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Jabiru j160 Technical Manual

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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
This document is controlled while it remains on the Jabiru server. Once this no longer applies
Should you have any questions or doubts about the contents of this manual, please contact
TECHNICAL MANUAL
JABIRU AIRCRAFT MODELS:
J120 Variants
J160 Variants
J170 Variants
J200/J400 Variants
J230/J430 Variants
J250/J450 Variants
DOCUMENT No. JTM001-5
th
DATED: 29
Jabiru's Limited, Express Warranty.
the document becomes uncontrolled.
Jabiru Aircraft Pty Ltd.
FOR
October 2014

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  • Page 1 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...

  • Page 2: Table Of Contents

    SPECIAL INSPECTIONS – MAIN WHEEL ALIGNMENT ....................63 5.19 SPECIAL INSPECTIONS – FUEL GAUGE DECAL SETUP ..................... 66 5.20 This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS...
  • Page 3 6.49 BRAKE DISC WEAR LIMIT ............................138 6.50 TROUBLE SHOOTING - BRAKES ..........................138 This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS...
  • Page 4 PROPELLER SERVICE MANUAL .................. 236 CERTIFIED PROPELLER MODELS ..........................236 APPROVED INSTALLATIONS ............................236 This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS...
  • Page 5 22.4 CONTROL SURFACE BALANCING ..........................297 22.5 MANDATORY INSPECTIONS AND REPLACEMENTS ....................298 This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS Page: 5 of 298...

  • Page 6: Table Of Figures

    Figure 46 – J200-Type Rear Door Assy ........................86 Figure 47 – J200-Type Door Latch Mechanism Assembly ..................87 This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...
  • Page 7 Figure 94 – Clamp Comparison & Installation (Rudder Cable) ................148 Figure 95 – Clamp Installations (Elevator & Aileron) ....................148 This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...
  • Page 8 Figure 142 – Typical Lower Cowl Assy ........................197 Figure 143 – Fuel Hose Assy – Engine Bay ......................200 This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...
  • Page 9 Figure 190 – Hall Effect Sensor Inst. (For Tach with Jabiru Logo on Face) ............259 Figure 191 – Wiring Diagram Sheet 1........................264 This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...
  • Page 10 Figure 199 – Propeller Installation ..........................239 Figure 200 - Typical Scimitar propeller installation ....................240 This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 11: List Of Tables

    Table 27-2 – Mandatory Inspection Times ....................... 298 Table 27-3 – Mandatory Replacement Times ......................298 This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 12: Section 2 - General Information

    It is the owner’s responsibility to become fully aware of the particular maintenance requirements and limitations applicable to the appropriate registration. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...
  • Page 13 However, the final decision on their adoption or otherwise rests with JABIRU AIRCRAFT Pty Ltd. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...
  • Page 14 Jabiru harmless from any injury, loss, damage, or mishap that I, my spouse, heirs, or next of kin may suffer as a result of my use of any Jabiru product, except to the extent due to gross negligence or willful misconduct by Jabiru. I understand that proper skills and training are essential to minimize the unavoidable risks of property damage, serious bodily injury and death that arise from the use of Jabiru products.

  • Page 15: List Of Effective Pages / Issue Status

    For example, searching for the word “life” will allow you to quickly find all reference to lifed maintenance items. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 16: Degree Of Difficulty

    They are equipped with fixed tricycle landing gear of composite construction. The steerable nose gear is a welded metal, trailing link assembly with rubber springs. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 17: Owner Maintenance

    Ensure a minimum of 1 full thread is clear of nuts.  Do not exceed 3 threads clear on nuts (use extra washers). This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 18: Aircraft Structure

     Up-to-date engine manuals are available from the Jabiru Aircraft website; www.jabiru.net.au. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 19: Equipment List

    Cabin Heater Wheels Spats Cargo Restraint Three point personal harness This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS Page: 19 of 298...

  • Page 20: Source Of Purchase Parts

    Owner/Operator COSM (Continued Operating Safety Management) requirements. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 21: Aircraft Specifications

    (at gross weight)  Engine Oil Type Refer Engine Manuals This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS Page: 21 of 298...

  • Page 22: Figure 1 – J120-C General Arrangement

    193 kPa (28 psi) 137 kPa (20 psi) Figure 1 – J120-C General Arrangement This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS...

  • Page 23: Figure 2 – J160 General Arrangement

    193 kPa (28 psi) - Nose Figure 2 – J160 General Arrangement This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS...

  • Page 24: Figure 3 – J170-C & Variants General Arrangement

    137 kPa (20 psi) - Nose Figure 3 – J170-C & Variants General Arrangement This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS...

  • Page 25: Figure 4 – J170-D General Arrangement

    JTM001-5 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 4 – J170-D General Arrangement This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS...

  • Page 26: Figure 5 – J200 / J400 General Arrangement

    207 kPa (30 psi) 207 kPa (30 psi) Figure 5 – J200 / J400 General Arrangement This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 27: Figure 6 – J230 / J430 General Arrangement

    207 kPa (30 psi) - Nose Figure 6 – J230 / J430 General Arrangement This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS...

  • Page 28: Figure 7 – J250 / J450 General Arrangement

    207 kPa (30 psi) 207 kPa (30 psi) Figure 7 – J250 / J450 General Arrangement This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 29: Torque Values (In Fibreglass)

     The above values are not to be used for checking tightness of installed parts during service. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 30: Maintainer Requirements

    Safety wire pliers & 0.032” stainless steel safety wire.  Inspection mirror / Boroscope This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS...

  • Page 31: Equipment

     Scratch-removing compounds such as Novus Plastic Polish for windows. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS...

  • Page 32: Special Tools & Compounds

    A medium-strong threadlock. Typically used for cap screws into castings or Aluminium. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 33: Figure 9 – Optical Tachometer

    3.9.1 Torque / Tension Wrench Figure 12 – Torque Wrench & Crowsfoot Adaptor Setting 1 This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 34: Figure 13 – Torque Wrench & Crowsfoot Adaptor Setting 2

    No Correction Required. Corrected Torque Setting Required Figure 14 – Using A Crowsfoot Adaptor This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS...
  • Page 35 Where directed otherwise it is vital that the directions are followed exactly. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 36: Cleaning, Ground Handling & Storage

    Pay particular attention to wheels and external controls. Always hose down wheels and spats after landings in mud or sand to ensure brakes, wheels and spats are free of dirt build-up. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 37: Ground Handling

    Where equipped, the fuel filler cap vent of the wing which is not being jacked may be blocked using a vent cap. This is to prevent fuel leaking onto the wing while the aircraft is jacked. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...
  • Page 38 Park into the wind and tie down the aircraft as outlined in below if a hangar is not available. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 39: Storage

    Treat as for flyable storage (see Paragraph 3.1.7), plus: For temporary storage, fill fuel tank with AVGAS (to prevent moisture accumulation). This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...
  • Page 40 Install spark plugs – torque to 11 nm (8 ft/lbs). Check fuel filter – replace if necessary. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...
  • Page 41 Check that the fuel tank breathers are clear. Perform a thorough pre-flight inspection. Start and warm engine. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 42: Inspection & Servicing

    Hoses which show visible deterioration (cracking, excessive hardening) must be replaced immediately, irrespective of age. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 43: Figure 15 – Undercarriage

    7 Bolts & nuts in total to be replaced. Figure 15 – Undercarriage (all J-Series) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 44: Inspection Chart

    Engine baffles and air ducts Oil Hoses, lines, fire-sleeve & fittings Fuel Hoses, lines, fire-sleeve & fittings This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...
  • Page 45 Fuel tank vent ball valve check Fuel Tanks Fuel shut-off valve & placards This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS...
  • Page 46 Instrument plumbing & wiring Instrument panel, shock mounts, decals & labels Fresh air ventilation system This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...
  • Page 47 Elevator control & linkages Rudder pedals & linkages Exterior surfaces of control surfaces This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS...

  • Page 48: Servicing

     FILTERS, SCREENS and FLUIDS: Cleanliness, contamination and/or replacement at specified intervals. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS...

  • Page 49: Engine Pre-Inspection Run-Up

    Additional details of engine maintenance are contained in the appropriate engine manual. This manual must be followed in conjunction with the engine manual to ensure a proper inspection. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...
  • Page 50 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 This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 51: Fuel System 100-Hourly

    Check the function of the fuel shut-off valve(s). Ensure that all placards are in place and in good condition. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 52: Landing Gear 100-Hourly

    The JABIRU uses automotive brake fluid (DOT 3 or DOT 4). DO NOT use Aircraft hydraulic fluid (mineral based) or damage to the brake system will result. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 53: Airframe 100-Hourly

    If equipped, ensure that the emergency beacon is within its useful life and test in accordance with manufacturer’s instructions. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 54: Control Systems 100-Hourly

    Aircraft fitted with propellers other than the approved types listed herein as subject to inspections above and beyond those listed below – as detailed in Jabiru Service Bulletin JSB014. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 55: Special Inspections - Weighing

    11. Due to the light weight of the aircraft, the scales used must have an accuracy of at least +/-0.5kg and distances must be measured to within +/-1mm to ensure accurate results. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 56: Figure 16 – Weighing Diagram

    Most CG calculations must be carried out relative to this datum. Figure 16 – Weighing Diagram. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 57: Special Inspections - Control Cables

    Control Free-Play Elevator 3.5-mm Rudder 3.5-mm Aileron 3.5-mm This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS Page: 57 of 298...

  • Page 58: Special Inspections - Control Surfaces

    A gap like this combined with excess flexing of the control surface hinges will lead to control surface jamming. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 59: Figure 17 – Normal And Jammed Control Illustration

     Rectification work is necessary whenever any of the following criteria are met: This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS...

  • Page 60: Figure 18 – Rudder Gap Cross Section

    “Control gap” Figure 19 – Aileron Clearance (all J-Series) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS...

  • Page 61: Figure 20 – Test Load Application

    Note that for the rudder and elevator the fixed stops fitted at the rear of the aircraft are located approx 2mm beyond the normal travel limit. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 62: Figure 22 – Scratches On Rudder

    (illustration) Figure 22 – Scratches on Rudder (all J-Series) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 63: Special Inspections - Main Wheel Alignment

    50mm high from the floor in order to touch enough of the tyre side wall. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 64: Figure 24 – Alignment Straight Edge In Position

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

  • Page 65: Figure 26 – Camber / Toe-In Adjustment

    If the wheel remains outside the given limits the alignment procedure above must be repeated. Figure 26 – Camber / Toe-In Adjustment (all J-Series) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 66: Special Inspections - Fuel Gauge Decal Setup

    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 damaged and return to their original shape This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 67: Figure 27 – Max Empty (Left) And Acceptable Empty (Right) Indications

    Figure 28 - Fuel Gauge Calibration Decal Parts (all J-Series, n/a J120) Figure 29 – 20L Indication on Sender & Decal to Match (all J-Series, n/a J120) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 68: Special Inspections - Fuel Sender Calibration

     Drain the fuel system completely. There are two ways to do this. They are: This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 69: Figure 31 – Fuel Line Clamps

     At the completion of your fuel level calibration, the EMS-D10 will present you with a table of values in the format “pour #: mV gallons/litres”. If you wish, record these numbers for This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 70: Figure 32 – Ems Calibration Screen #1

    Figure 32 – EMS Calibration Screen #1 (all J-Series, n/a J120) Figure 33 – EMS Calibration Screens #2 and #3 (all J-Series, n/a J120) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 71: Special Inspections - Wing & Strut Bush Service

    Rest the wing on the outboard wing stand. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 72: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Note that small errors here will have noticeable effect on the dihedral angle of the wing. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 73: Figure 34 – Wing Lug Versions

    Prepare the Aluminium lugs for bonding: Lightly sand bonding faces using 400-grit sandpaper to remove dirt etc from the surface. After sanding, wipe bonding faces with a rag moistened with This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 74: Figure 35 – Bond Details

    Clean the replacement bush / bolt assembly in an acetone bath. Blow dry using clean air before installation. Mix Jabiru Epoxy resin & hardener according to the manufacturer instructions. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 75: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Fit the wing & test the connection for free-play as detailed in Section 5.12. Ensure a new bolt is used on the attachment which has been serviced. CAUTION This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 76: Structures

    Elevator Control System – Section 6F  Rudder Control System – Section 6G This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS...

  • Page 77: Fuselage

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

  • Page 78: Shockwatch Indicator

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

  • Page 79: Figure 36 – Shockwatch Indicator

    Note visible red dot Figure 36 – ShockWatch Indicator (all J-Series) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS...

  • Page 80: J160-Type Cabin Doors

    6.5.3 Adjustment  Door latches or their component parts must be replaced if worn or damaged. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 81: Figure 37 – J160-Type Door Hinge Assy

    Figure 37 – J160-Type Door Hinge Assy (all J-Series, n/a J200/J400) Figure 38 – J160-Type Door Assembly (all J-Series, n/a J200/J400) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 82: Figure 39 – J120-Type Door Assembly

    Figure 39 – J120-Type Door Assembly (J120) Figure 40 – J200-Type Door Assembly, J160-Type (J200/J400) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 83: Figure 41 – J160-Type Rear Door Assy

    Figure 41 – J160-Type Rear Door Assy (J200/400, J230/430, J250/450) Figure 42 – J160-Type Door Latch Mechanism Assembly (all J-Series, n/a J200/J400) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 84: J200 Type Cabin Doors

     Cabin doors should be adjusted so that the door skin fairs with the fuselage skin. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 85: J200-Type Cabin Door Latches

    Door latches or their component parts must be replaced if worn or damaged. Figure 44 – J200-Type Door Hinge Assy (J200/J400) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 86: Figure 45 – J200-Type Front Door Assembly

    Figure 45 – J200-Type Front Door Assembly (J200/J400) Figure 46 – J200-Type Rear Door Assy (J200/J400) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 87: Seats

    DO NOT MODIFY SEATS. The seats are an integral part of the structure of the aircraft and must not be modified. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 88: Upholstery

    Testing of the beacon must be carried out in accordance with the manufacturer’s instructions during scheduled maintenance. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 89: Wings & Empennage

    Wing removal is most easily achieved if two persons are available to handle the wing. Remove wing root fairings. Remove wing strut fairings – top and bottom. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 90: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    On RH wing, reconnect Pitot tube. Replace wing strut fairings – top and bottom. Replace wing root fairings. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 91: J160 Wings

     All repairs must be referred to Jabiru Aircraft Pty Ltd or our approved local agent. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 92: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    1-2 minutes. This must be repeated for the right wing. If a wing is not flowing correctly, check lines for kinks, blockages & airlocks. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 93: Figure 48 – J160 Wing Assembly Sheet 1 (Ser X)

    Figure 48 – J160 Wing Assembly Sheet 1, Ser X (J160) Figure 49 – J160 Wing Assembly Sheet 2, Ser X (J160) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 94: Figure 50 – J160 Wing Assembly Sheet 1 (Ser Xiv)

    Figure 50 – J160 Wing Assembly Sheet 1, Ser XIV (J160) Figure 51 – J160 Wing Assembly Sheet 2, Ser XIV (J160) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 95: J170 Wings

    For these aircraft, refer to Figure 54 and Figure 55 for details. 6.15.2 Removal  Refer to Section 6.14 for removal details. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS...

  • Page 96: Figure 53 – J170 Friese Aileron Installation

    Refer to Section 6.14 for installation details. Figure 53 – J170 Friese Aileron Installation (J170) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 97: Figure 54 – J170-Ul Wing Assy Sheet 1 (Ser Ix)

    Figure 54 – J170-UL Wing Assy Sheet 1 Ser IX (J170) Figure 55 – J170-UL Wing Assy Sheet 2 Ser IX (J170) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 98: J200 Wings

    All repairs must be referred to Jabiru Aircraft Pty Ltd or our approved local agent. 6.17.4 Installation  Refer to Section 6.14 for installation details. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS...

  • Page 99: Figure 56 – J230 Wing Assembly Sheet 1 (Ser 13)

    Figure 56 – J230 Wing Assembly Sheet 1, Ser 13 (J230/J430) Figure 57 – J230 Wing Assembly Sheet 2, Ser 13 (J230/J430) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 100: J250 / J450 Wings

     All repairs must be referred to Jabiru Aircraft Pty Ltd or our approved local agent. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 101: Figure 59 – J250 Family Wing Assy (Sp-I Type)

    Figure 59 – J250 Family Wing Assy, SP-I Type (J250/450) Figure 60 – J250 Family Wing Assy, SP-III Type (J250/450) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 102: Wing Struts

     A dented, cracked or deformed wing strut should be replaced prior to next flight. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 103: Landing Light(S)

    Note that Figure 61, Left, shows the light during a test fit; the trim ring, internal paint and Aluminium tape (see Figure 63) have not been fitted yet. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 104: Figure 61 – Light Installed (Left) & Slotted Hole In Housing

    LANDING light is aimed straight ahead. 15 meters Figure 62 – Night-VFR Lighting Aim Diagram (all J-Series) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 105: Figure 63 – Night-Vfr Landing / Taxi Light Assy

    Figure 63 – Night-VFR Landing / Taxi Light Assy (all J-Series) Figure 64 – Day-VFR Light Assembly (all J-Series) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 106: Dynon Pitot

     Installation is the reverse. Figure 65 – Dynon Pitot Installation (all J-Series) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS...

  • Page 107: Wing Inspection Window

    Also refer to wing assembly drawings shown above. Figure 66 – Wing Inspection Panel (all J-Series) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 108: Fin

     All repairs must be referred to Jabiru Aircraft Pty Ltd or our approved local representative. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 109: Landing Gear & Brakes

    Only jack 1 undercarriage leg at a time using this method. If both legs must be removed simultaneously, support the aircraft on trestles or similar supports under the fuselage belly. WARNING This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 110: Main Wheel Fairing (Spats)

    During assembly ensure that the brake line is not rubbing against the fairing or mounting screws. Rubbing can lead to failure of the brake line and wheel brake failure. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 111: Main Gear Top Fairing (Speed Fairing)

    During assembly ensure that the brake line is not rubbing against the fairing or mounting screws. Rubbing can lead to failure of the brake line and wheel brake failure. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 112: Main Wheels

    L2 or LAME (A&P or LSA Repairman / Maintenance) Return to Service: L2 or LAME (A&P or LSA Repairman / Maintenance) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 113: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Place outboard brake pad plate and springs in position and secure with bolts/nuts/washers. Install spats and speed fairing (if used) as outlined in Section 6.28 and 6.29. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 114: Figure 68 – Main Wheel To Leg Assy

    Figure 68 – Main Wheel to Leg Assy (all J-Series) Figure 69 – Main Wheel Assembly (all J-Series) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 115: Main Wheel Stub Axle

    Remove inboard brake plate. Remove axle from leg. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS...

  • Page 116: Wheel Balancing

    Where equipped, note the orientation and remove the undercarriage leg wedge. Remove Undercarriage Leg Assembly. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 117: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Inspect bolts and nuts for signs of stress, bending or corrosion – replace if in any doubt. Inspect clamp for damage. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 118: Trouble Shooting - Main Undercarriage

    Dragging Brakes Refer to Section 0 Figure 71 – Main Undercarriage (Type 1) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS...

  • Page 119: Nose Wheel Speed Fairing (Spat)

    Remove the machine screws around the forward and rear sections of the fairing and remove the rear section. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 120: Nose Wheel

    L2 or LAME (A&P or LSA Repairman / Maintenance) Return to Service: L2 or LAME (A&P or LSA Repairman / Maintenance) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 121: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Inflate tyre to seat the tyre beads, adjust to correct tyre pressure – Refer Aircraft Specifications above. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 122: Nose Wheel Steering / Centring System

    The systems are shown in Section 0.  Repair of these systems is limited to the replacement of parts. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 123: Figure 74 – Nose Leg Soft Link Assy (J160 Family)

    Figure 74 – Nose Leg Soft Link Assy, J160 Family (J120, J160, J170) Figure 75 – Nose Leg Soft Link Assy, J200 Family (J200/400, J230/430, J250/450) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 124: Nose Undercarriage Leg

    Repairs to the welded nose leg assembly beam must be referred to Jabiru Aircraft Pty Ltd or our approved local agent. 6.38.4 Nose Gear End Float Adjustment This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 125: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    It is good practice to paint the flock with resin before it cures – this gives a smooth, shiny finish to the flock bed. Allow the resin to cure. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 126: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Two people are required to perform this job safely. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 127: Trouble Shooting - Nose Leg

    Nose Wheel Balancing  Refer to Section 6.32 for wheel balancing information. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS...

  • Page 128: Figure 77 – 4" Wheel Nose Leg Assy

    Figure 77 – 4” Wheel Nose Leg Assy (J120) Figure 78 – Nose Leg Assy This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 129: Nose Leg Housing

    Figure 79 – Nose Leg Assy – Long Trail (J160, J170) Figure 80 – Fabricated Nose Wheel Yoke Assy Nose Leg Housing This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 130: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    L2 or LAME (A&P or LSA Repairman / Maintenance)  Reverse procedure above for installation. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 131: Figure 81 – Machined Nose Leg Housing

    Ensure fresh nyloc nuts are used. Figure 81 – Machined Nose Leg Housing (all J-Series) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 132: Brake Master Cylinder

    Reverse the preceding steps to install brake master cylinder, then fill and bleed brake system in accordance with Section 6.46. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 133: Figure 82 – Brake Master Cylinder & Lever Assy (Type 1)

    DO NOT use aircraft grade hydraulic fluid or damage will result. Figure 82 – Brake Master Cylinder & Lever Assy (Type 1) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 134: Hydraulic Brake Lines

    Older aircraft use a slightly different caliper as shown in Figure 86. Maintenance, inspection & repair of this system is the same as for later variants. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 135: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Visually inspect. Ensure there is clearance between the brake components and the tyre. Fill master cylinder reservoir with brake fluid. Bleed brakes – Refer to Section 6.46. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 136: Parking Brake

    If required, re-fit the axle and wheel assembly as detailed in Sections 6.30 and 6.31. Install outboard brake pad and refix with through-bolts and springs. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 137: Brake System Bleeding

    DO NOT attempt to adjust mark III brakes if these are fitted to the aircraft, damage may result. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 138: Brake Disc Wear Limit

    Repair or install new parts Brake pads worn Replace with new parts This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS...

  • Page 139: Figure 84 – Dual Calliper Brake Assy (Quick Change Pads)

    Figure 84 – Dual Calliper Brake Assy (Quick Change Pads) (J200/J400, J230/J430, J250,J450) Figure 85 – Single Calliper Detail (Mk III brakes) (all J-Series, n/a J120) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 140: Figure 86 – Single Calliper (Legacy Brake System)

    J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 86 – Single Calliper (Legacy Brake System) (J120, J160, J170) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 141: Aileron Control System

    Figure 87 – Aileron Controls – Type 1 This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 142: Figure 88 – Aileron System Schematic – Type 2

    Figure 88 – Aileron System Schematic – Type 2. Figure 89 – Aileron System Schematic – Type 3. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 143: Control Column

    6.51.4 Control Column Installation  Installation is the reverse of the procedure given above. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS...

  • Page 144: Figure 90 – Control Column Assy – Type 1

    J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 90 – Control Column Assy – Type 1 This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 145: Figure 91 – Control Column Assy – Type 2

    Figure 91 – Control Column Assy – Type 2 Figure 92 – Control Column Assy – Type 3 This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 146: Control Cables

    Both cables use clamps which work by the same means: the clamp has a locking tang which inserts into a groove machined in the cable end fitting. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 147: Figure 93 – Clamp Comparison (Primary Cable Clamp Upper On Right Picture)

    Backing Plate Figure 93 – Clamp Comparison (Primary Cable Clamp Upper on Right Picture) (all J-Series) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 148: Figure 94 – Clamp Comparison & Installation (Rudder Cable)

    Figure 95 – Clamp Installations (Elevator & Aileron) (all J-Series) Figure 96 – Trim Cable Clamp Installation (all J-Series) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 149: Figure 97 – Cable & Clamp Comparison

    WARNING Failure to properly install control cables may result in loss of control of the aircraft. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 150: Ailerons

    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) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 151: Aileron Rigging

    DO NOT CROSS CABLES This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 152: Figure 99 – Aileron Stops – Type 1

    J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 99 – Aileron Stops – Type 1 This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 153: Figure 100 – Aileron Stops – Type 2

    Figure 100 – Aileron Stops – Type 2 Figure 101 – Aileron Stops – Type 3 This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 154: Wing Flap Control System

    Ensure flaps are moving together through their full range of travel. Figure 102 – Manual Flap Control System (all J-Series, n/a J200/J400) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 155: Figure 103 – J200 Family Manual Flap System Sheet 1

    Figure 103 – J200 Family Manual Flap System Sheet 1 (J200/J400) Figure 104 – J200 Family Manual Flap System Sheet 2 (J200/J400) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 156: Manual Flap Lever Assembly

     Ensure tape is removed from flaps and an operational test carried out before use. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 157: Electric Flap Drive Assembly

    Re-assemble, taking care to line up the key slots on the motor housing.  Test and repeat cleaning process if required. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 158: Figure 105 – Linear Actuator Disassembled

    Figure 106 – Commutator Ring Close-Up (all J-Series) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS...

  • Page 159: Figure 107 – Flap Controls – Sheet 1 (Fibreglass Motor Mount)

    Ensure tape is removed from flaps and an operational test carried out before use. Figure 107 – Flap Controls – Sheet 1 (Fibreglass Motor Mount) (all J-Series) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 160: Figure 108 – Flap Controls – Sheet 1 (Aluminium Motor Mount)

    J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 108 – Flap Controls – Sheet 1 (Aluminium Motor Mount) (all J-Series) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 161: Figure 109 – Flap Controls – Sheet 2

    Figure 109 – Flap Controls – Sheet 2 (J120, J160, J170) Figure 110 – Flap Controls – Sheet 3 (Fibreglass Motor Mount) (J120, J160, J170) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 162: Figure 111 – Flap Controls – Sheet 3 (Aluminium Motor Mount)

    Figure 111 – Flap Controls – Sheet 3 (Aluminium Motor Mount) (J120, J160, J170) Figure 112 – J200 Family Electric Flap System Sheet 1 (J200/J400, J230/J430, J250/J450) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 163: Flap Cross Shaft Assembly

    Disconnect the flap drive motor or manual lever from the cross shaft input arm. Remove external flap drive arm from the end of the shaft nearest the remaining wing. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 164: Figure 114 – Flap Cross Tube Assy J160 Family

    Figure 114 – Flap Cross Tube Assy J160 Family (J160) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 165: Figure 115 – Flap Cross Tube Assembly J200 Family, Electric

    Figure 115 – Flap Cross Tube Assembly J200 Family, Electric (J200/J400, J230/J430, J250/J450) Figure 116 - Flap Cross Tube Assembly (J170) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 166: Flap Position Indicator

    For Type 1 indicators: drill rivets and disassemble indicator. Loosen bolt on flap drive motor shaft & remove cable. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 167: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    L1, L2 or LAME (Owner, A&P or LSA Repairman / Maintenance) Figure 118 – Flap Position Indicator – Type 1 This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 168: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Figure 119 – Flap Position Indicator – Type 2 Figure 120 – Flap Position Indicator Drive Cable Assembly (all J-Series) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 169: External Flap Push Rod

     Repairs must be referred to Jabiru Aircraft Pty Ltd or our approved local agent. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 170: Flap Rigging (As Per Template)

    Jabiru Aircraft Pty Ltd). Please note: There is only a requirement to check the down deflection because it has the highest value in travel. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 171: Elevator Control System

    Figure 121 – Elevator Control System – Type 1, Sheet 1 (J200/J400, J230/J430, J250/J450) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 172: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Figure 122 – Elevator Control System – Type 1, Sheet 2 (J200/J400, J230/J430, J250/J450) Figure 123 – Elevator Control Assy Type 2 (J120, J160, J170) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 173: Control Column

     For the J160-C, balance may be checked with the control fitted to the aircraft & the control & trim removed. Measure the force at the trailing edge required to keep the elevator level. Weight & hinge...

  • Page 174: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Figure 124 – J160 Models – Horizontal Tail & Elevator Assembly (J120, J160) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 175: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Figure 125 - Horizontal Tail & Elevator Assembly – Type 1 (all J-Series, n/a J120, n/a J160) Figure 126 – Horizontal Tail & Elevator Assembly Type 2 (all J-Series, n/a J120, n/a J160) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 176: Elevator Control Cables

    Control templates are available for all models from Jabiru Aircraft. Using the factory anchor points, make sure each end of the cable is secure. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 177: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Ensure lock nut is tight on rod ends and that cable is visible through hole in spherical bearing. Figure 127 – Elevator Travel Limits (all J-Series) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 178: Elevator Trim - Control Lever Assy

    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 of a bearing failure. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 179: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Figure 128 – Trim Lever Assy – Type 1 (J200/J400) Figure 129 – Trim Lever Assy – Type 2 (J200/J400) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 180: Elevator Trim - Aft Assembly

    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) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 181: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    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 of a bearing failure. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 182: Trim Control Cables

    Draw the cable out of the aircraft, leaving the string/wire in place to allow installation of a replacement part. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 183: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Reverse the steps detailed above for installation.  Ensure the required inspections are carried out and the cable is clamped securely. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 184: Rudder Control System

    – part description, aircraft model, serial number etc to Jabiru to ensure accurate part identification. Figure 132 – Typical Rudder System Schematic (all J-Series) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 185: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    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 of a bearing failure. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 186: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 133 – Rudder Pedal - Non-Adjustable (all J-Series) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 187: Rudder Centring System

    To disconnect the rudder centring system, remove the bolts and the pushrods connecting the pedals to the nose leg or centring bellcrank. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 188: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Figure 136 – Steering/Rudder Centring Assy – Type 1 (all J-Series) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 189: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Figure 137 – Steering/Rudder Centring Assy – Type 2 Figure 138 – Steering/Rudder Centring Assy – Type 3 (Sheet 1) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 190: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Figure 139 – Steering/Rudder Assy – Type 3 (Sheet 2) Figure 140 – Steering/Rudder Centring Assy – Type 3 (Includes Soft Link) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 191: Rudder

     Repairs must be referred to Jabiru Aircraft Pty Ltd or our approved local agent. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 192: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Figure 141 – Typical Rudder Installation (Alloy Hinges) (all J-Series) Figure 142 – Typical Rudder Installation (Steel Hinges) (all J-Series) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 193: Rudder Control Cable

    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) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 194: Rigging

    The Rudder Pedal Stops should engage – NOT the Control Surface Stops on the tail. DO NOT move the Cable Anchor Points or adjust control surface stops – These are factory set. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 195: Engine & Engine Installation

    Disconnect the engine air inlet SCAT hose and cabin heat inlet hose (if fitted) Remove lower cowl screws at rear of cowl. Reverse the preceding steps for installation. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 196: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Repair is limited to replacement cam locks. Rivets fixing cam lock anchor lugs should be backed with washers. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 197: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Figure 143 – Typical Upper Cowl Assy (all J-Series) Figure 144 – Typical Lower Cowl Assy (all J-Series) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 198: Engine

    For major engine repairs, refer to Jabiru Aircraft Pty Ltd or an Approved Jabiru Service Centre. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 199: Flexible Hoses

    Excessively hard hoses must be discarded. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 200: Cooling Air Baffles

     In most cases the spark plug leads must also be removed with the duct. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 201: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    In addition, cases have been recorded where a poorly fitted duct lifted from the engine and pulled the spark plug leads off the engine, resulting in engine stoppage. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 202: Engine Mount

     Un-bolt the engine mount fasteners and remove the mount from the aircraft. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 203: Engine Fuel System

    Fuel lines within the engine compartment are fitted with fireproof sleeves. These sleeves must not be removed. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 204: Engine Throttle Control

    7.7.5 Throttle Installation  Reverse the removal procedure given above for installation. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS...

  • Page 205: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    CASES OF SEVERE DAMAGE TO AIRCRAFT DUE TO THESE EFFECTS HAVE BEEN RECORDED Figure 147 – Throttle Assy (Seat Mounted) (all J-Series) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 206: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Figure 148 – Throttle Assy (Panel Mounted) (all J-Series) Figure 149 – Throttle Assy (Large Panel Mount) (all J160) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 207: Choke Cable

    (available from Jabiru Aircraft) must be replaced to ensure a flame-proof seal. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 208: Air Intake System & Carburettor Heat

    Dirty filters can be cleaned once by blowing out with compressed air – when the filter becomes dirty again it must be replaced. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 209: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Figure 151 – Typical Carburettor Heat Box (all J-Series) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 210: Exhaust System

     Disconnect carburettor heat pipes and, if necessary, remove the heat muff from the muffler. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 211: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Poor alignment will result in exhaust port damage (particularly for 2-bolt flanges). Tighten all extractor screws & assemble. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 212: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Figure 153 – 2200 Exhaust System (J120, J160, J170) Figure 154 – 3300 Exhaust System Type 1 (J200/J400, J230/J430, J250/J450) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 213: Cabin Heater System

    Remove locking pin, disconnect control cable. Loosen hose clamp screws. Remove hose. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS...

  • Page 214: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    For installation, reverse removal procedure above. Figure 156 – Cabin Heat Mixer Assembly (all J-Series) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 215: Extreme Climatic Conditions

     In humid areas, fuel should be checked frequently and drained of condensed moisture. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 216: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Figure 158 – 2200 Engine Installation (J120, J160) Figure 159 – 2200 Engine Installation (J120, J160) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 217: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Figure 160 – 2200 Engine Installation, Long Engine Mount (J170) Figure 161 – J200 Family Engine Installation Type 1 (J200/J400, J230/J430, J250/J450) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 218: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 162 – J200 Family Engine Installation Type 2 (J200/J400, J230/J430, J250/J450) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 219: Fuel System

    Cap open hoses and cover connections to prevent the entrance of foreign matter. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 220: Figure 164 – Fuel System Schematic – Type 3

    Figure 163 – In-Cabin Fuel System (J120) Figure 164 – Fuel System Schematic – Type 1 (all J-Series, n/a J120) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 221: Figure 165 – Fuel System Schematic – Type 4

    Figure 165 – Fuel System Schematic – Type 2 (all J-Series, n/a J120) Figure 166 – Fuel System Schematic – Type 3 (all J-Series, n/a J120) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 222: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Drain fuel tank sump, fuel lines Water in fuel and filter This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS...

  • Page 223: Fuel Lines

    Fasteners such as screws, which damage the structure, should not be used. Figure 168 – Schematic (all J-Series) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 224: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Figure 170 – Fuel Lines Showing Typical “U” Requiring Correction (all J-Series) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 225: Fuel Tanks

    Disconnect the earth wire between the tank and the fuel filler earth point. Lean the tank to one side to allow access to disconnect the fuel line. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 226: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    For installation, reverse removal procedure given above. Figure 172 – Header Tank Installation – Type 1 (all J-Series, n/a J120) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 227: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Figure 173 – Header Tank Installation – Type 2 (Sheet 1) (all J-Series, n/a J120) Figure 174 – Header Tank Installation – Type 2 (Sheet 2) (all J-Series, n/a J120) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 228: Fuel Vents

    Blow into the cap vent on the other wing. If the balloon/glove inflates the breather lines between the tanks are open and the tanks are cross-feeding. Correct any blockage. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 229: Fuel Shut-Off Valve

    The fuel shut-off valve is a two-position ON – OFF valve. This valve is normally located in front of the main longitudinal beam between the crew seats. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 230: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Ensure wing tank cap vent covers and fuel line clamps are removed. Figure 176 – Single Line Fuel Tap (all J-Series) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 231: Fuel Gauges

    Contact Jabiru Aircraft for reads full, tanks low calibration detailed advice & spare parts. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS...

  • Page 232: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Figure 177 – Fuel Gauge – Electric Sender Installation (all J-Series, n/a J120) Figure 178 – Fuel Gauge – Electric Sender Assembly (all J-Series, n/a J120) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 233: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 179 – Fuel Gauge – Sight Glass (all J-Series, n/a J120) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 234: Fuel Filters

    L2 or LAME (A&P or LSA Repairman / Maintenance) Return to Service: L2 or LAME (A&P or LSA Repairman / Maintenance) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 235: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    The fuel filter must only be installed in one direction. An arrow on the side of the filter marks the fuel flow direction. Ensure this arrow is pointed towards the Firewall and Engine. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 236: Propeller Service Manual

    (60” x 55”) or pitch wooden. 1524 x 1422 (60” x 56”) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS...

  • Page 237: Identification Stampings

    The diameter and pitches in metres, preceded by the letters "D" and "P" respectively. The type of engine for which the propeller has been designed. Manufacturing Serial Number: This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 238: Description

     Bolts should be torqued to 6 lb.ft (72 inch/lbs) in a standard torque sequence. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 239: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    JTM001-5 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 180 – Propeller Installation (all J-Series) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 240: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 181 - Typical Scimitar propeller installation (all J-Series) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 241: To Remove Existing Propeller

    Only nicks within the size tolerances described above may be repaired. All propellers with cracks or splits (or any delamination of the composite sheath in the case of sheathed Propellers) must be This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 242: Propeller Balancing Procedure

    The only ‘Utility System’ Features on Jabiru aircraft is a cabin heater. A description of this system, and instructions for the maintenance and repairs of this system is provided in Section 7.11 This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 243: Instruments & Instrument Systems

    Remove the fascia. Assembly is the reverse of the above procedure. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 244: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Figure 182 – Instrument Panel Layout Type 1 (all J-Series) Figure 183 – Instrument Panel Layout Type 2 (all J-Series) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 245: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Figure 184 – Instrument Panel Layout Type 3 (all J-Series) Figure 185 – Instrument Panel Layout Type 4 (all J-Series) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 246: Instrument Panel Mount

    Assembly is the reverse of the above procedure. Figure 186 – Instrument Panel Mount Installation (all J-Series) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 247: Instruments

    Cleanliness and security are the principal rules for system maintenance. The pitot tube and static ports MUST be kept clean and unobstructed. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 248: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    JTM001-5 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 187 – Pitot Assembly (all J-Series) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 249: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

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

  • Page 250: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Figure 189 – Pitot / Static Water Trap (all J-Series) Figure 190 – Pitot-Static System – Water Trap Locations (all J-Series) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 251: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Reconnect airspeed and vertical speed indicators into static pressure systems and repeat negative pressure test detailed above. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 252: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    L2 or LAME (A&P or LSA Repairman / Maintenance) Return to Service: L2 or LAME (A&P or LSA Repairman / Maintenance) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 253: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Leaks or obstruction in static line obstructions. Repair or replace instruments) line, blow out obstructed line. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS...

  • Page 254: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Blow speed indicator installations out lines, tighten connections This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS...

  • Page 255: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Substitute known-good indicator Defective diaphragm and check for vibration. Replace instrument. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS Page: 255 of 298...

  • Page 256: Alternate Static Source

     In the Jabiru this system consists of a section of the static tube which is exposed at the underside of the instrument at a position where the pilot can reach it in flight. Where a problem is detected the pilot reaches down and pulls on the tube, disconnecting it from the static probe in the tail.

  • Page 257: Analogue Tachometer

     Refer to the Engine Maintenance Manual for additional details. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS...

  • Page 258: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Same probable causes as for Hand oscillates “Incorrect Indication” above. indication” above. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS...

  • Page 259: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Figure 193 – Hall Effect Sensor Wiring (For Tach with Jabiru Logo on Face) (all J-Series) Figure 194 – Hall Effect Sensor Inst. (For Tach with Jabiru Logo on Face) (all J-Series) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 260: Analogue Engine Gauges

    Incorrect indication Check and repair wiring & Poor connections connections. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS Page: 260 of 298...

  • Page 261: Digital Displays

    Check connection, replace / fluctuating between display and engine improve as required. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS...

  • Page 262: Magnetic Compass

    Where this option is provided, a different instrument panel fascia is fitted.  Repair should only be performed by an approved instrument workshop. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 263: Electrical Systems

     The wiring diagram for night-VFR lighting is shown in Figure 197 and Figure 198. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 264: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 195 – Wiring Diagram Sheet 1. (all J-Series) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 265: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Figure 196 – Wiring Diagram Sheet 2. (all J-Series) Figure 197 – Night-VFR Lighting Sheet 1 (all J-Series) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 266: Minor Electrical Equipment

    To determine which solenoid is which check for continuity between the earth pole and the body of the solenoid. No continuity indicates the need for a separate earth connection. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 267: Battery System

    (baking soda) and water. Rinse with clear water, wipe off excess water and allow battery to dry. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 268: Electrical Load Analysis (Ela)

    Figure 201  The radio system diagram is provided with the radio manuals. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS...

  • Page 269: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Figure 199 – VHF Antenna Installation (all J-Series) Figure 200 – Second VHF Antenna Installation (J120, J160, J170) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 270: Transponder

     For details of electrical connection refer to the transponder manufacturer’s data. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS...

  • Page 271: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

     For installation: reverse removal steps above. Figure 202 – Transponder Antenna Installation (all J-Series) This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 272: Structural Repair

    Repairs without consultation are limited to those described in the manual within each individual section. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 273: Painting & Finishing

    Random Orbital Sander and 150mm Stickit discs. Note: Ensure that glass is not cut into in the sanding process This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 274: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    In addition, colour (including stripes etc) must not be applied to horizontal, upper surfaces. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 275: Placards

    Use for J160-D, J170-C, J170-D, J120-C, J230-C and J230-D P/No. 5A060A0D This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS Page: 275 of 298...

  • Page 276: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Fitted above windscreen in front of wing carry through beam across to the left side. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 277: Placards General

    Locate vertical line in line with rear of baggage shelf. J200 Families: Position as noted in Flight Manual. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 278: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Fitted on inside of fuselage of RHS of cabin below rear quarter window. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 279: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Fitted to the Outsides of LH Door Above the Door Catch Lever Door Open RHS OPEN P/No 5028094 This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS...

  • Page 280: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Fitted on the rear of the fuselage beam next to the wing tank valves J400 DECAL #2 - P/No. 502329N This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 281: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Qty 8 Required Attach to the fuselage and wings beside each wing, and lift strut attachment fitting. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 282: Fairings

    5-minute Araldite. If the hole has suffered damage and is too large, fill the hole in with Araldite and re-drill, then bond the insert. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 283: 18 Revisions

    - Reclassification of required level of certification for several 29/10/14 tasks - LSA Owner/operator responsibilities added This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS...

  • Page 284: 19 Feedback And Reporting

    This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS Page: 284 of 298...

  • Page 285: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Previous Owner: New Owner: Contact Details of New Owner This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS Page: 285 of 298...

  • Page 286: Appendix A - Worksheets

    Propeller Tracking – Check propeller tracking (see section 9) Comments: hourly This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS...

  • Page 287: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Fuel flow Rate – Check as detailed in JEM0002 Comments: Annual This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS...

  • Page 288: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Rod ends – Check condition, freedom of movement Comments: hourly This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS Page: 288 of 298...

  • Page 289: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Aircraft Ground Tracking – Check and adjust as required Comments: hourly Brake operational check Comments: hourly This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS Page: 289 of 298...

  • Page 290: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Cabin upholstery & trim – Inspect for condition Comments: hourly This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS Page: 290 of 298...

  • Page 291: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Landing / Taxi light alignment – (Night VFR equipped aircraft only) Comments: hourly This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS...

  • Page 292: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Exterior surface of control surfaces – Check for cracking, fraying and other damage Comments: hourly This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014...

  • Page 293: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Annual Check control surface clearances – as per section 5.18 Annual Comments: This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS...

  • Page 294: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Hand brake Comments: Flight Test Radio Comments: Flight Test This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS Page: 294 of 298...

  • Page 295: This Document Is Controlled While It Remains On The Jabiru Server. Once This No Longer Applies The Document Becomes Uncontrolled

    Other (note on separate page if required) Comments: Flight Test This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS Page: 295 of 298...

  • Page 296: Appendix B - Airworthiness Limitations

    CASA APPROVED SECTION Airworthiness Limitations Jabiru J160-C Appendix B – Airworthiness Limitations This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE Dated: 29th October 2014 Issued By: AS...

  • Page 297: General

    Balance checks of the controls are only required after repair or refinishing or at the 5000-hourly major airframe inspection. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

  • Page 298: Issue Dated: 29Th October 2014 Issued By: As Page: 2 Of

    * see Section 5.3 Mandatory Inspections & Lifed Items ** 2 years or at engine overhaul, whichever comes first This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE...

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