Aircraft Technical Manual
Jabiru Aircraft
Pty Ltd
J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants
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ISSUE
1
2
3
4
5
Dated: 29th October 2014
Issued By: AS
Page: 50 of 298
WARNING
Before starting work on the engine it is recommended that the engine starter be disabled (via
disconnecting the starter solenoid or similar) to reduce the risk of injury from inadvertent engine
start.
It is recommended that the
engine compartment be visually inspected twice: once while “dirty” – i.e.
fresh from operation
– and again after cleaning. The “dirty” inspection allows the inspector to see
patterns of leakage etc which are lost when the engine compartment is cleaned whi
le the “clean”
inspection may show items which were obscured by “dirt” previously. The engine and engine
compartment must be cleaned in accordance with Section 4 as a part of the inspection.
The Carburettor air filter keeps dust and dirt from entering the induction system. The value of
maintaining the air filter in a good, clean condition cannot be overstressed. More engine wear is
caused through the use of a dirty or damaged air filter than is generally believed.
The frequency with which the filter should be removed, inspected and cleaned will depend on the
operating conditions. A good general rule, however, is to remove, inspect and clean the filter ever
100 hours of engine operating time and more frequently if warranted by the operating conditions.
Clean only with compressed air and replace regularly.
Engine baffles and ram-air ducts must be visually inspected. Check for cracking, fraying and
evidence of rubbing. Ensure that the hold-down points are in satisfactory condition and that the ram-
air ducts are securely attached to the engine.
Inspect all sealing rubbers on the ram-air ducts, oil cooler openings etc and repair & replace as
required.
Inspect all oil Hoses, lines, fire-sleeve & fittings. Check for hardening, cracking, leakage and any
other signs of deterioration.
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 flexible
hoses
– i.e. they must extend past the hose clamp to the very tip of the hose.
Check SCAT hose interior and exterior condition.
Ensure that 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 issue
– particular the connections to the regulator and starter solenoid.
Check that all engine controls and linkages work smoothly and through their full travel. A Second
person is required to watch the linkages move on the engine while the first person works the controls
inside the cabin. Ensure all stops are set correctly and that all lock nuts are secure.
Visually inspect the engine mounts, mount structure and mount rubbers for cracking or other signs of
degradation.
Visually inspect the ignition coils and electrical connections. Ensure the coils and electrical
connections are secure.
Verify that the carburettor heat system is functioning correctly
– remove the SCAT hose and verify
that the flap inside the air box is moving correctly and sealing properly.
Visually inspect the firewall. Ensure that all firewall fittings (where equipped) are secure and properly
filled with fireproof putty. Ensure there are no screws or rivets missing and that there are no open
holes through the firewall.
Visually inspect the exhaust system (Including Muffler). Check for the condition of the restraining
springs and spring tabs. Check for cracks, dents or other damage. Particularly check for signs of
leakage.
Inspect the cabin heat system, ensuring that the control valve operates correctly
– sealing at both
positions
– and that the heat exchanger is secure on the tailpipe.
Inspect the engine cowlings, fasteners and clips. Check for cracks, fraying, signs of rubbing and
other damage.
Inspect the battery, battery cradle & cables for condition.
The Battery is a sealed type and so is not a serviceable item. If electrolyte corrosion occurs, Use
bicarbonate of soda (baking soda) and clean water to neutralise electrolyte of corrosion. Follow with
