pty Ltd or our approved local agent 9 4 4 AILERON BALANCING The aileron does not have balancing weights fitted The A...

Page 121: ...vement i e UP travel and use cable adjustment as previously described to proportion UP and DOWN travel Note that while it is possible to adjust the Type 3 aileron stops using the eccentrics using the...

Page 122: ...ce 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 122 of 233 Figure 90 Aileron Stops Type 2 Figure 91 Aileron...

Page 123: ...aircraft a manual lever located above the pilot s door drives the system Refer to sections below for details on removal maintenance and installation of the various parts of the system Due to space con...

Page 124: ...ircraft Pty Ltd JTM001 1 J120 J160 J170 J200 J400 J230 J430 J250 J450 Variants REVISION 1 Dated Nov 2011 Issued By SW Page 124 of 233 Figure 93 J200 Family Manual Flap System Sheet 1 Figure 94 J200 Fa...

Page 125: ...the handle for wear or cracking of the fiberglass Small cracks between the moulded handgrip and the structural plate forming the handle may be repaired using 5 minute araldite Inspect hardware for da...

Page 126: ...needs cleaning Use a rag lightly moistened with solvent such as acetone to remove as much of the black material from the ring as possible Use a tooth brush or other similar small brush to clean betwee...

Page 127: ...W Page 127 of 233 Figure 96 Commutator Ring Close Up 10 3 4 INSTALLATION Installation is the reverse of removal Ensure the flap position indicator is positioned correctly Ensure tape is removed from f...

Page 128: ...ft Pty Ltd JTM001 1 J120 J160 J170 J200 J400 J230 J430 J250 J450 Variants REVISION 1 Dated Nov 2011 Issued By SW Page 128 of 233 Figure 97 Flap Controls Sheet 1 Fibreglass Motor Mount Figure 98 Flap C...

Page 129: ...iru Aircraft Pty Ltd JTM001 1 J120 J160 J170 J200 J400 J230 J430 J250 J450 Variants REVISION 1 Dated Nov 2011 Issued By SW Page 129 of 233 Figure 99 Flap Controls Sheet 2 Figure 100 Flap Controls Shee...

Page 130: ...aft Pty Ltd JTM001 1 J120 J160 J170 J200 J400 J230 J430 J250 J450 Variants REVISION 1 Dated Nov 2011 Issued By SW Page 130 of 233 Figure 101 Flap Controls Sheet 3 Aluminium Motor Mount Figure 102 J200...

Page 131: ...al of shaft Refer to Section 7 for details on wing removal procedure 2 Either use heavy duty tape to hold the remaining flap in the up position or remove the flap from the aircraft 3 Disconnect the fl...

Page 132: ...procedure is the reverse of assembly After installing carry out a test run while watching the external flap drive arms Ensure the arms do not rub against the fuselage or wing mounts WARNING All spheri...

Page 133: ...manual flap variants Both indicators consist of a cable driven indicator which moves inside a housing Indicators are mounted to the windscreen door pillars 10 5 2 FLAP POSITION INDICATOR REMOVAL 1 Un...

Page 134: ...abiru Aircraft Pty Ltd JTM001 1 J120 J160 J170 J200 J400 J230 J430 J250 J450 Variants REVISION 1 Dated Nov 2011 Issued By SW Page 134 of 233 Figure 106 Flap Position Indicator Type 1 Figure 107 Flap P...

Page 135: ...or similar to both wing flaps holding them up To remove unbolt at both ends and remove Reverse for installation WARNING All spherical rod end bearings must be fitted with a large washer on the outside...

Page 136: ...P BALANCING The flaps on the J160 J170 are not balanced 10 7 6 FLAP RIGGING J170 SP MODEL The J170 SP has a special requirement for its wing flap rigging To attain the required clean stall speed the J...

Page 137: ...ush pull cable fitted with rod ends at both ends Due to space constraints not all different variations are shown herein When ordering spare parts provide as must detail as possible part description ai...

Page 138: ...ru Aircraft Pty Ltd JTM001 1 J120 J160 J170 J200 J400 J230 J430 J250 J450 Variants REVISION 1 Dated Nov 2011 Issued By SW Page 138 of 233 Figure 110 Elevator Control System Type 1 Sheet 2 Figure 111 E...

Page 139: ...rews in hinge pin retainers and lift hinge pin retainers from hinge pins It is not necessary to remove these parts 5 Remove hinge pins 6 Remove Elevator 7 Reverse the preceding steps for installation...

Page 140: ...Issued By SW Page 140 of 233 WARNING All spherical rod end bearings must be fitted with a large washer on the outside of the through bolt to prevent the bearing case and cable releasing in the event o...

Page 141: ...the cable 7 Unbolt the clamps at either end of the cable 8 Where required remove any ties etc used to restrain the cables in the aircraft 9 Tie a string or light wire to one end of the cable 10 Draw...

Page 142: ...Aircraft 3 Using the factory anchor points make sure each end of the cable is secure 4 Set the full up travel first using the factory templates Making sure both the control column and the elevator tr...

Page 143: ...crew attaching the control cable to the lever If required drill the TLR rivets to remove the housing from the centre console For a type 2 assembly Remove the cotter pin and lock nut from the pivot sha...

Page 144: ...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 144 of 233 Figure 116 Trim Lever Assy Type 1 Figure 117 Trim L...

Page 145: ...g loading force is used to trim the aircraft 11 7 2 OPERATIONAL CHECK Movement of the Trim Lever FORE and AFT should result in movement of the Main Control FORE and AFT and movement of the Elevator UP...

Page 146: ...erse the removal procedure above for installation WARNING All spherical rod end bearings must be fitted with a large washer on the outside of the through bolt to prevent the bearing case and cable rel...

Page 147: ...e cable out of the aircraft leaving the string wire in place to allow installation of a replacement part 11 8 3 CONTROL CABLE INSPECTION The Control Cable may not be repaired or removed without refere...

Page 148: ...justable rudder pedals may be fitted These pedals are adjusted by means of a spring loaded pin that allows each pedal to be moved to one of three positions Due to space constraints not all different v...

Page 149: ...wear and elongation 5 Inspect bolts and nuts for distortion and wear 6 Replace any distorted or worn parts If the optional adjustable rudder pedals are fitted these steps must also be performed 7 Insp...

Page 150: ...Aircraft Pty Ltd JTM001 1 J120 J160 J170 J200 J400 J230 J430 J250 J450 Variants REVISION 1 Dated Nov 2011 Issued By SW Page 150 of 233 Figure 122 Adjustable Rudder Pedal Assy Type 1 Figure 123 Adjust...

Page 151: ...OVAL For details on removing the nose leg and rudder pedals refer to the appropriate sections of this manual To disconnect the rudder centring system remove the bolts and the pushrods connecting the p...

Page 152: ...raft Pty Ltd JTM001 1 J120 J160 J170 J200 J400 J230 J430 J250 J450 Variants REVISION 1 Dated Nov 2011 Issued By SW Page 152 of 233 Figure 125 Steering Rudder Centring Assy Type 2 Figure 126 Steering R...

Page 153: ...Pty Ltd JTM001 1 J120 J160 J170 J200 J400 J230 J430 J250 J450 Variants REVISION 1 Dated Nov 2011 Issued By SW Page 153 of 233 Figure 127 Steering Rudder Assy Type 3 Sheet 2 Figure 128 Steering Rudder...

Page 154: ...move hinge pins 4 Remove rudder 5 Reverse the preceding steps for installation 12 3 3 INSPECTION REPAIR Inspect rudder for any signs of delamination or cracking Pay particular attention to the Control...

Page 155: ...d end bearings at either ends of the cable 12 Unbolt the clamps at either end of the cable 13 Where required remove any ties etc used to restrain the cables in the aircraft 14 Tie a string or light wi...

Page 156: ...milar mixture The hinge moment can be measured using masses on the trailing edge or by measuring the force needed to maintain the rudder for aft centreline horizontal Weight and moment values are give...

Page 157: ...cowl 5 Replace the cam locks in the cowling to ensure they are not misplaced NOTE Always ensure that the cowl is placed in a position where it cannot be damaged by persons walking around the aircraft...

Page 158: ...anual 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 158 of 233 Figure 131 Typical Upper Cowl Assy Figure 132 Typica...

Page 159: ...pad at the rear of the engine All Jabiru engines are fitted with a permanent magnet alternator at the rear of the engine This is considered a part of the engine and is discussed in the engine Instruc...

Page 160: ...oses to assess the hardness of the hose Excessively hard hoses must be replaced as they are likely to be subject to cracking Replace any doubtful hoses 13 3 4 FLEXIBLE HOSE INSTALLATION Hoses should n...

Page 161: ...CTION Engine baffles should be cleaned with a suitable solvent Mineral Turpentine to remove dirt and oil Inspect baffles for cracks splits or damage In particular ensure that the hard points where the...

Page 162: ...e instructions given in the engine Instruction Maintenance manual Cut the zip ties holding wires vents and lines to the engine mount In some cases the instrument panel covers the bolts for the engine...

Page 163: ...While most aircraft use a throttle control mounted on the instrument panel some are equipped with a throttle fitted to the front of the crew seat Figure 135 and Figure 136 13 7 2 THROTTLE REMOVAL Loo...

Page 164: ...n above for installation Adjust throttle stops mounted on the throttle pushrods for panel mount throttle and on the seat front floor for seat mounted throttle to give full throttle and correct idle sp...

Page 165: ...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 165 of 233 Figure 136 Throttle Assy Panel Mounted Figure 137 Throttle...

Page 166: ...emove the cable end fitting remove the cotter pin Figure 138 Note that for older aircraft the soldered end fitting must be heated with a powerful soldering iron or small gas burner and removed when th...

Page 167: ...he rivets holding it to the firewall drilled This is not required during routine maintenance To remove heat muff from the exhaust undo the hose clamps holding it in position The air filter should be i...

Page 168: ...xtractors manifolds using springs Note that the majority of exhaust maintenance is detailed in the engine Instruction Maintenance Manuals 13 10 2 EXHAUST SYSTEM REMOVAL Remove both top and bottom engi...

Page 169: ...manifolds and or muffler 2 Use rubber expansion plugs to seal openings 3 Using a manometer or gauge apply approximately 1 1 2 psi 3 inches of mercury air pressure while the manifold and or muffler are...

Page 170: ...al 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 170 of 233 Figure 142 3300 Exhaust System Type 1 Figure 143 3300 E...

Page 171: ...isconnect spring from Lever arm Remove Split Pin from cable locking pin Remove locking pin disconnect control cable Loosen hose clamp screws Remove hose For the heat exchanger Loosen the hose clamps a...

Page 172: ...ual 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 172 of 233 Figure 144 Cabin Heat Mixer Assembly Figure 145 Cabin...

Page 173: ...ngle cause of early engine wear When operating under high dust conditions the carburettor air filters should be serviced regularly Servicing intervals for aircraft operating in extreme conditions are...

Page 174: ...ru Aircraft Pty Ltd JTM001 1 J120 J160 J170 J200 J400 J230 J430 J250 J450 Variants REVISION 1 Dated Nov 2011 Issued By SW Page 174 of 233 Figure 147 2200 Engine Installation Figure 148 2200 Engine Ins...

Page 175: ...rcraft Pty Ltd JTM001 1 J120 J160 J170 J200 J400 J230 J430 J250 J450 Variants REVISION 1 Dated Nov 2011 Issued By SW Page 175 of 233 Figure 149 J200 Family Engine Installation Type 1 Figure 150 J200 F...

Page 176: ...tanks are structural and are integral parts of the wings A header tank is fitted The tank may be located under the baggage shelf behind the crew seats J160 family behind the sound curtain at the rear...

Page 177: ...nual 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 177 of 233 Figure 151 In Cabin Fuel System Figure 152 Fuel Syste...

Page 178: ...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 178 of 233 Figure 153 Fuel System Schematic Type 2 Figure 154 Fuel S...

Page 179: ...ot turned ON Turn valve ON Fuel tank empty Service with proper grade and amount of fuel Fuel line disconnected or broken Connect or repair fuel lines Fuel tank outlet strainer plugged Remove and clean...

Page 180: ...family aircraft Ensure there are no U s or inverted U s in the lines Ensure line restraints are spaced at intervals no greater than 400mm In some cases fuel lines are bundled inside tubes which are V...

Page 181: ...s Figure 158 Fuel Lines Showing Typical U Requiring Correction Figure 159 Corrected Fuel Lines Lines dip slightly as they exit the header tank and pass through the side of the baggage shelf Hole in ba...

Page 182: ...enclosure For kit built models where the tank is under the passenger s seat this may require cutting a hole into the seat pan Remove tank restraints Loosen hose clamps remove hoses remove tank Install...

Page 183: ...Aircraft Pty Ltd JTM001 1 J120 J160 J170 J200 J400 J230 J430 J250 J450 Variants REVISION 1 Dated Nov 2011 Issued By SW Page 183 of 233 Figure 160 Header Tank Installation Type 1 Figure 161 Header Tan...

Page 184: ...d a header tank all three tanks are interconnected to ensure uniform breather pressure and even feeding from all tanks For aircraft with a single fuel tank fitted behind the crew seats a single vent l...

Page 185: ...y blockage reassemble To check the operation of the filler cap fuel vent check valve where equipped Remove the cap and shake it The ball inside should move freely producing a rattling sound An alterna...

Page 186: ...to the valve requires the removal of the section of fuel line containing the tap To achieve this loosen the hose clamps disconnect the hose and draw it carefully out of the centre console Where equipp...

Page 187: ...ws and disassemble the gauge Reverse the preceding steps for installation For wing root electric float gauges Remove the fairings from between the wings and the fuselage Disconnect the fuel lines and...

Page 188: ...TM001 1 J120 J160 J170 J200 J400 J230 J430 J250 J450 Variants REVISION 1 Dated Nov 2011 Issued By SW Page 188 of 233 Figure 165 Fuel Gauge Electric Sender Installation Figure 166 Fuel Gauge Electric S...

Page 189: ...e this arrow is pointed towards the Firewall and Engine 14 8 FUEL PUMPS 14 8 1 DESCRIPTION The Primary Fuel Pump is located on the Starboard rear of the Engine Refer to engine Maintenance Instruction...

Page 190: ...e 190 of 233 Allow the Loctite to cure Reverse the preceding steps for installation Ensure waste cloth is removed WARNING Ensure tank vents are open no vent covers fitted The fuel filter must only be...

Page 191: ...repaired must be decided on the basis of the individual circumstances Due to space constraints not all different variations are shown herein When ordering spare parts provide as must detail as possib...

Page 192: ...d JTM001 1 J120 J160 J170 J200 J400 J230 J430 J250 J450 Variants REVISION 1 Dated Nov 2011 Issued By SW Page 192 of 233 Figure 168 Instrument Panel Layout Type 1 Figure 169 Instrument Panel Layout Typ...

Page 193: ...s mount and it also supports the panel throttle assembly where equipped 15 3 2 INSTRUMENT PANEL REMOVAL INSTALLATION To remove the fibreglass panel mount from the firewall Remove the fascia as noted a...

Page 194: ...screws and take instrument out from behind or in some cases from the front of the panel In some cases due to access it may be easier to partially remove the panel fascia as noted above before attempti...

Page 195: ...rcraft the pitot and static systems each have a water trap or low point fitted which must be checked during scheduled maintenance or after flying through rain CAUTION Proper maintenance of pitot and s...

Page 196: ...positioned in a U shape with a connector at the lowest point in the U Water collects at this point and can be drained by disassembling the fitting or by undoing the connection The water trap for the s...

Page 197: ...biru Aircraft Pty Ltd JTM001 1 J120 J160 J170 J200 J400 J230 J430 J250 J450 Variants REVISION 1 Dated Nov 2011 Issued By SW Page 197 of 233 Figure 175 Pitot Static Water Trap Figure 176 Pitot Static S...

Page 198: ...ctions then repeat leakage test If leakage rate still exceeds maximum allowable use the following procedure Fault Location Tests Disconnect static pressure lines from airspeed indicator and vertical s...

Page 199: ...line at first instrument to which it is connected then blow the line clear with low pressure air Check all static pressure lines for tightness If hose or hose connections are used check for general co...

Page 200: ...ent Hand vibrates Excessive vibration Check panel shock mounts Replace defective shock mounts Excessive tubing vibration Check clamps and line connections for security Tighten clamps and connections r...

Page 201: ...tions Incorrect indication Partially plugged static line Check line for obstructions Blow out lines Ruptured diaphragm Substitute known good indicator and check reading Replace instrument Pointer off...

Page 202: ...imary static source become blocked the pilot may switch to an alternate supply In the Jabiru this system consists of a section of the static tube which is exposed at the underside of the instrument at...

Page 203: ...ending on the aircraft model In some the sensor is positioned so that the teeth of the flywheel ring gear pass close by and produce a signal In others the same sensor reads off metal tags bolted to th...

Page 204: ...anism Substitute known good tachometer and check reading Replace instrument Incorrect indication Sensor not positioned correctly Adjust sensor per Engine Manual Instructions Analogue Tacho Incorrectly...

Page 205: ...exception of the CHT gauge the instruments require power to operate which is supplied from the main bus bar The CHT gauge does not require power it connects only to a thermocouple which is fitted to...

Page 206: ...tage RPM fuel level fuel flow system voltage fight timers etc Setup of these instruments must be carried out in accordance with manufacturer s instructions 15 9 1 REMOVAL INSTALLATION Remove the instr...

Page 207: ...tted where required GPS Data not displayed No GPS source fitted Install GPS Connection between GPS and display failed Check and repair connection Settings on Display or GPS incorrect Check settings an...

Page 208: ...f power during flight and maintains a battery charge controlled by a voltage regulator Depending on the aircraft model a 120 Watt or 200 Watt alternator may be fitted The following paragraphs provide...

Page 209: ...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 209 of 233 Figure 181 Wiring Diagram Sheet 1...

Page 210: ...nual 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 210 of 233 Figure 182 Wiring Diagram Sheet 2 Figure 183 Night VF...

Page 211: ...efer to Wiring Diagram for details 16 2 3 STARTER SOLENOID The starter solenoid is a sealed unit Service is limited to inspection of terminals for security and replacement of the unit Note that the bo...

Page 212: ...box is located on the firewall in the engine compartment 16 3 2 REMOVAL AND INSTALLATION 1 Disconnect the battery security strap 2 Disconnect the ground cable from the negative battery terminal black...

Page 213: ...ysis is not required as failure of the electrical generation system would have a limited effect on the length of time of radio transmissions and no effect on aircraft performance as the engine electri...

Page 214: ...y Ltd JTM001 1 J120 J160 J170 J200 J400 J230 J430 J250 J450 Variants REVISION 1 Dated Nov 2011 Issued By SW Page 214 of 233 Figure 186 Second VHF Antenna Installation J120 J160 Families Figure 187 Sec...

Page 215: ...ASA authorised technician All transponder maintenance must be carried out by qualified technicians To remove transponder move the mounting screws holding it to the panel fascia Disconnect it from the...

Page 216: ...Lts MUST BE WHITE Base Coat 4 Lts Ensure compatibility with top coat Polyester Filler 4 kg Spot Putty 1 lb tube Claw Glaze recommended 18 1 2 2 SANDPAPER Note aluminium oxide type most effective 1st...

Page 217: ...e of sins 11 The factory uses a low pressure pot gun for spraying at pressures from 60 100 psi 12 It is mandatory that exterior colour is WHITE only broken if desired by pin stripes on the vertical su...

Page 218: ...he rear Face of the Forward Wing Spar Carry through Beam in the Cabin Ceiling Warning Placard J170 C P No 5A069A0D Fitted on the rear Face of the Forward Wing Spar Carry through Beam in the Cabin Ceil...

Page 219: ...ng carry through beam across to the left side Warning Placard J170 P No 5A015A0D Fitted above windscreen in front of wing carry through beam across to the left side Warning Placard J200 P No 5073624 F...

Page 220: ...Attach to outsides of main wheel spats Nose Wheel Inflation J170 C J170 D J230 C J230 D P No 5A062A0D Attach to left side of nose wheel spat Main Wheel Inflation J170 C J170 D J230 C J230 D P No 5A06...

Page 221: ...de just below rear quarter window Loading Limitations 540kg P No 5098854 J160 J170 Family Some J200 J250 variants Fitted on inside of fuselage of RHS of cabin below rear quarter window Loading Limitat...

Page 222: ...eat P No 5A030A0D Fitted to lower central section of instrument panel Earth on Post P No 5A066A0D Attach to upper wing skin beside fuel filler earth post No Step P No 5A006A0D Qty 2 required Fit to to...

Page 223: ...rument panel Fuel Contents P No 5A022A0D Where Equipped Fitted to sight glasses of wing fuel tanks Fuel Contents P No 5A053A0D Where Equipped Fitted around the fuel gauge opening to the wing fuel tank...

Page 224: ...the base of the choke cable Carb Heat P No 5026194 Where Equipped Fitted at the base of the CARBY Heat Cable Static Port P No 5043094 Attach to LHS of Vertical Fin in line with Static Tube Door Lean P...

Page 225: ...e aircraft or fairing The fairings can be removed once these screws have been taken out When removing the wing strut fairings care should be take to avoid scratching the strut Installation is the oppo...

Page 226: ...biru 2200 C000242 or 4A401 Series 1524 x 1067 60 x 42 Not above 3300 RPM Jabiru J160 D J170 C J170 D Jabiru 2200 C000242 or 4A401 Series 1524 x 1067 60 x 42 Not above 3300 RPM Sensenich 2 bladed Fixed...

Page 227: ...han Australia different maintenance requirements will apply It is the owner s responsibility to become fully aware of the particular maintenance requirements and limitations applicable to the appropri...

Page 228: ...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 228 of 233 Figure 189 Propeller Installation...

Page 229: ...blade clears the object by the same amount If the Propeller is outside the approved tolerance refer to JABIRU Aircraft Pty Ltd or a JABIRU Approved Service Centre Maximum Tracking Error Tolerance is...

Page 230: ...sin to a smooth surface matching exactly the previous aerofoil 6 Refurbish with clear Epoxy paint JABIRU Part No PP0069N 7 Rebalance Propeller see below 8 Reassemble and replace Propeller and Spinner...

Page 231: ...ments_Edited Generic_Tech_Mannual Generic_Tech_Rev1_Unsigned docx Print Date 8 05 2012 1 11 00 PM 23 APPENDIX AIRWORTHINESS LIMITATIONS THIS AIRWORTHINESS LIMITATIONS SECTION IS APPROVED BY THE CIVIL...

Page 232: ...proved Composites Licence or a Jabiru Approved Certification Jabiru Aircraft offers training certification for people wishing to gain Jabiru approval to inspect maintain J160 C structures Note this do...

Page 233: ...Table 25 Control Surface Balancing Limits Control Hinge Moment Limits Weight Limits Manual Section Rudder 17500g mm 4000g mm 2100g 100g 12 5 RUDDER BALANCE Aileron 94000g mm 4000g mm 1150g 100g 9 4 4...

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