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JSA-SM170SP-A1 J170-SP Aircraft Service Manual

1. 9 8 10 1 Stall Warning 5 024000 0000 10 5 Systems 11 7 JSA SM170SP A1 Page 7 Jabiru J170 SP Aircraft Service Manual Title of Figure Page 11 2 Static mete eee debe ep bite 11 8 11 3 Sport HS EFIS 11 11 11 4 Magnetometer Location 11 13 11 5 External Power Receptacle 11 20 11 6 Finished External Power Receptacle Installation 11 21 11 7 Single EFIS Electrical 11 22 11 8 Dual EFIS Electrical 11 23 11 9 Dual EFIS Electrical Diagram with 11 24 12 1 Door Hinge ee 12 5 12 2 Door Lock Slot 12 5 Page 8 JSA SM170SP A1 Jabiru J170 SP Aircraft Service Manual List of Tables Title of Table Page 1 1 J170 SP Specifications 1 1 1 2 Standard and Optional 2 1 5 1 3 List of Disposable Replacement 5 1 9 1 4 Recommended Fastener Torque
2. 1 10 2 1 Aircraft Empty Weight and Moment 2 5 2 2 Aircraft Empty Weight 2 7 7 1 Replacement Flexible 7 22 9 2 Approved Propeller 9 4 JSA SM170SP A1 Page 9 Jabiru J170 SP Aircraft Service Manual Foreword This manual contains recommended procedures and instructions for ground handling servicing and maintaining the Jabiru J170 SP Special Light Sport Aircraft S LSA This manual is provided by Jabiru USA Sport Aircraft LLC to owners operators and maintenance technicians as re quired by the applicable ASTM standards The Jabiru J170 SP complies with the following ASTM standards for design construction and continued airworthiness F2245 Standard Specification for Design and Performance of a Light Sport Airplane F2279 Standard Practice for Quality Assurance the Manufacture of Fixed Wing Light Sport Aircraft e F2295 Standard Practice for Continued Operational Safety Monitoring of a Light Sport Air craft e F2483 Standard Practice for Maintenance and the Development of Maintenance Manuals for Light Sport Aircraft Should certification documentation need to be recovered for this aircraft please contact the manufacturer This handbook includes the material required to be fu
3. 091410388 SS37 INC 698 010 NOW cm Figure 5 8 Nose Wheel Assembly JSA SM170SP A1 Page 5 26 Jabiru J170 SP Section 6 Aircraft Service Manual Flight Controls Section 6 Flight Controls 6 1 Control Column 6 1 1 Description The control column is a machined aluminum assembly mounted in the center console of the cockpit that directly controls the ailerons and elevator It has a machined aluminum hand grip and lower lever arm that attaches to the elevator control cable on the front end The hand grip is hinged to move fore and aft for elevator control It rotates around a horizontal column that extends rearward through the center console and exits out the back where a mixer horn attaches to the Teleflex aileron cables between the seat backs The column rotates along the longitudinal axis of the aircraft inside a pair of nylon bushings that are epoxied and flocked permanently into the fiberglass center con sole Refer to Figure 6 1 Control Column Assembly 6 1 2 Removal and Reinstallation The control column is a primary control and may not be removed or repaired without reference to Jabiru USA Sport Aircraft LLC or a local approved agent 6 1 3 Inspection Check for worn nylon bushings Replace as needed 6 1 4 Repair Replace all worn or damaged parts 6 2 Control Cables 6 2 1 Description All control cabl
4. 2 4 2 4 Aircraft Moment Arm 2 6 3 1 Window 3 4 3 2 Window Clamps In 3 4 3 3 3 6 3 4 Door Hinge 02 20 000 nennen 3 7 3 5 Doot Str ct re 255 3 8 3 6 Old Style Door Hinge eco 3 9 3 7 New Style Door Hinge tiun De Here 3 9 3 8 Interior Door Hinge Bolts New Style 3 10 3 9 Upper Door Hinge New 5 3 10 4 1 Wing Assembly 3250 5 nennen nennen nnns 4 6 5 1 Main Landing Gear Assembly 5 3 5 2 Assembly of Matco Wheel 5 12 5 3 Axle Alignment s s teret et eee ct e eet ite te pcdes 5 13 5 4 Brake Master Cylinder 5 16 5 5 Nose Leg Assembly 5 23 5 6 Nose Leg Suspension 5 24 5 7 Nose Leg cereo 5 25 5 8 Nose Wheel 5 26 6 1 6 2 JSA SM170SP A1 Jabiru J170 SP Aircraft Service Manual Title of Figure
5. 7 1 7 2 Basic Engine Compartment 7 3 723 Engine RM PEE RC RRE ERREUR TRAE 7 5 7 4 Cooling Ait Baffles toten tote date do ee eden eve 7 6 7 5 Engine Mouht rcr e rette eerte 7 10 7 6 Shock MOUNTS 7 10 ee td e 7 12 7 8 Oil Cooling use eid rere tet inen deer iE 7 14 7 9 Oil Recovery 5 7 17 7 10 dece edet e petet eR opens 7 18 7 11 Induction Air 5 eene a innare na 7 19 7 12 Flexible 0565 net en tO Pe d 7 21 7513 Throttle Controle sits ird d e edo dete eq es 7 22 7214 Choke ob dng BREACH edi den 7 23 7 15 Carburetor Heat iuit e GR CR PR LEUR Es 7 24 Section Title Section 8 Fuel System Section 9 Propeller amp Spinner Section 10 Utility Systems Page 4 Jabiru J170 SP Aircraft Service Manual Page 7 16 Ignition 7 26 7 17 ete 7 26 7 18 EXNAUSE ae cei ed 7 27 7 19 Head Bolt Tension Check Head Torque 7 29 8 1 General 8 1 8 2 Fuel ase tant 8 1 8 3 Fuel and Vent Lines nnne 8 2
6. LON SNOJSNAWIC Figure 7 4 Shock Mounts Page 7 11 JSA SM170SP A1 Section 7 Engine Systems 7 7 Jabiru J170 SP Aircraft Service Manual 7 6 2 Removal Tools Required See Engine Removal 7 1 5 Parts Required New mounts if necessary AN4 31A bolts and AN363 428 nuts for reinstallation Level of Certification Required A amp P or LSA R M M Remove engine as described in 7 1 5 then remove mounts 7 6 3 Inspection Inspect for cracking checking or deformation Check for excessive engine sag evident when spinner and cowl no longer align Replace shock mounts if indicated See Figure 7 4 7 6 4 Repair Repair is limited to replacement Replace worn or damaged shock mounts with new parts 7 6 5 Reinstallation Refer to Figure 7 4 Install female mounts in the rear on top and males in the rear on the bottom Lift engine into place on the mount Install the males in the front on the top and the females in the front on the bottom This arrangement is necessary to limit the sagging of the engine over time due to gravity Tighten the AN4 31A bolts with AN363 428 nuts one washer to 8 ft lbs Oil System 7 7 1 Description Page 7 12 This manual details the oil cooler and oil recovery systems because their installation is unique to Jabiru S LSA aircraft Refer to Instruction amp Maintenance Manual for Jabiru 2200 Aircraft Engine for other oil system details The engine oil
7. gt gt Joyainquez 391 qua Fuel System Schemati Figure 8 1 Page 8 9 25 SM170SP A1 Section 8 Jabiru J170 SP Fuel System Aircraft Service Manual THIS PAGE INTENTIONALLY BLANK Page 8 10 25 SM170SP A1 Section 9 Jabiru J170 SP Propeller amp Spinner Aircraft Service Manual Section 9 Propeller and Spinner 9 1 Spinner Assembly 9 1 1 Description Each Jabiru S LSA aircraft is equipped with a spinner to protect the propeller hub area and help direct cooling air into the cowling inlets Early models were equipped with a fiberglass spinner while later models are delivered standard with a Cummins polished aluminum spinner 9 1 2 Removal Level of Certification Required A amp P or LSA R M M 1 Remove machine screws and nylon washers from spinner 2 Remove spinner cone 3 Remove the nuts from the six propeller bolts 4 Remove the AN960 616 washers Belleville washers two per bolt aluminum crush plate and propeller 5 Remove spinner backing plate 9 1 2 Inspection 1 Inspect spinner for cracks and dents 2 Inspect spinner back plate for cracks warps or bends and loose nutplates 9 1 3 Repair 1 Dented and or cracked spinners and damaged back plates must be replaced Spin ner cones and backplates come match drilled and must be replaced as a set 2 Replace loose 8 nutplates using solid AD co
8. orm D J160 DOOR HINGE ASSY oen IREFER TO PART DRAWINGS 1 Figure 3 4 Door Hinge Assembly J160 170 230 250 Page 3 7 JSA SM170SP A1 Jabiru J170 SP Aircraft Service Manual Section 3 Fuselage Structure NOVOLOVZ N d OWH 350940 QOv600 L N d NMNNO SY ASSY 8009 POLS SUIVI 2 3058 18354 3009 E _ 3wos sworsnawia 2 40 22403 170 eo 5 Door Structure Figure 3 JSA SM170SP A1 Page 3 8 Jabiru J170 SP Section 3 Aircraft Service Manual Fuselage Structure 3 3 1 3 Door Seals Weather strip is glued around all edges of the door and door sill Apart from excluding wind and water the weather strip is important in minimizing exhaust fume entry to the cabin It should be maintained in good condition and fit at all times To replace the weather strip use household door amp window EDPM rubber weather seal 7 16 thick x 3 8 wide for gaps 1 8 to 7 32 It may be found at major hardware stores Make sure surfaces are clean dry and free from oil and grease Use superglue to reinforce the bond of the self adhesive backing 3 3 2 Door Removal Tools Required 7 16 wrenches old style or 5 32 hex new style Level of Certification Required A amp P or LSA R M M The old style door hinges are not visible from the outside of the aircraft They are simple to remove
9. DESIGNATIOI 5 SPECIFIC PART of component CAUSING TROUBLE MFG Model or Part No Part Defect Location 6 APPLIANCE COMPONENT Assembly that Includes part Comp Appl Name Model or Part No Serial Number Part TSO 7 Date Sub Check a box below if this report is related to an aircraft crs one oono SUBMITTED BY REP STA AIR TAXI COMMUTER OTHER DISTRICT OFFICE JSA 501 Use this space for continuation of Block 8 if required Return this form with any additional information to Jabiru USA Sport Aircraft LLC 2842 Highway 231 North helbyville TN 37160 931 680 2800 TELEPHONE NUMBER Jabiru J170 SP Aircraft Service Manual Appendix Vendor Contact Information Aircraft Manufacturer Jabiru USA Sport Aircraft LLC 2842 Highway 231 Shelbyville TN 37160 Phone 931 680 2800 Fax 931 680 1817 http www usjabiru com Engine Information For all correspondence regarding Jabiru S LSA aircraft engines please contact Jabiru USA Sport Aircraft LLC Installation and Instruction Manual for Jabiru 3300 Aircraft Engines Available for free download in PDF format http www usjabiru com engine manuals html Propeller Information Sensenich Wood Propeller Co Inc 2008 Wood Court Plant City FL 33563 Phone 813 752 3711 Fax 813 752 2818 http www sensenichprop com Wood Propellers Installation Operation amp Maintenance Available for free d
10. MOD 31 25 10 oa 6 NI SNOISN3WIO MAS 0 SdVHS OL WW aovsrov CINOW ISN L vlad ees z E3NVISHOOWWO Gzrziz 9 H3HSVM SS3 INIVLS SO 2106616 S 9 M3HOSSSHINIVIS YSO ig0 69v2SW v o JAM dOd 6696 SZSc0zSW z L _ 7 9 Lower Eng 3 igure 7 JSA SM170SP A1 Section 7 Engine Systems 7 5 7 6 Jabiru J170 SP Aircraft Service Manual Engine Mount 7 5 1 7 5 2 7 5 3 7 5 4 7 5 5 Description The engine mount is a welded assembly Its purpose is to support the engine and at tach the engine to the airframe The engine is attached to the mount with rubber lord mounts that absorb engine vibration Removal Tools Required 7 16 and 3 8 wrenches screwdriver set Parts Required New AN4 21A bolts and AN363 428 nuts for reinstallation Level of Certification Required A amp P or LSA R M M 1 Remove engine and accessories from the mount as described in 7 1 2 Spacers may be used to correctly align the engine Ensure that they are correctly marked on removal and correctly reinstalled during reassembly 3 Remove nuts and bolts attaching mount to firewall
11. Inspection Belts should be replaced if frayed or cut latches are defective or stitching is broken Repair Repair is limited to replacement Belts should be replaced if frayed or cut latches are defective or stitching is broken Attachment parts should be replaced with equivalent grade parts if excessively worn or defective Reinstallation Reinstall belts as described in 3 7 2 using all new AN hardware 3 8 Horizontal Stabilizer 3 8 1 Page 3 12 Description The horizontal stabilizer is a molded monocoque structure of rigid cellular polystyrene bonded to a fiberglass skin and rear spar The stabilizer is bonded into a flange and slot molded into the aft fuselage with epoxy and cotton flock The bond joint is overlaid JSA SM170SP A1 Jabiru J170 SP Section 3 Aircraft Service Manual Fuselage Structure with multiple layers of fiberglass extending several inches either side of the joint Hinges attach the rear horizontal spar to the elevator 3 8 2 Removal and Installation The horizontal stabilizer is permanently bonded to the fuselage and is an integral part of the fuselage If the stabilizer structure is damaged the entire stabilizer may be re moved and replaced Contact Jabiru USA Sport Aircraft for further instructions 3 8 3 Inspection Check for cracks or breaks in the skin Look carefully at the joint area between fuse lage and horizontal for cracks or delamination If cracks in paint are found sand into the p
12. Stall Warni 1 igure 10 F Page 10 5 JSA SM170SP A0 Section 10 Jabiru J170 SP Utility Systems Aircraft Service Manual THIS PAGE INTENTIONALLY BLANK Page 10 6 JSA SM170SP A0 Jabiru J170 SP Section 11 Aircraft Service Manual Electrical System and Instruments Section 11 Electrical System and Instruments 11 1 General Description The electrical system of the aircraft is supplied by an alternator that is built into the flywheel of the engine A voltage regulator converts AC from the alternator to 14 volt DC current which is then routed from the regulator rectifier to the battery Aircraft electrical power is conducted to the master switch breaker and then to the main and instrument buses Switch breakers and circuit breakers feed and circuit protect the electrical appliances in the aircraft Electrical circuit diagrams are provided for the three available Grand Rapids panel layouts and other standard and optional electrical devices in this section Consult the Engine Instruction amp Maintenance Manual for Jabiru 2200 Aircraft Engine for guidance on removal inspection and reinstallation of the electrical generating system 11 2 Alternator 11 2 1 Description Electrical power is generated by a 20 amp permanent magnet alternator that is inte gral to the flywheel AC current is rectified to DC current and is regulated to 14 volt DC by a solid state regulator mounted on the firewall 11 2 2 Removal Inspection Rep
13. 2 After First 25 Hours After the first 25 hours recheck the propeller bolt torque 3 Every 50 Hours After the first 25 hour recheck it is MANDATORY that the propel ler bolt torque be rechecked every 50 hours 4 Environmental changes Should the operating environment change significantly in temperature and or humidity for a long period of time i e seasonal changes the propeller bolt torque must be rechecked Jabiru S LSA aircraft use nyloc nuts to attach wood propeller bolts to the hub Safety wire should not be used however if the nuts are removed they MUST be replaced with new hardware Propeller Bolt Tension Check Procedure Required Tools Calibrated torque wrench with 1 2 socket 1 2 wrench screwdriver set Required Parts 6 new AN365 524 nyloc nuts Level of Certification Required A amp P LSA R M 1 Ensure ignition switch is in the OFF position and set parking brake 2 Remove spinner using procedure in Section 9 1 3 Set torque wrench to 15 17 ft lbs Check tension of nuts by moving a criss cross pattern around the hub see Figure 9 1 for torque pattern Use box end wrench to hold bolt heads secure 4 If nuts move during the procedure this means the propeller has contracted Finish tightening nuts to 15 17 ft lbs of torque and move onto Step 7 If nuts do not move during the procedure the propeller has expanded To achieve proper tension the nuts must be removed and replaced with new h
14. For aircraft built in 2009 or newer substitute steps 1 and 2 above with 1 Remove the nut and washer from the actuator arm 2 Slide the control wire off of the bolt 7 15 3 Inspection Inspect for cracks and loose rivets on muff Inspect valve for smooth and proper opera tion Inspect SCAT hose for damage and replace if necessary 7 15 4 Repair Repair is limited to replacement of components 7 15 5 Reinstallation Reverse the steps in 7 15 2 JSA SM170SP A1 Page 7 25 Section 7 Jabiru J170 SP Engine Systems Aircraft Service Manual 7 16 Ignition System Refer to Instruction amp Maintenance Manual for Jabiru 2200 Aircraft Engine 7 17 Spark Plugs 7 17 1 Description Each magneto powers one of the two spark plugs per cylinder See Section 1 9 for re placement spark plug type 7 17 2 Removal Tools Required 18mm deep well socket 3 16 Allen key nee dle nose pliers spark plug gap tool Level of Certification Required Owner A amp P or LSA R M M 1 Remove cooling air baffles according to Section 7 4 2 Disconnect the spark plug wires from the plugs 3 Using an 18mm socket remove the spark plug and CHT probe if necessary 7 17 3 Inspection Check for cracks in the insulator or damage to the electrode Check the color of the electrode insulator Medium brown indicates correct mixture White or light gray color indicates a lean mixture Black and sooty indicates a rich mixture 7 17 4 Repair Repair is limited to
15. Loose nose strut bolts or steer Inspect nose strut assembly for loose worn or ing link defective parts Section 5 10 Wheel out of balance Balance nose wheel tire assembly 5 9 5 Worn wheel bearings Replace nose wheel bearings 5 9 3 Main gear legs Uneven runway surface Some brake shimmy is normal during heavy brak shimmy when ing on rough or uneven surfaces brakes applied heavily Warped brake disc severe Inspect brake disc and replace or resurface as shimmy cases necessary Section 5 7 5 JSA SM170SP A1 Page 5 1 Section 5 Jabiru J170 SP Landing Gear and Brakes Aircraft Service Manual 5 3 Main Wheel Fairings 5 3 1 5 3 2 5 3 3 5 3 4 Page 5 2 Description The wheel fairings are single piece fiberglass finished with the same type of automo tive paint and clear coat as the rest of the airframe The main fairings are attached to the main landing gear legs using aluminum brackets screws and plastic spacers See Paragraph 5 9 2 for information regarding removal and reinstallation of the nose wheel fairing Removal Tools Required 2 Phillips screwdriver Level of Certification Required Owner A amp P LSA R M M 1 Remove the screw on the outboard side of the fairing 2 Remove the small machine screws 2 on the inboard side of the leg 3 Lift fairing from its mounting brackets Inspection Check for cracks or worn areas inside the fiberglass pant Check for elongation of screw holes and lo
16. MI SECTION 8 SUSPENSION ASSY DETAIL Figure 5 6 Nose Leg Suspension Detail Page 5 24 JSA SM170SP A1 Section 5 Jabiru J170 SP 5 V 2 os wamu 646 981 00 pyy 42345 59 SINT 5 011 Ald HO3LAV 30 INSSNOO 3HL 3 800 Vid Lon SSELSWITIIW NI 48 38 LON 181 1 SIHL Em 009591 2014 NOLLOO ONISN _ 63118 OL 5 SNISHIN3O ONISNOH 9313SON 31 14 aoacoove 2 ONISNOH ISON 51 TVNH31NI 909600 9 or SU 1 14 SNDIOVE H3NNI ONISNOH 237 GANIHOWN _ 3600 9 6 5 gt MIYOS dVO ONN 0 97 NsesoHd _ 2 2 2 voiwelo b 5830 O fo o lt 7 Nose Leg Housing Figure 5 Page 5 25 25 SM170SP A1 Jabiru J170 SP Aircraft Service Manual Section 5 Landing Gear and Brakes 1 620 129 Wl 1005919 1SVO ASSY T33HM 3SON os 1 H3 DINIH
17. 11 14 3 Inspection Inspection is limited to the pins and wiring 11 14 4 Repair Repairs to the intercom must be referred to PS Engineering 11 14 5 Reinstallation Reverse the steps in Paragraph 11 14 2 for reinstallation JSA SM170SP A1 Page 11 19 Section 11 Jabiru J170 SP Electrical System and Instruments Aircraft Service Manual 11 15 External Power Booster Cable 11 15 1 Description An External Power booster cable comes standard with new Jabiru S LSA aircraft It en ables the operator to use an external battery to start the engine without removing the cowlings The following describes the installation procedure for retro fit kits available through Jabiru USA Sport Aircraft LLC for aircraft built before the plug became stan dard 11 15 2 Installation Page 11 20 Tools Required Ruler marker 3 16 drill 3 8 and 10mm wrenches Parts required Booster plug kit part no JU 46 Level of Certification Required A amp P LSA R M M or Avionics Repair Station Remove upper and lower engine cowlings 2 Make sure receptacle mounting area see Figure 11 5 is free of grease and dirt 3 The receptacle must be mounted slightly off center so the bolts clear the rudder pedal assembly inside the cabin To find the proper location for the receptacle Using a ruler make a mark in the center of the recessed area under the passenger side of the firewall B From the center mark measure 1 toward the pilot s s
18. 4 Remove mount Inspection Inspect engine mount for cracks and rub amp abrasion marks Repair V CAUTION The engine mount should not be repaired Repair is limited to replacement Reinstallation Use new AN4 21A bolts and AN363 428 nuts to install the engine mount Tighten to standard torque V WARNING The bolts on the engine mount must only be fitted with high temperature nuts DO NOT USE NYLOC NUTS as the nylon insert may melt causing failure Shock Mounts 7 6 1 Page 7 10 Description The engine is mounted to the welded engine mount using rubber lord mounts for re ducing engine vibration Each shock mount consists of one male and one female part 25 SM170SP A1 Section 7 Engine Systems Jabiru J170 SP Aircraft Service Manual 01 Lavaoulv nulave suw rmi NOLVTWISNI 1 NOLVSBIA mul uoapw 1 mon 2 LAVUDUIY NI SNOLLVTTVISNI ANION 0055 0022 nNigVP 3189V9rTddV 2409 NOILVUNDIANOD LNNOW 3NISN3 726 90 29 qn WN LL INOYOL i 4 SIN LAN cea ra an ASSV M INNON 3NION3 1 INNON 3NION3 NV3N qn WN LL SS SON L3 E
19. 80 61 80 ee L 119 sof 1 en 608 NOISN3LX3 508 NIVM 508 LN3WNXLSNI 15 L4 AN 30005 SNIONVT Savi 1543 1533 du 0 5 9 pO 9 9 9 D 0 X ve 5 t 2 1 2 9 9 09 9 d d 9 uva 2 2 2 0 6 105 m RE 193039 al y 1 AOV ZAN 52 C 31915 13 sia 1 1 L 5 gt 5 IM 17 8 8 2 60 m i 55 19 av 380515 508 11 23 ical VOR typ Diagram Dual EFIS Electrica Figure 11 8 25 5 1705 1 Jabiru J170 SP Aircraft Service Manual Electrical System and Instruments Section 11 80 61 80 dew XXXN 3290 4 ASVNIIAFT3Sd NOISN3LX3 508 508 LNAWNYLSNI SQ dX 9 9 9 zH sH sH se 143234 22 WOOM31NI S d 38045 508 annoys JSA SM170SP A1 1 Ica ith VOR typi Diagram wi Dual EFIS Electrica Figure 11 9 Page 11 24 Jabiru J170 SP Section 12 Aircraft Service Manual Fiberglass Repai
20. Comments Static Port Check for blockages Check static probe for condition Pass Fail Comments Antennas Check for condition and security Pass Fail Comments 8 General Airplane cleaned and serviced Pass Fail Comments Inspect all placards to assure they are easily readable and securely attached Pass Fail Comments Ensure that all Service Bulletins Air Safety Alerts and previously issued Service Instructions are reviewed and complied with as required Pass Fail Comments For a complete annual or 100 hour inspection of the airplane all items on the airplane that are noted in this guide must be inspected Pass Fail Comments JSA 100HR A1 100 Hour Annual Inspection Checklist Jabiru J170 SP Appendix Aircraft Service Manual Jabiru J170 SP Quick Reference Maintenance Guide il Type Oil Quantity park Plug park Plug Gap park Plug Tension gnition Coil Gap ead Bolt Tension rop Bolt Tension ose Tire Pressure _ _ JSA 5 1705 0 Quick Ref Guide Page 1 of 1 2 8 Comments Describe the malfunction or defect and the circumstances under which it OPER Control No Jabiru USA Sport Aircraft LLC OPER contorno occurred State probable cause and recommendations to prevent recurrence Guta MALFUNCTION OR DEFECT REPORT 2 3 4
21. Inspection Inspect door for cracks and latch alignment Inspect hinges for signs of cracks due to over extension Inspect upper ball latch for spring effectiveness Replace if necessary Slight inward bowing of the door skin is normal in Jabiru models from early 2009 and older especially when parked in the hot sun This is due to tension on the skin from the upholstery panels It may be corrected by removing the upholstery panel and installing additional padding between the skin and the upholstery Repair Repair of fiberglass cracks or delamination in the doors can be done by following the general fiberglass repair procedures or door hinge and lock slot repair supplement in Section 12 For repairs to windows see Section 3 2 Reinstallation Reverse the steps in Paragraph 3 3 2 Follow the steps in 3 3 6 for adjustment if neces sary after reinstallation Adjustment Cabin doors should be adjusted by shims at the hinge attach points so that the door skin fairs with the fuselage skin and the door latch pin lines up with the hole in the door frame 3 4 1 Description 3 4 2 3 4 3 3 4 4 3 4 5 The Jabiru seats are an integral part of the structure of the aircraft they are therefore fixed in position V WARNING DO NOT MODIFY SEATS Removal Seats may not be removed Inspection Inspect fiberglass layups in the seat structure for cracking and delamination Repair Seats are a structural element in the fuselage and the
22. Reverse the steps in 8 4 2 for installation 2 test pump function turn master switch ON engine not running and then turn fuel pump ON There should be an audible tapping sound The frequency of the taps will change slightly when the carburetor bowl is filled with fuel V WARNING All fuel line firesleeve removed during maintenance must be reinstalled before the aircraft is returned to service 8 5 Fuel Filters 8 5 1 Description There is one removable brass finger filter in each fuel tank exit line two in each main tank and one in the header tank to filter large particles exiting the fuel tanks There is one automotive type main fuel filter located between the center console shutoff valve and the firewall between the rudder pedal units 8 5 2 Removal of Finger Filters Level of Certification Required A amp P or LSA R M M 1 Drain fuel from the affected fuel tank using procedure outlined in Paragraph 8 8 2 Remove wing root fairings or header tank as necessary see Paragraph 8 2 of this section for removal of header tank 3 Remove hose clamp and fuel line Remove finger filter using deep well socket Page 8 4 JSA SM170SP A1 Jabiru J170 SP Section 8 Aircraft Service Manual Fuel System 8 6 8 5 3 Removal of Main Fuel Filter Tools Required 7 16 deep well socket flat screwdriver fuel line pliers Level of Certification Required A amp P or LSA R M M 1 Run engine if possible Empty fuel from the main fuel
23. example Revision 1 would look like JSA SM170SP A1 A list of affected pages is found in the Revision Summary in the front of this manual sn on a THIS PAGE INTENTIONALLY BLANK Jabiru J170 SP Aircraft Service Manual Table of Contents Section Title Foreword Section 1 General Description 1 1 Description tec oc tede dte tne e 1 2 Aircraft Specifications rasini a a 1 3 Three View 5 erre ct ci dr c ee ibo 1 4 Engine Specifications isatsean ani eaaa aait aeea iadt 1 5 Weight amp Balance Information sse 1 6 Tire Inflation 1 7 Equipment nae a ees 1 8 Sources to Purchase 1 9 Disposable Replacement 1 10 Approved Oils and 1 11 Recommended Fastener Torque 1 12 General Safety Information sss 1 13 Reporting Safety of Flight or Service 1 14 Extreme Climactic Conditions seen 1 15 Approved Fuels sss nnn nennen nnns nn Section 2 General Care and Inspection 2 1 Ground 2 tdt eld e
24. lines and clamps for condition and attachment Check plumbing clearance and secure against possible chafing Pass Fail Comments Engine Sump Check for cracks leaks proper fluid level and security Pass Fail Comments Oil Service Remove oil filter Inspect oil sump drain and install new filter Drain and replace crankcase oil Empty oil overflow bottle Pass Fail Comments Oil Cooler Check oil cooler lines and fittings for condition security chafing and leaks Pass Fail Comments Firewall Check for wrinkles damage or cracks Check all electrical and control access holes for proper sealing Pass Fail Comments Engine Accessories Check for condition security and leaks Check wiring hoses and tubes for chafing security and leaks Pass Fail Comments Cabin Heat System Check for cracks distortion corrosion leaks and obstructions Pass Fail Comments JSA 100HR A1 100 Hour Annual Inspection Checklist Page 10 of 17 Jabiru J230 SP J250 SP and J170 SP Aircraft Service Manual All Drains and Plugs Check for condition cleanliness and security Check for leaks and correct tension Comments Cowling skin Check for deformation delamination and obvious damage or cracks Check for rub points on the interior surfaces Cowling
25. security of switches and knobs Pass Fail Comments JSA 100HR A1 100 Hour Annual Inspection Checklist Page 5 of 17 Jabiru J230 SP J250 SP and J170 SP Aircraft Service Manual Flaps check for noisy operation full travel and proper installation Pass Fail Comments Flight Instruments Check for condition and proper operation Pass Fail Comments Brakes Check for condition and wear ease of operation and proper release of parking brake Check for unusual brake chatter Pass Fail Comments Emergency Locator Transmiter Check for proper operation and ensure the ELT is armed when the airplane is returned to service Check ELT battery expiration date and replace batteries if necessary Pass Fail Comments Switches Circuit Breakers Check for proper operation Pass Fail Comments Flight and Trim Controls Check freedom of movement and proper operation through full travel with and without flaps extended Check trim controls for proper operation Pass Fail Comments 2 Powerplant Refer to nstruction amp Maintenance Manual for Jabiru 3300 Aircraft Engine Spinner and Spinner Flange Check for deformation security and cracks Comments JSA 100HR A1 Propeller and mounting bolts Check tension on all propeller bolts Check propeller for conditi
26. the paper in gasoline or similar solvent Inspect the filter media for metal debris Some amount of non magnetic aluminum particles is to be expected Fine rusty bronze colored particles that look the size of squashed sugar grains indicate rocker bushing wear Larger copper or bronze colored particles indicate main or rod bearing wear Ex cessive amounts and or size of these particles may indicate need for further engine in spection or repair Reinstallation of Oil and Filter 1 2 JSA SM170SP A1 Lubricate the rubber seal of the new filter with engine oil Screw the filter onto the threaded adapter and turn clockwise until the filter con tacts the cooler adapter Continue clockwise for 2 3 turn There is no need to lock wire the filter in place Reinstall cooling baffle Refill crankcase with appropriate amount and type of oil Total oil capacity is 2 2 quarts To check oil quantity screw dipstick cap all the way into the case then unscrew lift out and check Normal oil level range is depicted by the cross hatched area on the dipstick Do not overfill Clean all excess oil from exterior surfaces of engine especially around the filter area and quick drain Run engine for at least 30 seconds to check oil pressure and other engine vitals Page 7 13 Section 7 Engine Systems Jabiru J170 SP Aircraft Service Manual 8 Shut engine down and check for oil leaks Investigate source of any leaks and cor rect 9 Rein
27. 1 Place scales under each wheel 2 Level aircraft as described in Section 2 5 3 With the airplane level and brakes released record the weight shown on each scale in the appropriate places on Table 2 1 Deduct the tare if any from each reading 2 6 4 Determine Moment Arms Refer to Figure 2 4 To find empty moment of aircraft measure distance from datum wing leading edge to center of wheel axles while the aircraft is level 1 Measure from the center of each main wheel axle to a plumb bob dropped from the wing leading edge to obtain Distance A Measurement must be parallel to aircraft centerline 2 Measure from the plumb bob to the center of the nose wheel axle to obtain Dis tance B keeping measurement parallel to aircraft centerline 3 Record the measurements in Table 2 1 4 To find the moments of the weighing points multiply net weight by the arm of each weighing point Add all weights to calculate Basic Empty Weight of aircraft Add all moments to find Empty Moment of aircraft To find empty Center of Gravity CG divide the Total Moment by the Basic Empty Weight 2 6 5 Aircraft Empty Weight Record Use Table 2 2 to maintain a continuous history of changes and modifications to the air craft structure or equipment affecting weight and balance Page 2 6 JSA SM170SP A2 Jabiru J170 SP Section 2 Aircraft Service Manual General Care amp Inspection Registration No Running Basic Change in Weight and Moment Emp
28. 1 Remove ground cable from aircraft battery 2 Loosen set screw at rear of light assembly 3 Slide unit forward on its mounting track Light tapping on the set screw may be re quired 4 Remove unit from wing and disconnect wires 11 6 3 Repair Repair of wingtip lighting is limited to replacement of the unit 11 6 4 Reinstallation Tools Required Phillips screwdriver RTV silicone Level of Certification Required Owner A amp P or LSA R M M GS Air 1 Connect wires 2 Reinstall ground on battery and test light for proper color and operation 3 Apply small bead of silicone around the edge of the light unit to form a gasket between the unit and the wingtip 4 Press the unit into place Reinstall the two screws to hold it in position 5 Clean up excess silicone AeroLEDs 1 Connect wires 2 Reinstall ground on battery and test light for proper color and operation 3 Slide light unit onto mount making sure O ring is in place It may help to apply small bead of superglue to keep the O ring in place 4 Tighten set screw Page 11 4 25 SM170SP A1 Jabiru J170 SP Section 11 Aircraft Service Manual Electrical System and Instruments 11 7 Recognition Landing Light 11 7 1 Description The strut mounted recognition light contains one 50W incandescent bulb Aircraft built after May 2009 had the option of an AeroLED MicroSun LED landing light mounted in the leading edge of one or both wingtips 11 7 2 Remova
29. 19400 SI 9 SIHL System Ic Pitot Stati 11 1 Figure Page 11 7 JSA SM170SP A1 Jabiru J170 SP Aircraft Service Manual Section 11 Electrical System and Instruments 30 133HS 608201 ASSY 1014 OILYLS 984 010 SINSWNYLSNI OL 3801 006051 40 401 94044 ODIS 008901 HOVLLV OL 31 3 1 6 4 JO 401 SI 4 5 OL AXOd3 C 40014 NOLIOO SNOISN3NWIG 011 Ald HO31AV JO 1 35 02 LNOHLIM 03403 38 LON 15 LHOINAdOD SI 5 Vent Detail Static Figure 11 2 JSA SM170SP A1 Page 11 8 Jabiru J170 SP Section 11 Aircraft Service Manual Electrical System and Instruments 11 9 Engine Information System EIS 11 9 1 Description The Grand Rapids Technologies Engine Information System EIS Model 40002 is used to monitor all engine parameters The instrument monitors RPM OAT CHT 4 EGT 4 Oil Pressure Oil Temp Voltmeter Flight Timer and Hobbs Meter High and low limits are programmed into the unit for all measurable parameters A warning light and the EIS screen flashes to highlight information sets that are outside of programmed limits 11 9 2 Removal Tools Required 9 64 Allen key screwdriver set Level of
30. 2 years whichever comes first Hoses which show visible deterioration cracking excessive hardening should be replaced immediately regardless of age JSA SM170SP A1 Page 7 3 Section 7 Jabiru J170 SP Engine Systems Aircraft Service Manual A C N 010 910 077 JABIRU AIRCRAFT P L 0 BOX 5186 BUNDABERG 4670 QUEENSLAND AUSTRALIA 07 4155 1778 FAX 07 4155 2669 2200 JABIRU ENGINE OPTIONAL FRONT uu BED MOUNT DIMENSIONS IN ARE INCHES OPTIONAL FRONT BED MOUNT Figure 7 1 Engine Dimensions Page 7 4 JSA SM170SP A1 Jabiru J170 SP Section 7 Aircraft Service Manual Engine Systems 7 3 Engine Cowls 7 3 1 Description The engine cowls consist of one upper and one lower composite structure The upper cowl is fitted with three cam locks in the rear and two machine screws in the front one inside each air inlet The lower cowl is attached to the fuselage with 10 machine screws mounting into anchor nuts with Tinnerman washers One long hinge pin connects the two cowls together along each side with the hinge pin entering and exiting the hinge through the cabin door frame 7 3 2 Removal Tools Required Phillips 2 screwdriver Level of Certification Required Owner A amp P or LSA R M M Upper Cowl 1 Remove the three cam locks from the rear of the top cowling and the two screws from the nose cone of the cowl 2 Remove hinge pin located in the door frame on each side 3 From the
31. 8 4 Fuel Pumps de mee iR bn 8 3 8 5 Fuel Eilters oce tte Pe a ue d cv de e Rune crat 8 4 8 6 Fuel Sump Dral S 8 5 8 7 8 6 8 8 Fuel Draining Procedure 8 8 9 1 Spinner Assembly 2 eet Belen a es Ee Oe 9 1 9 2 net tt iain 9 2 9 3 Balancing Een ERE 9 4 9 4 Propeller Tracking 9 4 9 6 Approved nnn 9 4 9 7 Identification 5 0 5 eene 9 4 9 8 Propeller Bolt Tension 9 7 10 1 Cabin epe repe He f tg edid 10 1 10 2 Cabin Ventilation sss enne 10 2 10 3 Stall Warning System 10 2 JSA SM170SP A1 Jabiru J170 SP Aircraft Service Manual Section Title Page Section 11 Electrical System and Instruments 11 1 General 020044 044 00 000 11 1 11 2 11 1 11 35 11 1 11 4 Switches and 11 2 11 5 Starter ue e e e 11 3 11 6 Navigation Lights and 5 11 3 11 7 Recognition Landing 1
32. A1 Page 9 3 Section 9 Jabiru J170 SP Propeller amp Spinner Aircraft Service Manual 9 3 Balancing Procedure After any repair work is done to a wood or carbon propeller it must be rebalanced Re fer to Sensenich Wood Propeller Company for approved balancing procedures 9 4 Propeller Tracking Procedure After removing and reinstalling any propeller the blade tracking must be measured be fore the aircraft is returned to service V WARNING Before handling any propeller ensure the ignition and master switches are in the OFF position 1 Check tracking of propeller by placing a fixed object on the floor in front of the air craft so that it just clears the propeller tips when rotating the propeller by hand Ensure the floor is a level surface 2 Check that each blade clears the object by the same amount Maximum tracking error tolerance is 2mm If the propeller is outside the approved tolerance refer to Sensenich Wood Propeller Company or Jabiru USA Sport Aircraft for service 9 5 Approved Installations for J170 SP W60HJ 45 to W62HJ 40 to 2 WOOD NOTE Any change in propeller pitch or diameter will likely require carburetor jet ting adjustment See appropriate Jabiru 2200 engine manual for details Table 9 2 Approved Propeller Installations 9 6 Identification Stampings Each wood propeller is marked with the model number the diameter and pitch in inches part of model number and manufacturer s serial numbe
33. Certification Required A amp P LSA R M M or Avionics Repair Station 1 Remove the four screws at the corners of the unit 2 Pull the unit from the panel and disconnect the D sub connectors from the rear of the unit 11 9 3 Inspection and Repair Inspection is limited to checking the cables and D sub connectors for damage or bad pins Any other repair must be done by Grand Rapids Technologies at their facility 11 9 4 Reinstallation 1 Reverse steps in 11 9 2 for reinstallation 2 Run engine and check EIS unit for proper operation 11 9 5 Reprogramming Instructions 1 If default settings the EIS become corrupted and reprogramming is necessary contact Jabiru USA Sport Aircraft LLC for further instructions JSA SM170SP A1 Page 11 9 Section 11 Jabiru J170 SP Electrical System and Instruments Aircraft Service Manual 11 10 Electronic Flight Information System EFIS 11 10 1 Description The Jabiru S LSA instrument panel features a Grand Rapids Technologies Sport EFIS unit for primary flight instrumentation and navigation The three panel options include a four pack of traditional round dial instruments one EFIS on the left side only or two EFIS units where one is a primary flight display PFD and one is a multi function dis play MFD Single EFIS units are plumbed to the pitot static lines and a GPS antenna in addition to the 37 pin D sub connector In aircraft equipped with a second EFIS as a multi function displ
34. ELT Installation Operation Manual DOCO6006E A amp P or LSA R M M A amp P LSA R M M or rated avionics technician A amp P LSA R M M rated avionics technician Owner Operator Owner Operator FAR Part 145 Repair Station All aircraft except those equipped with ground adjustable carbon propeller Aircraft equipped with 406 MHz satellite ELT Aircraft equipped with 406 MHz satellite ELT Recommended by engine manufacturer Propeller manufacturer FAA Order 8130 2F Change 3 Section 126 FAR 91 207 d FAR 91 413 a Recommended by aircraft manufacturer Recommended by aircraft manufacturer Title 47 Parts 80 87 and 95 of U S Code of Federal Regulations FAR 91 207 Owner Operators of S LSA aircraft that hold at least a Sport Pilot or Private Pilot Certificate may only perform maintenance items listed in FAR Part 43 Appendix A Maintenance Preventive Maintenance Rebuilding and Alteration Section C Owner operators performing preventive maintenance must return the aircraft to service by endorsing the aircraft or engine logbook as specified in FAR 43 9 All other maintenance tasks must be performed by an A amp P LSA Repairman with Maintenance Rating or FAA certified repair station Owner operators of E LSA aircraft that hold a minimum maintenance certification of LSA Repairman with Inspection Rating are authorized under FAR 43 1 b 2 to perform maintenance as permitted in the Airc
35. Perform two or three high speed taxi runs Apply firm braking at 30 40 mph down to 5 mph to generate the necessary 300 400 degree temperatures at the brake pads DO NOT bring the aircraft to a complete stop during taxi runs and continue to roll aircraft until reaching the tie down area Release brake pressure at tie down area as soon as practical and park with brake pressure released Allow brakes to cool for 10 15 minutes Repeat step one and note RPM at creep if any occurs There should be a noticeable increase in holding torque If properly conditioned the pads will have a uniform shiny appearance glaze on the surface Repeat steps 1 3 if necessary to produce glaze NOTE Forward movement of the aircraft during static run up could be caused by the wheels skidding and not brake malfunction JSA SM170SP A1 Jabiru J170 SP Section 5 Aircraft Service Manual Landing Gear and Brakes 5 9 Nose Wheel Fairing 5 9 1 Description Wheel fairings pants are optional on J170 SP aircraft The nose wheel fairing is com posed of two pieces for easy installation and removal 5 9 2 Removal and Installation Tools Required Phillips screwdriver 7 16 wrenches Parts Required Loctite 242 for installation Level of Certification Required Owner A amp P or LSA R M M 1 Weight down tail of aircraft to raise nose wheel off floor as described in Section 2 2 Remove the machine screws that join the forward and rear sections of the fairing an
36. Propeller manufacturer Each 50 Hour Interval 50 Hour Service and Inspection JSA 50HR All Aircraft manufacturer Each 100 Hour Interval 100 Hour Inspection JSA 100HR Commercial Operators FAA Order 8130 2F Change 3 Section 126 Each 200 Hour Interval Replacement of Engine Ignition Wires Caps and Rotors Jabiru 2200 Installation and Instruction Manual Recommended by aircraft manufacturer Each 500 Hour Interval Landing Gear Bolt Replacement JSA 003 1 Aircraft manufacturer Each 1000 Hour Interval Engine Top Overhaul Jabiru 2200 Overhaul Manual Recommended by engine manufacturer Each 2000 Hour Interval Significant temp humidity change over several weeks or months Every 12 Calendar Months Every 24 Calendar Months Every 24 Calendar Months and at change of ownership Every 72 Calendar Months Engine Complete Overhaul Propeller Hub Bolt Tension Check Annual Inspection Transponder Inspection Aircraft Battery Replacement Replacement of Engine Compartment Flexible Hoses ELT Registration Renewal 406 MHz ELT Six Year Inspection and Battery Replacement Jabiru 2200 Overhaul Manual Aircraft Service Manual or Sensenich Doc WOOD CF REV A DOC 5 20 04 JSA 100HR ELT operation manual Transponder operation manual Aircraft Service Manual Aircraft Service Manual 1 800 212 SAVE or www beaconregistration noaa gov Kannad
37. Required Screwdriver set long piece of 1 4 ID fuel hose gasoline approved amp clean fuel contain ers with enough capacity to hold contents of tank to be drained plus header tank Level of Certification Required Owner A amp P or LSA R M M To drain fuel from the header tank 1 Close both left and right fuel valves Make sure main fuel valve is ON 2 Disconnect fuel line between the electric and the mechanical fuel pump 3 Connect a long fuel line from the output fitting on the electric pump to a container approved to hold gasoline 4 Turn on master switch Turn on electric fuel pump Run fuel pump until all fuel is pumped from the header tank NOTE The capacity of the header tank is approx 1 5 U S gallon Allow extra room for fuel in the lines To drain fuel from a wing tank 1 Make sure the fuel valve appropriate to the tank being drained left or right is switched ON and turn the other one OFF Make sure the main fuel valve is turned ON 2 Follow steps 2 through 4 above until fuel is drained from the wing tank NOTE The capacity of each wing tank is approx 18 U S gallons Page 8 8 JSA SM170SP A1 Section 8 Fuel System Jabiru J170 SP Aircraft Service Manual Japuas 4 4 janj 2u329 3 293114 330 3145 2945 AJN yue Hurm ry 03 4
38. SP Aircraft Service Manual 7 9 5 Reinstallation 1 Secure the bottle inside the firewall clamp 2 Reconnect the hoses 7 10 Carburetor 7 10 1 Description The Jabiru 3300 utilizes a Bing 64 altitude compensating carburetor Refer to the Instruction amp Maintenance Manual for Jabiru 3300 Aircraft Engine for de tailed carburetor data See Section 7 13 of this manual for information on the carbure tor heat system 7 10 2 Removal Tools Required 5 16 wrenches screwdriver set needle nose pliers Level of Certification Required A amp P or LSA R M M V WARNING Fuel lines within the engine compartment are fitted 5 6 with fireproof sleeves If removed the sleeves must be reinstalled before the aircraft is returned to service Disconnect fuel line from carb Disconnect throttle cable from carb Disconnect choke cable from carb Disconnect ground strap from carb Loosen clamp on rubber carb adapter Pull the carb to the rear and down to remove 7 10 3 Inspection and Repair Page 7 18 1 Inspect rubber carb connector for cracks or deformation Repair is limited to re placement Remove carb dome and inspect diaphragm for cracks or breaks Replace if damage is observed Inspect the needle for damage or deformation Repair is limited to replacement Inspect floats for damage or fuel saturation Repair is limited to replacement Inspect float valve for rubber tip damage or deformation Repair is limite
39. and Figure 7 7 7 11 2 Removal and Replacement of Air Filter 1 Disconnect SCAT hose from airbox outlet 2 Remove screws 4 from corners of filter box 3 Remove filter 7 11 3 Inspection and Repair 1 Inspect for breaks in the filter medium by shining a light through Repair is limited to replacement 2 Inspect for dirt clean by blowing air back through the filter Replace if dirt does not blow away JSA SM170SP A1 Page 7 19 Jabiru J170 SP Aircraft Service Manual Section 7 Engine Systems wid 25 ONISMOH 131 i Z amp 63BZ r ONAA 24093 53801 Sar Mad ONOMA 48 24141843110 ONY 5 031008 SION HEE OFL GEL OI sumi JSA SM170SP A1 Figure 7 8 Air Mixer Box Page 7 20 Jabiru J170 SP Section 7 Aircraft Service Manual Engine Systems 7 11 4 Reinstallation 1 Place new filter into airbox base 2 Position cover in place over the filter 3 Install screws 4 4 Reconnect SCAT hose to airbox cover and tighten clamp 7 12 Flexible Hoses 7 12 1 Description Fuel lines and SCAT hoses run throughout the engine compartment and should be checked periodically Replacement of all engine compartment flexible hoses is recom mended every 24 calendar months 7 12 2 Removal Tools Required Screwdriver set compressed air blower Parts Required Replacement air filter See Section 1 9 Level of Certification Required
40. and avoid swirling motions Heavy accumulation of bugs and grease on painted surfaces should be removed with a light mixture of soap and water and then rinsed The TurtleWax may then be applied for a smooth protective shine Specialty plastic cleaners such as Plexus will also work on the windows which are acrylic based Perspex If tape or sticker residue gets on the windows GooGone citrus stain remover dabbed onto a soft microfiber cloth will remove it without harming the windows Light scratches and swirl marks may be buffed out using a Plexiglas window buffing system such as Scratch Off available through Aircraft Spruce and Specialty V CAUTION Use only cleansers approved for acrylic based plastics on and near the windows V CAUTION Do not use silicone based cleansers as these may soak through the finish and into the fiberglass and af fect future reparability of the components V CAUTION DO NOT use glass window cleaning spray gasoline alcohol benzene acetone carbon tetrachloride fire extinguisher fluid de icer fluid or lacquer thinner These solvents will soften and craze the plastic CAUTION DO NOT use a canvas cover on the windshield or win dows as the cover may scratch the plastic Factory issued aircraft covers have a cotton inner layer to pro tect the windows 2 11 2 Interior Surfaces and Upholstery The interior may be cleaned using standard automotive upholstery cleaners made for the particular
41. area When dry fol low with a base color coat and clear coat Jabiru USA uses PPG brand but any compati ble automotive base coat clear coat is acceptable After paint cures use a buffer to blend the repair area into the rest of the paint Page 12 4 25 5 1705 0 Jabiru J170 SP Section 12 Aircraft Service Manual Fiberglass Repair 12 4 4 Complete Repaint For a complete repaint of the airframe the clear coat and most of the base coat and primer sealer should be removed Wet sanding is the preferred method to remove paint Take care not to sand through gel coat or fiberglass strands Repaint with a quality brand of primer sealer that includes a UV barrier base color coat and finally a clear coat following the paint manufacturer s instructions 12 5 Door Repair Supplement The following procedure should be used in cases where the door has been overex tended by force wind gust etc and suffered a broken door frame near the hinge points It also covers damage due to a locked door being pried open This non structural procedure may be used to repair cracks and breaks in any portion of the door frame The hinge structures are bonded to the inside of the door frame and door skin When damage to the hinge structure or door frame occurs it is necessary to drill or cut an access hole big enough to inspect the damage and add epoxy and flock to repair the broken area The inspection hole will later be covered up with two or more lay
42. battery may need to be replaced 11 3 4 Reinstallation Reverse the steps in 11 3 2 for reinstallation 11 3 5 Trickle Charger Newer aircraft beginning in 2008 are equipped with a trickle charger lead accessible through the oil access door in the upper engine cowling Use the Battery Tender Jun ior a 1 amp hr charger which is delivered with each new aircraft equipped with the charging lead Replacement chargers are available from Aircraft Spruce amp Specialty p n 11 05164 11 4 Switches and Breakers 11 4 1 Description Tools Required 1 2 deep well socket or pliers Phillips screwdriver Level of Certification Required A amp P or LSA R M M Jabiru S LSA aircraft utilize 5w toggle type circuit breaker switches of different sizes Circuit breakers are either of the flush type pre 2009 models or pull type 2009 and newer 11 4 2 Removal Page 11 2 1 Remove ground wire from aircraft battery 2 Taking care not to scratch the face of the instrument panel remove the nut on the front of the switch using the socket or the thumb screw on the front of the breaker using a pliers JSA SM170SP A1 Jabiru J170 SP Section 11 Aircraft Service Manual Electrical System and Instruments 3 Remove screw from bus bar 4 Remove screw from accessory that the switch or breaker is attached to 5 Depending on location along the bus bar other switches may need to be removed to access the affected switch 11 4 3 Repair Rep
43. be downloaded from the manufactuer s website www usjabiru com 25 50 Hour Inspection Checklist Page 2 of 9 Jabiru J230 SP J250 SP and J170 SP Aircraft Service Manual 1 Operational Inspection Starter Check for proper operation unusual noises and dragging Fuel Pressure or Fuel Flow Check within normal limits if installed Cylinder Head Temperature Check for proper operation temperatures and fluctuations Alternator Check for proper output Propeller Check for smoothness of operation Oil Pressure and Temperature Check for proper pressure temperature limits and unusual fluctuations JSA 50HR A1 25 50 Hour Inspection Checklist Page 3 of 9 Jabiru J230 SP J250 SP and J170 SP Aircraft Service Manual Magnetos Check the performance of the magneto as outlined under the heading NORMAL PROCEDURES in the appropriate Pilot s Operating Handbook Lights Check function condition attachment cracked or broken lenses Check switches knobs and circuit breakers for looseness and operation Flight and Trim Controls Check freedom of movement and proper operation through full travel with and without flaps extended Check trim controls for proper operation Propeller and mounting bolts Check tension on all propeller bolts Check propeller for condition and security Inspect blades for cracks dents nicks scratches erosion delamination in the case of fiberglass sheathed propellers security and move
44. cessories amp components as appropriate During removal of all parts carefully examine amp tag defective parts for repair or replacement with a new part NOTE All openings exposed by the removal of an item should be closed by installing a suitable cover or cap over the opening This will prevent the entry of foreign particles If suitable covers are not available tape may be used to cover the opening 7 2 Basic Engine Compartment Inspection For specific items to be inspected and for periodic inspection details refer to Instruction amp Maintenance Manual for Jabiru 2200 Aircraft Engine 1 Visually inspect the engine for loose bolts nuts cracks leaks amp cooling fin damage Blis tered paint around the base of the cylinders may indicate an overheating issue Inspect baffles baffle seals amp brackets for cracks deterioration or damage Inspect all control linkages for security and operation Inspect wiring for chafed areas and security Inspect hoses for internal swelling chafing cuts breaks stiffness or loose connections Excessive heat on hoses will cause them to become brittle amp easily broken Hoses are most likely to crack or break near the ends amp at support points Check fire sleeves on fuel lines within the engine compartment Avoid excessive flexing amp sharp bends when exam ining hoses for stiffness All flexible hoses in the engine compartment should be replaced at engine overhaul or every
45. cleaning and re gapping if plug is in good shape Otherwise repair is limited to replacement 7 17 5 Installation 1 Adjust plug gap to 022 inch 2 Apply nickel anti seize to threads 3 Install CHT probe on plugs where appropriate by removing the compression washer from the plug installing the probe washer and reinstalling the compression washer Be sure the washers go back on the same way they came off which is flat side to ward the top of the spark plug 4 Install the plug into the head and torque to 8 ft lbs DO NOT OVERTIGHTEN 5 Reattach spark plug leads 6 Reinstall engine cooling baffles Page 7 26 25 SM170SP A1 Jabiru J170 SP Section 7 Aircraft Service Manual Engine Systems 7 18 Exhaust System 7 18 1 Description The exhaust system consists of individual exhaust manifolds attached to the cylinder heads and a muffler assembly that is attached to the bottoms of the manifolds with springs Refer to Figure 7 8 for more information 7 18 2 Removal Tools Required Screwdriver set 3 16 hex driver Level of Certification Required A amp P or LSA R M M V WARNING Never remove coupling spring with a sharp object or one which can mark the spring material A rounded screwdriver shank or a hook fashioned from 14 bar stock is ideal 1 Disconnect the carb heat and cabin heat SCAT hoses 2 Remove muffler springs 3 Remove muffler assembly If necessary loosen exhaust manifold bolts 4 Remove individual exhaus
46. control horn 3 With the aileron supported remove hinge pin 6 3 3 Inspection Inspect ailerons for any signs of delamination or cracking Pay particular attention to the control horn and hinges and their surrounding fiberglass areas See Section 6 2 for inspection of control cables JSA SM170SP A1 Page 6 3 Section 6 Jabiru 2170 5 Flight Controls Aircraft Service Manual 6 3 4 Repair All damage involving cracking delamination or hinge damage must be referred to Jabiru USA Sport Aircraft LLC or approved local agent for an appropriate repair proce dure 6 3 5 Reinstallation Reverse the removal processes of Paragraph 6 3 2 for reinstallation V WARNING All spherical bearings on control cable ends 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 6 3 6 Aileron Rigging Tools Required Screwdriver set 7 16 and 3 8 wrenches 36 straightedge Aileron Rigging Template see Ap pendix or angle finder Parts Required Level of Maintenance Level of Certification Required A amp P or LSA R M M 1 Park aircraft on a level surface With the control stick in the neutral position use a straightedge not less than 1 meter long Hold the straightedge flush on the under side of the wing airfoil and adjust aileron to sit on the straightedge Make this ad justment with the cable rod ends ensuring that on completion the locknut is
47. fiberglass with a marker then tape 1 8 inside the line on both outside and inside with painter s tape to protect the windscreen from glue Be sure all surfaces of windscreen inside the line are cov ered Rough up the edge about 34 inch wide of the windscreen with 220 grit sandpaper then again with 80 grit Wet the window frame joggle and the outer edge of the windscreen with a light coat of epoxy Mix cotton flock with epoxy to the consistency of soft peanut butter Apply a bed of epoxy amp flock in the joggle to form a bed for the windscreen about 1 8 thick Place windscreen accurately onto the joggle Secure in place with the clamps shown in Figure 3 1 Install the first clamp above the top center of the windscreen and the second bottom center Install all clamps in a zig zag pattern radiating out from the center so the windscreen does not get pushed to one side or the other see Figure 3 2 Clean up excess epoxy flock and allow it to cure for 24 hours Be sure to clean off all epoxy that overlaps the tape inside the windscreen as the tape may become Page 3 3 Section 3 Jabiru J170 SP Fuselage Structure Aircraft Service Manual Figure 3 1 Window clamps made from 0 125 aluminum stock and sheet metal screws left Clamp in position holding upper portion of windshield to fuselage right Figure 3 2 Window clamps in position Install following the pattern shown working from the center outward and checking align
48. hinges and their surrounding areas 2 Check for continuity in all switch positions JSA SM170SP A1 Page 6 7 Section 6 Flight Controls Jabiru J170 SP Aircraft Service Manual 6 4 6 Reinstallation of Flap Components V WARNING All spherical rod end bearings must be fitted with a 3 4 large washer on the outside of the through bolt to pre vent the bearing case and cable from releasing in the event of a bearing failure Reverse the steps in 6 4 3 1 for installation of flap control surface Replace all four nyloc nuts Torque only until the flap hinge begins to bind then loosen slightly Reverse the steps in 6 4 3 2 for flap switch installation Reverse the steps in 6 4 3 3 for flap control rod installation Reverse procedure in 6 4 3 4 for flap motor assembly installation 6 4 7 Flap Rigging Tools Required Angle finder 3 8 or 7 16 wrenches Page 6 8 Level of Certification Required A amp P or LSA R M M Ensure the flap motor is in the full UP position Park the aircraft on a level surface Hold a protractor flush on the underside of the wing airfoil and note the angle of the bottom wing surface Adjust each flap so that it sits with a 2 degree droop in the full UP position Adjust flap position with the rod ends Ensure the lock nut is tight on the control ends and the thread is visible through the hole in the rod Check for FULL DOWN travel using a protractor Full travel should be 30 degrees 1 5 degr
49. line by turning the main fuel valve to the OFF position and letting the engine quit due to fuel starvation Turn master and ignition switches to the OFF position after the engine quits 2 Remove fuel filter by loosening the hose clamps and pulling the lines off of the filter fittings 8 5 4 Inspection 1 Inspect finger filters by looking for blockages Clean if necessary 2 If the main fuel filter is housed in clear plastic visually inspect by checking for dirt particles or blockages 8 5 5 Repair 1 Repair of finger filters is limited to cleaning 2 Repair of main fuel filter is limited to replacement See Section 1 9 for part number 8 5 6 Reinstallation 1 Reverse instructions in 8 5 2 for finger filters or 8 5 3 for main fuel filter 2 Reinstall wing root fairings according to the appropriate section of this manual Fuel Sump Drains 8 6 1 Description Three spring loaded fuel sump drains allow pilot or mechanic to drain fuel from the tanks for daily sample or fuel removal There is one sump drain in the rear root end of each wing tank and one in the bottom of the header tank which protrudes from the belly of the aircraft 8 6 2 Removal Tools Required 5 8 wrench Level of Maintenance Line Level of Certification Required A amp P or LSA R M M 1 Drain fuel from the affected fuel tank as described in Paragraph 8 8 JSA SM170SP A1 Page 8 5 Section 8 Fuel System 8 6 3 8 6 4 8 6 5 Jabiru J170 SP Aircra
50. manufacturer The manufacturer must evaluate the damage and in consultation with Jabiru Aircraft Pty Ltd will make a determination of whether the damage is repairable The manufacturer will then issue an appropriate repair procedure or will specify that components must be replaced The integrity of the underlying structure is critical to the structural integrity of the air craft Any damage to any of the underlying structure is considered major damage and careful application of specific repair procedures provided by the manufacturer is re quired 12 4 Paint and Finishing 12 4 1 Description The paint finish is an automotive base coat clear coat system similar to modern auto mobiles Most Jabiru J170 aircraft use PPG paint code WA8624 or Chevy Fleet White as the base white 12 4 2 Repair Repair procedures are similar to those used in auto body shops 12 4 3 Paint Repair Paint repairs are the done the same way whether over a fresh fiberglass repair or sim ply over a scrape or mar Sand off existing clear coat and base color coat over and around the repair area Ex tend the surface prep about 2 inches from the damage Sand off the sealer primer as well Be careful to not remove the underlying gel coat and use extreme caution to avoid sanding into or cutting any fiberglass strands Fill and smooth the area with Evercoat Lightweight Fiberglass body filler or equivalent Apply a coat of automotive primer sealer primer over the damage
51. manufacturer must approve all repairs to the seats Adjustment Forward and upward adjustment can be achieved by placing a cushion behind and or under the occupant Rudder pedal extensions may be installed as an option JSA SM170SP A1 Page 3 11 Section 3 Jabiru J170 SP Fuselage Structure Aircraft Service Manual 3 5 Upholstery Seat upholstery is provided through removable cushions These are easily removed for cleaning and inspection of the seat structures Upholstery is available in automotive cloth vinyl or leather Cabin lining is standard together with door pockets 3 6 Baggage Area The baggage area is the floor directly behind the front seats All baggage must be se cured before flight Tiedown rings are installed in the floor of the baggage area and may be used with cargo nets or straps as appropriate The rear baggage bulkhead is velcroed to the fuselage frame and may be pulled forward and removed for access to controls and electronics in the rear fuselage 3 7 Seat Belts 3 7 1 3 7 2 3 7 3 3 7 4 3 7 5 Description One aircraft grade seatbelt and shoulder harness is provided for each occupant and is bolted to the fuselage structure Belts are rated to 9G and have metal to metal buck les Removal Tools Required 3 8 wrenches Level of Certification Required A amp P or LSA R M Belts are attached in three places and can be removed by removing the AN3 attach bolts at the belt anchor locations
52. not used should be charged every 30 days Disconnect spark plug leads and remove spark plugs from each cylinder Using an oil can or spray atomizer spray preservative oil through a spark plug hole of each cylinder with the piston in the down position NOTE Use AeroShell fluid 2UN MIL C 6529C Type 1 or similar engine corrosion inhibitor CAUTION Ensure that the Master and Ignition Switches are OFF Rotate the propel ler 10 12 times leaving it in the horizontal position Install spark plugs and connect leads Seal exhaust pipes Attach a red streamer to each DO NOT seal fuel tank vents Cover the vents to prevent bugs and dirt from accumulating but still allow the sys tem to breathe Place protective covers over pitot tube static source vents air vents and openings in engine cowl to prevent the entry of foreign material or insects especially wasps 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 Every 7 days the propeller should be rotated CAUTION Ensure that the Master and Ignition Switches are OFF 2 8 4 Inspection During Temporary or Indefinite Storage 1 2 JSA SM170SP A2 Generally inspect airframe and clean as necessary Inspect the interior of at least one cylinder through the spark plug hole for corro sion at least once a month Page 2 9 Section 2 Jabiru J170 SP General Care amp Inspection
53. rudder pedal stops as required Test fly the aircraft noting any slip or skid tendencies in level flight as de scribed in 6 7 2 Adjust length of the rudder control cable in 1 2 turn incre ments to achieve coordinated wings level flight WARNING The rudder pedal stops must engage BEFORE the control surface stops on the tail WARNING DO NOT move the cable anchor points or adjust control surface stops These are factory set Page 6 21 Section 6 Jabiru J170 SP Flight Controls Aircraft Service Manual CHEMATIC 34057 J160 FAMILY a n 5 5 7 ST 55 SECTION B8 SCALE 1 1 12 Pcorsos came ruooer 1 032 1 STEERING CENTRING 1 Figure 6 10 Rudder Cable Schematic Page 6 22 25 SM170SP A1 Section 6 Flight Controls 090232050408 vsa 48 961 010 50 29444340 0240249 SITNA SUNN VERS ERE 10 95 Em 24 4135 OVIH 01 ALVIA 75 5 0 RD Bo a Figure 6 11 Rudder Pedals Page 6 23 25 SM170SP A1 Jabiru J170 SP Aircraft Service Manual Section 6 Flight Controls ASSY ur 98 0
54. shoes From Matco Mfg Technical Service Bulletin for MHE51 Series Wheels and Brakes Revi sion D June2007 1 JSA SM170SP A1 Remove the caliper from the wheel by removing the two MSCAN4H9 16A bolts that hold it on Remove old linings by drilling the crimped side of the rivet Do not use a punch amp hammer Using a 25 drill 0 1495 diameter drill through rivet taking care to avoid damaging the rivet hole After drilling crimped edge off rivets lift old lining and remaining rivet pieces from the brake shoe Inspect the brake shoe for any bending or other damage that may have occurred during service A shoe with more than 0 010 bend should be replaced Inspect rivet holes to ensure that no damage has occurred during removal Using a brake relining tool MA7CO recommends a Threaded Screw Action such as the W404 from Aircraft Tool Supply Co or pneumatic press replace the lining us ing the brass rivets shown on the illustrated parts list and install the hub Page 5 9 Section 5 Jabiru 2170 5 Landing Gear and Brakes Aircraft Service Manual 5 7 6 Wheel Reassembly Refer to the Matco Service Instructions located in the Appendix of this manual for addi tional information regarding wheel assembly Tools Required 7 16 wrenches tire pressure gauge Parts Required Wheel rim lubricant new inner tube if neces sary Level of Certification Required A amp P or LSA R M M 1 Apply automotive tire mounting lubricant to th
55. side of the aircraft grasp the front edge of the cowl with one hand and slide fingers of the other hand under the rear edge Pull carefully upward until the lower edge of the cowl clears the upper edge of the spinner then lift the cowl off 4 Replace the cam locks in the cowling to ensure they are not misplaced NOTE Always ensure that the cowl is placed in a position where it cannot be damaged by people walking around the aircraft or by wind Lower Cowl 1 Remove the upper cowl 2 Disconnect the engine air inlet SCAT hose and cabin heat inlet hose 3 Remove screws at rear of cowl Support the lower cowl as screws are being moved It helps to have an assistant while removing lower cowl JSA SM170SP A1 Page 7 5 Section 7 Engine Systems 7 4 7 3 3 7 3 4 7 3 5 Jabiru J170 SP Aircraft Service Manual Inspection and Cleaning Inspect upper and lower cowls for cracks tears in the fiberglass or delamination In spect cowling camloc mounts for rigidity bonding and wear Inspect locking pins for damage Inspect rubber grommets in firewall for wear or damage 1 Wipe the inner surfaces of the cowlings with a cloth saturated with mineral spirits 2 Wash with a solution of mild soap and water and rinse thoroughly After cleaning inspect for dents burns rubbing marks cracks and any signs of delamination Repair Repair of cracks or tears can be made using the general fiberglass repair procedure out lined i
56. the ground remove any foreign mate rial from the screen bugs dirt etc and then place a suction source mouth or vac uum over the opening Have a helper listen inside the cabin for the stall warning tone If no tone is observed remove the reed bell housing from the air line and check to make sure the line is not blocked or kinked If air flows freely through the line then the reed should be replaced If the stall warning operates on the ground but fails to operate in the air the airflow divider plate needs to be calibrated See Paragraph 10 3 6 for calibration instructions 10 3 4 Repair Repair of the stall horn is limited to cleaning of the screen calibrating the divider plate as detailed above or replacement of the affected part s 10 3 5 Reinstallation To reinstall or replace the reed bell housing 1 Attach the reed bell housing firmly to the air line using safety wire and superglue Reattach the housing to the ceiling using a Velcro strap To reinstall or replace the aluminum funnel 1 Attach the aluminum funnel to the air line in the same manner as the reed bell housing Make sure there is enough extra air line to provide easy access to either end but not so much that it will kink inside the wing Prepare the area of the funnel that will contact the wing skin A new funnel should be scuffed for proper adhesion to the epoxy Clean up a reused funnel so that it fits nicely within the hole in the wing skin Rece
57. tificate may only perform maintenance items listed in FAR Part 43 Appendix A Mainte nance Preventive Maintenance Rebuilding and Alteration Section C Owners of E LSA aircraft that hold an LSA Repairman with Inspection Rating 16 hr course may perform head torques and other maintenance tasks on their own aircraft 1 JSA SM170SP A1 Allow engine to cool to room temperature oil temp less than 100 degrees Fahren heit or colder Plan ahead as this may take 6 to 8 hours after an engine run Remove top and bottom engine cowls Refer to Section 7 3 Remove engine cooling baffles Note The bolts that hold the engine cooling baffles in place are also valve cover bolts Unbolt the cooling baffles unhook the tension spring on the inboard side of each baffle and slide the baffles back along the spark plug wires to get them up and out of the way of all the top head bolts Remove spark plug wires from spark plugs if necessary Starting with cylinder 1 remove valve cover Use rag or pan to catch oil that will drip from head Refer to Figure 7 10 Head Bolt Locations Note that there are 6 head bolts Bolt Number 5 is located atthe 6 o clock position of the head behind the rocker cham ber To access this bolt the plug must be removed from under the rocker arm shaft center bolt Use the 3 16 Allen key to remove the plug Torque head bolts to 20 ft lbs moving in a criss cross pattern around the head see Figure 7 10 Do not loosen bolt
58. tightening OR failure to tighten both bolts adequately can cause bolt failure See Table 1 4 Torque Values for proper bolt torque 3 Inspect composite beam for damage indicated by cracks or delamination Pay par ticular attention to the area around the center bend and to areas around drilled holes 4 Inspect main gear mounting hardware for wear bending and signs of damage Replace hardware if necessary 5 Inspect bolt seats in fuselage for signs of damage or wear JSA SM170SP A1 Page 5 5 Section 5 Jabiru J170 SP Landing Gear and Brakes Aircraft Service Manual 5 5 4 Repair All damage involving cracking or delamination must be referred to Jabiru USA Sport Air craft LLC or an approved local agent for an appropriate repair procedure Repair is generally restricted to replacement of the gear leg 5 5 5 Reinstallation Tools Required Screwdriver set 7 16 1 2 and 9 16 wrenches Parts Required New AN bolts and nuts as required length varies with thickness of fiberglass mounting areas Level of Certification Required A amp P LSA R M M 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 Position the main gear leg under the fuselage and install clamp rubber cushion and bolts nuts 2 OFF Do not tighten at this stage 2 Locate inboard bolt install and tighten nut See Tab
59. 1 5 11 8 Pitot Static o eed age Re gelu etu 11 6 11 9 Engine Information System 5 11 9 11 10 GRT Electronic Flight Information System EFIS 11 10 11 11 Garmin Nav Com enne nennen enne nnn 11 16 11 12 Garmin Transponder essen 11 17 11 13 Emergency Locator 11 18 11 14 PS Engineering PM1000 11 19 11 15 External Power Booster 11 20 Section 12 Fiberglass Repair 12 1 Description rn rere en eo aee cc 12 1 12 2 General Non Structural Fiberglass 12 1 12 3 Structural Fiberglass 2 2 200044 12 2 12 4 Paint and 12 4 12 5 Door Repair Supplement 12 5 oe e ente e eee Follows Section 12 JSA SM170SP A1 Page 5 Jabiru J170 SP Aircraft Service Manual List of Figures Title of Illustration Page 1 1 Three View Drawing 7170 5 1 2 2 1 Approved Push Pull Areas 2 2 2 2 Plywood Jacking Platform on Engine 5 2 3 2 3 Jacking Aircraft with Engine
60. 1 of 17 Jabiru J230 SP J250 SP and J170 SP Aircraft Service Manual JSA 100HR A1 Airworthiness Responsibility Jabiru USA Sport Aircraft s recommended inspection program in accordance to FAR Parts 43 and 91 consists of but is not limited to inspection items listed in this Inspection Guide any applicable Service Bulletins or Air Safety Alerts issued against the airframe or any equipment installed therein The owner or operator is primarily responsible for maintaining the aircraft in an airworthy condition including compliance with all applicable Service Bulletins and Air Safety Alerts issued by the manufacturer It is further the responsibility of the owner or operator to ensure that the airplane is inspected in conformity with the requirements of Parts 43 and 91 of the Federal Aviation Regulations Jabiru USA Sport Aircraft LLC has prepared this inspection guide to assist the owner or operator in meeting the foregoing responsibilities This inspection guide is not intended to be all inclusive for no such guide can replace the good judgment of a certified airframe and powerplant mechanic in the performance of his or her duties As the one pimarily responsible for the airworthiness of the airplane the owner or operator should select only qualified personnel Jabiru USA Sport Aircraft LLC issues service and safety information for the benefit of owners and operators It is the responsibility of the owner operator to review and comply with each Servi
61. 10 272 Figure 6 12 Adjustable Rudder Pedals 25 SM170SP A1 Page 6 24 Jabiru J170 SP Section 7 Aircraft Service Manual Engine Systems Section 7 Engine Systems 7 1 Engine 7 1 1 Description The J170 SP is powered by the Jabiru 2200A engine equipped with hydraulic lifters It is a 4 cylinder 4 stroke direct drive air cooled engine driving a fixed pitch wood or ground adjustable carbon propeller When viewing the engine in a tractor configuration From the pilot s seat cylinders 1 and 3 are on the right co pilot side of the case while 2 and 4 are on the left side Cylinders 1 and 2 are the closest to the propeller flange The firing order is 1 3 2 4 For repair 8 overhaul of the engine refer to Instruction amp Maintenance Manual for Jabiru 2200 Aircraft Engine 7 1 2 Engine Data Refer to Instruction amp Maintenance Manual for Jabiru 2200 Aircraft Engine 7 1 3 Engine Troubleshooting Refer to Instruction amp Maintenance Manual for Jabiru 2200 Aircraft Engine 7 1 4 Engine Cleaning See Section 2 of this manual for cleaning instructions 7 1 5 Engine Removal Phillips screwdriver straight screwdriver 3 16 Allen key 3 8 7 16 9 16 amp 10mm wrenches 3 8 amp 9 16 regular socket 7 16 deep well 1 4 drive socket with ratchet wire cutter pliers engine hoist with lifting strap Level of Certification Required LSA R M M with Jabiru USA Engine Seminar Task Specific Training or A amp P 1
62. A1 25 50 Hour Inspection Checklist Page 8 of 9 Jabiru J230 SP J250 SP and J170 SP Aircraft Service Manual 7 Rear Fuselage and Empennage Skin Check for deformation cracks and obvious damage If damage is found check adjacent structure Control Surfaces Check for deformation cracks security of hinges freedom of movement and travel limits Static Port Check for blockages Check static probe for condition 8 General Airplane cleaned and serviced Inspect all placards to assure they are easily readable and securely attached Ensure that all Service Bulletins Air Safety Alerts and previously issued Service Instructions are reviewed and complied with as required JSA 50HR A1 25 50 Hour Inspection Checklist Page 9 of 9 Jabiru J230 SP J250 SP and J170 SP Aircraft Service Manual Owner s Name Annual or 100 Hour Inspection Guide For Jabiru 2170 J230 and 3250 Models A amp P or LSA Repairman with Maintenance Rating Required Address City State Zip Registration Number Airframe Serial Number Engine Serial Number Hours Date Inspection Completed Servicing Agency Address City State Zip Phone Number A amp P Repairman Name JSA 100HR A1 Inspection Intervals The time periods for the inspections noted in this schedule are based on normal usage under average environmental conditions Airplanes operated in humid tropics cold damp climates etc may need mor
63. Aircraft Service Manual 3 At the end of an initial 90 day temporary storage period if the aircraft is to be continued in non operational storage repeat the process in Paragraph 2 8 2 most will only need to be checked 2 8 5 Returning the Aircraft to Service after Temporary or Indefinite Storage Page 2 10 After temporary storage the procedures for returning the aircraft to service are as follows Remove aircraft from blocks and check tires for proper inflation Check battery charge if needed and install Check carburetor air filter and service if necessary Remove materials used to cover openings Remove warning placard from propeller Remove clean and gap spark plugs 40 While spark plugs are removed rotate propeller several revolutions to clear excess preservative oil from cylinders Install spark plugs torque to 8 ft lbs or 96 in Ibs 9 Check fuel filter replace if necessary 10 Check brake fluid level 11 If returning to service after indefinite storage fill fuel tanks with correct grade of fresh 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 vents are clear 14 Perform a thorough pre flight inspection 15 Start and warm engine JSA SM170SP A2 Jabiru J170 SP Section 2 Aircraft Service Manual General Care amp Inspection 2 9 Inspection Intervals Refer to Jabi
64. ILIGGY 3802 40 QN3 OL 08 309 3H3HM 3903 lt 0 SH3JAVI 30 1 358092 LNOHL 4405 3999 eor Sii c Vim 20 03fSd O1 AXOd3 009601 ISN 2 INOW OL TildOHd WIHL ONY JNI430 OL INOW ISN L 3003 100 119 N3NNIdS SLINA M3AO 0 dv SH3AVI Q3sn 38 Q0VI80VI ASSY 3000 MOO OL 39NIH 3LIQ IV3V S pe 2 _ ___ ASSY HOOQ 1 S X QhisoOWvo 99 0092 05 dOd 6686 EU 9 3 szszoesw 8 SNIQT1OW 1MOO H3dd rosassa 7 owwa Cowl Ine Upper Engi 2 7 igure F JSA SM170SP A1 Page 7 8 Section 7 Engine Systems Jabiru J170 SP Aircraft Service Manual 130 133 5 30 133 5 esaiuas MOdMIV M319NIH 038150530 Sv wevn 10 03 5 OL 1676 0091 002 43907 n d HO3IAV i sunn 43 0096911390 2 19 3309 40 3 BHL WOMJ 0 3V 40 3402 30 QN3 OF 5 SLINY 1 3809 072 M3AVI MOI S NI
65. JSA 5 1705 1 Figure 5 4 Brake Master Cylinder Assembly Page 5 16 Jabiru J170 SP Section 5 Aircraft Service Manual Landing Gear and Brakes 5 8 6 Reinstallation of Master Cylinder Tools Required Allen key set 1 2 and 7 16 wrenches Level of Certification Required A amp P LSA R M M 1 Connect the master cylinder using the retaining bolts 2 2 Remove plug or cap from hydraulic fittings and hoses 3 Reconnect the flexible hose at the master cylinder 4 Reinstall the brake handle 5 Reconnect the flexible hose to the wheel brake assembly 6 Fill and bleed brake system in accordance with Paragraph 5 8 7 5 8 7 Bleeding Brake System Tools Required 1 4 wrenches brake fluid injector Parts Required Dot 4 automotive brake fluid Level of Certification Required A amp P LSA R M M V WARNING Use only automotive DOT 4 brake fluid DO NOT use aircraft grade hydraulic fluid or damage will result 1 Open the brake bleeder valve slightly to facilitate bleeding of air from the system 2 Attach a tube from the nozzle of a squirt can of brake fluid to the top of the brake bleeder valve Pump the handle until fluid flows bubble free from service hose be fore attaching 3 Make sure that the master cylinder shaft is fully extended to open up the internal bypass valve 4 Inject brake fluid DOT 4 or equivalent into the puck housing and continue inject ing until the fluid travels through the system in to the mast
66. JSA SM170SP A1 Page 6 5 Section 6 Jabiru J170 SP Flight Controls Aircraft Service Manual 6 4 Wing Flap Control System 6 4 1 Description The electric wing flap control system consists of one fiberglass control surface on each wing driven by a single linear actuator The flaps are operated by one pre 2010 or two manual toggle switches on the instrument panel Position is indicated with a flap posi tion sensor in the left wing root and an LED position indicator mounted on the instru ment panel GRT and analog panels or a display on the primary EFIS The linear actua tor is 12 volt DC with a 2 inch stroke and drives a common shaft assembly with push rods connecting the shaft to the flap surface control horns Each flap control surface is a molded and bonded monocoque fiberglass structure incorporating a composite control horn at the inboard end 6 4 2 Operational Check Operate flaps through their full range of travel observing for uneven or jumpy motion or binding in the system Ensure flaps move together through their full range of travel and surfaces and pushrods do not interfere with wing fairings or fuselage structure 6 4 3 Removal of Flap Components 6 4 3 1 Flap Control Surface Tools Required Screwdriver set 3 8 wrenches Level of Certification Required A amp P or LSA R M M 1 Remove wing root fairings 2 Support the flap so it will not fall against the fuselage 3 Unbolt rod end from flap control arm 4 Remove
67. Jabiru J170 SP Special Light Sport Aircraft Aircraft Service Manual Publication No JSA SM170SP A1 Jabir port Aircraft LLC Jabiru USA Sport Aircraft LLC Copyright 2010 Jabiru USA Sport Aircraft LLC 2842 Highway 231 N Shelbyville Tennessee 37160 USA JSA SM170SP Record of Revisions ds Jabiru USA Sport n Aircraft LLC Al 1 April 2011 1 3 5 9 11 12 Periodic Update Jabiru USA Sport Appendix See Revision Aircraft LLC Summary THIS PAGE INTENTIONALLY BLANK JSA SM170SP Revision Summary Section Pages Affected Revision Description Date ToC All Al Updated Table of Contents 1 April 2012 1 9 1 9 Al Corrected air filter part number 1 April 2012 1 15 1 12 Al Revised approved fuels ethanol prohibited 1 April 2012 2 1 2 1 Al Added towbar information 1 April 2012 2 7 2 8 Al Added parking tiedown information 1 April 2012 2 10 9 2 12 A1 Reversed steps 6 and 7 1 April 2012 2 11 1 2 13 1 Added window buffing information 1 April 2012 2 11 3 2 14 Al Clarified paragraph 1 April 2012 2 12 2 15 Al Clarified inspection procedures and defined Line 1 April 2012 and Heavy maintenance 3 8 2 3 13 Al Added horizontal stabilizer replacement 1 April 2012 3 9 2 3 13 Al Added vertical stabilizer replacement 1 April 2012 5 7 1 5 8 Al Added brake O ring fluid compatibility caution 1 April 2012 5 7 5 8 to 5 10 Al Removed owner authorization for main w
68. ONM3OVdS ONGI LAAN dod 6 30018 LNNOW LOAid m JOMINOO SIHL 40 SL33H8 NI NMOHS SY 55 7IOHLNOO WWL 313709 IHL HOJ NSAID SILLILNVNO SUSSNNN NYIEYF NON 72 LON MOHL 672 30 IN 41 51708 IVNINON SHLONTT pie Figure 6 9 Rear Trim Assembly JSA SM170SP A1 Page 6 18 Jabiru J170 SP Section 6 Aircraft Service Manual Flight Controls 6 7 Rudder Control System 6 7 1 6 7 2 6 7 3 Description The rudder system is made up of one rudder hinged to the vertical stabilizer which is controlled by two sets of rudder pedals two push rods a centering mechanism and an enclosed push pull cable The rudder pedals also control the nose wheel via direct link steering pushrods The rudder consists of a molded and bonded monocoque fiberglass structure with a front spar that is attached to the rear spar of the vertical stabilizer via three hinges It incorporates a composite control horn on the lower right side The rudder control cable is of the enclosed push pull type fitted with spherical bearings at both ends as described in Section 6 2 The nose wheel steering pushrods are solid aluminum with ball link ends See Sect
69. O_ lnstrumentPanelPackage 2 GRT Sport EFIS displays PFO and WFO armin Mode Trarsporar O O y 2 1 4 Airspeed Indicator JSA SM170SP A1 Jabiru J170 SP Section 1 Aircraft Service Manual General Description 1 7 Equipment List continued 2 1 4 Airspeed Indicator Grand Rapids GRT Sport SX EFIS unit replaces GRT Sport JSA SM170SP A1 Page 1 5 Section 1 Jabiru J170 SP General Description Aircraft Service Manual Equipment Options and Upgrades wingtip av Srobe Lighting Package with mounted Aero Wing 80 owing Mounts she b b 0 0 Pant sereme 1 Wite base b Pant 2 Wite base up to ree colors on bely and tps w ing Page 1 6 JSA SM170SP A1 Jabiru J170 SP Section 1 Aircraft Service Manual General Description options Table 1 2 Standard and Optional Equipment 5 s son 5 JSA SM170SP A1 Page 1 7 Section 1 Jabiru J170 SP General Description Aircraft Service Manual 1 8 Sources to Purchase Parts All airframe and engine parts are available from any Jabiru USA full service distributor As of this printing those distributors are Jabiru USA Sport Aircraft LLC 2842 Highway 231 Shelbyville TN 37160 931 680 2800 www usjabiru
70. Owner A amp P or LSA R M M V WARNING DO NOT substitute SCEET hose for SCAT hose as the inner lining may pull away from the hose structure and block carburetor or air inlets 1 Shut off fuel valves before removing any fuel lines 2 Loosen clamps and pull to remove lines and hoses from fittings 7 12 3 Inspection 1 After each 50 hours of operation flexible hoses should be checked for leaks 2 Remove fire sleeve from fuel hoses Examine the exterior of hoses for evidence of leakage or wetness 3 Replace any worn or cracked hoses 7 12 4 Repair Repair of hoses is limited to replacement JSA SM170SP A1 Page 7 21 Section 7 Engine Systems Jabiru J170 SP Aircraft Service Manual 7 12 5 Reinstallation Parts Required Replacement hoses if necessary Level of Certification Required Owner A amp P or LSA R M M NOTE Rubber hoses will take a permanent set during extended use in service Straightening a hose with a bend having a permanent set will result in hose crack ing Care should be taken during removal so that hose is not bent excessively and during reinstallation to assure hose is returned to its original position 1 2 Lines and hoses must not be twisted on installation Provide as large a bend radius as possible Lines and hoses must have a minimum of 12mm clearance from other hoses or surrounding objects or be tie clamped to them to minimize chafing WARNING Fuel lines within the engine compartment a
71. P Section 2 Aircraft Service Manual General Care amp Inspection 2 8 2 Returning Aircraft to Service after Flyable Storage After flyable storage returning the aircraft to service is accomplished by performing a thorough pre flight inspection Ensure all protective covers are removed 2 8 3 Temporary or Indefinite Storage Temporary storage is defined as aircraft in non operational status for a maximum of 90 days any storage period over 90 days is considered indefinite storage Treat as for fly able storage see Paragraph 2 8 1 plus 1 10 11 12 13 For temporary storage fill fuel tank with 100LL aviation fuel to prevent moisture accumulation DO NOT store aircraft for any length of time with auto fuel of any grade in the tanks as fuel degradation may occur causing engine damage when aircraft is removed from storage For indefinite storage drain fuel tanks and ensure carburetor bowl is empty by run ning engine with fuel valve off until it stops or by draining carburetor bowl Clean aircraft thoroughly Clean any dirt oil or grease from tires and coat tires with a tire preservative Cover tires to protect against dirt and oil Either block up undercarriage fuselage to relieve pressure on tires or rotate wheels every 30 days to prevent flat spotting the tires Remove battery and store in a cool dry place Charge as required or place on a battery maintainer NOTE It is recommended that a battery which is
72. Page 6 2 Control Stop and 6 5 6 3 Drive System nnne nnne nennen nennen 6 9 6 4 Flap Control Tube Assembly 6 10 6 5 Elevator Control 6 13 6 6 Elevator Control 6 14 6 7 Trim Control 6 16 6 8 Trim Control Assembly Side 6 17 6 9 Rear Trim lt 6 18 6 10 Rudder Cable Schematic 6 22 6 11 5 eren dite 6 23 6 12 Adjustable Rudder 6 24 7 1 Engine 7 4 7 2 Upper Engine 7 8 7 3 Lower Engine 7 9 7 4 Shock e diee eren 7 11 7 5 Oil Cooler new nennen nnn nnn 7 15 7 6 Oil Cooler old lt 1 1 6 6 nnn nnn nnn nnns 7 16 7 7 Recovery 7 17 7 8 Air Mixer erede tete 7 20 7 9 Head Bolt 7 30 8 1 Fuel System 5 nennen nnne nen 8 9 971 Prop Mount Detall 2 504036 erri ce tette eric verc edes tese deir e 9 5 9 2 Assembly of Ground Adjustable
73. Paragraph 9 2 2 of this section It must be checked for balance prior to reinstallation checked for tracking after reassembly and the spinner checked for balance after reassembly 9 2 5 Reinstallation Tools Required 1 2 wrenches screwdriver set calibrated torque wrench Parts Required Six new AN365 524 nyloc nuts Level of Certification Required A amp P or LSA R M M Propeller installation must be done in accordance with Sensenich Doc WOOD CF REV A DOC Wood Propellers Installation Operation amp Maintenance found in the Appen dix of this manual Check the Sensenich website for latest revision to this document 1 Ensure the propeller drive bushings are in place in the crankshaft propeller flange 2 Insert the AN5 37A bolts from the rear 3 Position the spinner back plate on the crankshaft propeller flange with the back plate flange facing aft Insert the prop drive bushings through the back plate 4 Install prop over back plate and drive bushings Make sure the prop and spinner back plate are in the correct position for spinner cone installation 5 Install crush plate over the bolts 6 Install two Belleville washers on each prop bolt as shown in Figure 9 1 7 Install one AN960 516 washer on each bolt 8 Install AN365 524 nuts on bolts Use new nuts 9 Torque to 15 17 ft lbs in the sequence indicated in Figure 9 1 10 Check propeller tracking as outlined in Paragraph 9 5 of this section JSA SM170SP
74. Raise the aircraft up as necessary for the job to be performed For longer term re pairs involving removal of the main gear legs the fuselage may be blocked up with a padded sawhorse or crate minimum 24 square inches of surface area under the lower wing strut carry through beam and under the tail boom Lower the hoist to lower the aircraft back down JSA SM170SP A2 Page 2 3 Section 2 Jabiru J170 SP General Care amp Inspection Aircraft Service Manual Figure 2 3 Jacking Aircraft with Engine Hoist 2 3 Jacking Nose Gear 1 a cushion on the floor under the ventral fin 2 Press down on the root of the horizontal stabilizer until nose gear is off the ground and set the rear fuselage down gently on the cushion 3 Weigh down the inboard half of the horizontal stabilizer with a sandbag or similarly heavy and cushioned material The aircraft should remain in a three point stance without much added weight V CAUTION Do not press or lift on the control surfaces Damage to the control surface or control system may result 2 4 Hoisting This procedure should not be necessary for most service or maintenance procedures Should hoisting be necessary Drain fuel from both wings amp remove wings See Sections 8 8 and 4 1 Fit shackles to the four wing support brackets Fit cables rope to shackles and to a center lift shackle pee S que d Hoist only from this point ensuring that cables ropes do not damage the top o
75. SA Sport Aircraft LLC has prepared this inspection guide to assist the owner or operator in meeting the foregoing responsibilities This inspection guide is not intended to be all inclusive for no such guide can replace the good judgment of a certified airframe and powerplant mechanic in the performance of his or her duties As the one pimarily responsible for the airworthiness of the airplane the owner or operator should select only qualified personnel to maintain the aircraft Jabiru USA Sport Aircraft LLC issues service and safety information for the benefit of owners and operators It is the responsibility of the owner operator to review and comply with each Service Bulletin and Air Safety Alert While this guide may be used as an outline detailed information of the many systems and components in the airplane will be in the various section chapters of its service manual and the pertinent vendor publications It is also recommended that reference be made to the applicable airframe and engine service manuals previously issued Service Instructions Jabiru Service Bulletins applicable FAA regulations and publications Vendors Bulletins and specifications for torque values clearances settings tolerances and other requirements It is the responsibility of the owner or operator to ensure that the airframe and powerplant mechanic inspecting the airplane has access to the previously noted documents as well as this inspection guide These documents may
76. Support tail of aircraft with a sturdy tail stand or padded sawhorse set just forward of the ventral fin 2 Remove engine cowling as described in Section 7 3 3 Remove cooling air ducts from engine as described in Section 7 4 4 Remove spinner and propeller as described in Section 9 5 Disconnect main ground cable from battery JSA SM170SP A1 Page 7 1 Section 7 Engine Systems 7 1 6 Page 7 2 10 11 12 13 14 15 16 Jabiru J170 SP Aircraft Service Manual Shut main fuel valve off Drain fuel from carburetor bowl and main fuel line Disconnect fuel line from mechanical fuel pump Loosen carburetor coupling clamp and remove carburetor from intake manifold Disconnect oil temperature oil pressure CHT and EGT sender wires starter ground cable and starter wire off starter contactor Clip cable ties as necessary to move wiring out of the way Cut alternator wires at one of the connections Remove all SCAT hoses Remove muffler by disconnecting springs Use flat screwdriver and take care not to gouge or damage exhaust Attach engine hoist to the engine by running a cargo strap around rearmost intake and exhaust pipes up to the hook on the engine hoist and back down around the crankshaft Support engine with hoist Remove two LOWER engine mount bolts Remove two upper engine mount bolts Pull engine out of area using hoist Engine Installation 1 10 11 Align engine with airframe us
77. Tools Required Screwdriver set 7 16 1 2 and 9 16 wrenches Level of Certification Required A amp P or LSA R M M The following procedural steps involve removal of one side of the landing gear as a complete assembly Refer to applicable paragraphs for removal of the individual com ponents 1 Peel back the carpet in the baggage area to reveal the main landing gear mounting bolts 2 Jack the aircraft in accordance with the details given in Section 2 3 Disconnect the top end of flexible brake hose catching brake fluid in a container Take care to avoid dripping brake fluid onto the center console as it will damage the finish 4 Remove bolt and nut from top inboard end of undercarriage beam Remove rubber bushings 2 5 Remove bolts nuts 2 from the clamp at the bend in undercarriage beam 6 Remove clamp and main landing gear leg assembly 5 5 3 Inspection NOTE Gear leg attach bolts must be replaced every 500 hours total time Re fer to Jabiru USA Service Bulletin JSA 003 1 for more information 1 Check for looseness of main gear legs by lifting each wing and trying to move gear legs fore and aft with main gear still installed 2 If movement beyond normal flexing of the leg is observed Tighten clamp bolts 2 evenly to take beam movement out Do not over tighten Add washers if necessary max 4 until between 3 and 5 threads show on the bolt If more washers are necessary use a shorter bolt B Over
78. Y BLANK Page 4 of 4 Vendor Information JSA SM170SP A0
79. abiru J230 SP J250 SP J170 SP Aircraft Service Manual Crankcase Check for security of crankcase half bolts Check front seal for leaks Comments Hoses and Ducts Check all fuel oil and SCAT hose or duct for leakage cracks deterioration and damage Check fittings for security Comments Intake and Exhaust Check for deformation security cracks leaks loose or missing nuts and clamps Check for thin wall condition which may occur due to normal internal erosion on exhaust stacks which have long service time Comments Ignition Check for proper connection security and fraying Check gap between coil and flywheel magnets should not exceed 010 Comments Distributor Caps amp Rotors Check for wear at the contact points Replace every 200 hours Comments Spark Plugs amp Ignition Leads Clean inspect regap test and replace spark plugs as necessary Tighten spark plugs to proper torque Check ignition harness condition and for proper attachment Comments Compression Perform differential compression test Comments Pass JSA 100HR A1 100 Hour Annual Inspection Checklist Page 8 of 17 Jabiru J230 SP J250 SP and J170 SP Aircraft Service Manual Electrical Wiring and Equipment Inspect electrical wiring and associated equipment and accessories for fraying and attachment Pass Fail Comments Battery Inspect clean
80. acement may be the least expensive method of repair Re place with Wilwood Master Cylinder model 950 260 1304 V WARNING Use only automotive DOT 4 brake fluid DO NOT use aircraft grade hydraulic fluid or damage will result JSA SM170SP A1 Page 5 15 Jabiru J170 SP Aircraft Service Manual Landing Gear and Brakes Section 5 10 220 9 ASSY H3A31 8 YSGNITAO H31S VI 3XVMH8 S3 NV 500 Full 46 982 010 ECON B3ONVETIOI Ald 40 1N3SNOO LNOHLIM Q3ldOO Wd HO3LAV 38 LON LSNW 1H9IHAdOO SI SIHL 3105 LON WV38 NI SNILNNOW ASSY HSGNITAO 5 290004 9 NZOOVEHd Si 1708 8 ONN 217 NeooveHd vi pb Z2HLXMSH9HE M3HOS 6 0 Zi v 0ctOE 4MOHSSONW4zMVHS 0 Ol 4fNZUSVO 9HS SOIENV 6 5 5 8 5 4fN3HSVO vih vOLENV St 4 5 HB3HSVM1VIJ P L 9HrO96NV 9 9094808 v 1 008 2049 z 83 1
81. ach string to one end of the old line prior to removal to aid in re threading the new lines The forward portion of the pitot tube may be re moved from the strut by pulling it from hose that connects it to the aft portion To re move the aft portion 1 Drill out the 3 16 pop rivets that hold the bracket in place 2 Remove the bracket 3 If preserving the pitot line tape it to the outside of the strut so it will not fall back inside Clip the safety wire that holds the pitot line to the probe 11 8 3 Reinstallation Reverse the steps in Paragraph 11 7 2 for reinstallation of pitot static lines Superglue and safety wire must be used on all connections to steel tubes Page 11 6 JSA SM170SP A1 Section 11 Electrical System and Instruments Jabiru J170 SP Aircraft Service Manual JO 133HS 2 091 ASSY LOLId OllvIS ssi 39913813 JASNI OL 31OH NYHL 381 39913513 395110 OL NYHL 38nl S 338 3 1 I 31 25 LON 00 1139 03395 ff 339 S3HL3ATTIN 246 98 010 sa Nau 422221 SINA __ ASSY 1014 911 0 1 1 215 14 ASSY M3lvM 3ovi3sfd OLNI NYHL 531 412 SONILLIJ 9 SLNAWNYLSNI OL Q3HOVLLIV 53901 91 29 1014 Ald 30 INGSNOO INOHIM NI_SNOISNAWIG 031900 38 ION ISN
82. aft LLC or our ap proved local agent for an appropriate repair procedure Replace any distorted or worn parts of the rudder pedal assembly 6 7 6 Reinstallation of Components V WARNING All spherical bearings on control cable ends must be fitt ed 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 Reverse the steps of Paragraph 6 7 3 1 for reinstallation of the rudder Be sure rud der cable is attached to TOP of rudder horn otherwise rudder will be out of rig Reverse the steps of Paragraph 6 7 3 2 for reinstallation of the rudder pedal assem bly 6 7 7 Rigging the Rudder JSA SM170SP A1 1 To establish the neutral position raise the nose wheel off the ground by having a helper press down on the rear fuselage near the joint of the verti cal and horizontal stabilizers Allow the nose wheel and therefore the rudder pedals to neutralize Align the rudder 5mm to the right of center Adjust the rod ends on the cable so that the hole in the rear rod end aligns with the hole in the control horn Fit bolt nut and washers Mark or tape a line from the center of the rudder trailing edge onto the fu selage Displace the right rudder pedal to the rudder pedal stop Measure the rudder displacement at the rudder trailing edge with reference to the previously marked line It should be 98mm 2mm Repeat Step 6 for left pedal and adjust
83. ail Comments Flap Position Indicator Check for security and operation Pass Fail Comments Wing Bolts Check wing bolts for security DO NOT overtighten Pass Fail Comments JSA 100HR A1 100 Hour Annual Inspection Checklist Page 14 of 17 Jabiru J230 SP J250 SP and J170 SP Aircraft Service Manual Fuel Vents Pitot Tube and Stall Warning Check for condition and obstructions Comments Drain Ports Check drain holes in wing and surfaces to assure they are free of obstructions 5 Nose Gear Wheel and Tire Check wheel for cracks and tire for wear damage condition and proper inflation Check sealed bearings for condition and wear Pass Fail Landing gear strut Inspect rubber shock strut and components for cracks wear and attachment Inspect wheel yoke and strut for straightness and security Pass Fail Comments Actuating Linkages Check for wear at attach points Check for cracks and security Pass Fail Comments Nose Gear Steering Linkage Inspect linkages for tightness condition and security Pass Fail Comments Nose Gear Operation Check for condition smooth operation and security Pass Fail Comments JSA 100HR A1 100 Hour Annual Inspection Checklist Jabiru J230 SP J250 SP and J170 SP Aircraft Service Manual 6 M
84. ain Gear and Brakes Brakes Lines Lining and Discs Check for condition wear and security Check lines for chafing and signs of leakage and cracks Check brake discs for cracks Comments Pass Wheels and Tires Check wheels for cracks and tires for wear damage condition and proper inflation Check and repack wheel bearings Comments Pass Landing Gear Legs Inspect legs for cracks overextension or signs of delamination Comments Pass 7 Rear Fuselage and Empennage Skin Check for deformation cracks and obvious damage If damage is found check adjacent structure Comments Internal Fuselage Structure Check for cracks and deformation Check bulkheads door posts and center tunnel for cracks or delamination Comments Control Cables Check elevator and rudder push pull cables for condition attachment alignment clearance and proper operation Check cable clamps on both ends for proper attachment and placement Check rod ends for security and freedom of motion Comments Control Surfaces Check for deformation cracks security of hinges freedom of movement and travel limits Comments JSA 100HR A1 100 Hour Annual Inspection Checklist Page 16 of 17 Jabiru J230 SP J250 SP and J170 SP Aircraft Service Manual Fixed Trim Tabs Check for security and obvious damage Pass Fail
85. aint and body filler to determine whether the crack penetrates a layer of fiberglass or just through the body filler Cracks only involving body filler may be repaired using paint and finishing procedures in Section 12 3 8 4 Repair The horizontal stabilizer is a composite monocoque structure All damage involving a break or deformation in the skin or damage to the spar must be referred to JABIRU USA SPORT AIRCRAFT LLC for an appropriate repair procedure Repair must be made be fore the next flight Dents crush damage or tears in the fiberglass end caps of the stabilizer are in a non structural area and can be repaired using the standard fiberglass repair procedures in Section 12 3 9 Vertical Stabilizer 3 9 1 Description The vertical stabilizer is a molded composite structure supported by ribs and a rear spar The vertical stabilizer is bonded to a raised ridge on the aft fuselage with epoxy and cotton flock The bond joint is overlaid with three layers of fiberglass extending two inches either side of the joint Hinges attach the rear vertical spar to the rudder 3 9 2 Removal and Installation The vertical stabilizer is permanently bonded to the fuselage and is an integral part of the fuselage structure If the vertical stabilizer structure is damaged beyond repair the entire stabilizer may be removed and replaced Contact Jabiru USA Sport aircraft for further instructions 3 9 3 Inspection Inspection is limited to inspection
86. air and Reinstallation Refer to the Instruction and Maintenance Manual for Jabiru 2200 Aircraft Engine for information on removal inspection repair and reinstallation of the alternator volt age regulator and their components 11 3 Battery 11 3 1 Description The Odyssey PC625 battery is a 12 volt drycell which is mounted on the firewall 11 3 2 Removal Tools Required 10mm wrench or socket Level of Certification Required Owner A amp P or LSA R M M 1 Remove battery ground cable and undo strap buckle 2 Disconnect the battery positive cable 3 Remove the battery strap 4 Remove the battery JSA SM170SP A1 Page 11 1 Section 11 Jabiru J170 SP Electrical System and Instruments Aircraft Service Manual 11 3 3 Inspection and Repair Jabiru USA recommends replacing the battery every two years The battery is a dry cell battery therefore repair is limited to replacement Recharging Dead Battery Left the Master On NOTE If battery is drained completely down its ability to hold a full charge may be compromised Perform the following procedure 1 Place battery on trickle charge for minimum of one hour 2 Start aircraft engine Jump start if necessary 3 aircraft at cruise power for one hour while operating the minimum electrical equipment required for safe flight Alternator must run at cruise RPM for proper charge GROUND RUNNING WILL NOT CHARGE BATTERY 4 If voltage is not up to normal level after flight
87. air is limited to replacement 2 Fuel valve and check valve repair is limited to replacement 8 3 5 Reinstallation 1 Reverse steps in 8 3 2 for reinstallation of fuel lines Make sure they are recon nected to the correct fittings 2 Reinstall the wing root fairings bottom fairing first Fuel Pumps 8 4 1 Description The mechanical fuel pump is mounted to the passenger side of the engine See Jnstruc tion and Maintenance Manual for Jabiru 2200 Aircraft Engine for information about ser vicing the mechanical fuel pump The electric fuel pump is mounted in series with the mechanical pump It is bolted to the firewall inside the engine compartment 8 4 2 Removal Tools Required 3 8 wrench wire cutter screwdriver set Level of Certification Required A amp P or LSA R M M 1 If possible run engine Shut off by turning fuel valve in the center console to OFF position and waiting for engine to quit from fuel starvation 2 Make sure master and ignition switches are OFF 3 Disconnect electrical wire 4 Unbolt pump from firewall JSA SM170SP A1 Page 8 3 Section 8 Jabiru J170 SP Fuel System Aircraft Service Manual 5 Remove safety wire and pull back firesleeve to access fuel pump fittings 6 Remove fuel lines from pump 8 4 3 Inspection Check electrical connector for corrosion cracks or frays Replace connector if necessary 8 4 4 Repair Electric fuel pump repair is limited to replacement 8 4 5 Reinstallation 1
88. air of switches and breakers is limited to replacement 11 4 4 Reinstallation Reverse steps in 11 4 2 for reinstallation 11 5 Starter 11 5 1 Description The starter is a Bosch 1 5 kw electric motor which is activated with the ignition key and a solenoid The starter is equipped with a standard Bendix which engages a gear with the teeth on the engine flywheel when activated 11 5 2 Removal Inspection Repair and Reinstallation Refer to the Instruction and Maintenance Manual for Jabiru 2200 Aircraft Engine for information on removal inspection repair and reinstallation of the starter 11 6 Navigation Lights and Strobes 11 6 1 Description Tools Required 10mm wrench Phillips screwdriver razor knife Parts required Level of Certification Required Owner A amp P or LSA R M M Jabiru S LSA aircraft are equipped with external navigation and strobe wingtip lighting Each wingtip light unit consists of one red or green navigation light in the front one white navigation light in the rear and one strobe anti collision light in the center Air craft built after May 2009 have either the GS Air unit or an AeroLEDs Pulsar unit 11 6 2 Removal GS Air 1 Remove ground cable from aircraft battery 2 Remove the two screws from lens 3 Cut silicone bead around lens 4 Pull unit from wingtip and disconnect wires JSA SM170SP A1 Page 11 3 Section 11 Jabiru J170 SP Electrical System and Instruments Aircraft Service Manual AeroLED
89. and aft force to the strut during the installation as this may damage strut attach points 1 inboard end of strut onto the fuselage strut attachment lug 2 Insert a new 5 NAS bolt through the strut and the lug bushing 3 Install the washer and nut and tighten carefully to the point where the washer can not be rotated Then loosen the nut slightly until the washer will rotate The washer must be free to rotate 4 Install the outboard end or the strut onto the wing spar strut fitting Attach lug and line up the hole 5 Install the AN5 NAS bolt washer and nut 6 Tighten the nut in the same manner as the lower strut attach bolt making sure the bolt is just free enough for the washer to rotate 7 Reconnect the flaps and remove supporting tape 8 Reconnect recognition light wires and or pitot tube 9 Reinstall upper and lower strut fairings by installing the self tapping screws 10 Look over the fuel lines and stall warning tube LH wing only in the wing root to check for kinks or pinches 11 Reinstall upper and lower wing root fairings JSA 5 1705 0 Page 4 5 Section 4 Jabiru J170 SP Wing Structure Aircraft Service Manual Figure 4 1 Wing Assembly J250 SP similar to 2170 3230 Page 4 6 JSA 5 1705 0 Jabiru 2170 5 Section 5 Aircraft Service Manual Landing Gear and Brakes Section 5 Landing Gear and Brakes 5 1 General Description The main landing gear legs consist of two separate compo
90. and tighten connections Check for security and proper attachment Check for corrosion Make certain battery is clean Water or dirt on battery surfaces can cause battery to discharge Pass Fail Comments Fuel Pump Inspect fittings and pump for leaks Pass Fail Comments Engine Controls and Linkages Check controls and associated equipment for condition attachment alignment and rigging Check control operation Pass Fail Comments Engine Mounts Check for cracks corrosion and security Inspect rubber cushions mount bolts and nuts and grounding straps for condition and security Pass Fail Comments Starter and Solenoid Check for condition attachment and chafed or loose wires Pass Fail Comments Alternator and Electrical Connections Check for condition and attachment Check wiring for proper attachment and possible chafing Check for unsusual noise Pass Fail Comments Carburetor Heat System Check for blockage security operation and wear Pass Fail Comments JSA 100HR A1 100 Hour Annual Inspection Checklist Page 9 of 17 Jabiru J230 SP J250 SP and J170 SP Aircraft Service Manual Carburetor Check overall condition Inspect for leaks Remove bowl and check for sediment Check condition of floats Pass Fail Comments Plumbing Inspectall hoses
91. ardware Move on to Step 6 JSA SM170SP A1 Jabiru J170 SP Section 9 Aircraft Service Manual Propeller amp Spinner 5 Remove propeller nuts and thread new nuts onto the bolts Snug lightly into posi tion 6 Use torque wrench to tighten bolts to between 15 and 17 ft lbs of torque moving in a criss cross pattern around the hub see Figure 9 1 for torque pattern 7 Check propeller tracking as described in Section 9 5 8 Reinstall spinner as described in Section 9 1 V WARNING Tighten spinner cone mounting screws only until washer be gins to compress Do not over tighten screws as cracking of spinner may result JSA SM170SP A1 Page 9 7 Section 9 Jabiru J170 SP Propeller amp Spinner Aircraft Service Manual THIS PAGE INTENTIONALLY BLANK Page 9 8 25 SM170SP A1 Jabiru J170 SP Section 10 Aircraft Service Manual Utility Systems Section 10 Utility Systems 10 1 Cabin Heat 10 1 1 Description Cabin heat is provided by air from a cowl intake that is warmed over the muffler and delivered to a firewall mounted mixer box Hot air is introduced to the cabin through use of a push pull knob on the instrument panel 10 1 2 Removal L 1 evel of Certification Required A amp P or LSA R M M Disconnect SCAT intake hose from muff and from cowl intake Disconnect SCAT duct from muff and firewall mixer box Loosen strap clamps from muffler to remove heat muff Firewall mixer box is riveted to firewall and ca
92. ary JSA SM170SP A2 Page 2 15 Section 2 Jabiru J170 SP General Care amp Inspection Aircraft Service Manual THIS PAGE INTENTIONALLY BLANK Page 2 16 JSA SM170SP A2 Jabiru J170 SP Aircraft Service Section 3 Manual Fuselage Structure Section 3 Fuselage Structure 3 1 Description The fuselage is a composite monocoque self supporting structure and includes both the horizontal stabilizer and vertical fin All repairs to structural components must be approved by Jabiru USA Sport Aircraft LLC or approved local representative 3 2 Windows 3 2 1 3 2 2 JSA SM170SP A1 Description The windshield is a one piece acrylic plastic Perspex amp panel bonded into a joggle with epoxy resin amp fiber flock and secured to the fuselage with screws and nuts Windows are one piece acrylic plastic Perspex panels bonded into a joggle with ep oxy resin amp fiber flock NOTE 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 General Upkeep 3 2 2 1 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 c
93. at http www ps engineering com downloads shtml Page 2 of 4 Vendor Information JSA SM170SP A0 Jabiru J170 SP Aircraft Service Manual Appendix Emergency Locator Transmitter Aircraft manufactured before 2009 AK 450 121 5 243 MHz ELT Ameri King Corporation 17881 Sampson Lane Huntington Beach CA 92648 Phone 714 842 8555 Fax 714 842 4235 Email ameriking9 aol com http www ameri king com Free manual in PDF format available for download in Manuals section of website Aircraft manufactured in 2009 and newer Kannad 406 AF Compact KANNAD Z I des 5 Chemins BP 23 56520 GUIDEL France Phone 33 2 97 02 49 49 Fax 33 2 97 65 00 20 http www kannad com index php Free manual available in PDF format for download http www kannad com upload contenu fichier 78fichier2 pdf Navigation Anti collision Lights Aircraft manufactured prior to June 2009 GS AIR A Division of GS Developments LLC 130 Cheval LN NE Rochester MN 55906 USA E mail support qs air com www gs air com Aircraft manufactured June 2009 and newer AeroLEDs 967 East Park Center Boulevard Suite 381 Boise ID 83706 6700 Phone 208 850 3294 Fax 208 246 0552 http www aeroleds com home aspx Free manual available in PDF format for download http www aeroleds com resources installationmanuals aspx JSA 5 1705 0 Vendor Information Page 3 of 4 Jabiru J170 SP Appendix Aircraft Service Manual THIS PAGE INTENTIONALL
94. ately three inches beyond the damaged area Take care to sand only paint and gel coat not into the glass fiber as well To prep non gel coated areas rough up the fiberglass and epoxy coat with 220 grit sandpaper to allow mechanical adhesion of the repair epoxy 2 Cut2 pieces of AF303 fiberglass cloth that will cover that affected area plus 2 inches in all directions on a bias 3 Mix an amount of 24 hour epoxy sufficient to wet out the fiberglass cloth 4 Using a small paint brush apply a thin coat of 24 hour epoxy on the affected area of the fuselage 5 Laythe first piece of cloth on the area 6 Finish wetting out the first piece of fiberglass cloth with a generous amount of ep OXy 7 Apply the second piece of fiberglass cloth over the first on a bias 8 Usingthe paint brush pressthe second piece of fiberglass intothe first Don t add any additional epoxy until the excess from the first application has been soaked into the second layer If there are any dry spots in the second layer add only the amount needed to fully wet the cloth 9 Cuta piece of peel ply to cover the entire affected area Peel ply will make the fin ishing and paint process easier 10 Using the paint brush press the peel ply into the fiberglass cloth No additional ep is needed 11 Allow 24 hours to cure Page 12 2 JSA SM170SP A0 Jabiru J170 SP Section 12 Aircraft Service Manual Fiberglass Repair 12 Remove peel ply Carefully sand a
95. ay the pitot static lines run to the PFD while the GPS is part of the MFD For detailed EFIS installation and user manuals refer to the Grand Rapids Technologies website and contact information found in the Appendix of this manual 11 10 2 Removal Tools Required 9 64 Allen key screwdriver set knife heat gun for reinstallation Level of Certification Required Owner A amp P LSA R M M or Avionics Repair Station 1 Remove the four screws at the corners of the unit 2 Pull the unit from the panel and disconnect the D sub connectors from the rear of the unit 3 If the unit is a primary flight display disconnect pitot static lines If lines cannot be pulled cut them just behind the fitting If slave multi function display unit dis connect GPS antenna 11 10 3 Inspection and Repair Inspection is limited to checking the cables and D sub connectors for damage or bad pins and checking upgrading software See 11 10 5 for software upgrade instructions All repairs must be done by Grand Rapids Technologies at their facility 11 10 4 Reinstallation 1 Cut away any remaining pitot static line material from the fittings at the back of the unit Heat the end of the pitot line until it is soft then press it onto the fitting Re peat process for the static line 2 Reconnect D sub connector 3 Reconnect GPS antenna if necessary 4 Power up unit and check for proper operation The magnetometer may need to be recalibrat
96. ble through hole in spheri cal bearing JSA SM170SP A1 Section 6 Flight Controls Jabiru J170 SP Aircraft Service Manual t3 DINIH 690100 50 wwvea Vd NI r 1708 HOV LLV 3 1HYO HOLVA3 13 L _ ooe Ob ____ 6 _ _____________ 560024 8 5 ___ 1 _ 9 Noudmosso See Figure 6 5 Elevator Control System Page 6 13 JSA SM170SP A1 Jabiru J170 SP Aircraft Service Manual 609106 QNIDOIN MOIVAGT3 04 amni 28 98 010 N2V 1 4 HO31AV JSA SM170SP A1 Flight Controls Section 6 BRE PRP eee NMOG 7 13AVML MOIVA3I3 01 S3iVidWS3l 3SN wouosrosd 31 25 10N 5 SNOISN3WIG Figure 6 6 Elevator Control Rigging Page 6 14 Jabiru J170 SP Section 6 Aircraft Service Manual Flight Controls 6 6 Elevator Trim Control System 6 6 1 Description Refer to Figures 6 7 6 8 and 6 9 for illustrations of the trim system The elevator trim control system consists of a covered cable running from the trim han dle in the cockpit to a spring mechanism in the tail that is connected to the elevator The cable is conn
97. ce Bulletin and Air Safety Alert While this guide may be used as an outline detailed information of the many systems and components in the airplane will be in the various section chapters of its service manual and the pertinent vendor publications It is also recommended that reference be made to the applicable airframe and engine service manuals previously issued Service Instructions Jabiru Service Bulletins applicable FAA regulations and publications Vendors Bulletins and specifications for torque values clearances settings tolerances and other requirements It is the responsibility of the owner or operator to ensure that the airframe and powerplant mechanic inspecting the airplane has access to the previously noted documents as well as this inspection guide These documents may be downloaded from the manufactuer s website www usjabiru com 100 Hour Annual Inspection Checklist Page 2 of 17 Jabiru J230 SP J250 SP and J170 SP Aircraft Service Manual 1 Operational Inspection Starter Check for proper operation unusual noises and dragging Comments Fuel Pressure or Flow Check within normal limits if installed Comments Cylinder Head Temperature Check for proper operation temperature and fluctuations Comments Alternator Check for proper output and unusual noises Comments Propeller Check for smoothness of operation Comments Oil Pressure and Temperature Che
98. ck for proper pressure temperature limits and unusual fluctuations Comments Magnetos Check the performance of the magneto as outlined under the heading NORMAL PROCEDURES in the appropriate Pilot s Operating Handbook Comments JSA 100HR A1 100 Hour Annual Inspection Checklist Page 3 of 17 Jabiru J230 SP J250 SP and J170 SP Aircraft Service Manual Power Check Refer to NORMAL PROCEDURES in the appropriate Pilot s Operating Handbook Comments Voltmeter Check for proper indication and unusual fluctuations Comments Heating and Ventilating System Check for proper operation heat and airflow output Check controls for freedom of operation Comments Front Console Main Fuel Shutoff Valve Check for proper operation and freedom of movement Comments Induction Airbox Valve Doors and Controls Remove air filter and inspect hinges doors seals and attaching parts for wear and security Check operation Comments Oil Cooler Check for obstructions leaks and security of attachment Comments Doors Check latches hinges and seals for condition operation and security of attachment Comments Idle RPM and Mixture Settings Check for both proper RPM and mixture settings Check controls for freedom of operation Comments JSA 100HR A1 100 Hour Annual Inspection Checklist Page 4 of 17 Jabiru J230 SP J250 SP and J170 SP Aircraft Service Ma
99. com Jabiru Power Solutions LLC 136 Millbrook Road Hudson NY 12534 518 929 4307 www jabirups com 1 9 Disposable Replacement Parts Some disposable airframe and engine parts can be sourced from automotive parts and other local retail stores Items marked with an asterisk may be difficult to find lo cally but are readily available from Jabiru USA Sport Aircraft LLC Part Part amp amp ne Regulator Kubota RP5017211 Tre Man 5 00 x 5 Ribbed Six Ply Aircraft Tires Trelleborg or m Nose equivalent 13x5 00 6 6 ply M 092 308 0 Michelin Inner Tube Michelin or 500 5 TR67A 90 valve Inner Tube optyres or 13x5 00 6 TR87 90 valve Nose equivalent stem short Table 1 3 List of Disposable Replacement Parts Page 1 8 JSA SM170SP A1 Jabiru J170 SP Section 1 Aircraft Service Manual General Description 1 10 Approved Oils and Capacities Oils developed and branded for use in air cooled aircraft piston engines which conform to the requirements of SAE J 1899 formerly MIL L 22851D Textron Lycoming Specifi cation No 301F or Teledyne Continental Motors MHS 24B are approved Oils meeting these requirements include but are not limited to AeroShell W100 and AeroShell part synthetic 15W 50 with Aeroshell 15W 50 being the preferred oil Aeroshell 15W 50 is the recommended oil for all temperatures after the i
100. ction Manual Magneto drop also refer to Engine Instruction Manual 1 2 3 4 Engine response to changes in power 5 Any unusual engine noises 6 Idling speed 7 Fuel shut off valve operate engine in ON position and in OFF position long enough to ensure shut off functions properly After the inspection has been completed an engine run up should again be performed to determine that any discrepancies or abnormalities have been corrected and to check engine for oil leaks Page 2 12 JSA SM170SP A2 Jabiru J170 SP Section 2 Aircraft Service Manual General Care amp Inspection 2 11 Cleaning Keeping the aircraft clean is important Besides maintaining the appearance of the air craft cleaning makes inspection and maintenance easier 2 11 1 Exterior The exterior finish used on Jabiru aircraft is a two part automotive type paint system that utilizes a base and clear coat For optimum performance and aesthetics the exte rior surfaces of the aircraft should be kept clean and free of bugs and grease The painted surfaces and windows of Jabiru USA factory demonstrator airplanes are routinely cleaned and polished with Turtle Wax Express Shine a spray type cleaner that leaves a thin protective coating This coating aids in removal of dirt and bugs if kept up regularly It is applied directly to the surface with the spray bottle and simply wiped dry with a clean microfiber cloth When cleaning windows always use a new clean cloth
101. ctions provided by the manufacturer 2 Each owner operator of this aircraft shall be responsible for providing the manufacturer with current contact information where the manufacturer may send the owner operator supple mental notification bulletins 3 The owner operator of this aircraft shall be responsible for notifying the manufacturer of any safety of flight issue or significant service difficulty upon discovery JSA SM170SP A1 Jabiru J170 SP Aircraft Service Manual 4 The owner operator of this aircraft shall be responsible for complying with all manufacturer notices of corrective action and for complying with all applicable aviation authority regula tions in regard to maintaining the airworthiness of this aircraft 5 The owner operator of this aircraft shall ensure that any needed corrective action be com pleted as specified in a notice or by the next scheduled annual inspection 6 Should an owner not comply with any mandatory service requirement the aircraft shall be considered not in compliance with applicable ASTM standards and may be subject to regula tory action by the presiding aviation authority Handbook Revisions It is the responsibility of the owner to maintain this manual in a current status when it is being used for maintenance purposes A major release of the handbook is called an Issue while a section revision is called a Change This manual utilizes section level revision control revision ind
102. d in master Fill and bleed system inder check for leaks Defective master cylinder Repair or install new parts Rough or uneven runway surface Warped or worn brake disks severe chatter Some main gear chatter is normal during heavy brak ing on rough surface Inspect disks for wear resurface or replace as necessary JSA SM170SP A1 Jabiru J170 SP Section 5 Aircraft Service Manual Landing Gear and Brakes 5 8 3 Removal Tools Required Allen key set 1 2 and 7 16 wrenches Level of Certification Required A amp P or LSA R M M Refer to Figure 5 4 Brake Master Cylinder Assembly Take care to avoid dripping brake fluid onto interior surfaces of cabin as this may damage the finish 1 Remove the flexible hose from one wheel brake assembly and drain the hydraulic fluid from the brake system 2 Remove brake handle 3 Disconnect flexible hose at master cylinder 4 Plug or cap hydraulic fittings and hoses to prevent the entry of foreign material 5 Unbolt master cylinder retaining bolts 2 5 8 4 Inspection Inspect for leaks at fittings Check for damage to brake piston and diaphragm 5 8 5 Repair Hydraulic Brake Lines Repair is limited to replacement Master Cylinder Figure 5 4 Brake Master Cylinder Assembly 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 Master cylinder repl
103. d remove the rear section 3 Use a set of 7 16 wrenches to remove the nose wheel axle bolt Support the nose wheel as it falls from the nose fork and take care that it does not catch on the edge of the fairing 4 Remove the upper screw and washer from each side of the forward half of the wheel fairing and nose gear fork and remove the front half of the fairing 5 If returning the aircraft to service without the nose wheel fairing reinstall wheel and axle bolt Add spacers to each side of the nose wheel yoke to take up the extra space 6 Reverse the preceding steps for installation using Loctite 242 on the screws that attach to the aluminum nose wheel fork to keep them from coming loose 5 9 3 Inspection and Repair See Section 5 3 for information regarding inspection and repair of nose wheel fairing The procedure is the same as for the main wheel fairings 5 10 Nose Gear Leg 5 10 1 Description The nose gear is a welded steel and aluminum trailing arm assembly with a rubber spring cushion system The nose wheel is mounted in an aluminum yoke which is bolted to the steerable welded steel tube nose leg Two aluminum brackets and Delrin bush ings form a housing which attaches the steel tube nose leg to the firewall Nose wheel steering is achieved by connecting the rudder pedal assembly to the nose wheel steering link by push rods The nose wheel is centered by springs attached to the pedals and a bracket on the center console insi
104. d to re placement JSA SM170SP A1 Jabiru J170 SP Section 7 Aircraft Service Manual Engine Systems 6 Inspect all o rings and seals for evidence of leaking or damage Repair is limited to replacement 7 10 4 Reinstallation Follow the instructions in section 7 10 2 in reverse order for reinstallation 7 10 5 Idle Speed Adjustment Refer to Instruction amp Maintenance Manual for Jabiru 3300 Aircraft Engine for detailed carburetor jet removal idle adjustment and carburetor bowl cleaning procedures V WARNING A qualified person must be in the cockpit of the aircraft at all times the engine is running V WARNING BEWARE OF PROPELLER ALL TIMES Tools Required 2 foot long flat head screwdriver or 5 16 wrench Level of Certification Required A amp P or LSA R M M 1 Run engine until warmed to operating temperature 2 Turn idle limit screw until an idle rpm of 800 850 is achieved with throttle closed 7 11 Induction Air System 7 11 1 Description The engine air intake system includes a cold air inlet in the lower cowl a hot air muff attached to the exhaust system and a mixer assembly mounted on the firewall and connected to the carburetor The mixer box incorporates the air filter and a pressure relief dump valve For information on the carburetor heat system see Section 7 13 The air filter should be cleaned every 100 hours or more regularly if the engine is oper ated in dusty conditions Refer to Paragraph 7 11 2
105. de the cockpit The springs extend and contract as the nose leg is moved left and right and are critical to the rudder rig ging and handling characteristics of the aircraft JSA SM170SP A1 Page 5 19 Section 5 Jabiru J170 SP Landing Gear and Brakes Aircraft Service Manual 5 10 2 Removal Tools Required Screwdriver set 7 16 wrenches and or sock ets pliers Level of Certification Required A amp P or LSA R M M Refer to Figures 5 5 to 5 8 1 2 6 Remove engine cowlings as described in Section 7 Weigh down tail of aircraft to raise nose wheel off floor as described in Section 2 Disconnect nose wheel steering pushrods from steering cross beam Unbolt steering cross beam Remove upper collar steering yoke dependant on aircraft serial number from the top of the leg Pull the nose wheel strut assembly down from the bushings in the fuselage 5 10 3 Inspection and Repair 1 Inspect steel tube and attachments for dents and straightness If bent or dented replace steel nose leg assembly Repair is limited to replacement Inspect rubber suspension assembly for damage or cracking of the rubber or de lamination of the rubber from the aluminum spacers between the rubber blocks If weather checked cracked or otherwise damaged replace rubber suspension spring assembly Inspect aluminum wheel yoke for damage or bending If cracked bent or other wise damaged replace the yoke Check bolt nut tension on enti
106. de the control wire off of the bolt 7 13 3 Inspection Inspect all parts for damage or wear When adjusting any engine control it is impor tant to check that the control slides smoothly throughout its full range of travel amp that the lever or knob moves through its full range of travel 7 13 4 Repair Repair is limited to replacement 7 13 5 Reinstallation Reverse steps in 7 13 2 7 13 6 Adjustment 1 Adjust cable end connection at firewall and at carb so that the throttle arm at the carb rests against the full throttle stop when throttle is open and against firewall 2 Adjust tension on the bolts holding the acetal blocks to the firewall to provide proper throttle friction to hold throttle setting at idle 7 14 Choke 7 14 1 Description The choke control is located in the center of the main instrument panel amp is connected to the carburetor by a solid wire control cable JSA SM170SP A1 Page 7 23 Section 7 Engine Systems Jabiru J170 SP Aircraft Service Manual 7 14 2 Removal Tools Required Screwdriver set 3 8 and 5 8 wrenches Level of Certification Required A amp P or LSA R M M For aircraft built in 2008 or older 1 Disconnect choke from carburetor by removing the cotter pin from the cable ferrule and pulling ferrule from choke arm 2 Remove jam nuts from cable end adjuster at the carb bracket 3 Remove jam nut from back side of instrument panel 4 Pull cable from the aircraft For aircraft buil
107. e 12 6 JSA SM170SP A0 Jabiru J170 SP Aircraft Service Manual Appendix Appendix Log The table below shows the current effective appendices and revision dates Appendices must be kept updated to ensure use of the most current inspection checklists and ser vice information A current Appendix Log with the latest change notices may be found on the manufacturer s website www usjabiru com change Date J170 SP S LSA AO 1 March 2011 Service Schedule 25 and 50 Hour Inspection Al 1 March 2011 Guide JSASOHR A1 100 Hour Annual Inspection Al 1 March 2011 Guide JSA100HR A1 Jabiru J170 SP AO 1 March 2011 Quick Reference Mainte nance Guide JSA 501 1 Malfunction or 0 1 5 2010 Defect Report Vendor Contact Information 1 March 2011 JSA SM170SP A1 Appendix Log Page 1 of 2 Jabiru J170 SP Aircraft Service Manual Appendix THIS PAGE INTENTIONALLY BLANK JSA SM170SP A1 Appendix Log Page 2 of 2 Jabiru J170 SP Aircraft Service Manual Jabiru J170 SP S LSA Maintenance Schedule Task Reference Min Qualification Aircraft Affected Required By 25 Hours Total Time Initial oil change and 25 Hour Inspection JSA 50HR A amp P or LSA R M M All Engine manufacturer Each 25 Hour Interval Carbon Propeller Clamp Bolt Tension Check Aircraft Service Manual or Sensenich Doc COMP A amp P LSA R M M Only aircraft equipped with Sensenich Ground Adjustable Carbon Prop
108. e 6 of 9 Jabiru J230 SP J250 SP and J170 SP Aircraft Service Manual Drains and Plugs Check for condition cleanliness and security Check for leaks and correct tension Cowling skin Check for deformation delamination and obvious damage or cracks Check for rub points on the interior surfaces 3 Cabin and Baggage Compartment Rudder Pedals Check for freedom of movement Check push pull cables for proper routing condition and security Check rudder pedal springs for condition and correct placement Check pedal extensions for security if installed Instruments and Instrument Panel Inspect instrument panel placards and instruments for condition and attachment Check all knobs for security JSA 50HR A1 25 50 Hour Inspection Checklist Page 7 of 9 Jabiru J230 SP J250 SP and J170 SP Aircraft Service Manual 4 Wings and Carry Through Structure Skin Check for deformation and obvious damage Check for cracks If damage is found check adjacent structure Check for indications of excessive flight loading 5 Nose Gear heel and Tire Check wheel for cracks and tire for wear damage condition and proper inflation Check wheel bearings for condition and wear 6 Main Gear and Brakes Wheels and Tires Check wheels for cracks and tires for wear damage condition and proper inflation Check and repack wheel bearings Landing Gear Legs Inspect legs for cracks overextension or signs of delamination JSA 50HR
109. e and Engine Compartment The engine should be kept clean since dirty cooling fins and baffles can cause overheat ing of the engine Also cleaning is essential to minimize any danger of fire and provide easy inspection of components Recommended cleaning procedure is spray lightly with degreasing fluid after sealing coils and starter motor WIPE clean with brush and cloth V CAUTION DO NOT hose engine Electrical components may be damaged by moisture Ensure electrical components are protected against moisture Caustic cleaning solu tions should not be used 2 11 6 Propeller Wash with soap and water rinse with clean water and dry with cloth or chamois Wax the propeller with automotive wax for best results use a paste wax as opposed to a spray wax to help preserve the finish Empty the spinner of all water 2 11 7 Wheels The wheels should be washed at least annually more frequently if used in harsh envi ronments 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 5 Discard cracked wheel halves flanges or hubs and install new parts Page 2 14 JSA SM170SP A2 Jabiru J170 SP Section 2 Aircraft Service Manual General Care amp Inspection 2 12 Standard Practices for Maintenance Repair and Alteration 2 12 1 Approved Practices for Inspection Maintenance and Non Structural Repair Unless otherwise specified in this ma
110. e baggage bulkhead Figure 11 4 Magnetometer Location 11 10 6 2 Removal Tools Required Screwdriver set Level of Certification Required A amp P LSA R M M or Avionics Repair Station 1 Loosen clamp screws of D sub connector and remove from unit 2 Remove two mounting screws and remove unit from mount 11 10 6 3 Repair Magnetometer must be returned to Grand Rapids Technologies for repair or replacement Do not alter mounting pad If repair of mount becomes necessary contact Jabiru USA Sport Aircraft LLC for specific instructions JSA SM170SP A1 Page 11 13 Section 11 Jabiru 2170 5 Electrical System and Instruments Aircraft Service Manual 11 10 6 4 Reinstallation Reverse the steps in 11 10 6 2 for reinstallation 11 10 7 GPS Antenna 11 10 7 1 Description The GPS antenna may be located under the instrument panel or on the right side of the instrument panel next to the door frame It plugs into the rear of the EFIS MFD if in a dual EFIS panel with a simple push type connection 11 10 7 2 Removal Tools Required Small wire cutter Level of Certification Required A amp P LSA R M M or Avionics Repair Station 1 Locate GPS antenna head 2 Locate antenna cable Over door installations require cable to run alongside the snake skin wire bundle which is tied underneath the co pilot doorsill Clip zip ties as necessary 3 Follow wire up behind EFIS unit Pull connecter gently straight back out of uni
111. e frequent inspections for wear corrosion lubrication and or lack of maintenance Under these adverse conditions perform periodic inspections in compliance with this guide at more frequent intervals undil the owner or operator can set his or her own inspection periods based on the contingencies of experience The 100 hour inspection is required ONLY for aircraft used in commercial operations Airplanes operated commercially less than 100 hours per year must have a 100 hour inspection performed no later than 12 months following the date of the preceeding 100 hour inspection The 100 hour interval between performances of the procedures specified herein should NEVER be exceeded by more than 10 hours which can be used only if the additional time is required to reach a place where the inspection can be satisfactorily accomplished However any extension of the 100 hour interval must be subtracted from the following 100 hour interval with no time extension permitted For example if an inspection is done at 110 hours the next In addition to the inspections prescribed by this schedule the ATC transponder must be tested and inspected at 24 month intervals in compliance with the requirements specified in FAR Part 91 Placards Ensure that all placards are in place and legible whenever the airplane has been repainted or touched up after repairs Replace any placards that have been inadvertently defaced or removed 100 Hour Annual Inspection Checklist Page
112. e likely to affect the pilot s field of vision NOTE Cracks up to 25 mm in length should be stop drilled those longer than 25 mm should NOT be repaired the windshield or window must be replaced If 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 A non fluted drill should be used Window Removal Tools Required Small grinder 7mm socket 2 Phillips screwdriver Level of Certification Required A amp P or LSA R M M As the windscreen and windows are bonded into the fuselage it is not possible to re move them without destroying them Use the grinder to score the window near the paint line Once the window has been broken out any screws used in the original instal lation screws in windscreen only should be removed and old epoxy removed by grind ing it out of the joggle After removing the nuts from the screws the screw may have to be heated with a soldering iron to soften any epoxy that might hold it in the wind shield V Caution When grinding out the old epoxy and flock do not grind through the fiberglass of the joggle joint Window Inspection Inspect windows for scratches and cracks If cracks are greater than 25mm long placement is necessary Cracks in the body filler along the edge of the windscreen may occur due to rapid tem perature changes and expansion of the Persp
113. e the AN960 516 washers Belleville washers two per bolt aluminum crush plate and propeller Basic Inspection Before each flight and during each scheduled inspection the propeller should be looked over for damage including but not limited to nicks cracks and chips in the leading edge and blade surfaces Nicks in the paint surface are to be expected with age and if the aircraft is flown through heavy rain Nicks in the wood itself cracks splits or de lamination of any composite sheath must be either rejected as unserviceable or re turned to Sensenich Wood Propeller Company for assessment and possible repair Propeller bolt tension must be periodically checked Refer to Section 9 8 for schedule amp procedure Repair Any service or repair must take account of the risk of subsequent propeller failure All propeller repairs must be referred to Sensenich Wood Propeller Company for proper repair procedure 25 SM170SP A1 Jabiru J170 SP Section 9 Aircraft Service Manual Propeller amp Spinner For reference the maximum size of nicks that can be approved for repair is 1 Those in leading edge 4mm deep x 20mm long 2 Those across the drive face flat sides 2mm deep x 6mm diameter or scratches not more than 0 5mm deep Repairs must also take account of changes in the balance of the propeller Therefore before return to service after any repair the propeller must be removed in accordance with the procedure described in
114. e tire bead areas of the rim halves 2 Position tire and tube between wheel halves with tube inflation valve through hole in outside wheel half 3 Mate wheel halves While holding halves together assemble a washer and nut on one through bolt and tighten snugly 4 Assemble the remaining washers and nuts on the through bolts and torque to 16 ft Ibs V CAUTION Ensure tube is not pinched between wheel halves dur ing assembly Uneven or improper torque of through bolt nuts can cause bolt failure and subsequent wheel failure 5 Insert through bolts through brake disc and position disc on the inner wheel hub flange 6 Inflate tire to seat tire beads then adjust to correct tire pressure Refer to Para graph 1 6 5 7 7 Reinstallation of Wheel Brake onto Axle Tools Required Screwdriver 7 16 wrenches safety wire pliers adjustable wrench Parts Required New 1 8 by 2 cotter pin if necessary 032 safety wire Level of Certification Required A amp P or LSA R M M Refer to the Matco Service Instructions located in the Appendix of this manual for more information regarding wheel and bearing installation 1 Lightly coat axle with Anti Seize or a waterproof grease 2 Install the inboard tapered bearing to the axle Page 5 10 JSA SM170SP A1 Jabiru J170 SP Section 5 Aircraft Service Manual Landing Gear and Brakes 3 Place wheel assembly on axle 4 Install outboard tapered bearing to the axle 5 Install
115. each flap hinge bolt and spacer bushing 5 Remove flap 6 4 3 2 Flap Switch Assembly Tools Required Screwdriver set 7 16 wrenches Level of Certification Required A amp P or LSA R M M 1 Remove switch jam nut 2 Disconnect wires 3 Remove switch assembly Page 6 6 JSA SM170SP A1 Jabiru J170 SP Section 6 Aircraft Service Manual Flight Controls 6 4 3 3 Flap Control Rod Tools Required Screwdriver set 3 8 wrenches Level of Certification Required or LSA R M M 1 To remove clamp flaps in position so they do not fall against the fuselage 2 Unbolt control rod at both ends and remove 6 4 3 4 Flap Motor Assembly Tools Required Screwdriver set 7 16 wrenches Parts Required Level of Certification Required A amp P or LSA R M M 1 Remove wing root fairings 2 3 Disconnect electrical wires Support the flaps in the UP position so they do not fall against the fuselage 4 Remove the bolt in each end of the flap motor 5 Reverse procedure to install 6 4 3 5 Flap Position Sensor Parts Required Level of Certification Required amp or LSA R M M 1 Remove upper wing root fairing from left wing 2 Disconnect pushrod clevis and electrical connector from sensor 3 Remove mounting screws from nutplate bracket and remove sensor 6 4 4 Inspection of Flap Components 1 Inspect flaps for any signs of delamination or cracking Pay particular at tention to the control horn and
116. econd layer Ideally there should be no need to add any additional epoxy unless all the excess is soaked up however do not leave any dry spots or air bubbles inside the layup Any areas that appear whitish will become a weak area in the repair Cut a piece of peel ply large enough to cover the area Using the paint brush press the peel ply into the third glass layer Allow to cure for 24 hours If necessary reinstall the carpet that was pulled up in the first step using contact cement or upholstery glue If the carpet was destroyed in removal contact Jabiru USA for replacement pieces 12 3 3 Damage to Wing or Horizontal Stabilizer Damage to skin may be repaired using the procedures in this manual as long as there is no damage to underlying structures JSA SM170SP A0 Page 12 3 Section 12 Jabiru J170 SP Fiberglass Repair Aircraft Service Manual Damage to leading edge skin 1 Cut out damaged area Prep area as described in Paragraph 12 3 1 1 2 Carve a Styrofoam block insert to fit the contour of the leading edge Insert Styro foam into leading edge area to maintain shape Cover with four layers of 9 oz cloth as detailed in Paragraph 12 3 1 Overlap damaged area by two inches Apply peel ply Finish and repaint according to Section 12 4 Paint and Refinishing 12 3 4 Damage to Underlying Structure Damage of any kind to structures that support the skin of any of the aircraft structural components must be reported to the
117. ected to a lubron block so that the cable can move the block fore aft approximately 35mm An aluminum rod is free to slide through this lubron block and is centered by 2 compression springs The output end of the rod is connected to the elevator horn To operate outer covers of the cable must be clamped firmly at both ends NOTE Control cables may not be removed or repaired without reference to Jabiru USA Sport Aircraft LLC or our approved local agent for an approved repair procedure 6 6 2 Operational Check Movement of the trim control lever FORE and AFT should result in movement of the control column FORE and AFT and movement of the Elevator DOWN and UP respec tively V WARNING This operational check MUST be performed whenever the trim cable has been disconnected to ensure it has been correctly installed 6 6 3 Removal The trim control cable is a primary control and may not be removed or repaired without reference to Jabiru USA Sport Aircraft LLC or our approved local agent for an approved repair procedure 6 6 4 Inspection The trim mechanism must be kept clean and periodically lubricated with graphite See Annual Inspection Checklist in the Appendix for more information Inspect trim system generally for security and any signs of wear Pay particular atten tion to the bearing blocks friction plates bearing springs cable and attachments The spring rod can be lubricated with a graphite lubricant if any friction
118. ed and certain parameters may have to be reset Consult the GRT Sport installation manual for guidance Page 11 10 JSA SM170SP A1 Jabiru J170 SP Aircraft Service Manual Section 11 Electrical System and Instruments 11 10 5 Software amp Database Upgrade Tools Required Computer with USB port and Internet access USB flash drive with at least 256MB 25 SM170SP A1 Level of Certification Required Owner A amp P LSA R M M or Avionics Repair Station If not already known determine unit model EFIS software version and navigation database date by turning on the MASTER and INST switches and waiting for the unit to power up The Power Up page in Figure 11 3 will display on the PFD and MFD screen if installed Write down any information needed from both screens and shut off master switch Insert USB stick into computer Go to www grtavionics com click Support then Software Click the link to load the software appropriate to the EFIS in the aircraft It will be either the SWS older version wide screen or SHS all J230s later J250s taller high res screen Save the dat file to the main root directory of the USB drive not in a separate folder BIEFIS Sport HS Power Up 3 EFIS software integrity check PASS EFIS software version Date 2009 07 13 AHRS software version 0 28 Navigation database integrity check PASS Navigation database date 2009 11 19 AHRS Communication OK EIS Communication OK Int
119. ed hangar or with an external heat source that will heat the repaired area to at least 60 F With the door shut proper hinge align ment will be assured JSA 5 1705 0 Page 12 5 Section 12 Jabiru J170 SP Fiberglass Repair Aircraft Service Manual 7 If door frame pieces were removed during inspection and internal repair carefully glue them back into place with 5 minute epoxy If small pieces were crushed be yond repair the hole may be filled using an epoxy flock mixture 8 After the epoxy has cured sand away any rough edges or excess epoxy from the repair area 9 Lay at least 2 layers of 10 oz cloth over the hole taking care to avoid sags and wrinkles Use 2 layers for cosmetic areas and 3 layers for stressed areas such as the restraint strap attach point and the area around the door lock slot Let the epoxy cure fully 10 Follow the instructions in 12 4 to fill sand and paint the affected area 11 When paint has fully cured reinstall door restraint strap upholstery panels and weather stripping as necessary Upholstery should be glued in place with contact cement See Section 3 3 for information on replacing door seals 12 Re cut the door lock slots as necessary Lay 10 oz cloth over the door lock area ideally covering Least 2 from the ec Cut away broken area fo straint strap stress drill into door frame sary for access Figure 12 1 Hinge repair Figure 12 2 Door lock slot repair Pag
120. ees JSA SM170SP A1 Section 6 Flight Controls Jabiru J170 SP Aircraft Service Manual Figure 6 3 Flap Drive System Page 6 9 JSA 5 1705 1 Jabiru J170 SP Aircraft Service Manual M co Bue 9 of 0 9y 53143 ASSY OIH LLOS T3 1 ia DINIH SM oo verewv zi ONS SAMA waovesove Figure 6 4 Flap Control Tube Assembly 25 SM170SP A1 6 10 Jabiru J170 SP Section 6 Aircraft Service Manual Flight Controls 6 5 Elevator Control System 6 5 1 Description The elevator control system is comprised of the elevator control surface the control column described in Section 6 1 and one enclosed push pull cable fitted with rod bear ings at both ends as described in Section 6 2 The elevator control surface consists of a rigid cellular polystyrene core molded and bonded to a composite skin incorporating a composite control horn at the center An elevator trim system is attached and de scribed in Section 6 6 NOTE Control column and control cables are primary controls and may not be removed or repaired without reference to Jabiru USA Sport Aircraft LLC or our approved local agent 6 5 2 Troubleshooting Operate the elevator control while observing for friction and interference The t
121. eighing procedure and Section 4 of the Pilot s Operating Handbook for center of gravity calculation instructions and limitations Dati aa eite eem td Leading Edge of Wing Most Forward Location 992 IDS gross 7 9 inches aft of datum Most Forward Location 1320 Ibs gross 9 17 inches aft of datum Most Aft Location all weights 11 9 inches aft of datum 1 6 Tire Inflation Pressures JSA SM170SP A1 Standard Mains Page 1 3 Section 1 Jabiru J170 SP General Description Aircraft Service Manual 1 7 Equipment List Page 1 4 The following is a list of all available equipment that affects aircraft weight and bal ance Each aircraft is equipped with one of the four instrument panel packages and may include upgrades or substitutions listed in the Panel Upgrades section of Table 1 2 5 Standard all aircraft O Optional equipment on all aircraft S O Standard on some aircraft see note in parentheses Instrument Panel Package 0 p 3 1 8 Airspeed Indicator 2 2 3 1 8 Altimeter 3 1 8 Vertical Speed Indicator 3 1 8 Pictorial Pilot Turn amp Bank a EIS 4000 Engine Monitor HK Garmin SL40 Com Radio az PM1000II Intercom o Instrument Panel Package 1 GRT Sport EFIS PFD EIS 4000 Engine Monitor jemesecmmd s1827 mode pwemmes rdum 01
122. els and single piston external caliper brakes for ease of maintenance and availability of parts The master brake cylinder is a Jabiru product See Section 5 8 for information on the master cylinder and brake bleeding procedures CAUTION When replacing a brake caliper assembly the brake pis ton BUNA N O ring MUST be replaced with a VITON O ring compatible with DOT 4 fluid p n 1201T71 Removal and Disassembly 5 7 2 1 Wheel Removal Tools Required Wire cutter Phillips screwdriver needle nose pliers 7 16 wrenches Level of Certification Required A amp P or LSA R M M 1 Remove wheel pant as described in Section 5 3 2 Remove outer wheel pant bracket by cutting the safety wire and removing the two bolts 3 Remove the brake caliper bolts by cutting the safety wire and removing the two bolts 4 Support the airframe using the jacking procedure in Section 2 2 5 Remove cotter pin from axle nut 6 Remove axle nut 7 Support wheel as it comes off 5 7 2 2 Wheel Disassembly V WARNING Do not attempt to separate wheel halves with tire in flated as injury may result Avoid damaging wheel flanges when breaking beads loose as a scratch nick or gouge may cause wheel failure 1 Deflate tire and break tire beads loose from tire rims 2 Remove brake disc 3 Remove through bolts nuts and separate wheel halves removing tire tube and wheel hub JSA SM170SP A1 Jabiru J170 SP Section 5 Aircraft Service Ma
123. er Display Communication OK Primary Speed Distance units Knots nautical miles Feedback Report Generated Push FEED BACK for options Figure 11 3 GRT Sport HS EFIS unit power up page Save the newest Navigation Database NAV DB file to the main root directory of the USB drive Power up the EFIS units by turning on the MASTER and INST switches Accept the power up screen On the PFD or MFD default screen press the NEXT soft key until SET MENU ap pears over one of the soft keys Press that key Page 11 11 Section 11 Jabiru J170 SP Electrical System and Instruments Aircraft Service Manual 6 Turn the right knob to move the cursor over Display Unit Maintenance then press the knob to activate 7 Use the right knob to move the cursor over Load EFIS Software and press the knob to activate 8 Rotate the same knob clockwise to activate the EFIS upgrade page 9 Insert the USB drive into the USB port in the back of the unit on the upper co pilot s side corner The back of the unit is accessible through the access opening in the bottom of the instrument panel 10 Wait for the EFIS to detect the USB drive and download the files The EFIS may take up to one minute to detect the USB drive The light on the USB drive should blink faster when detected and when data is being copied The light will blink slower when the operation is complete 11 When the EFIS has completed copying files from the USB drive the display un
124. er cylinder 5 Air in the system will be pushed up and out in to the master cylinder ONLY IF the master cylinder or remote reservoir is at the highest point in the system and there are no loops in the brake lines 6 Fluid should be pushed through the system until it reaches approximately 1 4 inch from the top of the master cylinder 7 Close the brake bleeder valve and remove the service hose JSA SM170SP A1 Page 5 17 Section 5 Jabiru J170 SP Landing Gear and Brakes Aircraft Service Manual 5 8 8 Page 5 18 8 10 If the brake system is free of air the brake lever should feel firm and not spongy If not repeat steps 1 through 7 until the system is free of trapped air Fluid leakage from the top of the master cylinder during operation indicates too high a fluid level Ensure that all drilled bolts are properly safety wired NOTE The Master Cylinder is NOT approved for inverted flight Matco Mfg Brake Conditioning Procedure It is important to condition the new linings after installation to obtain maximum service life and performance Conditioning removes high spots and creates a layer of glazed material at the lining surface Normal braking will produce enough heat to maintain glazing during the life of the lining Glazing can be worn off during light use such as taxiing 1 After the linings have been installed apply brake pressure during high throttle static run up Note RPM at creep if any occurs
125. er vent The oil line is connected to the engine crankcase filler neck and deposits excess oil into a bottle mounted on the firewall The bottle will also collect excess fuel in the event of a fuel pump failure Fluid level is visible through the side of the bottle It should be emptied at each oil change or when oil is seen dripping from the overflow tube 7 9 2 Removal Tools Required Flat head screwdriver Parts Required Level of Certification Required Owner A amp P or LSA R M M 1 Loosen the clamps around the hoses on top and on the side of the oil bottle 2 Pull the clear tube out of the top 3 Lift the bottle from the clamp on the firewall 4 Dispose of collected oil 5 Clean bottle and mount area as necessary and reinstall to firewall Be sure to reconnect breather hose and fuel pump vent line 7 9 3 Inspection Clean bottle and mounting area if nec essary Look the bottle over for cracks or blockages Check for kinks in the lines The oil breather vent line may become saturated after one or two years or several hundred hours of operation and weep oil Replacement of a weepy oil breather line is recom mended every 24 calendar months or as needed to keep a clean engine com partment 7 9 4 Repair Figure 7 7 Oil Recovery Bottle Repair is limited to replacement of components See Table 7 1 for re placement hose information 25 SM170SP A1 Page 7 17 Section 7 Engine Systems Jabiru J170
126. ere the inspection can be satisfactorily accomplished However any extension of the 100 hour interval must be subtracted from the following 100 hour interval with no time extension permitted For example if an inspection is done at 110 hours the next inspection is due 90 hours later with no extension allowed In addition to the inspections prescribed by this schedule the altimeter static system and ATC transponder MUST be tested and inspected at 24 month intervals in compliance with the requirements specified in FAR Part 91 Placards Ensure that all placards are in place and legible whenever the airplane has been repainted or touched up after repairs Replace any placards that have been inadvertently defaced or removed Airworthiness Responsibility Jabiru USA Sport Aircraft s recommended inspection program in accordance to FAR Parts 43 and 91 consists of but is not limited to inspection items listed in this Inspection Guide any applicable Service Bulletins or Air Safety Alerts issued against the airframe or any equipment installed therein The owner or operator is primarily responsible for maintaining the aircraft in an airworthy condition including compliance with all applicable Service Bulletins and Air Safety Alerts issued by the manufacturer It is further the responsibility of the owner or operator to ensure that the airplane is inspected in conformity with the requirements of Parts 43 and 91 of the Federal Aviation Regulations Jabiru U
127. ers of 10 oz glass cloth filled and painted to match 1 Remove all door upholstery and set aside to protect it from epoxy and paint Unbolt and remove restraint strap from forward edge of door to access stress cracks in that area Remove weather stripping from door edges near repair areas Remove door if necessary by following procedure in Section 3 3 2 Sand away the paint and gel coat at east 2 around the damaged area or to the edge of the structure 3 Carefully remove broken skin pieces or drill a hole into the door frame near the damaged area for inspection and application of epoxy and flock For example to repair a broken lower hinge drill near the area shown in Figure 12 1 Use a step drill or file to enlarge the hole big enough to inspect and repair the damage 4 Thoroughly inspect the damage and determine amount of epoxy and flock needed to repair the joint Mix up a batch of 24 hour epoxy and cotton flock to the consis tency of mayonnaise 5 Using a popsicle stick or other application tool thoroughly coat the cracked sur faces Cover as much of the cracked surface as possible and be generous with the epoxy mixture Fillet the flock into the inside of the door frame and skin to add rein forcement to the broken areas Clean up all epoxy that drips on the outside sur faces of the door with acetone 6 When satisfied with an internal hinge repair shut the door latch it and let it sit untouched overnight inside a heat
128. es used in Jabiru aircraft are of the enclosed push pull type with the ca ble bolted directly to the control surface horn at one end and to the pilot control at the other end To operate correctly outer covers of the cable must be clamped firmly at both ends V WARNING All spherical bearings on control cable ends must be fit ted 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 6 2 2 Removal The control cables are primary controls and may not be repaired or removed without reference to Jabiru USA Sport Aircraft LLC or our approved local agent for an appropri ate procedure 6 2 3 Inspection Check for broken sheaths broken or frayed cables and loose fittings Make sure the cable sheath is clamped securely in the correct position at each end JSA SM170SP A1 Page 6 1 Jabiru J170 SP Aircraft Service Manual Section 6 Flight Controls Tee FOOViS0vt 091 ASSY NOLS TOMLNOD n uu Ald HO2LAV 30 LN3SNOO LNOHUM 031900 6 LON ONV S SML jawosionooj NoUDaroUd om NE a PALO ____________ Figure 6 1 Control Column 25 SM170SP A1 Page 6 2 Jabiru J170 SP Section 6 Aircraft Service Manual Flight Controls 6 2 4 Repair Repair is limi
129. ex windshield Sand and repair filler using basic bodywork paint procedures in Section 12 JSA SM170SP A1 Jabiru J170 SP Section 3 Aircraft Service Manual Fuselage Structure 3 2 6 Repair Repair is limited to scratch polishing as outlined in Paragraph 3 2 2 or crack repair out lined in Paragraph 3 2 3 Otherwise repair is limited to replacement 3 2 7 Replacement of Windscreen and Side Windows File or small grinder drill with 1 8 unfluted drill bit 7mm socket 2 Phillips screwdriver small flat clamps sandpaper 24 hour epoxy cotton flock Parts Required Windscreen or window M4X12 countersunk screws and nuts hardware to make window clamps see Figure 3 1 Level of Certification Required A amp P or LSA R M M Windscreen 1 10 JSA SM170SP A1 Fabricate about 20 small simple clamps as shown in Figure 3 1 One small piece of sheet metal stock with one small sheet metal screw will suffice for each clamp These will be used to hold the windshield in place while the epoxy cures Ensure all old epoxy resin has been removed from the fuselage sealing strips around the window frames Peel away the plastic coating on the inside of the windscreen only about 2 back from the edge Check new windscreen for fit inside the joggle File or grind away any excess windscreen material to ensure a close fit Do not attempt to cut with any type of saw file only Fit windscreen in the joggle Trace the edge of the
130. f the fuselage at corners above wing support brackets Page 2 4 JSA SM170SP A2 Jabiru J170 SP Section 2 Aircraft Service Manual General Care amp Inspection 2 5 Leveling 1 Place a spirit level along the lower edge of the door frame left or right side and make adjustments as necessary to level the aircraft in the longitudinal direction 2 Place a spirit level across the fuselage between the door sills use blocking of equal height on each side to clear seats and obstructions and make adjustments as nec essary to level the aircraft in the lateral direction 2 6 Weighing the Aircraft Tools Required 3 aircraft weighing scales spirit level plumb bob tape measure Level of Maintenance Line Level of Certification Required Owner A amp P LSA R M 2 6 1 Preparation 1 Thoroughly clean aircraft and remove all baggage tools and personal items 2 Drain all fuel 3 Confirm that oil level is full 4 Inflate tires to recommended operating pressures 5 Raise flaps to the fully retracted position 6 Place all control surfaces in neutral position bs b Table 2 1 Aircraft Empty Weight and Moment Determination JSA SM170SP A2 Page 2 5 Section 2 Jabiru J170 SP General Care amp Inspection Aircraft Service Manual Datum Wing Leading Edge Station 0 0 Eo 2057 Figure 2 4 Aircraft Moment Arm Measurements 2170 1230 2250 2 6 2 Weighing Aircraft
131. ft Service Manual 2 Turn sump drains out of the bottom of the tank with the wrench Inspection Inspect sump drains for proper seating If a sump drain sticks or drips fuel there is probably debris in the seat that needs to be washed away Repair Repair of sump drains is limited to cleaning or replacement Reinstallation Reverse the steps in 8 6 2 for installation Add a small amount of fuel to tank then check drain for leaks Fuel Gauges 8 7 1 Page 8 6 Description There is one resistive float type fuel quantity sender in the root end of each main wing tank Each sender is wired to its own set of LED fuel gauge indicator lights on the in strument panel Each fuel gauge consists of a group of four green LEDs and one red LED Each LED represents approximately two gallons of fuel When the corresponding tank contains two gallons or less the red LED will light and the four greens will be dark Because of the shape of the fuel tank the wing dihedral and the placement of the sender any thing over 10 gallons will register as four green LEDs NOTE When the aircraft is flown in an uncoordinated condition the fuel gauges may temporarily read inaccurately due to float position and sloshing of fuel in the tanks The fuel quantity reading should return to normal within several seconds of aircraft stabiliza tion Pilots are strongly encouraged to visually check fuel quantity before each flight using a calibrated fuel dipstick Fue
132. fuel valves pump about quart out of the header tank and then turn the left wing valve on The wing tank will gravity feed to the header tank and 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 Page 4 3 Section 4 Wing Structure Jabiru 2170 5 Aircraft Service Manual 4 2 Wing Struts 4 2 1 4 2 2 4 4 Description 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 bolted to two end fit tings which attach to the fuselage and wing V WARNING Do Not Tighten Strut Attachment Bolts Damage to wing attach hardware may result Bolt must be free to rotate Removal Tools Required Screwdriver set 1 2 wrenches tall padded saw horse or wing stand Level of Certification Required A amp P or LSA R M M 1 Remove wing root fairings 2 If planning to leave the wing blocked up more than a few minutes drain fuel out of the wing tank to lighten it up Note This will take some time 3 Remove wing strut fairings top and bottom 4 Disconnect pitot tube RH wing only Pitot connection is underneath lower strut fairing 5 Disconnect the recognition light wires LH wing Rec light connection is under neath lower strut fairing 6 Making sure the flap is suppo
133. g strut attach bolt in your pocket JSA SM170SP A0 Jabiru J170 SP Section 4 Aircraft Service Manual Wing Structure 5 Lift wing tip and install wing strut to wing strut attachment with bolt from pocket 6 Install nut DO NOT tighten nut or damage to strut attach hardware may result 7 Connect all fuel and vent lines to wing making sure there are no lines that have kinked Reinstall stall warning reed bell 8 Reconnect electrical wires to strobes and wingtip lights 9 Put about 3 gallons of fuel in each tank amp check for any leaks 10 Attach flap to wing ensuring all bushings are in place 11 Install bolt nut in flap control rod 12 Install bolt nut in aileron control cable on main control stick horn 13 Install clamp on aileron control cable clamp between the seats 14 For RH wing reconnect pitot tube 15 For LH wing reconnect recognition light 16 Replace wing strut fairings top and bottom 17 Replace wing root fairings 18 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 a minimum of 0 25 gal lon per minute flow rate 19 After carrying out the fuel flow test check that both wing tanks are feeding fuel 25 5 1705 0 Turn off both of the doorpost
134. h a carburetor see Section 7 10 mounted behind the en gine and a fuel pump at the starboard rear of the engine There is one fiberglass main fuel tank in each wing Fuel is routed from each wing through a shutoff valve on each side of the cockpit interior mounted aft of the cockpit doors It then flows into a header tank located behind the passenger seat Fuel is fed from the header tank to the engine through a filter located between the two sets of rudder pedals As long as there is fuel inside the wing tanks there is enough pressure to force fuel from the header tank through the firewall An engine driven mechanical fuel pump helps provide pressure to feed the carburetor An electric boost pump is available to fill the carburetor bowl with fuel prior to engine start and also to function as a backup in case the mechanical pump fails There is one main fuel shutoff valve located on the center console between the master brake cylinder and the rudder pedals A vent line for each tank runs to the wing tip where it exits the leading edge of the winglet The header tank is vented into both main tanks Check valves reduce the amount of fuel allowed to back out of the vents Three fuel sumps allow sampling of fuel for water and sediment There is one sump at the root end of each wing tank and one in the header tank that protrudes out the belly of the fuselage 8 2 Fuel Tanks 8 2 1 Description Each fuel tank consists of a fiberglass shell that is
135. he battery followed by the power cable and nut Last install the black jumper cable end to the negative termi nal of the battery followed by the aircraft ground cable and nut 9 Make sure the cables do not contact any part of the exhaust system Tie the two jumper cables together using zip ties or other acceptable wire tie method to finish up the installation 10 Reinstall the cowls 11 15 3 Removal Reverse steps in 11 15 2 for removal 11 15 4 Repair Repair is limited to replacement of components Figure 11 6 Finished Installation JSA SM170SP A1 Page 11 21 Jabiru 2170 5 Aircraft Service Manual Section 11 Electrical System and Instruments 80 61 80 9184 deu Aqud XXXN AMWVNIIAFT3Sd T3NVd 9 so 85 1 s 504 508 NIV NOISN31X3 508 NIV 508 IN3ADMISNI 5 AVN AVN 015 0435 23 58 C 3191 2 9 4 5 9 2 S d 380815 WOO83IN 193934 29 9 508 ical typ ical Diagram le EFIS Electr ing 5 Figure 11 7 JSA SM170SP A1 Page 11 22 Section 11 Electrical System and Instruments Jabiru J170 SP Aircraft Service Manual dew XXXN 359644 ASVNIIAIT38d 19 ML LAT EE 2155
136. heels 1 April 2012 5 11 5 21 to 5 22 Al Removed owner authorization for nose wheel 1 April 2012 5 11 5 5 22 Al Removed reference to brake assembly 1 April 2012 6 4 6 7 to 6 9 Al Added flap position sensor information 1 April 2012 7 19 7 30 Al Removed owner authorization for head torque 1 April 2012 Changed head torque value to 20 ft lbs 8 8 8 9 Al Added fuel system schematic diagram 1 April 2012 9 1 9 1 Al Removed owner authorization for spinner removal 1 April 2012 Added spinner replacement information Added note on over tightening spinner screws 9 7 9 6 Al Removed owner authorization for wood prop 1 April 2012 torque 11 3 3 11 2 Al Added instructions for recharging dead battery 1 April 2012 11 10 5 11 11 to 11 12 Al Added instructions for GRT map features update 1 April 2012 11 10 8 11 15 Al Added note on WxWorx radio static 1 April 2012 11 11 11 16 Al Added note on WxWorx radio static 1 April 2012 12 3 12 2 Al Revised structural fiberglass repair section 16 May 2011 12 4 12 4 to 12 6 Al Added paint codes for base white 16 May 2011 Section Pages Affected Revision Description Date JSA SM170SP List of Effective Sections The table below shows the effective sections and dates for the most current revision of this manual Appendices are issued and controlled separately by the Appendix Log The revision number is found in the footer of each page after the document number For
137. hieved if two people 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 Pitot connection is under lower strut fairing 5 Disconnect landing light wires Wire connection is under lower strut fairing 6 Making sure the flap is supported unbolt flap control rods 1 each wing 7 Remove from wing so it does not crush the fuselage when lowering down 8 Unbolt aileron control cables 2 from rear of control stick horn inside cabin 9 Remove clamp block or cable clamps from aileron control cable clamps at rear of seat 1 each seat 10 Loosen hose clamps from fuel lines and vent lines If removing the left wing re move stall warning reed bell 11 Disconnect wiring to strobes and wingtip lighting 12 With one person supporting wing tip unbolt top wing strut bolt and lower the wing strut to the ground JSA 5 1705 0 Page 4 1 Section 4 Wing Structure 4 1 3 4 1 4 4 1 5 Page 4 2 Jabiru J170 SP Aircraft Service Manual 13 Lower wing tip toward the ground making sure you do not crush the underside of the wing on the fuselage wing root Rest the wing tip on a sawhorse or other suit able stand 14 Unbolt and remove front wing attachment bolt 15 Unbolt and remove rear wing attachment bolt It may be necessary to roc
138. however they sag over time and are damaged easily so the hinge design was changed to create a tougher door in 2008 see Figures 3 6 and 3 7 Figure 3 6 Old style door hinge Figure 3 7 New style door hinge pilot s side passenger side JSA SM170SP A1 Page 3 9 Section 3 Jabiru J170 SP Fuselage Structure Aircraft Service Manual Removal of Old Style Door 1 Open door Have a helper support the door until hinge bolts are removed 2 Remove the hinge bolts that attach the hinges to the door frame 3 Remove the door Removal of New Style Door 1 Access the hinge bolts by gently peeling back the upholstery adjacent to the door hinge See Figure 3 8 for a view of the bolts before the fuselage is upholstered 2 Open the door Have a helper support the door until it is removed 3 Remove the cap screws that hold the hinge into position labeled 1 in Figures 3 8 and 3 9 Some filing of the fiberglass door frame or the lower fairing may be re quired to remove the hinge hardware as shown by the dashed line in Figure 3 9 Avoid filing outer fuselage skin 4 Remove door Figure 3 9 Upper door hinge new style passenger side File fiberglass as needed from dashed area to remove hinge hardware Figure 3 8 Interior door hinge bolts new style pilot s side Page 3 10 JSA SM170SP A1 Jabiru J170 SP Aircraft Service Manual Fuselage Structure 3 3 3 3 3 4 3 3 5 3 3 6 Seats Section 3
139. icators are consistent throughout an entire section but may vary among sections as they are revised Each page of the manual lists the document number with an issue letter and change indicator suffix For example JSA 5 1705 0 is the original release of a section in Issue A of JSA SM170SP JSA SM170SP B3 is the third revision of a section in Issue B of JSA SM170SP These revisions are listed on the List of Effective Sections page near the front of the manual Appendix documents are controlled separately by the Appendix Log located immediately after the last Section of the manual Owners are responsible for keeping the List of Effective Sections Appendix Log and the Record of Revisions updated when handbook revisions are issued by JSA A current List of Effective Sections and the Appendix Log may be found at the Jabiru USA web site www usjabiru com Revisions to this Aircraft Service Manual will be distributed via free PDF download from the Jabiru USA website www usjabiru com Owners should contact Jabiru USA whenever the revi sion status of their service manual is in question JSA SM170SP A1 Page 11 Jabiru J170 SP Aircraft Service Manual THIS PAGE INTENTIONALLY BLANK Page 12 JSA SM170SP A1 Jabiru J170 SP Section 1 Aircraft Service Manual General Description Section 1 General Description 1 1 Aircraft Description The Jabiru J170 SP is a 2 seat high wing aircraft of fiberglass composite monoco que constructio
140. ide of the aircraft and make another mark C Draw aline from that mark aft 3 or 4 and parallel to the centerline of the aircraft Hold the receptacle in place centered on the line with its flat side against the fuse lage skin and its forward edge about 1 1 4 inches aft of the lower edge of the fire wall The exact placement is not critical but the receptacle should sit as flat as pos sible on the surface of the fuselage and be far enough forward that the bolts are accessible from behind the rudder pedal assembly See Figure 11 5 Carefully drill through one of the bolt holes in the receptacle into the bottom skin of the fuse lage be prepared to stop the drill as soon as it breaks through so that it does not tear up the inte rior carpet Place one bolt through the hole square the receptacle into final position and drill the second hole Figure 11 5 Booster Receptacle Position JSA SM170SP A1 Jabiru J170 SP Section 11 Aircraft Service Manual Electrical System and Instruments 6 Attach the nuts to the bolts inside the cabin under the rudder pedal assembly 7 Plug the lower portion of each cable into the receptacle Black goes to the negative terminal and red goes to the positive terminal 8 Ensure Master switch is OFF Using the 10mm wrench disconnect the aircraft ground cable black from the battery followed by the power cable red Install the red jumper cable end to the positive terminal of t
141. ing delamination or hinge damage must be referred to Jabiru USA Sport Aircraft LLC or an approved local agent for an appropriate repair pro cedure Reinstallation Reinstall by reversing steps in Paragraph 6 5 3 V WARNING All spherical bearings on control cable ends must be fit ted with a large washer on the outside of the through bolt to prevent the bearing case and cable from release ing in the event of a bearing failure Rigging the Elevator Control Tools Required Screwdriver set 3 8 wrenches Elevator Rigging Template see Appendix or angle finder Level of Certification Required A amp P or LSA R M M Refer to Figure 6 6 1 Using the factory set cable anchor points make sure each end of the cable is se cure 2 Setthe full up travel first using the factory templates Make sure the control column is hard back Adjust the female ball ends in or out if adjustment is needed Refer to Figure 6 1 for an illustration of the elevator cable control stick connection 3 To establish the neutral position align elevator counterbalance with horizontal sta bilizer 4 Adjust cable rod ends to achieve UP and DOWN travel using the Elevator Rigging Template see Appendix If template not available set up travel to a minimum 18 degrees from neutral and down travel to at least 7 degrees from neutral 5 DO NOT move the cable anchors These are factory set 6 Ensure lock nut is tight on rod ends and that cable is visi
142. ing hoist Install engine mounts and bolts as described in Section 7 6 Reinstall exhaust carburetor SCAT hose wiring and fuel lines by reversing descrip tion in 7 1 5 Rewire alternator using a soldered butt splice Reconnect all engine sensors Tie all wires neatly using cord or zip ties to avoid interference with moving or hot parts and airflow Reconnect starter and aircraft ground cables Check security of all spark plug wires on both ends Reinstall cooling baffles as described in 7 4 Reinstall propeller and spinner as described in Section 9 using all new propeller nuts and correct propeller torque values Ensure crankcase is filled with proper amount and kind of engine oil Turn main fuel valve ON JSA SM170SP A1 Jabiru J170 SP Section 7 Aircraft Service Manual Engine Systems 12 Start engine as described in POH and check for correct oil pressure oil tempera ture and other engine vital signs 13 Adjust carburetor as necessary refer to Instruction amp Maintenance Manual for Jabiru 2200 Aircraft Engine 14 Shut down engine and check for oil and fuel leaks 15 When satisfied with engine operation reinstall cowlings as described in Section 7 3 16 Consult Instruction amp Maintenance Manual for Jabiru 2200 Aircraft Engine for new or rebuilt engine break in schedule if necessary 7 1 6 Engine Accessories Removal Removal of engine accessories for inspection involves stripping the engine of parts ac
143. ing to an area ap proximately two inches beyond the damage area Take care to sand only paint and gel coat not into the glass fiber 2 To prep non gel coated areas rough up the fiberglass and epoxy coat with 220 grit sandpaper to allow mechanical adhesion of the repair epoxy 3 After sanding clean with acetone or water to remove all dust DO NOT use soap or silicone based cleaners 4 Apply a light coat of epoxy to the repair area Align the broken parts Apply two layers of 9 oz fiberglass cloth to the area and wet out Apply two layers of cloth to the other side if necessary 5 Allow to cure Finish as described in 12 4 Page 12 1 Section 12 Jabiru J170 SP Fiberglass Repair Aircraft Service Manual 12 3 Structural Fiberglass Repair It is strongly recommended that any damage to fiberglass in structural areas be re ported to manufacturer and manufacturer s advice be considered in the repair process Structural fiberglass repair should only be attempted by personnel with previous fiber glass experience Tools Required 220 grit aluminum oxide sandpaper NOT silicon based epoxy brush mixing cups stir sticks Parts Required 9 oz fiberglass cloth System 2000 epoxy Aero poxy or other aircraft laminating epoxy Dacron peel ply Level of Certification Required A amp P or LSA R M M 12 3 1 Exterior Fuselage Skin Repair Procedure 1 Remove paint and gel coat from the damaged area extending to an area approxi m
144. ingle cause of early engine wear When operating under high dust conditions the carbu retor air filter should be serviced daily as outlined in Section 7 11 B In saltwater areas special care should be taken to keep the engine and accessories clean to prevent oxidization C In humid areas fuel should be checked frequently and drained of condensed mois ture D The maximum ambient outside air temperature for aircraft operation is 104 F 1 14 1 Cold Weather Engine Operation Before starting engine in temperatures below 32 F preheating is recommended A warm air source should be directed through the rear opening in the lower cowling to warm the carburetor intake manifold and engine oil sump Once the intake area is sufficiently warm start engine using the Cold Engine Start pro cedure found in the Pilot s Operating Handbook LET ENGINE WARM ITSELF to normal operating oil temperature and CHT with not more than 1200 rpm Installation and use of a Tanis engine heater is recommended for frequent operation in cold weather They are available through Jabiru USA Sport Aircraft CAUTION Use caution when preheating engine to avoid directing extremely hot air onto SCAT hoses cowling skins or other materials that may be damaged by heat Page 1 10 25 SM170SP A1 Jabiru J170 SP Section 1 Aircraft Service Manual General Description 1 15 Approved Fuels The recommended fuel for Jabiru S LSA aircraft is 100LL Approved fuels are
145. ings and Carry Through Structure Skin Check for deformation and obvious damage Check for cracks If damage is found check adjacent structure Check for indications of excessive flight loading Comments Access Panels Inspect for cracks proper fit and attachment Comments JSA 100HR A1 100 Hour Annual Inspection Checklist Page 13 of 17 Jabiru J230 SP J250 SP and J170 SP Aircraft Service Manual Control Cables Check aileron controls for smoothness and ease of operation Check aileron cable clamps for security and proper placement Check control cable ends for security alignment corrosion and binding Comments Ailerons Check control surfaces for proper clearance and freedom of movement Check hinges and hinge pins for security Check aileron skin and visible structure for cracks Comments Fuel Tanks Caps and Vents Inspect bottom of wing for evidence of fuel tank leakage Inspect vents for blockages Check filler caps for ease of operation Pass Fail Comments Plumbing Check for leakage chafing condition and security Pass Fail Comments Electrical Wiring and Equipment Inspect for chafing damage security and attachment Pass Fail Comments visible structure for cracks Flaps and Actuators Check for condition security binding or chafing of actuator rods Check flap skin and Pass F
146. internally coated with sealant There is one main tank in the root end of each wing and one header tank behind the passen ger seat The main tanks are an integral part of the wing structure and may not be re moved 8 2 2 Removal of Header Tank Level of Certification Required A amp P or LSA R M M 1 Shut off the Left and Right fuel valves located on the doorposts aft of the cabin doors 2 Drain the fuel out of the header tank into an approved container by following the procedure in Paragraph 8 8 3 Mark the fuel lines to avoid getting vent lines and fuel lines mixed up during reas sembly JSA SM170SP A1 Page 8 1 Section 8 Jabiru J170 SP Fuel System Aircraft Service Manual 4 Unbolt the header tank 5 When all fuel is drained from the header tank remove the hose clamps to discon nect the fuel and vent lines 8 2 3 Inspection 1 Inspect header tank for evidence of fuel leakage Inspect fuel lines and fittings for cracks 2 Check for fuel stains on the bottom of the wing near the inboard rib If stains are evident determine whether stains come from leaking fittings or from the tank itself 8 2 4 Repair 1 Repair of header tank is limited to replacement 2 Wing tanks can be resealed sloshed if a leak appears Contact the aircraft manu facturer for procedure and materials 8 2 5 Reinstallation Reverse steps in 8 2 2 for reinstallation of header tank Be sure to reconnect fuel and vent lines to the correct f
147. ion 5 Landing Gear for more information NOTE Rudder control cables are primary controls and may not be removed or repaired without reference to Jabiru USA Sport Aircraft LLC or our approved local agent Troubleshooting Have an assistant push the tail down until the nose wheel is off the ground Operate the rudder pedals Rudder amp steering should operate smoothly without mechanical in terference Isolate the cause of any interference The aircraft is rigged at the factory to fly hands off in level flight at 2850 RPM wings level with one 200 Ib pilot in the left seat If the aircraft sideslips or flies crooked in this configuration with equal amounts of fuel in each tank the rudder may be out of rig Inspect the rudder pedal springs for correct placement and or adjust the rudder control deflection as described in 6 7 7 Removal of Components 6 7 3 1 Rudder Control Surface Tools Required Screwdriver set 7 16 wrenches Level of Certification Required A amp P or LSA R M M For aircraft with three rudder hinge pins models 2008 and older 1 Unbolt push pull cable from rudder horn 2 Loosen screws in hinge pin retainers amp lift retainer from hinge pin It is not necessary to remove these parts 3 Remove hinge pins and remove rudder JSA SM170SP A1 Page 6 19 Section 6 Jabiru J170 SP Flight Controls Aircraft Service Manual For aircraft with a single hinge pin models 2009 and newer 1 push pu
148. ire 3 4 inflated or injury may result Avoid damaging wheel flanges when breaking beads loose as a scratch nick or gouge may cause wheel failure Completely deflate tire and break tire beads loose at wheel rim Refer to Figure 5 8 Nose Wheel Assembly Remove through bolts and separate wheel halves Remove wheel hub Remove tire and tube from wheel halves NOTE The bearings are press fit in the wheel hub and should not be removed unless a new part is to be installed 5 11 4 Nose Wheel Inspection and Repair 1 3 JSA SM170SP A1 Clean metal parts in mineral spirits and dry thoroughly NOTE Bearings are pre packed Avoid cleaning with solvents as they will remove the packing Inspect wheel halves for cracks Cracked wheel halves should be discarded and new parts used Sand out nicks gouges and corroded areas Clean thoroughly Inspect bearings for damage and discoloration Refit bearings or replace if necessary Page 5 21 Section 5 Jabiru 2170 5 Landing Gear and Brakes Aircraft Service Manual 5 11 5 Nose Wheel Reassembly Tools Required Phillips screwdriver 7 16 wrenches Level of Certification Required A amp P or LSA R M M 1 Ensure bearings are properly reinstalled in wheel hub 2 Apply automotive tire mounting lubricant to the tire bead faces on the inside of the wheel rims 3 Position tire and tube between wheel halves with tube inflation valve through hole in outside wheel ha
149. ires to get it out of the way for head torque or other maintenance To remove baffle entirely thread spark plug wires through the grommet hole and remove 7 4 3 Inspection and Cleaning Engine baffles should be cleaned with detergent and water or a suitable solvent mineral spirits to remove dirt and oil Inspect baffles for wear marks cracks splits or other damage 7 4 4 Repair 1 3 Rubber seals may be replaced by removing the existing rubber seals sanding back the bonding face of the fiberglass baffles to bare glass using 80 grit sandpaper or similar and bonding new rubber strips in place with 5 Minute epoxy Repair of cracks or tears can be made using the general fiberglass repair procedure outlined in Section 12 Replace defective parts if worn beyond reasonable repair 7 4 5 Reinstallation 1 JSA SM170SP A1 Reinstall the spark plug leads through the grommet in the aft portion of the baffle Slide the baffle forward along the spark plug leads Reinstall or check security of all spark plug leads Set the baffle down on top of the cylinder heads taking care to install the edge of the fiberglass without crossing over one or more cooling fins Reinstall spring and bolts Page 7 7 Jabiru 2170 5 Aircraft Service Manual Section 7 Engine Systems 1 76 oovf o02f 102 YaddN 7 guu N3AVI EO H1019 lavd 30 QN3 OL AWW 3802 30 ONJ NOUS lt 06 30 TNO
150. is observed during operation of trim or elevator 6 6 5 Repair Repair is limited to the replacement of defective parts As the trim control cable is a primary control it may not be repaired without reference to Jabiru USA Sport Aircraft LLC or our approved local agent for the appropriate repair procedure 6 6 6 Reinstallation Trim cable reinstallation requires a special procedure from the manufacturer There fore it may not be reinstalled without reference to Jabiru USA Sport Aircraft LLC or our approved local agent for the appropriate reinstallation procedure JSA SM170SP A1 Page 6 15 Jabiru J170 SP Aircraft Service Manual Section 6 Flight Controls LYT 18 086 62 1108 03 8 vid Figure 6 7 Trim Control Assembly 25 SM170SP A1 Page 6 16 SIHL 40 6 1 SLSSHS NMOHS SV 8 4355 Section 6 Flight Controls 00970027 ATEWASSVTOULNOD ozar exsevonne taav or uama ven Ald 30 INSSNOO LNOHUM 031902 IN SI ONI Jabiru J170 SP Aircraft Service Manual Side Figure 6 8 Trim Control Assembly Page 6 17 JSA SM170SP A1 Jabiru J170 SP Aircraft Service Manual Section 6 Flight Controls QLI Ald HO3LAV 40 LN3SNOO 031502 38 LON LSNW ONY LHORHAdOO ONIMVHO 7 3 8107 ON3d
151. it will reboot After reboot verify the power up page displays the new EFIS software ver sion 12 Repeat for the MFD OR load navigation database into the PFD as described below Update Navigation Database 1 2 Page 11 12 Repeat steps 4 6 above Use the right knob to move the cursor over Load Navigation Database and press the knob to activate Wait for the EFIS to detect the USB drive and download the files The EFIS may take up to one minute to detect the USB drive The light on the USB drive should blink faster when detected and when data is being copied The light will blink slower when the operation is complete When the EFIS has completed copying files from the USB drive the display unit will reboot After reboot verify the power up page displays the new EFIS software ver sion Repeat software and or nav database update for the MFD if installed 25 SM170SP A1 Jabiru J170 SP Section 11 Aircraft Service Manual Electrical System and Instruments 11 10 6 Magnetometer 11 10 6 1 Description The Grand Rapids Sport utilizes an external magnetometer to sense information about aircraft heading This information enables the Attitude Heading and Ref erence System AHRS to determine aircraft attitude and other data The mounting angle of the magnetometer unit and position within the aircraft are critical to the functionality of the unit It is mounted to a fiberglass pad on the co pilot s side of the fuselage behind th
152. ittings 8 3 Fuel and Vent Lines 8 3 1 Description The fuel and vent lines are made from 1 4 I D rubber hose and held in place with hose clamps There is a check valve in each vent line that allows air into each fuel tank The check valves are bleed valves which restrict some fuel from escaping out of the vent but allow for the release of air pressure inside the tanks therefore it is normal for small amounts of fuel to reach the fuel tank vents 8 3 2 Removal Level of Certification Required A amp P or LSA R M M Consult Jabiru USA Sport Aircraft LLC for any necessary removal of vent lines as they are built into the wing structure V WARNING Make sure all fuel is drained from system before remov ing fuel lines See Paragraph 8 8 for fuel draining in structions To remove or inspect fuel lines and check valves 1 Remove the top and bottom wing root fairings to access the fuel lines and check valves in the wing roots Page 8 2 JSA SM170SP A1 Jabiru J170 SP Section 8 Aircraft Service Manual Fuel System 2 Remove lines or valves as necessary by loosening hose clamps 8 3 3 Inspection 1 Remove the caps from the wing root check valves to avoid building pressure in the tanks Then blow air through the vent lines to make sure they are clear Replace the caps 2 Inspect the fuel lines for cracks or leaks 3 Inspect all three fuel valves for smooth operation and full fuel flow shutoff 8 3 4 Repair 1 Fuel line rep
153. k the wing slightly while pulling attaching bolt or carefully use a long drift punch to drive out attaching bolt 16 Carefully remove wing by moving it outward to clear the aileron cable from the fu selage 17 Place wing on cushioned structure to avoid damage to wing skin and strut attach ment 18 Unbolt lower wing strut bolt and remove wing strut 19 Repeat Steps 1 18 to remove other wing if necessary Inspection Inspect wing skin for cracks breaks or delamination Check closely around flap and aileron hinges for signs of stress Look for signs of leaking fuel from the wing fuel tank or tank fittings Repair The wing is a composite monocoque structure All damage involving a break delamina tion or deformation in the wing skin must be referred to Jabiru USA Sport Aircraft LLC or an approved local agent for an appropriate repair procedure Reinstallation Tools Required Screwdriver set 1 2 and 7 16 wrenches tall pad ded sawhorse or wing stand Level of Certification Required A amp P or LSA R M M V WARNING Do not tighten wing attach nuts or damage to wing at tach hardware may result Washer must be free to ro tate 1 Fit the lower strut attach bolt leaving the top end of the strut on the ground 2 Fit wing to fuselage leaving wing tip on the saw horse and routing aileron cable fuel lines and wiring through holes in fuselage wing root 3 Install front and rear wing attach bolts nuts 4 Puttop win
154. l Tools Required Phillips screwdriver Level of Certification Required Owner A amp P or LSA R M M Strut Mounted Recognition Light 1 Disconnect ground wire from aircraft battery 2 Remove 2 screws from sides of aluminum collar 3 Slide collar off 4 Remove and disconnect light bulb Strut Mounted Recognition Light Housing 1 Disconnect ground wire from aircraft battery 2 Remove 8 screw and nut from rear of housing 3 Slide housing off wing strut AeroLED Landing Light 1 Disconnect ground wire from aircraft battery 2 Remove 6 screws from clear Lexan lens 3 Remove 4 mounting screws from LED unit 4 Slide LED unit out 5 Disconnect wires 11 7 3 Repair Repair of landing and recognition light is limited to replacement of components 11 7 4 Reinstallation Reverse steps in 11 7 2 for reinstallation JSA SM170SP A1 Page 11 5 Section 11 Jabiru J170 SP Electrical System and Instruments Aircraft Service Manual 11 8 Pitot Static System 11 8 1 Description The pitot static system provides ram air and ambient air pressure for the Air Data Com puter within the EFIS the backup airspeed indicator and autopilot if installed The static vent is located on a probe mounted into the leading edge of the vertical sta bilizer One hole is drilled on each side of the probe just behind an aluminum bullet The bullet protects the static port from the relative wind and must be present for the static port to function The static li
155. l dipsticks are available through Jabiru USA Sport Aircraft LLC Gauge Reading Fuel Quantity 4 GREEN 8 17 gal 3 GREEN 6 8 gal 2 GREEN 4 6 gal 1 GREEN 2 4 gal RED Less than 2 gal 25 SM170SP A1 Jabiru J170 SP Section 8 Aircraft Service Manual Fuel System 8 7 2 Removal of Float Senders Level of Certification Required A amp P or LSA R M M 1 Drain fuel from fuel tank as described in Paragraph 8 8 2 Remove wing root fairings 3 Remove wing as described in Section 4 1 4 Remove the 4 screws that mount the sender in the tank 5 Remove sender 8 7 3 Inspection Inspection is limited to checking the float for pin holes or leaks 8 7 4 Repair Repair is limited to replacement of the float sender 8 7 5 Reinstallation 1 Prior to reinstallation clean all sealant from the mounting surfaces 2 Apply a small amount of Permatex 2 gasket sealant to the mating surface of the sender 3 Install the sender the wing 4 Install the four Z8 truss head machine screws with a small amount of Loctite 242 5 Reinstall wing and fairings as described in Section 4 JSA SM170SP A1 Page 8 7 Section 8 Jabiru J170 SP Fuel System Aircraft Service Manual 8 8 Fuel Draining Procedure From time to time it may be necessary to drain fuel from the aircraft for disassembly or inspection and repair of fuel system components Fuel should be drained from the wing tanks before the wings are removed for any reason Tools
156. ld down clamp or undo the Velcro strap as appropriate Remove unit 11 13 3 Inspection 1 2 3 Both models of ELT must be inspected according to FAR 91 207 d For inspection of Kannad 406 AF Compact refer to Installation Operation Man ual for Kannad 406 AF Compact DOCO6006E Initial battery replacement time line is found in the aircraft logbook and documents provided with the ELT DO NOT shock test Kannad ELT 11 13 4 Repair 1 2 3 Cable connections can be replaced with standard radio connection procedures Repair of batteries is limited to replacement Further repairs of ELT unit must be referred to ELT manufacturer 11 13 5 Reinstallation Reverse steps of Paragraph 11 13 2 for reinstallation Page 11 18 25 SM170SP A1 Section 11 Jabiru J170 SP Electrical System and Instruments Aircraft Service Manual 11 14 PS Engineering PM1000 Intercom 11 14 1 Description The 10001 is a four place mono intercom The PM1000II features an isolation circuit to enable the pilot to be the only one to hear and speak over the radio 11 14 2 Removal Tools Required 7 64 Allen key screwdriver set Level of Certification Required A amp P LSA R M M or Avionics Repair Station 1 Ensure the master switch is off 2 Remove the pilot and copilot knobs by gently pulling them 3 Remove the two small mounting screws from the front of the unit 4 Disconnect the 25 pin D sub plug from the rear of the unit
157. le 1 4 Torque Values 3 Tighten the two clamp bolts nuts See Table 1 4 Torque Values 4 Connect flexible brake line 5 Fill brake master cylinder with fresh brake fluid and bleed brakes see Paragraph 5 8 7 6 Lower aircraft to the ground 5 6 Main Wheel Stub Axle 5 6 1 Description The main stub axle Matco part number WHLA3A is a machined aluminum axle 1 25 inches in diameter It is designed to accept the Matco wheel amp brake system and fea tures machined bearing stops to ensure brake caliper alignment 5 6 2 Removal Tools Required Screwdriver set 7 16 1 2 and 9 16 wrenches Page 5 6 Level of Certification Required A amp P or LSA R M M JSA SM170SP A1 Jabiru J170 SP Section 5 Aircraft Service Manual Landing Gear and Brakes 1 Remove speed fairing if installed in accordance with Paragraph 5 3 2 2 Remove wheel in accordance with Paragraph 5 7 2 3 Note number and position of the wheel alignment shims if any between the axle flange and composite leg If shims are not epoxied in place mark them or tape them together carefully so that they can be installed in exactly the same position to ensure that wheel alignment is not disturbed 4 Remove 4 bolts nuts washers securing axle to main gear leg 5 6 3 Inspection 1 Check to see if axle is bent or cracked 2 Check for gouges or scratches in bearing seat areas 5 6 4 Repair Repair is limited to replacement with new part 5 6 5 Reinstallatio
158. lean dry flannel cloth See Section 2 for more information on cleaning and maintaining windows V CAUTION Silicon based waxes and polishes are not rec ommended as silicon may be absorbed into the glass fiber laminate around the windows and affect reparability due to impairing bonding 3 2 2 2 Scratches Scratches on clear plastic surfaces can be removed by buffing and polishing using plastic polish available from most aircraft supply companies 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 Page 3 1 Section 3 Jabiru J170 SP Fuselage Structure Aircraft Service Manual 3 2 3 3 2 4 3 2 5 Page 3 2 Window Crack Repair Tools Required 1 16 drill Level of Certification Required A amp P or LSA R M M 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 The procedure for repairing cracks is only recommended for low stress areas No re pairs of any kind are recommended on highly stressed or compound curved areas or where repair would b
159. lf 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 1 4 Torque Values V WARNING Ensure tube is not pinched between wheel halves dur ing assembly Uneven or improper torque of through bolt nuts can cause failure of bolts with resultant wheel failure 5 Inflate tire to seat the tire beads adjust to correct tire pressure Refer to Section 1 6 5 11 6 Nose Wheel Balancing Phillips screwdriver 7 16 wrenches Parts Required Wheel weights various sizes Level of Certification Required A amp P or LSA R M M Since uneven tire wear is usually the cause of tire imbalance replacing the tire will probably correct this condition Slight shimmy felt after takeoff is usually a result of tire imbalance If a wheel shows evidence of imbalance during service it may be statically balanced Page 5 22 25 SM170SP A1 Section 5 Landing Gear and Brakes SON wa suu 6 698 060 NOV 38 Vd SIHLIWITIIN NI 75 5 fo gt oc H D SWAN Led 5 6 a Figure 5 5 Nose Leg Assembly Page 5 23 JSA SM170SP A1 Section 5 Jabiru J170 SP Landing Gear and Brakes Aircraft Service Manual
160. limited to 10011 aviation gasoline or fresh automotive gasoline MOGAS of 93 octane and higher The Jabiru is a high compression engine which may be damaged by detonation of low octane or degraded fuel Jabiru has not tested and does not recommend use of any fuel additives including octane boost or stabilizers Use of ethanol or other alcohol based additives is prohibited in all Jabiru aircraft manu factured by Jabiru USA Sport Aircraft See Service Bulletin JSA 006 for more informa tion V WARNING Gasoline with an octane rating of less than 91 may cause engine damage due to detonation V WARNING Auto fuel degrades quickly with age Use of auto fuel more than 60 days old may damage engine and fuel system CAUTION Use of any unauthorized fuel additives will void the engine and aircraft warranty JSA SM170SP A1 Page 1 11 Section 1 Jabiru J170 SP General Description Aircraft Service Manual THIS PAGE INTENTIONALLY BLANK Page 1 12 25 SM170SP A1 Jabiru J170 SP Section 2 Aircraft Service Manual General Care amp Inspection Section 2 General Care amp Inspection 2 1 Ground Handling The Jabiru aircraft is very light and should always be moved by hand Press down lightly on the joint between the rear fuselage and the horizontal and vertical stabilizers to raise the nose wheel When the nose wheel is not touching the ground the aircraft may be pivoted on the main wheels and pushed in any direction Use the wing struts p
161. ll cable from rudder horn 2 Loosen hinge pin retainer screw on top of vertical fin beneath rudder coun terbalance 3 Remove hinge pin and remove rudder 6 7 3 2 Rudder Pedals Tools Required Screwdriver set 7 16 wrenches Level of Certification Re A amp P or LSA R M M quired 1 Unbolt push pull cable 2 Unbolt both steering push rods 3 Unbolt rudder pedal bearings 4 Remove cover plates and nylon bearings 5 Remove both pedal bars 6 Reverse the preceding steps for installation 6 7 4 Inspection of Components 6 7 4 1 Rudder Control Surface Inspect rudder for any signs of delamination cracking or warping Pay particu lar attention to the control horn and hinges and their surrounding areas In spect hinge pin anchor s and pushrod connections for security 6 7 4 2 Rudder Pedals 1 Inspect nylon bearings for wear Replace if worn 2 Inspect pedal bars for wear around bearing area and for distortion 3 Inspect pedals for distortion or loose rivets in end stops 4 Inspect bolt holes for wear and elongation 5 Inspect bolts and nuts for distortion and wear 6 7 4 3 Rudder Cables See Section 6 2 for inspection of control cables Page 6 20 25 SM170SP A1 Jabiru J170 SP Aircraft Service Manual Section 6 Flight Controls 6 7 5 Repair of Components 1 2 All damage involving cracking warping or delamination of the rudder control sur face or hinge damage must be referred to Jabiru USA Sport Aircr
162. ment frequently Page 3 4 JSA SM170SP A1 Jabiru J170 SP Aircraft Service Manual Fuselage Structure 3 3 Doors 3 3 1 Section 3 permanently bonded and visible from outside the aircraft when the installation is finished 11 Carefully drill holes for M4x12 countersunk mounting screws with dull drill or Per magrit 1 8 bit Holes should be 3 4 apart centered on the joggle Countersink holes so screw heads are slightly below surface 12 DO NOT over tighten screws cracking will result Tighten until snug only 13 See Section 12 4 for paint bodywork procedures to finish the repair Side Windows 1 Install side windows in the same manner as the windshield except that no screws will be driven through the plastic The simple clamps are screwed to the door frame alongside the window plastic to hold it in place while the epoxy cures 2 After epoxy cures see Section 12 4 for paint bodywork procedures to finish the repair Inspection of Finished Window Windscreen Installation 1 All clamps removed 2 Excess epoxy and flock removed from underneath clamped area and all window windscreen edges Windscreen screws countersunk below surface with no cracks 4 Window windscreen surfaces free of scratches cracks gouges and excess epoxy flock 5 See Section 12 4 for paint bodywork procedures to finish the repair Description Cabin doors are composed of a fiberglass sandwich skin bonded to a molded fiberglass frame o
163. ment in hub JSA 50HR A1 25 50 Hour Inspection Checklist Page 4 of 9 Jabiru J230 SP J250 SP and J170 SP Aircraft Service Manual Induction Air Filter Check for condition cleanliness and security Replace if necessary Induction System Check the SCAT hose for damage and wear Check the carburetor heat box for blockage security cracks operation and wear Cylinders Check cylinders and exhaust manifold for obvious leaks security and cracks Check cylinders for broken cooling fins and loose or missing base nuts Exhaust Check for deformation security cracks leaks loose or missing nuts springs and clamps Check for thin wall condition which may occur due to nromal internal erosion on stacks which have long service time Ignition System Clean inspect regap test and replace spark plugs as necessary Tighten spark plugs to proper torque Check condition and attachment of all ignition leads at plug and distributor Battery Inspect clean and tighten connections Check for security and proper attachment Check for corrosion Make certain battery is clean Water or dirt on battery surfaces can cause battery to discharge JSA 50HR A1 25 50 Hour Inspection Checklist Page 5 of 9 Jabiru J230 SP J250 SP and J170 SP Aircraft Service Manual Engine Controls and Linkages Check controls and associated equipment for condition attachment alignment and Check control operation JSA 50HR A1 25 50 Hour Inspection Checklist Pag
164. n 1 Secure axle and brake assembly to composite leg with the proper AN4 bolts mak ing sure that any wheel alignment shims are installed in their original position 2 Install wheel assembly on axle in accordance with Paragraph 5 7 7 5 6 6 Main Wheel Realignment Tools Required 7 16 wrenches Parts Required AN washers 5 min epoxy and cotton flock Level of Certification Required A amp P LSA R M M 1 Main wheel axles must be aligned for proper ground tracking Refer to Figure 5 3 2 Axles must be parallel with no toe in or toe out Positive camber is acceptable amount of camber is not critical to handling but may affect tire wear 3 Very small adjustments can be made by sanding the fiberglass gear leg as shown in Figure 5 3 Adjustments more than 1 32 must be accomplished using shims 4 Shim with AN 4 washers on bolts between gear leg and axle as necessary Epoxy and flock washers into place when proper alignment is established JSA SM170SP A1 Page 5 7 Section 5 Jabiru J170 SP Landing Gear and Brakes Aircraft Service Manual 5 7 Main Wheels and Brakes 5 7 1 5 7 2 Page 5 8 For more detailed information on Matco components refer to the Matco Mfg Technical Service Bulletin for MHE51 Series wheels and brakes which can be found on the Matco website A link to the website is located in the Appendix of this manual Description All Jabiru LSA aircraft utilize Matco MHE51J E series 5 aluminum alloy whe
165. n It is equipped with fixed tricycle landing gear The main gear is composite construction The steerable nose gear is a welded metal trailing link as sembly with rubber springs The aircraft is equipped with one Jabiru 4 cylinder 4 stroke engine driving a Sensen ich wooden fixed pitch propeller 1 2 Aircraft Specifications E S 3 i 3 Fuel Consumption 3 5 4 0 galons hour Cruise Table 1 1 J170 SP Specifications A Em U S U E JSA SM170SP A1 Page 1 1 Section 1 Jabiru J170 SP General Description Aircraft Service Manual 1 3 Three View Drawing Figure 1 1 Three View Drawing J170 SP dimensions in inches Page 1 2 JSA SM170SP A1 Jabiru J170 SP Section 1 Aircraft Service Manual General Description 1 4 Engine Specifications Jabiru Aircraft Pty Ltd Aero Engines Division 2200 Air Cooled Power t 81 hp 2950 RPM ta RE de 85 hp 3300 RPM Displacement istae tcn ted 2200 cc 134 cu in Rotation deas Clockwise when viewed from accessory case 1 5 Weight amp Balance Information The Jabiru J170 SP is a very light aircraft The installation of equipment may signifi cantly alter the center of gravity of the aircraft Therefore all proposed fixed instal lations must be approved by Jabiru USA Sport Aircraft LLC Refer to Section 2 of this manual for w
166. n Section 12 Replace damaged or worn cam locks and anchor lugs with new parts Repair is limited to replacement cam locks Rivets fixing cam lock anchor lugs must be backed with washers Reinstallation 1 Install the lower cowl before the upper Reverse the removal steps for reinstalla tion Do not fully tighten the lower cowl screws until after the top cowl has been installed V WARNING Ensure the cam locks are properly engaged before starting engine Cooling Air Baffles 7 4 1 Description The fiberglass baffles installed on top of the engine direct the cooling air flow to the cylinder heads and to other engine components to provide optimum engine cooling V Caution The baffles air inlets outlets and scoops are accurately posi tioned to maintain engine cooling efficiency Their removal or modification may cause improper air circulation and engine overheating 7 4 2 Removal Page 7 6 Tools Required 3 16 Allen key needle nose pliers rag or con tainer to catch oil Parts Required Level of Certification Required Owner A amp P or LSA R M M JSA SM170SP A1 Jabiru J170 SP Section 7 Aircraft Service Manual Engine Systems 1 prepared to catch oil that may leak from the valve covers when removing bolts 2 Remove the necessary valve cover bolts from the engine and the tension spring from the inboard side 3 Carefully lift the baffle off the cylinders 4 Move the baffle back along the spark plug w
167. n be removed only by drilling out the blind rivets 10 1 3 Inspection and Repair 1 2 JSA SM170SP A0 Check the SCAT for cracks or breaks Replace if damage found Check the aluminum muff for cracks or deformation Small cracks can be repaired by riveting a 025 aluminum patch over the crack Otherwise repair is limited to replacement Inspect the firewall mixer box for cracks or damage Replace mixer box if damage found Check push pull cable for smooth operation Replace cable if damage found or smooth operation cannot be achieved When heat muff is removed from muffler inspect muffler for cracks or signs of exhaust leaks WARNING Cracks in exhaust system underneath heat muff may lead to carbon monoxide poisoning See Section 7 18 for information on exhaust system inspection and re pair Page 10 1 Section 10 Utility Systems Jabiru J170 SP Aircraft Service Manual 10 1 4 Reinstallation Reverse steps in 10 1 2 for reinstallation 10 2 Cabin Ventilation 10 2 1 Description Cabin ventilation is provided through aluminum vents bolted to NACA inlets in the cabin side walls 10 2 2 Removal Tools Required Screwdriver set 11 32 wrench Level of Certification Required A amp P or LSA R M M 1 Remove the vents by unbolting them from the cabin side wall 10 2 3 Inspection and Repair 1 Check the vents for smooth operation and proper closure 2 Repair is limited to replacement 10 2 4 Reinstalla
168. n the interior side of the skin A simple spring bolt latch system is used as a door latch and a spring ball upper latch is used to secure the upper door frame Hinges are machined aluminum or molded fiberglass A hinge stop or nylon strap is used to prevent damage from doors opening too far 3 3 1 1 Cabin Door Latches There is one main latch on each door of a simple spring bolt type This is comple mented by a spring ball latch at the top front quadrant of each door An assembly drawing of the latch mechanism is provided in Figure 3 3 Door Latch Mechanism As sembly Door latches or their component parts must be replaced if worn or damaged 3 3 1 2 Locks A cylinder and key lock is installed at each door The keyed barrel lock is located in the fuselage at the rear of the left and right cabin doors Spare keys are available to Jabiru registered owners by quoting the aircraft serial number JSA SM170SP A1 Page 3 5 Jabiru J170 SP Aircraft Service Manual Section 3 Fuselage Structure 091 SY ASSY 1 1 76 982 0 0 Figure 3 3 Door Latch Assembly JSA SM170SP A1 Page 3 6 Section 3 Fuselage Structure al 5 0 gt 5 gt 34 6 ay 1 DIMENSIONS loo NOT SCALE SP 1 IN MILLIMETRES DO NOT SCALE AVTECH P L D 05 0 A C N 010 786 973
169. nding Gear and Brakes 5 1 General 00040 a nnne 5 1 5 2 Landing Gear Troubleshooting 5 1 5 3 Main Wheel 5 2 5 4 Main Gear Top Fairing Lower Strut 5 4 5 5 Main Gear Leg Assembly 5 4 5 6 Main Wheel Stub re t pede eee dn 5 6 5 7 Main Wheels and nennen 5 8 5 8 Master Cylinder Parking Brake 5 14 Page 2 JSA SM170SP A1 Jabiru J170 SP Aircraft Service Manual Section Title Section 6 Flight Controls Section 7 Engine Systems JSA SM170SP A1 Page 5 9 Nose Wheel nennen 5 19 5 10 Nose Gear a eH RC et ttu ede Cue t 5 19 5 11 Nose Wheel ine dte e diae die e ena 5 21 6 1 Control Column ode Lee ee depen ve e De ec eu 6 1 6 2 Control Cables e ee ee Mint oa te eet eds 6 1 6 3 Aileron Control 5 6 3 6 4 Wing Flap Control 6 6 6 5 Elevator Control System sse nennen nnne 6 11 6 6 Elevator Trim Control 0010 6 15 6 7 Rudder Control 5 6 19 7 1
170. ne is safety wired and glued to the back of the probe and runs down through the vertical fin through the fiberglass tunnel on the inside of the lower fuselage skin through the center console and into the instrument panel A splice is built into the line just below the vertical stabilizer If necessary the static line may be drained of water by disconnecting it from the splice under the instrument panel and blowing through it with compressed air The pitot tube is mounted to the right wing strut The forward portion of the tube is mounted on flexible tubing to prevent damage to the tube and injury to people who bump into it The aft portion of the tube is welded to a bracket that is pop riveted to the wing strut The pitot line runs through the lower half of the strut into the belly of the fuselage in front of the main gear legs up through the center console and into the instrument panel The line is concealed by the lower wing strut fairing 11 8 2 Removal and Repair Tools Required 3 16 drill wire cutter safety wire pliers Parts required Superglue 032 safety wire Level of Certification Required A amp P or LSA R M M The static probe is bonded permanently to the vertical stabilizer Contact Jabiru USA Sport Aircraft LLC for instructions on removal or repair of the static probe and line within the vertical stabilizer structure Repair of pitot static lines and probes is limited to replacement If replacing pitot or static lines att
171. nent 7 18 5 Reinstallation 1 Reverse the steps in 7 16 2 for installation 2 If reinstalling the exhaust manifold pipes install bolts hand tight to allow wiggle room until the muffler is in place then tighten them the rest of the way 3 Run engine until it reaches normal operating temperature Shut it down and while it is still warm torque exhaust manifold bolts to final torque value See Instruction amp Maintenance Manual for Jabiru 2200 Aircraft Engine for specific torque values Page 7 28 JSA SM170SP A1 Jabiru J170 SP Aircraft Service Manual Section 7 Engine Systems 7 19 Head Bolt Tension Check Head Torque Procedure 7 19 1 Description All Jabiru engines require periodic check of head bolt tension to maintain a proper seal between the heads and the cylinders New engines require a head bolt tension check at each 5 hour interval for the first 15 hours of operation then again at 25 hours After the 25 hour inspection Jabiru USA Sport Aircraft LLC recommends that head bolts are torqued to 20 ft lbs every 50 hours usually during the 50 hour inspection NOTE Engine must be at room temperature or colder to achieve proper head bolt ten sion 7 19 2 Procedure Calibrated torque wrench with 4 long 1 4 hex driver and 1 2 deep well socket 3 16 Allen key screwdriver set Level of Certification Required A amp P LSA R M Owner Operators of S LSA aircraft that hold at least a Sport Pilot or Private Pilot Cer
172. nitial break in period Oil additives of any type are NOT recommended for use in Jabiru aircraft engines CAUTION DO NOT USE oil or additives containing LinKite as this will dam age the engine and void the engine warranty oil Sump Capacity eR eee tede 2 2 US Quarts 1 11 Recommended Fastener Torque Values Torque inch Ib 20 25 2 ft b 50 70 4 5 1 5 100 140 8 12 ft b ANS Propeller 180 228 17 19 ft b Table 1 4 Torque Values A These values relate only to steel nuts on oil free cadmium plated threads B For Engine Bolt Torque Values see Engine Instruction amp Maintenance Manual C Except where other values are specified the above values are recommended for all installation procedures contained in this manual 1 12 General Safety Information Safety information will be maintained by Jabiru USA Sport Aircraft LLC and will be made available to interested parties 1 13 Reporting Safety of Flight or Service Difficulties Report any maintenance difficulty or safety of flight concerns to Jabiru USA Sport Air craft LLC on form JSA501 Malfunction or Defect Report found in the Appendix of this manual The form may be downloaded online at www usjabiru com in the LSA Owners Info section JSA SM170SP A1 Page 1 9 Section 1 Jabiru J170 SP General Description Aircraft Service Manual 1 14 Extreme Climatic Conditions A Dust inducted into the carburetor air intake system is probably the greatest s
173. nual 3 Approved push pull points Do not push or pull on propeller tips Figure 2 1 Approved Push Pull Areas J170 J230 and J250 Page 2 2 JSA SM170SP A2 Jabiru J170 SP Section 2 Aircraft Service Manual General Care amp Inspection 2 2 Jacking the Aircraft The easiest way to jack the aircraft for access to the main wheels is to lift up on the wing spar just outboard of the wing strut attach point NOT at the wing tip The pro cedure used at Jabiru USA is as follows 1 Empty the aircraft of excess cargo to make the lift easier Shut off fuel valves to avoid fuel cross feeding out of the wing to be jacked Find an engine hoist with enough height to raise the wing a few inches Make a flat lifting platform to fit securely to the tip of the hoist arm The platform used at JSA is made from 3 4 plywood and straddles the top of the hoist arm as shown in Figure 2 2 The platform should be wide enough to distribute the weight of the aircraft across about 2 square feet of wing surface Pad the platform with a folded shipping blanket piece of carpet or other soft mate rial Place the hoist into position under the wing tip and raise it so the platform lifts the wing underneath the spar just outboard of the wing strut attach point The hoist needs to point toward the fuselage as shown in Figure 2 3 so the platform can remain squarely under the wing and pivot with the wing undersurface as it tilts up ward
174. nual Ignition switch Rotate the ignition switch through the OFF position to the extreme limit of switch travel If the engine stops firing the switch is normal If the engine continues to run with the switch held in the past OFF position it is an indication that the magneto is still hot or ungrounded When the switch is released from the past OFF position it should automatically return to normal OFF and the engine should stop running However any ignition switch exhibiting this abnormal condition should be replaced Pass Fail Comments Engine Controls With the engine running check for proper operational limits engine response and rigging Check friction locks for proper operation Pass Fail Comments Fuel Quantity Gauges Check for proper operation and unusual fluctuation Pass Fail Comments Auxilliary Fuel Pump Check for proper operation unusual noise and fluctuations Pass Fail Comments Fuel Tank Selector Valves Check for smooth operation and proper placarding Pass Fail Comments AII Lights Check function condition attachment cracked or broken lenses Check switches knobs and circuit breakers for looseness and operation Pass Fail Comments Stall Warning System Check for proper operation Pass Fail Comments Radio Operation Check for proper operation
175. nual Landing Gear and Brakes 5 7 3 Wheel Inspection 1 2 Clean all metal parts in solvent and dry thoroughly Inspect wheel halves for cracks Cracked wheel halves should be discarded and new parts used Sand out nicks gouges and corroded areas Carefully inspect bearings for damage and discoloration Repack bearings as needed NOTE Bearing cleaning solvents will remove the pack ing grease therefore bearings must be repacked after cleaning 5 7 4 Brake Inspection 1 2 Check assembly and fittings for evidence of leaks Check safety wire and security of caliper bolts Look for the half moon shaped wear mark on the fore and aft faces of the brake pads If the mark is not visible the pads are worn beyond service limits and must be replaced Check disks for wear grooves deep scratches pitting or coning Isolated grooves up to 0 030 inch deep are acceptable but any grooving will reduce service life of the pads Coning beyond 0 015 in in either direction requires disk replacement Minimum serviceable disk thickness is 0 167 inches Excessive rust not removable by normal braking should be cleaned using a wire brush followed by 220 grit sandpaper Take care not to remove plating from areas not contacted by brake pads 5 7 5 Replacement of Brake Pads Contact Matco Mfg for replacement brake shoes with pads already installed for a fast replacement Follow instructions below to replace the pads linings on the existing
176. nual or the most current revision of applicable Jabiru engine manuals or task specific repair procedures issued by Jabiru USA Sport Aircraft all work completed on Jabiru S LSA aircraft must follow the standard practices of aviation maintenance alteration and repair as defined in FAA Ad visory Circular AC 43 13 2B or if applicable its latest revision Following performance of any task outlined in this manual the repairman or mechanic must check their work against the published standard practices Tasks that involve spe cialized work not discussed in AC 43 13 2B have detailed test and inspection procedures in the task description presented in this manual 2 12 2 Definition of Line and Heavy Maintenance Each Task in this manual is given a Level of Maintenance of either Line or Heavy Items defined as Line Maintenance are generally tasks that any licensed and competent LSA Repairman with either an Inspection E LSA owners only or Maintenance rating can perform using the guidance in this manual and the standard aviation maintenance prac tices defined in 2 12 1 Any A amp P mechanic should also be able to perform Line tasks which generally do not require specialized knowledge or equipment to perform Tasks defined as Heavy Maintenance are those which require expert knowledge or ex perience with Jabiru airframes or engines or in the case of structural repairs advanced composite repair experience Please consult Jabiru USA technicians with any
177. ny rough areas 13 Refer to Paragraph 12 4 for prep and paint instructions 14 Remove peel ply Carefully sand any rough areas 15 Refer to Paragraph 12 4 for prep and paint instructions 12 3 2 Interior Fuselage Crack Repair 1 10 11 12 13 14 Remove any carpet from the area affected at least six inches in all directions If the carpet is difficult to remove acetone may be used to dissolve the contact cement Sand all carpet glue residue from the affected area at least three inches in all direc tions Do not sand into the fiberglass structure Cut three pieces of AF303 on a bias to cover the affected area by two inches in all directions Mix an amount of 24 hour epoxy sufficient to wet out the fiberglass cloth Using a small paint brush apply a thin coat of 24 hour epoxy on the affected area of the fuselage Lay the first piece of cloth on the area Finish wetting out the first piece of fiberglass cloth with a generous amount of epoxy Lay the second piece of fiberglass cloth over the first on a bias Using the paint brush press the second piece of fiberglass into the first Soak the second layer in the excess epoxy from the first layer If there are any dry spots in the second layer add the amount needed to fully wet the cloth Applying too much is ok Apply the third piece of fiberglass on a bias Press it into the second piece using the paint brush Soak the third layer in the excess from the s
178. o available from Jabiru USA and recommended for outdoor tie down 2 8 1 Placing Aircraft in Flyable Storage Page 2 8 Flyable storage is defined as a maximum of 30 days non operational storage 1 Ensure that the engine has been stopped by turning off the fuel valve and running the engine until it quits to remove the fuel from the carburetor bowl Remember to turn OFF the Master and Ignition switches Every 7th day the propeller should be rotated through 5 revolutions without run ning the engine Leave the propeller in the horizontal position to ensure even dis tribution of moisture in the wood If left in the vertical position moisture will drain to the lower tip resulting in an unbalanced propeller In ideal conditions the aircraft should be stored away from direct sunlight At a minimum the cabin area should be covered with a cotton lined canvas cover Fitted J170 covers are available through Jabiru USA Sport Aircraft LLC DO NOT use a tarp or unlined canvas cover as these may scratch the windows In addition the pitot tube static vent air vents openings in the engine cowl and other similar openings should have protective covers fitted to prevent entry of wa ter foreign materials and insects especially wasps Cover fuel vents for protection but do not seal completely as the system must be allowed to breathe Cowl plug and cover sets are available through Jabiru USA Sport Aircraft LLC JSA SM170SP A2 Jabiru J170 S
179. of the stabilizer skin for cracks or delamination and inspection of the vertical spar for cracking or delamination or other damage 3 9 4 Repair All damage involving a break or deformation in the skin or damage to the spar or ribs must be referred to JABIRU USA SPORT AIRCRAFT LLC for an appropriate repair proce dure Repair must be made before the next flight JSA SM170SP A1 Page 3 13 Section 3 Jabiru J170 SP Fuselage Structure Aircraft Service Manual THIS PAGE INTENTIONALLY BLANK Page 3 14 JSA SM170SP A1 Jabiru J170 SP Section 4 Aircraft Service Manual Wing Structure Section 4 Wing Structure 4 1 Wings 4 1 1 Description Each composite wing is a semi cantilever monocoque type with a main spar The wing is a molded structure with a series of ribs that are bonded through the molding process to the fiberglass skin fuel tanks and to the spar The forward wing attachment is an extension of the forward sub spar The rear at tachment is a composite block heavily bonded to the reinforced wing skin and at taches to the main spar through the Wing End Plug Both attachments are through stainless steel threaded bushings bonded into the attachment blocks 4 1 2 Removal Tools Required Screwdriver set 1 2 and 7 16 wrenches tall pad ded sawhorse or wing stand Level of Certification Required A amp P or LSA R M M The Jabiru aircraft is designed with wings that are removable for storage or transport Wing removal is most easily ac
180. on Reverse steps in Paragraph 11 10 8 2 for reinstallation JSA SM170SP A1 Page 11 15 Section 11 Jabiru J170 SP Electrical System and Instruments Aircraft Service Manual 11 11 Garmin Nav Com Radio 11 11 1 Description Each Jabiru S LSA aircraft is equipped with one Garmin communications radio either an SL 40 com only or SL 30 with built in VOR navigation capability The radio antenna is attached to the aft face of the vertical stabilizer spar See Section 11 11 6 for information on the antenna For specific technical information about the radios refer to the Garmin website or con tact information located in the Appendix of this manual NOTE The WxWorx XM weather module may cause random intermittent radio static on isolated frequencies in the SL30 or SL40 To troubleshoot pull the WX circuit breaker or disconnect power from the WxWorx module and see if the static disappears A WxWorx hardware upgrade is available to fix this problem Contact Grand Rapids Technologies for more information 11 11 2 Removal Tools Required 7 64 Allen key screwdriver set Parts required Level of Maintenance Line Level of Certification Required A amp P LSA R M M or Avionics Repair Station 1 Using the 7 64 Allen key loosen the retaining screw through the radio face 2 Turn counterclockwise until it stops 3 Pull radio from tray 11 11 3 Inspection 1 Check pin connections at rear of radio for damage 2 Inspect tray for bent pins o
181. on and security Inspect blades for cracks dents nicks scratches erosion delamination in the case of fiberglass sheathed propellers security and movement in hub Comments 100 Hour Annual Inspection Checklist Page 6 of 17 Jabiru J230 SP J250 SP and J170 SP Aircraft Service Manual Spinner Propeller Tracking Check that propeller blade and spinner tracking is in alignment Pass Fail Comments Propeller Hub Flange Check for cracks and condition Pass Fail Comments Leak Check Check for oil fuel and induction leaks then clean entire engine and compartment before inspection Pass Fail Comments Flywheel Screw Tension Check 24 ft lbs Pass Fail Comments Induction Air Filter Check for condition cleanliness and security Replace if necessary Pass Fail Comments Induction System Check the SCAT hose for damage and wear Check the carburetor heat box for blockage security cracks operation and wear Pass Fail Comments Cooling Baffles Check for cracks worn areas and security Pass Fail Comments Cylinders Check cylinders and exhaust manifold for obvious leaks security and cracks Check cylinders for broken cooling fins and loose or missing base nuts Pass Fail Comments JSA 100HR A1 100 Hour Annual Inspection Checklist J
182. oosen the retaining screw through the transponder face 2 Turn counterclockwise until screw stops turning 3 Pull transponder from tray 11 12 3 Inspection 1 Check pin connections at rear of transponder for damage 2 Inspect tray for bent pins or loose connections 3 Inspect antenna coax for damage 4 The transponder must be tested as required by FAR 91 413 11 12 4 Repair 1 Repair of bent pins can be made by standard radio repair procedures 2 Repair of the transponder itself is limited to sending it to an approved repair center 11 12 5 Reinstallation Reverse the steps in Paragraph 11 12 2 for reinstallation JSA SM170SP A1 Page 11 17 Section 11 Jabiru J170 SP Electrical System and Instruments Aircraft Service Manual 11 13 Emergency Locator Transmitter 11 13 1 Description All Jabiru S LSA aircraft are equipped with an Emergency Locator Transmitter The unit is located on the floor of the fuselage behind the baggage area A remote switch is located in the instrument panel for testing the unit Aircraft built prior to 2009 are equipped with an AK 450 VHF radio based ELT Aircraft built in 2009 and newer are equipped with a Kannad AF Compact 406 MHz satellite based ELT 11 13 2 Removal Tools Required 7 64 Allen key Level of Certification Required A amp P LSA R M M or Avionics Repair Station 4 5 Turn off the ELT Disconnect remote cable Disconnect antenna coax cable Loosen ho
183. orn sound at a faster airspeed lower angle of attack Bending it downward will make it sound at a slower airspeed higher angle of attack 1 Fly the aircraft to a safe altitude and enter slow flight Note the speed at which the stall horn sounds 2 Bend the plate up or down as necessary to adjust the warning speed angle of at tack Page 10 4 25 5 1705 0 Section 10 Utility Systems Jabiru J170 SP Aircraft Service Manual pW 30 1934 9838VONn8 Z Al 531835 ASSY TIYIS 18088 46 984 010 NOV 03395 SNINNVM TIYIS 15 01 UBLV1 38 AVA 39Nv13 Q3NInO38 31 Wy OL 39 13 ONIM 30 3 3 32 OL 406 JANV TVIS 804 319NV L1nv33d 6 31 25 NOILO3S NIMS 33110 38 OL 3Z0W9 AXOd3 6 100103 OLNI 13315 SS3INIVIS ONOG 3903 03395 3598 01 QN38 Q33dS N3MO OL NMOG N38 14 9NION38 A8 013345 TVIS SNNL AXOd3 NIN S 170115 OINI 39NV1J4 wee TANNA NINYYM TIVLS 910080 s s qo 015 96190 325 OQ SNOISN3AIQ 031 130 SV 1004 5121 3HIN39 50 OL ISN NDIS NYHL 6l X 21 102 Ald HO3IAV 30 IN3SNOO LINOHLIM 031402 38 LON LSAW 402 SI ONIMVSO SIHL System ing
184. ose nutplates Check that clearance between wheel and pant is at least 1 2 inch Check security of inboard and outboard mounting brackets Check that outboard main wheel pant brackets are updated and installed as per Service Bulletin JSA 004 1 Wheel Pant Bracket Replacement Repair Tools Required 220 grit aluminum oxide sandpaper basic ep oxy mixing supplies fiberglass cutter Parts Required 9 oz fiberglass cloth 24 hr Aeropoxy or equiv Level of Certification Required A amp P LSA R M M Field repair of wheel fairings is authorized 1 Sand off the paint and gel coat 2 inches each side of the crack or tear with 220 grit aluminum oxide sandpaper 2 Overlay with two layers of 9 oz fiberglass cloth and wet out with 24 hour epoxy Allow to cure 3 Fill and sand until smooth See Section 12 4 for body filler information JSA SM170SP A1 Section 5 Landing Gear and Brakes Jabiru J170 SP Aircraft Service Manual 60050298 6 091 007 ASSY NOISNAdSNS eoj s a 9604808 00 002 0371 NIVN zOvOc9 2 Figure 5 1 Main Landing Gear Assembly Page 5 3 JSA SM170SP A1 Section 5 Jabiru J170 SP Landing Gear and Brakes Aircraft Service Manual 4 Repaint See Section 12 4 for paint details Jabiru USA Sport Aircraft LLC will re paint damaged wheel pants upon reques
185. ownload in PDF format http www sensenichprop com sen_html aircraft_cet install cf a pdf Wheels and Brakes Matco Manufacturing 2361 South 1560 West Woods Cross UT 84087 Phone 801 335 0582 Fax 801 335 0581 www matcomfg com MHE51 Technical Manual available for free download in PDF format http www matcomfg com TechnicalManualsServiceBulletins tp2 23 html JSA 5 1705 0 Vendor Information Page 1 of 4 Jabiru J170 SP Appendix Aircraft Service Manual Electronic Flight Information System EFIS and Engine Information Sys tem EIS Grand Rapids Technologies Inc 3133 Madison Ave Wyoming MI 49548 1211 Phone 616 245 7700 Fax 616 245 7707 Free user manuals available for download in PDF format http www grtavionics com XM Weather WxWorx receiver provided and supported by Grand Rapids Technologies Inc Free manual available in PDF format for download http www grtavionics com default aspx id 4 Radio and Transponder Garmin Aviation Support USA Phone 913 397 8200 USA Toll Free 1 866 739 5687 Canada 1 866 429 9296 http www garmin com Free user manuals are available for download in PDF format http www8 garmin com support userManual jsp Intercom PS ENGINEERING Inc 9800 Martel Rd Lenoir City TN 37772 Technical Support 865 988 9800 Fax 865 988 6619 E Mail contact ps engineering com http www ps engineering com Free user manuals available for download in PDF form
186. pump is located at the end of the cam shaft Oil is pumped out the side of the crankcase through an oil cooler adapter and oil cooler radiator and then through the oil filter Oil is then fed under pressure to the interior of the engine and returns to a wet sump at the bottom of the engine Oil pressure is monitored just before the oil leaves the crankcase on the way to the cooler Oil temperature is measured in the sump A pressure regulating valve is under the oil cooler adapter 25 SM170SP A1 Jabiru J170 SP Section 7 Aircraft Service Manual Engine Systems 7 7 2 Oil and Oil Filter Change Tools Required Phillips screwdriver oil filter wrench oil collec tion pan of at least 1 gal capacity 5 6 Parts Required 3 quarts oil and new filter see Section 1 9 Level of Certification Required Owner A amp P or LSA R M M If possible run engine until oil is up to normal operating temperature Remove upper and lower engine cowl as described in Section 7 3 Open quick drain valve if installed in bottom of oil sump and let oil drain If no quick drain valve is installed remove plug Empty oil breather vent collector bottle as described in Section 7 9 Remove left side cooling baffle as described in Section 7 4 Using the oil filter wrench turn the filter counter clockwise to remove the oil filter Oil Filter Inspection optional Using an oil filter cutter open the filter can and remove the filter paper Carefully wash
187. questions before attempting any tasks defined as Heavy Maintenance Items listed as Task Specific require an A amp P mechanic who has attended a Jabiru USA engine maintenance seminar OR has extensive prior experience rebuilding Jabiru en gines Owners with mechanics who are not adequately trained or experienced may visit the Jabiru USA website to find Jabiru Service Centers approved to perform such mainte nance Jabiru USA offers a full service heavy maintenance facility in Shelbyville Ten nessee for such cases 2 12 3 Major Repairs and Alterations of Jabiru LSA Aircraft Major repairs and alterations are defined as any repair addition or removal of equip ment or modification not specifically outlined in this manual In the interest of safety no major repairs or alterations shall be performed on Jabiru J250 SP J230 SP or J170 SP Special Light Sport Aircraft without prior consultation and written approval of Jabiru USA Sport Aircraft LLC Owners of S LSA aircraft with unauthorized major repairs and alterations risk loss of their Airworthiness Certifi cate When major repairs or alterations are required contact Jabiru USA at the contact infor mation provided in Section 1 8 of this manual Jabiru technicians will create and provide a detailed repair procedure specific to the aircraft in question usually at no cost to the owner or mechanic This procedure will also include instructions for proving post repair ASTM compliance if necess
188. r Section 12 Fiberglass Repair 12 1 Description Structural repairs beyond those described in this manual are not authorized without the consent of the manufacturer Jabiru USA will provide specific or expanded proce dures for any structural repair after receipt of full details of the extent of the dam age Non structural repairs as described in 12 2 are authorized if completed accord ing to the procedures in this section 12 2 General Non Structural Fiberglass Repair JSA 5 1705 0 Tools Required 220 grit aluminum oxide sandpaper NOT silicon based epoxy brush mixing cups stir sticks Parts Required 9 2 fiberglass cloth System 2000 epoxy Aero poxy or other aircraft laminating epoxy Level of Certification Required A amp P or LSA R M M Most non structural fiberglass is in wing tips horizontal stabilizer end caps cowls fairings or wheel pants These parts are generally made from three layers of 9 oz fiberglass or from a sandwich of two layers glass one layer of Cormat and another two layers of glass Repair of breaks delaminations or tears can easily be made by applying fiberglass cloth to one or both sides of the damaged area The epoxy used in Jabiru aircraft manufacture is System 2000 from Fiberglast Devel opments Inc System 2000 is the preferred repair epoxy Other laminating epoxy resins can be used if they have similar properties Procedure 1 Remove paint and gel coat from the damaged area extend
189. r loose connections 3 Inspect antenna coax for damage 11 11 4 Repair 1 Repair of bent pins can be made by standard radio repair procedures 2 Repair of the radio itself is limited to sending the radio to an approved repair cen ter 11 11 5 Reinstallation Reverse steps in Paragraph 11 11 2 for reinstallation Page 11 16 25 SM170SP A1 Jabiru J170 SP Section 11 Aircraft Service Manual Electrical System and Instruments 11 12 Garmin Transponder 11 12 1 Description Both Garmin transponder options the GTX327 and GTX330 are capable of Mode C altitude encoding The GTX330 is also capable of Mode S communication which enables traffic information to be displayed on the EFIS within airspace supported by Traffic In formation Service TIS Transponders in aircraft equipped with at least one GRT EFIS get their altitude informa tion from the EFIS and do not need a separate altitude encoder for the transponder If the aircraft is not equipped with a GRT EFIS or GDU 375 the encoder box is located under the panel and is plumbed into the aircraft s static system 11 12 2 Removal Tools Required Electrical pliers screwdriver set heat gun tools required for rudder removal Section 6 7 Parts required 20 ferrite single hole baluns 1 double hole ferrite balun 2 ring terminals 14 of 1 2 dia heat shrink tubing Level of Certification Required A amp P LSA R M M or Avionics Repair Station 1 Using the 7 64 Allen key l
190. r on the propeller hub Page 9 4 JSA SM170SP A1 Jabiru J170 SP Section 9 Aircraft Service Manual Propeller amp Spinner SEQUENCE FOR TIGHTENING PROPELLER BOLTS 1 4 6 3 5 2 DETAIL BELLEVILLE WASHER ASSY 3 5 4 8 5 2 22 SEE DETAR SECTION AA 4 OG Figure 9 1 Prop Mount Detail Note Spinner mount screw 4 in diagram has been replaced with 8 truss head machine screw Washer 3 in diagram has been replaced with one flat Nylon washer JSA SM170SP A1 Page 9 5 Section 9 Jabiru 2170 5 Propeller amp Spinner Aircraft Service Manual 9 7 Propeller Bolt Tension Check 9 7 1 Description 9 7 2 Page 9 6 Because of natural expansion and contraction due to normal use and environmental conditions the hub bolt tension of wood propellers MUST be periodically checked ac cording to the propeller manufacturer s timetable which is outlined in this paragraph For detailed information regarding torque procedure and propeller maintenance refer to Section 9 8 and Sensenich Propeller Co Wood Propeller Installation Operation and Maintenance Guide Doc WOOD CF REVC A doc in the Appendix of this manual Check the Sensenich website www sensenichprop com for the latest revision of wood propeller installation and maintenance instructions Sensenich Required Propeller Bolt Torque Schedule 1 After First Flight After the first flight using a new propeller recheck the bolt torque
191. raft Service Manual JSA 5 1705 on E LSA aircraft that they own and make the logbook endorsement for return to service as specified by FAR 43 9 25 SM230SP 0 Page 1 of 1 THIS PAGE INTENTIONALLY BLANK Jabiru J230 SP J250 SP and J170 SP Aircraft Service Manual 25 and 50 Hour Inspection Guide For Jabiru 2170 3230 and 2250 Models The 25 hour service and inspection is done only one time at the end of the engine break in period at 25 hours total time The break in oil and filter must be removed and replaced head bolts torqued to proper tension cold engine and a general inspection logged At each 50 hour interval after the initial 25 hour inspection the oil must be changed and the 50 hour inspection must be completed and logged Owner Operators of S LSA aircraft that hold at least a Sport Pilot or Private Pilot Certificate may perform maintenance items listed in FAR Part 43 Appendix A Maintenance Preventive Maintenance Rebuilding and Alteration Section C Owner operators performing preventive maintenance must return the aircraft to service by endorsing the aircraft or engine logbook as specified in FAR 43 9 All other S LSA maintenance tasks must be performed by an A amp P LSA Repairman with Maintenance Rating or FAA certified repair station Owner operators of E LSA aircraft that hold a minimum maintenance certification of LSA Repairman with Inspection Rating are authorized under FAR 43 1 b 2 to perform maintenance as pe
192. re assembly see Table 1 4 Torque Values Inspect steering rod connections and rudder springs for security and condition Re placed if bent sprung or otherwise damaged Check for bending or deformation of nose leg housing assembly Check Delrin bushes for wear or breakage Repair of nose leg housing is limited to straightening or replacement of aluminum brackets and replacement of Delrin bushes 5 10 4 Reinstallation 1 Reverse the steps in Paragraph 5 10 2 for reinstallation 2 When replacing Delrin bushings install with a mixture of epoxy and cotton flock Page 5 20 and bed in place 25 SM170SP A1 Jabiru J170 SP Section 5 Aircraft Service Manual Landing Gear and Brakes 5 11 Nose Wheel 5 11 1 Description The nose wheel is a Jabiru cast aluminum wheel with sealed bearings The wheel is in two halves which are joined by through bolts to the wheel hub as shown in Figure 5 8 Nose Wheel Assembly 5 11 2 Removal and Installation Tools Required Phillips screwdriver 7 16 wrenches Level of Certification Required A amp P or LSA R M M 1 2 3 4 Weight down tail of aircraft to raise the nose wheel off the floor as described in Section 2 Remove wheel fairing and axle bolt as described in Section 5 9 Pull nose wheel from yoke Take note of position of spacers Reverse the preceding steps to install nose wheel 5 11 3 Disassembly V WARNING Do not attempt to separate wheel halves with the t
193. re fitted with fireproof sleeves If removed the sleeves must be reinstalled before aircraft is returned to service Cabin heat amp ventilation 2 Aeroduct SCAT hose Carburetor induction hoses 2 1 4 Aeroduct SCAT hose Fuel lines 1 4 1 2 50 PSI Firesleeve 1 2 ID fiberglass Oil breather line 1 2 ID marine fuel line or automotive heater hose Fuel pump overflow line General purpose clear PVC tubing 3 16 ID 3 8 OD 3 32 wall Table 7 1 Replacement Flexible Hoses 7 13 Throttle Control 7 13 1 Description A stiff stranded wire throttle cable is attached from carb throttle arm to a cross rod supported in acetal blocks attached to the cabin side of the firewall Control input is fed to the cross rod from a knob and push pull rod through the panel face Page 7 22 JSA SM170SP A1 Jabiru J170 SP Section 7 Aircraft Service Manual Engine Systems 7 13 2 Removal Tools Required Screwdriver set 7 16 3 8 wrenches Level of Certification Required A amp P or LSA R M M For aircraft built in 2008 or older 1 Disconnect throttle cable from carb and from throttle cross rod 2 Remove the bolts through the firewall that hold the acetal blocks 3 Disconnect push pull rods from cross rod by loosening jam nut and unscrewing push pull rods 4 Remove cross rod For aircraft built in 2009 or newer substitute steps 1 and 2 above with 1 Remove the nut and washer from the actuator arm 2 Sli
194. reedom of movement Check push pull cables for proper routing condition and Control Column Check for freedom of movement Inspect rod ends for condition security and operation Comments Trim Control Check for freedom of movement Inspect rod ends for condition security and operation Comments Engine Controls Check for ease of operation through full travel Comments Plumbing Check all plumbing and connections for security leakage and general condition Comments 100 Hour Annual Inspection Checklist Page 12 of 17 Jabiru J230 SP J250 SP and J170 SP Aircraft Service Manual Windows and Doors Inspect windows for scratches crazing and general condition Inspect doors for security and attachment Check latching mechanism for proper engagement and ease of operation Comments Seats Seat Belts and Shoulder Harnesses Inspect cabin seats seat belts and shoulder harnesses for proper operations condition and security of attachment Comments Ventilation System Check all fresh air vents for obstructions proper movement and operation Comments Fuel System Inspect for leakage security freedom of movement and condition Inspect fuel filter and replace if necessary Check security of all fuel line hose clamps Check for proper placarding Comments Headset Jacks Inspect for cleanliness security and evidence of damage Comments 4 W
195. rim spring mechanism places some tension on the control however the elevator should move stop to stop with no rubbing scraping or other mechanical interference If inter ference is detected isolate problem and correct Sudden onset of friction or strange interference in the elevator control may be due to a damaged autopilot servo 6 5 3 Removal of Elevator Tools Required Screwdriver set 7 16 wrenches Level of Certification Required A amp P or LSA R M M 1 Remove ventral fairing from lower rear fuselage 2 Unbolt elevator cable from control horn 3 Unbolt trim linkage from control horn For aircraft with six hinge pins in the elevator 2008 models and older 4 Loosen screws in hinge pin retainers and lift hinge pin retainers from hinge pins It is not necessary to remove these parts 5 Remove hinge pins 6 Remove elevator For aircraft with two elevator hinge pins 2009 models and newer 4 Remove hinge pin retaining screws 5 Supporting elevator remove hinge pins 6 Remove elevator JSA SM170SP A1 Page 6 11 Section 6 Flight Controls 6 5 4 6 5 5 6 5 6 6 5 7 Page 6 12 Jabiru J170 SP Aircraft Service Manual Inspection Inspect elevator for any signs of delamination or cracking Pay particular attention to the control horn and hinges and their surrounding areas See Section 6 1 for inspection of control column and 6 2 for inspection of control cable Repair All damage involving crack
196. rived 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 tight ness of installed parts during service 2 10 6 Filters Screens and Fluids Check for contamination and condition Replace at specified intervals or when condi tion warrants JSA SM170SP A2 Page 2 11 Section 2 Jabiru J170 SP General Care amp Inspection Aircraft Service Manual 2 10 7 Lubrication There are no special lubrication requirements for Jabiru aircraft other than those listed below Reference Undercarriage and Controls sections for lubricating instructions 1 Wheel Bearings 2 Nose Gear Leg Housing 3 Control Stick Housing 4 Trim Spring Assembly 2 10 8 Aircraft Documents To be displayed in the aircraft at all times a Placards as detailed in Pilot s Operating Handbook b Airworthiness Certificate c Aircraft Registration To be carried in the aircraft at all times a Current version of Pilot s Operating Handbook b Operating Limitations c Weight and Balance 2 10 9 Engine Run Up Before beginning the step by step inspection start warm run up and shut down the engine in accordance with instructions in the Pilot s Operating Handbook During the run up observe the following making note of any discrepancies or abnormalities Engine temperatures and pressures Static RPM also refer to Engine Instru
197. rmitted in the Aircraft Service Manual JSA SM170SP on E LSA aircraft that they own and make the logbook endorsement for return to service as specified by FAR 43 9 Owner s Name Address City State Zip Registration Number Airframe Serial Number Engine Serial Number Hours Date Inspection Completed Servicing Agency Address City State Zip Phone Number Name of Repairman JSA 50HR A1 25 50 Hour Inspection Checklist Page 1 of 9 Jabiru J230 SP J250 SP and J170 SP Aircraft Service Manual JSA 50HR A1 Inspection Intervals The time periods for the inspections noted in this schedule are based on normal usage under average environmental conditions Airplanes operated in humid tropics cold damp climates etc may need more frequent inspections for wear corrosion lubrication and or lack of maintenance Under these adverse conditions perform periodic inspections in compliance with this guide at more frequent intervals undil the owner or operator can set his or her own inspection periods based on the contingencies of experience Airplanes operated commercially less than 100 hours per year must have a 100 hour inspection performed no later than 12 months following the date of the preceeding 100 hour inspection The 100 hour interval between performances of the procedures specified herein should NEVER be exceeded by more than 10 hours which can be used only if the additional time is required to reach a place wh
198. rnished to the owner operator by ASTM Standard F2483 The information in this manual is based upon data available at the time of pub lication and is supplemented and kept current by Service Bulletins and Air Safety Alerts pub lished by Jabiru USA Sport Aircraft LLC These are posted on the Jabiru USA website www usjabiru com and are available through local authorized Jabiru dealers In addition to the information in this service manual installation and maintenance publications are available from component manufacturers which describe disassembly overhaul and parts breakdown of some of the various vendor equipment items A listing of vendors their contact information and available user documentation is published in the Appendix of this manual Owner Operator Responsibility Page 10 To maintain compliance with ASTM Standard F2295 the owner or operator of this aircraft must follow six rules that are listed below and specified in Section 5 4 of F2295 Failure to comply with these responsibilities could result in an aircraft that may be out of compliance with the ASTM standards and could lead to revocation of the aircraft airworthiness certificate It is the owner s responsibility to become fully aware of the particular maintenance requirements and limitations applicable to the LSA airworthiness certification 1 Each owner operator of this aircraft shall read and comply with the maintenance and con tinued airworthiness information and instru
199. rop hub or inboard leading edge of the horizontal stabilizer as push points The aircraft may be moved from the front by placing the propeller in the horizontal position and then plac ing one hand on the propeller on either side of the spinner The aircraft can then be pulled forward and nose wheel lifted off the ground if necessary See figure 2 1 for ap proved push pull points Jabiru USA offers a towbar kit which utilizes a Bogi Bar towbar and pins that screw into the existing nose pant nose fork hold down screws on most Jabiru aircraft Contact Jabiru USA for more information WARNING V Do not use control surfaces to move the aircraft as damage to the con trol system may result V Do not push on the tips of the propeller as damage may result When moving the aircraft never turn the nose wheel more than 15 de grees either side of center or nose gear may be damaged V Always remember the rudder is connected to the nose gear Keep hands clear of the rudder hinge line during ground handling or pinched fingers may result V Never move the propeller when the engine is hot as it may fire unex pectedly and result in severe injury V Always ensure that the Master and Ignition switches are OFF before touching the propeller V Never approach the propeller when anyone is in the aircraft V Always treat the propeller as LIVE JSA SM170SP A2 Page 2 1 Section 2 Jabiru J170 SP General Care amp Inspection Aircraft Service Ma
200. rted disconnect flap control rods 1 each wing Flap may be supported by using generous amounts of masking tape to hold in the up position 7 Support the wing using a padded sawhorse or brace structure just outside the strut attach point with the lowest amount of wing tip droop as possible 8 Remove the bolts from the top attachment and the bottom attachment These are NAS close tolerance bolts and may be difficult to remove Pull strut away from the fuselage attachment while moving the strut up and down V WARNING DO NOT put fore and aft pressure on the strut or strut attachment while removing as this may damage strut attach points 25 5 1705 0 Jabiru J170 SP Section 4 Aircraft Service Manual Wing Structure 4 2 3 Inspection Check for any loose or damaged bolts at each end of the strut Check for nicks cracks or dents in the strut body Check to see that struts are straight and not twisted 4 2 4 Repair Wing struts are structural components and repairs are mostly limited to replacement The strut bolts that attach the ends to the main body of the strut may be replaced if the strut itself shows no signs of other damage Nicks cracks and other damage must be referred to Jabiru USA Sport Aircraft LLC for determination of reparability and issuance of repair instructions A dented cracked or deformed wing strut must be replaced prior to next flight 4 2 5 Reinstallation V WARNING Do not apply any fore
201. ru J170 S LSA Maintenance Schedule found in the Appendix of this man ual for detailed schedule of service and inspections All 25 50 hour 100 hour and Annual inspections must follow the guidelines set in the appropriate maintenance checklists Doc No JSA 50HR JSA 100HR also found the Appendix of this manual The Engine Instruction Manual also details engine inspection schedules and should be consulted in addition to this manual 2 10 General Inspection Guidelines 2 10 1 Moveable Parts Inspect for adequate lubrication 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 2 10 2 Fluid Lines and Hoses Check for leaks cracks kinks chafing proper radius security corrosion deteriora tion obstruction and foreign matter 2 10 3 Metal Parts Check for security of attachment cracks metal distortion broken welds corrosion and any other apparent damage 2 10 4 Wiring Check for security chafing burning defective insulation loose or broken terminals heat deterioration and corroded terminals 2 10 5 Bolts in Critical Areas Correct torque in accordance with torque values given in the chart in Table 1 4 Torque Values when installed or when visual inspection indicates the need for a torque check NOTE Torque values listed in Table 1 4 are de
202. s NI SNOISN3INKD 931 40 3993405 ONIONYS 1Snrav WINOZINOH 38 OL NXV 8 15 but alignment procedure is the same Figure 5 3 Axle Alignment Note Drawing refers to Jabiru UL model Page 5 13 JSA SM170SP A1 Section 5 Landing Gear and Brakes 5 8 5 8 1 Description Master Cylinder Parking Brake Assembly Jabiru J170 SP Aircraft Service Manual The brake master cylinder located between the seats on the front of the main longitu dinal beam is actuated by applying rearward pressure to the brake handle A small res ervoir is incorporated into the master cylinder for the fluid supply The parking brake consists of an over center cam on the brake handle Flexible lines carry fluid from the master cylinder through the belly of the aircraft inside the trailing edges of the main landing gear legs and into the Matco wheel cylinders 5 8 2 Troubleshooting Brake handle binding Check and adjust Page 5 14 Dragging brakes Brakes fail to operate Shimmy or chatter when brakes applied heavily Worn or broken master cylinder piston return spring Restriction in brake lines or in master cylinder Repair or install new mas ter cylinder Drain brake line clear with compressed air If cleaning lines fails inspect and re pair or replace master cyl inder Worn brake pads Replace with new parts Leak in system Check for leaks and repair or install new parts Lack of flui
203. s first just apply 20 ft Ibs to the head bolts as they are A 4 long 1 4 Allen key is needed for the head bolt behind the plug at the 6 Page 7 29 Section 7 Engine Systems 10 11 12 Jabiru J170 SP Aircraft Service Manual o clock position Reinstall rocker chamber oil plug Torque plug to 8 ft Ibs DO NOT over tighten Reinstall valve cover making sure O ring is seated in the groove on the head Repeat with all heads Reinstall spark plug leads and cooling baffles Make sure all tools are removed from engine compartment and the crankcase con tains the proper amount of oil Run the engine briefly Test both magnetos to make sure all plug wires are secure on both ends Check engine compartment for any oil leaks Complete 50 hour service and inspection as necessary When satisfied rein stall engine cowlings On a new engine if head bolt tension continues to change after the 10 hour check investigate whether the heads are receiving enough cooling Overheated heads will cause head bolt tension to change as the heads expand beyond engineered limits and then contract Correct the cooling problem ASAP or contact Jabiru USA for as sistance Figure 7 9 Head Bolt Locations Number 5 is hidden behind rocker chamber oil plug Page 7 30 25 SM170SP A1 Jabiru J170 SP Section 8 Aircraft Service Manual Fuel System Section 8 Fuel System 8 1 General Description The engine is equipped wit
204. site beams which are bolted to the fuselage at the top and center and to the wheel stub axle at the bottom The main wheels are Matco aircraft wheels and brakes are Matco aircraft hydraulic brakes Wheel pants are optional 5 2 Landing Gear Troubleshooting Chart Aircraft leans to Incorrect tire inflation Inflate or deflate main tires to 35 40 psi one side on level ground Landing gear attaching hard and tighten Section 5 5 5 replace hard with equal ware not tight ware if damaged or beyond 500 hours of life JSA amounts of fuel Service Bulletin JSA 003 1 Undercarriage Bolt in each tank Replacement Stretched or cracked fiberglass Inspect gear leg for cracks replace a cracked or gear leg hard landing delaminated leg before next flight Bent axle stub Replace axle stub Section 5 6 Main tires wear Incorrect tire inflation Inflate or deflate main tires to 35 40 psi excessively It is normal for Main wheels out of alignment Install axle shims to realign wheels see Section 5 tires to wear on 6 outboard side regular rotation Bent axle stub Replace axle stub Section 5 6 is recom mended Dragging or skidding tires with Avoid locking brakes taxi and landing use less brakes on engine rpm during run up Nose wheel Improper takeoff technique See J230 Flight Training Supplement for normal shimmy after holding nose wheel on runway takeoff technique description www usjabiru com rotation liftoff too long
205. ss the surface of the funnel enough that the screen can be laid over the top of it and be flush with the outer surface of the wing skin When satisfied with the fit attach the funnel securely to the wing skin using 5 minute epoxy To reinstall or replace the air line 1 JSA 5 1705 0 Remove the both the reed bell end and the aluminum funnel from the air line but DO NOT pull the line out of the wing Thread a long flexible piece of cord or wire through the air line so that it extends out of both ends of the line Firmly attach one end of the cord to the new air line Carefully pull the cord and old line out threading the new line through the wing Page 10 3 Section 10 Jabiru J170 SP Utility Systems Aircraft Service Manual To reinstall the screen and divider plate 1 Clean up the edges of the hole and slot for the divider plate as necessary Mix a batch of 5 minute epoxy and glue screen and divider plate in place taking care to keep all glue and debris out of the aluminum funnel The divider plate should pro trude out of the leading edge approximately 1 2 and a 30 angle down from the chord line of the wing 2 After the epoxy cures touch up the edges of the screen as necessary with body filler and paint Keep the screen clear of dust and paint 10 3 6 Calibration of Stall Horn The default angle of the plate is 30 down from the wing chord line Bending the divider plate upward will make the stall h
206. stall engine cowls as described in Section 7 3 7 8 Oil Cooling System 7 8 1 7 8 2 7 8 3 7 8 4 7 8 5 Page 7 14 Description An oil cooling radiator is mounted at the bottom front of the oil sump Hoses route the oil from the oil cooler adapter under the filter to the cooler and back Early J170s have the smaller flat oil cooler with NACA duct under the cowl Later models have a larger cooler with chin scoop See Figures 7 5 and 7 6 Tools Required 3 8 7 16 11 16 wrenches Phillips 2 screw driver Parts Required Permatex No 2 gasket sealant for reinstallation Level of Certification Required A amp P or LSA R M M Removal 1 Disconnect braided hoses from oil cooler and oil cooler adapter 2 Remove cooler from engine by removing attachment bolts See Figure 7 5 Inspection 1 Inspect hoses for kinks leaks cracks or loose fittings 2 Inspect radiator for leaks bent fins impacted debris damaged fittings or damaged attachment brackets Repair 1 Repair of hoses is limited to replacement of the stainless braided hose The AN fittings are removable and can be reused if not damaged 2 Repair of radiator should be referred to a qualified radiator repair facility for inspec tion testing and repair Repair is usually limited to replacement 3 Fittings are standard AN flare fittings Reinstallation 1 See Figure 7 5 Reinstall fittings into radiator using Permatex 2 gasket sealant 2 Reinstall radia
207. structure Check for cracks and delamination Check hinge pin structure for loose rivets or deformation Comments Head Bolt Tension Torque head bolts to proper tension Comments 3 Cabin and Baggage Compartment Skin Inspect skins for deformation or cracks If damage is found check adjacent structure Comments Structure Check for cracks and deformation Check for concealed damage Comments clearance and proper operation splits bends or cracks Check control cables and associated equipment for condition attachment alignment Comments Teleflex cables Check the flight control components Replace control system components that have bulges JSA 100HR A1 100 Hour Annual Inspection Checklist Page 11 of 17 Jabiru J230 SP J250 SP and J170 SP Aircraft Service Manual Aileron Quadrant Inspect for condition attachment and proper operation Check for binding Pass Fail Comments Flap Motor and Shafts Check for condition security and wear at all points Pass Fail Comments Brake Master Cylinder Check for condition security and leaks Check lines for signs of chafing or cracks Pass Fail Comments JSA 100HR A1 security Check rudder pedal springs for condition and correct placement Check pedal extensions for security if installed Comments Rudder Pedals Check for f
208. t 4 Remove antenna from aircraft 11 10 7 3 Inspection Inspect wire and connector for condition 11 10 7 4 Repair Unit must be sent to Grand Rapids Technologies for repair or replacement 11 10 7 5 Reinstallation Reverse steps in 11 10 7 2 for reinstallation Replace zip ties as necessary Page 11 14 JSA SM170SP A1 Jabiru J170 SP Section 11 Aircraft Service Manual Electrical System and Instruments 11 10 8 WeatherWorx XM Weather Module 11 10 8 1 Description EFIS equipped aircraft have the option of a WeatherWorx XM Weather module that can show radar METARs TAFs etc on the EFIS screens depending on subscription level NOTE See Section 11 11 for more information on radio static caused by the WxWorx module 11 10 8 2 Removal Tools Required Tail stand screwdriver set Level of Certification Required Owner A amp P LSA R M M or Avionics Repair Station The weather module is located on the back of the pilot s seat or behind the baggage compartment on the floor 1 Brace the tail of the aircraft with a tail stand or padded sawhorse to allow entry of personnel into the baggage compartment 2 Remove the screws from the mounts 3 Disconnect the power wire from the unit 4 Disconnect the 9 pin connector 11 10 8 3 Inspection Inspect the wires and connections 11 10 8 4 Repair Any unit repairs should be referred to Grand Rapids Technologies See Appen dix for vendor information 11 10 8 5 Reinstallati
209. t 5 3 5 Reinstallation 5 5 Reverse the steps in 5 3 2 for reinstallation of main wheel fairings Main Gear Top Fairing Lower Strut Fairing 5 4 1 5 4 2 5 4 3 5 4 4 Description The main gear leg top fairing is a molded fiberglass part laminated from three layers of 9 oz fiberglass cloth It also functions as the lower strut fairing There is one fairing on each side of the aircraft Removal and Installation Phillips screwdriver Parts Required Level of Maintenance Level of Certification Required Owner A amp P LSA R M M 1 Remove the screws 2 Remove the fairing carefully so the paint is not cracked or the edges damaged 3 reinstall the fairing carefully work the fairing around the gear leg and strut mount until it is back in place Take care not to pinch any wires brake lines or pi tot static lines that may run underneath the fairing 4 Reinstall the screws Inspection Check for cracks tears or delamination in the fiberglass Repair Repair cracks or tears by overlaying with fiberglass as in the procedure for wheel fair ing repair See Paragraph 5 3 4 Main Gear Leg Assembly 5 5 1 Page 5 4 Description The main gear leg is a molded fiberglass lamination of 10 oz unidirectional fiberglass Figure 5 1 Main Undercarriage Assembly illustrates the main landing gear 25 SM170SP A1 Jabiru J170 SP Section 5 Aircraft Service Manual Landing Gear and Brakes 5 5 2 Removal
210. t in 2009 or newer substitute steps 1 and 2 above with 1 Remove the nut and washer from the actuator arm 2 Slide the control wire off of the bolt 7 14 3 Inspection 1 Check for kinks or breaks in the cable sheath 2 Check for smooth operation 7 14 4 Repair Repair is limited to replacement 7 14 5 Reinstallation Reverse steps in section 7 14 2 7 15 Carburetor Heat 7 15 1 Description Page 7 24 The carburetor heat unit consists of an stainless steel heat muff riveted to the cabin heat muff Carburetor heat is activated by a push pull knob on the instrument panel which activates a butterfly that closes the opening to ambient induction air forcing the engine to draw air through a SCAT hose connected to the heat muff NOTE Because the Bing carburetor automatically adjusts mixture with changes in air density there should be no noticeable change in RPM when carburetor heat is applied on the ground JSA SM170SP A1 Jabiru J170 SP Section 7 Aircraft Service Manual Engine Systems 7 15 2 Removal Tools Required Screwdriver set 3 8 and 5 8 wrenches Level of Certification Required A amp P or LSA R M M For aircraft built in 2008 or older 1 Disconnect cable from air box by removing the cotter pin from the cable ferrule and pulling ferrule from control arm 2 Remove jam nuts from cable end adjuster at the butterfly bracket 3 Remove jam nut from back side of instrument panel 4 Pull cable from the aircraft
211. t manifolds as needed 7 18 3 Inspection As all exhaust systems are subject to burning cracking and general deterioration from alternate thermal stress and vibration inspection is very important and should be car ried out every 50 hours of operation In addition an inspection of the exhaust system must be undertaken anytime exhaust fumes are noticed in the cabin Inspect complete system starting at the connection to the head Inspect the securing bolts and move outwards looking for cracks Especially check areas adjacent to welds Look for exhaust gas deposits in surrounding areas indicating that exhaust gas is es caping through a hole or crack For a more thorough inspection the following procedure is recommended 1 Remove manifolds and or muffler 2 Use rubber expansion plugs to seal openings 3 Using a manometer or gauge apply approximately 1 1 2 psi 3 inches of mercury of air pressure while the manifold and or muffler are submerged in water All leaks will appear as bubbles and can be readily detected 4 It is recommended that any exhaust system component found to be defective is repaired or replaced with a new part before the next flight JSA SM170SP A1 Page 7 27 Section 7 Jabiru J170 SP Engine Systems Aircraft Service Manual 7 18 4 Repair 1 Cracks or leaks can be welded by a technician skilled in TIG welding of stainless exhaust pipes 2 Cracks not suitable for welding require replacement of the exhaust compo
212. ta 222 Jacking the Aircraft nunc atn C ride 2 3 Jacking Nose Gear inpet ge daa eee i edes 2 4 nier Enea Cod HEP RP it to ne Bes 2 5 cio ee e eR Rr TOR REP FE RO DH anne aes 2 6 Weighing the Aircraft iter er e te T o 2 7 Parking and 2 20 440 24 22 0 000000000000 enne JSA SM170SP A1 Jabiru J170 SP Aircraft Service Manual Section Title Page 2 8 detenti ebrei 2 8 2 9 Inspection 5 2 11 2 10 General Inspection 2 11 2 11 61 10 5 iue P REFS ORI ELO RR 2 13 2 12 Standard Practices for Inspection Repair and Alteration 2 15 Section 3 Fuselage Structure 3 1 Descriptionz OVA iw Anis 3 1 322 WINDOWS dier dnce den eeu 3 1 353 a 3 5 T 3 11 2 5 Upholstery 25722255 ee 3 12 3 6 ca e E e e a eed an er e Eug nad 3 12 3 7 Seat Belts nee 3 12 3 8 Horizontal i a a ee be n dine Pg 3 12 3 9 Vertical Stabilizer 5 reiten etre ace 3 13 Section 4 Wing Structure Section 5 La
213. ted to the replacement of defective parts Because control cables are con sidered primary controls they may not be repaired without reference to Jabiru USA Sport Aircraft LLC or our approved local agent for the appropriate repair procedure 6 3 Aileron Control System 6 3 1 Description The aileron control system consists of one movable control surface on the trailing edge of each wing tip control cables and the control column The control surface is a molded and bonded monocoque fiberglass structure incorporating a composite control horn 10 from the inboard end The aileron control cables are of the enclosed push pull type fitted with spherical bear ings at both ends as described in Section 6 2 NOTE Control column and control cables are primary controls and may not be removed or repaired without reference to Jabiru USA Sport Aircraft LLC or their approved local agent 6 3 2 Removal of Aileron Tools Required Screwdriver set pliers 3 8 wrenches Level of Certification Required A amp P or LSA R M M For aircraft with multiple hinge pins 2008 models and older 1 Loosen screws in hinge pin retainers and lift hinge pin retainer away from the hinge pin It is not necessary to completely remove these parts 2 Unbolt cable from aileron control horn 3 With the aileron supported remove hinge pins For aircraft with a single hinge pin 2009 models and newer 1 Remove hinge pin retaining screw 2 Unbolt cable from aileron
214. tight on the rod ends and the cable is visible through the inspection hole in the rod end 2 Check UP travel on both ailerons Up travel should be 18 20 degrees Down travel should equal 10 degrees or more 3 Usethe aileron control stop adjustment see Figure 6 2 Aileron Rigging to adjust the total aileron movement i e UP travel and use cable adjustment as previously described to proportion UP and DOWN travel The aileron control stop should en gage before the aileron arm hits the UP travel stop at the wing tip DO NOT move the cable anchors these positions have been set using a jig V WARNING Aileron cable must be connected to the same side of the control column bell crank as the wing to which the aileron is fitted otherwise control surface reversal will result DO NOT CROSS CABLES Page 6 4 JSA SM170SP A1 Jabiru J170 SP Section 6 Aircraft Service Manual Flight Controls 2 131 1 4 2 4 stub meron cowmo 2 Drawing 5011094 2 AILERON CONTROL STOP ASSEMBLY LOCATE TEMPLATE ON TOP OF WING AND ADJUST AILERON UP 4 amp DOWN TRAVEL Qmm ROD END BALL NOTE THIS WASHER IS LARGER TO COVER ADJUST STOP STUDS amp CABLES TO ACHIEVE AILERON TRAVEL USE TEMPLATE TO MEASURE amp ENSURE BOTH AILERONS ARE ADJUSTED TO TEMPLATE ANGLE Drawing 9014093 1 AILERON RIGGING INSTRUCTIONS Figure 6 2 Aileron Control Stop and Rigging
215. tion Reverse steps in 10 2 2 for reinstallation 10 3 Stall Warning System 10 3 1 Description The stall warning system is of the suction reed type It consists of a screened opening in the leading edge of the left wing an airflow divider plate an air line that runs to the cabin and a reed with an amplifier bell mounted inside the cockpit The airflow divider plate is calibrated to match the critical angle of attack of the wing When the wing ap proaches the critical angle of attack the divider plate disturbs the airflow in front of the screen creating a low pressure area that sucks air from inside the cabin through the reed and out the screen The reed is mounted inside the left doorpost so that it is eas ily audible from the left seat 10 3 2 Removal Page 10 2 The reed bell assembly is mounted to cockpit ceiling above the pilot s seat The bell is held to the air line with small safety wire 032 The screen and divider plate are epoxied into the leading edge of the wing before the wing is painted To remove them file away the paint and body filler from around the 25 5 1705 0 Jabiru J170 SP Section 10 Aircraft Service Manual Utility Systems opening until the edges of the screen are visible Pry the screen and divider plate away from the opening The aluminum funnel may then be removed allowing access to the air line inside the wing 10 3 3 Inspection To check function of the stall warning system on
216. tor onto sump 3 Reconnect braided hoses to cooler and adapter 4 Run engine for at least 30 seconds verifying that it has at least the minimum oil pressure in the system Shut down and inspect for leaks JSA SM170SP A1 Section 7 Engine Systems Jabiru J170 SP Aircraft Service Manual Z COWSZZVH 0066 ASSY LNNOW 331009 110 HOALISOd Om 92 0 3U1 26 994 010 0 5 310HM 5 1 TVH3N35 911 Ald HO3LAV 30 LNSSNOS LNOHLIM 0319002 LON LENN LHOIMAdOO 8 BIHL NOLLVTTV LSNI LNNOW t e v Gy NES oO SINTON OL NOLLVTIVLSNI ao wau wau Piss Figure 7 5 Oil Cooler newer large style Page 7 15 JSA SM170SP A1 5 es N 55 CE EET TIC m 1 WTNH 58 avrszvs 020 52 avo 58 5 nme w 5 2 Engine Systems Section 7 JSA SM170SP A1 Figure 7 6 Older style oil cooler Page 7 16 Jabiru J170 SP Section 7 Aircraft Service Manual Engine Systems 7 9 Oil Recovery System 7 9 1 Description The primary purpose of the oil recovery system is to collect excess oil thrown out of the crankcase breath
217. ty Weight and Description of Item Moment Modification or Repair WT MOM WT Ibs aman MOM Ibs 1000 Table 2 2 Aircraft Empty Weight Record JSA SM170SP A2 Page 2 7 Section 2 Jabiru J170 SP General Care amp Inspection Aircraft Service Manual 2 7 Parking and Tie Down 2 8 Storage 1 When mooring the aircraft in the open head into wind if possible and set the park ing brake The ailerons may be secured by tying the control yoke to one side with a seat belt Attach ropes to the tie down rings on each wing strut If the tie down rings are too small for the available ropes a high quality carabiner or D ring may be installed through the ring to provide a wider opening for the rope Secure the 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 attachments should a tire deflate while the aircraft is tied down Tie a third rope to the tail tie down hole in the ventral fin and secure to ground an chor To keep rain water animals and curious onlookers out of the aircraft always use a Jabiru USA Bruce s Custom Covers aircraft cabin cover and close all fresh air vents when parking the aircraft outside Make sure the cover s under wing straps are snugged up tight to seal the wing roots from rainwater entry Cowl pitot static and fuel vent plug cover sets are als
218. type of covering carpet leather vinyl or cloth EFIS screens and instruments may be cleaned using a soft cloth and a cleanser made for LCD screens V CAUTION Do not use silicone based cleansers as these may soak through the carpet and into the fiberglass affecting fu ture reparability of the components JSA SM170SP A2 Page 2 13 Section 2 Jabiru J170 SP General Care amp Inspection Aircraft Service Manual Volatile substances such as those mentioned in Paragraph 2 11 1 must never be used Interior painted surfaces may be cleaned using the same automotive cleaning materials as the exterior surfaces 2 11 3 Aluminum Surfaces The aluminum surfaces require a minimum of care but should not be neglected Wash and clean as detailed in paragraph 2 11 1 above Scratches in the spinner may be re moved using an aluminum polishing compound such as Flitz or Nuvite 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 exter nal controls Always hose down wheels and wheel fairings after landings in mud or sand to ensure brakes wheels and fairings are free of dirt build up For regular landings on soft conditions removal of wheel fairings is recommended 2 11 5 Engin
219. untersunk aluminum rivets 3 Scratches may be polished from spinner with Flitz Nuvite or other similar aluminum polishing compounds 9 1 4 Reinstallation 1 Reverse steps in 9 1 2 for reinstallation of spinner components using propeller in stallation procedure in 9 3 5 2 Reinstall spinner cone Tighten screws JUST UNTIL SNUG or until the plastic wash ers begin to compress slightly DO NOT OVERTIGHTEN as this may cause the spin ner cone to crack over time JSA SM170SP A1 Page 9 1 Section 9 Jabiru J170 SP Propeller amp Spinner Aircraft Service Manual 9 2 Propeller 9 2 1 9 2 2 9 2 3 9 2 4 9 2 Description The wood propeller is constructed from four laminations of approved species timber and is manufactured in accordance with the relevant Sensenich specifications It is a single piece two blade propeller with polyurethane leading edge protection The propeller finish is a either a clear marine polyurethane varnish or epoxy paint Pro pellers with a G suffix in the model number are covered with a layer of fiberglass for extra strength and durability Removal Level of Certification Required A amp P or LSA R M M V WARNING Make sure ignition system is OFF before commencing work on propeller V WARNING Do NOT run engine with propeller removed or seri ous engine damage will result 1 Remove spinner as described in Section 9 1 2 Unbolt the six AN5 37A propeller bolts 3 Remov
220. washer and axle nut Tighten until the outer part of the bearing does not spin but everything else does Some drag force is normal for the roller bearings to work properly 6 Install cotter pin to axle nut 7 Place outboard brake pad plate and spacer in position and secure with bolts Re place safety wire Note Newer J230 SP models use lock washers in lieu of safety wire on the brake pad plates 8 Install wheel pant if used as outlined in Paragraph 5 3 JSA SM170SP A1 Page 5 11 Jabiru J170 SP Aircraft Service Manual Section 5 Landing Gear and Brakes Install Valve Stem Thru Hole in Back Half and Align VMth Slot Install Valve Stem Washer dimple up amp Valve Nut Stem into Valve Hole in Valve Half amp Align Figure 5 2 Assembly of Matco Wheel Halves JSA SM170SP A1 Page 5 12 Section 5 Landing Gear and Brakes Jabiru J170 SP Aircraft Service Manual ES LON 00 5 1N3W32 TAII HIOONS X 61 583708 INGNNSITY 338 931 NOISN3dDSNS NIW 1N3ANOITwW 133HM SIHL 100 OL LHOGM 55089 01 Livaduivy QvOl 0191 MJA IN3WNOMY T33HM X9IML 61 SNOT 002 0355340 931 NOISN3dSNS 89 5 SNO 0191 X 09 X OF 319NV QN3 HOV3 SLINY 91 Z HUM T3NNVHO HOVLLV 931 30 3ovdun

JSA-SM170SP-A1 J170-SP Aircraft Service Manual

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