Jabiru j160 User Manual Download

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TECHNICAL MANUAL

FOR

JABIRU AIRCRAFT MODELS:

J120 Variants
J160 Variants
J170 Variants

J200/J400 Variants
J230/J430 Variants
J250/J450 Variants

DOCUMENT No. JTM001-5

DATED: 29

October 2014

This Manual has been prepared as a guide to correctly maintain Jabiru Aircraft Models.

It is the owner's responsibility to regularly check the Jabiru web site at www.jabiru.net.au for

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 or aircraft with current service information may render the aircraft un-airworthy and void

Jabiru’s Limited, Express Warranty.

This document is controlled while it remains on the Jabiru server. Once this no longer applies

the document becomes uncontrolled.

Should you have any questions or doubts about the contents of this manual, please contact

Jabiru Aircraft Pty Ltd.

Summary of Contents for j160

Page 1: ...for 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 engin...

Page 2: ...FT SPECIFICATIONS 21 2 18 TORQUE VALUES IN FIBREGLASS 29 3 MAINTAINER REQUIREMENTS 30 3 1 FACILITIES 30 3 2 TRAINING 30 3 3 RATING 30 3 4 EXPERIENCE 30 3 5 TOOL GAUGE CONTROL 30 3 6 TOOLS 30 3 7 EQUIP...

Page 3: ...250 J450 WINGS 100 6 19 WING STRUTS 102 6 20 LANDING LIGHT S 103 6 21 LANDING LIGHT ADJUSTMENT NIGHT VFR MODELS 103 6 22 DYNON PITOT 106 6 23 WING INSPECTION WINDOW 107 6 24 FIN 108 6 25 HORIZONTAL ST...

Page 4: ...171 6 65 CONTROL COLUMN 173 6 66 ELEVATOR 173 6 67 ELEVATOR CONTROL CABLES 176 6 68 RIGGING 176 6 69 ELEVATOR TRIM CONTROL LEVER ASSY 178 6 70 ELEVATOR TRIM AFT ASSEMBLY 180 6 71 TRIM CONTROL CABLES 1...

Page 5: ...LTERNATE STATIC SOURCE 256 11 7 ANALOGUE TACHOMETER 257 11 8 ANALOGUE ENGINE GAUGES 260 11 9 DIGITAL DISPLAYS 261 11 10 MAGNETIC COMPASS 262 11 11 GYRO INSTRUMENT PACKAGE OPTION 262 12 ELECTRICAL SYST...

Page 6: ...on 59 Figure 18 Rudder Gap Cross Section 60 Figure 19 Aileron Clearance 60 Figure 20 Test Load Application 61 Figure 21 Elevator Gap Cross Section 61 Figure 22 Scratches on Rudder 62 Figure 23 Wheel A...

Page 7: ...Wing Inspection Panel 107 Figure 67 Wheel Spat Installation 111 Figure 68 Main Wheel to Leg Assy 114 Figure 69 Main Wheel Assembly 114 Figure 70 Directional Brake Disc Installation 115 Figure 71 Main...

Page 8: ...embly J200 Family Electric 165 Figure 116 Flap Position Indicator Type 1 167 Figure 117 Flap Position Indicator Type 2 168 Figure 118 Flap Position Indicator Drive Cable Assembly 168 Figure 119 Elevat...

Page 9: ...Figure 163 Fuel System Schematic Type 2 221 Figure 164 Fuel System Schematic Type 3 221 Figure 165 Fuel System Schematic Type 4 222 Figure 166 Schematic 223 Figure 167 Sample Fuel Line Details 224 Fig...

Page 10: ...ctober 2014 Issued By AS Page 10 of 298 Figure 192 Wiring Diagram Sheet 2 265 Figure 193 Night VFR Lighting Sheet 1 265 Figure 194 Night VFR Lighting Sheet 2 266 Figure 195 VHF Antenna Installation 26...

Page 11: ...Undercarriage 118 Table 8 2 Trouble shooting Nose Leg 127 Table 8 3 Trouble Shooting Brakes 138 Table 14 1 Trouble Shooting Fuel System 222 Table 14 2 Trouble Shooting Fuel Gauge 231 Table 15 1 Troubl...

Page 12: ...J230 J430 Kit built aircraft J230 C Factory Built Light Sport Aircraft J230 D Factory Built Light Sport Aircraft J250 J450 Kit built aircraft Model MTOW kg Category J120 C 500 LSA Experimental LSA Al...

Page 13: ...cturer are incorporated on the aircraft The aircraft complies with all safety directions issued by the manufacturer The aircraft has been maintained in accordance with the manufacturer s requirements...

Page 14: ...which is not strictly in accordance with these manuals may lead to dramatic changes in the performance of the aircraft and may cause unexpected engine stoppage loss of control or have other detriment...

Page 15: ...ies guidance for each variant Before working on an aircraft the technician must be fully conversant with the appropriate Aircraft Technical Manual Engine Maintenance Manual Propeller Manual and any re...

Page 16: ...d to be sufficient reference for a person with no other training to safely maintain an aircraft In this manual we have used a spanner scale to help technicians approach a job Anyone considering undert...

Page 17: ...the factory built aircraft is correctly maintained for the intended use 2 8 2 Kit Built Models Many models discussed in this manual can be registered under a variety of different categories worldwide...

Page 18: ...ance on accepted means for carrying out typical aircraft maintenance tasks such as safety wiring etc WARNING Thread bound nuts can carry far less load and are much more susceptible to failure WARNING...

Page 19: ...e typical EMS Dynon D10 is typical EFIS EMS Dynon FlightDEK D180 GPS Garmin GPSmap296 or Aera 500 are typical Voltage meter Pressure Gauges Engine Oil Pressure analogue part of EMS display Engine Oil...

Page 20: ...d in the ASTM standard F2295 Each owner operator of a LSA shall read and comply with the maintenance and continued airworthiness information and instructions provided by the manufacturer Each owner op...

Page 21: ...nds containing up to 10 Ethanol may be used only where the aircraft is equipped with appropriate fuel tank sealant and fittings Refer to Service Letter JSL007 the Pilot Operating Handbook or Flight Ma...

Page 22: ...ts Aircraft Maximum Weight 500kg 1102lb 500kg 1102lb Fuel 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...

Page 23: ...kg 1190lb Fuel Capacity 135 litres 135 litres 135 litres Oil 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...

Page 24: ...992lb 544kg 1190lb Fuel Capacity 135 litres 75 litres 135 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...

Page 25: ...0 J200 J400 J230 J430 J250 J450 Variants This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th Octo...

Page 26: ...umber of Seats 2 4 Aircraft Maximum Weight 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...

Page 27: ...s 135 litres 135 litres Oil Capacity 3 5 litres 3 5 litres 3 5 litres Engine Model Jabiru 3300A Jabiru 3300A Jabiru 3300A Propeller Pitch Jabiru 53 pitch 1346mm or Jabiru 55 pitch 1397mm or Sensenich...

Page 28: ...umber of Seats 2 4 Aircraft Maximum Weight 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...

Page 29: ...r to corrode in place If that happens the friction of the corrosion will seize the fastener ensuring that it appears to pass torque checks but in fact has lost tension and is no longer holding the ass...

Page 30: ...ool Gauge Control Tool gauge control is an important part of aviation maintenance systems Tools gauges must be accurate enough for the intended use i e a 12 steel ruler is not the appropriate tool to...

Page 31: ...nd press Heat gun or small butane propane torch with a soft pencil flame Multimeter or an ohmmeter Imperial thread taps UNF and UNC Adjustable wing stands Saw horses Fuel proof container with accurate...

Page 32: ...spray Loctite 7471 is used Only use as much as required specified Excess compound can make it nearly impossible to disassemble the parts later Surface preparation is critical Threads must be cleaned a...

Page 33: ...to secure items nuts bolts etc to prevent rotation in service 3 9 1 Torque Tension Wrench Figure 12 Torque Wrench Crowsfoot Adaptor Setting 1 An accurate optical tachometer Reads directly from reflect...

Page 34: ...Figure 10 is sometimes necessary it allows high torque settings to be used on small nuts without damaging them and access to difficult locations However when using the extension as shown in Figure 12...

Page 35: ...ing to be obtained Firstly the nut must be tightened smoothly Any jerks or bumps can cause the torque reading to be obtained prematurely The torque must be obtained while the nut is turning If you sto...

Page 36: ...s such as those mentioned in the previous section must never be used Note that 4 1 3 Exterior Surfaces The exterior surfaces under normal conditions require a minimum of polishing and buffing CAUTION...

Page 37: ...iscard cracked wheel halves flanges or hubs and install new parts 4 2 Ground Handling 4 2 1 Towing All Jabiru aircraft are relatively light and should always be moved by hand Moving the aircraft is ac...

Page 38: ...avy absorbent material do not use anything hard as items like bricks are likely to damage the aircraft material Place weights as close as possible to the aircraft centreline and where possible apply w...

Page 39: ...s tied down 2 Tie rope to the Tail Tie down Hole in the Ventral Fin Secure the opposite end of rope to ground anchors 4 3 Storage 4 3 1 Flyable Storage Flyable storage is defined as a maximum of 30 da...

Page 40: ...h a red streamer to each 9 Cover but DO NOT seal fuel tank breathers breather covers must be a loose fit to prevent the possibility of pressure related damage to the fuel tanks 10 Place protective cov...

Page 41: ...ntrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued By AS Page 41 of 298 10 Check brake fluid level 11 If returning to service after indefinite storage fill fuel tanks with correct grade of fuel 1...

Page 42: ...e the aircraft Test fly if required 5 3 Mandatory Inspections Lifed Items 5 3 1 Airframe At intervals of 5000 hours the Jabiru all models airframe must be subject to an overall condition inspection by...

Page 43: ...ns on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued By AS Page 43 of 298 5 3 4 Undercarriage Main undercarriage bolts a...

Page 44: ...nnually When conducting an inspection at 100 hours all items marked under Each 100 Hours is inspected serviced or otherwise completed At each 200 hours inspection the 100 hours items are completed in...

Page 45: ...Engine controls and linkages 8 Engine mounts mount structure 9 Starter solenoid and electrical connections 10 Coils and electrical connections 11 Carburettor heat system 12 Firewall 13 Exhaust System...

Page 46: ...s 3 Nose gear wheel steering links tension links fairings 4 Wheel bearings 5 Nose gear strut 6 Nose gear housing bushes 7 Main gear struts clamps bolts nuts 8 Main gear bolt inspection Check life repl...

Page 47: ...Pitot static system 14 Radio intercom headsets 15 Antenna cable 16 Door catches 17 Stall warning 18 Battery battery cradle cables 19 Carbon Monoxide Detector where equipped 20 Emergency Beacon where...

Page 48: ...on Guidelines As all possible circumstances cannot be listed here the following is provided as guidance only A critical trained eye is required and inspections should include but not be limited to the...

Page 49: ...gine Maintenance Manual Magneto drop Also refer to Engine Maintenance Manual Engine response to changes in power Any unusual engine noises Fuel shut off valve operate engine in ON position and in OFF...

Page 50: ...ation Inspect all fuel Hoses lines fire sleeve fittings Check for hardening cracking leakage and any other signs of deterioration Ensure that fire sleeves are long enough to completely cover all flexi...

Page 51: ...ird drain is located under the fuselage This drain may be under the passenger seat just aft of the main undercarriage or just aft of the sound curtain the rear of the cabin depending on the model and...

Page 52: ...nsure there is no excess vertical or horizontal slop in the fit of the leg to the housing Inspect the main gear struts clamps bolts nuts Check for rubbing cracks corrosion missing or damaged hardware...

Page 53: ...pect seatbelts shoulder harnesses for condition Ensure all latches function correctly and do not have excess slop Check joint pin between shoulder and lap belts and ensure it is secure and the connect...

Page 54: ...unds uneven or jerky Inspect elevator control linkages Ensure all hardware is secure and in good condition Inspect rudder pedals linkages Ensure all hardware is secure and in good condition Inspect ex...

Page 55: ...e can cause significant 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 remove...

Page 56: ...ains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued By AS Page 56 of 298 NOTE The CG datum point for the J120 C is an...

Page 57: ...e trailing edge of each control allowed by cable free play Disconnect both ends of the cable Move the cable by hand through its full range of movement to check freedom of movement Using a spring balan...

Page 58: ...rcraft requires adjustment Jabiru Aircraft or our local representative must be consulted for an appropriate rectification method In Figure 17 several terms are defined This is provided to clarify the...

Page 59: ...s of the results of Inspection A Check the clearance between the control surface and the aircraft at the point of overlap as detailed below Set the controls so that the control being tested is at the...

Page 60: ...lap The control clearance changes by 5mm or more when the test load of Inspection B is applied This is irrespective of if the control has a point of overlap or not Carry on to Inspection C in all case...

Page 61: ...l as detailed below Inspect the control for scratches and marks as shown in Figure 22 in the overlap area where the control runs inside the aircraft If no marks are found further inspection and or rec...

Page 62: ...ough its normal travel range while pushing against each hinge in the direction that would close the control clearance with a force of approximately 5 7kg 11 15lb Note if there is any travel restrictio...

Page 63: ...raft or if adverse tyre wear indicates alignment outside of tolerance Before alignment the aircraft must be pulled forwards for several metres to position it in the location where the wheel alignment...

Page 64: ...wheels Positions are marked at 1 5m nominally either side of the wheel centre Take measurements from the straight edge positions to the centreline of the fuselage Compare the measured distances to se...

Page 65: ...e if the aircraft is normally loaded heavily a slightly higher camber angle may be used Toe in for the main wheels is set at between 10mm and 0 mm This is for an empty aircraft If adjustments are requ...

Page 66: ...he wing tanks and the header tank Before starting the fuel gauge calibration the aircraft needs to be laterally left right level See the aircraft flight manual for the levelling datum details Add 1 5L...

Page 67: ...biru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued By AS Page 67 of 298 Figure 27 Max Empty Left and Acceptable Empty Right Indica...

Page 68: ...ccuracy of the fuel indication system of the aircraft depends on careful and accurate completion of this process Each fuel gauge indicator on the instrument panel or in the EMS needs to be connected t...

Page 69: ...tanks or to the header tank Use fuel line clamps as shown in Figure 31 Figure 31 Fuel Line Clamps all J Series n a J120 Before starting the fuel gauge calibration the aircraft must be laterally left...

Page 70: ...of entering them into the EMS so it is not required Repeat this procedure for the other fuel tank CAUTION There is often a degree of friction within the gauge sender Tap gently with a finger after ad...

Page 71: ...ng attachment To determine which connection requires attention Remove the wing root fairing from the aircraft to expose the attachments between the wing and the fuselage Have an assistant shake the wi...

Page 72: ...bolt and the lugs may be corrected by replacing these bolts with new AN174 1 4 or AN175 5 16 close tolerance bolts Similarly strut connections normally use AN5 bolts and excess movement between the b...

Page 73: ...below is recommended before replacing fuselage lugs Either remove the wing from the aircraft completely or place on stands as detailed above Remove any upholstery covering the plates inside the cabin...

Page 74: ...cured re fit the upholstery Re assemble the aircraft and test to ensure the free play has been removed Ensure a new bolt is used on the attachment which has been serviced Figure 35 Bond Details all J...

Page 75: ...aft or mount it on stands as detailed above If the bush is an eccentric type where the hole for the bolt is not in the centre of the bush make a note of the orientation of the original part Use a larg...

Page 76: ...ply any load to the bush until it has cured Do Not use rapid set i e 5 miniute epoxy 6 Structures all J Series A description of and instructions for the maintenance repair and alteration of the aircra...

Page 77: ...t be maintained in excellent condition Cracks up to 25 mm in length should be stop drilled those longer than 25 mm should NOT be repaired the windshield must be replaced 6 2 2 Cleaning Refer to Sectio...

Page 78: ...creen for fit File or grind away any excess material to ensure a close fit Do not attempt to cut with any type of saw Wet the window frame joggle with raw epoxy resin Apply a bead of Epoxy Flock aroun...

Page 79: ...security Carefully inspect the leg for cracking or other damage Brakes check for bent discs loose or damaged hardware Check security of brake lines i e they are strapped to the undercarriage leg and a...

Page 80: ...ng the machined screws that attach the hinges to the door frame Refer to Figure 37 below 6 4 3 Adjustment Cabin doors should be adjusted so that the door skin fairs with the fuselage skin 6 4 4 Door S...

Page 81: ...s document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued By AS Page 81 of 298 Figure...

Page 82: ...50 Variants This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued By AS Page 82...

Page 83: ...nt is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued By AS Page 83 of 298 Figure 41 J160...

Page 84: ...ation L1 L2 or LAME Owner A P or LSA Repairman Maintenance Return to Service L1 L2 or LAME Owner A P or LSA Repairman Maintenance 6 6 1 Description J200 Type cabin doors are those which use the door h...

Page 85: ...d condition and fit at all times New weather strip may be applied after mating surfaces of weather strip and door are clean dry and free from oil and grease 6 7 J200 Type Cabin Door Latches J200 J400...

Page 86: ...0 Variants This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued By AS Page 86...

Page 87: ...ce 6 8 1 Description The JABIRU seats are an integral part of the structure of the aircraft they are therefore fixed in position Forward and upward adjustment can be achieved by placing a cushion behi...

Page 88: ...ib of the fuselage using velcro straps Its purpose is to minimise drumming of the fuselage as well as restricting material falling aft of the curtain and resulting in a severe aft centre of gravity co...

Page 89: ...0 knots CAUTION Always ensure that the correct part is specified when ordering parts Provide Jabiru with as much information about the aircraft model S No etc as possible 6 13 J120 Wings J120 6 13 1 D...

Page 90: ...lower wing strut bolt and remove wing strut 15 Repeat Steps above to remove other wing 6 13 3 Repair All repairs must be referred to Jabiru Aircraft Pty Ltd or our approved local agent 6 13 4 Installa...

Page 91: ...vice L1 L2 or LAME Owner A P or LSA Repairman Maintenance Wing removal is most easily achieved if two persons are available to handle the wing 1 Remove wing root fairings 2 Drain Fuel out of Quick Dra...

Page 92: ...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...

Page 93: ...0 Variants This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued By AS Page 93...

Page 94: ...Variants This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued By AS Page 94 of...

Page 95: ...wing attachments 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...

Page 96: ...the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued By AS Page 96 of 298 6 15 3 Repair All repairs must be referred to Jabiru...

Page 97: ...0 Variants This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued By AS Page 97...

Page 98: ...48 Figure 49 for earlier aircraft and Figure 50 Figure 51 Figure 52 for later variants 6 16 2 Removal Refer to Section 6 14 for removal details 6 16 3 Repair All repairs must be referred to Jabiru Ai...

Page 99: ...ants This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued By AS Page 99 of 298...

Page 100: ...nd to the wing skins The Wing End Plug distributes load from the attachments to the main spar Both attachments are through stainless steel threaded bushes bonded into the attachment blocks The wing in...

Page 101: ...while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued By AS Page 101 of 298 6 18 4 Installation Refer to S...

Page 102: ...rt of the wing load to the lower portion of the fuselage The strut consists of a streamlined tube bolted to two end fittings which attach to the fuselage and wing WARNING Do Not Tighten Strut Attachme...

Page 103: ...g from the strut then disconnect the light wires Remove light mounting screws to allow removal of the light from the housing Visually inspect the light housing for cracks or damage Check the strut for...

Page 104: ...out in a dark hangar or outdoor at night Turn the lights on and mark a distance 15 meters away from the wing Aim the lights at the focal points given in Figure 62 Lock the position of the lamp by tigh...

Page 105: ...riants This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued By AS Page 105 of...

Page 106: ...h allows the measurement of the angle of attack of the aircraft in flight CAUTION This probe incorporates water drain holes for flying in rain and must be removed before leak testing the pitot system...

Page 107: ...utboard aileron clamp In some models this window is a simple rectangular piece of clear acrylic screwed to the wing using machine screws and anchor nuts Later variants use a machined acrylic sheet wit...

Page 108: ...ar to the rudder 6 24 1 Removal Installation Inspection 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 o...

Page 109: ...the removal of the main undercarriage is necessary adopt the following procedure 1 Manufacture a wing stand A wing stand is a simple structure standing around 180cm high a frame of 90 x 45 DAR Pine a...

Page 110: ...reamlined covers reduce the drag of the undercarriage and significantly improve the efficiency of the aircraft 6 28 2 Removal And Installation Required Tools Screwdrivers Spanners Socket wrench Parts...

Page 111: ...leg and the fuselage These smooth the airflow in this area and significantly improve the efficiency of the aircraft 6 29 2 Removal And Installation Required Tools Screwdrivers Parts and Material N A...

Page 112: ...above 2 Remove the upper leg fuselage fairing and the wheel spat if equipped as detailed above 3 Remove outboard brake pad plates 4 Remove lock bolt nut through the axle extension 5 Remove axle exten...

Page 113: ...ate value specified in Table 7 CAUTION Ensure tube is not pinched between wheel halves during assembly Uneven or improper torque of through bolt nuts can cause failure of bolts with resultant wheel fa...

Page 114: ...J450 Variants This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued By AS Page...

Page 115: ...Zip ties Type of Maintenance Line Maintenance Level of Certification L2 or LAME A P or LSA Repairman Maintenance Return to Service L2 or LAME A P or LSA Repairman Maintenance 1 Remove wheel spat in a...

Page 116: ...ed composite spring forms the leg which is bolted to the fuselage at one end and the main wheels at the other 6 33 2 Removal Required Tools Tools as required in Section 6 28 and Section 6 27 Parts and...

Page 117: ...s cured around 24 hours possibly more in cold climates fully tighten the outboard clamp bolts Torque to solid laminate value give in Table 2 8 Note straight legs are handed ensure the legs are install...

Page 118: ...the composite undercarriage beams must be referred to JABIRU AIRCRAFT Pty Ltd or our local approved agent 6 34 Trouble Shooting Main Undercarriage all J Series Table 0 1 Trouble Shooting Main Underca...

Page 119: ...aircraft In some cases the nose wheel spat is complimented by a nose leg fairing which covers the nose leg and rubber spring assembly 6 35 2 Removal Installation Required Tools Screwdrivers Spanners S...

Page 120: ...L1 L2 or LAME Owner A P or LSA Repairman Maintenance Return to Service L1 L2 or LAME Owner A P or LSA Repairman Maintenance 1 Weight or tie down tail of aircraft to raise the nose wheel off the floor...

Page 121: ...im lubricant Type of Maintenance Line Maintenance Level of Certification L2 or LAME A P or LSA Repairman Maintenance Return to Service L2 or LAME A P or LSA Repairman Maintenance 1 Replace bearings in...

Page 122: ...Series 6 37 1 Description For all models the nose wheel steering system consists pushrods directly connecting the rudder pedals to the nose leg assembly The systems are shown in Section 0 For some mod...

Page 123: ...ment is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued By AS Page 123 of 298 Figure 74 No...

Page 124: ...bolts and hardware if required Type of Maintenance Line Maintenance Level of Certification L2 or LAME Owner A P or LSA Repairman Maintenance Return to Service L2 or LAME Owner A P or LSA Repairman Mai...

Page 125: ...LSA Repairman Maintenance Return to Service L2 or LAME A P or LSA Repairman Maintenance To replace the Ertalyte bush es 1 This task can be done with the housing mounted on the fuselage removal is not...

Page 126: ...isassemble the nose leg spring assembly i e to replace the rubber spring or pivot bushes 1 The following requires a heavy workbench fitted with a strong vice and thick soft jaws 2 Remove the leg assem...

Page 127: ...ctober 2014 Issued By AS Page 127 of 298 Figure 76 Nose Leg Housing Assembly all J Series 6 39 Trouble Shooting Nose Leg all J Series Table 0 2 Trouble shooting Nose Leg Trouble Probable Cause Remedy...

Page 128: ...230 J430 J250 J450 Variants This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issu...

Page 129: ...iants This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued By AS Page 129 of 2...

Page 130: ...assembled by removing the assembly cap screws Note that strong thread retaining compound is used on the cap screws holding the housing together To remove it may be necessary to heat the part to about...

Page 131: ...nium parts using a UNC tap Use compressed air or similar to blow out all blind holes to remove all debris If re using hardware thoroughly clean cap screw threads using a wire wheel or similar to remov...

Page 132: ...to remove the cylinder from the bracket in situ it is much more difficult due to the limited access It is generally faster to drill the rivets the replace them during re installation 3 Place a rag un...

Page 133: ...ce this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued By AS Page 133 of 298 6 41 4 Brake Master Cylinder Repair Repair is limited to installation o...

Page 134: ...ce Return to Service L2 or LAME A P or LSA Repairman Maintenance 6 42 1 Description Jabiru Aircraft use flexible black nylon brake hoses On most models they are connected to the master cylinder via a...

Page 135: ...ntenance Return to Service L1 L2 or LAME Owner A P or LSA Repairman Maintenance 1 Clean all parts except brake linings in dry cleaning solvent and dry thoroughly 2 New piston sealing O Rings should be...

Page 136: ...e pad on a table with lining side down flat Centre a 1 8 or slightly smaller punch on the rolled rivet and hit the punch sharply with a hammer alternatively the rivet may be drilled however take care...

Page 137: ...s normal 5 When air is fully expelled tighten bleed nipples check fittings for leaks 6 Repeat steps 1 4 for other side brake WARNING Use only automotive brake fluid DO NOT use aircraft hydraulic fluid...

Page 138: ...brake disc is below minimum thickness install a new part For directional brake discs refer to Figure 70 for installation details 6 49 Trouble Shooting Brakes Table 0 3 Trouble Shooting Brakes Trouble...

Page 139: ...ontrolled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued By AS Page 139 of 298 Figure 84 Dual Callip...

Page 140: ...230 J430 J250 J450 Variants This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issu...

Page 141: ...d in Jabiru Aircraft is shown in drawings below Figure 87 and Figure 88 The aileron control system is comprised of a control column and two enclosed push pull cables fitted with spherical bearings Due...

Page 142: ...0 J450 Variants This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued By AS Pag...

Page 143: ...ice L1 L2 or LAME Owner A P or LSA Repairman Maintenance 1 If required unbolt remove the control stick from the pivot plate 2 Unbolt and remove the aileron cable ends from the aileron drive arms at th...

Page 144: ...J200 J400 J230 J430 J250 J450 Variants This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th Octob...

Page 145: ...0 J250 J450 Variants This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued By A...

Page 146: ...r Required Tools Those as required in Section 5 17 Parts and Material Those as required in Section 5 17 Type of Maintenance Line Maintenance Level of Certification L2 or LAME A P or LSA Repairman Main...

Page 147: ...trolled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued By AS Page 147 of 298 Figure 93 Clamp Compari...

Page 148: ...148 of 298 Figure 94 Clamp Comparison Installation Rudder Cable all J Series Figure 95 Clamp Installations Elevator Aileron all J Series Figure 96 Trim Cable Clamp Installation all J Series Primary Co...

Page 149: ...erial Replacement control cables and clamps Type of Maintenance Line Maintenance Level of Certification L2 or LAME A P or LSA Repairman Maintenance Return to Service L2 or LAME A P or LSA Repairman Ma...

Page 150: ...etely remove these parts 3 Remove hinge pins 4 Remove aileron WARNING All spherical bearings must be fitted with a large washer on the outside of the through bolt to prevent the bearing case and cable...

Page 151: ...4 Aileron Rigging all J Series Required Tools Straight edged timber or steel length 1m length Spanners Socket Wrench Screwdrivers Parts and Material N A Type of Maintenance Line Maintenance Level of C...

Page 152: ...170 J200 J400 J230 J430 J250 J450 Variants This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th Oc...

Page 153: ...0 J430 J250 J450 Variants This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued...

Page 154: ...inside the cabin driving the flaps via pushrod however in these aircraft a manual lever located above the pilot s door drives the system Refer to sections below for details on removal maintenance and...

Page 155: ...is document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued By AS Page 155 of 298 Figur...

Page 156: ...heavy duty tape or similar to both wing flaps holding them up Remove the cotter pin and nut from the lever Remove the lever from the mount plate Remove the screw holding the drive shaft to the handle...

Page 157: ...damage to the flaps wings or fuselage may result 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 158: ...longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued By AS Page 158 of 298 Figure 105 Linear Actuator Disassembled all J Series Figure 106 Commutator Ring Cl...

Page 159: ...6 57 4 Installation Required Tools Spanners Socket Wrench Screw drivers Parts and Material N A Type of Maintenance Line Maintenance Level of Certification L2 or LAME A P or LSA Repairman Maintenance...

Page 160: ...J430 J250 J450 Variants This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued B...

Page 161: ...his document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued By AS Page 161 of 298 Figu...

Page 162: ...ontrolled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued By AS Page 162 of 298 Figure 111 Flap Contr...

Page 163: ...turn this shaft is an assembly of 2 different sized steel tubes with input and output arms attached 6 58 2 Flap Cross Shaft Removal Required Tools Tools as required in Section 0 Parts and Material He...

Page 164: ...ion Repair Required Tools N A Parts and Material Replacement parts as needed Type of Maintenance Line Maintenance Level of Certification L2 or LAME A P or LSA Repairman Maintenance Return to Service L...

Page 165: ...ocument is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued By AS Page 165 of 298 Figure 11...

Page 166: ...us the manual handle which also acts as the position indicator for manual flap variants Both indicators consist of a cable driven indicator which moves inside a housing Indicators are mounted to the w...

Page 167: ...L2 or LAME Owner A P or LSA Repairman Maintenance Return to Service L1 L2 or LAME Owner A P or LSA Repairman Maintenance Repair of the position indicator is limited to replacing worn or damaged parts...

Page 168: ...ts This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued By AS Page 168 of 298...

Page 169: ...ge washer on the outside of the through bolt to prevent the bearing case and cable releasing in the event of a bearing failure 6 61 Flap all J Series 6 61 1 Description The flaps comprise a moulded an...

Page 170: ...ing a special template P No 8206Q5N 6 62 Flap RIGGING As Per Template J170 SP Required Tools Rigging template Straight edged timber or steel length 1m length Spanners Socket Wrench Parts and Material...

Page 171: ...trol system is comprised of a control column and one enclosed push pull cable fitted with rod ends at both ends Due to space constraints not all different variations are shown herein When ordering spa...

Page 172: ...ment is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued By AS Page 172 of 298 Figure 122 E...

Page 173: ...e J160 This elevator is driven by the same control assembly as the J160 6 65 2 Removal Installation Required Tools Screwdrivers Spanners Socket Wrench Parts and Material N A Type of Maintenance Line M...

Page 174: ...of delamination or cracking Pay particular attention to the Control Horn and hinges and their surrounding areas Inspect the front underside of the elevator for any signs of rubbing against the horizon...

Page 175: ...ed while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued By AS Page 175 of 298 Figure 125 Horizontal Tail E...

Page 176: ...strain the cables in the aircraft 9 Tie a string or light wire to one end of the cable 10 Draw the cable out of the aircraft leaving the string wire in place to allow installation of a replacement par...

Page 177: ...lates Making sure both the control column and the elevator trim is hard back Adjust the female ball ends in or out if adjustment is needed 5 To establish the neutral position align balance horn with h...

Page 178: ...vot shaft Remove the machine screw attaching the control cable to the lever Remove the assembly from the centre console For a type 2 assembly Remove the cotter pin and lock nut from the lever pivot Re...

Page 179: ...J450 Variants This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued By AS Page...

Page 180: ...h this lubron block and is centred by 2 compression springs The output end of the rod is connected to the Elevator Horn This assembly allows a spring loaded connection between the elevator trim lever...

Page 181: ...ot arm and remove Un bolt the pivot assembly from the fibreglass tail horn and remove from the aircraft 6 69 4 Inspection Repair Required Tools Spanners Socket Wrench Parts and Material Graphite lubri...

Page 182: ...e must be clamped firmly at each end 6 70 2 Control Cable Removal Required Tools Spanners Socket Wrench Side cutters or similar to remove ties String or light wire Parts and Material Replacement Cable...

Page 183: ...ated 29th October 2014 Issued By AS Page 183 of 298 6 70 3 Control Cable Inspection The Control Cable may not be repaired or removed without reference to Jabiru Aircraft Pty Ltd or our approved local...

Page 184: ...he nose leg to control nose wheel steering in addition to the rudder control surface The system is comprised of rudder pedals two push rods a centring mechanism and an enclosed push pull cable Optiona...

Page 185: ...Wrench Parts and Material Replacement parts if required Type of Maintenance Line Maintenance Level of Certification L1 L2 or LAME Owner A P or LSA Repairman Maintenance Return to Service L1 L2 or LAME...

Page 186: ...00 J230 J430 J250 J450 Variants This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014...

Page 187: ...d directly to the nose leg This gives both nose wheel steering and the mechanism connecting the left and right pedals The drawings shown in Figure 136 through to Figure 140 show several variations of...

Page 188: ...aintenance Line Maintenance Level of Certification L1 L2 or LAME Owner A P or LSA Repairman Maintenance Return to Service L1 L2 or LAME Owner A P or LSA Repairman Maintenance Ensure lock nuts are secu...

Page 189: ...iants This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued By AS Page 189 of 2...

Page 190: ...This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued By AS Page 190 of 298 Fi...

Page 191: ...r horn 2 Loosen screws in hinge pin retainers lift retainer from hinge pin It is not necessary to remove these parts 3 Remove hinge pins 4 Remove rudder 5 Reverse the preceding steps for installation...

Page 192: ...cument is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued By AS Page 192 of 298 Figure 141...

Page 193: ...to one end of the cable 5 Draw the cable out of the aircraft leaving the string wire in place to allow installation of a replacement part 6 74 3 Control Cable Inspection Required Tools N A Parts and M...

Page 194: ...given below Weight 2100g 100g Hinge Moment 17500g mm 4000g mm 6 76 Rigging all J Series Required Tools Spanners Socket Wrench Marker Parts and Material Type of Maintenance Line Maintenance Level of Ce...

Page 195: ...wdrivers Parts and Material N A Type of Maintenance Line Maintenance Level of Certification L1 L2 or LAME Owner A P or LSA Repairman Maintenance Return to Service L1 L2 or LAME Owner A P or LSA Repair...

Page 196: ...of Certification L1 L2 or LAME Owner A P or LSA Repairman Maintenance Return to Service L1 L2 or LAME Owner A P or LSA Repairman Maintenance 1 Wipe the inner surfaces of the cowlings with a cloth satu...

Page 197: ...Variants This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued By AS Page 197...

Page 198: ...anual 7 2 5 Engine Cleaning Refer to Section 4 1 the Engine Maintenance Manual 7 2 6 Engine Accessories Jabiru engines may be fitted with an accessory vacuum pump mounted to a pad at the rear of the e...

Page 199: ...to the hose barb This makes it impossible in most cases to remove these hoses without cutting them 7 3 3 Inspection Required Tools Screwdrivers Parts and Material Replacement hoses if required Lockwi...

Page 200: ...er and to other engine components to provide optimum engine cooling The baffles air inlets and outlets and air scoops are accurately positioned to maintain engine cooling efficiency and their removal...

Page 201: ...ndition 7 4 4 Repair Required Tools Allen key 80 grit sandpaper Parts and Material 5 minute araldite Replacement rubber seals if required Type of Maintenance Line Maintenance Level of Certification L1...

Page 202: ...rrectly marked on removal and correctly replaced on reassembly 7 5 2 Engine mount removal Required Tools Tools as required for engine removal see Engine Maintenance Manual Side cutters or similar Scre...

Page 203: ...engine mounts should not be repaired If damaged replace with a new part 7 5 4 Installation Required Tools Torque wrench Spanners Socket Wrench Parts and Material N A Type of Maintenance Heavy Maintena...

Page 204: ...shaft clamp blocks Disassemble and remove the throttle shaft from inside the instrument panel If required undo the fasteners and remove the input and output arms from the throttle shaft Note that pai...

Page 205: ...throttle to give full throttle and correct idle speed Details for procedures can be found in the Engine Maintenance Manual Adjust friction of shaft clamps to ensure throttle does not move from a set...

Page 206: ...iants This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued By AS Page 206 of 2...

Page 207: ...proof putty Type of Maintenance Line Maintenance Level of Certification L1 L2 or LAME Owner A P or LSA Repairman Maintenance Return to Service L1 L2 or LAME Owner A P or LSA Repairman Maintenance Disc...

Page 208: ...Carburettor Heat Control on the panel OUT This opens the hot air valve in the mixer assembly and permits hot air to flow from the muff into the carburettor 7 9 2 Removal Inspection Installation Requir...

Page 209: ...ditions and to make sure they are clean and dry inside Ensure that the carburettor heat valve is operating correctly SCAT hoses must be inspected for condition and replaced if they are ripped etc Visu...

Page 210: ...The muffler is attached to the extractors manifolds using springs Note that the majority of exhaust maintenance is detailed in the Engine Maintenance Manuals 7 10 2 Exhaust System Removal Required To...

Page 211: ...ing outwards Especially check areas adjacent to welds Look for exhaust gas deposits in surrounding areas indicating that exhaust gas is escaping through a hole or crack For a more thorough inspection...

Page 212: ...This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued By AS Page 212 of 298 Fi...

Page 213: ...stalled on the exhaust tailpipe through a control valve and into the cabin WARNING A malfunctioning cabin heat system has potential to release harmful gases such as carbon monoxide into the cabin Airc...

Page 214: ...acement parts if required Type of Maintenance Line Maintenance Level of Certification L2 or LAME A P or LSA Repairman Maintenance Return to Service L2 or LAME A P or LSA Repairman Maintenance Check fo...

Page 215: ...matic Conditions all J Series 7 12 1 Dust Dust induced into the carburettor air intake system is probably the greatest single cause of early engine wear When operating under high dust conditions the c...

Page 216: ...50 Variants This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued By AS Page 21...

Page 217: ...nt is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued By AS Page 217 of 298 Figure 160 220...

Page 218: ...250 J450 Variants This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued By AS P...

Page 219: ...ss housing fitted between the centre console and the firewall inside the cabin The main fuel tanks are structural and are integral parts of the wings A header tank is fitted The tank may be located un...

Page 220: ...Variants This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued By AS Page 220 o...

Page 221: ...document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued By AS Page 221 of 298 Figure...

Page 222: ...l System Trouble Probable Cause Remedy No fuel to carburettor Fuel shut off valve not turned ON Turn valve ON Fuel tank empty Service with proper grade and amount of fuel Fuel line disconnected or bro...

Page 223: ...he hose tails due to lack of access hard tight lines etc Care must be taken that sufficient spare line remains to re connect for assembly alternately a new line must be fitted 8 2 3 Inspection Require...

Page 224: ...hen re routing lines to avoid bending the hose around too sharp a corner the flexible hose used can crimp itself off if bent too sharply If a sharp bend is unavoidable a spring may be threaded over th...

Page 225: ...vel of Certification L2 or LAME A P or LSA Repairman Maintenance Return to Service L2 or LAME A P or LSA Repairman Maintenance As the wing fuel tanks are part of the wing integrity these fuel tanks ca...

Page 226: ...8 3 3 Fuel Tank Inspection Required Tools N A Parts and Material N A Type of Maintenance Line Maintenance Level of Certification L2 or LAME A P or LSA Repairman Maintenance Return to Service L2 or LA...

Page 227: ...s controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued By AS Page 227 of 298 Figure 173 Header...

Page 228: ...ure and even feeding from all tanks For aircraft with a single fuel tank fitted behind the crew seats a single vent line is fitted to the underside of the fuselage 8 4 2 Inspections Required Tools Rub...

Page 229: ...positioned at carburettor height during this test Correct any blockage reassemble To check the operation of the filler cap fuel vent check valve where equipped Remove the cap and shake it The ball in...

Page 230: ...enance Where equipped turn OFF both taps between wing tanks and header tank Cover both tank cap vents Alternately removable fuel line clamps may be used Remove fuel shut off valve cover where equipped...

Page 231: ...P or LSA Repairman Maintenance For wing root sight gauges Remove the fairings from between the wings and the fuselage Disconnect the fuel lines running between the wing tanks and the sigh gauges It i...

Page 232: ...is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued By AS Page 232 of 298 Figure 177 Fuel...

Page 233: ...J230 J430 J250 J450 Variants This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Is...

Page 234: ...urned off or that the fuel system wing tanks and header tanks be drained where equipped Alternatively fuel line clamps Figure 31 may be used to close the fuel lines so that the filter can be changed w...

Page 235: ...e cabin Disconnect the pumps electrical connections Place a cloth beneath the pump to collect any fuel which may be split during removal of the filter Disconnect the fuel lines at both ends of the pum...

Page 236: ...ng the composite scimitar propellers 4A482U0D or 4A484E0D must maintain their propeller in accordance with the propeller technical manual JPM0001 9 2 Approved Installations all J Series The following...

Page 237: ...D Jabiru J230 D Jabiru 3300 4662084 Family 1524 x 1321 60 x 52 Not Above 3300 RPM Table 9 3 Approved Scimitar Propeller Installations Kit built Models Propeller Airframe Engine Propeller Flange Dia x...

Page 238: ...nts and limitations applicable to the appropriate registration WARNING ENSURE IGNITION SYSTEM IS OFF BEFORE COMMENCING ANY WORK ON PROPELLER DO NOT RUN ENGINE WITH PROPELLER DISCONNECTED OR ENGINE DAM...

Page 239: ...J400 J230 J430 J250 J450 Variants This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 20...

Page 240: ...0 J430 J250 J450 Variants This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued...

Page 241: ...that each 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 Tol...

Page 242: ...Epoxy paint JABIRU Part No PP0069N 7 Rebalance Propeller see below 8 Reassemble and replace Propeller and Spinner see above 9 Check Propeller tracking and Spinner balance see above 10 Damaged urethane...

Page 243: ...nly in the sense of physical replacement in the aircraft Whether replacement is to be with a new instrument an exchange one or an original instrument is to be repaired must be decided on the basis of...

Page 244: ...emoving fascia it is common for some wires connecting to switches on the bottom of the panel to be dislodged Ensure all wires are securely re connected before fitting fascia Take care not to strain be...

Page 245: ...ts This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued By AS Page 245 of 298...

Page 246: ...l Installation Required Tools Tools as required in Section 7 1 2 and Section 11 2 2 Parts and Material N A Type of Maintenance Line Maintenance Level of Certification L2 or LAME A P or LSA Repairman M...

Page 247: ...structions for removal and installation procedures In all cases when an instrument is removed disconnected lines or wires should be protected Cap open lines and cover pressure connections on instrumen...

Page 248: ...J200 J400 J230 J430 J250 J450 Variants This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th Octobe...

Page 249: ...the trap assembly shown below or of a low point where the tube is deliberately 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...

Page 250: ...s This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued By AS Page 250 of 298 F...

Page 251: ...icates a 1000 foot increase in altitude CAUTION When applying or releasing suction do not exceed the range of either the vertical speed indicator or the airspeed indicator Cut off suction source to ma...

Page 252: ...ic tubing over pitot tube close opposite end of tubing and slowly roll up tube until airspeed indicator registers in the cruise range Secure tube and after a few minutes recheck airspeed indicator Any...

Page 253: ...ust be cut into the fin Consult Jabiru Aircraft or our local approved representative before making access holes In all cases installation of tubing will be simplified if a guide wire is drawn in as th...

Page 254: ...phragm Substitute known good indicator and check reading Replace instrument Hand vibrates Excessive vibration Check panel shock mounts Replace defective shock mounts Excessive tubing vibration Check c...

Page 255: ...ge connections for security Repair or replace damaged line tighten connections Incorrect indication Partially plugged static line Check line for obstructions Blow out lines Ruptured diaphragm Substitu...

Page 256: ...ay be equipped with an alternate static source This system is for Night VFR aircraft so that should the primary static source become blocked the pilot may switch to an alternate supply In the Jabiru t...

Page 257: ...panel and remove Disconnect static system tubes For installation reverse removal steps listed above Figure 192 Alternate Static Source Assy all J Series 11 7 Analogue Tachometer all J Series 11 7 1 De...

Page 258: ...t 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 11 5 Trouble Shooting Tachome...

Page 259: ...ed while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued By AS Page 259 of 298 Figure 193 Hall Effect Senso...

Page 260: ...exhaust side spark plug of the hottest cylinder of the engine 11 8 2 Gauge Removal Installation Required Tools Tools as required in Section 11 2 2 Screwdrivers Parts and Material N A Type of Maintenan...

Page 261: ...s and Material N A Type of Maintenance Line Maintenance Level of Certification L2 or LAME A P or LSA Repairman Maintenance Return to Service L2 or LAME A P or LSA Repairman Maintenance Remove the inst...

Page 262: ...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 and correct...

Page 263: ...l power system failure An engine driven Alternator is the normal source of power during flight and maintains a battery charge controlled by a voltage regulator Depending on the aircraft model a 120 Wa...

Page 264: ...J400 J230 J430 J250 J450 Variants This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 20...

Page 265: ...Variants This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued By AS Page 265 o...

Page 266: ...ng a key switch the Master Switch activates a relay which in turn powers the bus bars When using a toggle switch it activates the power direct from the battery Refer to Wiring Diagram for details 12 2...

Page 267: ...circuit breaker for this plug is rated a 5 Amps 12 3 Battery System all J Series 12 3 1 Description The battery is 12 volts and approximately 16 ampere hour capacity The battery is mounted in the engi...

Page 268: ...junction with a CAR 35 Authorised Person or equivalent Engineering Order Note that this applies in Australia in other countries the local Airworthiness Authority must be consulted for procedures 12 4...

Page 269: ...ants This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued By AS Page 269 of 29...

Page 270: ...uired in Section 11 2 2 Screwdrivers Parts and Material N A Type of Maintenance Line Maintenance Level of Certification L2 or LAME A P or LSA Repairman Maintenance Return to Service L2 or LAME A P or...

Page 271: ...riants This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued By AS Page 271 of...

Page 272: ...ority of repair instructions are either replacement of new components in the case of removable parts such as control cables wheel and brake assemblies and engine mount OR the repair instruction is a s...

Page 273: ...previous painting experience a short course may be available from TAFE NOTE It is very easy to dramatically increase the weight of the aircraft with a heavy paint job Care must be taken to use the abs...

Page 274: ...primer is required only on the discoloured areas i e Body Filled areas Pin holes become evident after the primer is applied so use spot putty to fill Be careful and meticulous to find all pin holes b...

Page 275: ...iling Warning Placard J160 use for both J160 C and J160 D P No 5A016A0D Fitted on the rear Face of the Forward Wing Spar Carry through Beam in the Cabin Ceiling Warning Placard J170 C P No 5A069A0D Fi...

Page 276: ...arning Placard J160 P No 5A011A0D Fitted above windscreen in front of wing carry through beam across to the left side Warning Placard J170 P No 5A015A0D Fitted above windscreen in front of wing carry...

Page 277: ...eel spat Main Wheel Inflation J160 C J160 D J120 C P No 5A018A0D 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...

Page 278: ...ading Limitations 500kg P No 5118024 J120 Family Fit to inside of fuselage on right side just below rear quarter window Loading Limitations 540kg P No 5098854 J160 Family Fitted on inside of fuselage...

Page 279: ...rim control Brake On P No 5A031B0D Fit to centre console beside brake lever arrow pointing aft Carby Heat P No 5A030A0D Fitted to lower central section of instrument panel Earth on Post P No 5A066A0D...

Page 280: ...No 5A037A0D Fit to right side of fuselage between window and beam No Smoking P No 5A035A0D Fit to instrument panel Fuel Contents P No 5A022A0D Where Equipped Fitted to sight glasses of wing fuel tanks...

Page 281: ...cent to the fuel valve Choke Cable P No5051094 Where Equipped Fitted at 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 50...

Page 282: ...crews holding fairing to aircraft NOTE some fairings usually the engine cowls or the ventral fin may be fitted with lead ballast Care must be taken when removing fairings containing lead to ensure tha...

Page 283: ...tainer requirements Revise logbook worksheet format Add notes regarding Shock watch indicator AS 08 04 14 4 Include both Australian Maintainer types L1 L2 LAME etc and American Maintainer types Owner...

Page 284: ...ted 29th October 2014 Issued By AS Page 284 of 298 19 Feedback and Reporting Any issues or corrections required of Jabiru publications are requested to be passed on to Jabiru in writing for incorporat...

Page 285: ...proforma may be used Date Aircraft Model Aircraft Registration Aircraft S No Propeller Model Propeller S No Engine Model Engine S No Details of item Name of Reporter Preferred Contact Details of Repor...

Page 286: ...HESE CHARTS WORKSHEETS AIRCRAFT MAKE MODEL REGO S N ENGINE MAKE MODEL S N TT AIRFRAME TT ENGINE INSPECTION TYPE circle 50 hourly 100 hourly Annual 21 1 1 Propeller refer to section 5 8 CARRIED OUT BY...

Page 287: ...Placards Check function check placard placement Fuel tanks Inspect for signs of leakage or damage on tanks and wing root fittings and lines Tank attachments Check correct fitting Fuel shut off valve...

Page 288: ...nks tension links and fairings Inspect for damage Wheel bearings Check for smooth rotation Nose gear strut Check for rubbing cracks missing hardware etc Nose gear housing bushes Inspect for sign of we...

Page 289: ...document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued By AS Page 289 of 298 Aircraf...

Page 290: ...ing degradation etc Seatbelts and shoulder harnesses Check condition and latch functions correctly Seat structure Remove seat covers check for cracks de lamination etc Instruments and markings Inspect...

Page 291: ...ction and condition Antenna cables Check condition Door catches Check condition and function Stall warning Check correctly functions Battery battery cradle cables Check condition Battery electrolyte C...

Page 292: ...Check all hardware and cables ensure good condition and secure Travel stops Check they are correctly adjusted and secure Decal labels Ensure they are in place and in good condition Flap control linkag...

Page 293: ...ontrolled ISSUE 1 2 3 4 5 Dated 29th October 2014 Issued By AS Page 293 of 298 Control horns hinges hinge lock tabs check condition and wear replace as required Rigging check flight Check all system f...

Page 294: ...e components legs brakes wheels etc o Control surface components control surfaces cables linkages etc o Fitting a new or overhauled propeller o Fitting a new or overhauled engine o Fitting new or repa...

Page 295: ...correct range Oil Pressure kPa Oil Temperature o C CHT o C EGT o C o F ASI Tacho Carburettor Heat Tachometer Check correct reading Charging Circuit D C Bus Bar Full Power Vibration Trim range Stall Ch...

Page 296: ...Limitations Jabiru J160 C This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 Dated 29th October 2014 Issued B...

Page 297: ...ed of a Fibreglass Epoxy composite which can be weakened by extreme heat Because of this the outer finish is subject to the following limitations Overall paint colour must be white Registration markin...

Page 298: ...cing 22 5 Mandatory Inspections and Replacements Table 22 2 Mandatory Inspection Times Description Part No Interval Rudder Cable PC01404 1000 hours Elevator Cable PC3A001 1000 hours Aileron Cable 2 PC...

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Jabiru j160, Technical Manual

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