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1. 48 6 SECTION 6 LANDING GEAR AND 49 6 1 INAID INEKE 7AN E 49 6 2 TROUBLE SHOOTING MAIN 49 6 3 MAINGEA e Rum LM 49 6 3 1 Removal 53 6 3 2 VASAT ON s o E 53 6 3 3 Inspection and Rep ios D 53 6 3 4 Main Wheel Fairing Removal and Installation eene eene 54 6 3 5 Main Gear Fairing Removal and Installation deeem 54 6 4 MAIN e 54 6 4 1 Main Wheel M eee tee eee 54 6 4 2 Main Wheel Disassembly sssini EH E c 54 6 4 3 Main Wheel Inspection Assembly Repair esee eene enne 55 6 4 4 Main Wheel Installation 55 6 4 5 Main Wheel Stub Axle Remoyal 56 6 4 6 Main Wheel Stub Axle Installation 202022122100 56 6 4 7 Main Wheel Alignment nor opone pneri ees e Ee 56 6 4 8 Wheel enne 58 6 5 NOSE GEAR cete H 58 6 5 1 Trouble Shooting Nose Leg ai cie eta oiie 58 6 5 2 Nose Gear Removal and Installation esee
2. recte 141 14 2 2 Materials Recommended 141 Revision Dated July 2005 Issued By RAS Page 7 of 156 Lies Technical manuals160 17010160 A J170 working files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM Jabiru Aircraft pty un Aircraft Service Manual Jabiru J160 J170 Variants 14 2 3 Painting Equipment Required acus ee eoe ie Rad 141 14 2 4 Painting Procedure 142 15 SECTION 16 PALCARDS saia 144 151 ee 144 15 2 COCKPIT CONTROE BOES EC EEN dee 145 15 3 EXTERNAL 5 entente nn 146 16 APPENDIX I JABIRU 2200 e eee tn s eese saa asses eese ena 147 17 APPENDIX JABIRU ENGINE PARTS 2400 0000 148 18 APPENDIX III ENGINE INSTALLATION asses sees assess 149 19 APPENDIX IV PROPELLER SERVICE MANUAL 150 19 1 APPROVED INSTALLA
3. 121 159 FILTERS sais itis en nein RR ROUND Oeo Epp e onan 121 11 5 1 CS VLA filter ten Kerana 121 revision Dated July 2005 Issued By RAS Page 6 of 156 Lies Technical manuals160 17010160 A J170 working files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM Jabiru Aircraft pty pta MEN un Aircraft Service Manual Jabiru J160 J170 Variants 11 5 2 Non CS VLA Model Variant Filter 121 11 5 3 CS vla model Fuel Filter Removal amp Installation eene 121 11 54 CS vla model Fuel Filter Removal amp Installation 122 11 6 FUEL PUMPES ap D 122 11 04 Pump 122 116 2 Secondary PUMP sirsiran dE 122 11 6 3 cs vla Secondary Pumn 122 12 SECTION 12 INSTRUMENTS amp INSTRUMENT 5 8 8 123 124 GENERAL ones 123 12222 INSTRUMENT PANEL 123 12 2 1 Instrument Panel Removal amp Installation eee deseen eene 123 1222 INSTRUMENTS eoa gui cu cda epe VE 123 1223 Instrument Removals ope E D
4. sv CORREO YEE ONIM LSM LHOTT 871 ASSY YIS 1 sel SATONY OA FVII SEAS 402 6 0 STOHM S3ONVHSTO1 TAINIO Vd Ald HOSLAY HO LNASNOD JHL LNOHLI Q3IdO3 39 LON 15 ONY LHS AdO2 ircraft pty A Aircraft Service Manual Jab Jabiru 9160 J170 Variants 3179 LON OG Ede 31ISOddO SH SV 61 LAN DOTAN 918 ASSY NOM3 Iv WAINIAINTY Jv3139NIH 002 871 SNISHOSANISY N 0Z 02 ASSY dV14 111 HAS z608S02 91 096 LAN 17871 ASSY TWHNLONYLS NIA XI YIS aevetovz ER Svc 902SESIA 11708 ONO 1 97 26 1 6 6 9 NGCLOHd ANNS N66 0Hd M3HSVAA D1 096NV SNIA III YAS 21v 1d NOLLO3dSNI
5. INV38 NI 511134 3NI1831N39 gt 1109 8 X NZ00VEHd GL 1109 8 30 ONN L 2 X MS8 9L MANOS N6crOHd CL L MASA 9L LON 6160 cl 3 vug 602606 LYOHS 8ONM 601 606 OL LAN 81575 98 9 016 6 1108 OL SNV 8 LAN 311SVO TOLENV 4 1104 LL PNV 9 YSHSVM 917 096 4 DON 9094209 ONILLIS H3ONITAO H31SVI dovooove LNNOW 00842099 YALSVW 3 v38 N6 00dd ALO ON 1994 Figure 17 Brake Master Cylinder Assy 10 e 0 D x 02 a 2 o 0 LO 2 75 z 9 o 2 D 9 files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 L Miles Technical_manuals J160_J170 J160_ amp _J170_workin Jabiru Aircraft pty Msn un Aircraft Service Manual Jabiru J160 J170 Variants 7 SECTION 7 AILERON CONTROL SYSTEM 7 1 AILERON CONTROL SYSTEM Refer to Figure 20 The aileron control system is comprised of a control column and two enclosed push pull cables fitted with spherical bearings WARNING All spherical bearings
6. Aircraft Service Manual Jabiru J160 J170 Variants Table 2 J170 Specifications ena J170 A J170 UL J170 SP J170 SPC Aust Kit Europe Kit USALSA Canada LSA 540kg 450kg 540kg 119015 99215 119015 119015 Fuel Capacity 135 litres 75 litres 135 litres 135 litres AVGAS 100 130 MOGAS with Octane Rating 95 RON or above may be used if AVGAS is not available Fuel Type Fuels Containing Alcohols Ethanol etc will damage the fuel tank sealant and MUST NOT BE USED IN JABIRU AIRCRAFT Oil Capacity 2 3 litres 2 3 litres 2 3 litres 2 3 litres Oil Refer Engine Refer Engine Refer Engine Refer Engine Manuals Manuals Manuals Manuals Engine Model Refer To Appendix For Jabiru 2200 Jabiru 2200 Jabiru 2200 Jabiru 2200 Engine Data Jabiru Jabiru Jabiru Jabiru Propeller Type 2 bladed 2 bladed 2 bladed 2 bladed Wooden Wooden Wooden Wooden ZE Diameter 60 dia 60 dia 60 dia 60 dia P 1524mm 1524mm 1524mm 1524mm Jabiru 44 Jabiru 42 Jabiru 44 Jabiru 44 Propeller Pitch pitch pitch pitch pitch 1117mm 1067mm 1117mm 1117mm Wheel Sizes Standard 500 x 6 rim 400 x 4 rim 500 x 6 rim 500 x 6 rim Tyres Standard 6 wide 6 Ply 4 wide 4 ply 6 wide 6 Ply 6 wide 6 Ply Tyre Pressures Standard 179 kpa 26 179 kpa 26 79 kpa 26 79 kpa 26 Mains psi psi
7. D D x 02 a 2 o 0 LO 2 75 z 9 o 2 D 9 files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 L Miles Technical_manuals J160_J170 J160_ amp _J170_workin Jabiru Aircraft pty un Aircraft Service Manual Jabiru J160 J170 Variants 5 2 WING STRUTS Each wing strut is a single lift strut which transmits a part of the wing load to the lower portion of the fuselage The strut consists of a streamlined tube riveted to two end fittings which attach to the fuselage and wing WARNING Do Not Tighten Strut Attachment Bolts Metal fatigue may result Bolt must be free to rotate 5 2 1 REMOVAL AND INSTALLATION See Wing Removal Paragraph 5 2 1 and Wing Installation Paragraph 5 2 3 5 2 2 REPAIR Wing struts are structural components and therefore all repairs must be referred to JABIRU AIRCRAFT Pty Ltd or our approved local agent A dented cracked or deformed wing strut should be replaced prior to next flight 53 FIN The Fin is a moulded composite structure supported by a rib and a rear spar Hinges attach the rear spar to the rudder 5 3 1 REMOVAL INSTALLATION INSPECTION AND REPAIR The fin is an integral part of the fuselage structure and cannot be removed All repairs must be referred to JABIRU AIRCRAFT Pty Ltd or our approved local agent 5 4 HORIZONTAL STABILISER The horizontal
8. 0 00 F 230 290 MT Esch 90 E Sr ON 53204943101 Tio JON OQ SONO 50440 SH NAVYO SV 51 00 820 2 1 800 WAASIA 3NOLOOV 9 S32vdHhS TW ANYS dl WIHS MOOTA AXOd3 BELE 31950r 40 M3ONn 014 9 AXOd3 31719 HOVLLY OL ANG 01 103 8 896 L 0r 0 2 2 NOILO3S HEOT2 9 TSNNVHO H3AO 002 X 002 09 X 0021 001 X 002 LAN T SNIM OL THNNYH2 131114 amp 8 NOLLO3S HLM YOH 8 AXOd3 0 0 3 3 NOILO3S 3903 NONY ASSY NO Lld OL WIL 3903 H3AO SNYH OL MOTIV HLSN31 7703 H3AO OSL 086 0 2v L SNITINOW H3AO OSL X 022 SH3AV I C 9 AXOd3 NI 8 033 135 Figure 9 J170 UL Wing Assy Sheet 2 Ww e
9. SIHL SNOISN3IAIG 74920714 34814 ONISN Way OL 7490 18 YOO 09 7 ONO18 8801 AGNNE 39NIH HOOG d08000vZ NOQ000vZ LAN JOTAN 912 MIYOS ANNSHALNNODS 91 6 c 01 S9 0cSIA 8SS P69PCSIN NIMS H3HSVM DL 01 096NV 2 1 91 6 39NIH 531435 L 2 H3HSVA ANN3d d3av3sH L C 0L 026NV vezyeoc 1911 gt 2 lt 90 E x Ei 10 e uw en 0 D x 02 a 2 o 0 LO 2 75 z 9 o 2 D 9 files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 L Miles Technical_manuals J160_J170 J160_ amp _J170_workin ircraft pty A Aircraft Service Manual Jab Jabiru 4160 J170 Variants Wo sw 2130346 SENINA 1 Woe NTDINH 46 PEL 010 0917 AlgW3ssv 51 4000 0v6o0v SUAN NOYOLOYZ N d 3llSOddO SY 00460041 N d Sv ASSY 51 AXOd3 ONY 2014 34814 HIIHM 3Wvi 01 MOONIM ONOG
10. 76 Figure 21 Flap Controls Sheet 17 MA A eese Nnm tienen enn 79 Figtire 22 Flap Controls 5 Esse eee ec deem terere 80 Figure 23 Flap Controls Sheet 4 4 1 81 Figure 24 Flap Cross Tube Assy ofr Nissen 82 Figure 25 Elevator Control ASSy oer p ON eR PER Rte rre tha ei count are p OR pe 85 Figure 26 1160 Models Horizontal Tail amp Elevator 86 Figure 27 J170 Models Horizontal Tail amp Elevator Assy sese 87 Figure 28 Elevator Travel Lirnits cie devote 88 Figure 29 Elevator Trim Handle te ise eee eere ere 90 Figure 30 Figure 31 Figure 32 Figure 33 Figure 34 Figure 35 Figure 36 Figure 37 Figure 38 Tim Controls At Tail ete droit dti eati EE 91 Rudder Assyria teterisid tesis iae n recens establecen bli CER EET 93 Rudder System Schematic 96 Rudder Installation ee eei 97 Upper ode Fre EEE 99 Lower Cowl Assy EATER I 100 CS VLA Variant Throttle Panel Mounted 105 Non CS VLA Variant Throttle Seat Mounted eese seen enne 106 Car
11. v IJJHS 049v Su3avaNunga LHVd OL 33H sq Nava SION 1840 3HAL 9 X 006 ASSY T33HM 9 3MVHga ON SMA SUL 26 982 NOV S 0 F SON TIOHA SAONYHAIO THANAD 31v 7881 011 Ald HOALAW 40 LN3SNO2 3409 Vd HOSLAY 3395s 5 1 5022 Em LON 15 LHOIMAdOS SI 5 Ee 272 72 22 Porfa v lfiNOO1AN 9HE 2601 58602584 1VdS LNNOW 509 09 LL LAN OOTAN vil 82 5860258 DL H3HSVAA bil 81 096 1108 8 653 H3HSVA 1914 ALE 101 096 4 1708 91 6 VZL ENY 9 ANLS NOISN3IX3 17890009 6 09 18 41355 NIVA LSY 202129 v 0978 ASSY TWHOSLNI 502009 8015 31 7620009 2 009 9007 39viuu vOH3ONf 6207009 L ALO Wall sueg gt lt en 2 en E Ww C1 N D D lt 02 tn 2 o 0 LO N 2 5 75 z
12. GE onore 37 4 3 4 DOORS e t Ru 39 4 4 JU UN M 39 4 4 1 E 39 4 5 UPHOESTERY 39 4 5 1 Upholstery 39 4 6 ME 39 4 SAFETY PROVISIONS irte 39 4 7 1 e 39 5 SECTION 5 WINGS AND cdcsssccssssssssscsscsesssssssscessssssscccbesssssscchosssssccssssssnsassesssessacsssssnsssseses 41 5 1 WINGS Sonic mU eMe 41 5 1 1 REMOVAL 41 5 1 2 IT don EE 42 5 1 3 Installation E EE d d d ON e reed 42 5 2 WINGGSIRUTS 0 48 5 2 1 Removal and Installation sa Niesna wiesen oreet 48 5 2 2 REPAIR e ALL ER 48 5 3 5 48 5 3 1 Removal Installation Inspection Rengir 48 5 4 HORIZONTAL STABILISER uide de ipe ote 48 5 4 1 Removal and Installation
13. Aircraft Service Manual Jabiru J160 J170 Variants The procedure for repairing cracks is only recommended for low stress areas No repairs of any kind are recommended on highly stressed or compound curved areas or where repair would be likely to affect the pilot s field of vision 4 2 5 SCRATCHES Scratches on clear plastic surfaces can be removed by hand buffing and polishing using Plastic Polish available from JABIRU as Part No NOVUS 2 NOTE Rubbing plastic surface with a dry cloth will build up an electrostatic charge which will attract dirt particles and may eventually cause scratching of the surface After applying polish dissipate this charge by rubbing surface with a slightly damp chamois This will also remove dust particles which have collected while wax is hardening 4 2 6 CRACKS When a crack appears drill a hole at the end of the crack to prevent further spreading Hole should be approximately 1 16 inch in diameter depending on length of crack and thickness of material An unfluted drill should be used 4 2 7 REMOVAL As the windscreen and windows are bonded into the fuselage it is not possible to remove them without destroying them Once windows have been broken out any screws used in the original installation should be removed 4 2 8 INSTALLATION 1 Ensure all old epoxy resin has been removed from the fuselage sealing strips around the window frames 2 Check new windscreen for fit File or g
14. REVISION lo Dated July 2005 Issued By RAS Page 29 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM Jabiru Aircraft me un Aircraft Service Manual Jabiru J160 J170 Variants Annual Inspection Each 200 Hours Each 100 Hours Each 50 Hours 9 Compression check or leak down check 10 Electrical wiring S 11 Fuel pump 12 Engine controls and linkages 13 Engine mounts mount structure 1 5 14 Starter solenoid and electrical connections 1 15 Coils and electrical connections n 16 Carburettor heat system 17 Throttle and linkage 1 18 Carburettor 1 19 Oil system tubes and hoses 1 1 20 Firewall 21 Engine cowlings and clips 5 22 Exhaust system including muffler 2 1 23 Head bolt tension 24 Oil amp filter change n 25 SCAT hose condition 5 5 Fuel System 1 Fuel filters drain valves carburetor bowl 1 1 2 Electronic fuel boost pump and fittings i 3 Fuel lines and connectors 7 Revision Dated July 2005 Issued By RAS Page 30 of 156 L Miles Technical manuals160 17010160 A J170 working files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM Jabiru Aircraft me un Aircraft Service Manual Jabiru J160 J170 V
15. A Aircraft Service Manual Jab Jabiru J160 J170 Variants 30 133 5 IMSNNSITS EE sy 608106 SCH Her NON sun 1 4 1 30934 15 LN3A32 OSL TIVA S IL 14 41 HLOOWS X 61 NIA 581103 MOIHL 61 NIA 3GlM ONO 000 044355340 f 931 NOISN3dSfIS NIYA 931 NOISN3dSNS N IN3NNOITV T33HM SIHL LNG AYYVO OL 1 55049 OL lJvHONIv QVO on 5 SIHL lSnP v 1 1 021 01 31 9015 0191 T33HA 88 NOLLO3S ONO 0191 X OF X OF WAINIANTY SISAM 91 6 77 HOVLLY SNO SS X Go X OF T3NNYHO ANININNTY 9 931 30 5 g SIHL SNIQNVS 15 13 38 01 531 8115 I EK Ll Ald HALAY 40 IN3SNOO L OHLIM LON 04 SNOISN3AIG 31402 3H JON 5 ONY IHOlHAdOOJ 5 SIHL Figure 13 Main Wheel Alignment 10 N 0 D lt 02 tn
16. Dated July 2005 Issued By RAS Page 60 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM Jabiru Aircraft pty Msn un Aircraft Service Manual Jabiru J160 J170 Variants 6 6 5 WHEEL BALANCING Refer to Paragraph 6 4 8 for wheel balancing information revision Dated July 2005 Issued RAS Page 61 of 156 Lies Technical manuals160 17010160 A J170 working files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM ircraft pty iru A Jab 2 t y Z 1004 918 0 0099 Q3NIHOVIN ASSY T33HM 931 ISON 0 97 S3 DINIH L d 01 RIVA dSIMYAHLO 031512395 SSIINN SLIAIT 5 TU 6 6997 010 N O V 2 Ald HOSLAV 30 LN3SNOO JHL LNOHLIM 0314020 D En a om 38 LON 18011 LHOIAdOO SI SIHL Vd gt 37998 LON OQ cog 20 9 9 gt voeozo v Wa e N E sal e qm gt gt 2 2 LAN 2OT1AN 9L E ZEOL S9EOZSIN 6 SSSNMOIH L
17. ceto eer E 101 102 4 Engine Accessories Removal o etai ed ebd de 101 10 5 ANSDOCHON en o e rc recreo eap o rof EYE qus 102 10 3 COOLING AIR BAFFLES teet eere Rr rere diete e E Ete Robe te Sie PUER EE PAS Ene 103 10 3 1 Cleaning and Inspection sss eene 103 10 3 2 Cooling Air Baffle Removal amp Installation 103 WIESEN ume 103 10 4 ENGINEMOUNT d E otn 103 10 5 ENGINE FUEL SYSTEM LA E X eee aaa rr enr nir te nint scene sete 103 1031 Fuel System General AE M ausu tiec ie toad eene tale 103 10 3 2 Aircraft Fuel System d Een 104 10 5 3 160 170 Fuel System non cs vla Vorionis 104 10 06 SPARK PLUGS EE WR 104 107 ENGINE CONTROLS 5 dice eg be Exp YE rea eue eR naan gp ces ERN EU eae 104 IU 200108 Hiss pte 104 10 7 2 CS VLA Throttle System 104 10 7 3 J160 J170 Throttle non cs vla variants esee eterne eene 104 P Et 107 10 7 5 Air Intake System amp Carburetor 107 10 8 EXHAUST SYSTEM ierit tr seen ttes erp e RH Spr 109 10 8 1
18. 10 2 SECTION 2 SERVICE 0 11 2 1 LIS TOF EFFECTIVE PAGES eet wah eet 11 22 5 4 5 E E 12 23 252 nete epe 12 24 CENTRE OF GRAVITY LIMITATIONS eene denen 12 25 D 12 2 6 AIRCRAFT Ee Ile E 12 27 RECOMMENDED TORQUE VALUES IN 55 eren 16 3 SECTION 3 GROUND HANDLING SERVICING LUBRICATION amp INSPECTION 17 3 1 GROUND HANDLING en Ne ite 17 3 1 1 yn 17 3 1 2 17 3 1 3 E E EE 18 3 1 4 19 3 1 5 ET E ATE D EE ETTE E o 19 3 1 6 Tie DOWN MM 19 3 1 7 EEN 19 3 1 8 Returning Aircraft to Service issi Nieisen iiaii eaa 20 3 1 9 Temporary or Indefinite Storage otro oe ed
19. 2 o 0 LO 2 75 REVISION al 9 files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 L Miles Technical_manuals J160_J170 J160_ amp _J170_workin Jabiru Aircraft pty me un Aircraft Service Manual Jabiru J160 J170 Variants 6 4 8 WHEEL BALANCING Since uneven tyre wear is usually the cause of tyre imbalance replacing the tyre will probably correct this condition If a wheel shows evidence of imbalance during service it may be statically balanced 65 NOSE GEAR The nose gear comprises a steerable nose wheel mounted on a welded steel assembly with an aluminium wheel yoke and a rubber spring system The steel tube is constrained within two Ertalite bushes mounted in an aluminium housing which is attached to the front of the firewall Nose wheel steering is achieved by connecting the rudder pedal assembly to the nose wheel steering link by push rods The nosewheel is centred by springs A nose wheel speed fairing wheel spat is standard equipment Disassembly inspection repair and reassembly of the nose wheel assembly are described in separate paragraphs The wheel is in two halves which are joined by through bolts to the wheel hub as shown in Figure 15 During assembly of the nose wheel the through bolts must be tightened evenly and torqued to the value specified in Table 3 6 5 1 TROUBLE SHOOTING NOSE LEG Table 6 Trouble Sh
20. 26 3 5 2 INSPECTION GUIDELINES ete te 26 3 5 3 INSPECTION GHAR ibd nete t de e Een eese ta ete ce 29 4 SECTION E DEO M 33 4 1 FUSELAGE 33 42 WINDSHIELD AND WINDONWS eite 33 4 2 1 Desiri pt om NM NC 33 4 2 2 QUI 33 Revision Dated July 2005 Issued By RAS Page 3 of 156 Lies Technical manuals160 17010160 A J170 working files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM Jabiru Aircraft pty pta MEN un Aircraft Service Manual Jabiru J160 J170 Variants 4 2 3 33 4 2 4 Pg up IC eave ast evs sued 33 4 2 5 ICEL CCS o A 34 4 2 6 101 27151 34 4 2 7 Removal OE cete in OU 34 4 2 8 Installat On ERE 34 4 3 5 E 34 4 3 1 Removal and Installation ccc 220202212000 34 4 3 2 MEM REA 37 4 3 3 Door Seuls
21. 20 31 10 Inspection During Storage e ere en pass e er p aves rto epe Re cet 21 3 1 11 Returning Aircraft to Reruiee 21 3 2 SERVICING icnn 22 3 2 1 Y AU 22 3 2 2 23 3 2 3 M TD ER 23 3 2 4 Carburetor AP 3 23 3 2 5 ET DE 23 3 2 6 UI 23 3 2 7 Hydraulic EE e on M 23 3 39 CLEANING efie gite ite tertie tete pf ciet tee etie WE 24 3 3 1 Windshield and mter 24 3 3 2 Interior S rfa sf EE nne 24 3 3 3 Exterior Surfabgs 24 3 3 4 25 3 3 3 Engine and Engine Compartments don ode Se eoe Mia nito 25 3 3 6 1217 2717 C 25 3 3 7 D 25 3 4 E UE DE 25 3 4 1 Wheel Bearing Mains and 25 33 2 INSPEC NEE E EE 26 3 5 1 nspechon Charts usses
22. 65 6 8 5 Brake Systemi Bleeding tete E ee ue bee 67 6 8 6 Brake Pad Adjustment a ce eo DE 67 6 8 7 Parking Brakes E 66 7 SECTION 7 AILERON CONTROL 5 8 0 8 8 71 7 1 AILERON CONTROL SYSTEM bone beides ep eer epa Deva s 71 7222 GARNECH 73 7 2 1 Control Column Removal amp Installation sse seen eene tenens 73 137 CONTROL CADBUBS ctetu poe eie Poeti edente 75 7 3 1 Control Cable Removal amp Installation essendi eee 75 T4 AILERONS neo AO e e NE pO 75 7 4 1 Aileron Removal amp 5 75 7 4 2 Aileron Inspections amp 79 T3 CONTROL RIGGING on ett teet eer 75 8 SECTION 8 WING FLAP CONTROL 5 8 00 77 8 1 WING FLAP CONTROL SYSTEM 77 8 1 1 RE EE EE TE DEET 77 8 1 2 FLAP Switch ASSEMBLY 77 8 1 3 FLAP cross SHAFT 55 77 8 1 4 Removal and Installation uu iie i en evi ect be esi 77 8 1 5 Flap Control Rod esos DE 77 82 0o sedens abr esto e
23. LON 15 ONY 1 SI 5 31725 576 987 010 VE m SUC SSIONY SQU F O30 S20 230 INO 50 T S ON 530 101 7 HO31AV 37955 LON S3HL3ATTIIW NI ONVH 380990 SH SV 51 00 296 2 l13AIMH dOd ZEE 902928 N66 0Hd 1104 125511 OL O96NV SNO v X 559 SNIddV L S 5 2 210 13AIM dOd 9L E N6S00Hd LOAld dV14 30 48 609602 3S 31914 NOLLOAdSNI 6 lt 002 3H 1N32 9NIOHOJNI3H 08 02 WHY 4914 609202 318 2 7191029 807 6901 25 29119 39NIH 11 NO28Z0v2Z 1108 v9 ENV Nid 39NIH H3NIv L34 65 002 S412 52 318 2 680024 1108 26 3ONIH 691002 541292 WIHS 27892 660024 LN 201 3v3139NIH
24. 9 ATEWSSSY ANH T33HM ms sa Lie lt sss wn SLINN 017 Ald HOSLAY JO LN3SNO2 031409 SE NEN SIJYLIWITIIH NI 5 ION 15714 1HOIHAdOO SI SIHI Vd HOSLAY SIVOSLON 00 eN3WiQ 2 KI lt Z 2 o E 5 50 E 10 e uw D D lt 02 tn 2 o 0 LO 2 75 z o o 2 D files J160_ amp _J170_Tech doc OVA 3HAL HUAA 0939 OLNO 53441 3 18 A3SSV ALIENCTO LON 3801 ALON 6 X 005 DOTAN Obie OL M3HSVM 1913 91 01 0986 6 1708 91 90 6 8 LON JOTAN IL 2 tih 9H096NV 9 1108 VLPNV 8 2610 7620009 2 0 6 9 133HAA 1579 620119 2 L HINNI 1579 2200129 MO Wall L Miles Technical_manuals J160_J170 J160_ amp _J170_workin 9 Print Date 15 08 2005 9 57 00 ircraft pty A Aircraft Service Manual Jab Jabiru 9160 J170 Variants
25. reg 100 918 340A Q3NIHOVM 931 ISON ASSY 002200 9 lt 1003 918 1579 ASSY 133HM ISON 206 29 2 L 1004 918 G3NIHOVM ASSY ISON OH ALD H3SWN Lid WALI 1511 sued SHLONAT 1108 55 9310 1 HVTIOO 9 AOA 30551 330A 04141400 927 NI QN38 SMOHS 31551 gt E lt en a zZ o Ep E 10 N 0 D x 02 a 2 o 0 LO 2 5 75 z 9 gt D files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 L Miles Technical_manuals J160_J170 J160_ amp _J170_workin Jabiru Aircraft pty pta Jabiru J160 J170 Variants Aircraft Service Manual issus 6206129 Wid 1005918 1599 ASSY T33HM 38 evere Ald HOSLAY 30 LNSSNOD JHL 1 0 031409 ION 15714 ANY I SIHI 1108 2 8 EL 917 096 __ 9 HU Braas 6 2 620084 L 9 Wid T33HM YILNO LSYI L 9 H3NNI 15 2 221129 ALO 5 HASWAN IMvd Wall OL 3438
26. 92 Revision Dated July 2005 Issued By RAS Page 5 of 156 Lies Technical manuals160 17010160 A J170 working files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM Jabiru Aircraft pty pta un Aircraft Service Manual Jabiru J160 J170 Variants 92 RUDDER C 94 9 2 1 Renioyal amp Installation n onde nen HERRERA EES 94 9 2 2 Inspection Repair srce ce e t re ette teta tenter Metern erbe eae 94 93 CONTROLCABLE amp ATTACHMENTS entier tdt tipi contorta s e ases 94 9 3 1 Removal amp Installatiohi 2 ise de GIN SH nabs out oan 94 9a RIGGING EE 94 10 SECTION 11 ENGINE amp ENGINE INSTALLATION 98 104 ENGINE E irren Lopes 98 10 1 1 Engine Cowls Removal amp Installation 8 98 10 1 2 Cleaning Inspection 101 DUE NES 5 m 101 10 2 Sip C core A ented aie aan 101 105221 101 10 2 2 Engine Trouble Shooting essere eene eene 101 1023 1
27. Th DT 98 AXOd3 ONY HOO HLA 01 En ONOG 901 030 08 34 SNDIS Sv 031835 38 OL ASSY Woo AXOd3 COOL 3884 CANOA SNIMS 7 H3NNI 32N3H34J3H HO NMOHS 53215 3dNHS ONY 3215 E 456 9 4 HLOTO 9 052 DCH 06 9 SHAW C t0C4Y SHAY Z Gy L 3015 1435 8000 004300 4 0 5 1435 109900 4 83110 LASNI 4000 00460012 9 DIEN 0050094 9 L 51 MOQONIM 4000 DON 8 51 MOUNIM 00420042 G 4 Way 39NIH 4000 00200072 00300092 58 ASSY 4000 00410062 bi L S1 4859 0092 L NDS 8000 4 0 NIMS YANNI YOO 028007 2 3000 08010 NIMS Hop SH ASSY Moon NOWOL NMvHO Sv 51 ASSY MOO 20480092 ub Mode ON Lift wall ON Die vau 40 Uu NOLLO3POHd 31725 00 5 SNOISNSHKI Figure 4 Door Assembly Page 36 of 156 Issued By RAS de 2 3 a les Technical manuals 160 17019160 8 J170 worki
28. 9 Print Date 15 08 2005 9 57 00 Jabiru Aircraft pty me un Aircraft Service Manual Jabiru J160 J170 Variants 7 3 CONTROL CABLES Control Cables are of the enclosed push pull type fitted with spherical bearings at both ends To operate the outer cover of the cable must be clamped firmly at each end T 3 1 CONTROL CABLE REMOVAL amp INSTALLATION Control Cables are Primary Control and may not be removed or repaired without reference to JABIRU AIRCRAFT Pty Ltd or our approved local agent 7 4 AILERONS Ailerons comprise a moulded and bonded monocoque structure embodying a composite control horn at the outboard end 7 4 1 AILERON REMOVAL amp INSTALLATION 1 Unbolt cable from aileron control arm 2 Loosen screws in hinge retainers and lift hinge pin retainer away from the hinge pin It is not necessary to completely remove these parts Remove hinge pins 4 Remove aileron 5 Reverse the preceding steps for installation 7 4 2 AILERON INSPECTION amp REPAIR Inspect ailerons for any signs of delamination or cracking Pay particular attention to the Control Horn and hinges and their surrounding areas Repairs must be referred to JABIRU AIRCRAFT Pty Ltd or our approved local agent 7 5 CONTROL RIGGING 1 With the control stick in the neutral position use a straight edge not less than 1 metre long Hold the straight edge flush on the underside of the wing aerofo
29. H3HSVM 1 14 91 6 101 096 Le gt 2 1108 9L VcC t NV 06 515 LNOtH 7001619 62 1 46 931 GANIHOVW 16 7100029 82 7631 ISON GANIHOVW 06020099 zz 1004 918 NOISNSdSNS 60 09 92 l 340A H3HSVM dOL Y3ggNY 937 ISON 4032009 01 096 vz 1108 SUE 0 330A GANIHOVW 01 14 9313S0N Qo3coov9 cc HALLOO ZEL SO9PZSIN 12 m LAN 3115 0 S 0L NV 02 1109 91 9 6L 5 LAN DOTAN 82 592006 81 YIHSYM 9L 096NV 21 G3TTIVISNI 33V S1VdS N3HM 1108 ISN S1VdS LNOHLIM 5 N3HM 1108 VE9 YNV 91 2 LAN 2 9 6 2601 596026 GL 1108 9 6 V90 ENV Q 931 ISON 109 SNINIVL3H 7701909 L L LAN DOTAN 21 gt v 919 096 1 1108 995 VSL SNV OL o HSN AAS 8 6 GO 8 I 94 9 Nooovedd 6 1003 918 1 1 5 H3OVdS 07909 8 1004 918 1 1 4 vv0s909 1 340A H3HSVM 931 350 0 0 9 9 340A 3SV8 LAVHS 931 85 Gogcoovo 9 1003 919 340A T33HM ISON Qovioovo
30. ONY LHOlHAdOO SI SIHL LON od 331317114 NI 599 Nouoaroua Jabiru J160 J170 Variants ircraft pty A Jab Aircraft Service Manual 0917 HOLY 5000 L 3HSVM 098 096 0 0910092 0911 4000 w2018 0 100 2 8L H3HSVA LV TH IL 1811 096 Sl 1108 918 vOLSNV FL 09 7 42018 LNNOW HOLY 8008 1009 EL 1108 9 5 ve tNv ZL 0917 H3A31HO1v13000 1 00910052 LL LIAN DOTAN 91 2201 9920250 OL SSSNMOIHL 1914 91 101 098 4 6 1108 91 V90 ENV 8 0917 INIT SNLLOANNGS H21V1 Hood 0091009 1 681836 HOOd 01 9 2 TOHINOO H3NIVL3H SNIHdS H3HSVAA 006 5 6 2 Nid 31100 zel soorzsw t MNMISYSLNNOD 915 8 2 5697054 6 31n0 43431 122202 2 21 2 4004 SH 003 004 NOlLdIH2S3 Wall 1511 filesJ160 8 J170 Tech doc 9 E lt ep KI 2 KI KZ wi o E 5 50 LL E Ww en 0 lt 02 tn 2 o 0 LO 2 75 z 9 o 2 D Print
31. 58 6 5 3 Nose Gear Inspection and 59 6 5 4 Nose Wheel Speed Fairing Removal and Installation deseen 59 6 6 NOSE WHEBLD s ottiene aiebat E DE 59 6 6 1 Nose Wheel Removal and Installation sse eene eee enne eene eene nennen ne 59 6 6 2 Nose Wheel Disassembly eet ente e SEENEN 59 revision Dated July 2005 Issued By RAS Page 4 of 156 Lies Technical manuals160 17010160 A J170 working files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM Jabiru Aircraft pty pta MEN un Aircraft Service Manual Jabiru J160 J170 Variants 6 6 3 Nose Wheel Inspection Gnd Repair ui ty sedans ce eo eT eo po 60 6 6 4 Nose Wheel Reassembly eee opto EE 60 6 6 5 Wheel BALANCING eme A 61 67 NOSE WHEEL STEERING 5 64 6 7 1 2 4 1 Steering Centring Assembly 64 6 7 2 Nose Wheel Steering Assembly 64 BRAKESYSDIEM E eee eee eee 64 6 8 1 Trouble Shooting Brakes ere E 64 6 8 2 Drake Master e uie ido db ee ud nata ef oie pe e caedi eot 65 6 8 3 HydraulicBrake Lines ra ione ar 65 6 8 4 Wheel Brake Assemblies
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33. 66 002 5 51 209802 004 N6L008d ONIM 571 NOSHJTIV NEOLE0e 09 ASSY 491411 YAS 2606202 e e 09 w 7 H3HSVA 1914 21 91 7 096 LAN 9 ONIM 0917 571 55 YAS aovrrove NOlLdldH 2S3 ON 1 4482530 ON Lad 5 ON Assembly Sheet 1 6 J160 Wing Figure 10 e D D lt 02 tn 2 o 0 LO 2 75 z 9 o 2 D 9 files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 L Miles Technical_manuals J160_J170 J160_ amp _J170_workin ircraft pty A Aircraft Service Manual Jab Jabiru J160 J170 Variants 0297 OH3gvONnas ONIM LIM dS 50911 871 ASSY X YIS 1 HIM Ald HO31AV JO LN3SNOO JHL 1 0 2314809 16 ONY 1 SI SIHL 3uu 76 982 010 NOW 900 F 230 OML 929 230 INO 50 T 5 ON 101 WHANSD SNOLODV 9
34. 931 lt 61108 H39NOT LSYd 123 0 67 NIA SYNSNA N3AIS SHLSN311108 2 NMOHS LON 39v DS JO 3 108NOO 3HLN32 L t 1108 48 V9C ONV CL 9 ALAN DOTAN 8 6 LL 9 H3HSVAA IN 13 88 919 096 OL 4 l1O8 8 Vbc 9NV 6 2 18 ANVHLAYN 8 2 008002 56808009 2 2 3OvidMvOH3ONn H3HSVM 60 809 9 t 7607609 5 v 1388 ONIMOVE 7609809 alvid ONIMOVE 2 1 7602609 t 2 00 002 931 NIVIA ASSY 3504 duva ALO YASAINN gt 2 9 lt en H 2 2 5 en Ww D D lt 02 a 2 o 0 LO N 2 5 75 z 9 o 2 D 9 files J160_ amp _J170_Tech doc L Miles Technical_manuals J160_J170 J160_ amp _J170_workin Print Date 15 08 2005 9 57 00 AM Jabiru 4160 J170 Variants Jabiru Aircraft pty pta Aircraft Service Manual gv Loss 0497 wee Lud 01 83438 grs
35. Aircraft Service Manual Jabiru J160 J170 Variants TABLE OF FIGURES 7160 General e eee nme ond re e ao cen 13 1170 General Arrangement eite etre teret reete raise etie es 15 Door Hinge ASSY iiic ecd espe 35 D or snl 36 Door Latch Mechanism Assembly esee ehe derent tenere 38 60 Wing Assembly Sheet 1 4 24 44 4 0 4 00 enne tenente denne nennen nennen nnne nene nnne 44 J160 Wing Assembly Sheet 2 nennen nennen trennen trennen nennen nennt rennen nnne 45 1170 Wang Assy Sheet 1 E bre 46 Wing Assy Sheet 2 iiec eet nie er ee 47 Main Undercarriage Assembly 50 Wheel Assembly MR 51 Main Wheel to Leg AS8Y C E ees 52 Wheel Alhignmerni 2 eR AER Y HER TIE 57 te Ge Nes tea Let EIE 62 Nose Wheel Hub 5 63 Brake ASSy inning D ee PEE egere eder eek 69 Brake Master Neteco it ei e re ee run 70 Aileton System Schematic e rho Dette beer rre EE Rn pep co exe beso ba LE 72 Figure 19 Control Column Assen ul 74 Figure ERGO E d i
36. Page Revision Date Page Revision Date Page Revision Date 1 0 25 7 05 56 0 25 7 05 111 0 25 7 05 2 0 25 7 05 57 0 25 7 05 112 0 25 7 05 3 0 25 7 05 58 0 25 7 05 113 0 25 7 05 4 0 25 7 05 59 0 25 7 05 114 0 25 7 05 5 0 25 7 05 60 0 25 7 05 115 0 25 7 05 6 0 25 7 05 61 0 25 7 05 116 0 25 7 05 7 0 25 7 05 62 0 25 7 05 117 0 25 7 05 8 0 25 7 05 63 0 25 7 05 118 0 25 7 05 9 0 25 7 05 64 0 25 7 05 119 0 25 7 05 10 0 25 7 05 65 0 25 7 05 120 0 25 7 05 11 0 25 7 05 66 0 25 7 05 121 0 25 7 05 12 0 25 7 05 67 0 25 7 05 122 0 25 7 05 13 0 25 7 05 68 0 25 7 05 123 0 25 7 05 14 0 25 7 05 69 0 25 7 05 124 0 25 7 05 15 0 25 7 05 70 0 25 7 05 125 0 25 7 05 16 0 25 7 05 71 0 25 7 05 126 0 25 7 05 17 0 25 7 05 72 0 25 7 05 127 0 25 7 05 18 0 25 7 05 73 0 25 7 05 128 0 25 7 05 19 0 25 7 05 74 0 25 7 05 129 0 25 7 05 20 0 25 7 05 75 0 25 7 05 130 0 25 7 05 21 0 25 7 05 76 0 25 7 05 131 0 25 7 05 22 0 25 7 05 77 0 25 7 05 132 0 25 7 05 23 0 25 7 05 78 0 25 7 05 133 0 25 7 05 24 0 25 7 05 79 0 25 7 05 134 0 25 7 05 25 0 25 7 05 80 0 25 7 05 135 0 25 7 05 26 0 25 7 05 81 0 25 7 05 136 0 25 7 05 27 0 25 7 05 82 0 25 7 05 137 0 25 7 05 28 0 25 7 05 83 0 25 7 05 138 0 25 7 05 29 0 25 7 05 84 0 25 7 05 139 0 25 7 05 30 0 25 7 05 85 0 25 7 05 140 0 25 7 05 31 0 25 7 05 86 0 25 7 05 141 0 25 7 05 32 0 25 7 05 87 0 25 7 05 142 0 25 7 05 33 0 25 7 05 88 0 25 7 05 143 0 25 7 05 34 0 25 7 05 89 0 25 7 05 144 0 25 7 05 35 0 25 7 05 90 0 25 7 05 145 0 25 7 05 36 0 25 7 05
37. Unbolt pushrod amp remove brake handle Disconnect flexible hose at master cylinder 4 Unbolt master cylinder retaining bolts 2 b Plug or cap hydraulic fittings and hoses to prevent the entry of foreign material 6 Reverse the preceding steps to install brake master cylinder then fill and bleed brake system in accordance with Paragraph 6 8 5 6 8 2 2 BRAKE MASTER CYLINDER REPAIR Figure 19 may be used as a guide during disassembly repair and reassembly of the brake master cylinder Repair is limited to installation of new parts cleaning and adjustment Use only automotive brake fluid DO NOT use aircraft grade hydraulic fluid or damage will result 6 8 3 HYDRAULIC BRAKE LINES These lines are flexible hoses connected through a tee piece Repair is limited to replacement 6 8 4 WHEEL BRAKE ASSEMBLIES The Wheel Brake Assemblies use a disc which is attached to the main wheel hub with through bolts and a floating brake assembly Refer to Figure 18 for caliper details Figure 12 for installation of the caliper to the leg 6 8 4 1 REMOVAL The Wheel brake assemblies can be removed by disconnecting the brake hose and unbolting the brake cylinder from the backing plate The brake disc is removed after the wheel is removed and disassembled Refer to Figure 18 for disassembly of either wheel brake assembly 6 8 4 2 WHEEL BRAKE INSPECTION AND REPAIR 1 Clean all parts except brake linings in dry cleaning solvent and dry thor
38. psi psi Tyre Pressures Standard 137 kpa 20 137 kpa 20 137 kpa 20 137 kpa 20 Nose psi psi psi psi Wheel Alignment At 8 T 0 0 0 0 oe In Battery Locatan Compartment Compartment Compartment Compartment REVISION Print Date 15 08 2005 9 57 00 AM Dated July 2005 Issued By RAS Page 14 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Jabiru Aircraft pty pta 22 un Aircraft Service Manual Jabiru J160 J170 Variants Figure 2 J170 General Arrangement revision Dated July 2005 Issued By RAS Page 15 of 156 Lies Technical manuals160 17010160 A J170 working files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM Jabiru Aircraft pty Msn un Aircraft Service Manual Jabiru J160 J170 Variants 27 RECOMMENDED TORQUE VALUES FIBREGLASS Table 3 Recommended Bolt Torque Values BOLT SIZE TORQUE INCH LB AN3 20 25 2FTLB AN4 50 70 4 5 FT LB 5 100 140 8 12 FT LB PROPELLOR 72 6 FT LB e These values relate only to steel nuts on oil free cadmium plated threads e For Engine Bolt Torque Values see Engine Instruction amp Maintenance Manual e The above values are recommended for
39. 12 times leaving it in the horizontal position REVISION lo Dated July 2005 Issued By RAS Page 20 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM Jabiru Aircraft pty Msn un Aircraft Service Manual Jabiru J160 J170 Variants CAUTION Ensure that the Master and Ignition Switches are OFF T Install spark plugs and connect leads 8 Seal exhaust pipes Attach a red streamer to each DO NOT seal fuel tank breathers 9 Place protective covers over pitot tube static source vents air vents and openings in engine cowl to prevent the entry of foreign material or beings especially wasps 10 Attach a warning placard to the propeller stating that vents and breathers have been sealed The engine must not be started with the seals in place 11 Every 7 days the propeller should be rotated through 5 revolutions without running the engine leave propeller in the horizontal position CAUTION Ensure that the Master and Ignition Switches are OFF 3 1 10 INSPECTION DURING STORAGE 1 Generally inspect airframe and clean as necessary 2 Inspect the interior of at least one cylinder through the spark plug hole for corrosion at least once a month 3 If at the end of the 90 day period the aircraft is to be continued in non operational storage repeat Steps 1 13 above most will only need to be checked
40. 3 1 11 RETURNING AIRCRAFT TO SERVICE After temporary storage the procedures for returning the aircraft to service are as follows 1 Remove aircraft from blocks and check tyres for proper inflation 2 Check battery and install Check carburettor air filter and service if necessary 4 Remove warning placard from propeller 5 Remove materials used to cover openings 6 Remove clean and gap spark plugs 7 While spark plugs are removed rotate propeller several revolutions to clear excess preservative oil from cylinders REVISION lo Dated July 2005 Issued By RAS Page 21 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM Jabiru Aircraft pty Msn un Aircraft Service Manual Jabiru J160 J170 Variants CAUTION Ensure that the Master and Ignition Switches are OFF 8 Install spark plugs torque to 20 nm 180 inch Ibs 9 Check fuel filter replace if necessary 10 brake fluid level 11 If returning to service after indefinite storage fill fuel tanks with correct grade of fuel 12 Check fuel tank and fuel lines for moisture and sediment Drain enough fuel to eliminate any moisture and sediment 13 Check fuel tank breather is clear 14 Perform a thorough pre flight inspection 15 Start and warm engine 3 2 SERVICING Servicing requirements are shown in the ser
41. 77 8 2 1 Removal and Installation eese eene trennen entente nter enne tree enn nn nennen 77 8 2 2 Inspection and E E 78 8 2 3 Flap Rigging J170 SP EE Nt etie eei ene 78 8 2 4 flap RIGGING as per template 78 83 ELEVATOR CONTROL SYSTEM cerent 83 84 CONTROL COLUMN DESCRIPILION retener 83 8 4 1 Removal and Jnstoallorton 83 89 ELEVATOR detis oen Re teas 83 8 5 1 Removal and Jnstoallorton eene entree 83 8 5 2 Inspection and Repair iB ede e oben d D deo ein 83 8 6 CONTROL CABLE AND 84 8 6 1 Removal and Installation 84 EE E D E 84 88 ELEVATOR TRIM CONTROL SYSTEM 89 8 8 1 Operational Checks toj 89 8 8 2 Trim Handle 5 89 8 8 3 Control Cable and 5 89 8 8 4 Removal and Installation v E 89 8 8 5 Inspection and Repair D TEE 89 9 SECTION 10 RUDDER CONTROL 5 5 0 9 92 9 1 RUDDER PEDAL SYSTEM E ME 92 9 I 1 Removal and Installation eese esee ener 92 9 1 2 Inspection and Repair e e tert bea e etat ie e ete eo
42. 9 o 2 D 9 files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 L Miles Technical_manuals J160_J170 J160_ amp _J170_workin Jabiru Aircraft pty Msn un Aircraft Service Manual Jabiru J160 J170 Variants 6 3 1 REMOVAL The following procedural steps remove one side of the landing gear as a complete assembly Refer to applicable paragraphs for removal of the individual components 1 Jack the aircraft in accordance with the details given in Section 3 2 Unbolt wheel end of flexible brake hose catching brake fluid in a container 3 Remove bolt nut from top inboard end of undercarriage beam Remove rubber bushes 2 4 Remove bolts nuts 2 from the clamp at bend in undercarriage beam 5 Remove clamp 6 Remove Undercarriage Leg Assembly 6 3 2 INSTALLATION The following procedural steps install the landing gear as a complete assembly Refer to applicable paragraphs for installation of the individual components With aircraft jacked 1 Offer the beam to the fuselage and install clamp and bolts nuts 2 OFF Do tighten at this stage 2 Locate top end bolt install and tighten nut See Torque Value in Table 3 Tighten clamp bolts nuts 2 OFF See Torque Value in Table 3 4 Connect flexible brake line 5 Top up brake master cylinder with fresh brake fluid and bleed brakes see Paragraph 6 8 5 6 Lower aircraft 6 3 3 INSPECTION AND REPAI
43. HO31AV 31 26 Od E LON ONVH SLISOddO SH NAVYO SV 61 0 0 LiL YAMAJA 9692 WIHS 013 9 AXOd3 ONOG NI HSM 9 AXOd3 HOVLLY 1 0 0 O NOILOJ HLOT 979 NOLLO3S OLNO 9 T3NNYH2 6 1 0 v X OOZ 1 9 OSL X OOZ 005 X 0021 AYT ONIM 88 HLIM 20149 AXOd3 T13NNVH2 1114 1 070 3 3 NOILO3S OL 3903 H3AO OL MOTT HLON31 11014 H3AO OSL X 092 0 dv L H3AO 09 X 022 Gre SH3AVTZ AVI W2014 8 AXOd3 NI O34 135 Figure 7 J160 Wing Assembly Sheet 2 10 Ke D D x 02 a 2 o 0 LO 2 75 REVISION lot 9 files J160_ amp _J170_Tech doc L Miles Technical_manuals J160_J170 J160_ amp _J170_workin Print Date 15 08 2005 9 57 00 AM 736 13388 029
44. Parking Brake consists of an over centre cam on the brake handle Should the cam have insufficient travel for the brakes to hold the aircraft with a propeller thrust of 2500rpm adjust by one or all of the following 1 Adjust brakes as described in Paragraph 6 8 6 2 Bleed air from brake system described Paragraph 5 8 5 REVISION lo Dated July 2005 Issued By RAS Page 68 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM Jabiru Aircraft pty me un Aircraft Service Manual Jabiru J160 J170 Variants Figure 16 Brake Calliper Assy Revision Dated July 2005 Issued By RAS Page 69 of 156 L Miles Technical manuals160 17010160 A J170 working files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM ircraft pty A Aircraft Service Manual Jab Jabiru J160 J170 Variants LON LSNW LH9IHAdOO SI SIHL 029 Oudavawnga 6 98 010 NOV Vd 0319130 5 80 F SHIONV S00 F 290 OML SZO F 230 F S ON FIOHM SHONVH3S IOL IVe3N39 AWOS LON Ir LS d
45. RAS Page 12 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM Jabiru Aircraft pty pta 2 Aircraft Service Manual Jabiru 4160 J170 Variants Model J160 A J160 C Oil Type Refer Engine Manuals Refer Engine Manuals Engine Model Refer Appendix For Engine Data Jabini 2290 Jabiru Jabiru Propeller Type 2 bladed Wooden 2 bladed Wooden Propeller Diameter 60 dia 1524mm 60 dia 1524mm Propeller Pitch Jabiru 44 pitch Jabiru 42 pitch 1117mm 1067mm Wheel Sizes Standard 500 x 6 rim 500 x 6 rim Tyres Standard 6 wide 6 Ply 6 wide 6 Ply Tyre Pressures Standard Mains 179 kpa 26 psi 179 kpa 26 psi Tyre Pressures Standard Nose 137 kpa 20 psi 137 kpa 20 psi Wheel Alignment At Gross Weight Camber 0 G Toe In 0 cd Battery Location Compartment Compartment ab 1 ie p PA 1 2 Be T t t do Figure 1 J160 General Arrangement REVISION L files Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM Dated July 2005 Issued By RAS Page 13 of 156 Jabiru Aircraft pty pta 2
46. all installation procedures contained in this Manual except where other values are stipulated e The above values are not to be used for checking tightness of installed parts during service CAUTION GENERAL RULE DO NOT REUSE SELF LOCKING NUTS REVISION lo Dated July 2005 Issued By RAS Page 16 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM Jabiru Aircraft pty Msn un Aircraft Service Manual Jabiru J160 J170 Variants Section Ground Handling Servicing Lubrication amp Inspection 3 1 GROUND HANDLING 3 1 1 TOWING The JABIRU aircraft is very light and should always be moved by hand Moving the aircraft is accomplished by using the wing struts or prop hub or landing gear struts as push points together with the solid rear fuselage join of the fin to the tail plane CAUTION Do not use control surfaces to move the aircraft Damage to the control system may result When pushing at the join of the fin and Tail Plane take care that you do not jam your fingers under the rudder the rudder hinge remember that it is Connected to the Nose Wheel CAUTION When moving the aircraft never turn the Nose Wheel more than 15 degrees either side of centre or Nose Gear may be damaged The aircraft may also be moved by placing the propeller in the horizontal and then placing one hand on the propel
47. inflation Inflate to pressure shown in above Main wheels out of alignment Align as specified above Tyres wear excessively Bent axle stubs Install new part s Dragging Brakes Refer to Para 6 8 6 3 MAIN GEAR Figures 10 11 an 12 illustrate the main landing gear The illustrations should be used in conjunction with the following procedures during removal and installation of component parts WARNING Check looseness of main U C beams by lifting each wing and trying to move beam back and forth If movement tighten clamp bolts 2 evenly to take beam movement out Do not over tighten or exceed 3 threads clear on the nuts use extra washers Over tightening can cause bolt fracture and failure to tighten both can also cause bolt failure See Torque Value Figure 1 2 The wheels comprise two wheel halves which are assembled as shown in Figure 11 During assembly of the main wheels the through bolts nuts should be tightened to the value specified in Table 3 The assembly of the wheels to the undercarriage leg is shown in Figure 12 REVISION lo Dated July 2005 Issued RAS Page 49 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM ircraft pty A Aircraft Service Manual Jab Jabiru J160 J170 Variants 205029 6 091 0 ASSY
48. keeps dust and dirt from entering the induction system The value of maintaining the air filter in a good clean condition cannot be overstressed More engine wear is caused through the use of a dirty or damaged air filter than is generally believed The frequency with which the filter should be removed inspected and cleaned will depend on the operating conditions A good general rule however is to remove inspect and clean the filter ever 50 hours of engine operating time and more frequently if warranted by the operating conditions Clean only with compressed air Under extreme operating conditions daily servicing of the filter is recommended 3 2 5 BATTERY The Battery is a gel 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 a thorough flushing with clean water Remove battery and clean residue from aircraft Tighten cable and terminal connections with a wire brush then coat with petroleum jelly before connecting cables Check the battery every 50 hours or at least every 30 days more often in hot weather Inspect the Battery Box and attachments Clean and remove any signs of spillage or corrosion 3 2 6 TYRES Maintain tyre pressure at the air pressure specified in Aircraft Specifications above When checking tyre pressure examine tyres for wear cuts bruises and slippage Remove grease and mud from t
49. pitch propeller 23 AIRCRAFT SPECIFICATIONS Leading particulars of this aircraft with dimensions based on gross weight are given in Figure 1 1 If these dimensions are used for constructing a hangar or computing clearances remember that such factors as tyre pressure tyre size and load distribution may result in some dimensions that may be somewhat different from those listed 2 4 CENTRE OF GRAVITY LIMITATIONS The JABIRU is a very light aircraft The installation of equipment may significantly alter the approved CG limits of the aircraft Therefore all proposed fixed installations must be approved by JABIRU AIRCRAFT Pty Ltd 25 TORQUE VALUES A chart of recommended torque values is shown in Figure 1 2 These torque values are recommended for all service procedures contained in this manual except where other values are stipulated They are not to be used for checking tightness of installed parts during service 2 6 AIRCRAFT SPECIFICATIONS Table 1 J160 Specifications Model J160 A J160 C 540kg 540kg Aircraft Maximum Weight 119015 119015 Fuel Capacity 135 litres 135 litres AVGAS 100 130 MOGAS with Octane Rating 95 RON or above may be used if AVGAS is not available Fuel Type Fuels Containing Alcohols Ethanol etc will damage the fuel tank sealant and MUST NOT BE USED IN JABIRU AIRCRAFT Oil Capacity 2 3 litres 2 3 litres REVISION lo Dated July 2005 Issued By
50. stabiliser is a moulded monocoque structure of rigid cellular polystyrene bonded to a fibreglass skin and rear spar Refer to Figure 30 5 4 1 REMOVAL AND INSTALLATION The horizontal stabiliser is an integral part of the fuselage to which it is bonded It cannot be removed All repairs must be referred to JABIRU AIRCRAFT Pty Ltd or our approved local representative REVISION lo Dated July 2005 Issued By RAS Page 48 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM Jabiru Aircraft pty Msn un Aircraft Service Manual Jabiru J160 J170 Variants 6 SECTION 6 LANDING GEAR and BRAKES 6 1 LANDING GEAR Main gear comprises two separate composite beams which are bolted to the fuselage at the top and centre and to the wheel stub at the bottom The nose gear is a welded steel trailing arm assembly with a rubber spring system The nose wheel is steerable with the rudder pedals Nose Wheel and Main Wheel Speed Fairings are optional equipment 62 TROUBLE SHOOTING MAIN UNDERCARRIAGE Table 5 Trouble Shooting Main Undercarriage Trouble Probable Cause Remedy Inflate to pressure shown at Incorrect tyre inflation above Aircraft leans to one Landing gear attaching parts Tighten loose parts Replace side not tight defective parts Bent axle stubs Install new part s Incorrect tyre
51. support brackets 4 off REVISION lo Dated July 2005 Issued RAS Page 18 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM Jabiru Aircraft pty Msn un Aircraft Service Manual Jabiru J160 J170 Variants 3 Fit cables rope to shackles and to a centre lift shackle 4 Hoist only from this point ensuring that cables ropes do not mark the top of the fuselage at corners above wing support brackets 3 1 4 LEVELLING Method 1 For both lateral and longitudinal levelling use a spirit level on either side of the lower door sills Method 2 Use the join line of the cowl top amp bottom halves 3 1 5 PARKING Parking precautions depend principally on local conditions As general precaution check the wheels and tie the control handle back firmly with a seat belt to lock the controls Park into the wind and tie down the aircraft as outlined in below if a hangar is not available 3 1 6 TIE DOWN When mooring the aircraft in the open head into wind if possible Secure control surfaces by tying the control handle back firmly with a seat belt Then 1 Tie ropes to the top end of each wing strut Secure opposite end of the ropes to ground anchors located at approximately 30 degrees to the vertical outboard of the top wing attachment point Ensure that the ropes have sufficient slack to not strain the wing
52. um E ee 16 982 010 N O V lt 1313192345 SSIINN 5 S3u L3INETTIALNT LIA eds Figure 15 Nose Wheel Hub Assembly 10 en D D lt 02 tn 2 o 0 LO 2 75 z 9 gt D 9 files J160_ amp _J170_Tech doc L Miles Technical_manuals J160_J170 J160_ amp _J170_workin Print Date 15 08 2005 9 57 00 AM Jabiru Aircraft pty Msn un Aircraft Service Manual Jabiru J160 J170 Variants 67 NOSEWHEEL STEERING SYSTEM 6 7 1 5 7 1 STEERING CENTRING ASSEMBLY The Nosewheel Centring Assembly consists of springs which are compressed when the nose leg is moved to the left or the right Repair is limited to replacement of parts 6 7 2 NOSE WHEEL STEERING ASSEMBLY Refer to Figure 15 The Nosewheel Steering Assembly comprises of two Steering push rods attaching the Rudder Pedals and the Steering Link Repair is limited to the replacement of parts 68 BRAKE SYSTEM The hydraulic brake system consists of one master cylinder located between the seats in the main longitudinal beam flexible hoses connecting the master cylinder to each wheel brake cylinder and the single disc floating cylinder type brake assembly located at each main landing gear wheel 6 8 1 TROUBLE SHOOTING BRAKES Table 7 Trouble Shoot
53. 10 Cabin upholstery trim 5 1 11 Switches fuses S 12 Pitot amp static system slips P d 13 Radio intercom amp headsets 14 Antenna amp cable 15 Battery battery cradle amp cables E Control Systems In addition to the items listed below always check for correct direction of movement particularly if controls have been disconnected and correct travel 1 Cables amp clamps 2 Rod ends 1 3 Trim control amp cable 1 5 4 Travel stops 1 5 Decals amp labels 2 5 6 Flap control amp linkages 7 Elevator control amp linkages 5 8 Rudder pedals amp linkages 9 Exterior surfaces of control surfaces 5 Revision Dated July 2005 Issued By RAS Page 32 of 156 Lies Technical manuals160 17010160 A J170 working files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM Jabiru Aircraft me un Aircraft Service Manual Jabiru J160 J170 Variants Annual Inspection Each 200 Hours Each 100 Hours Each 50 Hours 10 Control horns hinges amp hinge lock tabs 4 Section 4 Fuselage 41 FUSELAGE The Fuselage is a composite monocoque self supporting structure and includes both the Horizontal Stabiliser and Vertical Fin All repairs must be referred to Jabiru Aircraft Pty Ltd or approved local representative 4 2 WINDSHIELD AND WINDOWS 4
54. 2 1 DESCRIPTION The windshield and windows are one piece acrylic plastic panels set in sealing strips with Epoxy Resin amp Fibre Flock and secured to the fuselage with screws nuts IMPORTANT In the event of a bird strike the windshield is the only protection for the crew and therefore must be maintained in excellent condition Cracks up to 25 mm in length should be stop drilled those longer than 25 mm should NOT be repaired the windshield must be replaced 4 2 2 CLEANING Refer to Section 3 4 2 3 WAXING Waxing will fill in minor scratches in clear plastic and help protect the surface from further abrasion Use a good grade of commercial wax NOT SILICON BASED applied in a thin even coat Bring wax to a high polish by rubbing lightly with a clean dry flannel cloth CAUTION Silicon based waxes and polish are not recommended as silicon may be absorbed into the glass fibre laminate and effect the reparability due to impairing bonding 4 2 4 REPAIRS Damaged window panels and windshield may be removed and replaced if damage is substantial However certain minor repairs as prescribed in the following paragraphs can be made successfully without removing the damaged part from the aircraft REVISION lo Dated July 2005 Issued By RAS Page 33 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM Jabiru Aircraft pty Msn un
55. 91 0 25 7 05 146 0 25 7 05 37 0 25 7 05 92 0 25 7 05 147 0 25 7 05 38 0 25 7 05 93 0 25 7 05 148 0 25 7 05 39 0 25 7 05 94 0 25 7 05 149 0 25 7 05 40 0 25 7 05 95 0 25 7 05 150 0 25 7 05 41 0 25 7 05 96 0 25 7 05 151 0 25 7 05 42 0 25 7 05 97 0 25 7 05 152 0 25 7 05 43 0 25 7 05 98 0 25 7 05 153 0 25 7 05 44 0 25 7 05 99 0 25 7 05 154 0 25 7 05 45 0 25 7 05 100 0 25 7 05 155 0 25 7 05 46 0 25 7 05 101 0 25 7 05 156 0 25 7 05 47 0 25 7 05 102 0 25 7 05 157 48 0 25 7 05 103 0 25 7 05 158 49 0 25 7 05 104 0 25 7 05 159 50 0 25 7 05 105 0 25 7 05 160 51 0 25 7 05 106 0 25 7 05 161 52 0 25 7 05 107 0 25 7 05 162 53 0 25 7 05 108 0 25 7 05 163 54 0 25 7 05 109 0 25 7 05 164 55 0 25 7 05 110 0 25 7 05 165 Issue Notes revision Dated July 2005 Issued By RAS Page 11 of 156 Lies Technical manuals160 17010160 A J170 working files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM Jabiru Aircraft pty Msn un Aircraft Service Manual Jabiru J160 J170 Variants 2 2 GENERAL DESCRIPTION The JABIRU J160 aircraft described in this manual are 2 seat high wing monoplane composite aircraft of monocoque construction 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 The aircraft is equipped with JABIRU 4 cylinder 4 stroke engines driving a wooden fixed
56. Aircraft Service Manual Service Schedule Inspection Schedule Engine Instruction amp Maintenance Manual Propeller Instruction Manual Airworthiness Limitations Mandatory Replacement Times Structural Inspection Intervals Structural Inspection Procedures Jabiru Aircraft pty Msn un Aircraft Service Manual Jabiru J160 J170 Variants FOREWORD This manual contains JABIRU recommended procedures and instructions for ground handling servicing and maintaining The following Jabiru aircraft models J160 Jabiru 2200 powered J170 Jabiru 2200 powered In Australia either model may be registered either by CASA in the general aviation category as a prefix amp have MTOW of 540kg or the AUF in the Ultralight category as a 19 prefix amp have a MTOW of 540kg In countries other than Australia other registration requirements will apply It is the owner s responsibility to become fully aware of the particular maintenance requirements and limitations applicable to the appropriate registration The information in this manual is based upon data available at the time of publication and is supplemented and kept current by Service Bulletins amp Service Letters published by JABIRU AIRCRAFT Pty Ltd These are posted on the JABIRU website or your local dealer of Distributor as recorded by JABIRU so that they have the latest authorised recommendations for servicing the aircraft New owners of
57. CTION 14 ELECTRICAL 5 8 8 0 136 13 1 ELECTRICAL POWER SUPPLY SYSTEM eee 136 13 2 WIRING DIAGRAM cnet oorr E ete 136 13 35 E 138 1331 Master Switch EE DN 138 134 POWER TYP THM 138 194 E E E WE E ex M E eee 138 1342 Battery Trouble 138 1343 Installation e se pde eel stia 138 1344 Cleaning the Battery a i sii 138 1323 BATTERY BOX gies EE ere tete tes 139 13 5 STARTER SOLENOID r i e A 139 13 6 VOLTAGE REGULATOR eee rene Pe cretion 139 13 7 STROBES Y STEM OPTION enti ID An RERO 139 13 8 ELECTRICAL LOAD ANATLNSIR 139 139 RADIO WIRING DIAGRAM OPTION 139 1391 VHF ANTENNA INSTALLATION i eod 139 14 SECTION 15 PAINTING amp 0 0 141 JA INTERIOR Et puri beni rid decim it Me seve ettet eris tees 141 V 141 142
58. Carefully inspect bearings for damage and discolouration NOTE Bearings are pre packed DO NOT clean with solvents as it will remove the packing 5 Replace bearings 6 Apply automotive wheel rim lubricant to the bead areas of the rim halves 7 Position tyre and tube between wheel halves with tube inflation valve through hole in outside wheel half 8 Mate wheel halves While holding halves together assemble a washer and nut on one through bolt and tighten snugly Assemble the remaining washers and nuts on the through bolts and torque to the value specified in Table 3 CAUTION Ensure tube is not pinched between wheel halves during assembly Uneven or improper torque of through bolt nuts can cause failure of bolts with resultant wheel failure 9 Insert through bolts through brake disc and position disc on the inner wheel hub flange 10 Inflate tyre to seat tyre beads then adjust to correct tyre pressure Refer Aircraft Specifications above 6 4 4 MAIN WHEEL INSTALLATION 1 Lightly coat axle with Anti Sieze or a Water Proof grease 2 Place wheel assembly on axle REVISION lo Dated July 2005 Issued By RAS Page 55 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM Jabiru Aircraft pty Msn un Aircraft Service Manual Jabiru J160 J170 Variants Install spacer and lock bolt nut thro
59. D 31v 1d 31990 dido 9299174 NEEDING SWE 1914 917 096 1108 96 1108 916 V9L ENV MONN OO H3Ovds v6g000 les 1108 9L LAN DOTAN 9 VEL ENV 2601 998 02511 YAHSVAA 1914 DL 01 096 2118 LOAld 310NVH 050 OZt S9 O0ZSIN LOAld H32vdS v82000 7TOH1NO2 NOYATI 0715 9621106 H3HSVA NOTAN 6 000 H3MIHIS MN 32138 NOMA TI 20 60 ONIAA 9NIQ O3 3404 104100 11 v9000L 1108 91 WEN LOAld 15 103920 dOd 92 LSVHS 10 14 YOILS 3H1N32 08920 6 3903M ANNOY SHY 31892 L30vuga 1091100 602001 3903M 3 18v29 Iv LH340vuga 96061165 LHvd 1817 SHEd 157 Sped Figure 19 Control Column Assy Page 74 of 156 Issued By RAS de 2 3 a les Technical manuals 160 17019160 8 J170 workin REVISION filesJ160 8 J170 Tech doc
60. Date 15 08 2005 9 57 00 L Miles Technical_manuals J160_J170 J160_ amp _J170_workin Jabiru Aircraft pty Msn un Aircraft Service Manual Jabiru J160 J170 Variants 4 3 4 LOCKS An optional cylinder and key lock is available When fitted the keyed barrel lock is located in the fuselage at the rear of the Port amp Starboard amp Rear doors Spare keys are available to JABIRU registered owners by quoting the aircraft Serial Number 44 SEATS The JABIRU seats are an integral part of the structure of the aircraft they are therefore fixed in position Forward and upward adjustment can be achieved by placing a cushion behind and or under the occupant The seat pans incorporate crushable foam which is essential in providing shock absorption in crash conditions WARNING DO NOT MODIFY SEATS 4 4 1 REPAIR As seats are integral to the aircraft structure any repair must be referred to JABIRU AIRCRAFT Pty Ltd 4 5 UPHOLSTERY Seat upholstery is provided through slip on covers These are easily removed for cleaning and inspection of the seat structures Optional Hood and Cabin lining is available together with Door Pockets 4 5 1 UPHOLSTERY CLEANING The upholstery used in the J160 C has been treated with a flame retardant to meet the flammability requirements of CS VLA formerly JAR VLA This treatment will withstand 5 washes or dry cleans before requiring re application The washing of cabin u
61. E 125 DI MEME IMS a ee 125 12 3 PIFOT 8 STATIC SYSTEMS entretient ME posee ceo vents cts 125 12 3 1 Pitot Static System Maintenance esee 125 12 3 2 Static Pressure System Inspection amp Leakage Test 125 12 3 3 Pitot System Inspection amp Leakage Tee 126 1234 Blowing Out Lines E E 127 12 3 5 Removal amp Installation of Compoente essent denen 127 12 3 6 Trouble Shooting Pitot Static Aveienm 127 12 3 7 Trouble Shooting Airspeed Indicator 128 12 3 8 Trouble Shooting 128 12 3 9 Trouble Shooting Vertical Speed Indicator Option 129 12 3 10 Pitot Tube Alignment N ios Niom ere A eme pride S 129 124 TACHOMETER er ENSE eR 132 12 5 CH PRESSURE GAUGE 133 12 6 OIL TEMPERATURE GAUGE eie cele aati ies Nose gege 133 12 7 CYLINDER HEAD TEMPERATURE 134 12 8 EXHAUST GAS TEMPERATURE GAUGE 134 12 9 tHOURMIETER eret 134 1210 MAGNETIC COMPASS iet eR eee Peek ned be breed ek eee tbe de poen 134 12 11 GYRO INSTRUMENT PACKAGE seen enne denen enne 135 13 SE
62. Exhaust System Removal and Installation eese 109 10 8 2 Inspections d a E a andes CN 109 10 9 EXTREME CLIMATIC CONDITIONS eese eene endrerit nennen eene 111 10 52 E e 111 10 22 Seacoast and Hunfid 111 11 SECTION 12 FUEL BYXS WE My tertie TT 113 11 1 DESCRIPTION fee eet eee ee a D ers cosh REN CER 113 Fuel System iia e ca cub ege Pa cea Reo 113 11 1 2 J160 F170 Fuel System non cs vla variants 113 11 13 Precu uliOns nnda r 114 11 1 4 Fuel System Trouble Shooting 117 11 2 FUEL TANK C 117 LL ve bee dep Pre 117 11 2 2 Fuel Tank Removal amp Jnstolletion 117 11 3 ISRAEL E DE 118 11 34 Description 4e E 118 EE DE 118 114 2 121 1541 ee died 121 11 42 Fuel Valve Removal amp
63. I OH SIHL o Ko E E o 2 KI KZ gt Q lt Sr em E Ww 0 lt 02 tn 2 o 0 LO N 2 75 z 9 o 2 D 9 files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 L Miles Technical_manuals J160_J170 J160_ amp _J170_workin Jabiru Aircraft pty Msn un Aircraft Service Manual Jabiru J160 J170 Variants 7 2 CONTROL COLUMN Refer to Figure 21 7 2 1 CONTROL COLUMN REMOVAL amp INSTALLATION The Control Column is a Primary Control and may not be removed or repaired without reference to JABIRU AIRCRAFT Pty Ltd or our local approved agent REVISION lo Dated July 2005 Issued By RAS Page 73 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM ircraft pty A Aircraft Service Manual Jab Jabiru J160 J170 Variants a 09920 6 ON SAAC Ald HO31 V JO LN3SNOO JHL 931902 LON LSNH LHOIAdOO SI SIHL LYYd OL H333H SOF S319Nv SUD F 230 MOL X 230 INO 90 T S ON 1 WHANSD S3u L3MATTTIIA NI SNOISN3MIIG TOYLNOD NOMA TY 7611106 STOULNO
64. ION 3 5 1 INSPECTION CHARTS The chart at Paragraph 3 5 2 shows the recommended intervals at which items are to be inspected As shown in the chart there are items to be inspected each 50 hours each 100 hours and each 200 hours There are also special inspection items which require inspection of servicing at intervals other than 50 100 and 200 hours The engine Instruction Manual also details engine inspection schedules and should be consulted in addition to this chart e When conducting an inspection at 50 hours all items marked under EACH 50 HOURS would be inspected serviced or otherwise completed as necessary to ensure continuous airworthiness e At each 100 hours the 50 hours items would be completed in addition to the items marked under EACH 100 HOURS necessary to insure continuous airworthiness An inspection conducted at 200 hours would likewise include the 50 hour items and 100 hour items in addition to those at EACH 200 HOURS complete aircraft inspection includes all 50 100 and 200 hour items together with those shown in the Engine Instruction Manual 3 5 2 INSPECTION GUIDELINES 3 5 2 1 MOVEABLE PARTS lubrication servicing security of attachments binding excessive wear safety proper operation proper adjustment correct travel cracked fittings security of hinges defective bearings cleanliness corrosion deformation sealing and tension 3 5 2 2 FLUID LINES AND HOSES leaks cracks kinks c
65. R d Inspect composite beam for damage indicated by cracks or delamination particular attention to the area around the centre bend and to areas around drilled holes 2 Inspect bolts and nuts for signs of stress or bending replace if in any doubt Inspect clamp for damage REVISION lo Dated July 2005 Issued By RAS Page 53 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM Jabiru Aircraft pty Msn un Aircraft Service Manual Jabiru J160 J170 Variants 4 Inspect bolt seats in fuselage for signs of damage wear or perishing Repairs to the composite undercarriage beams must be referred to JABIRU AIRCRAFT Pty Ltd or our local approved agent 6 3 4 MAIN WHEEL FAIRING REMOVAL AND INSTALLATION 1 Remove the machine screws around the join of the inner and outer sections of the fairing 2 Remove the bolt on the outside of the fairing Remove the machine screws 2 OFF on the inboard side of the leg 4 Reverse the preceding steps for installation 6 3 5 MAIN GEAR TOP FAIRING REMOVAL AND INSTALLATION The fairing at the top of the main undercarriage leg is removed by removing the securing screws To install reverse this procedure 64 MAIN WHEEL Refer to Figure 12 6 4 1 MAIN WHEEL REMOVAL 1 Jack aircraft as outlined Section 3 above 2 Remove speed fairing if installed in ac
66. RAFT Pty Ltd or our approved local agent 5 1 3 INSTALLATION T Fit the lower strut attaching bolt leaving the top end of the strut on the ground WARNING Do Not Tighten nut or metal fatigue may result Washer must be free to rotate 2 Fit wing to fuselage leaving wing tip on the saw horse and routing aileron cable through hole in fuselage wing root Install front and rear wing attaching bolts nuts 4 Put top wing strut attaching bolt in your pocket 5 Lift wing tip and install wing strut to wing strut attachment with bolt from pocket Install nut WARNING Do Not Tighten nut or metal fatigue may result Washer must be free to rotate 6 Connect all fuel lines to wing fuel gauge making sure there are no lines that have kinked 7 Put about 1015 of fuel in each tank amp check for any leaks 8 Attach flap to wing ensuring all bushes are in place 9 Install bolt nut in flap control rod 10 Install bolt nut in aileron control cable on main control stick horn 11 Install clamp block and pin in aileron control cable clamp at rear of seat REVISION lo Dated July 2005 Issued By RAS Page 42 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM Jabiru Aircraft pty Msn un Aircraft Service Manual Jabiru J160 J170 Variants 12 13 14 15 On RH wing reconnect Pitot tube Replace w
67. TIONS iskerne WE Ee Pe ees evo e 150 19 2 IDENTIFICATION RTAMPINOGS 00 150 19 3 RI ONE 150 10 3 INSTAEBATION D br EU EM 151 19 5 TO REMOVE EXISTING 153 19 6 ASSEMBLE AND REPLACE PROPELLER ASSEMBLY eene eene 153 19 7 SERVICING AND REPAIRS pn pheeseseeeersessseeesressoseoeeeesrese 154 19 8 PROPELLER BALANCING DROCEDURE 155 20 APPENDIX V AIRWORTHINESS LIMITATIONS scsccccocssssssssscccsssssscstecsescssssceecccsssscsssenscescssssssners 156 201 ic NO ite eee 156 20 22 MANDATORY REPLACEMENT TIME 156 20 3 STRUCTURAL INSPECTION INTERVALS 156 20 4 INSPECTION PROCEDURES 156 Revision Dated July 2005 Issued By RAS Page 8 of 156 Lies Technical manuals160 17010160 A J170 working files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM Jabiru Aircraft pty pta un 1 1 Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18
68. ariants Annual Inspection Each 200 Hours Each 100 Hours Each 50 Hours 4 Fire sleeves 1 5 Fuel tank vents caps amp placards 1 6 Fuel Tanks 5 i 7 Fuel shut off valve amp placards Landing Gear 1 Main gear wheels amp fairings 1 n 2 Nose gear wheel steering links tension links 2 amp fairings 3 Wheel bearings 4 Nose gear strut 5 Nose gear housing amp bushes 6 Main gear struts clamps bolts amp nuts 7 7 Tyres amp tubes 8 Brake fluid hoses linings discs brake assemblies amp master cylinder 9 Brake operational check 5 1 Aircraft exterior 5 2 Aircraft structure 1 5 3 Windows windshield doors amp seals i 4 Seatbelts amp shoulder harnesses B 5 Seat structure 5 4 6 Instruments amp markings Revision Dated July 2005 Issued By RAS Page 31 of 156 Lies Technical manuals160 17010160 A J170 working files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM Jabiru Aircraft me un Aircraft Service Manual Jabiru J160 J170 Variants Annual Inspection Each 200 Hours Each 100 Hours Each 50 Hours 7 Instrument plumbing amp wiring 8 Instrument panel shock mounts decals amp labels 9 Ventilation system E
69. attachments should a tyre deflate while the aircraft is tied down 2 Tie rope to the Tail Tie down Hole in the Ventral Fin Secure the opposite end of rope to ground anchors 3 1 7 FLYABLE STORAGE Flyable storage is defined as a maximum of 30 days non operational storage Ensure that the engine has been stopped by turning off the fuel valve thereby not leaving any fuel in the carburettor bowl Every 7 day the propeller should be rotated through 5 revolutions without running the engine Leave the propeller in the horizontal position to ensure even distribution of liquids in the wood If left in the vertical position liquids will drain to the lower tip resulting in an unbalanced propeller CAUTION Ensure that the Master and Ignition Switches are OFF Store under cover away from direct sunlight as ultra violet rays damage composite structures REVISION Dated July 2005 Issued By RAS Page 19 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM Jabiru Aircraft pty Msn un Aircraft Service Manual Jabiru J160 J170 Variants In addition the Pitot tube static air vent air vents openings in the engine cowl and other similar openings should have protective covers fitted to prevent entry of foreign materials and beings especially wasps 3 1 8 RETURNING AIRCRAFT TO SERVICE After flyable storage retu
70. biru Aircraft pty Msn un Aircraft Service Manual Jabiru J160 J170 Variants 5 SECTION 5 Wings And Empennage 51 WINGS Refer to Figures 6 7 8 and 9 NOTE J170 J170 SP and J170 SPC models use the same wing assembly as shown for the J170 UL below in Figures 8 and 9 with the exception of the Bare Wing Assembly which is P No 2095023 in place of Each composite wing is a semi cantilever monocoque type with a main spar The wing is a moulded structure with a series of ribs that are bonded through the moulding process to the fibreglass skin fuel tanks and to the spar The forward wing attachment is an extension of the forward sub spar The rear attachment is a composite block heavily bonded to the reinforced wing skin and attaches to the main spar through the Wing End Plug Both attachments are through stainless steel threaded bushes bonded into the attachment blocks 5 1 1 REMOVAL The JABIRU aircraft is designed with wings which are removable for storage or transport Wing removal is most easily achieved if two persons are available to handle the wing 1 Remove wing root fairings 2 Drain Fuel out of Quick Drain Note This will take some time 3 Remove wing strut fairings top and bottom 4 Disconnect Pitot tube RH wing only 5 Unbolt flap control rods 1 each wing 6 Remove flap from wing so it does not crush the fuselage when lowering down 7 Unbolt aileron cont
71. buretor Heat 108 Figure 39 Exhaust System JL ee t E ME 110 Figure 40 Engine Installatio f X idee pharetr 112 Figure 41 Fuel System Schematic CS VLA 115 Figure 42 Fuel System Schematic Non CS VLA 116 43 Vented Fuel Cap cep 120 Figure 44 Instrument Panel Layout Basic Panel 124 Figure 45 Pitot Assembly pee eee 130 Figure 46 Static Probe System Assembly esses enne nennen 131 Fig re 47 Static System E E eria te ie besito epis 132 Fig re 48 Wiring Dia Starnes unco i eire reiner tir eiie ded areae be sue 137 Figure 49 Antenna Installation center eee D ette herein eere 140 Figure 50 Propeller Installation TE m EET 152 REVISION Lies Technical manuals160 17010160 A J170 working files J160_ amp _J170_Tech doc Print Date 15 Dated July 2005 Issued By RAS Page 9 of 156 08 2005 9 57 00 Jabiru Aircraft pty pta un Aircraft Service Manual Jabiru J160 J170 Variants 12 LIST OF TABLES Table 1 J160 Specifications nier en ner ei er nei e e 12 Table 2 1170 er doti eat
72. ch doc Print Date 15 08 2005 9 57 00 AM Jabiru Aircraft pty Msn un Aircraft Service Manual Jabiru J160 J170 Variants 7 Idling speed After the inspection has been completed an engine run up should again be performed to determine that any discrepancies or abnormalities have been corrected revision Dated July 2005 Issued By RAS Page 28 of 156 Lies Technical manuals160 17010160 A J170 working files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM Jabiru Aircraft pty Msn un Aircraft Service Manual Jabiru J160 J170 Variants 3 5 3 INSPECTION CHART IMPORTANT READ ALL INSPECTION RQUIREMENTS PRIOR TO USING THESE CHARTS Table 4 Inspection Chart Annual Inspection Each 200 Hours Each 100 Hours Each 50 Hours PROPELLER 1 Spinner 2 4 3 Spinner screws 4 Propeller 5 Propeller bolts nuts Tension d 6 Spinner Prop Tracking x ENGINE COMPARTMENT Check for oil fuel exhaust amp induction leaks then clean entire engine amp compartment before inspection 1 Carburetor air filter 1 2 Engine baffles air ducts i 3 Cylinders KR 4 Crankcase amp front crankcase seal S 5 Hoses lines and fittings 6 Intake and exhaust systems 7 Ignition harness distributor caps amp rotors 5 8 Spark plugs 1
73. components or Wheel Spat attachments 4 Repeat for other side if necessary The above procedure is useful for wheel brake servicing or repairs but is of no value in removing the main undercarriage If the removal of the main undercarriage is necessary adopt the following procedure 1 Obtain a trestle 20Itr drum or similar object 600mm high 2 Mount a solid foam block sandbag pillow or similar compliant material on top of the trestle compliant material should distribute load over minimum 150 square centimetres Place under the lower wing strut attachment Support under both wings at the Wing Spar to prevent the aircraft from rocking Ensure that no fittings are strained 3 1 2 2 JACKING NOSE GEAR 1 Push down on tail Plane THE ELEVATOR until nose gear is off the ground 2 Place trestle or drum under rear fuselage together with absorbent material such as foam block sandbags or a pillow CAUTION Ensure trestle does not foul Ventral Fin J Weigh down tail plane with sandbags or similar heavy absorbent not hard hard items like bricks are likely to damage the aircraft material CAUTION Do not lift using control surfaces Damage to the control surface or control system may result 3 1 3 HOISTING This procedure should not be necessary for most service or maintenance procedures Should hoisting be necessary 1 Drain Fuel from both wings amp Remove wings See details below 2 Fit shackles to wing
74. cordance with paragraph 6 3 4 3 Remove outboard brake pad plate 4 Remove lock bolt nut through centre of axle and spacer 5 Remove lock spacer 6 Pull wheel from axle 6 4 2 MAIN WHEEL DISASSEMBLY 1 Deflate tyre and break tyre beads loose from tyre rims WARNING Injury can result from attempting to separate wheel halves with the tyre inflated Avoid damaging wheel flanges when breaking beads loose as a scratch nick or gouge may cause wheel failure 2 Remove through bolts nuts separate wheel halves removing tyre tube and wheel hub 3 Remove brake disc REVISION Dated July 2005 Issued By RAS Page 54 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM Jabiru Aircraft pty Msn un Aircraft Service Manual Jabiru J160 J170 Variants 4 Remove bearings from hub NOTE The bearing are press fit in the wheel hub and should not be removed unless new part is to be installed 6 4 3 MAIN WHEEL INSPECTION ASSEMBLY AND REPAIR 1 Clean all metal parts solvent dry thoroughly 2 Inspect wheel halves for cracks Cracked wheel halves should be discarded and new parts used Sand out nicks gouges and corroded areas If excessively warped or scored or worn to a thickness of 2 mm brake discs should be replaced with a new part Sand smooth small nicks and scratches 4
75. ean moist chamois DO NOT rub the plastic with a dry cloth as this builds up an electrostatic charge which attracts dirt Oil and grease may be removed by using a soft cloth moistened with mineral turpentine CAUTION DO NOT use gasoline alcohol Buzene Acetone Carbon Tetrachloride fire extinguisher fluid de icer fluid lacquer thinner or glass window cleaning spray These solvents will soften and craze the Plastic DO NOT use a canvas cover on the windshield or windows as the cover may scratch the plastic 3 3 2 INTERIOR SURFACES Interior surfaces should be cleaned with a soft cloth fresh water and a mild detergent Volatile substances such as those mentioned in the previous section must never be used 3 3 3 EXTERIOR SURFACES The exterior surfaces under normal conditions require a minimum of polishing and buffing CAUTION DO NOT polish or buff the aircraft within the first 2 weeks after delivery from the factory as surface treatments take up to 14 days to properly cure Generally the exterior surfaces can be kept bright by washing with water and a mild soap or detergent followed by a rinse with water and drying with a cloth or a chamois Remove stubborn oil and grease with a cloth moistened with mineral turpentine then wash with water and a mild soap rinse and dry as stated before After the curing period the aircraft may be waxed with a good quality automobile wax A heavier coating of wax on the leading edges of the win
76. el assembly see Paragraph 6 4 1 2 Remove stub axle see Paragraph 6 4 5 Remove brake cylinder backing plate 4 Replace lining in accordance with steps 3 7 above 5 Install axle and wheel assembly see Paragraph 6 4 6 6 Install outboard brake pad and refix with through bolts and springs 6 8 5 BRAKE SYSTEM BLEEDING 1 Fill the brake master cylinder with automotive brake fluid 2 Loosen the bleed nipple at the brake cylinder Pull the handbrake back to the rear stop amp hold in same position until nipple has been re torque Release the hand brake amp repeat step 3 until all air is expelled from Nom Ensure brake master cylinder remains full above the outlet hose 4 When air is fully expelled tighten bleed nipples amp check fittings for leaks 5 Repeat steps 1 4 for other side brake WARNING Use only automotive brake fluid DO NOT use aircraft hydraulic fluid or damage will result 6 8 6 BRAKE PAD ADJUSTMENT Brake Pads may be adjusted by removing the Main Wheel Spats and tightening the brake pad attaching bolts and nuts until the wheel just rotates freely REVISION lo Dated July 2005 Issued By RAS Page 67 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM Jabiru Aircraft pty Msn un Aircraft Service Manual Jabiru J160 J170 Variants 6 8 7 PARKING BRAKE The
77. g tail and on the engine nose cap will help reduce abrasion encountered in these areas CAUTION DO NOT use Silicon based cleaning materials as Silicon is absorbed into the composite Materials and may affect reparability REVISION Dated July 2005 Issued By RAS Page 24 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM Jabiru Aircraft pty un Aircraft Service Manual Jabiru J160 J170 Variants 3 3 4 ALUMINIUM SURFACES The aluminium surfaces require a minimum of care but should not be neglected Wash and clean as detailed in paragraph 3 3 3 above CAUTION JABIRU aircraft are designed for minimum maintenance However special attention should be applied when the aircraft has been used in extremely corrosive conditions e g beach landings with sand and salt Always ensure the aircraft is thoroughly hosed and washed immediately after such use 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 3 3 5 ENGINE AND ENGINE COMPARTMENT The engine should be kept clean since dirty cooling fins and baffles can cause overheating of the engine Also cleaning is essential to minimise any danger of fire and provide easy inspection of components CAUTION DO NOT hose engine Elec
78. hafing proper radius security corrosion deterioration obstruction and foreign matter 3 5 2 3 METAL PARTS security of attachment cracks metal distortion broken welds corrosion and any other apparent damage 3 5 2 4 WIRING security chafing burning defective insulation loose or broken terminals heat deterioration and corroded terminals REVISION lo Dated July 2005 Issued By RAS Page 26 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM Jabiru Aircraft pty un Aircraft Service Manual Jabiru J160 J170 Variants 3 5 2 5 BOLTS IN CRITICAL AREAS correct torque in accordance with torque values given in the chart in Section 1 when installed or when visual inspection indicates the need for a torque check NOTE Torque values listed in section 1 are derived from oil free cadmium plated threads and are recommended for all installation procedures contained in this manual except where other values are stipulated They are not to be used for checking tightness of installed parts during service 3 5 2 6 FILTERS SCREENS AND FLUIDS cleanliness contamination and or replacement at specified intervals 3 5 2 7 AIRCRAFT FILE Various data information and licenses are part of the aircraft file Check that the following documents are up to date accordance with current Civil Aviation Autho
79. il and adjust aileron to et the straight edge Make this adjustment with the cable rod ends ensuring that on completion the locknut is tight on the rod ends and that cable is visible through the inspection hole in the rod end 2 Check UP travel on both ailerons using the Aileron Rigging Template see Appendix 3 3 Use the Aileron Control Stop adjustment see Figure 22 to adjust the total aileron movement ie UP travel and use cable adjustment as previously described to proportion UP and DOWN travel The Aileron Control Stop should engage before the Aileron Arm hits the UP travel stop at the Wing Tip 4 DO NOT move the Cable Anchors these positions have been set using a jig REVISION Dated July 2005 Issued RAS Page 75 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM
80. ing Brakes Trouble Probable Cause Remedy Brake handle binding Check and adjust Worn or broken master Repair or install new master cylinder piston return spring cylinder Dragging brakes Drain brake line clear with compressed air If cleaning lines fails the master cylinder may be faulty and should be repaired or replaced If master cylinder or wheel Leak in system cylinders are leaking repair or install new parts Restriction in hydraulic lines or in master cylinder Air in system Bleed system Lack of fluid in master cylinder Fill and bleed system Master cylinder defective Repair or install new parts Brake pads worn Replace with new parts REVISION o Dated July 2005 Issued By RAS Page 64 of 156 L files Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM Jabiru Aircraft pty me un Aircraft Service Manual Jabiru J160 J170 Variants 6 8 2 BRAKE MASTER CYLINDER The brake master cylinder located between the seats on the front of the main longitudinal beam is actuated by applying rearward pressure to the brake handle A small reservoir is incorporated into the master cylinder for the fluid supply 6 8 2 1 BRAKE MASTER CYLINDER REMOVAL amp INSTALLATION 1 Remove the flexible hose from one wheel brake assembly and drain the hydraulic fluid from the brake system 2
81. ing strut fairings top and bottom Replace wing root fairings Perform a fuel flow test Disconnect the fuel line from the mechanical fuel pump in the engine compartment Have a second person catch any fuel that flows out of the line in a container with accurate volume marks Turn electric fuel pump on and pump fuel through the lines into container Ensure there is about 1 litre per minute flow rate NOTE After carrying out the fuel flow test check that both wing tanks are feeding fuel by turning off both wing tanks pumping about a litre out of the header tank then turning the left wing tap on The wing tank will gravity feed to the header tank it should re fill within approximately 1 2 minutes This must be repeated for the right wing If a wing is not flowing correctly check lines for kinks blockages amp airlocks Ensure both wing taps are wired in the position using fuse wire before returning the aircraft to service revision Dated July 2005 Issued RAS Page 43 of 156 Lies Technical manuals160 17010160 A J170 working files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM ircraft pty A Aircraft Service Manual Jab Jabiru 9160 J170 Variants ONIM LIM dS 09173 871 ASSY X ON SAAC 0 95 M3S 1 H3TINIH ddv sv OU Ald HSALAY JO LN3SNOO JHL LNOHLIM 31909
82. ler on either side of the spinner The aircraft can then be pulled forward and nose wheel lifted off the ground if necessary CAUTION Never move the aircraft in this manner whilst the engine is hot as it may fire when the propeller is moved and result in severe injury Always ensure that the Master and Ignitions are OFF Never approach the propeller when anyone is in the aircraft Always treat the propeller as LIVE IT KILLS 3 1 2 JACKING JABIRU is a very light aircraft Before jacking ensure that it is as light as possible by removing luggage and any unnecessary fuel 3 1 2 1 JACKING MAIN GEAR 1 Remove main gear spat on the side to be jacked or both spats if both wheels to be jacked REVISION o Dated July 2005 Issued By RAS Page 17 of 156 L files Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM Jabiru Aircraft pty Msn un Aircraft Service Manual Jabiru J160 J170 Variants 2 The aircraft be lifted on side by a person of reasonable strength 2 of lesser strength by lifting on the Wing Spar at the outboard part of the wing strut attachment or towards the wing tip Be careful lifting at the Wing Tip 3 Place a solid block preferably wood under the bottom of the composite glass leg which will result in the wheel being off the ground when the aircraft is lowered Be careful not to interfere with brake
83. move bearings NOTE The bearings are press fit in the wheel hub and should not be removed unless a new part is to be installed 6 6 3 NOSE WHEEL INSPECTION AND REPAIR 1 Clean metal parts in solvent and dry thoroughly 2 Inspect wheel halves for cracks Cracked wheel halves should be discarded and new parts used Sand out nicks gouges and corroded areas Clean thoroughly 3 Carefully inspect bearings for damage and discolouration NOTE Bearings are pre packed DO NOT clean with solvents as it will remove the packing 4 Refit bearings 6 6 4 NOSE WHEEL REASSEMBLY 1 Replace bearings in wheel hub 2 Apply automotive wheel rim lubricant to the tyre bead faces on the inside of the wheel rims 3 Position tyre and tube between wheel halves with tube inflation valve through hole in outside wheel half 4 Mate wheel halves While maintaining a light force assemble a washer and nut on one through bolt and tighten snugly Assemble the remaining washers and nuts on the through bolts and torque to the value specified in Table 3 WARNING Ensure tube is not pinched between wheel halves during assembly Uneven or improper torque of through bolt nuts can cause failure of bolts with resultant wheel failure 9 Insert through bolts through brake disc and position disc on the inner wheel hub flange 6 Inflate tyre to seat the tyre beads adjust to correct tyre pressure Refer Aircraft Specifications above REVISION lo
84. 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 See Figure 20 REVISION lo Dated July 2005 Issued By RAS Page 71 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM Jabiru Aircraft pty pta Jabiru J160 J170 Variants 40 DAS L doverove 231 92 0917 TOXLNOS NOHZIIV Aircraft Service Manual EC 7 ND NOUdI 2530 ON Loyd 1 ASSY 108109 40 9204 L 901 4 8 ANN 3901 8 816 9004 21 01 086 8 4 9 996 3794335 004 8 31899 39434 605 6 SNINITL3H N6SZOHd GL 4 NOL ENY Lb 2 WIHS N88002d HOHONY L 57 L SH SL SL 434 334 434 3105 LON 00 SNOISEN3HIG Ald dO 1 35 02 OH 131400 LON LSM ONY LHOlHAdOO S
85. n REVISION filesJ160 8 J170 Tech doc 9 Print Date 15 08 2005 9 57 00 Jabiru Aircraft pty Msn un Aircraft Service Manual Jabiru J160 J170 Variants 4 3 2 ADJUSTMENT Cabin doors should be adjusted so that the door skin fairs with the fuselage skin 4 3 3 DOOR SEALS A weather strip is glued around all edges of the door Apart from excluding wind and water the weather strip is important in minimising exhaust fume entry to the cabin lt should be maintained in good condition and fit at all times New weather strip may be applied after mating surfaces of weather strip and door are clean dry and free from oil and grease 3 1 1 Cabin Door Latches There is one main latch on each door of a simple spring type This is complemented by two Aluminium catches at the top front quadrant of each door An assembly drawing of the latch mechanism is provided as Figure 5 below Door latches or their component parts must be replaced if worn or damaged REVISION lo Dated July 2005 Issued RAS Page 37 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM 1MOdMIV FUL 26982010 NOV 00 7100 09 7 SH ASSY HOLY HOOGQ 031319395 SS37IND Ald HOSLAY JO LN3SNO2 JHL 931902 LON 5
86. oen denice 14 Table 3 Recommended Bolt Torque Values 16 Table 4 Inspection eite E BE 29 Table 5 Trouble Shooting Main Undercarriage 49 Table 6 Trouble Shooting Nose 58 Table 7 Trouble Shooting Brakes 64 Table 8 Trouble Shooting Fuel 5 117 Table 9 Trouble Shooting Pitot Static 127 Table 10 Trouble Shooting Airspeed Indicator 128 Table 11 Trouble Shooting 128 Table 12 Trouble Shooting Vertical Speed Indicator Option eese 129 Table 13 General Cockpit Decals nct eei nepote iva reete rr 144 Table 14 Cockpit Control ene EE 145 Table 15 External Fuselage 146 Table 16 Approved Propeller Installations Au 150 Table 17 Mandatory Replacement Ames ecce cete tiere eben 156 revision Dated July 2005 Issued By RAS Page 10 of 156 Lies Technical manuals160 17010160 A J170 working files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM Jabiru Aircraft pty Msn Aircraft Service Manual Jabiru J160 J170 Variants 2 Section 2 Service Manual 2 14 LIST OF EFFECTIVE PAGES
87. ooting Nose Leg Trouble Probable Cause Remedy Nose strut bolts loose Tighten bolts Loose or worn steering link Tighten replace defective Nose wheel shimmy parts Nose wheel out of balance Refer Paragraph 5 6 5 Wheel bearings loose Replace 6 5 2 NOSE GEAR REMOVAL AND INSTALLATION See Figures 16 and 15 1 Weight or tie down tail of aircraft to raise nose wheel off floor 2 Disconnect nose wheel steering pushrods steering cross beam 3 Unbolt steering cross beam 4 upper collar steering yoke dependant on aircraft S No from the top of leg REVISION lo Dated July 2005 Issued By RAS Page 58 of 156 Lies Technical manuals160 17010160 A J170 working files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM Jabiru Aircraft pty Msn un Aircraft Service Manual Jabiru J160 J170 Variants 5 Disconnect the nosewheel centring mechanism 6 Pull the nose wheel strut assembly down from the bushes in the fuselage 7 To install the nose gear reverse the preceding steps 6 5 3 NOSE GEAR INSPECTION AND REPAIR 1 Inspect steel tube and attachments for dents and straightness 2 Inspect rubber spring assembly for damage or perishing of the rubber delamination of the rubber from the aluminium spacers between the rubber blocks 3 Inspect aluminium wheel yoke for damage or bending 4 Inspect bolts nuts for torque see to
88. oughly REVISION lo Dated July 2005 Issued By RAS Page 65 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM Jabiru Aircraft pty Msn un Aircraft Service Manual Jabiru J160 J170 Variants 2 New piston sealing O Rings should be installed each time the brakes are disassembled If re use is necessary they should be wiped with a clean cloth saturated in automotive brake fluid and inspected for damage NOTE Thorough cleaning is important Dirt and chips are the greatest single cause of malfunctions and leaks in hydraulic brake systems 3 Check brake linings for deterioration or excessive wear 4 Inspect brake cylinder bore for scoring A scored cylinder will leak or cause rapid bucket wear If wear is evident install a new brake cylinder 5 If the anchor bolts on the brake assembly are nicked gouged replace with new bolts 6 Inspect wheel brake disc for a minimum thickness of 2mm f brake disc is below minimum thickness install a new part 6 8 4 3 WHEEL BRAKE INSTALLATION 1 Place brake cylinder assembly in position on backing plate 2 Install bolts springs outboard pad nuts washers d Reconnect flexible hose 4 Fill master cylinder reservoir with brake fluid 5 Bleed brakes Refer to Paragraph 6 8 5 6 8 4 4 BRAKE LINING INSTALLATION New brake linings should be in
89. pholstery must be noted in the aircraft s maintenance log book and the flame retardant re applied by an authorized person after 5 washes 4 6 SOUNDPROOFING Soundproofing material is normally used on the Firewall In addition a curtain of soundproofing material can be used at the rear of the cockpit baggage area This curtain is attached to the forward rib of the fuselage using velcro straps Its purpose is to minimise drumming of the fuselage as well as restricting material falling aft of the curtain and resulting in a severe aft centre of gravity condition The curtain should be in place for all flights 4 7 SAFETY PROVISIONS 4 7 1 SEATBELTS Aircraft grade Seatbelts bolted to the fuselage structure are provided for both seats Belts should be replaced if frayed or cut latches are defective of stitching is broken REVISION lo Dated July 2005 Issued RAS Page 39 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM Jabiru Aircraft 2 Aircraft Service Manual Jabiru J160 J170 Variants Attaching parts should be replaced with equivalent grade parts if excessively worn or defective revision Dated July 2005 Issued By RAS Page 40 of 156 Lies Technical manuals160 17010160 A J170 working files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM Ja
90. pre owned aircraft should ensure that the transfer of their aircraft has been advised to JABIRU AIRCRAFT Pty Ltd or your local dealer of distributor Existing owners should ensure that their postal address remains current In addition to the information in this Service Manual vendor publications will periodically be available from JABIRU which describe disassembly overhaul and parts breakdown of some of the various vendor equipment items A listing of the available publications is issued from time to time in service letters IMPORTANT maintenance should be undertaken with careful regard for the procedures outlined in this manual A detailed record of maintenance undertaken should be recorded in the Aircraft Log Books In the interests of product development we encourage owners to make suggestions related to design improvements However the final decision on their adoption or otherwise rests with JABIRU AIRCRAFT Pty Ltd REVISION lo Dated July 2005 Issued By RAS Page 2 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM Jabiru Aircraft pty pta un Aircraft Service Manual Jabiru J160 J170 Variants 1 Table of Contents TABLE OF EG EO V ctc 3 onec vier E reme tir 9 L2 LIST OF TABLES entreprise E ertet eee pe
91. rind away any excess material to ensure a close fit Do not attempt to cut with any type of saw Wet the window frame joggle with raw epoxy resin Apply a bead of Epoxy amp Flock around the outer edge of the windscreen 4 Place windscreen accurately over the sealing strips and locate with one screw top and bottom 5 Fit other screws 6 Take care not to crack windscreen when installing DO NOT over tighten screws cracking will result 43 CABIN DOORS 4 3 1 REMOVAL AND INSTALLATION Removal of doors is achieved by removing the hinge bolts or removing the machined screws that attach the hinges to the door frame Refer to Figures 4 and 3 below REVISION lo Dated July 2005 Issued RAS Page 34 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM ircraft pty A Aircraft Service Manual Jab Jabiru J160 J170 Variants 3O IJJHS 1 0296 Udd LYYd OL3433H Weal 3 TMNIH 90 000 2 ASSV 091 26 982 010 sa F SSIMYSHLO SSI YYA HO31AV JO 1 LNOHLIM Vd HO3LAV SISLINITIIN NI 0 1 62 L 31725 LON 15 ANY LHOIHAdOD SI
92. rity Regulations Most of the items listed are required by the Australian Civil Aviation Authority Regulations Since the regulations of other nations may require other documents and data owners of exported aircraft should check with their own aviation officials to determine their individual requirements To be displayed in the aircraft at all times Placards as detailed in Flight Manual Owner s Manual To be carried in the aircraft at all times Flight Manual Owner s Manual To be made available on request Aircraft Registration Radio Station License Pilot License Certificate including Medical Certificate if appropriate 3 5 2 8 ENGINE RUN UP Before beginning the step by step inspection start run up and shut down the engine in accordance with instructions in the Flight Manual and Appendix 1 of this manual During the run up observe the following making note of any discrepancies or abnormalities 1 Engine temperatures and pressures 2 Static RPM Also refer to Engine Instruction Manual 3 Magneto drop Also refer to Engine Instruction Manual 4 Engine response to changes in power 5 Any unusual engine noises 6 Fuel shut off valve operate engine in ON position and in OFF position long enough to ensure shut off functions properly REVISION Dated July 2005 Issued RAS Page 27 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Te
93. rning the aircraft to service is accomplished by performing a thorough pre flight inspection Ensure all protective covers are removed 3 1 9 TEMPORARY OR INDEFINITE STORAGE Temporary storage is defined as aircraft in non operational status for a maximum of 90 days Treat as for flyable storage see Paragraph 2 1 7 plus For temporary storage fill fuel tank with correct grade of gasoline to prevent moisture accumulation For indefinite storage drain fuel tank ensure carburettor bowl is empty by running engine with fuel valve off until it stops or by draining bowl Then 1 Clean aircraft thoroughly 2 Clean any dirt oil or grease from tyres and coat tyres with a tyre preservative Cover tyres to protect against dirt and oil Either block up undercarriage fuselage to relieve pressure on tyres or rotate wheels every 30 days to prevent flat spotting the tyres 4 Seal or cover all openings 5 Remove battery and store in a cool dry place Service the battery periodically and charge as required NOTE It is recommended that a battery which is not used should be charged every 30 days 6 Disconnect spark plug leads and remove spark plugs from each cylinder Using an oil can or spray atomiser spray preservative oil through a spark plug hole of each cylinder with the piston in the down position NOTE Use shell Aero fluid 2UN MIL C 6529C Type 1 or similar engine corrosion inhibitor Rotate the propeller 10
94. rol cables 2 from rear of control stick horn inside cabin 8 Remove and clamp block from aileron control cable clamps at rear of seat 1 each seat 9 Loosen hose clamps from Fuel lines from Breather tubes Fuel Gauge 10 With one person supporting wing tip unbolt top wing strut bolt and lower wing strut to the ground 11 Lower wing tip to towards the ground making sure you do not crush the under side of the wing on the fuselage wing root Ret the wing tip on a saw horse or other suitable stand REVISION lo Dated July 2005 Issued By RAS Page 41 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM Jabiru Aircraft pty Msn un Aircraft Service Manual Jabiru J160 J170 Variants 12 and remove front wing attachment bolt 13 and remove rear wing attachment bolt Note It may be necessary to rock the wing slightly while pulling attaching bolt or carefully use a long drift punch to drive out attaching bolt 14 Carefully remove wing by moving it out to clear the aileron cable from the fuselage 15 Place wing on cushioned structure to avoid damage to wing strut attachment 16 Unbolt lower wing strut bolt and remove wing strut 17 Repeat Steps 5 16 to remove other wing 5 1 2 REPAIR The wing is a composite monocoque structure All repairs must be referred to JABIRU AIRC
95. rque values Table 3 5 Repairs to the welded nose leg assembly beam must be referred to JABIRU AIRCRAFT Pty Ltd or our approved local agent 6 5 4 NOSE WHEEL SPEED FAIRING REMOVAL AND INSTALLATION 1 Remove the machine screws around the forward rear sections of the fairing and remove the front section 2 Loosen the axle nuts and remove the rear section 3 Reverse the preceding steps for installation 66 NOSE WHEEL 6 6 1 NOSE WHEEL REMOVAL AND INSTALLATION 1 Weight or tie down tail of aircraft to raise the nose wheel off the floor 2 Remove nose wheel axle bolt Pull nose wheel assembly from yoke 4 Reverse the preceding steps to install nose wheel Tighten axle bolt 6 6 2 NOSE WHEEL DISASSEMBLY Completely deflate tyre and break tyre beads loose at wheel rim Refer to Figure 15 WARNING Injury can result from attempting to separate wheel halves with the tyre inflated Avoid damaging wheel flanges when breaking beads loose as a scratch nick or gouge may cause wheel failure REVISION lo Dated July 2005 Issued By RAS Page 59 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM Jabiru Aircraft pty un Aircraft Service Manual Jabiru J160 J170 Variants 1 Remove through bolts and separate wheel halves 2 Remove wheel hub 3 Remove tyre and tube from wheel halves 4 Re
96. stalled when the existing linings are worn to expose the rivet heads To replace outboard lining Remove bolts securing outboard brake pad and brake cylinder to backing plate 2 Remove outboard brake pad Place brake pad on a table with lining side down flat Centre 1 8 or slightly smaller punch on the rolled rivet and hit the punch sharply with a hammer Punch out all rivets securing the lining to the pad plate NOTE A replacement kit for brake pads and rivets is available from JABIRU 4 Clamp the flat side of an anvil in a vice REVISION lo Dated July 2005 Issued By RAS Page 66 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM Jabiru Aircraft pty Msn un Aircraft Service Manual Jabiru J160 J170 Variants 5 Align the new lining on the pad plate and place the brake rivet in the hole with the rivet head in the lining Place the head against the anvil 6 Centre the rivet setting punch on the lips of the rivet While holding the pad plate down firmly against the lining hit punch with hammer to set the rivet Repeat blows on the punch until the lining is firmly against the pad plate 7 Realign the lining of the pad plate and install and set rivets the remaining holes 8 Replace the brake pad and refix with through bolts and springs To replace inboard lining 1 Remove whe
97. trical components may be damaged by moisture Ensure electrical components are protected against moisture Caustic cleaning solutions should not be used Recommended cleaning procedure is lightly spray with degreasing fluid after sealing coils and starter motor WIPE clean with brush and cloth 3 3 6 PROPELLER Wash with soap and water rinse with clean water and dry with cloth or chamois Do not use a wax based substance as this would make it almost impossible to refurbish the prop if need at a later stage 3 3 7 WHEELS The wheels should be washed periodically and examined for corrosion cracks or dents in the wheel halves or in the flanges or hubs If defects are found remove and repair in accordance with Section 6 Discard cracked wheel halves flanges or hubs and install new parts 3 4 LUBRICATION There are no lubrication requirements for the JABIRU other than those detailed in Appendix 1 3 4 1 WHEEL BEARING MAINS AND NOSE At each 100 hour inspection jack the wheel spin the wheel and check for free running and any play on the shaft Remove and replace if there is any sign of binding or wear REVISION lo Dated July 2005 Issued By RAS Page 25 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM Jabiru Aircraft pty Msn un Aircraft Service Manual Jabiru J160 J170 Variants 3 5 2 5 INSPECT
98. ugh centre of axle 4 Place outboard brake pad plate and springs in position and secure with bolts nuts washers 5 Reconnect flexible brake line 6 Refill brake master cylinder with fresh brake fluid 7 Bleed brakes Refer to Section 7 8 5 8 Install speed fairing if used as outlined in Paragraph 7 3 4 6 4 5 MAIN WHEEL STUB AXLE REMOVAL 1 Remove speed fairing if installed in accordance with Paragraph 7 3 4 2 Remove wheel in accordance with Paragraph 5 4 1 Disconnect flexible brake hose and drain brake fluid 4 Remove 4 bolts nuts washers securing axle to leg NOTE When removing axle from leg note number and position of the wheel alignment shims if any between the axle flange and composite leg Mark these shims or tape them together carefully so that they can be installed in exactly the same position to ensure that wheel alignment 15 not disturbed 5 Remove inboard brake plate 6 4 6 MAIN WHEEL STUB AXLE INSTALLATION 1 Secure axle and inboard brake plate to composite leg making sure that any wheel alignment shims are installed in their original position 2 Install wheel assembly on axle in accordance with Paragraph 7 4 4 6 4 7 MAIN WHEEL ALIGNMENT Refer to Figure 13 REVISION lo Dated July 2005 Issued By RAS Page 56 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM ircraft pty
99. vice table below The following paragraphs supplement this table by adding details not included Note that Inspection Requirements are detailed at Paragraph 3 5 3 2 1 SERVICING SCHEDULE 3 2 1 1 PRE FLIGHT Refer to Flight Manual 3 2 1 2 25 HOUR SERVICE e Refer to Engine Instruction amp Maintenance Manual 3 2 1 3 50 HOUR SERVICE e Refer to Engine Instruction amp Maintenance Manual 3 2 1 4 100 HOUR SERVICE e Refer to Engine Instruction amp Maintenance Manual 3 2 1 5 OTHER INSPECTION amp MAINTENANCE PROCEDURES e Refer to Engine Instruction amp Maintenance Manual e Replace flexible oil amp fuel line in engine compartment every 2 years or when visible deterioration cracking hardening occurs REVISION lo Dated July 2005 Issued By RAS Page 22 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM Jabiru Aircraft pty Msn un Aircraft Service Manual Jabiru J160 J170 Variants 3 2 2 FUEL The fuel tanks should be filled immediately after flight to lessen condensation of moisture The tank capacity is listed in the Aircraft Specifications Above 3 2 3 FUEL DRAIN A fuel drain is located in the Left amp Right hand fuel tanks near the wing root Drain fuel after each refuelling to ensure moisture and contaminants are not present 3 2 4 CARBURETTOR AIR FILTER The Carburettor air filter
100. yres with soap and water NOTE Recommended tyre pressures should maintained especialy in cold weather Remember that any drop in temperature of the air inside the tyre causes a corresponding drop in tyre pressure 3 2 7 HYDRAULIC BRAKES Check brake master cylinder and refill with automotive brake fluid DOT 3 or DOT 4 Bleed the brake system of any trapped air whenever there is a spongy response on the brake lever Refer to paragraph 6 8 for filling and bleeding of the brake system CAUTION REVISION lo Dated July 2005 Issued By RAS Page 23 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 15 08 2005 9 57 00 AM Jabiru Aircraft pty me un Aircraft Service Manual Jabiru J160 J170 Variants The JABIRU uses automotive brake 3 or DOT 4 DO NOT use Aircraft hydraulic fluid mineral based or damage to the brake system will result 3 3 CLEANING Keeping the aircraft clean is important Besides maintaining the appearance of the aircraft cleaning makes inspection and maintenance easier 3 3 1 WINDSHIELD AND WINDOWS These should be cleaned carefully with plenty of fresh water and a mild detergent using the palm of the hand to feel and dislodge any caked dirt or A sponge soft cloth or chamois be used but only as a means of carrying water to the plastic Rinse thoroughly then dry with a cl

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