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Aircraft Service Manual

1. Aircraft Service Manual Jabiru J160 J170 Variants Annual Inspection Each 200 Hours Each 100 Hours Each 50 Hours 9 Compression check or leak down check 10 Electrical wiring E 11 Fuel pump 12 Engine controls and linkages 13 Engine mounts mount structure 14 Starter solenoid electrical connections 15 Coils and electrical connections n 16 Carburettor heat system 17 Throttle and linkage 18 Carburettor li 19 Oil system tubes and hoses i 20 Firewall 21 Engine cowlings clips 5 22 Exhaust system including muffler 23 Head bolt tension 24 Oil amp filter change n 25 SCAT hose condition Fuel System 1 Fuel filters drain valves carburetor bowl li 2 Electronic fuel boost pump and fittings i 3 Fuel lines and connectors Revision 0 Dated July 2005 Issued Page 30 of 156 L Miles Technical manuals160 1701160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants Annual Inspection Each 200 Hours Each 100 Hours Each 50 Hours 4 Fire sleeves 5 Fuel tank vents caps amp placards B 6 Fuel Tanks i 7 Fuel shut off valve amp placards
2. s E 53 6 3 3 Inspection and ios rede ete ese aa 53 6 3 4 Main Wheel Fairing Removal and Installation eene eene 54 6 3 5 Main Gear Fairing Removal and Installation deeem 54 6 4 MAIN WHEEL 54 6 4 1 Main Wheel M eee tee 54 6 4 2 Main Wheel Disassembly sssini di Ce c 54 6 4 3 Wheel Inspection Assembly and 55 6 4 4 Wheel 55 6 4 5 Wheel Stub Axle 1 56 6 4 6 Main Wheel Stub Axle Installation 56 6 4 7 Main Wheel Alignment nor opone pneri ees e Ee 56 6 4 8 Wheel Balancing es enne 58 6 5 NOSE GEAR es 58 6 5 1 Trouble Shooting Leg 58 6 5 2 Nose Gear Removal and 58 6 5 3 Nose Gear Inspection and 59 6 5 4 Nose Wheel Speed Fairing Removal and Installation shes 59 6 6 NOSE WEEE tect ottiene 59 6 6 1 Nose Wheel Removal and Installation sse eene eee enn
3. 116 Fipure 43 Vented Fuel Cap 120 Figure 44 Instrument Panel Layout Basic Panel 124 Figure 45 Pitot Assembly mime ea Ds eee 130 Figure 46 Static Probe System Assembly 131 47 Static System est ette 132 Fig re 48 Wiring Dia Starnes unco i eire rere reiner tir eiie 137 Figure 49 Antenna Installation center eee ence ette herein eere 140 Figure 50 Propeller Installation TE m EET 152 REVISION L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 12 N Dated July 2005 Issued By RAS Page 9 of 156 08 2005 12 19 00 PM Jabiru Aircraft Pty pta 5 22 un Aircraft Service Manual Jabiru J160 J170 Variants 1 2 LIST OF TABLES Table 1 J160 Specifications nier en ner ei er nei e 12 Table 2 J170 5 er doti eat oen b e niit tom 14 Table 3 Recommended Bolt Torque 16 Table 4 Inspection as oan Rosa 29 Table 5 Trouble Shooting Main 49 Table 6 Trouble Shooting Nose 58 Table 7 Trouble Shooting 5 64 Table 8 Trou
4. MOO H3 AO1 NOU dlH2S30 S 2SZ02SN NLWLPOWL 017 Ald 3 30 LN3SNOO L OOHLIA 0319 2 38 LCN 1504 LHEtldAcOO SI 5141 100 156 Issued By RAS Te Q 5 3 5 les Technical_manuals J160_J170 J160_ amp _J170_workin REVISION files J160_ amp _J170_Tech doc 9_ Print Date 12 08 2005 12 19 00 Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants 10 1 2 CLEANING AND INSPECTION 1 Wipe the inner surfaces of the cowlings with a cloth saturated with Mineral Turpentine 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 Inspect cowling mounts for rigidity amp bonding amp for wear Inspect locking pins for damage Inspect rubber grommets in firewall for wear or damage 4 Replace any damaged or worn parts with new parts 10 1 3 REPAIR Repair is limited to replacement cam locks Rivets fixing cam lock anchor lugs should be backed with washers 10 2 ENGINE The engine is a JABIRU 4 cylinder 4 stroke air cooled driving a fixed pitch wooden propeller The front Starboard cylinder is numbered 1 the front Port is numbered 2 the centre Starboard is numbered 3 the centre Port is numbered 4 the rear Starb
5. U lt 02 tn o 5 o 2 Ke N 5 gt 75 9 o 2 x g files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM L Miles Technical_manuals J160_J170 J160_ amp _J170_workin ircraft pty A Aircraft Service Manual iru Jab Jabiru J160 J170 Variants 19 SYaASVONNG ONIM LEA TIN LHOTT 871 ASSY SNIA 16 FOF F 930041 GED F USO SNO 826 982 010 uwao SU F SION S39 73101 217 Ald 30 1N3SNOO FH 03 09 30104 ASMA INY 1 SI SIHL Vd HOSLAY 5 1 IN NI ONVH 31ISOddO SY NAVYA SY 81 9058202 IN WNSITY HOS 4 VI HS MIO 9 AXOdz Sz 9NIH QNOE 9 1 OHYOANI 4 AASIA ONS 068 262 800 3195950r GEQINOW NI 42 3418 SSONN HS TE MIC AXOd3 HLM UV H2VLIV35NIH BUND TA Nn HLOTZ 1534 HUM JINE ENM ALNO TZNNVHZ E3AO 002 X 002 9 OSL Y 002 00 Y LAVT 3 NduCS 9NA OL T3NNVYH2 ONNCYY 12113 85 507 Y T1ZNNY H2 113 5 070 3 3 NOILO3S N N SNOLODW 3715 5 Sz2v4Hns SNIONOB TW CNVS ALON SNWAI tL OL 3n SONVHS
6. 82 Figure 25 Elevator Control ASSy oer p ON eR PER Rte rre 85 Figure 26 J160 Models Horizontal Tail amp Elevator Assy sees tenen 86 Figure 27 J170 Models Horizontal Tail amp Elevator Assy sese 87 Figure 28 Elevator Travel 118 raa aa 88 Figure 29 Elevator Trim Handle e te ise eee eere 90 Figure 30 Figure 31 Figure 32 Figure 33 Figure 34 Figure 35 Figure 36 Figure 37 Figure 38 Tim Controls At Tail ete droit dti eati EE 91 Rudder Pedal ASSY 93 Rudder System Schematic 96 Rudder Installations icc ee ainda 97 Upper Cowl ASSy ds esce iret tert rrt ode Fre 99 Lower Cowl Assy EATER I 100 CS VLA Variant Throttle Panel 105 Non CS VLA Variant Throttle Seat Mounted eese seen enne 106 Carburetor Heat BOK Afren 108 igure 39 Exhaust Systemic 110 Figure 40 Engine Installationy fi 112 Figure 41 Fuel System Schematic CS VLA Variants 22 440 04000 115 Figure 42 Fuel System Schematic Non CS VLA
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8. 111 10 22 Seacoast and Hunfid Axed ewa 111 11 SECTION 12 FUEL BYXS WE My 113 11 7 DESCRIPTION fee M 113 Fuel System iia e ea Med cub ege Pa cea Reo 113 11 1 2 J160 F170 Fuel System non cs vla variants 113 ADDS Precu uliOns nnda sun r 114 11 1 4 Fuel System Trouble Shooting 117 112 C 117 LL iDescrp ohncsewdensieniseneenteuier ve bee dep Pre 117 11 2 2 Fuel Tank Removal amp Installation 117 11 3 ISRAEL 118 Description 4e E 118 1L3 2 118 114 SHUT OFE VALVE rore 121 ILAT DeSCHD OH co ee died 121 1142 Fuel Valve Removal amp 121 TES FILTERS sais itis en nein RO RR ani Gun Epp e onan 121 11 5 1 CS VLA filter ten Kerana 121 Revision of Dated July 2005 Issued By RAS Page 6 of 156 L Miles Technical manuals1
9. EXISTING PROPELLER visceri esen 153 19 6 ASSEMBLE AND REPLACE PROPELLER ASSEMBLY sass 153 19 7 SERVICING AND REPAIRS 154 19 8 PROPELLER BALANCING PROCEDURE cccccccccseesssssseceeececDesseseeecccecceauecesececsessaaeteceeeceeeaeaeeeeceeessaaaeeeesecesensea 155 20 APPENDIX V AIRWORTHINESS LIMITATIONS scsccccocssssssssscccsssssscstecsescssssceecccsssscsssenscescssssssners 156 20 1 OO N RA Nn 156 20 2 MANDATORY REPLACEMENT 156 20 3 STRUCTURAL INSPECTION INTERVALS 156 20 4 INSPECTION PROCEDURES 156 revision 0 Dated July 2005 Issued By RAS Page 8 of 156 L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty pta AN un 1 1 Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Aircraft Service Manual Jabiru J160 J170 Variants TABLE OF FIGURES 7160 General Arranpemerit e eee nme ond re e ao cen 13 1170 General Arrangem
10. 39 4 5 UPHOLSTERY 39 4 5 1 he 39 4 6 SOUNDPROOEING 39 4 SAFETY PROVISIONS SRS 39 4 7 1 39 5 SECTION 5 WINGS AND 41 5 1 WINGS sro mU eMe 41 5 1 1 REMOVAL 41 5 1 2 IT don ccr EE 42 5 1 3 Installation 4 E A aeter cte e reed 42 5 2 WING STRUTS e CS tito 48 5 2 1 Removal Installation 48 5 2 2 REPAIR e tM ALL AU ER 48 5 3 48 5 3 1 Removal Installation Inspection 48 5 4 HORIZONTAL STABILISER 48 5 4 1 Removal and Installation 48 6 SECTION 6 LANDING GEAR AND 49 6 1 INAID INEKE 7AN E lasses lessees 49 6 2 TROUBLE SHOOTING MAIN 49 6 3 MAIN GEAR nee LM EE 49 3 1 Removal Ness 53 6 3 2
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15. WIHL HITNIH a pra 6960 alva ssi zi QL1A1d 4O LAV 40 IN SNOO 99469 Vd sSsusWrWN LON LSNA ANY LHOAcOO 8 S 5 5 A V V NOILOAS 2 m c SA A NA MA amp N 2 2 NIYA OL ONISNOH 2 s ONIHOVLLV 380458 1308 114 gt Lg S 5 KW d 3E1N39 E gt 9 8 21 f I tA 92 4 2 2 RY Ye a 29Z LOZSESIN amp WvAd WIL SONY 7600808 30 amp 9 0 81 0 9 6 LIAN WIL N6LLOHd 5 x LAON 3115 2 4NN 250 20 2 LL L ANN3d 91 8 2801 0264 V L 3201 NOLLORH WILL 00369076 aM L LAN 201 5902514 88 E3HSVM 91 01 096NVv aM 9Lt 096Nv aM 1130 310H dot N61008d 2 VOI ENV L YEAST aodsrove 2 YANNI NOLS 0 5 LNNOW aogsrove ALO ON Lewd 5 02 _ files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 L Miles Technical_manuals J160_J170 J
16. Aircraft Service Manual Jabiru J160 J170 Variants 10 5 2 CS VLA AIRCRAFT FUEL SYSTEM 1 A schematic drawing of the system is shown as Figure 46 2 The fuel filter and auxiliary electronic fuel pump are mounted inside the header tank enclosure All fuel lines inside the cabin are housed within plastic sheath 4 The main fuel valve is located on the Main Beam in the cabin 10 5 3 J160 3170 FUEL SYSTEM NON CS VLA VARIANTS 1 A schematic drawing the system is shown as Figure 47 2 The fuel filter and auxiliary electronic fuel pump are mounted in a fiberglass moulding immediately above the rudder pedals 3 The main fuel valve is located on the Main Beam in the cabin 10 6 SPARK PLUGS Refer to Engine Instruction amp Maintenance Manual 10 7 ENGINE CONTROLS 10 7 1 RIGGING When adjusting any engine control it is important 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 10 7 2 CS VLA THROTTLE SYSTEM The throttle system used is shown in Figure 41 10 7 3 4160 4170 THROTTLE NON CS VLA VARIANTS The throttle controls are shown at Figure 42 REVISION Dated July 2005 Issued By RAS Page 104 of 156 L Mfiles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM ircraft pty A Aircraft Service Manual iru Jab Jab
17. D 4142532 ON SINOS INOT ZT ZMA STAC INN 7 1 X MIEIS Lf 3eld 5 QOveSOovy 24 3eld 5 42 240 f 3cld 160 3 QOvISOVE 3cld 5 QOVOGOYE 1SN7HX3 5 4 7501034 wo mj ex 9 gt 2 5 gt e en o E 5 En 10 A lt 02 a 5 o 0 lO N 5 gt 75 9 o 2 x _ g files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM L Miles Technical_manuals J160_J170 J160_ amp _J170_workin Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants 10 9 EXTREME CLIMATIC CONDITIONS 10 9 1 DUST Dust induced into the carburettor air intake system is probably the greatest single cause of early engine wear When operating under high dust conditions the carburettor air filters should be serviced daily as outlined in Paragraph 11 7 5 10 9 2 SEACOAST AND HUMID AREA In salt water areas special care should be taken to keep the engine and accessories clean to prevent oxidisation In humid areas fuel should be checked frequently and drained of condensed moisture REVISION Dated July 2005 Issued By RAS Page 111 of 156 L Miles Technical_manuals J1
18. 10 2 SECTION 2 SERVICE 11 2 1 LIS TOF EFFECTIVE PAGES eet wah eet 11 22 GENERALDESCRIPTION 12 2 3 AIRCRAFT SPECIFICATIONS se ranma 12 24 CENTRE OF GRAVITY LIMITATIONS aes 12 25 TOROUEVAEDUBS 52 etr or tete tute erint te i e 12 2 6 AIRCRAFT SPECIFICATIONS 12 27 RECOMMENDED TORQUE VALUES IN 55 rennen eene nennen eren 16 3 SECTION 3 GROUND HANDLING SERVICING LUBRICATION amp INSPECTION 17 3 1 GROUND HANDLING 17 3 1 1 yn 17 3 1 2 17 3 1 3 HOURS rA M AL MM cp sates 18 3 1 4 ese 19 3 1 5 Parking E ATE A EE ae o 19 3 1 6 Tie DOWN MM 19 3 1 7 e Nee 19 3 1 8 Returning Aircraft to Service issi pee hesene 20 3 1 9 Temporary or Indefinite Storage opu Dada 20 31 10 Inspection During Storage e Re cet 21 3 1 11 Returning Aircraft to 21 32 SERVICING 22 3 2
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20. Zil X 9L HUY YOO 8319358 L Q02000vZ U3HSVM 9178 ZEOL OL6NV Hsnd 1S veeLeoc Ld Vd m lt o en A 5 o Ed E e 10 uw en U lt 02 tn o 5 o 0 Ke 5 gt 75 9 o 2 x _ 0 files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 L Miles Technical_manuals J160_J170 J160_ amp _J170_workin ircraft pty A Aircraft Service Manual iru Jab Jabiru J160 J170 Variants STNA 1 091 ATANISSY 51 000 a astam eren Ez 022 O10 au fi H AXOd3 ON 42214 25813 HUHN 0 MOONIM ONOG Tv DTI 94 1 043 ONY DOU ak FIM Sir 8009 01 SHYY 39NIH NOS BI3 0L CNCH SHINS S 3143641 38 OL ASSY 3009 AXOd3 ONY XOONI 38814 52 1350 SONOS 546 43 00 UINN KINO 803 NMOHS 53215 3dvHS ONY 1 NOYOLOYZ N d IWH 2150440 SY 3L0N QoveoQv N d SY ASSY 4000 S1 3 NOUCGBIC 987 9 0829 543 1 2 cog eg E J i am sr
21. eI i lt 25 Figure 38 Carburetor Heat Box revision Dated July 2005 Issued By RAS Page 108 of 156 L Miles Technical manuals160 17019160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty mm 524 Aircraft Service Manual Jabiru J160 J170 Variants 10 8 EXHAUST SYSTEM The exhaust system consists of front and rear exhaust manifolds attached to the engine block and a muffler assembly and springs which attach the muffler to the manifolds Refer to Figure 44 10 8 1 EXHAUST SYSTEM REMOVAL AND INSTALLATION 1 Remove both top and bottom engine cowls 2 Remove springs 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 bar stock is ideal 3 Remove muffler assembly 4 If necessary remove exhaust manifolds from engine 5 Reverse the preceding steps for installation 10 8 2 EXHAUST 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 carried 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 T Remove engine cowlings 2 Inspect complete system
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23. 310 4 SNE SNOISNANIO 3111 26 982 010 NOY UL Ald 301835509 JHL Q31c02 39 ION LSNA Qv 15144602 61 SIHL ASSY HV3t EOLVA3T3 A THW3SSV TOS LNOO HOJLVA3 T3 77772 Jabiru 9160 J170 Variants 2198 9 09 ASSY 5 0 3HIN33 VStNY N60Z0Hd HIHSVM 5949 LVT ZOG N69 0Hd 1104 SCXEW ircraft pty 513 2 318v 52 NIHS divs A T8N3SSV 318 2 A Aircraft Service Manual iru NHOH KIL NOISNELKS E3HSVM 114 8 3 IVW3 5 75 OIF ASSV 215 1 379100 Jab 39 158813 0 NO 1238 BALYAJ Ta 0 NYOH H3A31 N62000d N66000d 051024 E SLENY 7605905 CL CO6NY ZEOL S2ECZSA 610084 QOv9zove YJEWNN 1994 gt lt 9 5 2 ea N 8 omj rej oo U a lt 02 a 5 o 0 wo 5 gt 75 9 o 2 x files J160_ amp _J170_Tech doc B 9_ Print Date 12 08 2005 12 19 00 L Miles Technical_manuals J160_J170 J160_ amp _J170_workin ircraft pty A Aircraft Service Manual iru Jab Jabiru J160 J170 V
24. DEO M 33 4 1 FUSELAGE ised 33 42 WINDSHIELD AND WINDONWS eite aies 33 4 2 1 Desiri pt om NM NC 33 4 2 2 QUI 33 revision Dated July 2005 Issued By RAS Page 3 of 156 L Miles Technical manuals160 17019160 J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty pta 5 522 un Aircraft Service Manual Jabiru J160 J170 Variants 4 2 3 33 4 2 4 IC ast evs sued 33 4 2 5 o 34 4 2 6 Qiu 34 4 2 7 Removal OE cete 34 4 2 8 34 43 CABIN 34 4 3 1 Removal and Installation esses essiri eeii 34 4 3 2 AGjUSIMENE MEM REA 37 4 3 3 Door Seuls onore 37 4 3 4 DOORS e t 39 4 4 JU UN M 39 4 4 1 Pg E
25. REVISION Print Date 12 08 2005 12 19 00 PM N Dated July 2005 Issued By RAS Page 14 of 156 L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Jabiru Aircraft Pty pta GG un Aircraft Service Manual Jabiru J160 J170 Variants Figure 2 J170 General Arrangement Revision 0 Dated July 2005 Issued Page 15 of 156 L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants 2 7 RECOMMENDED TORQUE VALUES IN FIBREGLASS Table 3 Recommended Bolt Torque Values BOLT SIZE TORQUE INCH LB AN3 20 25 2 FTLB AN4 50 70 4 5 FT LB 5 100 140 8 12 FT LB AN4PROPELLOR 72 6 FT LB These values relate only to steel nuts on oil free cadmium plated threads For Engine Bolt Torque Values see Engine Instruction amp Maintenance Manual The above values are recommended for all installation procedures contained in this Manual except where other values are stipulated The above values are not to be used for checking tightness of installed parts during service CAUTION GENERAL RULE DO NOT REUSE SELF LOCKING NUTS REVISION gg Dated July 2005 Issued By RAS
26. 01820 2 H3HSvYA 1914 Fil 11093 1v 13 LW SE SSSNMOIHL 21 3 1 1 OLE t i HSNI J32vd8 2 mes 110E ALE VE ENV 1 110E OLE 90 2 3YOULS VUOS S3138 OWI 8 01412372 YOLYNLIY VENTI OAAS dv 1d 1519913 20 5 LW W34SVVM Ly T bE SANG 973 gt 541939 8 ASSY LAVHS 4 14 114442530 11 sped M38INDIN Fed o o 2 S E o 5 59 rel U lt 02 tn o 5 o 0 N 5 gt 75 9 o 2 x _ 9_ files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM L Miles Technical_manuals J160_J170 J160_ amp _J170_workin Jabiru 9160 J170 Variants 5 E 8 091 ASSY 1419973 2 90 2233018 8v m iin JHOdMHIV H3 T14NIH G 0 3SIMM3HLO 410345 SSIINN SLINN 46 982 OLO NOY Ald H231AV JO LNZSNOO JHL LNOALIM O3I2 C LON LSTW IHOIHAdOD SI Vd 3WOS LON CO SNOISNIWNIG Ee NOI
27. 125 12 3 2 Static Pressure System Inspection amp Leakage 5 eee eene 125 12 3 3 Pitot System Inspection amp Leakage 5 126 12 34 Blowing Out Lines cute ene 127 12 3 5 Removal amp Installation of Components essent denen 127 12 3 6 Trouble Shooting Pitot Static SysteMm 127 12 3 7 Trouble Shooting Airspeed Indicator 128 12 3 8 Trouble Shooting 128 12 3 9 Trouble Shooting Vertical Speed Indicator Option seen 129 12 3 10 Pitot Tube Alignment N oso figu aii err la pride S 129 124 TACHOMETER itinere Ner ree etti er ENSE eR 132 12 5 PRESSURE GAUGE titt entities saspe ots bv ede 133 12 6 OIL TEMPERATURE GAUGE Rasen dbase einen ees 133 12 7 CYLINDER HEAD TEMPERATURE 134 12 8 EXHAUST GAS TEMPERATURE GAUGE 134 12 9 tHOURMIETER 134 1210 MAGNETIC COMPASS Asesinas 134 12 11 GYRO INSTRUMENT PACKAGE OPTION 135 13 SECTION 14 ELECTRICAL 5 8 8 0 136 13 1 ELECTRICAL POWER SUPPLY SYSTEM eee lg 6 000000060000 136 13 2
28. 6 Install outboard brake pad and refix with through bolts and springs 6 8 5 BRAKE SYSTEM BLEEDING 1 Fill the brake master cylinder with automotive brake fluid 2 Loosen the bleed nipple at the brake cylinder Pull the handbrake back to the rear stop amp hold in same position until nipple has been re torque Release the hand brake amp repeat step 3 until all air is expelled from Nom Ensure brake master cylinder remains full above the outlet hose 4 When air is fully expelled tighten bleed nipples amp check fittings for leaks 5 Repeat steps 1 4 for other side brake WARNING Use only automotive brake fluid DO NOT use aircraft hydraulic fluid or damage will result 6 8 6 BRAKE PAD ADJUSTMENT Brake Pads may be adjusted by removing the Main Wheel Spats and tightening the brake pad attaching bolts and nuts until the wheel just rotates freely REVISION Dated July 2005 Issued By Page 67 of 156 L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants 6 8 7 PARKING BRAKE The Parking Brake consists of an over centre cam on the brake handle Should the cam have insufficient travel for the brakes to hold the aircraft with a propeller thrust of 2500rpm adjust by one or all of the following 1 Adjust brakes as descri
29. ASSY dV 1314 JTONIS 77 6202264 ASSY 39319 331 02 ON d YIAN ON d Nivea 3nd 100802 N d JNS 14915 End QOovoGOvp OMG YIEE 18 3559 dV2 TANA 011 Ald 20 N3SNOO 1 SNO 5 05 38 LON ISNA INY 400 SI SIAL wu om gt lt v 9 o 5 E E vo 2 vo gt 2 vo 5 E o 5 Eo E rel uw 5 A lt 02 a 5 o 0 wo 5 gt 75 9 o 2 x g files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM L Miles Technical_manuals J160_J170 J160_ amp _J170_workin Jabiru Aircraft Pty pta GG Aircraft Service Manual Jabiru J160 J170 Variants 2 ELEC 22222 Figure 42 Fuel System Schematic Non CS VLA Variants Revision 0 N Dated July 2005 Issued By RAS Page 116 of 156 L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants 11 1 4 FUEL SYSTEM T
30. The Upper Cowl is fitted with five locating Cam Locks two at the front amp three at the rear of the cowlings The Lower Cowl is attached to the Fuselage with 8 machine screws mounting into anchor nuts 10 1 1 ENGINE COWLS REMOVAL amp INSTALLATION 10 1 1 1 UPPER COWL Refer to Figure 39 1 Remove the Cam Locks from the front amp rear the cowling 2 Remove Hinge Pin 3 Grasping the cowl around the front nose pull carefully upwards and forwards until the lower edge of the cowl clears the upper edge of the Spinner then pull forward 4 Remove the cowl 5 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 can not be damaged by persons walking around the aircraft or by wind 6 Reverse the preceding steps for installation WARNING Ensure the cam locks are properly engaged before starting engine 10 1 1 2 LOWER COWL Refer to Figure 40 T Remove the top cowl Refer above 2 Disconnect the engine air inlet SCAT hose and cabin heat inlet hose if fitted 3 Remove lower cowl screws at rear of cowl 4 Reverse the preceding steps for installation REVISION gg Dated July 2005 Issued Page 98 of 156 L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Dza YINNE LMOdMN d FOzlAY wwop 5309
31. e o o a n A E 2 254 N o E 8 10 oo U lt 02 a 5 o 0 Ke 5 gt 75 9 o 2 x _ g files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 L Miles Technical_manuals J160_J170 J160_ amp _J170_workin Jabiru Aircraft Me un Aircraft Service Manual Jabiru J160 J170 Variants n ACD 3A08 45 THS DRAWING IS CCPYRG T ANDMUST NOT BE COPIED WITHOUT CONSENT OF TY J160 FLAP CONTROL TUBE ASSY ACN 010 786973 NOTSCALE HNKLERAIRPORT BUNDABERG 4670 ponore EZ v5 5 5 MTERA REFER TOPARTDRAWINGS alm Ls Parts List TIF FLATVASHER 3 15 NYLOC NUT 16POP RIVET 5 50 10 520365 1032 5 7 8 9 10 11 15 Figure 24 Flap Cross Tube Assy revision 0 Dated July 2005 Issued By RAS Page 82 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ filesJ160 amp J170 Tech doc 12 0 Print Date 8 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants SECTION 9 ELEVATOR CONTROL SYSTEM 8 3 ELEVATOR CONTROL SYSTEM See Figure
32. 1 Obtain a trestle 20 drum or similar object 600mm high 2 Mount a solid foam block sandbag pillow or similar compliant material on top of the trestle compliant material should distribute load over minimum 150 square centimetres Place under the lower wing strut attachment Support under both wings at the Wing Spar to prevent the aircraft from rocking Ensure that no fittings are strained 3 1 2 2 JACKING NOSE GEAR 1 Push down on tail Plane NOT THE ELEVATOR until nose gear is off the ground 2 Place trestle or drum under rear fuselage together with absorbent material such as foam block sandbags or a pillow CAUTION Ensure trestle does not foul Ventral Fin J Weigh down tail plane with sandbags or similar heavy absorbent not hard hard items like bricks are likely to damage the aircraft material CAUTION Do not lift using control surfaces Damage to the control surface or control system may result 3 1 3 HOISTING This procedure should not be necessary for most service or maintenance procedures Should hoisting be necessary 1 Drain Fuel from both wings amp Remove wings See details below 2 Fit shackles to wing support brackets 4 off REVISION Dated July 2005 Issued Page 18 of 156 L Miles Technical manuals160 17019160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524
33. 3 3 6 PROPELLER Wash with soap and water rinse with clean water and dry with cloth or chamois Do not use a wax based substance as this would make it almost impossible to refurbish the prop if need at a later stage 3 3 7 WHEELS The wheels should be washed periodically and examined for corrosion cracks or dents in the wheel halves in the flanges or hubs defects are found remove and repair in accordance with Section 6 Discard cracked wheel halves flanges or hubs and install new parts 3 4 LUBRICATION There are no lubrication requirements for the JABIRU other than those detailed in Appendix 1 3 4 1 WHEEL BEARING MAINS AND NOSE At each 100 hour inspection jack the wheel spin the wheel and check for free running and any play on the shaft Remove and replace if there is any sign of binding or wear REVISION Dated July 2005 Issued Page 25 of 156 L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants 3 5 2 5 INSPECTION 3 5 1 INSPECTION CHARTS The chart at Paragraph 3 5 2 shows the recommended intervals at which items are to be inspected As shown in the chart there are items to be inspected each 50 hours each 100 hours and each 200 hours There are also special inspection items which require inspect
34. 5 gt wu N lt w gt ES 1 Q 2 5 N 5 op emm e WwW nd oo 5 lt 02 a 5 o 0 Ko N Ea 5 gt 75 9 o 2 x files J160_ amp _J170_Tech doc 9 Print Date 12 08 2005 12 19 00 L Miles Technical_manuals J160_J170 J160_ amp _J170_workin 77772 Jabiru 9160 J170 Variants ircraft pty A Aircraft Service Manual iru Jab OO 002 015 ATSINASSV ANV 1d TWLNOZIMCH 1504419 S3TANIH 37 1 0 sv NMOHS SY 1191 OL Su 159620 0 SWHSHLO 1 4 SSIINN S LITT INN ENOHINY ISAM Ale 4931 V 30 LNSSNOD JAL LIOHLIW C3IcOO HOSLAY S3313INllN zs LON 1SnH HEE 1402 SI SND SIL AMOS 10N SNOISN3IIG ES p N Sy LS 2 1 31v5S 1 2 3705 Y y 9 1 31 28 O AMAIA 11 150 791939 3ONIH 717130 V ASIA NA OHS LON SIMS HOLVA3 3 ESMdWL 9N d2 LINY dOd 52 ZLE 1NN HOHONY Nid N d zVz139NIH HO1VvA 3 T3 7 YOLYA3 3 DIAY L ON 22 LAIN ANNS YSHSYM Wel 1914 39 10 OZ X B E X 0 1 8 069 ON dO L3A d d
35. Landing Gear 1 Main gear wheels amp fairings 2 Nose gear wheel steering links tension links n amp fairings 3 Wheel bearings 4 Nose gear strut 5 Nose gear housing amp bushes 6 Main gear struts clamps bolts amp nuts 7 7 Tyres amp tubes 8 Brake fluid hoses linings discs brake assemblies amp master cylinder 9 Brake operational check 1 Aircraft exterior 2 Aircraft structure 3 Windows windshield doors amp seals i 4 Seatbelts amp shoulder harnesses B 5 Seat structure j 6 Instruments amp markings revision 0 Dated July 2005 Issued By RAS Page 31 of 156 L Miles Technical manuals160 17019160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants Annual Inspection Each 200 Hours Each 100 Hours Each 50 Hours 7 Instrument plumbing amp wiring a 8 Instrument panel shock mounts decals amp labels 9 Ventilation system 10 Cabin upholstery trim 11 Switches fuses 12 Pitot amp static system slips P 13 Radio intercom amp headsets 14 Antenna amp cable 15 Battery battery cradle amp cables E Control Systems In addition to the items listed below alway
36. 1190 1190 Fuel Capacity 135 litres 75 litres 135 litres 135 litres AVGAS 100 130 MOGAS with Octane Rating 95 RON or above may be used if AVGAS is not available Fuel Type Fuels Containing Alcohols Ethanol etc will damage the fuel tank sealant and MUST NOT BE USED IN JABIRU AIRCRAFT Oil Capacity 2 3 litres 2 3 litres 2 3 litres 2 3 litres Oil Refer Engine Refer Engine Refer Engine Refer Engine Manuals Manuals Manuals Manuals Engine Model Refer To Appendix For Jabiru 2200 Jabiru 2200 Jabiru 2200 Jabiru 2200 Engine Data Jabiru Jabiru Jabiru Jabiru Propeller Type 2 bladed 2 bladed 2 bladed 2 bladed Wooden Wooden Wooden Wooden Propeller Diameter 60 dia 60 dia 60 dia 60 dia P 1524mm 1524mm 1524mm 1524mm Jabiru 44 Jabiru 42 Jabiru 44 Jabiru 44 Propeller Pitch pitch pitch pitch pitch 1117mm 1067mm 1117mm 1117mm Wheel Sizes Standard 500 x 6 rim 400 x 4 rim 500 x 6 rim 500 x 6 rim Tyres Standard 6 wide 6 Ply 4 wide 4 ply 6 wide 6 Ply 6 wide 6 Tyre Pressures Standard 179 kpa 26 179 kpa 26 79 kpa 26 79 kpa 26 Mains psi psi psi psi Tyre Pressures Standard 137 kpa 20 137 kpa 20 137 kpa 20 137 kpa 20 Nose psi psi psi psi Wheel Alignment At 8 T 0 0 0 0 In Engine In Engine In Engine In Engine Battery Locatan Compartment Compartment Compartment Compartment
37. ASSY 931 ISON G H 00 700 9 ALD NOlLdlsloS3d H3SWN WALI 1511 sued SHLONAT 1108 ASSV 9310 1 HVTIOO 9 340A AAY t INSSI 330A G3ISIGOW NI QN38 MAN SMOHS INSSI m a lt en Q Q a e o 71 E e Ww N U lt 02 a 5 o 0 Ko 5 5 75 9 o 2 x files J160_ amp _J170_Tech doc 9 Print Date 12 08 2005 12 19 00 L Miles Technical_manuals J160_J170 J160_ amp _J170_workin Jabiru 9160 J170 Variants ircraft pty A Aircraft Service Manual iru Jab ee 5205159 0 91 1890 ASSY 133HM 3SON Og ava ss WA Ale 30 IHL HEE 38 ION ISNA IHOHA OO SI SIHI 1108 vil Ne 2 8 WSSU 3if095Nv 9 t sSzt secocsM 5 7 2 62209 1 9 Wid T33HM 1592 220026 z L 9 AU YANNI 1592 021 08 ALD 3 sped 629 OH38YCN Ig lMHOdM v YINI sa 26 98Z 210 Vd HO31AV 10N oq SONWvHa Luvd OL 333 byt 3863 10 410349 SSTNN SLAN SIJYLINITNIW SNOISNIWIQ
38. Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants 2 Wipe the battery cable ends battery terminals and the entire surface of the battery with a clean cloth moistened with a solution of bicarbonate of soda baking soda and water 3 Rinse with clear water wipe off excess water and allow battery to dry 4 Brighten up cable ends and battery terminals with emery cloth or a wire brush 5 Install the battery in accordance with the preceding paragraphs 6 Coat the battery terminals with petroleum jelly or an ignition spray product to reduce corrosion 13 4 5 BATTERY BOX The battery box is located on the firewall in the engine compartment 13 5 STARTER SOLENOID The starter solenoid is a sealed unit Service is limited to inspection of terminals for security and replacement of the unit 13 6 VOLTAGE REGULATOR The voltage regulator is a sealed unit Service is limited to inspection of terminals for security and replacement of the unit 13 7 STROBE SYSTEM OPTION A white strobe light may be installed in the rear lower fuselage or in the cabin roof The power source for the strobe light is located behind the fuel tank WARNING The strobe system is a high voltage device Do Not remove or touch tube assembly while in operation Wait at least 5 minutes after turning off power before commencing any activity near the strobe light 13 8
39. sro cectzeSW _ z Zw 9199 ycoa SY OOH moudcesn HSN We sed gt o wu wu lt o 2 E o E 5 5 E en lt 02 tn o 5 o 0 wo 5 gt 75 REVISION fo _ g files J160_ amp _J170_Tech doc L Miles Technical_manuals J160_J170 J160_ amp _J170_workin Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants 4 3 4 LOCKS An optional cylinder and key lock is available When fitted the keyed barrel lock is located in the fuselage at the rear of the Port amp Starboard amp Rear doors Spare keys are available to JABIRU registered owners by quoting the aircraft Serial Number 44 SEATS The JABIRU seats are an integral part of the structure of the aircraft they are therefore fixed in position Forward and upward adjustment can be achieved by placing a cushion behind and or under the occupant The seat pans incorporate crushable foam which is essential in providing shock absorption in crash conditions WARNING DO NOT MODIFY SEATS 4 4 1 REPAIR As seats are integral to the aircraft structure any repair must be referred to JABIRU AIRCRAFT Pty Ltd 4
40. 0 Dated July 2005 Issued Page 43 of 156 L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM BIRT Jabiru J160 J170 Variants ircraft pty A Aircraft Service Manual iru Jab T TEAST 9 ONIM LEM dS 09L0 871 ASSY ONIM X HIS nodu SITNIH JuL SU 5 SOC OSC 2819205 032 SS RIO NON 6 SU F 5 532NYH TOL 7 Ale 4O31AV 40 IN3SNO2 IHL LIOHLIW Ve HO31AV 39858 1ON 3 15 dCO SI SND SIHL pas CNVH 3150540 SY NAWHC SV 1 F 5829025 54 02 LIMY 404 2 22 2 E I 599 M3H28 SNId VL S 0 DT 9 Nsco0Hd IIIS 31v1d t reooz z 3 835 NOUTIIv 9NIDEOJNISH NE EMEN S99 S1TAVONOUSY oz SCT6NIZSN 9 H3NIv 1 wc SONIH WNININMTW ZEE Nid EONIH vesio v 9 NNININNTY 3631 29NIM Em TON zz 1 ST9NI2HOJ3N 3H NOUV 5625 usdsvw 113 77 orogeny
41. 1 Y AU 22 3 2 2 23 3 2 3 M TD ER 23 3 2 4 Carburetor AP ier ues 23 3 2 5 E ETET 23 3 2 6 UI AREAREN E E AEE E 23 3 2 7 Hydraulic BI AICS e on M 23 3 39 CLEANING efie gite ite Rees ete e 24 3 3 1 Windshield and WA dO Sass 24 3 3 2 Interior S rfa sf ES 24 3 3 3 Exterior Surfabgs 24 3 3 4 Aluminium 25 3 3 3 Engine and Engine Compartments neds ily Se eoe 25 3 3 6 1217 2717 S 25 3 3 7 25 3 4 LUBRICATION essentials oscars Sessa 25 3 4 1 Wheel Bearing Mains and 25 39 129 INSPEC HON podio ptr I HEP o eO EU ERREUR 26 3 5 1 26 3 5 2 INSPECTION GUIDELINES ete te oae n tune need 26 3 5 3 INSPECTION GHAR ie iid ibd de 29 4 SECTION A FUSELAGE
42. 3lv d 9 32 8 YANNidS 0917 9906817 Lt 2 dvl 7 LN GOON 9C1690 2SW c ob NIL 1 dOHd 1934409 M04 AVM SHL 33 ISNAN 79 31lSOddO NI 32 3 lt 43 4 lt 3LON vv 1 035 E3NNICS NI 5 S3 OH 9211 49 334 48 1219201 SLNN YOHINY 9 i 14 5 oe Sy 3 D TOTNM 8 e V ve6e 9t SI C8 gt y W130 33S NOLLVTTVISNI TT SNIN3IHOIL 304 35497035 INN YOHINY HO 31925 LON 00 NI SNOISN3HId epe pur S wu p vo Q A 5 bp emm N uw lt 5 o N c 2 2 2 9 o gt 72 g filesJ160 amp J170 Tech doc Print Date 12 08 2005 12 19 00 PM L Miles Technical_manuals J160_J170 J160_ amp _J170_workin Jabiru Aircraft Instruction amp Maintenance Manual Jabiru 2200 Aircraft Engine IMPORTANT The Spinner is an important and integral part of the propeller Assembly It is essential to ensure adequate engine cooling The aircraft must not be flown with the Spinner removed 19 5 10 REMOVE EXISTING PROPELLER Remove Machine Screws and Tinnerman Washers from Spinner Remove S
43. 524 Jabiru 7160 4170 Variants CAUTION Ensure that the Master and Ignition Switches are OFF 7 Install spark plugs and connect leads 8 Seal exhaust pipes Attach a red streamer to each DO NOT seal fuel tank breathers 9 Place protective covers over pitot tube static source vents air vents and openings in engine cowl to prevent the entry of foreign material or beings especially wasps 10 Attach a warning placard to the propeller stating that vents and breathers have been sealed The engine must not be started with the seals in place 11 Every 7 days the propeller should be rotated through 5 revolutions without running the engine leave propeller in the horizontal position CAUTION Ensure that the Master and Ignition Switches are OFF 3 1 10 INSPECTION DURING STORAGE 1 Generally inspect airframe and clean as necessary 2 Inspect the interior of at least one cylinder through the spark plug hole for corrosion at least once a month 3 If at the end of the 90 day period the aircraft is to be continued in non operational storage repeat Steps 1 13 above most will only need to be checked 3 1 11 RETURNING AIRCRAFT TO SERVICE After temporary storage the procedures for returning the aircraft to service are as follows 1 Remove aircraft from blocks and check tyres for proper inflation 2 Check battery and install Check carburettor air filter a
44. 9L VEL ENV 62 1708 908 VZLENV 82 31IVW3H 9 veloogd 92 2 46 v6zevoc 9 9 pSWEL ONdD LINY dOd TV 8 4 N66L 0Hd vc 32018 INNON LOAld pereore ez Ya TOHINOO H3NIVIdS pezeore zz 1 N8 008d lz LAN 85 69508 OC D 1108 6l 0 48 78520 8 8 LAN DOTAN 98 201 9025 Zr OL u3HSVM 1914 96 OL O96NV SL ONIMVUYNG SIHL JO SL33HS NI NMOHS SV 55 4 1109 8 VOLENV vl 7031409 313 18WOO JHL NSAID OL H3HSVM LVI 9Lf 090NV 6 SYASWNN 19 NON TVIOH3IWINOO 72 A18NBSSV SLV1d ONILNNOW 7605908 LAN MOHL 52 JO IW UNSN3 41 S1709 SS3NXOIHL ASSV XOLVA H 208808 H31HOHS SSN IWNINON NSAID SHLON31 1108 19L 096NY ISN ALO M38ADN Wall S3LON 1911 sed 5 9 lt A e m E en o 5 5 E Ww nd lt 02 5 o 0 Ko Zz 5 5 75 9 o 2 x files J160_ amp _J170_Tech doc 9 Print Date 12 08 2005 1
45. ELECTRICAL LOAD ANALYSIS As this aircraft is only certified for VFR Daylight only operations an Electrical Load Analysis is not required as failure of the electrical generation system would have a limited effect on the length of time of radio transmissions and no effect on aircraft performance as the engine electrical system is totally isolated from the power supply and is self sustaining The battery is only used to crank the engine for starting 13 9 RADIO WIRING DIAGRAM OPTION The optional aircraft radio system diagram is provided with the radio manuals 13 9 1 VHF ANTENNA INSTALLATION The VHF antenna used consists of two aluminium bars permanently bonded in place inside the spar channel of the vertical fin Figure 49 shows the position details of the two bars REVISION Dated July 2005 Issued By Page 139 of 156 L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru 9160 J170 Variants ircraft pty A Aircraft Service Manual iru Jab 3199 SSI 590 NOLLVZlMY lOd 1934 31905 VNN31INV LeOdel MJTNIH dAldo 029 CAE 984 019 NOY zu 1 231 12 59 Mr NWO 02140345 SSN SINT NOLIN Adsl JIEVO 922 318vO XVOD N 98G 9e Ge HOv3 Figure 49 VHF Antenna In
46. IN3A 1I 88 92 90255 5 SNIH O NLOOWPSd INIA 1903 ONIM GALNSA aodssovr AGO YNWL 7913 GALNSA Q096S0vt Sen IN3A O1 114 5524 9 dVO MNV L 13613 SONIA 909550 01029 3111201 ALO LuVd 18 sued Figure 43 Vented Fuel Cap Assy rel T C1 5 lt 02 tn o 5 o 0 wo 5 gt 75 9 o 2 x _ g files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM L Miles Technical_manuals J160_J170 J160_ amp _J170_workin Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants 11 4 FUEL SHUT OFF VALVE See Figure 46 or 47 depending on model variant 11 4 1 DESCRIPTION The fuel shut off valve is a two position ON OFF valve which is located in front of the main longitudinal beam 11 4 2 FUEL VALVE REMOVAL amp INSTALLATION Turn OFF both taps between wing tanks and header tank Cover both tank cap vents 2 Remove fuel shut off valve cover Remove shut off valve handle 4 Remove cover plate 5 Disconnect and cap fuel lines at shut off valve 6 Remove shut off valve 7 Reverse the preceding steps for installation WARNING Fuel valves between wing tanks and header tanks must be in the ON
47. WIRING DIAGRAM cnet oorr ae ete Maece 136 1222 eee doeet tertia remi 138 13 31 Master Switch lesa 138 13 4 BATTERY POWER TYP THM laci 138 194 SB eby qd ex M E eee 138 13 42 Battery Trouble a hele es 138 13 23 Removal Installation 138 1344 Cleaning the Battery a i sii 138 134 3 BATTERY BON ceire deti edu ere tete tes 139 13 5 5 139 13 6 VOLTAGE REGULATOR deeb 139 13 7 STROBES Y STEM OPTION enti ID An RERO 139 13 8 ELECTRICAL LOAD ANALYSIS 139 13 9 RADIO WIRING DIAGRAM OPTION 139 13 01 VHF ANTENNA INSTALLATION i eod 139 14 SECTION 15 PAINTING amp 0 0 141 14 1 INTERIOR eid decim it Me seve ettet eris tees 141 TAD V 141 141 14 22 Materials 4 141 Revision o Dated July 2005 Issued By RAS Page 7 of 156 L MilesYTechnical manuals160 1701160 amp J170 w
48. amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM BIET Jabiru J160 J170 Variants ircraft pty A Aircraft Service Manual iru Jab 043p SY Sa ONNg ASSY MOILS 3H1N3O 18 1 EBLLELTLZTTITIL 452 SCTSSIENV 559401626 F 030 SNO 25 982 OLO NOW X SON SIONWESIOL Add H931AY JO IN3SNOO 2 Vd SNM CNY LHOUAdOS SIHL punte RN pose k zi ald 31514 oc 51051409 3 14 AH13NO39 31892 83149 aogorove 2 0 ooaj 21 ONA GOY IYA She 1610094 USHSVM 040 6 tt 2 QNaCOHMN3OVds 90 OTN ZEOT SSEOESNN 1 WaHSvMivii Sue oeny NOUSSNOT 10N4310NH3aM 2 zz OAMTwHiN32H39vds psow 9 2 JOULNOONGYTIVANLS bezlios 92 MAHSYMNOTN z INN 31 139 00 rzXS0c 62 ONIA 340 109170 vae v 2 0 e 9 1 z 1 HS 80115 1 qessezove 3903M aw
49. and landing REVISION Dated July 2005 Issued By RAS Page 122 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants 12 SECTION 12 INSTRUMENTS amp INSTRUMENT SYSTEMS 12 1 GENERAL This Section describes the typical instrument installation and its operating system Emphasis is placed on trouble shooting and corrective measures only It does NOT deal with specific instrument repairs as this usually requires special equipment and data and should be handled by instrument specialists Malfunctioning instruments should be either returned to JABIRU AIRCRAFT Pty Ltd or sent to an approved instrument overhaul and repair station for servicing Our concern here is with preventive maintenance on the various instrument systems and correction of system faults which will result in instrument malfunctions The descriptive material maintenance and trouble shooting information in this Section is intended to help the owner or mechanic determine malfunctions and correct them up to the defective instrument itself at which point an instrument technician should be called in Some instruments such as Oil Temperature and Pressure Gauges are simple and relatively inexpensive and repairs will usually cost more than a new instrument Flight instruments on th
50. axle and spacer 5 Remove lock spacer 6 Pull wheel from axle 6 4 2 MAIN WHEEL DISASSEMBLY 1 Deflate tyre and break tyre beads loose from tyre rims WARNING Injury can result from attempting to separate wheel halves with the tyre inflated Avoid damaging wheel flanges when breaking beads loose as a scratch nick or gouge may cause wheel failure 2 Remove through bolts nuts separate wheel halves removing tyre tube wheel hub Remove brake disc REVISION Dated July 2005 Issued By RAS Page 54 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants 4 Remove bearings from hub NOTE The bearing are press fit in the wheel hub and should not be removed unless a new part is to be installed 6 4 3 MAIN WHEEL INSPECTION ASSEMBLY AND REPAIR 1 Clean all metal parts solvent and dry thoroughly 2 Inspect wheel halves for cracks Cracked wheel halves should be discarded new parts used Sand out nicks gouges and corroded areas If excessively warped or scored or worn to thickness of 2 mm brake discs should be replaced with a new part Sand smooth small nicks and scratches 4 Carefully inspect bearings for damage and discolouration NOTE Bearings are pre packed DO NOT clean with
51. beides ep eer epa Deva s 71 72 CONTROL COLUMN seerne ne Een b mere pe ee ec reo Er 73 7 2 1 Control Column Removal amp Installation sse seen eene tenens 73 7 3 CONTROL CABLES Smite n se 75 7 3 1 Control Cable Removal amp Installation essendi eee 75 74 AILERONS neo AO e e NE 75 7 4 1 Aileron Removal amp Installation 75 7 4 2 Aileron amp 1 79 7 22 CONTROL RIGGING i ett teet eer tevin 75 8 SECTION 8 WING FLAP CONTROL 5 8 00 77 8 1 WING FLAP CONTROL SYSTEM 77 8 1 1 OPERATIONAL CHECK iere 77 8 1 2 FLAP Switch ASSEMBLY 77 8 1 3 FLAP cross SHAFT 55 77 8 1 4 Removal and Installation uu iie i teu ici 77 8 1 5 Flap Control Rod a 77 S2 PEAR SE O abr e 77 8 2 1 Removal and Installation eese eene trennen entente nter enne tree enn nn nennen 77 8 2 2 Inspection and E E 78 8 2 3 Flap Rigging J170 SP Nt etie eei 78 8
52. broken terminals heat deterioration and corroded terminals REVISION gg Dated July 2005 Issued By RAS Page 26 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants 3 5 2 5 BOLTS IN CRITICAL AREAS correct torque in accordance with torque values given in the chart in Section 1 when installed or when visual inspection indicates the need for a torque check NOTE Torque values listed in section 1 are derived from oil free cadmium plated threads and are recommended for all installation procedures contained in this manual except where other values are stipulated They are not to be used for checking tightness of installed parts during service 3 5 2 6 FILTERS SCREENS AND FLUIDS cleanliness contamination and or replacement at specified intervals 3 5 2 7 AIRCRAFT FILE Various data information and licenses are part of the aircraft file Check that the following documents are up to date accordance with current Civil Aviation Authority Regulations Most of the items listed are required by the Australian Civil Aviation Authority Regulations Since the regulations of other nations may require other documents and data owners of exported aircraft should check with their own aviation officials to determine their individual req
53. cleaning lines fails the master cylinder may be faulty and should be repaired or replaced If master cylinder or wheel Leak in system cylinders are leaking repair or install new parts Restriction in hydraulic lines or in master cylinder Air in system Bleed system Lack of fluid in master cylinder Fill and bleed system Master cylinder defective Repair or install new parts Brake pads worn Replace with new parts REVISION o Dated July 2005 Issued By RAS Page 64 of 156 L files Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants 6 8 2 BRAKE MASTER CYLINDER The brake master cylinder located between the seats on the front of the main longitudinal beam is actuated by applying rearward pressure to the brake handle A small reservoir is incorporated into the master cylinder for the fluid supply 6 8 2 1 BRAKE MASTER CYLINDER REMOVAL amp INSTALLATION 1 Remove the flexible hose from one wheel brake assembly and the hydraulic fluid from the brake system 2 Unbolt pushrod amp remove brake handle Disconnect flexible hose at master cylinder 4 Unbolt master cylinder retaining bolts 2 b Plug or cap hydraulic fittings and hoses to prevent the entry of foreign material 6 Reverse the prec
54. e E Ete Robe te Sie PUER EE PAS Ene 103 10 3 1 Cleaning and Inspection sss 103 10 3 2 Cooling Air Baffle Removal amp Installation 103 WIESEN ume 103 10 4 ENGINE MOUNT n E 103 10 5 ENGINE FUEL SYSTEM 2 0 E X eee aaa rr enr nir te nint scene sete 103 10 5 1 Fuel System General AE M ausu tiec crier th toad eene tale 103 10 3 2 Aircraft Fuel System d Een 104 10 5 3 J160 J170 Fuel System non cs vla variants 104 10 6 SPARK PLUGS EE 104 107 ENGINE CONTROLS assesses be naan gp ces ERN EU eae 104 TOA ARES OUND Hiss 104 10 7 2 CS VLA Throttle amp 104 10 7 3 J160 J170 Throttle non cs vla variants esee eterne eene 104 Et 107 10 7 5 Air Intake System amp Carburetor 107 10 8 EXHAUST SYSTEM ierit e rire e tI imo ern Bases these rp eb enti RH EUER PR RAE e 109 10 8 1 Exhaust System Removal and 1 109 108 2 _ Exhaust Inspection CURT Ee ota este celo ede CN 109 10 9 EXTREME CLIMATIC CONDITIONS sacs gest 111 OIE
55. files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants 17 APPENDIX II JABIRU ENGINE PARTS BOOK Please insert your copy of the INSTRUCTION AND MAINTENANCE MANUAL that comes with your engine into this section THIS PAGE IS INTENTIALLY LEFT BLANK REVISION Dated July 2005 Issued By RAS Page 148 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants 18 APPENDIX ENGINE INSTALLATION MANUAL Please insert your copy of the INSTALLATION MANUAL that comes with your engine into this section THIS PAGE IS INTENTIALLY LEFT BLANK REVISION gg Dated July 2005 Issued By RAS Page 149 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM 19 APPENDIX PROPELLER SERVICE MANUAL 19 1 APPROVED INSTALLATIONS The following combinations are approved Table 16 Approved Propeller Installations Airframe Engine Propeller Dia x Pitch Remarks Limits Jabiru J160 Jabiru 2200 C000 1924 x 1117 Mot above 3300 RPM 60 x 44 Jabiru J160 C Jabiru2200 C000 los Not above 3300 RPM Jabiru J
56. inspect the engine for loose bolts nuts cracks leaks amp cooling fin damage 2 Inspect baffles baffle seals amp brackets for cracks deterioration or damage 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 NOTE Avoid excessive flexing amp sharp bends when examining hoses for stiffness 4 All flexible hoses in the engine compartment should be replaced at engine overhaul or every 2 years whichever comes first Hoses which show visible deterioration cracking excessive hardening should be replaced immediately irrespective of age 5 major engine repairs refer to JABIRU AIRCRAFT Pty Ltd or Approved Jabiru Service Centre 10 2 5 1 FLEXIBLE HOSES Leak Test After each 50 hours operation flexible hoses should be checked for leaks Examine the exterior of hoses for evidence of leakage or wetness Replace any doubtful hoses Replacement Hoses should not be twisted on installation Provide as large a bend radius as possible Hoses should have minimum of 12mm clearance from other hoses or surrounding objects or be tie clamped to them NOTE Rubber hoses will take a permanent set during extended use service Straigh
57. is to be installed 6 6 3 NOSE WHEEL INSPECTION AND REPAIR 1 Clean metal parts in solvent and dry thoroughly 2 Inspect wheel halves for cracks Cracked wheel halves should be discarded and new parts used Sand out nicks gouges and corroded areas Clean thoroughly 3 Carefully inspect bearings for damage and discolouration NOTE Bearings are pre packed DO NOT clean with solvents as it will remove the packing 4 Refit bearings 6 6 4 NOSE WHEEL REASSEMBLY 1 Replace bearings in wheel hub 2 Apply automotive wheel rim lubricant to the tyre bead faces on the inside of the wheel rims 3 Position tyre and tube between wheel halves with tube inflation valve through hole in outside wheel half 4 Mate wheel halves While maintaining a light force assemble a washer and nut on one through bolt and tighten snugly Assemble the remaining washers and nuts on the through bolts and torque to the value specified in Table 3 WARNING Ensure tube is not pinched between wheel halves during assembly Uneven or improper torque of through bolt nuts can cause failure of bolts with resultant wheel failure 5 Insert through bolts through brake disc and position disc on the inner wheel hub flange 6 Inflate tyre to seat the tyre beads adjust to correct tyre pressure Refer Aircraft Specifications above REVISION Dated July 2005 Issued Page 60 of 156 L Miles Technical manuals160 J1701J160 amp J170 working
58. line blow out instruments obstructed line revision 0 Dated July 2005 Issued By RAS Page 127 of 156 L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants 12 3 7 TROUBLE SHOOTING AIRSPEED INDICATOR Table 10 Trouble Shooting Airspeed Indicator Trouble Probable Cause Remedy Pitot pressure connection not Test line and connections for leaks Repair or replace praperiy connecisd t damaged line tighten Hand fails to response pressure line from pitot tube 9 2 19 5 Pitot static lines clogged obstructions Blow out lines Test lines and connections for leaks Repair or replace Leak in pitot or static lines damaged lines tanten Incorrect indication or 9 mild connections ANG SNES Substitute known good Defective mechanism or l goor indicator and check reading leaking diaphragm Replace instrument Check panel shock mounts Excessive vibration Replace defective shock mounts Hand vibrates Check clamps and line connections for security Excessive tubing vibration Tighten clamps and connections replace tubing with flexible hose 12 3 8 TROUBLE SHOOTING ALTIMETER Table 11 Trouble Shooting Altimeter Tr
59. main control stick horn 11 Install clamp block and pin in aileron control cable clamp at rear of seat REVISION Dated July 2005 Issued By RAS Page 42 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants 12 13 14 15 On RH wing reconnect Pitot tube Replace wing strut fairings top and bottom Replace wing root fairings Perform a fuel flow test Disconnect the fuel line from the mechanical fuel pump in the engine compartment Have a second person catch any fuel that flows out of the line in a container with accurate volume marks Turn electric fuel pump on and pump fuel through the lines into container Ensure there is about 1 litre per minute flow rate NOTE After carrying out the fuel flow test check that both wing tanks are feeding fuel by turning off both wing tanks pumping about a litre out of the header tank then turning the left wing tap on The wing tank will gravity feed to the header tank it should re fill within approximately 1 2 minutes This must be repeated for the right wing If a wing is not flowing correctly check lines for kinks blockages amp airlocks Ensure both wing taps are wired in the position using fuse wire before returning the aircraft to service Revision
60. of pre owned aircraft should ensure that the transfer of their aircraft has been advised to JABIRU AIRCRAFT Pty Ltd or your local dealer of distributor Existing owners should ensure that their postal address remains current In addition to the information in this Service Manual vendor publications will periodically be available from JABIRU which describe disassembly overhaul and parts breakdown of some of the various vendor equipment items A listing of the available publications is issued from time to time in service letters IMPORTANT All maintenance should be undertaken with careful regard for the procedures outlined in this manual A detailed record of maintenance undertaken should be recorded in the Aircraft Log Books In the interests of product development we encourage owners to make suggestions related to design improvements However the final decision on their adoption or otherwise rests with JABIRU AIRCRAFT Pty Ltd REVISION Dated July 2005 Issued By RAS Page 2 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty pta 5 22 un Aircraft Service Manual Jabiru J160 J170 Variants 1 Table of Contents TABLE OF EG EO V ctc 3 1 1 mti GS reme tir 9 L2 LIST OF TABLES entreprise inire ah riii ertet eee pe
61. paint does NOT cover a multitude of sins 11 The factory uses a low pressure pot gun for spraying at pressures from 60 100 psi 12 Itis mandatory that exterior color is WHITE only broken if desired by pin strips on the vertical surfaces i e Sides of fuselage but not horizontal surfaces i e top of wings or fuselage as the heat build up under the tape in hot sun is considerable REVISION Dated July 2005 Issued By RAS Page 142 of 156 L Mfiles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants 13 14 15 16 After filling all pinholes spray another coat of primer the discolored areas all over primer coat is not required over the gel coat as gel coat is a sufficient undercoat The final rub is with 320 grit all over and if satisfied with the surface preparation remember paint will simply change color not hide lumps bumps scratches and holes blow off the dust and give an all over wipe with a tack cloth to pick up the final dust particles Wash down the floor of the spray area to settle dust and proceed to spray as per your selected technique You are now ready to spray final coat GOOD LUCK WARNING The Jabiru aircraft is only approved to be painted in basic White colour so as to minimise the effects of heat
62. solvents as it will remove the packing 5 Replace bearings 6 Apply automotive wheel rim lubricant to the bead areas of the rim halves 7 Position tyre tube between wheel halves with tube inflation valve through hole in outside wheel half 8 Mate wheel halves While holding halves together assemble a washer and nut on one through bolt and tighten snugly Assemble the remaining washers and nuts on the through bolts and torque to the value specified in Table 3 CAUTION Ensure tube is not pinched between wheel halves during assembly Uneven or improper torque of through bolt nuts can cause failure of bolts with resultant wheel failure 9 Insert through bolts through brake disc and position disc the inner wheel hub flange 10 Inflate tyre to seat tyre beads then adjust to correct tyre pressure Refer Aircraft Specifications above 6 4 4 MAIN WHEEL INSTALLATION 1 Lightly coat axle with Anti Sieze or a Water Proof grease 2 Place wheel assembly axle REVISION Dated July 2005 Issued Page 55 of 156 L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Jabiru 9160 4170 Variants Install spacer and lock bolt nut through centre of axle 4 Place outboard brake pad plate and springs in position and se
63. starting at the connection to the head securing bolts and moving outwards Especially check areas adjacent to welds Look for exhaust gas deposits in surrounding areas indicating that exhaust gas is escaping through a hole or crack For a more thorough inspection the following procedure is recommended 1 Remove manifolds and or muffler 2 Use rubber expansion plugs to seal openings Using a manometer or gauge apply approximately 1 1 2 psi inches of mercury 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 replaced with a new part before the next flight REVISION Dated July 2005 Issued By Page 109 of 156 L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru 9160 J170 Variants ircraft pty A Aircraft Service Manual iru Jab 27 430 13395 0 010 6 31616 LSNWHXG El 37925 ON SAI 1937539 NOLLVTIVISNI ASSY 0622 291f zu 7 3 9u38YQNng lHOdlv U3 DINIH 6 6 98 OLO 74447 11905 ION 00 53 SNOISN3HIG Ald 493 28 JCN 30 02 1fiCHLI 01 72259 01 Sid 5 4
64. the principal rules for system maintenance The pitot tube and static ports MUST be kept clean and unobstructed 12 3 2 STATIC PRESSURE SYSTEM INSPECTION amp LEAKAGE TEST The following procedure outlines inspection and testing of the static pressure system assuming that the altimeter has been tested and inspected in accordance with the current Regulations 1 Ensure the static system is free from entrapped moisture restrictions 2 Ensure no alternations of airframe surface have been made which would effect the relationship between air pressure in the static pressure system and truce ambient static air pressure for any flight configuration Attach source of suction to static pressure source opening Figure 50 shows method of obtaining suction 4 Slowly apply suction until the altimeter indicates a 1000 foot increase in altitude revision 0 Dated July 2005 Issued By RAS Page 125 of 156 L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty Aircraft Service Manual Jabiru J160 J170 Variants CAUTION When applying or releasing suction do not exceed the range of either vertical speed indicator or airspeed indicator 5 Cut off suction source to maintain a closed system for one minute Leakage shall not exceed 100 feet altitude loss as indicated on the alt
65. the engine has been stopped by turning off the fuel valve thereby not leaving any fuel in the carburettor bowl Every 7 day the propeller should be rotated through 5 revolutions without running the engine Leave the propeller in the horizontal position to ensure even distribution of liquids in the wood If left in the vertical position liquids will drain to the lower tip resulting in an unbalanced propeller CAUTION Ensure that the Master and Ignition Switches are OFF Store under cover away from direct sunlight as ultra violet rays damage composite structures REVISION gg Dated July 2005 Issued By Page 19 of 156 L MilesYTechnical manuals160 17019160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants In addition the Pitot tube static air vent air vents openings in the engine cowl and other similar openings should have protective covers fitted to prevent entry of foreign materials and beings especially wasps 3 1 8 RETURNING AIRCRAFT TO SERVICE After flyable storage returning the aircraft to service is accomplished by performing a thorough pre flight inspection Ensure all protective covers are removed 3 1 9 TEMPORARY OR INDEFINITE STORAGE Temporary storage is defined as aircraft in non operational status for a maximum of 90 days Treat as for fly
66. wing slightly while pulling attaching bolt or carefully use a long drift punch to drive out attaching bolt 14 Carefully remove wing by moving it out to clear the aileron cable from the fuselage 15 Place wing on cushioned structure to avoid damage to wing strut attachment 16 Unbolt lower wing strut bolt and remove wing strut 17 Repeat Steps 5 16 to remove other wing 5 1 2 REPAIR The wing is a composite monocoque structure All repairs must be referred to JABIRU AIRCRAFT Pty Ltd or our approved local agent 5 1 3 INSTALLATION T Fit the lower strut attaching bolt leaving the top end of the strut on the ground WARNING Do Not Tighten nut or metal fatigue may result Washer must be free to rotate 2 Fit wing to fuselage leaving wing tip on the saw horse and routing aileron cable through hole in fuselage wing root Install front and rear wing attaching bolts nuts 4 Put top wing strut attaching bolt in your pocket 5 Lift wing tip and install wing strut to wing strut attachment with bolt from pocket Install nut WARNING Do Not Tighten nut or metal fatigue may result Washer must be free to rotate 6 Connect all fuel lines to wing fuel gauge making sure there are no lines that have kinked 7 Put about 101 of fuel in each tank amp check for any leaks 8 Attach flap to wing ensuring all bushes are in place 9 Install bolt nut control rod 10 Install bolt nut in aileron control cable on
67. 0 25 7 05 117 0 25 7 05 8 0 25 7 05 63 0 25 7 05 118 0 25 7 05 9 0 25 7 05 64 0 25 7 05 119 0 25 7 05 10 0 25 7 05 65 0 25 7 05 120 0 25 7 05 11 0 25 7 05 66 0 25 7 05 121 0 25 7 05 12 0 25 7 05 67 0 25 7 05 122 0 25 7 05 13 0 25 7 05 68 0 25 7 05 123 0 25 7 05 14 0 25 7 05 69 0 25 7 05 124 0 25 7 05 15 0 25 7 05 70 0 25 7 05 125 0 25 7 05 16 0 25 7 05 71 0 25 7 05 126 0 25 7 05 17 0 25 7 05 72 0 25 7 05 127 0 25 7 05 18 0 25 7 05 73 0 25 7 05 128 0 25 7 05 19 0 25 7 05 74 0 25 7 05 129 0 25 7 05 20 0 25 7 05 75 0 25 7 05 130 0 25 7 05 21 0 25 7 05 76 0 25 7 05 131 0 25 7 05 22 0 25 7 05 77 0 25 7 05 132 0 25 7 05 23 0 25 7 05 78 0 25 7 05 133 0 25 7 05 24 0 25 7 05 79 0 25 7 05 134 0 25 7 05 25 0 25 7 05 80 0 25 7 05 135 0 25 7 05 26 0 25 7 05 81 0 25 7 05 136 0 25 7 05 27 0 25 7 05 82 0 25 7 05 137 0 25 7 05 28 0 25 7 05 83 0 25 7 05 138 0 25 7 05 29 0 25 7 05 84 0 25 7 05 139 0 25 7 05 30 0 25 7 05 85 0 25 7 05 140 0 25 7 05 31 0 25 7 05 86 0 25 7 05 141 0 25 7 05 32 0 25 7 05 87 0 25 7 05 142 0 25 7 05 33 0 25 7 05 88 0 25 7 05 143 0 25 7 05 34 0 25 7 05 89 0 25 7 05 144 0 25 7 05 35 0 25 7 05 90 0 25 7 05 145 0 25 7 05 36 0 25 7 05 91 0 25 7 05 146 0 25 7 05 37 0 25 7 05 92 0 25 7 05 147 0 25 7 05 38 0 25 7 05 93 0 25 7 05 148 0 25 7 05 39 0 25 7 05 94 0 25 7 05 149 0 25 7 05 40 0 25 7 05 95 0 25 7 05 150 0 25 7 05 41 0 25 7 05 96 0 25 7 05 151 0 25 7 05 42 0 25 7 05 97 0 25 7 05 152 0 25 7 05 43 0 25 7 05 98 0 25 7 05 153 0 25 7 05 4
68. 01 153 BSE 1 00 0 0 NOLLOAS 5 1 8 9 NOILO3S ASSY NO Liz OL wr 55593 NOW 2 X j 2 93515 WIL 354 SNVH OL MOV HLON31 1773 091 096 05 L SNITINOW H3AO 09L Y 022 SHz AVI MZOH AXO 3 SNS 32 74 8 03 13S Figure 9 J170 UL Wing Assy Sheet 2 10 5 lt 02 tn o 5 o 0 Ke 5 gt 75 9 o 2 x _ g files J160_ amp _J170_Tech doc L Miles Technical_manuals J160_J170 J160_ amp _J170_workin Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants 5 2 WING STRUTS Each wing strut is a single lift strut which transmits a part of the wing load to the lower portion of the fuselage The strut consists of a streamlined tube riveted to two end fittings which attach to the fuselage and wing WARNING Do Not Tighten Strut Attachment Bolts Metal fatigue may result Bolt must be free to rotate 5 2 1 REMOVAL AND INSTALLATION See Wing Removal Paragraph 5 2 1 and Wing Installation Paragraph 5 2 3 5 2 2 REPAIR Wing struts are structural components and therefore all repairs must be referred to JABIRU AIRCRAFT Pty Ltd or our approved local agent A dented cracked or deformed wing strut should be replaced
69. 01 31914 gt wu wu lt S o vo 5 24 e o 5 51 rel T en U lt 02 tn o 5 o 0 wo N 5 gt 75 9 o 2 x _ 0 files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 L Miles Technical_manuals J160_J170 J160_ amp _J170_workin Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants 9 2 RUDDER See Figures 37 and 38 9 2 1 REMOVAL amp INSTALLATION 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 Remove hinge pins 4 Remove rudder 5 Reverse the preceding steps for installation 9 2 2 INSPECTION amp REPAIR Inspect rudder for any signs of delamination or cracking Pay particular attention to the Control Horn and hinges and their surrounding areas Repairs must be referred to JABIRU AIRCRAFT Pty Ltd our approved local agent 9 3 CONTROL CABLE amp ATTACHMENTS The control cable is of the push pull type fitted with spherical bearings at both ends To operate the outer cover of the cable must be clamped firmly at each end 9 3 1 REMOVAL amp INSTALLATION The Control Cable is a Primary Control and may not be repaired or removed without reference to JABIRU AIRCRAFT Pty Ltd or ou
70. 0ve ASSY CL ran rie 327 surn JM 97 156 634 AXOd 209201 201 9403 HLM S 3NNVFO Nid S3 1v4 39NIH ONDE Issued RAS 6 52525 9 2735 Fim 3Ov ld N 54016 NIS34 AXOc3 009591 7 49073 1100 5 33913 54015 ONO 530 5 3Ow d 13 5 539914 CL SALWIdW3L TAYA JSN 15 9 40 5 OL 30014 0 3093 LYI OL 4015 3 3AVML e3qaana LINN OL 54015 30 14 33 Rudder Installation Q Q 5 3 5 39VH8 39NIH 401 8 7199 Figure 401 MOT38 C3NIVL34 Nid 32v ld NIS34 AXOd3 56951 9 42014 NOL OO 13 2 OL 39w43 M3l 719 32 Ol 83 34 2 T3NNYHO Nid 13 NNZINY OL zOvH8 SYANHXOS T3NNvHO N4 C 39W48 401 13 les Technical_manuals J160_J170 J160_ amp _J170_workin 017 Ald 30 LNZSNOO 93455 38 ISAW 9 SI SNIAYHO SIHL REVISION files J160_ amp _J170_Tech doc 9_ Print Date 12 08 2005 12 19 00 Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants 10 Section 11 Engine amp Engine Installation 10 1 ENGINE COWLS The engine cowls comprise both an Upper and Lower composite structure
71. 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants 12 11 GYRO INSTRUMENT PACKAGE OPTION A vacuum pump driven Artificial Horizon and Directional Gyro together with an electric Turn Coordinator is available as an option Where this option is provided a different instrument panel facia is fitted Repair should only be performed by an approved instrument workshop revision 0 Dated July 2005 Issued By RAS Page 135 of 156 L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants 13 SECTION 14 ELECTRICAL SYSTEMS 13 1 ELECTRICAL POWER SUPPLY SYSTEM Electrical energy for the aircraft is supplied by a 14 volt direct current single wire negative ground electrical system A 12 volt battery supplies power for starting and furnishes a reserve source of power in the event of electrical power system failure An engine driven Alternator is the normal source of power during flight and maintains a battery charge controlled by a voltage regulator The following paragraphs provide brief descriptions of the elements of the electrical system They should be read in conjunction with the Wiring Diagram at Figure 51 13 2 WIRING DIAGRAM The Wiring Diagram is
72. 160_ amp _J170_workin ircraft pty A Aircraft Service Manual iru Jab Jabiru 9160 J170 Variants L v evl eao Wiss LV 08 ATEWASSV 0297 on oma Su S NES 1 4 SSIMUBHLO 55314 ava ssi Ald JO LN3SNOO LNOHLIM T 38 LON 15 SI SIHL Vd HO31AV 395 LON OC SNOISNIWNIG 1108 91 V90 ENV 65 D LAN DOTAN YN N60Z0Hd zs 55 1913 2 9 19 1108 1 N6SE0Hd 05 dv10 3180 N68000d 9 WIHS 4 10 91895 6009 St ATSWASSV 91899 WIL p8rl00d zt 5 LNN 94 E 9LENY 0 ONINdS 6900 1708 908 VLO ENV 8 1X3 606906 LE GO SIV 9 9 NIdH3llOO 21 99750 SE YIHSYM 1914 8 QL9 096NV 2 YANIVLAY dvO ONINdS 710651 __ 8 COW SNINIVL3H ONIdS vloere 710018 LOAld 3 3318 9615708 16 32018 10Ald 601908 06 1708
73. 170 Jabiru 2200 CO00 1924 x 1117 Not above 3300 RPM 60 x 44 Jabiru J170 SP Jabiru 2200 C000 i s A Not above 3300 RPM Jabiru J170 SPC Jabiru 2200 000 ae a Not above 3300 RPM Jabiru J170 UL Jabiru2200 CO00 1 a Not above 3300 RPM 19 2 IDENTIFICATION STAMPINGS Each propeller is marked with the particulars indicated below 1 The Propeller Drawing 2 The diameter and pitches metres proceeded by the letters respectively The type of engine for which the propeller has been designed 4 Manufacturing Serial No DWG D 1524 P 1346 JABIRU 2200 J J 4 0001 LC 4 Stroke Serial No Leading Edge Composite Prop Engine Protection Sheath 19 3 DESCRIPTION The Propellers are constructed from 3 laminations of approved species timber and are manufactured in accordance with the relevant approved Drawing They are single piece 2 blade propellers with an inlaid leading edge urethane Jabiru Aircraft Instruction amp Maintenance Manual Jabiru 2200 Aircraft Engine The propeller finish is a composite sheath and clear epoxy paint JABIRU Part No PPOO39N WARNING In countries other than Australia different registration requirements will apply It is the owner s responsibility to become fully aware of the particular maintenance requirements and limitations applicable to the appropr
74. 170 J160_ amp _J170_workin Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants 6 3 1 REMOVAL The following procedural steps remove one side of the landing gear as a complete assembly Refer to applicable paragraphs for removal of the individual components 1 Jack the aircraft in accordance with the details given Section 3 2 Unbolt wheel end of flexible brake hose catching brake fluid in a container 3 Remove bolt nut from top inboard end of undercarriage beam Remove rubber bushes 2 4 Remove bolts nuts 2 from the clamp at bend in undercarriage beam 5 Remove clamp 6 Remove Undercarriage Leg Assembly 6 3 2 INSTALLATION The following procedural steps install the landing gear as a complete assembly Refer to applicable paragraphs for installation of the individual components With aircraft jacked 1 Offer the beam to the fuselage and install clamp bolts nuts 2 Do tighten at this stage 2 Locate top end bolt install and tighten nut See Torque Value Table 3 Tighten clamp bolts nuts 2 OFF Torque Value Table 3 4 Connect flexible brake line 5 Top up brake master cylinder with fresh brake fluid and bleed brakes see Paragraph 6 8 5 6 Lower aircraft 6 3 3 INSPECTION AND REPAIR T Inspect composite beam for damage indicated by cracks or delamination Pay particular attention to the
75. 2 19 00 L Miles Technical_manuals J160_J170 J160_ amp _J170_workin Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants 9 SECTION 10 RUDDER CONTROL SYSTEM 9 1 RUDDER PEDAL SYSTEM Refer to Figure 33 Rudder control is maintained through the use of rudder pedals which also control nose wheel steering The system is comprised of rudder pedals two push rods a centring mechanism and an enclosed push pull cable 9 1 1 REMOVAL AND INSTALLATION 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 9 1 2 INSPECTION AND REPAIR 1 Inspect nylon bearings for Replace if worn 2 Inspect pedal bars for wear around bearing area and for distortion 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 Replace any distorted or worn parts REVISION Dated July 2005 Issued Page 92 of 156 L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM ircraft pty A Aircraft Service Manual iru Jab Jabiru 9160 J170 Variants g 3C 13248 38 1ON LSNH
76. 2 4 flap RIGGING as per template esses 78 83 ELEVATOR CONTROL SYSTEM 2 212 2 2 144020 1 6 83 84 CONTROL COLUMN DESCRIPILION 83 8 4 1 Removal and 83 89 ELEVATOR 83 8 5 1 Removal and 83 8 5 2 Inspectioniand deo ein 83 8 6 CONTROL CABLE AND 84 8 6 1 Removal and 84 87 RIGGING 84 8 8 ELEVATOR TRIM CONTROL SYSTEM 89 8 8 1 Operational Checks toj 89 8 8 2 Trim Handle 5 89 8 8 3 Control Cable and 5 89 8 8 4 Removal and Installation 89 8 8 5 Inspection and Repair das one ee 89 9 SECTION 10 RUDDER CONTROL 5 5 0 9 92 9 1 RUDDER PEDALSYSTEM iicet 92 9 1 1 Removal and 92 9 1 2 Inspection and 92 revision of Dated July 2005 Issued By RAS Page 5 of 156 L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08
77. 2005 12 19 00 PM Jabiru Aircraft Pty pta 5 22 un Aircraft Service Manual Jabiru J160 J170 Variants 92 RUDDER C 94 9 2 1 Renioyal amp Installations naiean oson anr nen n aaa 94 9 2 2 Inspection amp Repair 2 ce e t re ette teta 94 93 CONTROLCABLE amp ATTACHMENTS entier tdt tipi contorta s e ases 94 9 3 1 Removal amp Installatiohi nabs 94 94 RIGGING 94 10 SECTION 11 ENGINE amp ENGINE 5 98 104 ENGINE deine pee eu ene deb tfi eee E b tese irren Lopes 98 10 1 1 Engine Removal amp Installation 8 98 10 1 2 Cleaning and Inspection 101 DUE NES 5 m 101 10 2 Sip SS 101 105221 ie oat e Hae Rod 101 10 2 2 Engine Trouble Shooting essere 101 1023 Engine CLEANING NET 101 102 4 Engine Accessories Removal o etai ed ebd de 101 10 5 ANSDOCHON oren a ee o e rc recreo eap o 102 10 3 COOLING AIR BAFFLES Rr rere diete
78. 39Nv 5301 Te 39 017 Ald H234 X 10 INZSNOD IHL avos 3150440 SY NCVBEOVZ SY S 1 COV LEOZ LON 1SCVI 1H9 3 4409 SI ENIA HO S id pz 2 Ole 3172 LON OG NOIO f ASSY NOMS TY 598202 2 WAINIANTY 4 31 SONIH i pennae a 671 SNIDYOJNIJY NOMS TY SNO1 ASSY 4973111 3S 97 M3HSVAM v7 SIPCO6NY BL 9 LAN 2201 9929 871 ASSY WH 8 3Hv8 ONIA XI YIS e e Stz 90zseSW O NOT X 999 MIHIS SNIddv SIO SNIM 1115235 3118 NOLLO3dSNI LIAI MNNS D ZEE N66 0Hd H3HSv A 01 096Nv dOd ANNSO 91 N6500Hd LOAld NII 4245 7695502 Vo ENY D 3E1N39 7508502 ONILNNOW dya 75290 voe t z 07 6001250 ek LAN 43201 8 JOv LLV 5 NOTI EN C OON 1 39 9 ONS 61008 NOI 4 830 ON Le Vd Nid JON H H3NIv134 765026 ZL 5410 ze 15 EVO ANIN 26 2 SONIH 7691095 L 5410 SC WIHS 316 2 NOlldtdosad E ALO NOI d d2s3 o Q lt S NH a a lt On H 2 gt On emm 10 nd
79. 4 0 25 7 05 99 0 25 7 05 154 0 25 7 05 45 0 25 7 05 100 0 25 7 05 155 0 25 7 05 46 0 25 7 05 101 0 25 7 05 156 0 25 7 05 47 0 25 7 05 102 0 25 7 05 157 48 0 25 7 05 103 0 25 7 05 158 49 0 25 7 05 104 0 25 7 05 159 50 0 25 7 05 105 0 25 7 05 160 51 0 25 7 05 106 0 25 7 05 161 52 0 25 7 05 107 0 25 7 05 162 53 0 25 7 05 108 0 25 7 05 163 54 0 25 7 05 109 0 25 7 05 164 55 0 25 7 05 110 0 25 7 05 165 Issue Notes revision 0 Dated July 2005 Issued By RAS Page 11 of 156 L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants 2 2 GENERAL DESCRIPTION The JABIRU J160 aircraft described this manual are 2 seat high wing monoplane composite aircraft of monocoque construction They are equipped with fixed tricycle landing gear of composite construction The steerable nose gear is a welded metal trailing link assembly with rubber springs The aircraft is equipped with JABIRU 4 cylinder 4 stroke engines driving a wooden fixed pitch propeller 2 3 AIRCRAFT SPECIFICATIONS Leading particulars of this aircraft with dimensions based on gross weight are given in Figure 1 1 If these dimensions are used for constructing a hangar or computing clearances remember that such factors as tyre pressure tyre size and load dis
80. 4 CARB HEAT C PULL ON Fitted at the base of the CARBY Heat Cable 15 3 EXTERNAL FUSELAGE Table 15 External Fuselage Decals Decal Detail Preview P No 5043094 Attach to LHS of Vertical Fin in line with Static Tube Electrical Earthing EARTH ON NOSE LEG oo didi Attach above the Earthing Pole adjacent to the Fuel Filler Cap Fuel Grade P No 5091344 AVGAS 1001 EARTH ON POS Attach to top skin of wing adjacent to Fuel Filler Cap Wing Bolt Tightening P No 5039094 Qty 8 Required DANGER DO NOT TIGHTEN Attach to the fuselage and wings beside each wing and lift strut attachment fitting REVISION N Dated July 2005 Issued By RAS Page 146 of 156 L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty Aircraft Service Manual Jabiru J160 J170 Variants 16 APPENDIX I JABIRU 2200 ENGINE Appendix 1 of this Manual is the Instruction and Maintenance Manual for the Jabiru 2200 engine Please insert your copy of the INSTRUCTION AND MAINTENANCE MANUAL that comes with your engine into this section if you are printing this out THIS PAGE ISINTENTIALLY LEFT BLANK REVISION Dated July 2005 Issued By RAS Page 147 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_
81. 5 9 o 2 x _ g files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM L Miles Technical_manuals J160_J170 J160_ amp _J170_workin Jabiru Aircraft Pty pta un Aircraft Service Manual Jabiru J160 J170 Variants N _ o gt i 9 D lt m i TRON gt 5 a 2 or lt COO e E N HEN 2 LI 8 NN EI O E gt te 2 Y 02 dj lt Ole gt 2 S x E o lt O T cu TA lt 5 5 E 2 we 5 tr lt B 3 2 THROTTLE ASSEMBLY Figure 37 Non CS VLA Variant Throttle Seat Mounted revision 0 Dated July 2005 Issued By Page 106 of 156 L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty mm 524 Aircraft Service Manual Jabiru J160 J170 Variants 10 7 4 CHOKE The Choke Control is located in the main instrument panel amp is connected to the carburettor by a control cab
82. 5 FLAP CONTROL ROD To remove unbolt at both ends and remove Reverse for installation 8 2 The flaps comprise a moulded and bonded monocoque structure embodying a composite control arm at the inboard end 8 2 1 REMOVAL AND INSTALLATION 1 Unbolt rod end from control arm 2 Remove each hinge bolt and spacer Remove 4 Reverse the preceding steps for installation Replace all three nyloc nuts torque in accordance with Table 3 REVISION Dated July 2005 Issued Page 77 of 156 L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants 8 2 2 INSPECTION AND REPAIR Inspect flaps for any signs of delamination or cracking Pay particular attention to the Control Horn and hinges and their surrounding areas Repairs must be referred to JABIRU AIRCRAFT Pty Ltd or our approved local agent 8 2 3 FLAP RIGGING J170 SP MODEL The J170 SP has a special requirement for it s wing flap rigging To attain the required clean stall speed the J170 SP must have it s flaps rigged using a special template P No 8206Q5N 8 2 4 FLAP RIGGING AS PER TEMPLATE T With the flap selector lever in the neutral position use a straight edge not less than 1 metre long Hold the straight edge flush
83. 5 UPHOLSTERY Seat upholstery is provided through slip on covers These are easily removed for cleaning and inspection of the seat structures Optional Hood and Cabin lining is available together with Door Pockets 4 5 1 UPHOLSTERY CLEANING The upholstery used in the J160 C has been treated with a flame retardant to meet the flammability requirements of CS VLA formerly JAR VLA This treatment will withstand 5 washes or dry cleans before requiring re application The washing of cabin upholstery must be noted in the aircraft s maintenance log book and the flame retardant re applied by an authorized person after 5 washes 4 6 SOUNDPROOFING Soundproofing material is normally used on the Firewall In addition a curtain of soundproofing material can be used at the rear of the cockpit baggage area This curtain is attached to the forward rib of the fuselage using velcro straps Its purpose is to minimise drumming of the fuselage as well as restricting material falling aft of the curtain and resulting in a severe aft centre of gravity condition The curtain should be in place for all flights 4 7 SAFETY PROVISIONS 4 7 1 SEATBELTS Aircraft grade Seatbelts bolted to the fuselage structure are provided for both seats Belts should be replaced if frayed or cut latches are defective of stitching is broken REVISION Dated July 2005 Issued Page 39 of 156 L Miles Technical manuals160 J1701J160 amp J170 working
84. 6 L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM 77772 Jabiru 9160 J170 Variants ircraft pty A Aircraft Service Manual iru Jab rv L 00Yt ON OMG 3190 551 TwA3H OL ONY dv OL 5 197 WCHA 5 10 3 1913 OL 5971 034 SdYl SINIY 5 CI 39 135 3 3015 10 NZOOYfId N d NI 5 38 OL 148009 SINZA 1303 ONY 3504 1203 30S 60500 CN J ONL x T NZCECIOd did T3fis NIN dOolMWh8ENYO GL 90902154 cM d ASSY TENI 219 15 NOLLVTIWISNI 4299 lt 2 7 BS ON d ATAFESSY HNL Y30vSH 7202287 ON d LX 2 Y 009667 ON d ASSY NO LO POUd 31 25 LON 04 LIM SILWWSHOS 1913 JUIL Siz ER 7X 1304 adiit t n d SAYIN IN NI HO 2M VY M3 MNIH 46 987 OLO SY 51 ATA 1373 4 730048 ON d FINU 692024 N d ONLI TWIESOH 1dN 8 1 77 dovoz Ivy 9 038 5109195 5
85. 6 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty N un Aircraft Service Manual Jabiru J160 J170 Variants 3 3 4 ALUMINIUM SURFACES The aluminium surfaces require a minimum of care but should not be neglected Wash and clean as detailed in paragraph 3 3 3 above CAUTION JABIRU aircraft are designed for minimum maintenance However special attention should be applied when the aircraft has been used in extremely corrosive conditions e g beach landings with sand and salt Always ensure the aircraft is thoroughly hosed and washed immediately after such use Pay particular attention to wheels and external controls Always hose down wheels and spats after landings in mud or sand to ensure brakes wheels and spats are free of dirt build up 3 3 5 ENGINE AND ENGINE COMPARTMENT The engine should be kept clean since dirty cooling fins and baffles can cause overheating of the engine Also cleaning is essential to minimise any danger of fire and provide easy inspection of components CAUTION DO NOT hose engine Electrical components may be damaged by moisture Ensure electrical components are protected against moisture Caustic cleaning solutions should not be used Recommended cleaning procedure is lightly spray with degreasing fluid after sealing coils and starter motor WIPE clean with brush and cloth
86. 60 C Oil Type Refer Engine Manuals Refer Engine Manuals Engine Model Refer Appendix For Engine Data Jabini 2290 Jabiru Jabiru Propeller Type 2 bladed Wooden 2 bladed Wooden Propeller Diameter 60 dia 1524mm 60 dia 1524mm Propeller Pitch Jabiru 44 pitch Jabiru 42 pitch 1117mm 1067mm Wheel Sizes Standard 500 x 6 rim 500 x 6 Tyres Standard 6 wide 6 Ply 6 wide 6 Ply Tyre Pressures Standard Mains 179 kpa 26 psi 179 kpa 26 psi Tyre Pressures Standard Nose 137 kpa 20 psi 137 kpa 20 psi Wheel Alignment At Gross Weight Camber 0 0 cd In Engine In Engine Battery Location Compartment Compartment ab 1 ie a m T t do Figure 1 J160 General Arrangement REVISION L files Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM N Dated July 2005 Issued By RAS Page 13 of 156 Jabiru Aircraft Pty pta Aircraft Service Manual Jabiru J160 J170 Variants Table 2 J170 Specifications ena J170 A J170 UL J170 SP J170 SPC Aust Kit Europe Kit USA LSA Canada LSA 540kg 450kg 540kg 1190 99216
87. 60 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty pta 5 522 un Aircraft Service Manual Jabiru J160 J170 Variants 11 5 2 Non CS VLA Model Variant Filter 121 11 5 3 CS vla model Fuel Filter Removal amp Installation eene 121 11 54 CS vla model Fuel Filter Removal amp Installation 122 116 RBUELPUMDBS tette Ee HH EIER SOR RENE 122 JPrim rty Pump 122 116 2 essvla Secondary PUMP fete e qni ise MERE 122 11 6 3 cs vla Secondary Pump sese eene ederent ene tretr eret reete eret nenne 122 12 SECTION 12 INSTRUMENTS amp INSTRUMENT 5 8 8 123 124 GENERAL 123 12 2 INSTRUMENT PANEL 123 12 2 1 Instrument Panel Removal amp Installation eee deseen 123 12222 INSTRUMENTS eoa gui cu cda epe 123 1223 Instrument Removals ope gen 125 DI E 125 12 3 PIFOT 8 STATIC SYSTEMS entretient i te etant sco Ng 125 12 3 1 Pitot Static System
88. 60_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru 9160 J170 Variants Jabiru Aircraft Pty pta Aircraft Service Manual Tin 70007 A 3594 fu N6100ld 2904 3NDN3 5 gt wu p pmi en 5 o en E e rel N lt 02 tn o 5 o 0 Xe 5 gt 75 9 o 2 x files J160_ amp _J170_Tech doc a sea _ SSO ao e i rocsits Surge sz 1 57 10 0 ww 8 IN uv moo INSA 6500 sc 1 E nae V MEN awsow7 2 NINE NN el am mam eps m L Miles Technical_manuals J160_J170 J160_ amp _J170_workin B 9_ Print Date 12 08 2005 12 19 00 Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants 11 SECTION 12 FUEL SYSTEM 11 1 DESCRIPTION Refer to Figures 46 and 47 for system schematic details Fuel is pump fed from two composite
89. Aircraft Service Manual Service Schedule Inspection Schedule Engine Instruction amp Maintenance Manual Propeller Instruction Manual Airworthiness Limitations Mandatory Replacement Times Structural Inspection Intervals Structural Inspection Procedures Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants FOREWORD This manual contains JABIRU recommended procedures and instructions for ground handling servicing and maintaining The following Jabiru aircraft models J160 Jabiru 2200 powered J170 Jabiru 2200 powered In Australia either model may be registered either by CASA in the general aviation category as a prefix amp have a MTOW of 540kg or the AUF in the Ultralight category as a 19 prefix amp have a MTOW of 540kg In countries other than Australia other registration requirements will apply It is the owner s responsibility to become fully aware of the particular maintenance requirements and limitations applicable to the appropriate registration The information in this manual is based upon data available at the time of publication and is supplemented and kept current by Service Bulletins amp Service Letters published by JABIRU AIRCRAFT Pty Ltd These are posted on the JABIRU website or your local dealer of Distributor as recorded by JABIRU so that they have the latest authorised recommendations for servicing the aircraft New owners
90. Aircraft Service Manual Jabiru J160 J170 Variants 3 Fit cables rope to shackles and to a centre lift shackle 4 Hoist only from this point ensuring that cables ropes do not mark the top of the fuselage at corners above wing support brackets 3 1 4 LEVELLING Method 1 For both lateral and longitudinal levelling use a spirit level on either side of the lower door sills Method 2 Use the join line of the cowl top amp bottom halves 3 1 5 PARKING Parking precautions depend principally on local conditions As general precaution check the wheels and tie the control handle back firmly with a seat belt to lock the controls Park into the wind and tie down the aircraft as outlined in below if a hangar is not available 3 1 6 TIE DOWN When mooring the aircraft in the open head into wind if possible Secure control surfaces by tying the control handle back firmly with a seat belt Then 1 ropes to the top end of each wing strut Secure opposite end 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 tyre deflate while the aircraft is tied down 2 Tie rope to the Tail Tie down Hole in the Ventral Fin Secure the opposite end of rope to ground anchors 3 1 7 FLYABLE STORAGE Flyable storage is defined as a maximum of 30 days non operational storage Ensure that
91. Figure 15 Nose Wheel Hub Assembly Page 63 of 156 Issued By RAS Q Q 5 3 5 les Technical_manuals J160_J170 J160_ amp _J170_workin REVISION files J160_ amp _J170_Tech doc 9_ Print Date 12 08 2005 12 19 00 Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants 67 NOSE WHEEL STEERING SYSTEM 6 7 1 5 7 1 STEERING CENTRING ASSEMBLY The Nosewheel Centring Assembly consists of springs which are compressed when the nose leg is moved to the left or the right Repair is limited to replacement of parts 6 7 2 NOSE WHEEL STEERING ASSEMBLY Refer to Figure 15 The Nosewheel Steering Assembly comprises of two Steering push rods attaching the Rudder Pedals and the Steering Link Repair is limited to the replacement of parts 68 BRAKE SYSTEM The hydraulic brake system consists of one master cylinder located between the seats in the main longitudinal beam flexible hoses connecting the master cylinder to each wheel brake cylinder and the single disc floating cylinder type brake assembly located at each main landing gear wheel 6 8 1 TROUBLE SHOOTING BRAKES Table 7 Trouble Shooting Brakes Trouble Probable Cause Remedy Brake handle binding Check and adjust Worn or broken master Repair or install new master cylinder piston return spring cylinder Dragging brakes Drain brake line clear with compressed air If
92. Issued By RAS Page 83 of 156 L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru 9160 4170 Variants 8 6 CONTROL CABLE AND ATTACHMENTS 8 6 1 REMOVAL AND INSTALLATION The Control Cable is a Primary Control and may not be repaired or removed without reference to JABIRU AIRCRAFT Pty Ltd or our approved local agent 8 7 RIGGING 1 Refer to Figure 31 2 Using the factory anchor points make sure each end of the cable is secure 3 Set the full up travel first using the factory templates Making sure the control column is hard back Adjust the female ball ends in or out if adjustment is needed 4 To establish the neutral position align balance horn with horizontal stabiliser 5 Adjust cable rod ends to achieve UP and DOWN travel using the Elevator Rigging Template see Appendix 3 6 DO NOT move the Cable Anchors These are factory set 7 Ensure lock nut is tight on rod ends that cable is visible through hole spherical bearing REVISION Dated July 2005 Issued Page 84 of 156 L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM 0297 cud v Nnag O1 63323 ua vw 20 STONY S00 230 OWL 520 0 S
93. LO3f Otd ATSINSSSY 3AIHC TIVNHZ 1X3 filesJ160 amp J170 Tech doc 9_ ircraft pty A Aircraft Service Manual iru Jab 9 2 oT NN 2 ND A S NN ues NN INDE 2 N Nw NS SL Sg s amp CO QA 31 o AS 20 y Na 255 5 AS N us 3 8 1109 91 8 VEL ENY 1 LAN 916 QLENV 9 W3HSV A 917 096 5 L 1108 91 VOL ENY v DOTAN SLE C 0L S9C0cS LL H3HSVM 1V 13 91 0L 096NYv ONS GOY 3 TVA 9018 14 S O 009 HSNd N6000dd 9 601506 Lb ALO NOLLdl 4oS3d 1511 sped Print Date 12 08 2005 12 19 00 L Miles Technical_manuals J160_J170 J160_ amp _J170_workin 10 U lt 02 tn o 5 o 0 Ke 5 gt 75 9 o 2 x ircraft pty A Aircraft Service Manual iru Jab Jabiru 9160 J170 Variants 0 37 313 THNI WO waa Add 30 LNSSNOD IHL 1 1 3 EEO NSS i d 38 ICR SAM SI
94. OT SONY 7602508 LL LUOHS 7601508 ol LAN AILSVD 918 S OLENY 6 Figure 17 Brake Master Cylinder Assy 1108 OL 5NV 8 4 moa 9 abil 9 96 S lfdNI3A31 d09420v9 ONILLIS H30N 1A2 YILSVW 00 000 9 1 LNNOW 009 200 2 M31SVIN 0 NOlLd HOSS ON Led WALI 10 lt 02 tn o 5 o 0 Ke 5 gt 75 9 o 2 x _ g files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM L Miles Technical_manuals J160_J170 J160_ amp _J170_workin Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants 7 SECTION 7 AILERON CONTROL SYSTEM 7 1 AILERON CONTROL SYSTEM Refer to Figure 20 The aileron control system is comprised of a control column and two enclosed push pull cables fitted with spherical bearings WARNING All spherical bearings must be fitted with a large washer on the outside of the through bolt to prevent the bearing case and cable releasing in the event of a bearing failure See Figure 20 REVISION Dated July 2005 Issued By RAS Page 71 of 156 L Miles Technical_manuals J160_J170 J160_ am
95. Od AL A313 NOISNSLXS DOPOD A THAVSSN YOLVAR 13 8225802 009 0 2 1190355 TIVL TYLNOZIHOH 8 6216902 19 2530 l va sped Horizontal Tail amp Elevator Assy J170 Models Figure 27 files J160_ amp _J170_Tech doc B 9_ Print Date 12 08 2005 12 19 00 rel oo U lt 02 tn o 5 o 0 wo 5 gt 75 9 o 2 x L Miles Technical_manuals J160_J170 J160_ amp _J170_workin Jabiru Aircraft Pty pta Mo Aircraft Service Manual Jabiru J160 J170 Variants Figure 28 Elevator Travel Limits Revision 0 Dated July 2005 Issued By RAS L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Page 88 of 156 Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants 8 8 ELEVATOR TRIM CONTROL SYSTEM See Figure 33 The elevator trim control system comprises a Trim Cable connected to a lubron block so that the cable is able to move the block fore and aft approximately 35mm An aluminium rod is free to slide through this lubron block and is centred by 2 compression springs The output end of the rod is connected to the Elevator Horn 8 8 1 OPERATIONAL CHECK Movement of the Trim Le
96. Page 16 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants 3 Section 3 Ground Handling Servicing Lubrication amp Inspection 3 1 GROUND HANDLING 3 1 1 TOWING The JABIRU aircraft is very light and should always be moved by hand Moving the aircraft is accomplished by using the wing struts or prop hub or landing gear struts as push points together with the solid rear fuselage join of the fin to the tail plane CAUTION Do not use control surfaces to move the aircraft Damage to the control system may result When pushing at the join of the fin and Tail Plane take care that you do not jam your fingers under the rudder the rudder hinge remember that it is Connected to the Nose Wheel CAUTION When moving the aircraft never turn the Nose Wheel more than 15 degrees either side of centre or Nose Gear may be damaged The aircraft may also be moved by placing the propeller in the horizontal and then placing one hand on the propeller on either side of the spinner The aircraft can then be pulled forward and nose wheel lifted off the ground if necessary CAUTION Never move the aircraft in this manner whilst the engine is hot as it may fire when the propeller is moved and result in severe injury Always ensure that the Master
97. ROUBLE SHOOTING Table 8 Trouble Shooting Fuel System Trouble Probable Cause Remedy Fuel shut off valve not turned ON Fuel tank empty Turn valve ON Service with proper grade and amount of fuel Fuel line disconnect r i uel line disconnected Connect or repair fuel lines broken No fuel to carburettor Fuel tank outlet strainer Remove and clean strainer plugged and flush out fuel tank Defective fuel shut off valve Replace shut off valve Plugged fuel filter Replace filter Fuel line plugged Clean out or replace fuel line Partial fuel flow from Use the preceding remedies preceding causes Fuel Starvation after starting Plugged fuel vent See Paragraph 11 3 Drain fuel tank sump fuel Water in fuel lines and filter 11 2 FUEL TANK 11 2 1 DESCRIPTION The composite fuel tanks are located in the left amp right hand wings A sump drain plug is provided in each wing root on the under side wing skin A third sump drain plug is provided in the header tank located behind the seats for CS VLA models and under the right side seat in non CS VLA variants These three points must be checked as part of the daily inspection and after each refueling to drain and trapped water or sediment 11 2 2 FUEL TANK REMOVAL amp INSTALLATION As the wing fuel tanks are part of the wing integrity these fuel tanks can not be removed The header tanks may be removed if necessary to ch
98. Tech doc Print Date 12 08 2005 12 19 00 PM L Miles Technical_manuals J160_J170 J160_ amp _J170_workin ircraft pty A Aircraft Service Manual iru Jab Jabiru J160 J170 Variants SeEzavawna ASSY IMOD 93401 0917 _ d son 9NINSITv 7 2 45 002 WOI dOL 0381 2530 Sw lt 5 NOILY201G MIHIS 06 A OL NIS3H 4XOd3 205627 JSN WSL NIVLNOS OL dflA V NI NISIH CINOW O_ 914994 3dvHS 3NI430 OL Wraoeieovi DINOW ISN ALCON SIS 700 NIMvEG 335 STILA LNAWHOVLIY HO3 LHOSIM 3OIXOIHL ANOINILNV 6 NISIH AXCd3 025621 EOE JV SH3AV1E Figure 35 Lower Cowl Assy OrOuFS 437009 IO 651 OD ONY 533 033 INOA ANY IMCS JHL ZAON3H ALCIYYY SLANIN 30914 431002 110 ONPOkY AT vHLIN3O 5 NOLISOd 13 NO MOI HLM 534 SNOISN3AIA I IYS LON 00 OL 331002 0 6 8 2009116 SE 21 212 LONG YOUN NSO 2 YENIVLEY 9OTWVO 9 HZFSVM NVINYSNNIL 2 106616 265 55 15 ISO 160 698560 2 LSA 4048495 1 ONVId WNINIAINTY
99. able storage see Paragraph 2 1 7 plus For temporary storage fill fuel tank with correct grade of gasoline to prevent moisture accumulation For indefinite storage drain fuel tank ensure carburettor bowl is empty by running engine with fuel valve off until it stops or by draining bowl Then 1 Clean aircraft thoroughly 2 Clean any dirt oil or grease from tyres and coat tyres with a tyre preservative Cover tyres to protect against dirt and oil Either block up undercarriage fuselage to relieve pressure on tyres rotate wheels every 30 days to prevent flat spotting the tyres 4 Seal or cover all openings 5 Remove battery and store in a cool dry place Service the battery periodically and charge as required NOTE It is recommended that a battery which is not used should be charged every 30 days 6 Disconnect spark plug leads and remove spark plugs from each cylinder Using an oil can or spray atomiser spray preservative oil through a spark plug hole of each cylinder with the piston in the down position NOTE Use shell Aero fluid 2UN MIL C 6529C Type 1 or similar engine corrosion inhibitor Rotate the propeller 10 12 times leaving it in the horizontal position REVISION Dated July 2005 Issued Page 20 of 156 L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me
100. amp _J170_workin 9 ANH 132 EM NIVA Levo 29 Sussvovne EN 2904519 1 73sWeu2H10 231415399 Ssz Nn SUNN 16 98 0 0 Ale 30 N3SNO2 L ICH LIM 991906 ION 1 SPH IHOIHACOD SI OHW VC SIH Vd HOSLAY BEN Jabiru J160 J170 Variants ircraft pty iru A Jab Aircraft Service Manual A 5 lt 2 2 en S1 Spez V V NOILOZS 5 INVIWSS CYA Ze AL 1 2 SIYAL 318AESSV ALUYT3 HO NMOHE LON ALON NAL X 205 tb INN 2201 695075 01 UIHSVM 1713 hE DL 0908NV 6 1709 91 v90tNv 8 LAN OCTAN 2 EW LVIA tih 81 095 9 osaaweaa 620008 v NoZX8d 9i 133HM yane svo 6281189 z 9 WR YANN 1595 60009 Wall rel T uw 5 lt 02 tn o 5 o 0 wo 5 gt 75 9 o 2 x _ g files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM L Miles Technical_manuals J160_J170 J160_ amp _J170_workin ircraft pty A Aircraft Service Manual iru Jab Jabir
101. and Ignitions are OFF Never approach the propeller when anyone is in the aircraft Always treat the propeller as LIVE IT KILLS 3 1 2 JACKING JABIRU is a very light aircraft Before jacking ensure that it is as light as possible by removing luggage and any unnecessary fuel 3 1 2 1 JACKING MAIN GEAR 1 Remove main gear spat on the side to be jacked or both spats if both wheels to be jacked REVISION Dated July 2005 Issued Page 17 of 156 L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants 2 The aircraft be lifted on side person reasonable strength 2 of lesser strength by lifting on the Wing Spar at the outboard part of the wing strut attachment or towards the wing tip Be careful lifting at the Wing Tip 3 Place a solid block preferably wood under the bottom of the composite glass leg which will result in the wheel being off the ground when the aircraft is lowered Be careful not to interfere with brake components or Wheel Spat attachments 4 Repeat for other side if necessary The above procedure is useful for wheel brake servicing or repairs but is of no value in removing the main undercarriage If the removal of the main undercarriage is necessary adopt the following procedure
102. and ultra violet light to the aircraft structure In addition colour including stripes etc must not be applied to horizontal upper surfaces REVISION gg Dated July 2005 Issued By RAS Page 143 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty pta Aircraft Service Manual Jabiru J160 J170 Variants 15 SECTION 16 PALCARDS 15 1 COCKPIT PLACARDS GENERAL Table 13 General Cockpit Decals Decal Detail Preview J160 Warning Placard P No 5A011A0D g is PROHIB Noise level at full power 95 dB A Ear KIT JABIR amp Manufactured JABIRU AIRCRAFT LTD 3UNDABERG Q Fitted on the rear Face of the Forward Wing Spar Carry D 4670 J170 Warning Placard P No 5A015A0D through Beam in the Cabin Ceiling Fitted on the rear Face of the Forward Wing Spar Carry through Beam in the Cabin Ceiling Owners Manual FLIGHT OWNERS MANUAL P No 5036194 Fitted to Inside of RH Door above the Door Pocket Door Open LHS TUSA Fitted to the Outsides LH Door Above the Door Catch Lever Door Open RHS P No 5028094 Fitted to the outside of RH Door Above the Door Catch Level Door String Placard 5026094 PULL TO OPEN Fitted on Inside of both Doors Above Door Handle Fuel Conte
103. area around the centre bend and to areas around drilled holes 2 Inspect bolts and nuts for signs of stress or bending replace if in any doubt Inspect clamp for damage REVISION Dated July 2005 Issued Page 53 of 156 L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru 9160 J170 Variants 4 Inspect bolt seats in fuselage for signs of damage wear or perishing Repairs to the composite undercarriage beams must be referred to JABIRU AIRCRAFT Pty Ltd or our local approved agent 6 3 4 MAIN WHEEL FAIRING REMOVAL AND INSTALLATION 1 Remove the machine screws around the join of the inner and outer sections of the fairing 2 Remove the bolt on the outside of the fairing Remove the machine screws 2 OFF the inboard side of the leg 4 Reverse the preceding steps for installation 6 3 5 MAIN GEAR TOP FAIRING REMOVAL AND INSTALLATION The fairing at the top of the main undercarriage leg is removed by removing the securing screws To install reverse this procedure 64 MAIN WHEEL Refer to Figure 12 6 4 1 MAIN WHEEL REMOVAL 1 Jack aircraft as outlined Section 3 above 2 Remove speed fairing if installed in accordance with paragraph 6 3 4 3 Remove outboard brake pad plate 4 Remove lock bolt nut through centre of
104. ariants PL 50 49 Sd A p 7 AINO 130OW 3 1 13 d 1 HV TIINIS 3019 LOH aniesadns ISN Gy 22 1 OL SOA 3M9 ff S Yo Y i 2 1 91995 0 0 NOILOAS _ WLNOZIMOH JO 3903 M HLIM 40 3H1N39 NONY C A 222 L e pem e N N gt 3 5 E 4 8 h SNDIS WOLLOG 9 401 NO 081 X 0621 L a mmeo OEL X 082 SHSAVT NIMS WILYWd E z z 5 D N amp al UVIINIS HO 3dVL HLOTO NV LOM WWOS ONISN 8 HOLVASTS 1 dVO WAS HOV3 30 NI 7 NI QNOG NISSY AXOd3 S LOHS Qva 30 16051 XIN A LAI gt AXOd3 M9014 NOLLOO NISA 42 OL SdIL WL ONOS wo e N
105. atic line at first instrument to which it is connected then blow line clear with low pressure air Check all static pressure lines for tightness If hose or hose connections are used check for general condition and clamps for security Replace hose which has cracked hardened or shows signs of deterioration 12 3 5 REMOVAL amp INSTALLATION OF COMPONENTS To remove pitot mast remove the two rivets fastening it to the wing strut and pull it out from the strut far enough to disconnect the pitot line The static mast is fixed and cannot be removed To gain access to disconnect the static tube from the static mast remove the VHF antenna cover at the tope of the fin Pitot and static tubing is removed in the usual manner Installation of tubing will be simplified if a guide wire is drawn in as the tubing is removed When replacing tubing and fittings tighten connections firmly but avoid overtightening and distortion of fittings or tubing 12 3 6 TROUBLE SHOOTING PITOT STATIC SYSTEM Table 9 Trouble Shooting Pitot Static System Trouble Probable Cause Remedy Low or sluggish Test pitot tube and line for airspeed indication Pitot tube obstructed leak or leaks or obstructions Blow normal airspeed and obstruction in pitot line out tube and line repair or vertical speed replace damaged line Incorrect or sluggish Tm Test for leaks and Leaks or obstruction in static obstructions Repair or line replace
106. bber seals rubbing 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 Araldite 10 4 ENGINE MOUNT The engine mount is a welded assembly Its purpose is to support the engine and attach the engine to the airframe The engine is attached to the mount with rubber cushions which absorb engine vibrations Spaces are used to correctly align the engine Ensure that they are correctly marked on removal and correctly replaced on reassembly IMPORTANT The engine mounts should not be repaired If damaged replace with a new part 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 10 5 ENGINE FUEL SYSTEM 10 5 1 FUEL SYSTEM GENERAL The engine is equipped with a carburettor mounted below the engine and a fuel pump at the Starboard rear of the engine Refer to engine Maintenance amp instruction manual for carburettor jet removal idle adjustment and carburettor bowl cleaning procedures WARNING Fuel lines within the engine compartment are fitted with fireproof sleeves These sleeves must not be removed REVISION Dated July 2005 Issued By Page 103 of 156 L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524
107. bed in Paragraph 6 8 6 2 Bleed air from brake system as described Paragraph 5 8 5 REVISION Dated July 2005 Issued By RAS Page 68 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty pta me 524 un Aircraft Service Manual Jabiru J160 J170 Variants Figure 16 Brake Calliper Assy Revision 0 Dated July 2005 Issued Page 69 of 156 L Miles Technical manuals160 J1701160 J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM ircraft pty A Aircraft Service Manual iru Jab Jabiru J160 J170 Variants D V c Qov2c0v9 9 ASSY H3A 31 H3QONI1AO H31ISVIA 3MVtH8 YITANIH p mm Ald HO3LAV 30 1LN3SNOO 344 LNOHLIA O3IdC2 38 LSNA LHOlMAdOO SI S SOF 5319 50 0 3 OML 5270 930 JNO E BEQ N EM 0 F SON 3 1OHM S3ONveH37 O1 THINS Vd HOALAV 1 SSyLSWIT NI S TIV L33 SNILNNOW 7 3NI 1831N39 00 1108 WHE NZOOVEHd 1108 8 3 vH9 ONN 211 vL MSS 91 8 M3HOS N6zPCHd EL ANS 1 NSLECHd SN
108. ble Shooting Fuel 5 117 Table 9 Trouble Shooting Pitot Static 127 Table 10 Trouble Shooting Airspeed Indicator 128 Table 11 Trouble Shooting 128 Table 12 Trouble Shooting Vertical Speed Indicator Option eese 129 Table 13 General Cockpit Decals 144 Table 14 Cockpit Control Decals oer enne ener ene dpn nennen 145 Table 15 External Fuselage 146 Table 16 Approved Propeller Installations 150 Table 17 Mandatory Replacement Ames cete tiere eben 156 Revision 0 Dated July 2005 Issued Page 10 of 156 L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants 2 Section 2 Service Manual 2 1 LIST OF EFFECTIVE PAGES Page Revision Date Page Revision Date Page Revision Date 1 0 25 7 05 56 0 25 7 05 111 0 25 7 05 2 0 25 7 05 57 0 25 7 05 112 0 25 7 05 3 0 25 7 05 58 0 25 7 05 113 0 25 7 05 4 0 25 7 05 59 0 25 7 05 114 0 25 7 05 5 0 25 7 05 60 0 25 7 05 115 0 25 7 05 6 0 25 7 05 61 0 25 7 05 116 0 25 7 05 7 0 25 7 05 62
109. ble with lining side down flat Centre 1 8 or slightly smaller punch on the rolled rivet and hit the punch sharply with a hammer Punch out all rivets securing the lining to the pad plate NOTE A replacement kit for brake pads and rivets is available from JABIRU 4 Clamp the flat side of an anvil in a vice REVISION Dated July 2005 Issued By Page 66 of 156 L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants 5 Align the new lining the pad plate and place the brake rivet the hole with the rivet head in the lining Place the head against the anvil 6 Centre the rivet setting punch on the lips of the rivet While holding the pad plate down firmly against the lining hit punch with hammer to set the rivet Repeat blows on the punch until the lining is firmly against the pad plate 7 Realign the lining of the pad plate and install and set rivets the remaining holes 8 Replace the brake pad and refix with through bolts and springs To replace inboard lining 1 Remove wheel assembly see Paragraph 6 4 1 2 Remove stub axle see Paragraph 6 4 5 Remove brake cylinder backing plate 4 Replace lining in accordance with steps 3 7 above 5 Install axle and wheel assembly see Paragraph 6 4 6
110. by locating a 16mm tube to firmly fit the centre mounting hole of the Propeller and balancing on knife edges Tolerances e Imbalance shall not exceed the following limit whatever the position of the Propeller the plane of rotation 750 mm gms approximately 1 gm at the tip The balance may only be corrected by the application of epoxy paint Any other method of securing balance is PROHIBITED Propellers outside these limits should be rejected as unserviceable or returned to JABIRU for assessment and possible repair REVISION ol Dated June 2005 Issued RAS Page 155 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft struction amp Maintenance Manual Jabiru 2200 Aircraft Engine 20 APPENDIX V AIRWORTHINESS LIMITATIONS 20 1 GENERAL This Section sets forth each mandatory replacement time structural inspection interval and related structural inspection procedure 20 2 MANDATORY REPLACEMENT TIME The following components MUST be replaced at the intervals described hereunder Table 17 Mandatory Replacement Times Description Part No Interval Hours Rudder Cable PC01714 2 2500 Elevator Cable 1814 1 2500 Aileron Cable 2 1614 2 2500 20 3 STRUCTURAL INSPECTION INTERVALS A visual inspection should be conducted each 100 hour
111. clear 4 Correct any blockage amp reassemble WARNING Fuel valves between wing tanks and header tanks must be in the ON position during flight CS VLA variants must have these taps wired ON using electrical fuse wire Revision 0 Dated July 2005 Issued By RAS Page 119 of 156 L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM ircraft pty A Aircraft Service Manual iru Jab Jabiru 9160 J170 Variants b 1 3 5 SONIANZ LHVd O1 4343 Widely T ASIMMYAHLO C3 319395 8891 SLINN SNOISNINIG E 029 ASSY dVO MNV L TaNA GALNAA 8 698 OLO Ald 30 LNASNCS AHL LNOHIW 400 HO3LAV 38 LON 5 LHOlHAdOO SI ONIMVSO SIHL 3728 LON OQ SV 033 dio d OL NYHL AA3HOS 134208 33 TIIJ 40 3GISNI 9 355 N33 A138 gt ONILLS SZQV3 1A 389S NZZOvvHd 2 4397114 AGO v 06202 2115 9 ONY 1058 N8S199d J3HV AOSVH 99 LINS d OILSV 14 NO0O0v cHd 999 3135 NE LOHd Nid TIOH SOHVANOL 93190 S370H ININ OSNA 3395 570
112. cure with bolts nuts washers 5 Reconnect flexible brake line 6 Refill brake master cylinder with fresh brake fluid 7 Bleed brakes Refer to Section 7 8 5 8 Install speed fairing if used as outlined in Paragraph 7 3 4 6 4 5 MAIN WHEEL STUB AXLE REMOVAL 1 Remove speed fairing if installed in accordance with Paragraph 7 3 4 2 Remove wheel in accordance with Paragraph 5 4 1 Disconnect flexible brake hose and drain brake fluid 4 Remove 4 bolts nuts washers securing axle to leg NOTE When removing axle from leg note number and position of the wheel alignment shims if any between the axle flange and composite leg Mark these shims or tape them together carefully so that they can be installed in exactly the same position to ensure that wheel alignment is not disturbed 5 Remove inboard brake plate 6 4 6 MAIN WHEEL STUB AXLE INSTALLATION 1 Secure axle and inboard brake plate to composite leg making sure that any wheel alignment shims are installed in their original position 2 Install wheel assembly on axle in accordance with Paragraph 7 4 4 6 4 7 MAIN WHEEL ALIGNMENT Refer to Figure 13 REVISION Dated July 2005 Issued Page 56 of 156 L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM ircraft pty A Aircraft Service Manual iru Jab Jabiru 9160 J170 Variants
113. d refill with automotive brake fluid DOT 3 or DOT 4 Bleed the brake system of any trapped air whenever there is a spongy response on the brake lever Refer to paragraph 6 8 for filling and bleeding of the brake system CAUTION REVISION Dated July 2005 Issued Page 23 of 156 L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants The JABIRU uses automotive brake fluid DOT 3 or DOT 4 DO NOT use Aircraft hydraulic fluid mineral based or damage to the brake system will result 3 3 CLEANING Keeping the aircraft clean is important Besides maintaining the appearance of the aircraft cleaning makes inspection and maintenance easier 3 3 1 WINDSHIELD AND WINDOWS These should be cleaned carefully with plenty of fresh water and a mild detergent using the palm of the hand to feel and dislodge any caked dirt or A sponge soft cloth or chamois may be used but only as a means of carrying water to the plastic Rinse thoroughly then dry with a clean moist chamois DO NOT rub the plastic with a dry cloth as this builds up an electrostatic charge which attracts dirt Oil and grease may be removed by using a soft cloth moistened with mineral turpentine CAUTION DO NOT use gasoline alcohol Buzene Acetone Carbon Tetrachloride
114. e eene eene nennen ne 59 6 6 2 Nose Wheel Disassembly eet a 59 revision Dated July 2005 Issued By RAS Page 4 of 156 L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty pta 5 522 un Aircraft Service Manual Jabiru J160 J170 Variants 6 6 3 Nose Wheel Inspection Gnd Repair ui eode a 60 6 6 4 Nose Wheel Reassembly eee opto EE 60 6 6 5 Wheel Balancing sere eme en 61 67 NOSE WHEEL STEERING 5 64 6 7 1 2 4 1 Steering Centring ASSEMBLY 64 6 7 2 Nose Wheel Steering Assembly 64 65 BRAKESYSDIEM 64 6 8 1 Trouble Shooting Brakes ere eo 64 6 8 2 Brake Master Cylinder ido aks ee ud nata ef oie 65 6 8 3 HydraulicBrake Lines cists las Saa 65 6 8 4 Wheel Brake Assemblies 65 6 8 5 Brake Systemi Bleeding tete nse eio 67 6 8 6 Brake Pad Adjustment a ce 67 6 8 7 Parking Brakes min bromide 66 7 SECTION 7 AILERON CONTROL SYSTEM 8 71 7 1 AILERON CONTROL SYSTEM assistant bone
115. e other hand are usually well worth repairing The words replace instrument in the text therefore should be taken only in the sense of physical replacement in the aircraft Whether replacement is to be with a new instrument an exchange one or an original instrument is to be repaired must be decided on the basis of the individual circumstances 12 2 INSTRUMENT PANEL The instrument panel assembly consists of a stationary panel The lower part of the panel contains switches and circuit breakers which are not sensitive to vibration The instruments are screw mounted to the panel 12 2 1 INSTRUMENT PANEL REMOVAL amp INSTALLATION The panel is secured to the Firewall and for normal maintenance is not considered removable Access to instruments etc is gained by removing the panel facia containing the instruments from the facia T Unscrew amp remove the facia retaining screws from around the perimeter if the panel 2 Remove the front facia It is normally best to lie the facia on a cushion or similar while working to reduce the risk of damaging the instruments or facia 3 Take care not to strain connections on wires or tubes 4 Assembly is the reverse of the above procedure 12 2 2 INSTRUMENTS Refer to Figure 44 Revision 0 Dated July 2005 Issued By RAS Page 123 of 156 L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabir
116. eck outlet strainers etc 11 2 2 1 HEADER TANK REMOVAL CS VLA MODELS 1 Break the fuse wire seal from the taps between the wing tanks the header tank and turn OFF 2 Remove the drain plug and drain the fuel from the header tank 3 Remove the cover from the header tank enclosure 4 Remove tank restraints REVISION Dated July 2005 Issued By RAS Page 117 of 156 L Mfiles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru 9160 J170 Variants 5 Loosen hose clamps remove hoses amp remove tank 6 Installation is the reverse of removal WARNING Fuel valves between wing tanks and header tanks must be wired in the ON position using electrical fuse wire during flight 11 2 2 2 HEADER TANK REMOVAL NON CS VLA VARIANTS 7 If fitted break the fuse wire seal from the taps between the wing tanks the header tank and turn OFF 8 Remove the drain plug and drain the fuel from the header tank 9 Remove the cover from the header tank enclosure note that in some cases this may require cutting the top out of the seat pan 10 Remove tank restraints 11 Loosen hose clamps remove hoses amp remove tank 12 Installation is the reverse of removal WARNING Fuel valves between wing tanks and header tanks must be in the ON posit
117. ect airspeed and vertical speed indicators into static pressure systems and repeat leakage test steps 3 through 6 12 3 3 PITOT SYSTEM INSPECTION amp LEAKAGE TEST To check pitot system for leaks place a piece of rubber or plastic tubing over pitot tube close opposite end of tubing and slowly roll up tube until airspeed indicator registers in the cruise range Secure tube and after a few minutes recheck airspeed indicator Any leakage will have reduced the pressure in the system resulting in a lower airspeed indication Slowly unroll tubing before removing it so pressure may be released gradually revision 0 Dated July 2005 Issued By RAS Page 126 of 156 L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru 9160 J170 Variants Otherwise instrument may be damaged If the test reveals a leak in the system check all connections for tightness 12 3 4 BLOWING OUT LINES Condensation may collect at points in the pitot system and produce a partial obstruction To clear line disconnect airspeed indicator Using low pressure air blow from indicator end of line toward pitot tube CAUTION Never blow through pitot or static lines towards the instruments Like pitot lines static lines may be kept clear and connections tight When necessary disconnect st
118. ection for the crew and therefore must be maintained in excellent condition Cracks up to 25 mm in length should be stop drilled those longer than 25 mm should NOT be repaired the windshield must be replaced 4 2 2 CLEANING Refer to Section 3 4 2 3 WAXING Waxing will fill in minor scratches in clear plastic and help protect the surface from further abrasion Use a good grade of commercial wax NOT SILICON BASED applied in a thin even coat Bring wax to a high polish by rubbing lightly with a clean dry flannel cloth CAUTION Silicon based waxes and polish are not recommended as silicon may be absorbed into the glass fibre laminate and effect the reparability due to impairing bonding 4 2 4 REPAIRS Damaged window panels and windshield may be removed and replaced if damage is substantial However certain minor repairs as prescribed in the following paragraphs can be made successfully without removing the damaged part from the aircraft REVISION Dated July 2005 Issued Page 33 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants The procedure for repairing cracks is only recommended for low stress areas No repairs of any kind are recommended on highly stressed or compound curved areas or where repair would be l
119. ed in the CS VLA variants is used fitted behind the seats 6 The fuel filter and auxiliary electronic fuel pump are mounted in a fiberglass moulding immediately above the rudder pedals 7 The main fuel valve is located on the Beam the cabin 8 Secondary valves are fitted between each wing tank and the header tank These valves are for maintenance purposes only and must be in the ON position during flight REVISION Dated July 2005 Issued By RAS Page 113 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants WARNING Fuel valves between wing tanks and header tanks must be in the ON position during flight 11 1 3 PRECAUTIONS There are certain general precautions and rules concerning the fuel system which must be observed when performing the operations and procedures in this Section 1 During all fuelling defuelling tank purging and tank disassembly ground the aircraft to avoid static electricity sparks 2 Residual fuel draining from hose constitutes a fire hazard Use caution to prevent the accumulation of fuel when hoses are disconnected 3 Cap open hoses and cover connections to prevent the entrance of foreign matter Revision 0 Dated July 2005 Issued By RAS Page 114 of 15
120. ed with wings which are removable for storage or transport Wing removal is most easily achieved if two persons are available to handle the wing 1 Remove wing root fairings 2 Drain Fuel out of Quick Drain Note This will take some time Remove wing strut fairings top and bottom 4 Disconnect Pitot tube RH wing only 5 Unbolt flap control rods 1 each wing 6 Remove flap from wing so it does not crush the fuselage when lowering down 7 Unbolt aileron control cables 2 from rear control stick horn inside cabin 8 Remove pin and clamp block from aileron control cable clamps at rear of seat 1 each seat 9 Loosen hose clamps from Fuel lines from Breather tubes Fuel Gauge 10 With one person supporting wing tip unbolt top wing strut bolt and lower wing strut to the ground 11 Lower wing tip to towards the ground making sure you do not crush the under side of the wing on the fuselage wing root Ret the wing tip on a saw horse or other suitable stand REVISION Dated July 2005 Issued By RAS Page 41 of 156 L Mfiles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru 9160 J170 Variants 12 and remove front wing attachment bolt 13 and remove rear wing attachment bolt Note It may be necessary to rock the
121. eding steps to install brake master cylinder then fill and bleed brake system in accordance with Paragraph 6 8 5 6 8 2 2 BRAKE MASTER CYLINDER REPAIR Figure 19 may be used as a guide during disassembly repair and reassembly of the brake master cylinder Repair is limited to installation of new parts cleaning and adjustment Use only automotive brake fluid DO NOT use aircraft grade hydraulic fluid or damage will result 6 8 3 HYDRAULIC BRAKE LINES These lines are flexible hoses connected through a tee piece Repair is limited to replacement 6 8 4 WHEEL BRAKE ASSEMBLIES The Wheel Brake Assemblies use a disc which is attached to the main wheel hub with through bolts and a floating brake assembly Refer to Figure 18 for caliper details Figure 12 for installation of the caliper to the leg 6 8 4 1 REMOVAL The Wheel brake assemblies can be removed by disconnecting the brake hose and unbolting the brake cylinder from the backing plate The brake disc is removed after the wheel is removed and disassembled Refer to Figure 18 for disassembly of either wheel brake assembly 6 8 4 2 WHEEL BRAKE INSPECTION AND REPAIR 1 Clean all parts except brake linings in dry cleaning solvent and dry thoroughly REVISION lo ft Dated July 2005 Issued By Page 65 of 156 L MilesYTechnical manuals160 1701160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty
122. el Speed Fairings are optional equipment 6 2 TROUBLE SHOOTING MAIN UNDERCARRIAGE Table 5 Trouble Shooting Main Undercarriage Trouble Probable Cause Remedy Inflate to pressure shown at Incorrect tyre inflation above Aircraft leans to one Landing gear attaching parts Tighten loose parts Replace side not tight defective parts Bent axle stubs Install new part s Incorrect tyre inflation Inflate to pressure shown in above Main wheels out of alignment Align as specified above Tyres wear excessively Bent axle stubs Install new part s Dragging Brakes Refer to Para 6 8 6 3 GEAR Figures 10 11 an 12 illustrate the landing gear The illustrations should be used in conjunction with the following procedures during removal and installation of component parts WARNING Check looseness of main U C beams by lifting each wing and trying to move beam back and forth If movement tighten clamp bolts 2 evenly to take beam movement out Do not over tighten or exceed 3 threads clear on the nuts use extra washers Over tightening can cause bolt fracture and failure to tighten both can also cause bolt failure See Torque Value Figure 1 2 The wheels comprise two wheel halves which are assembled as shown in Figure 11 During assembly of the main wheels the through bolts nuts should be tightened to the value specified in Table 3 The assembly of the wheels to the undercarria
123. ent eite etre teret reete raise etie es ee acte eee 15 Door Hinge ASSY iiic ecd espe deesse idisse 35 DOOR snl 36 Door Latch Mechanism Assembly esee ehe 38 60 Wing Assembly Sheet 1 44 60 Wing Assembly Sheet 2 45 1170 Wang Assy Sheet 46 70 1 Wing Assy Sheet 2 iiec eet nie a 47 Main Undercarriage 5 50 Wheel Assembly MR 51 Main Wheel to L g ASS C af 52 Wheel Alhignmerni 2 57 IN OSG 62 Nose Wheel Hub 5 63 Brake Callipet ASSy inning fe tr E eei be totes en Pe ee PEE egere eder eek 69 Brake Master Neteco it ei e re ee run 70 Aileton System Schematic IN rho Dette pep co exe beso ba LE 72 Figure 19 Control Column 5 feces 74 Figure 20 Stops d i 76 Figure 21 Flap Controls Sheet 17 MA 79 Figtire 22 Flap Controls ec deem terere eins 80 Figure 23 Flap Controls SBE Neisseria 81 Figure 24 Flap Cross Tube Assy ofr
124. er to engine Instruction amp Maintenance Manual Refer to an Authorised Service Centre to have Alternator and Regulator checked Refer instrument to VDO Service Centre or JABIRU AIRCRAFT Pty Ltd for inspection and possible repair 12 5 OIL PRESSURE GAUGE The Oil Pressure Gauge is an electronic instrument Should the instrument fail to operate 1 2 5 6 Check 10 instrument fuse and replace if necessary Check 30amp main fuse and replace if necessary Remove Instrument Panel see Paragraph 13 2 3 and check cable terminals for security Check wiring at Sender for security Replace Sender Replace Gauge 12 6 OIL TEMPERATURE GAUGE The Oil Temperature Gauge is an electronic instrument Should the instrument fail to operate 1 Check 10 instrument fuse and replace if necessary 2 Check 30amp main fuse and replace if necessary 3 Remove Instrument Panel see Paragraph 13 2 3 and check cable terminals for security REVISION Dated July 2005 Issued By Page 133 of 156 L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants 4 Check wiring at Sender for security 5 Replace Sender 6 Replace Gauge 12 7 CYLINDER HEAD TEMPERATURE GAUGE The Cylinder Head Temperature Gauge is a Thermo couple
125. erc S1 MOCNA 3006 2042007 Wy 25 3006 4 557 2191 3006 DOvLDOVZ wer r a se E ues ame sis ree are se sess 359 sooo gt o wu wu lt 8 o 5 Eo E Mo en lt 02 tn o 5 o 0 5 gt 75 9 o 2 x _ 9_ files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM L Miles Technical_manuals J160_J170 J160_ amp _J170_workin Jabiru Aircraft Pty mm 524 Aircraft Service Manual Jabiru J160 J170 Variants 4 3 2 ADJUSTMENT Cabin doors should be adjusted so that the door skin fairs with the fuselage skin 4 3 3 DOOR SEALS A weather strip is glued around all edges of the door Apart from excluding wind and water the weather strip is important in minimising exhaust fume entry to the cabin lt should be maintained in good condition and fit at all times New weather strip may be applied after mating surfaces of weather strip and door are clean dry and free from oil and grease 3 1 1 Cabin Door Latches There is one main latch on each door of a simple spring type This is complemented by two Aluminium catches at the top front quadrant of each door An assembly drawing of the latch mechanism
126. files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty MN 2 Aircraft Service Manual Jabiru J160 J170 Variants Attaching parts should be replaced with equivalent grade parts if excessively worn or defective revision 0 Dated July 2005 Issued By RAS Page 40 of 156 L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants 5 SECTION 5 Wings And Empennage 5 1 WINGS Refer to Figures 6 7 8 and 9 NOTE J170 J170 SP and J170 SPC models use the same wing assembly as shown for the J170 UL below in Figures 8 and 9 with the exception of the Bare Wing Assembly which is P No 2095023 in place of 2A039A0D Each composite wing is a semi cantilever monocoque type with a main spar The wing is a moulded structure with a series of ribs that are bonded through the moulding process to the fibreglass skin fuel tanks and to the spar The forward wing attachment is an extension of the forward sub spar The rear attachment is a composite block heavily bonded to the reinforced wing skin and attaches to the main spar through the Wing End Plug Both attachments are through stainless steel threaded bushes bonded into the attachment blocks 5 1 1 REMOVAL The JABIRU aircraft is design
127. files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants 6 6 5 WHEEL BALANCING Refer to Paragraph 6 4 8 for wheel balancing information revision 0 Dated July 2005 Issued RAS Page 61 of 156 L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM ircraft pty iruA Jab V t y V Z b 1009 919 0 0099 Q3NIHOVIN ASSY T33HM 9 931 ISON 0 97 Ou38vauna S3 DINIH sd LYYd 01 RIVA dSIMYAHLO 031512395 SSIINN SLIAIT 2 TU 6 6997 010 N O V E Ald HOSLAV 30 LN3SNOO JHL LNOHLIM 9913405 S En 2 om 38 LON SMW LHOIHAdOD SI Vd HO3LAY 3725 LON OG 50 9 94 2 sa 00 Sa gt 70 50 20 v Wa N gt sal qm gt 3 gt _ 2 2 OOTAN 98 _2801 598055 4 SS3NMOIHL H3HSVM 1973 91 8 7101 096NV 18 gt 1708 9 6 06 5 LNOtH HVT1OO
128. fire extinguisher fluid de icer fluid lacquer thinner or glass window cleaning spray These solvents will soften and craze the Plastic DO NOT use a canvas cover on the windshield or windows as the cover may scratch the plastic 3 3 2 INTERIOR SURFACES Interior surfaces should be cleaned with a soft cloth fresh water and a mild detergent Volatile substances such as those mentioned in the previous section must never be used 3 3 3 EXTERIOR SURFACES The exterior surfaces under normal conditions require a minimum of polishing and buffing CAUTION DO NOT polish or buff the aircraft within the first 2 weeks after delivery from the factory as surface treatments take up to 14 days to properly cure Generally the exterior surfaces can be kept bright by washing with water and a mild soap or detergent followed by a rinse with water and drying with a cloth or a chamois Remove stubborn oil and grease with a cloth moistened with mineral turpentine then wash with water and a mild soap rinse and dry as stated before After the curing period the aircraft may be waxed with a good quality automobile wax A heavier coating of wax on the leading edges of the wing tail and on the engine nose cap will help reduce abrasion encountered in these areas CAUTION DO NOT use Silicon based cleaning materials as Silicon is absorbed into the composite Materials and may affect reparability REVISION Dated July 2005 Issued By RAS Page 24 of 15
129. fuel tanks inside the wings through a header tank fuel filter amp shut off valves and through a bulkhead in the firewall to the carburettor The primary fuel pump is attached to the engine A secondary electronic pump is mounted in the cabin refer details below Positive ventilation is provided by vented fuel caps The airspaces of all tanks are connected to ensure even feeding 11 1 1 CS VLA AIRCRAFT FUEL SYSTEM 5 A schematic drawing of the system is shown Figure 46 6 The 5 Litre header tank is housed in an enclosure behind the seats This enclosure is sealed from the cabin amp vented overboard 7 The fuel filter and auxiliary electronic fuel pump are mounted inside the header tank enclosure 8 All fuel lines inside the cabin are housed within plastic sheath 9 The main fuel valve is located on the Beam the cabin 10 Secondary valves are fitted between each wing tank and the header tank These valves are for maintenance purposes only and must be wired into the ON position with electrical fuse wire during flight WARNING Fuel valves between wing tanks and header tanks must be wired in the position using electrical fuse wire during flight 11 1 2 J160 J170 FUEL SYSTEM NON CS VLA VARIANTS 4 A schematic drawing of the system is shown as Figure 47 5 A 6 Litre header tank is mounted inside the right seat pan moulding Note that for variants with sliding seats the 5 Litre header tank system us
130. ge leg is shown in Figure 12 REVISION Dated July 2005 Issued Page 49 of 156 L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM ircraft pty iruA Jab Aircraft Service Manual Jabiru 9160 J170 Variants 2090 9 SSNINV4 091 00 ASSY XN 931 NOISNAdSNS 31038738 AWW S110 H39NOT1 LSWe 123 SOVSYHL 9 TWNIWON NSA 9 SHLONS 1108 c NMAC HS LON 395713815 310SNOC 3 4N32 LON 1103 28 ANN OOTAN 88 9 69 025 1 Vld 6 3OviMMv73CNn Nece0z8 290710027 dINVIO ASWINNVONSCNAL 8009 9602909 Hsha t6CtE09 193 SLVISONDOVE DIN 6009 Ova 14 ONIvOvH 6 09 028 corryager 937 JONN NIVIA 55 5 3 aava 1517 sped gt 9 a lt o en E x 9 vo 2 gt 2 o x en _ es 10 c 5 lt 02 a 5 o 0 Ke N 5 gt 75 9 o 2 x _ g files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM L Miles Technical_manuals J160_J170 J160_
131. h L CTA _ 4 9 20449 BENT PIIOI 8 IOSE CLAMP MS8242 2 IOSE COUPLING 6 VC TUBE 1 4 ID RIVET 2 3 MOUNT PLATE PITOT TUBE 2 UBE STRAIGHT PITO WING STRUT ASSY ITEM PART DESCRIPTION QTY PITOT ASSEMBLY Figure 45 Pitot Assembly revision 0 Dated July 2005 Issued By Page 130 of 156 L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty pta Aircraft Service Manual Jabiru J160 J170 Variants E pen pn eel EF C Co OO Co Les JAE EH g mum h E qu E 9 a Z 3 21218518 lt e lt 9 gt e A 2 oh z D r m TI ce e es gt A COTTON FLOCK amp EPOXY TUBE TAIL FIN ENSURE TUBE IS ALIGNED WITH TOP OF FIN AND FUSELAGE Figure 46 Static Probe System Assembly Revision 0 Dated July 2005 Issued By RAS Page 131 of 156 L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraf
132. heck that the Spinner runs true Correct any imbalance by loosening and retightening Machine Screws REVISION Dated June 2005 Issued RAS Page 153 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Instruction amp Maintenance Manual Jabiru 2200 Aircraft Engine 19 7 SERVICING AND REPAIRS Any service or repair must take account of the risk of subsequent Propeller failure Therefore repairs are limited to the filling of small nicks in the Propeller Maximum size of nicks approved for repair is Those Leading Edge 4mm deep x 20mm long Those across the drive Face flat sides 2mm deep x 6mm diameter scratches not more than 0 5mm deep Repairs must also take account of the changes to balance of the Propeller and therefore the Propeller should be removed in accordance with the procedure described above It must be checked for balance see Paragraph 8 prior to refitting see Paragraph 6 checked for tracking after reassembly see Paragraph 6 4 and the Spinner checked for balance after reassembly see Paragraph 6 7 Only nicks within the size tolerances described above may be repaired All propellers with cracks or splits or any delamination of the composite sheath in the case of sheathed Propellers must be either Rejected as unserviceable or returned to JABIRU Airc
133. ht of the aircraft with a heavy paint job Care must be taken to use the absolute minimum amounts of filler undercoat and topcoat Certain brands of filler are significantly lighter that others checking densities and using lighter materials can save around 5kg on a typical Jabiru airframe 14 2 2 MATERIALS RECOMMENDED 14 2 2 1 PAINTS FILLERS e Top Coat 5 Lts MUST BE WHITE e Base Coat 4115 Ensure compatibility with top coat e Polyester Filler 4kg e Spot Putty 1 Ib tube Claw Glaze recommended 14 2 2 2 SANDPAPER Note aluminum oxide type most effective 1st all over sand 150 grit 20 3M Brand e Bog Sand 120 grit 20 3M Brand e Spot Putty Sand 180 grit 20 3M Brand e Final Sand 320 grit 20 3M Brand 14 2 3 PAINTING EQUIPMENT REQUIRED e Random Orbital Sander approximately A 70 00 e Gas Mask e Compressor REVISION Dated July 2005 Issued By RAS Page 141 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants e Spray Gun 14 2 4 PAINTING PROCEDURE T Wash all parts to remove release agent Note Prepare all parts separately and paint separately 2 Completely sand all outside surface area with 150 grit to give paint adhesion The factory uses a Random Orbital Sander and 150mm Stickit discs Note Ensure that glass
134. iate registration WARNING ENSURE IGNITION SYSTEM IS OFF BEFORE COMMENCING ANY WORK ON PROPELLER DO NOT RUN ENGINE WITH PROPELLER DISCONNECTED OR ENGINE DAMAGE WILL RESULT 19 4 INSTALLATION Refer to Figure 52 The Propeller is bolted to the Propeller Drive Flange with 6 x AN4 aircraft grade bolts attaching to Nyloc Nuts There are 8 Belleville Washers between the Aluminium Propeller Flange and each nut These Belleville washers fitted in pairs as shown the attached drawing Bolts should be torqued to 6 nm 72 inch lbs a standard torque sequence REVISION Dated June 2005 Issued By RAS Page 151 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM 5728 2200 ircraft pty A ion amp Ma iru Jab ine ircraft Eng iru Jab tenance Manual in Instruct 46 010 1 1 4 5 LAN jCHONY 7130 ASSY d3HS JNIA 7 136 U3NNIdS 051 0217 490681 21 ASW VC LIO SELEY 349 NIHOWIN ISOC69 ZSW 07739934 S L106 vi vNv 9 PLAN SZt S9C0ZSW ALNO STUNTS N 0V amp Hd 8 S S 5 8 3005 7808997 6 AINNOW dCHd 317e Pecleor
135. ikely to affect the pilot s field of vision 4 2 5 SCRATCHES Scratches on clear plastic surfaces can be removed by hand buffing and polishing using Plastic Polish available from JABIRU as Part No NOVUS 2 NOTE Rubbing plastic surface with a dry cloth will build up an electrostatic charge which will attract dirt particles and may eventually cause scratching of the surface After applying polish dissipate this charge by rubbing surface with a slightly damp chamois This will also remove dust particles which have collected while wax is hardening 4 2 6 CRACKS When a crack appears drill a hole at the end of the crack to prevent further spreading Hole should be approximately 1 16 inch in diameter depending on length of crack and thickness of material An unfluted drill should be used 4 2 7 REMOVAL As the windscreen and windows are bonded into the fuselage it is not possible to remove them without destroying them Once windows have been broken out any screws used in the original installation should be removed 4 2 8 INSTALLATION 1 Ensure all old epoxy resin has been removed from the fuselage sealing strips around the window frames 2 Check new windscreen for fit File or grind away any excess material to ensure a close fit Do not attempt to cut with any type of saw Wet the window frame joggle with raw epoxy resin Apply a bead Epoxy amp Flock around the outer edge of the windscreen 4 Place windscreen acc
136. imeter 6 If leakage rate is within tolerance slowly release suction source NOTE If leakage rate exceeds maximum allowable first tighten all connections then repeat leakage test If leakage rate still exceeds maximum allowable use the following procedure Disconnect static pressure lines from airspeed indicator and vertical speed indicator 2 Use suitable fittings to connect lines together so that the altimeter is the only instrument still connected into the static pressure system 3 Repeat leakage test to check whether static pressure system or the bypassed instruments are the cause of the leakage If instruments are at fault they must be repaired by an appropriately authorised repair station or replaced If static pressure system is at fault use the following procedure to locate the leakage 4 Attach a source of positive pressure to the static source opening Figure 50 shows one method of obtaining positive pressure CAUTION Do not apply positive pressure with airspeed indicator or vertical speed indicator connected to the static pressure system 5 Slowly apply positive pressure until altimeter indicates a 500 foot decrease altitude and maintain this altimeter indication while checking for leaks Coat line connectors and static course flange with solution of mild soap and water watching for bubbles to locate leaks 6 Tighten leaking connections Repair or replace parts found to be defective 7 Reconn
137. instrument and is not connected to the aircraft electrical system See Wiring Diagram Figure 51 Should the instrument fail to operate 1 Check for loose terminal connections and damage to wiring 2 Replace thermo couple 3 Replace Gauge 12 8 EXHAUST GAS TEMPERATURE GAUGE OPTION The Exhaust Gas Temperature Gauge is Thermo couple instrument and is connected to the aircraft electrical system See Wiring Diagram Figure 51 Should the instrument fail to operate 1 Check for loose terminal connections and damage to wiring 2 Replace thermo couple 3 Replace Gauge 12 9 HOURMETER The Hourmeter is an electronic instrument An optional Airspeed Switch may be fitted Should the instrument fail to operate Check 10amp instrument fuse and replace if necessary 2 Check 30amp main fuse and replace if necessary Remove Instrument Panel see Paragraph 13 2 3 and check cable terminals for security 4 Replace Gauge 12 10 MAGNETIC COMPASS The Magnetic Compass is liquid filled with expansion provisions to compensate for temperature changes It is equipped with compensating magnets adjustable from the front of the case No maintenance is required on the compass except an occasional check on a compass rose for adjustment and compensation REVISION Dated July 2005 Issued By RAS Page 134 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date
138. ion during flight 113 FUEL VENTS 11 3 1 DESCRIPTION Refer to Figure 48 Positive ventilation is provided by vented fuel caps All three tanks are interconnected to ensure uniform breather pressure and even feeding from all tanks 11 3 2 CHECKING Vent lines can become blocked resulting in fuel starvation of the engine Also the vent line if plugged can result in pressure from expanding fuel pressurising the tank The following procedure may be used to check the tank and tube 1 Have an assistant hold a rubber glove or balloon over the vent tube 2 Blow into the cap vent on the other wing If the balloon glove inflates the breather lines between the tanks are open and the tanks are cross feeding Correct any blockage To check the breather line for the header tank REVISION Dated July 2005 Issued By RAS Page 118 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru 9160 J170 Variants 1 Turn taps between the wing tanks and the header tank 2 Disconnect the fuel line from the mechanical fuel pump on the engine 3 Allow fuel to flow from the line for approximately a minute WITHOUT turning the electric boost pump on If the fuel flows freely the breather connection between the header tank and the main tanks is
139. ion of servicing at intervals other than 50 100 and 200 hours The engine Instruction Manual also details engine inspection schedules and should be consulted in addition to this chart e When conducting an inspection at 50 hours all items marked under EACH 50 HOURS would be inspected serviced or otherwise completed as necessary to ensure continuous airworthiness At each 100 hours the 50 hours items would be completed in addition to the items marked under EACH 100 HOURS necessary to insure continuous airworthiness An inspection conducted at 200 hours would likewise include the 50 hour items and 100 hour items in addition to those at EACH 200 HOURS complete aircraft inspection includes all 50 100 and 200 hour items together with those shown in the Engine Instruction Manual 3 5 2 INSPECTION GUIDELINES 3 5 2 1 MOVEABLE PARTS lubrication servicing security of attachments binding excessive wear safety proper operation proper adjustment correct travel cracked fittings security of hinges defective bearings cleanliness corrosion deformation sealing and tension 3 5 2 2 FLUID LINES AND HOSES leaks cracks kinks chafing proper radius security corrosion deterioration obstruction and foreign matter 3 5 2 3 METAL PARTS security of attachment cracks metal distortion broken welds corrosion and any other apparent damage 3 5 2 4 WIRING security chafing burning defective insulation loose or
140. iru J160 J170 Variants L QOVS00VE 4859 FILLOYHL LNNOW OL 9113 INNON 318vO SMOHS LNO Ald 30 1N3SNOO JHL LNCHLIM 021409 38 LSNA INY LEOIAdO9 SI SIHL SAIYAS ouaavanna SONIMVHC LHVd OL 3432 MSL 26 987 OLO 50 5 0315192348 SSSINN SLIAN Vd HO3LAV 3 0 LON Og SSYLAWITIIW NI D A NOLI Od 1708 YELENY ZL H3HSV A ANNAd P OLENY 9L 1709 3L YLLENY SL LAN DOTAN 9L 2001 89025 tL YIHSYM 1913 191 096 EL SSANMOIHL 2 1 H3HSV A 1v 13 9L J0L 096Nv Zl 2602206 6 JILLOYHL LNNOW 49018 aosascove 8 YSHSVAA 1015 98 OL O96NY 2 ATW 9L 60009 9 dAV19 38n L N6S00Zd 6 SILLOYHL LNNOW HOIH LAVHS doascove v 31LLOSH L E3 31 Lnd nO 7 90 LIVHS 55080 3 1LLOSWH L LNNOW acoscove STLLOYHL LNNOW ALO NOILdlHOS3d LHvd 1sr sued Figure 36 CS VLA Variant Throttle Panel Mounted e 10 U A lt 02 tn o 5 o 0 Ke 5 gt 7
141. is not cut into in the sanding process 3 Grind excess resin from joints being careful not to grind into fiberglass layers Take care not to grind into the horn of any control surfaces 4 A clean wire brush is used to search out any crab holes or pinholes Give the entire aircraft a good scrub all over especially around corners etc 5 Wear a breathing respirator with painting cartridges right from initial sanding through to painting Hint Body Filler sets quickly in high temperatures particularly when larger mixes are necessary Use cold packs under the Body Filler board to extend setting time 6 Follow instructions carefully and experiment with setting times T On large radius e g sides of fuselage an extra large homemade spatula 9 thin tin plate is very handy when applying Body Filler 8 When filling up to window edges grind chamfer onto edge of window to give depth for bog adhesion WARNING THE GEL COAT IS MICRO THIN SO SANDING 1 ALWAYS A CAREFUL PROCEDURE IF GEL COAT IS INADVERTENTLY PENETRATED DO NOT CONTINUE SANDING INTO STRUCTURAL GLASS 9 With the surface satisfactorily prepared white primer is required only on the discolored areas i e Body Filled areas Pin holes become evident after the primer is applied so use spot putty to fill Be careful and meticulous to find all pin holes because primer and top coat will not fill holes 10 Your final product can only be as good as your preparation Remember
142. is provided as Figure 5 below Door latches or their component parts must be replaced if worn or damaged REVISION gg Dated July 2005 Issued Page 37 of 156 L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM BEN Jabiru J160 J170 Variants ircraft pty A Aircraft Service Manual iru Jab 0092 OH OMG alva ss YVA ERSS 017 Alc H2z1 X 49 N3SNOO 3H1 LICHUN 231805 39 LON 5 LHDISACOS SI SIHL HOSLAY 31958 LON S3YLSWITTIM NI SNOISN3HIG qa31v130 Ew 0917 5 HALY ODA la d3 SVMO9ONV vL Sir095NV 02 Lt EE 9 HOLY 30IrS 8i a YIHSVAA LVIA whit 71917 095 51 tV 0617 0018 lij aste VSENV 0917 1 YOIYILNI LAN COTAN IL 0221 396026 0 1 SS3NMCIHLZ 1v 13 9L E 00 10L 095NV 6 E 8 3INITSNILO3NNOO HALY 2 1931435 HOLY 9 2 19HINCO 5 H3HSv podere 6 zci soetzSW v Ados 5 SWE
143. le 10 7 5 AIR INTAKE SYSTEM amp CARBURETOR HEAT The engine air intake system comprises a cold air inlet in the lower cowl a hot air muff attached to the exhaust system a mixer assembly mounted on the firewall and connected to a carburettor The mixer box incorporates the air filter control flaps etc Carburettor Heat is activated by pulling the Carburettor Heat Control on the panel OUT This opens the hot air valve in the mixer assembly and permits hot air to flow from the muff into the carburettor The air filter should be cleaned every 50 hours or more regularly if the engine is operated in dusty conditions Refer Paragraph 11 9 Refer to Figure 43 revision 0 Dated July 2005 Issued By Page 107 of 156 L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty pta Aircraft Service Manual Jabiru J160 J170 Variants 5 4 4 N lt Fd 1 1 2 8 5 a N SEG Lp i m ES JADE 5 1 1 5 B O 0 1 gt lt 1 1 m odi y i na Vo 5 9 c 5 52 e S NS 4o 8 1 1 1 2 E 1 1 1 la
144. line for damage connections for security Repair or replace damaged line tighten connections Incorrect indication Partially plugged static line Check line for obstructions Blow out lines Ruptured diaphragm Substitute known good indicator and check reading Replace instrument Pointer off zero Reset pointer to zero Pointer oscillates Partially plugged static line Check line for obstructions Blow out lines Leak in static line Test lines and connections for leaks Repair or replace damaged lines tighten connections Leak instrument case Substitute known good indicator and check reading Replace instrument Hand vibrates Excessive vibration Check shock mounts Replace defective shock mounts Defective diaphragm Substitute known good indicator and check for vibration Replace instrument 12 3 10 Refer to Figure 48 PITOT TUBE ALIGNMENT For correct airspeed indication pitot tube must be properly aligned Open end of tube must be perpendicular to longitudinal axis of the aircraft Refer to Figure 48 for alignment details REVISION N Dated July 2005 Issued By RAS Page 129 of 156 L MilesYTechnical manuals160 17019160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty pta AN E Aircraft Service Manual Jabiru J160 J170 Variants 230 H
145. lter should be removed inspected and cleaned will depend on the operating conditions A good general rule however is to remove inspect and clean the filter ever 50 hours of engine operating time and more frequently if warranted by the operating conditions Clean only with compressed air Under extreme operating conditions daily servicing of the filter is recommended 3 2 5 BATTERY The Battery is a gel type and so is not a serviceable item If electrolyte corrosion occurs Use bicarbonate of soda baking soda and clean water to neutralise electrolyte of corrosion Follow with a thorough flushing with clean water Remove battery and clean residue from aircraft Tighten cable and terminal connections with a wire brush then coat with petroleum jelly before connecting cables Check the battery every 50 hours or at least every 30 days more often in hot weather Inspect the Battery Box and attachments Clean and remove any signs of spillage or corrosion 3 2 6 TYRES Maintain tyre pressure at the air pressure specified in Aircraft Specifications above When checking tyre pressure examine tyres for wear cuts bruises and slippage Remove oil grease and mud from tyres with soap and water NOTE Recommended tyre pressures should maintained especially in cold weather Remember that any drop in temperature of the air inside the tyre causes a corresponding drop in tyre pressure 3 2 7 HYDRAULIC BRAKES Check brake master cylinder an
146. malities have been corrected revision 0 Dated July 2005 Issued Page 28 of 156 L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants 3 5 3 INSPECTION CHART IMPORTANT READ ALL INSPECTION RQUIREMENTS PRIOR TO USING THESE CHARTS Table 4 Inspection Chart Annual Inspection Each 200 Hours Each 100 Hours Each 50 Hours PROPELLER 1 Spinner 2 Spinner Flange i 3 Spinner screws 4 Propeller n 5 Propeller bolts nuts Tension d 6 Spinner Prop Tracking x ENGINE COMPARTMENT Check for oil fuel exhaust amp induction leaks then clean entire engine amp compartment before inspection 1 Carburetor air filter 2 Engine baffles and air ducts i 3 Cylinders 4 Crankcase amp front crankcase seal 5 Hoses lines and fittings 6 Intake and exhaust systems 7 Ignition harness distributor caps amp rotors 8 Spark plugs i REVISION Dated July 2005 Issued By RAS Page 29 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524
147. me 524 Aircraft Service Manual Jabiru J160 J170 Variants 2 New piston sealing O Rings should be installed each time the brakes are disassembled If re use is necessary they should be wiped with a clean cloth saturated in automotive brake fluid and inspected for damage NOTE Thorough cleaning is important Dirt and chips are the greatest single cause of malfunctions and leaks in hydraulic brake systems Check brake linings for deterioration or excessive wear 4 Inspect brake cylinder bore for scoring A scored cylinder will leak or cause rapid bucket wear If wear is evident install a new brake cylinder 5 If the anchor bolts on the brake assembly are nicked or gouged replace with new bolts 6 Inspect wheel brake disc for a minimum thickness of 2mm f brake disc is below minimum thickness install a new part 6 8 4 3 WHEEL BRAKE INSTALLATION Place brake cylinder assembly in position on backing plate 2 Install bolts springs outboard pad nuts washers d Reconnect flexible hose 4 Fill master cylinder reservoir with brake fluid 5 Bleed brakes Refer to Paragraph 6 8 5 6 8 4 4 BRAKE LINING INSTALLATION New brake linings should be installed when the existing linings are worn to expose the rivet heads To replace outboard lining Remove bolts securing outboard brake pad and brake cylinder to backing plate 2 Remove outboard brake pad Place brake pad a ta
148. nd service if necessary 4 Remove warning placard from propeller 5 Remove materials used to cover openings 6 Remove clean and gap spark plugs 7 While spark plugs are removed rotate propeller several revolutions to clear excess preservative oil from cylinders REVISION Dated July 2005 Issued By RAS Page 21 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants CAUTION Ensure that the Master and Ignition Switches are OFF 8 Install spark plugs torque to 20 nm 180 inch Ibs 9 Check fuel filter replace if necessary 10 Check brake fluid level 11 If returning to service after indefinite storage fill fuel tanks with correct grade of fuel 12 Check fuel tank and fuel lines for moisture and sediment Drain enough fuel to eliminate any moisture and sediment 13 Check fuel tank breather is clear 14 Perform a thorough pre flight inspection 15 Start and warm engine 3 2 SERVICING Servicing requirements are shown in the service table below The following paragraphs supplement this table by adding details not included Note that Inspection Requirements are detailed at Paragraph 3 5 3 2 1 SERVICING SCHEDULE 3 2 1 1 PRE FLIGHT e Refer to Flight Manual 3 2 1 2 25 HOUR SERVICE e Refer to Engi
149. ne Instruction amp Maintenance Manual 3 2 1 3 50 HOUR SERVICE e Refer to Engine Instruction amp Maintenance Manual 3 2 1 4 100 HOUR SERVICE e Refer to Engine Instruction amp Maintenance Manual 3 2 1 5 OTHER INSPECTION amp MAINTENANCE PROCEDURES e Refer to Engine Instruction amp Maintenance Manual e Replace flexible oil amp fuel line in engine compartment every 2 years or when visible deterioration cracking hardening occurs REVISION Dated July 2005 Issued By RAS Page 22 of 156 L Mfiles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants 3 2 2 FUEL The fuel tanks should be filled immediately after flight to lessen condensation of moisture The tank capacity is listed in the Aircraft Specifications Above 3 2 3 FUEL DRAIN A fuel drain is located in the Left amp Right hand fuel tanks near the wing root Drain fuel after each refuelling to ensure moisture and contaminants are not present 3 2 4 CARBURETTOR AIR FILTER The Carburettor air filter keeps dust and dirt from entering the induction system The value of maintaining the air filter in a good clean condition cannot be overstressed More engine wear is caused through the use of a dirty or damaged air filter than is generally believed The frequency with which the fi
150. nor SHH 318 2 2 0040 zz NAMOS TOHINOS HSnal 3903M 318 2 WN Led D OA 2 wu wu 4 s 5 5 E e o 8 E LL rel U lt 02 a 5 o 49 5 gt 75 9 o 2 x _ 0 files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 L Miles Technical_manuals J160_J170 J160_ amp _J170_workin Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants 7 3 CONTROL CABLES Control Cables are of the enclosed push pull type fitted with spherical bearings at both ends To operate the outer cover of the cable must be clamped firmly at each end 7 3 1 CONTROL CABLE REMOVAL amp INSTALLATION Control Cables are Primary Control and may not be removed or repaired without reference to JABIRU AIRCRAFT Pty Ltd or our approved local agent 7 4 AILERONS Ailerons comprise a moulded and bonded monocoque structure embodying a composite control horn at the outboard end 7 4 1 AILERON REMOVAL amp INSTALLATION 1 Unbolt cable from aileron control arm 2 Loosen screws hinge retainers and lift hinge pin retainer away from the hinge pin It is no
151. nt Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty pta 46 1 un Aircraft Service Manual Jabiru J160 J170 Variants WARNING The control cable must be connected to the same side of the control column bellcrank as the wing to which the aileron is fitted otherwise control surface reversal will result DO NOT CROSS CABLES 5 52 u I 5 5 LO 2 N gt 02 l p 2 2 lt jum lt gt Un U 5 _ fa gt C a 7 C __ C2 m E 2 lt 1 b m NY Y Ww MP IE a X al 2 gt ges Oeorg 2 Eds 5 lt 5 U g 2 al gt A 2 gt 3 19192 7 5 7 5 161 9 amp welt Z Oj amp OBESE 10 3 1 1 21 amp Za S EI lt j lt I F Z 5 gu E 6 lt Eis 5 gt gt 0 mz o v Ko 8 5 4 go amp Ce CN z a5 o a 5 N B lt ud N amp 2 n gt s 5 No 0 zx 5 Figu
152. nt Date 12 08 2005 12 19 00 PM L Miles Technical_manuals J160_J170 J160_ amp _J170_workin Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants 6 4 8 WHEEL BALANCING Since uneven tyre wear is usually the cause of tyre imbalance replacing the tyre will probably correct this condition If a wheel shows evidence of imbalance during service it may be statically balanced 6 5 NOSE GEAR The nose gear comprises a steerable nose wheel mounted on a welded steel assembly with an aluminium wheel yoke and a rubber spring system The steel tube is constrained within two Ertalite bushes mounted in an aluminium housing which is attached to the front of the firewall Nose wheel steering is achieved by connecting the rudder pedal assembly to the nose wheel steering link by push rods The nosewheel is centred by springs A nose wheel speed fairing wheel spat is standard equipment Disassembly inspection repair and reassembly of the nose wheel assembly are described in separate paragraphs The wheel is in two halves which are joined by through bolts to the wheel hub as shown in Figure 15 During assembly of the nose wheel the through bolts must be tightened evenly and torqued to the value specified in Table 3 6 5 1 TROUBLE SHOOTING NOSE LEG Table 6 Trouble Shooting Nose Leg Trouble Probable Cause Remedy Nose strut bolts loose Tighten bolts Loose or worn
153. nts Fitted to sight glasses of wing fuel tanks REVISION N Dated July 2005 Issued By RAS Page 144 of 156 L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants 15 2 COCKPIT CONTROL DECALS Table 14 Cockpit Control Decals Decal Detail Preview Loading Limitations P No 5098894 Fit to right side of fuselage between window and beam Trim Position 5024094 NOSE DOWN NEUTRAL TRIM NOSE UP BRAKE ON 4 Fitted on the Top of the Main Beam Beside the trim control Fuel Tap Position P No 502319N AN OFF Fitted on the Beam front of the Fuel SELECTOR Valve Fuel Tap Position P No 502329N OFF on FUE Fitted on the rear of the fuselage beam next to the wing tank valves Choke Cable P No5051094 CHOKE PULL ON REVISION Dated July 2005 Issued By RAS Page 145 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft 2 Aircraft Service Manual Jabiru 9160 J170 Variants Decal Detail Preview Fitted at the base of the choke cable Carby Heat P No 502619
154. oard is numbered 5 and the rear Port cylinder is numbered 6 Refer to Engine Instruction amp Maintenance Manual for detailed engine data For repair amp overhaul of the engine refer to the applicable publication issued by Jabiru Aircraft Pty Ltd 10 2 1 ENGINE DATA Refer Engine Instruction amp Maintenance Manual 10 2 2 ENGINE TROUBLE SHOOTING Refer Engine Instruction amp Maintenance Manual 10 2 3 ENGINE CLEANING Refer Paragraph 3 3 5 10 2 4 ENGINE ACCESSORIES REMOVAL Removal of engine accessories for inspection involves stripping the engine of parts accessories 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 should be used to cover the opening REVISION Dated July 2005 Issued By RAS Page 101 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty Aircraft Service Manual Jabiru J160 J170 Variants 10 2 5 INSPECTION For specific items to be inspected for periodic inspection details refer to Engine Instruction amp Maintenance Manual 1 Visually
155. on the underside of the wing aerofoil and adjust flap so that the trailing edge of the flap sits on the straight edge and there is 4mm clearance between straight edge and trailing edge of the wing 2 Adjust with the rod ends Ensure that the lock nut is tight on the control ends that the thread is visible through the hole in the rod 3 Check for FULL DOWN travel using the Flap Rigging Template see Appendix 3 Please note There is only a requirement to check the down deflection because it has the highest value in travel REVISION o Dated July 2005 Issued By RAS Page 78 of 156 L files Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM ircraft pty A Aircraft Service Manual iru Jab Jabiru J160 J170 Variants SY 229v 1 8371MNIF 225 982 OLO N 2 Vid HOSLAY 31925 10N OG ATAWBSS SAID 99 7 ASSY JAYA 21912313 Ale 30 _NISNOSD JHL 03 00 ICON SAW ONY THO AdO9 SI SIHI GO 25 0310348 55219 SLIATI SSYLaW THN ET 20998 LNNOW 935 2412212 091 Ce3ttovc OS LP NIVA LNNOW OASS 3513 21419313 Craetoys 3871 91 5 ASNA 3594 LON GOTAN
156. orking files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Aircraft Service Manual Jabiru J160 J170 Variants 1 PROJECTION NOT SCALE CONTROL ASSY 5 160 FAMILY RUDDE 785 973 DMENSIONS N HILINE RES AFFOT B NCAGCRC ACN em RRRS TOPET RO THIET NT OUT CONSENT Of LTO 2 Ax m 5 5 a See 52222 7 O 1 V p a h 5 S 5 OLS zl e 5 Sja 8 5 vd Es 5 EJE 2 CABLE CLAMP 2 AN3 064 BOLT 4 2 ACD END FEMALE WASHER LODE CABLE MOUNT J150 M820365 1032 NLT 12 2551404 11 POOCSON 10 POOCESN 9 8 7 6 5 4 3 2 1 Figure 32 Rudder System Schematic revision 0 Dated July 2005 Issued By RAS Page 96 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ filesJ160 amp J170 Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru 9160 J170 Variants ircraft pty A Aircraft Service Manual iru Jab 132 11335 29 5 i Sv davar
157. orking files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty AN un Aircraft Service Manual Jabiru J160 J170 Variants 14 2 3 Painting Equipment Required acus ee eoe ie Rad 141 14 2 4 Painting Procedure EI DO ea a 142 15 SECTION 16 Cae ern saia 144 15 17 ee 144 15 2 COCKPIT CONTROE DECALS 145 15 3 EXTERNAL 5 146 16 APPENDIX I JABIRU 2200 1 1 1 e eee tn 147 17 APPENDIX JABIRU ENGINE PARTS BOOK ssccccccssssssssteccssssssensesecsssssneecccsscsssssensceecsssssseceees 148 18 APPENDIX III ENGINE INSTALLATION asses sees assess 149 19 APPENDIX IV PROPELLER SERVICE MANUAL eren tenen eren nna ats asses eee assess essen 150 19 1 APPROVED INSTALLATIONS iskerne aer Ee Pe ees evo e 150 19 2 IDENTIFICATION 000404 00 150 19 3 150 10 3 INSTAEBATION 151 19 5
158. ouble Probable Cause Remedy Static line plugged Check line for obstructions Blow out lines Instrument fails to f operate Substitute known good Defective mechanism altimeter and check reading Replace instrument Hands not carefully set Reset hands with knob Substitute known good incorect indicato Leaking diaphragm altimeter and check reading Replace instrument Compare reading with known Pointers out calibration good altimeter Replace instrument Check lines for obstruction or Hand oscillates Static pressure irregular leaks Blow out lines tighten connections Revision 0 Dated July 2005 Issued By RAS Page 128 of 156 L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Aircraft Service Manual Jabiru J160 J170 Variants Trouble Probable Cause Remedy Leak in airspeed or vertical speed indicator installations Check other instruments and system plumbing for leaks Blow out lines tighten connections 12 3 9 Table 12 Trouble Shooting Vertical Speed Indicator Option TROUBLE SHOOTING VERTICAL SPEED INDICATOR OPTION Trouble Probable Cause Remedy Instrument fails to operate Static line plugged Check line for obstructions Blow out lines Static line broken Check
159. p _J170_working_ files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty pta Aircraft Service Manual Jabiru J160 J170 Variants 9 8 7 3 2 1 2 22 5 e lt 3 5 5 a z 143 E 4 alela 8 8 215 44 o 1 lt 2 9 15181 919 5 o o 819 5 2 8 58 2 2 21818 n 2 b 2 53 ARBAB BS 5 e 8 51 1 gt 583 8 213 2 OT 5 REF ONLY REF ONLY Figure 18 Aileron System Schematic Revision 0 Dated July 2005 Issued By RAS Page 72 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ filesJ160 amp J170 Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants 7 2 CONTROL COLUMN Refer to Figure 21 7 2 1 CONTROL COLUMN REMOVAL amp INSTALLATION The Control Column is a Primary Control and may not be removed or repaired without reference to JABIRU AIRCRAFT Pty Ltd or our local approved agent REVISION Dated July 2005 Issued Page 73 of 156 L Miles Technical manuals160 J1701J160 amp J170 working files J160_
160. pinner Unbolt Propeller Bolts 6 off Remove Bolts Spinner Flange Aluminium Propeller Flange Belleville Washers and Propeller TO ASSEMBLE AND REPLACE PROPELLER ASSEMBLY Ensure that Propeller drive bushes 6 off are in place in the Crankshaft Propeller Flange Fit the rear spinner backing plate to the flange Fit propeller to flange Ensure that the drive pins are snug fit in the propeller Loose pins can cause propeller fretting and engine damage Fit Propeller Bolts 6 off Fit front spinner backing plate to front of propeller The fit Aluminium Propeller Flange Belleville Washers 42 off 8 per Bolt assembled in pairs as shown Progressively tighten bolts ensuring equal distribution of load and in a normal criss cross torque sequence Using Torque Wrench tighten Bolts to 6nm 72 inch Ibs Check tracking of Propeller by locating a fixed object on a flat floor so that it just clears the Propeller tips when rotating the Propeller by hand Check that each blade clears the object by the same amount f the Propeller is outside the approved tolerance refer to JABIRU Aircraft Pty Ltd or a JABIRU Approved Service Centre Maximum Tracking Error Tolerance is 2mm Locate Spinner on Spinner Flange and fix with Machine Screws through tinnerman Washers Check Spinner for balance by locating a fixed object on a flat floor to just clear the lower edge of the front dome of the Spinner Rotate the propeller by hand and c
161. position during flight CS VLA variants must have these taps wired ON using electrical fuse wire Ensure wing tank cap vent covers are removed 11 5 FUEL FILTERS 11 5 1 CS VLA FILTER DESCRIPTION The fuel filter is of the in line type and is located inside the header tank enclosure behind the seats 11 5 2 NON CS VLA MODEL VARIANT FILTER DESCRIPTION The fuel filter is of the in line type and is located just inside the cabin above the rudder pedals 11 5 3 CS VLA MODEL FUEL FILTER REMOVAL amp INSTALLATION 1 Turn fuel valves between wing tanks and header tank to OFF Cover wing tank vents 2 Try to kink to main fuel line above the fuel filter being careful not to damage 3 Place a cloth beneath the filter to collect any fuel which may be split during removal of the filter REVISION Dated July 2005 Issued By RAS Page 121 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Jabiru 9160 4170 Variants 4 Disconnect the fuel lines at both ends of the filter 5 Remove filter 6 Reverse the preceding steps for installation Ensure waste cloth is removed WARNING Fuel valves between wing tanks and header tanks must be wired in the ON position using electrical fuse wire during flight Ensure wing tank cap vent cover
162. prior to next flight 5 3 FIN The Fin is a moulded composite structure supported by a rib and a rear spar Hinges attach the rear spar to the rudder 5 3 1 REMOVAL INSTALLATION INSPECTION AND REPAIR The fin is an integral part of the fuselage structure and cannot be removed All repairs must be referred to JABIRU AIRCRAFT Pty Ltd or our approved local agent 5 4 HORIZONTAL STABILISER The horizontal stabiliser is a moulded monocoque structure of rigid cellular polystyrene bonded to a fibreglass skin and rear spar Refer to Figure 30 5 4 1 REMOVAL AND INSTALLATION The horizontal stabiliser is an integral part of the fuselage to which it is bonded It cannot be removed All repairs must be referred to JABIRU AIRCRAFT Pty Ltd or our approved local representative REVISION Dated July 2005 Issued Page 48 of 156 L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants 6 SECTION 6 LANDING GEAR and BRAKES 6 1 LANDING GEAR Main gear comprises two separate composite beams which are bolted to the fuselage at the top and centre and to the wheel stub at the bottom The nose gear is a welded steel trailing arm assembly with a rubber spring system The nose wheel is steerable with the rudder pedals Nose Wheel and Main Whe
163. r approved local agent 9 4 RIGGING 1 To establish the neutral position raise the nose wheel off the ground by leaning down on the horizontal stabiliser 2 Allow the nose wheel and therefore the rudder pedals to centralise Align the rudder 5mm to the right at the top of the rudder when referenced to the lower lip of the fin 4 Adjust the rod ends on the cable so that the hole in the rear rod end aligns with the hole in the control horn 5 Fit bolt nut and washers 6 Scribe a line from the centre of the Rudder trailing edge onto the Fuselage Displace the Right Rudder Pedal to the Rudder Pedal Stop Measure the Rudder displacement at the Rudder trailing edge with reference to the previously scribed line It should be 98mm 2mm REVISION Dated July 2005 Issued By RAS Page 94 of 156 L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants 7 Repeat Step 6 for Left Pedal and adjust Rudder Pedal Stops as required WARNING The Rudder Pedal Stops should engage NOT the Control Surface Stops on the tail DO NOT move the Cable Anchor Points or adjust control surface stops These are factory set REVISION Dated July 2005 Issued Page 95 of 156 L Miles Technical manuals160 J1701J160 amp J170 w
164. raft Pty Ltd or our local approved agent for assessment and possible repair In composite leading edges nicks of a size described above may be repaired by filling with epoxy resin and Fibreflock using the procedure outlined below Propeller Repair Kit is available from JABIRU as Part No PP0049N 1 Remove Propeller as per Paragraph 5 2 Sand nick with abrasive paper to remove any fractured particles resin carefully and thoroughly equal parts resin and hardener and thicken with Fibreflock to form a paste 4 Apply paste to sanded nick and allow to cure in low moisture environment for 24 hours 5 Lightly and carefully sand excess cured resin to a smooth surface matching exactly the previous aerofoil 6 Refurbish with clear Epoxy paint JABIRU Part PPOO69N 7 Rebalance Propeller see Paragraph 8 8 Reassemble and replace Propeller and Spinner see Paragraph 6 9 Check Propeller tracking and Spinner balance see Paragraph 6 10 Damaged urethane leading edges should be referred to Jabiru Aircraft Pty Ltd for repair REVISION Dated June 2005 Issued By RAS Page 154 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Instruction amp Maintenance Manual Jabiru 2200 Aircraft Engine 19 8 PROPELLER BALANCING PROCEDURE Propeller balance should be checked
165. re 20 Aileron Stops revision Dated July 2005 Issued By RAS Page 76 of 156 L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants 8 SECTION 8 WING FLAP CONTROL SYSTEM 8 1 WING FLAP CONTROL SYSTEM Refer to Figures 23 to 26 The wing flap control system comprises a switch amp position indicator mounted on the instrument panel and a electronic linear actuator driven common shaft assembly with pushrods connecting to the flap control surface horns WARNING spherical rod end bearings must be fitted with a large washer on the outside of the through bolt to prevent the bearing case and cable releasing in the event of a bearing failure 8 1 1 OPERATIONAL CHECK Operate flaps through their full range of travel observing for uneven or jumpy motion or binding in the system Ensure flaps are moving together through their full range of travel 8 1 2 FLAP SWITCH ASSEMBLY The flap position controlling switch uses a manual toggle switch with position indicator to control the flap deflection 8 1 3 FLAP CROSS SHAFT ASSEMBLY See Figure 26 8 1 4 REMOVAL AND INSTALLATION The Flap Controls are Primary Controls and may not be removed or repaired without reference to JABIRU AIRCRAFT Pty Ltd or our approved local agent 8 1
166. s check for correct direction of movement particularly if controls have been disconnected and correct travel 1 Cables amp clamps 2 Rod ends 3 Trim control amp cable T 4 Travel stops 5 Decals amp labels 6 Flap control amp linkages 7 Elevator control amp linkages i 8 Rudder pedals amp linkages 9 Exterior surfaces of control surfaces 5 Revision 0 Dated July 2005 Issued By RAS Page 32 of 156 L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants Annual Inspection Each 200 Hours Each 100 Hours Each 50 Hours 10 Control horns hinges amp hinge lock tabs 4 Section 4 Fuselage 41 FUSELAGE The Fuselage is a composite monocoque self supporting structure and includes both the Horizontal Stabiliser and Vertical Fin All repairs must be referred to Jabiru Aircraft Pty Ltd or approved local representative 4 2 WINDSHIELD AND WINDOWS 4 2 1 DESCRIPTION The windshield and windows are one piece acrylic plastic panels set in sealing strips with Epoxy Resin amp Fibre Flock and secured to the fuselage with screws nuts IMPORTANT In the event of a bird strike the windshield is the only prot
167. s 27 28 and Figure 27 The elevator control system is comprised of a control column and one enclosed push pull cable fitted with rod ends at both ends WARNING All spherical bearings must be fitted with a large washer on the outside of the through bolt to prevent the bearing case and cable releasing in the event of a bearing failure 8 4 CONTROL COLUMN DESCRIPTION Refer to Figure 21 8 4 1 REMOVAL AND INSTALLATION Refer to Paragraph 7 2 1 8 5 ELEVATOR The elevator comprises a Rigid Cellular Polystyrene core moulded and bonded to a composite skin and embodying a composite control horn at the centre An elevator trim system is attached Refer Paragraph 9 6 Note that the J170 models use a wider span horizontal tail and elevator than the J160 This elevator is driven by the same control assembly as the J160 8 5 1 REMOVAL AND INSTALLATION 1 Unbolt cable from control horn 2 Unbolt trim linkage from control horn Loosen screws hinge pin retainers lift hinge pin retainers from hinge pins It is not necessary to remove these parts 4 Remove hinge pins 5 Remove Elevator 6 Reverse the preceding steps for installation 8 5 2 INSPECTION AND REPAIR Inspect elevator for any signs of delamination or cracking Pay particular attention to the Control Horn and hinges and their surrounding areas Repairs must be referred to JABIRU AIRCRAFT Pty Ltd or our approved local agent REVISION Dated July 2005
168. s are removed The fuel filter must only be installed in one direction arrow the side of the filter marks the fuel flow direction Ensure this arrow is pointed towards the Firewall and Engine 11 5 4 NON CS VLA MODEL FUEL FILTER REMOVAL amp INSTALLATION 7 Turn main fuel valve the cabin main beam OFF 8 Place a cloth beneath the filter to collect any fuel which may be split during removal of the filter 9 Disconnect the fuel lines at both ends of the filter 10 Remove filter 11 Reverse the preceding steps for installation Ensure waste cloth is removed WARNING The fuel filter must only be installed in one direction An arrow on the side of the filter marks the fuel flow direction Ensure this arrow is pointed towards the Firewall and Engine 11 6 FUEL PUMPS 11 6 1 PRIMARY PUMP The Primary Fuel Pump is located on the Starboard rear of the Engine Refer to engine Maintenance amp Instruction Manual for details 11 6 2 CS VLA SECONDARY PUMP A secondary electronic pump is mounted inside the header tank enclosure behind the seats This pump is a back up to the Primary Pump is recommended that the Secondary Pump be engaged at least during take off and landing 11 6 3 NON CS VLA SECONDARY PUMP A secondary electronic pump is mounted inside the centre console above the rudder pedals This pump is a back up to the Primary Pump It is recommended that the Secondary Pump be engaged at least during take off
169. s in accordance with the Inspection Schedules detailed at Paragraph 2 3 of the Service Manual e This inspection should identify the commencement of any structural deterioration which will be evidenced by cracking of the paintwork whiting of unpainted areas movement of wing attachments and threaded bushes movement of undercarriage attachments loosening of firewall engine attachments e Wing struts should be inspected for loose rivets excessive clearance in wing strut attachments or corrosion e Cable clamps should be inspected for evidence of movement and security 20 4 INSPECTION PROCEDURES All inspection is by visual means Refer Paragraph 3 above and Paragraph 3 3 of the Service Manual REVISION Dated June 2005 Issued By RAS Page 156 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM
170. s the power direct from the battery Refer to Wiring Diagram at Figure 51 13 4 BATTERY POWER SYSTEM Refer also to Wiring Diagram at Figure 51 13 4 1 BATTERY The battery is 12 volts and approximately 20 ampere hour capacity The battery is mounted in the engine compartment and is vented overboard 13 4 2 BATTERY TROUBLE SHOOTING Trouble Shooting is limited to inspection of wiring and terminals battery charge condition and battery solenoid 13 4 3 REMOVAL AND INSTALLATION 1 Disconnect the battery security strap 2 Disconnect battery drain 3 Disconnect the ground cable from the negative battery terminal black insulation WARNING When installing or removing battery always observe the proper polarity with the aircraft electrical system negative to ground Reversing the polarity even momentarily may result in failure of semi conductor devices alternator diodes radio protection diodes and radio transistors 4 Disconnect the cable from the positive battery terminal 5 Lift the battery out of the battery box 6 To replace the battery reverse this procedure 13 4 4 CLEANING THE BATTERY For maximum efficiency the battery and connections should be kept clean at all times T Remove the battery and connections in accordance with preceding paragraph REVISION o Dated July 2005 Issued By RAS Page 138 of 156 L files Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc
171. sconnect wiring or pluming to the instrument remove mounting screws and take instrument out from behind or in some cases from the front of the panel In all cases when an instrument is removed disconnected lines or wires should be protected Cap open lines and cover pressure connections on instrument to prevent thread damage and entrance of foreign matter Wire terminals should be insulated or tied up so that accidental ground or short circuiting will not occur 12 2 4 INSTALLATION Generally the installation procedure is the reverse of the removal procedure Ensure mounting screws and nuts are tightened firmly but do not over tighten particularly on instruments having plastic cases The same rule applies to connecting plumbing and wiring 12 3 amp STATIC SYSTEMS Refer to Figures 48 and 49 The pitot system conveys ram air pressure to the airspeed indicator The static system vents vertical speed indicator if fitted altimeter and airspeed indicator to atmospheric pressure through plastic tubing connected to a static port 12 3 1 PITOT STATIC SYSTEM MAINTENANCE Proper maintenance of pitot and static system is essential for proper operation of the altimeter airspeed indicator and vertical speed indicator if fitted Leaks moisture and obstructions in the pitot system will result in false airspeed indications while static system malfunctions will affect readings of all three instruments Cleanliness and security are
172. shown at Figure 51 REVISION gg Dated July 2005 Issued By Page 136 of 156 L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty pta 5 522 Aircraft Service Manual Jabiru J160 J170 Variants m E gt z In E 4 1 c 2 1 2 D ga gt Ko na E Q 1 a 52 Figure 48 Wiring Diagram revision 0 Dated July 2005 Issued By Page 137 of 156 L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty Aircraft Service Manual Jabiru J160 J170 Variants 13 3 BUS BARS Electrical power for electrical equipment and installations is supplied through Bus Bars The bus bars are mounted at the rear of the lower instrument panel Access is gained by removing the main instrument panel see Paragraph 13 2 3 13 3 1 MASTER SWITCH When using a key switch the Master Switch activates relay which in turn powers the bus bars When using a toggle switch it activate
173. stallation E 31905 LON NIHA 61 Od 53 if 510909 01 S 58 V X l A NI SNOISNZ IQ 58 Ll Ale 1 30 LN3SNOO 231909 ION ISAW ANY 1459144905 SI 10 T c 5 lt 02 tn o 5 o 0 Ke 5 gt 75 9 o 2 x _ g files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM L Miles Technical_manuals J160_J170 J160_ amp _J170_workin Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru 9160 J170 Variants 14 SECTION 15 PAINTING amp FINISHING 14 4 INTERIOR The interior is painted with BERGER Matt Vinyl Standard colour is Fumosus A154 Grey 14 2 EXTERIOR 14 2 1 PAINTING The following painting procedure as used at the Jabiru factory had proven successful in ensuring good presentation of the aircraft 2 part paint should be used for best results Due to the variation between different paints we recommend carefully following the pack recommendations relating to surface preparation and safety Use a bare minimum of undercoat preferably white or cream and topcoat to keep weight down If you have had no previous painting experience a short course may be available from TAFE NOTE It is very easy to dramatically increase the weig
174. steering link Tighten replace defective Nose wheel shimmy parts Nose wheel out of balance Refer Paragraph 5 6 5 Wheel bearings loose Replace 6 5 2 NOSE GEAR REMOVAL AND INSTALLATION See Figures 16 and 15 1 Weight tie down tail of aircraft to raise nose wheel off floor 2 Disconnect nose wheel steering pushrods steering cross beam Unbolt steering cross beam 4 1 upper collar steering yoke dependant aircraft S No from the top of leg REVISION Dated July 2005 Issued By Page 58 of 156 L MilesYTechnical manuals160 1701160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants 5 Disconnect the nosewheel centring mechanism 6 Pull the nose wheel strut assembly down from the bushes in the fuselage 7 To install the nose gear reverse the preceding steps 6 5 3 NOSE GEAR INSPECTION AND REPAIR 1 Inspect steel tube and attachments for dents and straightness 2 Inspect rubber spring assembly for damage perishing of the rubber or delamination of the rubber from the aluminium spacers between the rubber blocks 3 Inspect aluminium wheel yoke for damage or bending 4 Inspect bolts nuts for torque see torque values Table 3 5 Repairs to the welded leg assembly beam must be referred to JABIRU AIRCRAFT Pt
175. t Pty pta 5 22 un Aircraft Service Manual Jabiru J160 J170 Variants SURGICAL TUB P d MA THICK WAI URGICAL TUBE THICK WA APPLY SUCTION Squeeze air bulb suction hose f 4 After amount c indicator TO APPLY PRESSURE 9017093 1 STATIC 5 QUIPMENT g 9017095 TES EQUIPMEN Figure 47 Static System Test 12 4 TACHOMETER The tachometer is electronic and driven from a magnetic pick up Should the tachometer fail to operate 1 Check 10amp instrument fuse and replace if necessary 2 Check 30amp main fuse and replace if necessary Revision o Dated July 2005 Issued By RAS Page 132 of 156 L MilesYTechnical manuals160 1701160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants Remove Instrument Panel see Paragraph 13 2 3 and check cable terminals for security Check wiring see Wiring Diagram Figure 51 Check correct installation of magnetic sensor on engine Refer to engine Instruction amp Maintenance Manual Should the instrument give incorrect readings jJ 2 Check 10amp instrument fuse and replace if necessary Check 30amp main fuse and replace if necessary Check correct installation of magnetic sensor on engine Ref
176. t necessary to completely remove these parts Remove hinge pins 4 Remove aileron 5 Reverse the preceding steps for installation 7 4 2 AILERON INSPECTION amp REPAIR Inspect ailerons for any signs of delamination or cracking Pay particular attention to the Control Horn and hinges and their surrounding areas Repairs must be referred to JABIRU AIRCRAFT Pty Ltd or our approved local agent 7 5 CONTROL RIGGING 1 With the control stick in the neutral position use a straight edge not less than 1 metre long Hold the straight edge flush on the underside of the wing aerofoil and adjust aileron to sit on the straight edge Make this adjustment with the cable rod ends ensuring that on completion the locknut is tight on the rod ends and that cable is visible through the inspection hole in the rod end 2 Check UP travel on both ailerons using the Aileron Rigging Template see Appendix 3 3 Use the Aileron Control Stop adjustment see Figure 22 to adjust the total aileron movement ie UP travel and use cable adjustment as previously described to proportion UP and DOWN travel The Aileron Control Stop should engage before the Aileron Arm hits the UP travel stop at the Wing Tip 4 DO NOT move the Cable Anchors these positions have been set using a jig REVISION gg Dated July 2005 Issued Page 75 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Pri
177. tening a hose with a bend having a permanent set will result in hose cracking 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 revision 0 Dated July 2005 Issued By RAS Page 102 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty Aircraft Service Manual Jabiru J160 J170 Variants 10 3 COOLING AIR BAFFLES The baffles installed around the engine direct the cooling air flow to the radiator and to other engine components to provide optimum engine cooling The baffles air inlets and outlets and air scoops are accurately positioned to maintain engine cooling efficiency and their removal will cause improper air circulation and engine overheating 10 3 1 CLEANING AND INSPECTION Engine baffles should be cleaned with a suitable solvent Mineral Turpentine to remove dirt and oil Inspect baffles for cracks splits or damage Replace defective parts 10 3 2 COOLING AIR BAFFLE REMOVAL amp INSTALLATION Baffles are removed by unbolting from the engine and removing tension springs and their attaching wires Reverse the preceding steps for installation 10 3 3 REPAIR Repair of baffles is limited to the replacement of rubber seals These may be replaced by removing the existing ru
178. tribution may result in some dimensions that may be somewhat different from those listed 2 4 CENTRE OF GRAVITY LIMITATIONS The JABIRU is a very light aircraft The installation of equipment may significantly alter the approved CG limits of the aircraft Therefore all proposed fixed installations must be approved by JABIRU AIRCRAFT Pty Ltd 2 5 TORQUE VALUES A chart of recommended torque values is shown in Figure 1 2 These torque values are recommended for all service procedures contained in this manual except where other values are stipulated They are not to be used for checking tightness of installed parts during service 2 6 AIRCRAFT SPECIFICATIONS Table 1 J160 Specifications Model J160 A J160 C 540kg 540kg Aircraft Maximum Weight 119016 119016 Fuel Capacity 135 litres 135 litres AVGAS 100 130 MOGAS with Octane Rating 95 RON or above may be used if AVGAS is not available Fuel Type Fuels Containing Alcohols Ethanol etc will damage the fuel tank sealant and MUST NOT BE USED IN JABIRU AIRCRAFT Oil Capacity 2 3 litres 2 3 litres REVISION Dated July 2005 Issued By RAS Page 12 of 156 L Mfiles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty Aircraft Service Manual Jabiru 9160 J170 Variants Model J160 A J1
179. u 9160 J170 Variants 0436 LSvO 3HAL 9 X 009 ASSY TESHM 9 ZMVH8 1 YINI TVS EVI SON MVC Luc O1 Hz43H SAMA gase 0L0 Now ON TO TANID gt D PS 3 QL1 Ald 40 1IN3SNO2 lid H931AV N SZYLINITIN NI 2 di 5 wmz oe CNY 14944400 51 SIHL SNES AON OS INS Ie 3 ANN DOTAN STE 2501 95055 ZL L3 9VY8 LNNOW ALAN wtih 827695055 OL 13 vil 91 96 VS PNY 583 9 HL 2 0 HSHSWAA 1914 91 6 701 C96Nv 1109 SL E VEZ ENVY 1 NOISN31X3 7650009 S2 ASSY MVHS 2 5 L 5201029 8015 31 7690009 0001 2027 O31 NI 5207009 530 1219 3 1 1871 suec 8 4 9 9 ATEWASSY SNH 133HM NIYA 15 2 5202 9 v z gt 2 wu wu 4 en 2 2 en om E rel C1 5 lt 02 tn o 5 o 0 wo N 5 gt 75 9 o 2 x _ g files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM L Miles Technical_manuals J160_J
180. u 9160 J170 Variants ircraft pty A Aircraft Service Manual iru Jab 1935 0 VIDYA TANWd LNSWNULSNI 1352 TUL 1 4 avd 713 20 70 0 1 1 97995 i 100 112 E3 vaue MAMA X Ji Sof NN Af 8 68 2d 91 NN 4 8 1 134 325 m 7 286 S3ov d 9 110 A ew oe J X 850 719 N 0 9 e 6 o a 532914 ZS files J160_ amp _J170_Tech doc Figure 44 Instrument Panel Layout Basic Panel v MBIA 719220 335 n LON SSdINn 55124 H3Nz sv4 T o ve ES 39S 319719031 3NIInO TANYd I rwoucxosa FOS LON 53 NI SNO SN3NIC ENS L Miles Technical_manuals J160_J170 J160_ amp _J170_workin rel C1 5 lt 02 tn o 5 o 0 wo 5 gt 75 9 o 2 x B 9_ Print Date 12 08 2005 12 19 00 Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants 12 2 3 INSTRUMENT REMOVAL Most instruments are secured to the panel with screws inserted through the panel face To remove an instrument di
181. uirements To be displayed in the aircraft at all times e Placards as detailed in Flight Manual Owner s Manual To be carried in the aircraft at all times Flight Manual Owner s Manual To be made available on request e Aircraft Registration e Radio Station License e Pilot License Certificate including Medical Certificate if appropriate 3 5 2 8 ENGINE RUN UP Before beginning the step by step inspection start run up and shut down the engine in accordance with instructions in the Flight Manual and Appendix 1 of this manual During the run up observe the following making note of any discrepancies or abnormalities 1 Engine temperatures and pressures 2 Static RPM Also refer to Engine Instruction Manual 3 Magneto drop Also refer to Engine Instruction Manual 4 Engine response to changes in power 5 Any unusual engine noises 6 Fuel shut off valve operate engine in ON position and in OFF position long enough to ensure shut off functions properly REVISION Dated July 2005 Issued Page 27 of 156 L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty me 524 Aircraft Service Manual Jabiru J160 J170 Variants 7 Idling speed After the inspection has been completed an engine run up should again be performed to determine that any discrepancies or abnor
182. urately over the sealing strips and locate with one screw top and bottom 5 Fit other screws 6 Take care not to crack windscreen when installing DO NOT over tighten screws cracking will result 4 3 CABIN DOORS 4 3 1 REMOVAL AND INSTALLATION Removal of doors is achieved by removing the hinge bolts or removing the machined screws that attach the hinges to the door frame Refer to Figures 4 and 3 below REVISION Dated July 2005 Issued Page 34 of 156 L Miles Technical_manuals J160_J170 J160_ amp _J170_working_ files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM ircraft pty A Aircraft Service Manual iru Jab Jabiru J160 J170 Variants ASSY HOOT 091 93 NIH Ald HO3LAV JO LN3SNOO JHL LNOHLIM 38 LON LSNA ONY LH9IHAdOO SI 9NIA WHO 0297 DH398VONOS Vd HO31AV Lj L amp Yd OL 99495 L 26 982 0 0 sa g p j4 SSIMHSHLO 031412395 SENINA SLIT 39408 LON 8 NI SNOISNZ MIC 34 MOOT 33914 AXOd3 ONISN Wa OL HOO1d YOO 0917 SNO 18 3901 CO t l HSN 39NIH LAN 90 MIHIS ANNSHALNNGS 9178 Q08000vZ NOQ000vZ cE01 S9C0cSIN 8S5S P69bCSIN NIMS MOOG YSHSVM 918 MAYIS
183. ver FORE and AFT should result movement of the Control FORE and AFT and movement of the Elevator UP and DOWN See Figure 32 WARNING It is important to carry out this operational check whenever the trim cable has been disconnected to ensure it has been correctly installed 8 8 2 TRIM HANDLE ASSEMBLY See Figure 32 8 8 3 CONTROL CABLE AND ATTACHMENTS The control cable is of the enclosed push pull type with the cable bolted directly to the Trim Horn Extension at the rear end and to the trim control lever at the lever end To operate outer covers of the cable must be clamped firmly at both ends 8 8 4 REMOVAL AND INSTALLATION The Trim Control Cable is a Primary Control and may not be repaired or removed without reference to JABIRU AIRCRAFT Pty Ltd or our approved local agent 8 8 5 INSPECTION AND REPAIR Inspect Trim system generally for security and any signs of wear Pay particular attention to the bearing blocks friction plates bearing springs cable and attachments REVISION gg Dated July 2005 Issued By Page 89 of 156 L Miles Technical manuals160 J1701J160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru 9160 4170 Variants ircraft pty A Aircraft Service Manual Jab b 049v HddV 03117136 Sv 0 ASSY ONISNOH
184. y Ltd or our approved local agent 6 5 4 NOSE WHEEL SPEED FAIRING REMOVAL AND INSTALLATION 1 Remove the machine screws around the forward rear sections of the fairing and remove the front section 2 Loosen the axle nuts and remove the rear section 3 Reverse the preceding steps for installation 6 6 NOSE WHEEL 6 6 1 NOSE WHEEL REMOVAL AND INSTALLATION 1 Weight or tie down tail of aircraft to raise the nose wheel the floor 2 Remove nose wheel axle bolt Pull nose wheel assembly from yoke 4 Reverse the preceding steps to install nose wheel Tighten axle bolt 6 6 2 NOSE WHEEL DISASSEMBLY Completely deflate tyre and break tyre beads loose at wheel rim Refer to Figure 15 WARNING Injury can result from attempting to separate wheel halves with the tyre inflated Avoid damaging wheel flanges when breaking beads loose as a scratch nick or gouge may cause wheel failure REVISION Dated July 2005 Issued Page 59 of 156 L Miles Technical manuals160 17019160 amp J170 working files J160_ amp _J170_Tech doc Print Date 12 08 2005 12 19 00 PM Jabiru Aircraft Pty rN un Aircraft Service Manual Jabiru J160 J170 Variants 1 Remove through bolts and separate wheel halves 2 Remove wheel hub 3 Remove tyre and tube from wheel halves 4 Remove bearings NOTE The bearings are press fit in the wheel hub and should not be removed unless a new part

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