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Aircraft Service Manual - Jabiru USA Sport Aircraft

1. 16 Figure 2 Sealants Compounds amp Lubricants 22 11 00 eene nnne nnne nnn 21 Figure Optical TachofnlelBl 22 mile simae repe Mi FGA 22 Figure 5 Safety Wire Wire Pliers 22 Figure 6 Torque Wrench amp Crowsfoot Adaptor Setting 1 nennen 22 Figure 7 Torque Wrench Crowsfoot Adaptor Setting 2 23 Figure 8 Using Crowsfoot 23 Figure 9 Undercarriage tis gae s atu PUE C pucr esae Porc seu 32 Figure 10 Weighing 45 Figure 11 Normal and Jammed Control 48 Figure 12 Rudder Gap Cross serisine Genus a erue REIS 49 Figure 13 Aileron e n 49 Figure 14 Test Load besseres testae ____ 50 Figure 15 Elevator Gap Cross 50 Figure 16 Scratches on nna 51 Figure 17 Wheel Alignment Set 52 Figure 18 Alignment Straight Edge In nennen nennen nnns
2. m 175 11 6 PUELO 177 11 7 _____ _____ _ _ _6 68____ 178 11 8 178 12 INSTRUMENTS amp INSTRUMENT 5 180 12 1 e rend 180 12 2 CUNT zT 180 12 3 INSTRUMENT PANEL eterne tenerent neret neret nennen 182 12 4 Inu np S 183 12 5 TATIC OVa TEM anc ances 184 12 6 O COURO ____________ ee 192 12 7 ANALOGUE TACHOMETER 193 12 8 seu M JP c 194 12 9 MAGNETIC COMPAS S iesi 195 12 10 GYRO INSTRUMENT PACKAGE OPTION csssessssceesessstsseessesstsssecserseeussatesuecsesstsssecseeseeasecserseeaseaseseeseetateasecserateass 195 DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 4 of223 Jabiru Aircraft tc Aircraft Service Manual 13 ELECINIGAL SYSTEMS 197 13 4 ELECTRICAL POWER SUPPLY SYSTEM 197 13 2 MINOR ELECTRICAL EQUIPMENT eee ee 200 13 3 hac 201 13 4 ELECTRICAL LOAD
3. E Lee 7 ENT eme LL ulii X du _ De eme ees pene MT w a 2 SERES U si 1 nama 8 1 00007 CLAN e peme em ______ Elo 1 miu Figure 102 J200 Family Engine Installation Type 2 DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 167 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 11 Fuel System 11 11 Description e Refer to Figures below for system schematic details e Two basic types of systems are used a system where there is one fuel tank fitted behind the seats inside the cabin and a system with two main tanks one in each wing e For systems with the tank inside the cabin filler for the tank is located on the pilot s side of the fuselage The tank is vented via a fitting on the belly of the aircraft The primary mechanical fuel pump is fitted to the engine secondary electric fuel pump and the fuel filter are fitted to the belly of the aircraft under the tank itself main fuel tank is not structural and is held in place with straps A single ON OFF selector is fitted to the centre console between the seats
4. nnn nnns 194 Table 14 Trouble Shooting Digital Instruments 195 Table 15 Model Specific Decals 208 Table 16 General Decals 208 Table 17 Approved Scimitar Propeller Installations Factory built Models 213 DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 9 of223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 2 Section 2 General Information 21 Foreword Applicability e This manual contains JABIRU recommended procedures and instructions for ground handling servicing and maintaining the following Jabiru J230 D aircraft t is the owners responsibility to become fully aware of the particular maintenance requirements and limitations applicable to the appropriate registration 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 Model J230 D must be maintained by an Authorised Person Owner Licensed A amp P or Licensed Light Sport Repairman Maintenance LSR M Jabiru J230 D Light Sport Aircraft have a Special Certificate of Airworthiness which remains in force provided Only modifications and repairs approved by the manufacturer are incorpor
5. 123 Figure 68 Flap Controls 5 2 124 Figure 69 Flap Controls Sheet Fibreglass Motor 124 Figure 70 Flap Controls Sheet Aluminium Motor 125 Figure 71 J200 Family Electric Flap System Sheet 1 nnn 125 Figure 72 J200 Family Electric Flap System Sheet 2 eene nnne 126 Figure 73 Flap Cross Tube Assy J160 127 Figure 74 Flap Cross Tube Assembly J200 Family 128 Figure 75 Elevator Control System Type 1 Sheet 2 nn 131 Figure 76 Elevator Control Assy 2 132 Figure 77 Wide Span Models Horizontal Elevator Assembly Type 1 134 Figure 78 Wide Span Models Horizontal Elevator Assembly Type 2 134 Foure 1 Elevator BRI cm 136 Figure 80 Elevator Trim Handle Assy 138 Figure 81 Trim Controls WAM T c 139 Figure 82 Typical Rudder System Schematic
6. Aircraft Service Manual Jabiru J230 D Serial 868 DO NOT move the Cable Anchor Points or adjust control surface stops These are factory set DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 150 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 10 Engine amp Engine Installation 101 Engine Cowls Type of Maintenance Level of Certification 10 1 1 Description e The engine cowls comprise both an Upper and Lower composite structure e The Upper Cowl is fitted with locating Cam Locks at the front amp rear of the cowlings Hinges run along the join lines on either side holding the top amp bottom together The Lower Cowl is attached to the Fuselage with machine screws mounting into anchor nuts e Due to space constraints not all different variations are shown herein When ordering spare parts provide as must detail as possible part description aircraft model serial number etc to Jabiru to ensure accurate part identification 10 1 2 Upper Cowl Removal Y Y Remove the Cam Locks from the front amp rear of the cowling Remove Hinge Pin Grasping the cowl around the front nose pull carefully upwards Remove the cowl Replace the cam locks in the cowling to ensure they are not misplaced NOTE Always ensure that the cowl 1 placed in a position where it cannot be damaged by persons walking around the aircraft or by wind 6 Reverse the preceding steps for
7. IMENS ECTION II E WT THES DRAWING 15 COPYRIGHT MUST sorum PIL THIS DRAWING I gp CORED THOU DNSENT OF ENTECH n 155 DATE ME DEC 025 TOW DEC ODE ANWES 05 BUNDABERG ODER PEDAL ASSY ADJUSTABLE 2 SERIES Figure 84 Adjustable Rudder Pedal m Type 2 TO PART 9 2 Rudder Centering System Type of Maintenance Level of Certification 9 2 1 Description e In Jabiru Aircraft the rudder pedals are connected directly to the nose leg This gives both nose wheel steering and the mechanism connecting the left and right pedals e The drawings shown in Error Reference source not found through to Figure 87 show several variations of the systems used 9 2 2 Rudder Centering System Removal For details on removing the nose leg and rudder pedals refer to the appropriate sections of this manual e To disconnect the rudder Centering system remove the bolts and the pushrods connecting the pedals to the nose leg or Centering bellcrank 9 2 3 Rudder Centering System Inspection amp Repair 77 Ensure lock nuts are secure e Visually inspect the system for damage wear and corrosion DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 143 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Se
8. HES EQUIV ENT ok Se oft PRESSURE BLEED VALVE SURGICAL TUB THICK WALL CLAMP CHEGK VALVE AIR BULB amp CHECK VALVES The type used for measuring blood pressure o gt CHECK VALVE CN CLAMP SURGICAL TUBE THICK WALL ARPA STON di 10 expel Gs much dif de DOoSSIDIe 2 Hold suction hose firmly against static pressue tube opening 5 Slowly release air bulb to obtain desired suction then pinch hose tightly to maintain suction in the system After leak test slowly release suction by allowing a small amount of air into static system wait for vertical speed indicator to return to zero and repeat as required APPLY PES U CAUTION DO NOT APPLY PRESSURE WITH SPEED INDICATOR OR VERTICAL SPEED INDICATOR CONNEC IO STATIC SYSTEM 1 Hold pressure hose firmly against static pressue tube opening 2 slowly squeeze dir Bulb to apply gesired pressure to Static system 5 Release pressure slowly by opening bleed valve Drawing 9017093 1 STATIC TEST EQUIPMENT Figure 122 Static System Test 12 6 Alternate Static Source Type of Maintenance Level of Certification LSA repairman
9. S eS 9 5 SF 4 Mi INTROL STICK ASS 1 0 4 DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 110 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 Figure 56 Control Column Assy 3 DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 111 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 8 1 4 Control Cables 8 1 4 1 DESCRIPTION e 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 8 1 4 2 CONTROL CABLE REMOVAL Unbolt the connections rod end bearings at either ends of the cable Unbolt the clamps at either end of the cable Where required remove any ties etc used to restrain the cables in the aircraft Tie a string or light wire to one end of the cable Draw the cable out of the aircraft leaving the string wire in place to allow installation of a replacement part aS GO Tw et 8 1 5 Control Cable Inspection amp Repair 777 Required Tools Parts and Material of Maintenance Level of Certification LSA repairman inspection or maintenance e Control cables must be inspected in accordance with the details given in Section 6 16 Note that this is not normally part of a 100 Hourly Annual inspe
10. DRAWIND COPYRIGHT AND MUST MOT BE COPIED WETHCUT THE CONSENT OF AVTECH LTD atiis PUSH MOSE WHEEL 124 LG 2080400 ca UFFLATWASHER dE FLA WASHER 14 ROO SPANO BRACKET JTC TUBE SPACER S LONG 5 SPR STEEFSNO BALANCE CHI CEMTRING TAG WASHER Hi AMCE ASSY NOSE LEG TO MACHINED HOUSING LON STEERING TOKE NUT NOTE REPER TO POR pee I T On amm s Ex 3 25 J160 PEDALS amp NOSE LEG STEERING Figure 87 Steering Rudder Centering Assy Type 3 Includes Soft Link Paneer ASSY SOFT LINK DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 145 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 9 3 Rudder Type of Maintenance Level of Certification LSA repairman inspection or maintenance 9 3 1 Description e The rudder of Jabiru Aircraft is a stressed skin composite structure It is connected to the rudder pedals via a self contained push pull cable 9 3 2 Removal amp Installation 77 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 th
11. REFER TO PART AFFR 5 HNOERAFECEI JFLAPCCNTRCL TLEE in Figure 73 Flap Cross Tube n J160 Family DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 127 of 223 Jabiru Aircraft tc Figure 74 Flap Cross Tube Assembly J200 Family Electric 8 2 4 Flap Position Indicator Type of Maintenance Level of Certification 8 2 4 1 DESCRIPTION e 2 different flap position indicators have been used in Jabiru Aircraft plus the manual handle which also acts as the position indicator for manual flap variants Both indicators consist of cable driven indicator which moves inside a housing Indicators are mounted to the windscreen door pillars 8 2 4 2 FLAP POSITION INDICATOR REMOVAL 1 Undo screws holding indicator to pillar 2 For Type 1 indicators drill rivets and disassemble indicator 3 Loosen bolt on flap drive motor shaft amp remove cable 8 2 4 3 FLAP POSITION INDICATOR INSPECTION amp REPAIR 7 e Repair of the position indicator is limited to replacing worn or damaged parts 8 2 4 4 FLAP POSITION INDICATOR INSTALLATION e Installation procedure is the reverse of the removal procedure outlined above External Flap Push Rod DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 128 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 Type of Maintenance Level of Certification 8 2 4 5 DESCRIPTION e The external fla
12. main VHF radio antenna is installed within the spar at the rear of the tail fin It consists of two sections as shown in Figure 128 e Where equipped second VHF antennas are fitted at the rear of the cabin refer to Figure 129 and Figure 130 The radio system diagram is provided with the radio manuals DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 202 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 E COPYRIGHT AND MUST NOT BE COPIED WITHDUT CONSENT OF AVTECH PTY LTD DIMENSIONS MILIMETRES NOT SCALE PROJECTION 4 5 15 GAP WHEN MOUNTED 12 X 3 AL BAR 1 606075 1 HOLE EACH END 3 5 DIA FERRITE TOROIDS P No SATOBAOD RG 400 COAX CABLE ZIP 4 9 RED CRIMP TIE NOTE USE ZP STOP FERRITE 1088005 FROM SLIDING USE HEAT SHRINK TO ALONG COAX KEEP TORROIDS SEPARATE OAX 5 POSITION INSIDE FIN AS CLOSE To BY APPROX 6 3 12 09 END OF COAX AS POSSIBLE 010 780 97 5 010 ion 5061054 2 bs om ANTENNA VERT POLARIZATION 2951954 Figure 128 VHF Antenna Installation PLACE READ UP AGAINST _ AS CLOSE AS POSSIBLE TO FIRST BULKHEAD 50 CAN BE COVERED BY THE SOUND CURTAIN FLEXIBLE PART OF ANTENNA ATTACHES UNDER FUSELAGE MOUNT BASE INSIDE ANTENNA BASE FITS IN CORNER OF FUSELAGE
13. 6 46280001 _ SERIES II STUB AXLE SPACER 8 _10 Ansim _____ 3 16 BOLT 5 5 16 BOLT Nt snegotr 2 16 FLAT WASHER 172 THICKNESS i 3 60516 WASMER MALE WASHER __ _ ue Penny wanen usos wwe wo Nur O f 738 E 2 WASHER 520365 524 NUT DIMENSIONS THES DRAWING EE COPYRIGHT AND MUST n MILLIMETRES 5 AVTECH CORED WITHOUT THE CONSENT OF AVTECH LTD FRE RO SETS T A C N 010 768 973 ye a ee ee os TITLE ONE DEC 2 TOW DEC 0 08 ANGLES 0U r 05 HINKLER AIRPORT 3 t TO PART BRAKE amp WHEEL ASSY 500 X 6 TYRE 610201 __ REFER PART DRAWINGS ABERG Figure 43 Main Wheel to Leg Assy 1 82100231 CAST INNER WHEEL 167 520365428 NYLOXC NUT ie ____ ___ 316 FLAT WASHER 9 5 Jane N YLOC NUT ASSEMBLE TYRES ONTO DEAD WITH TYRE BEAD SEALANT D uer eT SSP THT THE CONSENT OF AyTECH iTO a 91 0 0 errorem um Figure 44 Main Wheel Assembly DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 88 of 223 Jabiru Aircraft tc DIRECTION OF BRAKE DISC LEGS ORIENTA
14. Fi ma TUE T PVC TUBE TO INSTRUMENTS STATIC ASSY 1048094 Figure 119 Static Probe System Assembly 12 5 2 Pitot Static Water Traps e A water trap is incorporated into both the pitot and the static systems for Jabiru Aircraft This may take the form of the trap assembly shown below or of a low point where the tube is deliberately positioned in a U shape with a connector at the lowest point in the U Water collects at this point and can be drained by disassembling the fitting or by undoing the connection e The water trap for the static system is located inside the ventral fin the faring under the tail which covers the trim mechanism e The water trap for the pitot system is located inside the fairing at the lower end of the wing strut e Both traps should be inspected and if necessary drained during scheduled maintenance In addition if the aircraft is parked flown or otherwise exposed to rain or moisture the water traps should be checked and if necessary drained DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 186 of 223 Jabiru Aircraft tc Parts List ITEM PART NUMBER DESCRIPTION 1 001 _ HOSE PVC 1 4 ID 1858114 RING TUBING MAY BE SECURED TC T USING CABLE TIES OR SAFETY WIRE FULLY TIGHTEN CAP WITH SPANNERS HAND TIGHT IS NOT ENOUGH DIMENSIONS j THIS DRAWING IS COPYRIGHT AND MUST NOT IN MILLIMETRES DO SC
15. VHF 2 ALT j CHT 1 1 lo AY Fi m 7 _ gt 0000000077 Et een r 0 O 88D Z Zo OO Instrument Panel Layout 2 Figure 114 DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 181 of 223 Jabiru Aircraft tc pt E rg 4 gt Q COMO N N e GARMIN AERA 500 GPS 5 Y DYNON SKYVIEW SV D1000 N 2b X P o va O oe ES P4 N N ETC Ex PONDI R J XN A A A ag p Ae 7 _ y 36 sO lt gt 4 i OF Figure 115 Instrument Panel Layout 3 Fi ES nears d x 72 N bd i T enon 5 i gt 1 VOPT NA L3 om edie 0 0 0 ovo 03007 WITCH E
16. 5 Engine cowlings clips Check fasteners inspect cowl for cracks fraying rubbing etc 100 hourly 100 hourly 100 hourly 100 hourly 100 hourly 100 hourly 100 hourly Comments 20 1 3 Fuel System refer to section 6 10 Fuel filters drain valves carburettor bowl Check values for leakage check and replace at required intervals remove and inspect carburettor bowl for contaminants Comments Electronic boost pump Check correct function and sufficient flow rate PP Comments 100 hourly fuel filters 100 hourly 100 hourly Fuel lines and connectors Check for signs of deterioration obstruction foreign matter etc Comments Fire sleeves Check condition and length of fire sleeves Comments Fuel line sheath inside cabin Check sheaths are secure check for rips tear leakage et Comments Fuel tank caps amp placards Check caps function properly and placards are in place RIF Comments Fuel tank vent ball valve Check correct function Comments 100 hourly 100 hourly C 100 hourly 100 hourly 100 hourly Fuel tanks Inspect for signs of leakage or damage on tanks and wing root fittings and lines RIF Comments Fuel shut off valve amp placards Check correct function and ensure placards are in place Comments 20 1 4 Landing Gear refer to section 6 11 shockwave ind
17. 141 Figure 83 Rudder Pedal 142 Figure 84 Adjustable Rudder Pedal Assy 2 143 Figure 85 Steering Rudder Centering Assy Type 1 144 Figure 86 Steering Rudder Assy Sheet 2 145 Figure 87 Steering Rudder Centering Assy Type Includes Soft 145 Figure 88 Typical Rudder Installation Alloy 147 Figure 89 Typical Rudder Installation Steel 148 Figure 90 Typical Upper Cowl ASSY ccccccccccecccccceecseeeseeeeeeeeeeeeeeeseeeeeeeesaeeeeeeeeeeseseaeeeeseeeeeeessaaaaeeeeeeeeesaaas 152 Figure 91 Typical Lower Cowl 99 152 Figure 92 Fuel Hose Assy Engine 155 Figure 93 Air Duct Hard Point nennen 156 DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 7 of 223 Jabiru Aircraft tc Aircraft Service Manual Figure 94 Throttle Assy Large Panel 159 Figure 95 Control Cable End Fitting Installation 160 Figure 96 Carburettor Heat 161 97 SOL 162 fthe exhaust manifolds extractors have been loosened or removed then during insta
18. 2 021 PLAIN GAL WASHER ID 5 OD 12 5 YES YES YES PROPERLY IF TAP TURNS FURTHER IT 7 PON BS010V O RING YES YES YES 8 PG4A024N BS013V RING 9 _ 4 120800 ____ SINGLE LINE FUEL TAP BODY 1 ves ves ves 10 4920223 HOSETAIL SIGHT GLASS eee YES YES 11 420 FUEL SHEATH SPIGOT 12 4 120000 SINGLE LINE FUEL TAP LARGE LEVER No ves NO __ _ SECURE WITH LOCTITE 243 sy 27 asd PAINT HANDLES RED BEFORE INSTALLATION EN E Pd 4 041005 21 8 05 28 THIS DRAWING IS COPYRIGHT AND MUST NOT SCALE 1 1009704 AVTECH COPIED WITHOUT THE CONSENT OF AVTECH PTY LTD 1 1 15 05 010786973 nme DWG No rc AIRPORT SINGLE LINE FUEL ASSY 4A120A0D 4 IN PART DRAWINGS m ERA sucer oe 1 1841 Figure 111 Single Line Fuel Tap DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 176 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 11 6 Fuel Gauges Type of Maintenance Level of Certification LSA repairman inspection or maintenance 11 6 1 Description e Fuel gauges may be sight gauges or electrical float gauges in the wing roots for aircraft with wing tanks or a direct reading scale fitted to the front of the fuselage fuel tank 11 6 2 Fuel Gauge Remo
19. 318 FLAT WASHER AOD END GAUGE HOLE DETAI 4 FLAT WASHER BOLT 318 NYLOC NUT RIVET 3 18 0 18 0 45 GRIF SECTION _ I ilii PBAETEIESR NOT SCALE AVTECH P m zn REA TY WHOLE 15 Lal D 016 373 TIT ID 3 Tu E DUAL LEVER ASSY 160 0 3 SHEET 1 MATERIA T LE m APRES E ur ak EG EXE ABT LLL em um 2225 THO a ANGL I2I l 1 SHEET 1 Figure 80 Elevator Trim Handle Assy Type 3 8 9 Elevator Trim Aft Assembly Type of Maintenance Level of Certification LSA repairman Inspector or Maintenance 8 9 1 Description e 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 e This assembly allows a spring loaded connection between the elevator trim lever and the elevator This spring loading force is used to trim the aircraft 8 9 2 Ope
20. 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 10 9 2 Removal Inspection amp Installation y remove hot air mixed box the cable must be disconnected then the rivets holding it to the firewall drilled This is not required during routine maintenance remove heat muff from the exhaust undo the hose clamps holding it in position e The air filter should be inspected every 100 hours or more regularly if the engine is operated in dusty conditions Dirty filters can be cleaned once by blowing out with compressed air when the filter becomes dirty again it must be replaced e Hot air mixer boxes must be inspected for conditions and to make sure they are clean and dry inside Ensure that the carby heat valve is operating correctly e SCAT hoses must be inspected for condition and replaced if they are ripped etc e Visually inspect the system looking for rubbing wear damage or corrosion DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 160 of 223 Jabiru Aircraft Aircraft Service Manual Jabiru J230 D Serial 868 e For installation reverse the procedure given above WARNING Incorrect function of carburettor heat valve can lead to engine failure Ensure flap of valve is securely attached to shaft moves with it correctly and seals when in posit
21. DESCRIPTION QT 1 merge amp 2 20046942 ELEVATOR HINGE LEAF amp 4 RO y S27 CSUNK POP RIVET 5 2 1 ELEVATOR ASS 40001200 SUITS ONE PIECE STAB ieee E S ee 1 B8 20019942 RETAINER HINGE 10 Lu mma ___ 2 068 HORIZONTAL STABILISER ASSY MOO FAMILY ONE 1 COMMERCIAL INON JABIRU PART NUMBER VIEW B TAB DETAIL HINGE DETAIL DETAIL VIEW D SCALE 1 4 SCALE 1 1 SCALE 1 2 m sm DIMENSIONS THES x PROJECTION EE ETT IU a ee IIS OM AIRPORT HORIZONTAL TAILPLANE ASSEMBLY Figure 78 Wide Span Models Horizontal Tail amp Elevator Assembly Type 2 DOCUMENT No JTM001 0 230 D 868 08 May 2014 134 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 8 6 Elevator Control Cables Type of Maintenance Level of Certification LSA repairman Inspector or Maintenance 8 6 1 Description e 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 8 6 2 Control Cable Removal Y Y v Unbolt the connections rod end bearings at either ends of the cabl
22. Machined Nose Leg 102 Figure 53 Brake Master Cylinder amp Lever Assy 2 104 Figure 54 Single Calliper Detail Mk 108 Figure 55 System Schematic Type 109 Figure 56 Control Column Assy Type 3 nnne nnne nnnnnan nnne nnns nnns aa narrans 111 Figure 57 Clamp Comparison Primary Cable Clamp Upper on Right Picture 113 Figure 58 Clamp Comparison amp Installation Rudder 114 Figure 59 Clamp Installations Elevator amp 114 Figure 60 Trim Cable Clamp 115 Figure 61 Gable amp Clamp COMP ANSON indus coisa tne tiicaianseteininsesinaiuiacesinaneutsinadumeatnwianeidcathasisaianetienlepaarniawecicetes 115 Figure 62 Correct and Incorrect Clamp 115 Figure 63 Aileron Stops Type 118 Figure 64 Linear Actuator 121 Figure 65 Commutator Ring 1 nennen nennen sss 122 Figure 66 Flap Controls Sheet 1 Fibreglass Motor 123 Figure 67 Flap Controls Sheet 1 Aluminium Motor
23. UP TIONAL FLOAT SWITCH PWJADOOH FINGER FILTER P Ms 4827004 4 CORRECT FUEL UNE ROUTE 4 OR INVERTED 1 5 ELECTRIC FUEL PUMP A PMDOZOUN FUEL QUICK DRAIN VALVE INCORRECT FUEL LME R UTE A amp INVERTED U FORU gt POTENTIAL AIR LOCKS NOTE SYSTEM SHOWS USES TAPS TO JOIN THE FUEL LIMES FROM THE TANKS IN SOME E TEL NU THESE TAPS ARE REPLACED BY THE UMTS 10 amn os AVTECH P U FUEL SYSTEM SCHEMATIC 4A124B00 2 IN LINE GASCOLATORS SHOWN IN DETAL MATERIAL VARIOUS ber WET WINGS HEADER TANK SHARKS FIN Figure 103 Fuel System Schematic Type 4 11 1 2 Fuel System Trouble Shooting Table 8 Trouble Shooting Fuel System Fuel shut off valve not turned ON Turn valve ON Fuel tank empty Service with proper grade and amount of fuel Fuel line disconnected or broken Connect or repair fuel lines No fuel to carburettor Fuel tank outlet strainer plugged d flush out fuel tank Defective fuel shut off valve Replace shut off valve Plugged fuel filter Replace filter Clean out or replace fuel line Fuel Use the preceding remedies DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 169 of 223 Jabiru Aircraft Aircraft Service Manual Jabiru J230 D Serial 868 Drain fuel tank sump
24. i e they must extend past the hose clamp to the very tip of the hose e Where equipped check that the fuel line sheaths inside cabin are in place and secure at their attachments Check for any tears rips or signs of fuel leakage pooling e Check the function of fuel tank caps Check that the required placards are in place and in good condition e Where equipped verify the function of the ball valve in the fuel tank vent cap air should flow out easily at slow flow rates but be blocked at high flow rates Air should be able to flow into the tank easily at all times e Visually inspect the fuel tanks in situ to check for staining and other signs of leakage or damage Check the condition of the lines and fittings inside the wing root to determine if there is any leakage e Check the function of the fuel shut off valve Ensure that all placards are in place and in good condition DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 40 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 611 Landing Gear 100 Hourly Annual all possible circumstances cannot be listed here the following is provided as guidance only A critical trained eye is required and inspections should include but not be limited to the following e Visually inspect the attitude of the aircraft on the ground if the aircraft has developed a lean to one side since its last maintenance it is a likely indicator of insuffici
25. systems with the tanks inside the wings The fillers for the tanks are located on the upper surface of the wings tank is vented a fitting built into the fuel caps Though in some cases a separate sharks fin vent fitted to the cabin roof may be used instead The primary mechanical fuel pump is fitted to the engine The secondary electric fuel pump and the fuel filter are fitted adjacent to the header tank This may be under the baggage shelf behind the seats J160 family or behind the sound curtain at the rear of the cabin J230 family Kit built models may have both pump and filter mounted inside a fiberglass housing fitted between the centre console and the firewall inside the cabin main fuel tanks are structural and are integral parts of the wings A header tank is fitted The tank may be located under the baggage shelf behind the crew seats J160 family behind the sound curtain at the rear of the cabin J230 family under the front passenger seat or behind the crew seats All aircraft are equipped with a drain sump in each tank Some aircraft may also be equipped with gascolators inside the cabin pillar For most aircraft a single ON OFF selector is fitted to the centre console between the seats Kit built models may be equipped with taps on each wing tank instead Some models are equipped with fuel line sheathing and shaped external air vents to prevent leaked fuel from entering the c
26. IN MILLIMETRES 025 TOW DEC 0 05 ANGLES 05 DRAWN HINKLER AIRPORT van ____ THICK CLEAR ACRYLIC SHEET BUNDABERG 4670 WING INSPECTION PANEL ASSY ERIALITO PSJED 07 MACHINED Figure 41 Wing Inspection Panel DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 81 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 7 2 8 Vertical Fin The Fin is a moulded composite structure supported by ribs and a rear spar Hinges attach the rear spar to the rudder 7 2 8 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 7 2 9 Horizontal Stabiliser e he horizontal stabiliser is a moulded stressed skin structure of rigid cellular polystyrene bonded to a fibreglass skin and rear spar 7 2 9 1 REMOVAL AND INSTALLATION e The horizontal stabiliser is an integral part of the fuselage to which it is bonded It cannot be removed repairs must be referred to Jabiru Aircraft Pty Ltd or our approved local representative DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 82 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 7 3 Landing Gear amp Brakes 7 3 1 General Description e Main gear comprises two separate composite beams which are bolted to the fuselage at the top
27. Use rubber expansion plugs to seal openings Using a manometer or gauge apply approximately 1 1 2 psi 3 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 is recommended that any exhaust system component found to be defective is replaced with a new part before the next flight 10 10 4 Exhaust Installation Y Y x47 For installation reverse the removal procedure given above If the exhaust manifolds extractors have been loosened or removed then during installation care must be taken to position the muffler correctly Carry out a test fit of the muffler to the system then stand back and check that it is positioned at the engine centreline and is true and straight If necessary adjust the manifold or extractors Before final fit ensure that extractors manifolds are aligned well with the exhaust ports Poor alignment will result in exhaust port damage particularly for 2 bolt flanges Tighten all extractor screws amp assemble Figure 98 3300 Exhaust System Type 1 DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 163 of 223 Jabiru Aircraft tc PARTNo DESCRIPTION 1 4 192 00 EXTRACTOR EXHAUST PIPE SET EXHAUST ASSY 3300 TRACTOR 4A293A0D 1
28. 11 5 1 Description e The fuel shut off valve is a two position ON OFF valve This valve is normally located in front of the main longitudinal beam between the crew seats 11 5 2 Fuel Valve Removal amp Installation Where equipped turn OFF both taps between wing tanks and header tank Cover both tank cap vents Alternately removable fuel line clamps may be used Remove fuel shut off valve cover where equipped Remove shut off valve handle Remove cover plate where equipped For some variants access to the valve requires the removal of the section of fuel line containing the tap To achieve this loosen the hose clamps disconnect the hose and draw it carefully out of the centre console Where equipped disconnect the fuel line sheath from the shut off valve Disconnect shut off valve from fuel line Remove shut off valve Reverse the preceding steps for installation WARNING Ensure wing tank vent covers and fuel line clamps are removed NUMBER DESCRIPTION 4 120 0 _ SPOOL FUEL TAP J SERIES ws ves mu PH4A020N ROLL PIN DIA 2 x 12 LONG 2 YES YES YES 1 ORIENTATION OF LEVER IN ASSY WHEN 145059 _ FUELTAP LEVER J SERIES 1 ves no ves CORRECTLY ASSEMBLED ARROWON 4 019 CIRCLIP EXT DIA 14 1 YES YES YES ARROW TAP BODY TAP WILL ONLY MS35206 2445 SCREW 1 YES YES YES THRUNTHRU 90 DEG WHEN ASSEMBLED 7 6
29. 7 3 13 1 DESCRIPTION e For all models the nose wheel steering system consists pushrods directly connecting the rudder pedals to the nose leg assembly The systems are shown in Section 9 For some models a soft link is fitted between the nose leg and the rudder pedals to absorb vibrations Details of this assembly are shown below Error Reference source not found and Figure 48 e For all models the nose wheel Centering system consists of springs which are stretched when the nose leg is moved to the left or the right The systems are shown in Section 9 DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 95 of 223 Jabiru Aircraft tc Repair of these systems 15 limited to the replacement of DESCRIPTION BADAGBOD 2 NOSE LEG RUBBER SOFT CONNECTION LEG EXTENSION 2 1 STEERING ARM SOFT CONNECTION LINK 6 045800 1 STEERING LINK MACHINED SOFT CONNECTION _ 5 6A045E0D 1 SLEEVE STEERING RUBBER CONNECTION B 164 045000 1 RUBBE R BUSH AN960 416 1 4 FLAT WASHER 520365 428 1 4 NYLOC NUT B 4 1 BOLT 10 ANS70 4 WASHER USE ROUND FILE TO REMOVE GREASE MATING SLIDING San wt LL es dci ON ASSEMBLY i OF LEG TUBE ON ASS frg j i USE FLAT FILE REMOVE BURRS FROM TOP OF TUBE ON ASSEMBLY PROJECTION SCALE TH
30. DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 93 of223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 7 3 11 3 NOSE WHEEL DISASSEMBLY e Completely deflate tyre by removing the valve stem and break tyre beads loose at wheel rim Refer to Figure 73 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 Remove through bolts and separate wheel halves Remove wheel hub Remove tyre and tube from wheel halves Remove bearings NOTE The bearings are press fit in the wheel hub and should not be removed unless a new part is to be installed 7 3 12 Nose Wheel Inspection and Repair Required Tools Solvent Course grit sand paper Parts and Material Type of Maintenance Level of Certification LSA repairman inspection or maintenance 1 Clean metal parts in solvent and dry thoroughly Inspect wheel halves for cracks Cracked wheel halves should be discarded and new parts used Sand out nicks gouges and corroded areas Clean thoroughly 3 Carefully inspect bearings for damage and discolouration NOTE Bearings are pre packed with grease DO NOT clean with solvents as it will remove the packing 4 Refit bearings 7 3 12 1 NOSE WHEEL REASSEMBLY Spanners Socket Wrench Torque Wrench Replacement bearings if requir
31. Figure 99 3300 Exhaust System Type 2 10 11 Cabin Heater System Type of Maintenance Level of Certification LSA repairman inspection or maintenance 10 11 1 Description cold air inlet is fitted to the front of the engine cowls From here the air flows through a heat exchanger installed on the exhaust tailpipe through a control valve and into the cabin WARNING A malfunctioning cabin heat system has potential to release harmful gases such as carbon monoxide into the cabin Aircraft equipped with a cabin heater must also be fitted with a current carbon monoxide detector tag at all times 10 11 2 Cabin Heat Removal For the control valve Disconnect spring from Lever arm Remove Split Pin from cable locking pin Remove locking pin disconnect control cable Loosen hose clamp screws Remove hose For the heat exchanger Loosen the hose clamps and disconnect the air hoses from the heat exchanger Loosen the cap screws holding the assembly to the tailpipe Remove the exchanger DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 164 of 223 Jabiru Aircraft tc 10 11 3 Cabin Heater Inspection Y Y Y Check for cracking or splitting of the cabin heat hose E Ensure there is free movement of the control cable Check for free movement of the butterfly valve Ensure the valve is closing fully in both the ON and OFF positions Ensure the locking pin components are all in working orde
32. e As a part of daily and maintenance inspections the aircraft is gripped by each wingtip and shaken to check for any free play in the wing or strut attachment points Section 6 12 The procedure below details how free play is corrected once detected e As detailed below there can be several different ways to correct free play in these connections is recommended that maintainers who have not carried out this task before contact Jabiru Aircraft or our local representative for advice before continuing e Free play can develop in any of the wing or strut attachments though it most commonly occurs in the front wing attachment To determine which connection requires attention Remove the wing root fairing from the aircraft to expose the attachments between the wing and the fuselage Have an assistant shake the wing tip While the wing is being shaken place a finger on each attachment in turn to feel which requires servicing A mechanic s stethoscope may also be used In rare cases both attachments may have free play f no movement is apparent in the wing attachments remove the fairings from the top and bottom of the wing strut and repeat the process have someone shake the wing while holding each attachment to feel for movement e The bolt fitted to a connection found to have free play must be replaced e lfawing fuselage attachment requires service the wing can be removed completely as detailed in Section 7 2 or placed on stands as follow
33. tc Aircraft Service Manual Jabiru J230 D Serial 868 8 1 3 1 CONTROL COLUMN REMOVAL Required Tools Spanners Socket wrench screwdrivers Parts and Material Replacement bushes if required Type of Maintenance Level of Certification LSA repairman inspection or maintenance 1 If required unbolt remove the control stick from the pivot plate Unbolt and remove the aileron cable ends from the aileron drive arms at the rear end of the control column 3 Unbolt amp remove the aileron drive yoke from the rear end of the control column 4 Draw the column forwards and out of the centre console note that it may be necessary to partially or fully remove the instrument panel to allow removal of the shaft 8 1 3 2 CONTROL COLUMN INSPECTION amp REPAIR e Before disassembly check the shaft installation for end float and radial wear in the bushings Excess wear must be corrected by replacing the bushings e Repair is limited to replacing worn parts 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 1 3 3 CONTROL COLUMN INSTALLATION e Installation is reverse of the procedure given above 20 CENCPALHIV mm REC En RER 5 ME 40 6 Ap F A IT FW
34. 11 MODELS USE FIREPROOF FITTING FOR ALL WIRE RUNS THROUGH FIREWALL 12 FIREWALL EARTHS CONNECT TO THE MAIN EARTH TAG BOLTED THE FIREWALL 13 UNLESS SHOWN OTHERWISE 1 WIRE GAUGE USED FOR EACH CIRCUIT AVTECH P U ELECTRICAL WIRING DIAGRAM 4 264 00 5 BUNDABERG 1160 CERTIFIED Figure 125 Wiring Diagram Sheet 2 GE DIMENSIONS IN MILIMETRES PROJECTION E j SEE INSET A 0 CIRCUIT DIAGRAM KEY LOW FUEL LIGHT WIRING DETAILS REFER 4426 4h00 FOR 1 CIRCUIT BREAKER 2 5 AMP CIRCUIT BREAKER 3 10 AMP CIRCUIT BREAKER 4 TOGGLE SWITCH SPST STANDARD PIO 16N FUEL PRESSURE SWITCH 5 TOGGLE SWITCH WIRED FOR i INST LIGHTS SEE INSET 6 TOGGLE SWITCH SPDT LANDING LIGHTS PI3AOZBADN TC PRL T VARIABLE HESISTOR SWITCHED OHM PISADOAN B VARIABLE RESISTOR 100 OHM 9 VARIABLE RESISTOR 5K OHM 10 LED WARNING LIGHT RED 11 LED WARNING LIGHT GREEN 12 BEZEL LIGHTS 13 MAP READING LIGHTS 14 INTERIOR LIGHT 10 15 LED INSTRUMENT STRIP FLOOD LIGHT 16 COMPASS LIGHT 17 RED BEACON 18 POSTION LIGHTS 19 LIGHT DRIVER 20 STROBE LIGHT 21 LANDING LIGHT Lm STANT LIHT SEE INSET FOS SWITCH GETAILS WIRE TYPE 16 GAUGE AIRCRAFT WIRE LANDS SWITCH TO INSTALLED SWITCHING LEFT RIGHT LE ROTATED 00 COM
35. 27 S 0 i 9 lt lt b Il AM HU E 7 v 0 r Nu 4 64 1 SECURE WITH NX OS mis LOCTITE 243 UA 8 5 2 5 lt _ 4 LAK 1 H NOTE ASSY P No 4A044A0D SHOWN 4A044CON OPPOSITE 2 1041006 ES SCALE PROJECTION ese DO NOT SCALE E 1 LIMITS UNLESS SPECIFIED OTHERWISE 0 5 prawn DS 010 786 973 DWG No inii HINKLER AIRPORT MATERIAL REFER TO PART DRAWINGS APPR BUNDABERG 4670 SIGHT GLASS ASSY SP WET WING Figure 112 Fuel Gauge Sight Glass DOCUMENT No JTM001 0 230 D 868 08 May 2014 177 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 11 7 Fuel Filters Type of Maintenance Level of Certification LSA repairman inspection or maintenance 11 7 1 Description e The fuel filter is of the in line type It is located Beside the header tank inside the fuselage aft of the sound curtain for J230 family aircraft 11 7 2 Fuel Filter Removal amp Installation 1 Shut off the fuel on the tank side of the filter This may require the fuel tap be turned off or that the fuel system wing tanks and header tanks be drained where equipped Alternatively fuel line clamps Figure 25 may be used to close the fuel lines so that the filter can be changed w
36. Checking the more common wear modes detailed below is recommended before replacing fuselage lugs Either remove the wing from the aircraft completely or place on stands as detailed above Remove any upholstery covering the plates inside the cabin Remove the bolts holding the lugs to the fuselage Remove the lugs from the fuselage These parts are bonded to the airframe with a bed of Flock cotton fibre flock mixed with Epoxy resin as well as bolts Once the bolts have been removed use a soft hammer or similar to break the lugs from their flock bed Use a remove some of the old flock bed Do not remove that portion of the bed where the bolts pass through this will be used to locate the replacement lugs See a cross section of the lug assembly shown in Figure 29 Leave a portion of the bed approximately 12mm in diameter around each bolt hole to support the new lugs Dry fit the replacement lugs to check for correct fit When ordering replacement parts note Figure 28 2 different model lugs have been used on Jabiru Aircraft the correct length must be fitted or dihedral angle errors will occur For J250 J450 models the hole in the tip of the lug must be reamed to suit an AN5 or AN175 bolt before installation CAUTION Reaming is necessary to achieve proper tolerances Do not drill 109 REF L 2x45 CHAMFER TO IDENTIFY PART P No 1005494 Figure 28 Wing Lug Versions D
37. IN THIS AREA s ee Le mee 290306 are MN ows eve em Figure 33 J230 D Rear Door Assy DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 72 of 223 MOULD DEFINES PART SHAPE DIMENSIONS ARE REF ONLY T APPLY PEEL PLY TO BONDED SURFACES L1157023 5 1 57 0235 5 J REAR DOOR ASSY J200 400 Jabiru Aircraft Aircraft Service Manual PARTNUMBER DESCHIPTION TAM E0D RODRSDOORCATCH 702724 DOORLEVERQUTER 1 MAMICA GN COUNTERSUNK SCREW 2 COTTER PIM 3130014 WASHER SPRING RETANERTRIM CONTROL 2 7027414 GUIDE BLOCK DOOR CATCH 2 SERIES L AN308A WMrBOLT 13 16 FLAT WASHER V2 THICKNESS 3 NUT INTERIOR DOOR LATCH LEVER J160 i 8 741000 _ i AHBOO 4 TEL trd PLAT WASHER 1 GUDE BLOCK DOCA LATCH 80 TADO VON BUSH Lo TA ANJGO WASHER 3 PRTA DOOR SPRUNG J180 THIS DRAGS 15 AMD HIEST NOT GE COPED WITHOUT THE CONSENT OF AYTECH PTY LTD YAR 168 1 010786373 UML ETS RPE
38. Operator Responsibilities To maintain compliance with ASTM Standard F2295 which establishes the parameters for continued operational safety and is an underlying requirement for a LSA Airworthiness Certificate the owner or operator of this aircraft must follow six rules that are specified in Section 5 4 of F2295 Failure to comply with these responsibilities could result in an aircraft that may be out of compliance with the ASTM standards and could lead to revocation of the aircraft airworthiness certificate 1 Each owner operator of this aircraft shall read and comply with the maintenance and continued airworthiness information and instructions provided by the manufacturer 2 Each owner operator of this aircraft shall be responsible for providing the manufacturer with current contact information where the manufacturer may send the owner operator supplemental notification bulletins 3 The owner operator of this aircraft shall be responsible for notifying the manufacturer of any safety of flight issue or significant service difficulty upon discovery 4 The owner operator of this aircraft shall be responsible for complying with all manufacturer notices of corrective action and for complying with all applicable aviation authority regulations in regard to maintaining the airworthiness of this aircraft 9 The owner operator of this aircraft shall ensure that any needed corrective action be completed as specified in a notice or by the nex
39. REMOVE THE COWL AND BOND WITH EPOXY RESIN AND FLOCK LAYERS 123600 EPOXY RESIN WITH 15 ANTIMONY TELE WIEGHT ALIGHIMG LUGS SCREW 4 LOCATION WITH WASHER 5 AVTECH P HIKLER ARFOR BUNDABERG Figure 91 Typical Lower Cowl Assy DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 152 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 10 2 Engine 10 2 1 Description e The engines used in Jabiru Aircraft are horizontally opposed 4 stroke air cooled designs driving a fixed pitch wooden propeller 80hp 4 cylinder 2200 versions are used in the J120 J160 and 9170 model families while the 120hp 6 cylinder 3300 engine is used in the J200 J230 and J250 model families In some kit built variants the 3300 engine may also be used in the smaller aircraft e The front Starboard cylinder is numbered 1 the front Port is numbered 2 with this numbering convention continuing for the remaining cylinders e Refer to Engine Maintenance Manual for detailed engine data e For repair amp overhaul of the engine refer to the Overhaul Manual issued by Jabiru Aircraft Pty Ltd 10 2 2 Engine Data e Refer Engine Maintenance Manual 10 2 3 Engine Removal amp Installation e Refer Engine Maintenance Manual 10 2 4 Engine Trouble Shooting e Refer Engine Maintenance Manual 10 2 5 Engine Cleaning e Refer to Section 5 1 amp the Engine Ma
40. REMOVING PEEL PLY BEFORE CL LEM DA GLAS 4 FLOR MOUNTS AH B MAD AG SHA 5 THER POS OF THE Se eT aan VERTICALLY AMI ASS COE HD T ARS UP APS UT CS TALL FOR CORRECT FLAP POSITION INSTALLATION VIEW THESE ARE OFEN ASU STMERT ELUL ORDER GSTs CT F AVTECH PA IRANTAJ P OFTHE ACH 000 973 TEE COPGENT OF yi pane DOCUMENT No JTM001 0 230 D 868 08 May 2014 124 of 223 Figure 69 Flap Controls Sheet 3 Fibreglass Motor Mount Jabiru Aircraft Aircraft Service Manual QA 710 4 eee n N FRAME OLAT TO DODR HTH FLOCK BEFORE BOL 2 TTS RED 3 WET BE Bante i PEE BEFORE Le DR Petr 4 FLOTE MOUNTS WiTH BEAD 5 THEN GLASS OVER PATH 7 LAYERS DF 0 CUT TO vane INCNIDUAL FLAP PUBHROO ARE ADJUETED ADJU FLAP POSTION AFTER TESE Grice ARE DPEN TE
41. 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 4 2 Cooling Air Baffle Removal are removed by unbolting from engine and removing tension springs and their attaching wires In most cases the spark plug leads must also be removed with the duct 10 4 3 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 In particular ensure that the hard points where the ducts are bolted to the engine are in good condition DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 155 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 10 4 4 Repair Rubber seals may be replaced by removing the existing rubber parts rubbing back the bonding face of the fibreglass baffles to bare glass using 80 grit sandpaper similar bonding new rubber strips in place with 5 Minute Araldite Damaged mounting hard points for the air ducts are best repaired by the installation of reinforcing tags as shown in Figure 93 10 4 5 Cooling Air Baffle Installation Reverse the preceding steps for installation WARNING An improperly secured air duct may result in poor cooling high engine temperatures and engine damage In addition cases h
42. e Inspect the seat structure Check for cracks or damage Remove the seat covers and pull fore and aft on the top of the seat back watching for signs of de lamination or other damage to the seat back Inspect instruments amp markings for security and indications of damage Inspect instrument plumbing amp wiring for damage kinks and security Inspect the instrument panel shock mounts decals amp labels Inspect the fresh air vents for correct function and condition Inspect the cabin heat system for correct function and condition Ensure the carbon monoxide indicator if equipped has not expired Inspect the cabin upholstery and trim for condition Inspect switches and fuses for condition security and function Check the pitot amp static system for condition leaks and blockages Check the radio intercom amp headsets for condition and correct function Check the transponder if equipped antenna amp cable for condition and function Check door catches for condition and function Check the stall warning system for function Wing struts should be inspected for loose bolts excessive clearance in wing strut attachments or corrosion e equipped ensure that the emergency beacon is within its useful life and test in accordance with manufacturer s instructions DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 42 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 6 13 Control
43. inspection or maintenance e 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 e Check UP travel on both ailerons using the Aileron Rigging Template see Appendix 3 e Use the Aileron Control Stop adjustment on the central control shaft to adjust the total aileron movement i e UP travel and use cable adjustment as previously described to proportion UP and DOWN travel Note that while it is possible to adjust the Type 3 aileron stops using the eccentrics using the limit screws shown in Figure 56 is easier DO NOT move the Cable Anchors these positions have been set using a jig 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 PART NUMBER DESCRIPTION 3A087COD 1 AILERON STOP ECCENTRIC PH4A003N 3 16 BELLEVILLE WASHER 3A087B0D 1 SKF BEARING MOUNT AIL STOP PLATE PB3A003N 1 BUSH 28 OD 25 ID 12 LONG 35 OD FLANGE SKF PCMF252811 58 3 16 x 3 4 UNC CAP SCREW ASSEMBLE HOUSING INTO CONTROL COLUMN ASSEMB
44. parts provide as must detail as possible part description aircraft model serial number etc to Jabiru to ensure accurate part identification 12 2 Instrument Panel Type of Maintenance Level of Certification 12 2 1 Description e The instrument panel consists of a fascia panel which attaches to the panel mount and contains all the instruments The fascia may be made from aluminium or composite materials 12 2 2 Instrument Panel Removal amp Installation remove the fascia Remove the screws holding the fascia to the fibreglass panel mount Carefully draw the fascia aft Normally there is sufficient slack in the electrical loom and instrument lines for the fascia to move aft by around 100mm Cushions or similar must be used to support the fascia talking care not to scratch the face or damage any instruments This position is usually the best to carry out any necessary maintenance adjustment or repairs to instruments etc Disconnect the panel Ensure that all wires and lines etc are clearly marked to aid re assembly Note that air lines tend to be a tight fit and a heat gun or similar may be necessary to soften the lines to allow removal Remove the fascia Assembly is the reverse of the above procedure WARNING When removing fascia it is common for some wires connecting to switches on the bottom of the panel to be dislodged Ensure all wires are securely re connected before fitting fascia Take care not
45. 104 Schematic 11 2 4 Installation 77 e Care must be taken when re routing lines to avoid bending hose around too sharp corner the flexible hose used can crimp itself off if bent too sharply If a sharp bend is unavoidable a DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 170 of 223 Jabiru Aircraft 44 4 Aircraft Service Manual Jabiru J230 D Serial 868 spring may be threaded over the line to prevent it crimping Springs must be a snug fit on the hose amp are available from Jabiru Aircraft if required Figure 105 refers Note that in some cases it may be necessary to shorten or lengthen lines to prevent 4 5 or tight bends e For installation reverse removal procedure given above Line crimped bend too tight 4 Fuel line clips opring preventing line from crimping on a tight bend Figure 105 Sample Fuel Line Details exit the header tank and pass through the side of the baggage shelf Figure 106 Fuel Lines Showing Typical 0 Requiring Correction DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 171 of 223 Jabiru Aircraft tc _ Hole in baggage shelf 8 Outlet from tank wall raised zip tie used enclosure raised to hold line bundle up slightly Figure 107 Corrected Fuel Lines 11 3 Fuel Tanks Type of Maintenance Line Maintenance Level of Certification LSA repairman inspection or maintenance 11 3 1 Descr
46. 2 A3 DESCRIBED Figure 71 J200 Family Electric Flap System Sheet 1 DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 125 of 223 Jabiru Aircraft tc _ nn HUMBER _ 2 PBo009N D 800 END E USH ROD FLAP DAIVE ADJUST ROD OUT RARE FLAPS 97 APPR T POR FLAP BRACKET bi ONE IFR EAR 5 REQUIRE FLAP DRIVE LAYOUT OUTSIDE FLAP PUSHROD ASSEMBLY DIMENSIONS PHHEC TUH OMT SCALE JECTION IN MILLIMETRES DO NOT SCAL Lm E I ECFE m mara 0 5 AoC ELECTRIC FLAP DRIVE ASSY J SERIES 028 00 2 Figure 72 J200 Family Electric Flap System Sheet 2 8 2 3 FLAP Cross SHAFT ASSEMBLY Type of Maintenance Level of Certification LSA repairman inspection or maintenance 8 2 3 1 DESCRIPTION As shown above the flaps are driven via a shaft which runs from one side of the fuselage to the other e In turn this shaft is an assembly of 2 different sized steel tubes with input and output arms attached 8 2 3 2 FLAP CROSS SHAFT REMOVAL Y Y x Remove one wing to allow removal of shaft Refer to Section 7 2 for details on wing removal procedure 2 Either use heavy duty tape to hold the remaining flap in the up position or remove the flap from the aircraft 3 Disconnect the flap drive motor or manual l
47. 53 Figure 19 Alignment 53 Figure 20 Camber Toe In 54 Figure 21 Max Empty Left and Acceptable Empty Right 5 56 Figure 22 Fuel Gauge Calibration Decal 56 Figure 23 20L Indication on Sender amp Decal to 56 Figure 24 EMS Fuel Calibration Screens 58 Figure 25 Fuel Line P H 59 Figure 26 EMS Calibration Screen 1 60 Figure 27 EMS Calibration Screens 2 and 3 61 Figure 28 Wing Lug 64 Figure 29 Detalls 65 Foure 30 SNOCKW AlCl INGIGAIOM 69 Figure 31 7280 0 Door Hinge ASSY 71 Figure 32 J230 D Door Assembly o n E AYER daa rear add 72 Figure 32 0 Door _______ 72 Figure 34 4230 09 Door Latch Mechanism 73 Figure 65 Door 73 Figure 36 J230 D Wing Assembly Sheet 1 Ser 13 7
48. 6 Coat the battery terminals with petroleum jelly or an ignition spray product to reduce corrosion 13 3 4 Battery Trouble Shooting e Trouble shooting is limited to inspection of wiring and terminals battery charge condition and battery solenoid 13 4 ELECTRICAL LOAD ANALYSIS Ela 13 4 1 Factory Built Variants An ELA has been carried out as part of the aircraft s certification basis Any changes to the electrical system which affect the ELA require a new ELA to be raised This work may only be carried out by Approved Personnel in conjunction with a CAR 35 Authorised Person or equivalent Engineering Order Note that this applies in Australia in other countries the local Airworthiness Authority must be consulted for procedures 13 4 2 Non Factory Built Variants e 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 e For other operations the builder operator must ensure that the electrical system is adequate and meets all regulatory requirements for the type of operation undertaken 13 5 Radio Installation 13 5 1 Description e Jabiru Aircraft are equipped as standard with a VHF radio
49. 8 5 1 Description 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 to Section 8 8 DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 132 of 223 Jabiru Aircraft tc 1 Remove ventral fin from under tail to expose control cables etc 2 Unbolt cable from control horn 3 Unbolt trim linkage from control horn 4 Loosen screws in hinge pin retainers and lift hinge pin retainers from hinge pins It is not necessary to remove these parts Remove hinge pins Remove Elevator Reverse the preceding steps for installation 94 8 5 3 Elevator Balancing e The J230 D Elevator is balanced during construction A standard weight of 750 grams of lead is placed in each control horn to balance the elevator In service there should be no reason to rebalance the elevator 8 5 4 Inspection And Repair e Inspect elevator for any signs of delamination or cracking Pay particular attention to the Control Horn and hinges and their surrounding areas e Inspect the front underside of the elevator for any signs of rubbing against the horizontal stabiliser at full down deflection when the elevator hinge is pressed down using thumb pressure there should be clearance between the elevator and the stabiliser Also refer to Section 6 17 e Repairs must be referred to Jabiru Aircraft Pty Ltd or our ap
50. ADS TET iN DADER OR AN CORRECT KLAR a LOST V TIL PROUJECTION ec SE TRES NOT SCALE _ DOMED COMMENT OF TE eT eS ou Laer arom ELECTRIC FLAP DRIVE ASSY J160 222 Figure 70 Flap Controls Sheet 3 Aluminium Motor Mount EE E BEARING BLOCK FLAP DAME ANSE ans FLAT WASHER a wewmee PUSHRODOSFIAPDAWE Li pes Hi ELECTRIC FLAP SERVO MOUNT 1 Mau B iSUPERJACK IMD 3 SERIES Smm STROKE es EL AN3 13A 3 ane MALE ROO 3239114 4 FLAP CONTROL TUBE S ASSY 1200400 1 SEAS SPACER AOD END BOLT 1 PRON PO FLAP DRIVE PUSH TO SUIT HOD END 7 ee SCRE RETANRUT EA C SUMK POP RNET H M INTERNAL FLAP DRIVE FLAP TRAVEL SHOULD BE CHECKED ONCE ASSEMBLED EE FOR J230 AMD 400 MODELS FULL FLAP DEFLECTION E PHROJECTIC DW NG OOP GH AND MUST WOT CTION ec MILLIMETRES DO NOT SCALE COPED WITHOUT THE CONSENT OF AvTECH PTY LTD Ex SPEER ICG CHECK THAT ALL AOD END THREADS ARE SAFETY pom nent M N ern 3A028A0D
51. AND BOND TO FUSE WITH 1 8 RIVETS AND 5 MINUTE ARALDITE OR SILICON ADHESIVE ANTENNA LOCATED BETWEEN HEEL WELLS ON FUSE CENTRE LINE ene te TF 2 250211 120106 s DATE 540441003 MAGSPONDER EREUBER INS eodd Lol Figure 131 Transponder Antenna Installation DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 205 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 15 Painting amp Finishing 15 1 Exterior Type of Maintenance Level of Certification Task Specific Training 15 1 1 Painting The following painting procedure as used at the Jabiru factory had proven successful in ensuring good presentation of the aircraft 2 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 e Use a bare minimum of undercoat preferably white or cream and topcoat to keep weight down e f you have had no previous painting experience a short course may be available from TAFE NOTE It is very easy to dramatically increase the weight 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 typi
52. Aircraft tc Aircraft Service Manual Parts List En cA 1 1 3051094 6 PUSH ROD O S FLAP DRIVE 960 10 Dn FLAT WASHER j 2 Eu MS20365 1032 3 16 NYLOC NUT 4 0 0 0 0 1 EX AN960 416 1 4 FLAT WASHER AN316 3 3 16 NUT 2 Sh ANFIA ___ 5 __ LAN 5 a ih lis y 7 1 2 EXTERNAL DRIVE ROO ASSEMBLY DIMENSIONS PROJECTION 46 PROJECTION E ww inermes LIMITS UNLESS SPECIFIED OTHERWISE 0 5 AVTECH 010 786 973 oman HINKLER AIRPORT BUNDABERG 4670 THIS DRAWING 15 COPYRIGHT AND MUST MOT COPIED WITHOUT THE CONSENT AVTECH LTD Dar Figure 68 Flap Controls Sheet 2 SHEET 2 OF 3 TITLE ELECTRIC FLAP DRIVE ASSY J160 REF HITES PETALS INDIVIDUAL FLAP ARE ADJUSTED TO ADULT AFTER INSTALLATION aon FLOCK FILLET EDHO TO FUSE REF MUTES FOR BORD DETAILS BRACE GETS FLOCH BEAD AND GLASS TAPE ALEGI FLAP SERV MOUNT EOR LIANT PRACE TO MOUNT AND FUSE P FOS BORO 5 OGD MOUNT T0 DOGA MOT 1 USE LEO Pe HOTES POR DONG CETAR 5 2 FLIA IS COTTON MA 2 SURFACE MUST PREPARED BT
53. Chock the opposite wheel 5 Repeat for other side if necessary 5 2 2 2 JACKING NOSE GEAR 1 Push down on Tail Plane NOT THE ELEVATOR until nose wheel is off the ground 2 Place trestle or drum under rear fuselage together with absorbent material such as foam block sandbags or a pillow Alternately a pillow or similar may be placed on the ground so that the ventral fin rests on it when the tail is pressed down CAUTION If using a trestle ensure it does not foul Ventral Fin 3 Protect the paint of the horizontal tail using rags pillows etc and weigh down tail plane with sandbags or similar heavy absorbent material do not use anything hard as items like bricks are likely to damage the aircraft material Place weights as close as possible to the aircraft centreline and where possible apply weight symmetrically to both sides of the aircraft CAUTION Do not lift using control surfaces Damage to the control surface or control system may result 4 Place a padded trestle or similar under the front of the fuselage immediately aft of the cowl outlet to ensure that the nose cannot drop down if the aircraft balance is disturbed 5 2 3 Hoisting e This procedure should not be necessary for most service or maintenance procedures Should hoisting be necessary Drain Fuel from both wings Wet Wing models only amp Remove wings Fit shackles to wing support brackets 4 off Fit cables rope to shackles and to a centre lift shackle
54. DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 21 of 223 Jabiru Aircraft tc required for servicing A medium strong threadlock Typically used for cap screws into castings or Aluminium An accurate optical tachometer Reads directly from reflective Strips fitted to the propeller and is used whenever an accurate check of RPM is required Will usually read propeller RPM in sunlight without reflective strips Used to confirm accuracy of RPM readings of standard instruments Figure 3 Optical Tachometer Commercially available tool designed for high torque applications on small nuts Also allows the use of a torque wrench in inaccessible locations Note usage instructions below Figure 4 Crowsfoot Adaptor per SE Age Us E ty Wire W e Wire used to secure items nuts bolts etc to prevent rotation in service 4 9 1 Torque Tension Wrench Figure 6 Torque Wrench amp Crowsfoot Adaptor Setting 1 DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 22 of 223 Jabiru Aircraft ME Aircraft Service Manual Jabiru J230 D Serial 868 Figure 7 Torque Wrench amp Crowsfoot Adaptor Setting 2 good torque wrench is an essential tool for maintaining Jabiru Aircraft It s important to realise however that even the best wrench needs calibrating occasionally This can be done using a dead weight on the end of a known arm or preferably sending the wrench away to b
55. EXCHANGER TUBE 2 TAILPIPE 2 3A079C0D 1 CABIN HEAT EXCHANGER END FITTING 2 TAILPIPE 3 079000 1 CABIN HEAT EXCHANGER INLET STUB 2 4 6 SOCKER HD SCREW 10 24 X 1 2 HAMMER FITTINGS ONTO TUBE WITH A SOFT HAMMER BEFORE WELDING STITCH WELD FITTING TO TUBE 4 PLACES EQUALLY SPACED NOT WELD BESIDE THREADED HOLES AVTECH P L THIS DRAWING IS COPYRIGHT AND MUST NOT BE S 4 COPED WITHOUT THE CONSENT OF PTY LTO 155 010786973 DWG No ay n QAO LPS uma CABIN HEAT HEAT EXCHANGER 2 3A079A0D 1 BUNDABERG 4670 TAILPIPE Figure 101 Cabin Heat Exchanger Assy 10 12 Extreme Climatic Conditions 10 12 1 Dust e 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 regularly Servicing intervals for aircraft operating in extreme conditions are at the operator s discretion 10 12 2 Seacoast And Humid Area In salt water areas special care should be taken to keep the engine and accessories clean to prevent oxidisation e n humid areas fuel should be checked frequently and drained of condensed moisture DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 166 of 223 Jabiru Aircraft tc Aircraft Service Manual
56. Inspect exterior surfaces of control surfaces check for damage including cracking fraying etc Inspect control horns hinges amp hinge lock tabs Check for condition and wear and replace as required Inspect aileron controls amp linkages Ensure all hardware is secure and in good condition Carry out a rigging check flight Check all systems for correct function e Inspect throttle controls for correct function smooth operation and correct adjustment of friction to prevent inadvertent throttle movement e Inspect Control Surfaces per Section 6 17 6 14 Lubrication e Refer to the appropriate engine manuals for engine lubrication requirements following points are designed to run dry if required however application of some graphite lubricant is recommended if excess friction is detected Rudder pedal pivots Wing flap cross shaft pivots Control stick pivot and control stick shaft bushings Nose leg pivot bushings Throttle shafts Note that this refers both to the throttle cross shafts floor and panel mount throttle systems and to the shafts which pass through the instrument panel and have the throttle knobs on the aft end Note that if fresh lubricant is applied to the throttle system it will be necessary to re adjust the friction lock when the lubricant is applied and again after a few hours of operation 6 15 Special Inspections Weighing y 4 4 4 Required Tools Chocks Calibrated scales
57. P No 5091344 AVGAS 10011 2 OFF 67 LITRE CAPACITY EARTH ON POST Attach to too skin of wing adjacent to Fuel Filler Cap Wing Bolt Tightening DANGER DO NOT TIGHTEN P No 5039094 Qty 8 Required Attach to the fuselage and wings beside each wing and lift strut attachment fitting DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 211 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 17 Fairings Type of Maintenance Level of Certification 17 1 Description e Jabiru Aircraft are fitted with fairings around the wing roots wing struts under the fuselage and wheel spats The ventral fin under the tail is also considered a fairing These fairings are attached using screws In some cases self tapping screws are used to attach the fairing directly to the airframe In other cases threaded inserts are glued into the fuselage and the fairing screws fit into these inserts Figure 41 shows these inserts as used to fit the inspection hatch to the wing Finally in some cases anchor nuts are fitted to the aircraft or to a fairing section and the remaining fairing attached to the anchor nuts using machine SCrews e Due to space constraints not all different variations are shown herein When ordering spare parts provide as must detail as possible part description aircraft model serial number etc to Jabiru to ensure accurate part identifica
58. Paint bonding surfaces lightly with epoxy resin mixture 11 Mix cotton fibre flock with epoxy resin to a gluey consistency similar to toothpaste 12 Assemble the bushes to the leg housing and fit the leg Place a jack or similar under the leg assembly so that the weight of the leg is not pulling down on the wet resin 13 Ensure there is a thick flock bed around the part as shown in Figure 49 left 14 It is good practice to paint the flock with resin before it cures this gives a smooth shiny finish to the flock bed 15 Allow the resin to cure 16 Remove the leg and clean off any excess grease or rough edges 17 Apply graphite lubricant to the leg housing Check for full and free movement 7 3 14 6 NOSE GEAR DISASSEMBLY Heavy workbench with strong soft jawed vice Spanners socket wrench Extension lever Replacement pivot bushes if required Replacement rubber spring if required Type of Maintenance Level of Certification LSA repairman inspection or maintenance Disassemble the nose leg spring assembly i e to replace the rubber spring or pivot bushes 1 The following requires a heavy workbench fitted with a strong vice and thick soft jaws 2 Remove the leg assembly from the aircraft 3 Clamp the leg in a vice as shown in Figure 49 right Ensure good soft jaws are used to avoid damaging the nose leg yoke 4 Remove the nut from the bolt on the top of the spring shaft 5 Fit an extens
59. Parts and Material Replacement Ertalyte bushes Grease or Wax Graphite lubricant DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 97 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 P Resinandflock _______ o T Level of Certification LSA repairman inspection or maintenance o replace the Ertalyte bush es This task can be done with the housing mounted on the fuselage removal is not necessary 2 Adjust the retaining collar s of the leg assembly to their largest setting 3 The new bushes will be bonded in place while installed on the nose leg Therefore it is necessary to apply a light coating of grease or wax to all parts which should not be bonded to the housing 4 Break the existing bushes out of the housing taking care not to scratch or damage the housing itself 9 Hemove any leftover flock 6 Dry fit the replacement bushes to the leg If they are too tight they may be reamed slightly to fit however a slightly firm fit is preferable during initial assembly to ensure a good fit once the initial wear in is complete Graphite lubricant may be used T Lightly sand the bonding surfaces of the nose leg housing and the new bushes using 240 grit or higher paper 8 Wipe the sanded areas with a rag moistened with acetone to remove any oils and excess dust from the surfaces 9 Very lightly sand the boding surfaces again and blow off dust using dry air 10
60. Service Manual 6 21 SPECIAL INSPECTIONS WING amp STRUT BUSH SERVICE 62 7 STRUCTURE 67 7 1 amc 67 7 2 WINGS amp EMPENNAGE 76 7 3 LANDING GEAR amp esso ttes teennaann 83 8 AILEHON CONIHOLE SYSTEM iiccuisiskwixcuxiscsuis tius s iri 109 8 2 WING FLAP CONTROL SYSTEM iine ive qnie UR E 119 8 3 af CONTROL 131 8 4 CONTROLE C OIMN P 9 132 8 5 212770 132 8 6 ELEVATOR CONTROL CABLES acertir eene umet 135 8 7 tree ter eee een ere ee ee 135 8 8 ELEVATOR CONTROL LEVER 137 8 9 ELEVATOR TRIM amp APT ASSEMBLY 138 8 10 TC ONTROL CABLE 140 9 RUDDER CONTROL SYSTEM 141 9 1 RUDOER PEDALS cauce 141 9 2 RUDDER CENTERING yz m 143 9 3 RODDE 146 9 4 RUDDER CONTROL CAB E ease 148 9 5 RUDDER BALIN
61. Systems 100 Hourly Annual all possible circumstances cannot be listed here the following is provided as guidance only A critical trained eye is required and inspections should include but not be limited to the following e Inspect all primary control cables amp clamps Ensure clamps are assembled correctly and indexed correctly on the cables Check all hardware 15 in good condition and is secure Move all controls through their full travel ensuring full and free movement with no binding e Inspect all rod ends and other hardware for condition and security Ensure all lock nuts are secure e Inspect all secondary trim throttle etc control cables amp clamps Ensure clamps are assembled correctly and indexed correctly on the cables Check all hardware is in good condition and is secure Move all controls through their full travel ensuring full and free movement with no binding Check control surface travel Ensure that control surface stops are correctly adjusted and secure Ensure all decals amp labels are in place and in good condition Cycle the flaps checking the flap control amp linkages for full and free operation with no binding Listen to the electric flap motor if equipped and clean or replace if it sounds uneven or jerky Inspect elevator control amp linkages Ensure all hardware is secure and in good condition Inspect rudder pedals amp linkages Ensure all hardware is secure and in good condition
62. Velted PUSLOSDUASSU 175 TGS Line Fuel 176 Figure 112 Fuel Gauge Sight 177 Figure 119 Instrument Panel Layout T E da FE Dra ER Rott epa 181 Figure 114 Instrument Panel Layout 2 181 Figure 115 Instrument Panel Layout 3 182 Figure 116 Instrument Panel Layout 4 182 Figure 117 Instrument Panel Mount 183 uadit 185 Figure 119 Static Probe System Assembly 4 186 Figure 120 Pitot Static Water 187 Figure 121 Pitot Static System Water Trap Locations 187 Figure 122 ecce i um 192 Figure 123 Alternate Static Source 193 Figure 124 Wiring Diagram Sheet 1 nnne nennen nennen nnne nnns 198 Figure 125 Wiring Diagram Sheet 2 enne nennen nnn nennen nnn nnne nennen 199 Figure 126 Night VFR Lighting Sheet 1 199 Figure 127 Night VFR Lighting Sheet 2 200 Figure 128 VHF Antenna 203 Figure 129 Second VHF Ant
63. WARNING All spherical rod end bearings must be fitted with a large washer on the outside of the through bolt to prevent the bearing case and cable releasing in the event of a bearing failure DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 119 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 8 2 1 5 INSPECTION amp REPAIR e Visually inspect the handle for wear or cracking of the fiberglass Small cracks between the moulded handgrip and the structural plate forming the handle may be repaired using 5 minute araldite e Inspect hardware for damage and replace as necessary 8 2 1 6 INSTALLATION e For installation reverse the removal procedure e Ensure tape is removed from flaps and an operational test carried out before use 8 2 2 Electric Flap Drive Assembly Type of Maintenance Level of Certification LSA repairman inspection or maintenance 8 2 2 1 DESCRIPTION e The flap position controlling switch uses a manual toggle switch to control the flap deflection e linear actuator is mounted in the wing root inside the cabin and drives the flap cross shaft directly Drawings of the systems are shown as Figure 66 through to Figure 72 8 2 2 2 REMOVAL e Apply heavy duty tape or similar to both wing flaps holding them up Un bolt the motor from the flap cross shaft position indicator and mounting bracket e Disconnect motor wires Ensure that wires are marked to allow re
64. When adjusting any engine control it is important to check that the control slides smoothly throughout its full range of travel and that the lever or knob moves through its full range of travel This must be verified both at the carburettor and inside the cabin e Check for chaffing or fraying of the cable 10 7 5 Throttle Installation e Reverse the removal procedure given above for installation e Adjust throttle stops mounted on the throttle pushrods for panel mount throttle and on the seat front floor for seat mounted throttle to give full throttle and correct idle speed Details for procedures can be found in the Engine Maintenance Manual Adjust friction of shaft clamps to ensure throttle does not move from a set position WARNING Adjustments must be set with care poorly adjusted throttle stops can result in engine stoppages apparent loss of power or increased landing distances due to high idle Poorly adjusted friction stops can result in throttle position creeping resulting in un commanded application of high power CASES OF SEVERE DAMAGE TO AIRCRAFT DUE TO THESE EFFECTS HAVE BEEN RECORDED DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 158 of 223 Jabiru Aircraft tc INSTRUMENT PANEL FASCIA GLASS COCKPIT SHAFT PANEL 3 TUBE CLAMP dus ER INPUT N SIDE PANEL z 3 AN3 134 y BOLT 4 _ 1032 vif PENNY WASHER DUTPLUT LE ER THRO TT H
65. When conducting an inspection at 100 hours all items marked under Each 100 Hours is inspected serviced or otherwise completed e At each 200 hours inspection the 100 hours items are completed in addition to the items marked under Each 200 Hours e An inspection conducted Annually would likewise include the 100 hour items and 200 hour items in addition to the items marked under Annual Inspection e Acomplete aircraft inspection includes all 100 200 hour and Annual items together with those shown in the Engine Maintenance Manual and Propeller Manual Special Inspection items are carried out as required or as specified in DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 32 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 Table below Table 3 Inspection Schedule Chart Annual Inspection Each 200 Hours Each 100 Hours PROPELLER 1 opinner i 2 Spinner Flange 3 Spinner screws 4 Propeller 5 Propeller bolts nuts Tension 6 Spinner Prop Tracking ENGINE COMPARTMENT Note refer to engine maintenance manual for engine specific inspections 1 Carburettor air filter 2 Engine baffles and air ducts 3 Oil Hoses lines fire sleeve amp fittings 4 Fuel Hoses lines fire sleeve amp fittings 5 SCAT Hose Condition 6 Electrical wiring 7 Engine controls and linkages DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 33 of 223 Jabiru Aircraft tc Aircraft Service Ma
66. aircraft Refer to Service Letter JSL007 for details 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 3 Either block up undercarriage fuselage to relieve pressure on tyres or rotate wheels every 30 days to prevent flat spotting the tyres 4 Seal or cover all openings Note that wing tank breather covers MUST BE LOOSE 5 Remove and store in cool dry place Service the battery periodically and charge as required NOTE It is recommended that batteries not being 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 Rotate the propeller 10 12 times leaving it in the horizontal position NOTE Use SHELL Aero fluid 2UN MIL C 6529C Type 1 or similar engine corrosion inhibitor 7 Install spark plugs and connect leads 8 Seal exhaust pipes Attach a red streamer to each 9 Cover but DO NOT seal fuel tank breathers breather covers must be a loose fit to prevent the possibility of pressure related damage to the fuel tanks 10 Place protective covers over pitot tube static source vents air vents and openings in engine cowl to prevent the entry of foreign material or pests especially wasps 11 Att
67. and Material Fuel Gauge AVGAS Fuel for filling Type of Maintenance Level of Certification A amp P or LSA Repairman Maintenance LSR M Return to Service A amp P or LSA Repairman Maintenance LSR M e This procedure is applicable for Jabiru Aircraft equipped with wing tanks and electronic fuel gauge senders e This procedure must be carried out during initial assembly of a new aircraft or when a new gauge sender is fitted e The accuracy of the fuel indication system of the aircraft depends on careful and accurate completion of this process e For this procedure the fuel tanks need to be filled from empty Therefore they must be emptied now e Apply fuel line clamps to close the fuel lines between the wing tanks and the header tank e Before starting the fuel gauge calibration the aircraft needs to be laterally left right level See the aircraft flight manual for the levelling datum details e Add 1 5L of fuel to each tank this is the unusable fuel Check the indication of the fuel gauge The fuel gauge needle must be pointing at the E or below If it is not then the gauge unit will need to be removed and adjusted See Figure 21 with the tank containing the unusable fuel amount the needle must indicate a position between the two extremes shown Accurately add 20L into the tank on top of the unusable fuel Then take the fuel gauge calibration decal see Figure 22 and align inner fuel gauge dial representation with t
68. and engine improve as required Wrong number of pulses set in Correct settings per tachometer setup manufacturer s instructions Some displays require a resistor Tachometer inaccurate be installed between the display fluctuating No resistor between display and and the alternator Check alternator some displays only manufacturer s installation instructions and ensure resistor is fitted where required No GPS source fitted Install GPS Connection between GPS and Check GPS Data not displayed display failed eck and repair connection Settings on Display or GPS oe to incorrect recommendations 12 9 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 12 10 Gyro Instrument Package Option e A vacuum pump driven Artificial Horizon and Directional Gyro together with an electric Turn Coordinator is available as an option e Where this option is provided a different instrument panel fascia is fitted e Repair should only be performed by an approved instrument workshop DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 195 of 223 Jabiru Aircraft Aircraft Service Manual Jabiru J230 D Serial 868 DOCUMENT No JTMO01 0 230 D
69. and fairings Replenishing hydraulic fluid in the hydraulic reservoir e Refinishing decorative coating of fuselage wings tail group surfaces excluding balanced control surfaces fairings cowlings landing gear cabin or cockpit interior when removal or disassembly of any primary structure or operating system is not required e Applying preservative or protective material to components where no disassembly of any primary structure or operating system is involved and where such coating is not prohibited or is not contrary to good practices DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 13 of 223 Jabiru Aircraft tc e Repairing upholstery and decorative furnishings of the cabin or cockpit interior when the repairing does not require disassembly of any primary structure or operating system or interfere with an operating system or affect the primary structure of the aircraft e Making small simple repairs to fairings nonstructural cover plates cowlings and small patches and reinforcements not changing the contour so as to interfere with proper air flow e Replacing seats or seat parts with replacement parts approved for the aircraft not involving disassembly of any primary structure or operating system Trouble shooting and repairing broken circuits in landing light wiring circuits Replacing bulbs reflectors and lenses of position and landing lights Replacing any cowling not requiring removal of the propeller or disc
70. and the lugs may be corrected by replacing these bolts with new 5 16 AN175 close tolerance bolts New bolts should be lightly hand polished before installation to improve the fit Note that the ideal fit has minimal or zero clearance and will require thumb pressure or a light tap with a soft hammer for installation If there is excess movement remaining even with new bolts fitted then further work must be carried out as detailed below This is a qualitative assessment which is best informed by experience If in doubt it is recommended that the maintainer re fit the wing with the new bolt and test for movement before continuing to any of the more significant repair processes such as replacing lugs etc f the replacement bolts are a tight fit re assemble the aircraft and re test as detailed in oection 6 12 Ensure a new bolt is used on the attachment which has been serviced e f the holes in the wing strut lugs have worn so that standard or close tolerance bolts have excess movement then the wing strut lug or the whole strut assembly must be replaced Note that this type of wear is unusual Checking the more common wear modes detailed below is recommended before replacing strut lugs Carefully measure from a fixed point on the strut to the tip of the strut lug amp record the reading Remove the bolts connecting the lug to the strut section Remove the lug from the end of the strut Paint replacement strut lug with a su
71. ap 5 SHAFT 3H SUNT T LE CMP 2 T ER BUNDY TUBE PIVOT 17 LG x 3 4 D 3 16 STRUMENT PANEL MOULDED SUPPORT DIMENSIONES Sc AIL THES DRAWING COFTRESHS AHD MUST NOT m METRES DO NOT SCALE TEGH digs DOPED WITHOUT THE CONSENT OF AVTEOH PTY LTO 55 05 HER ron INSTRUMENT PANEL ASSY GLASS 1 nio COCKPIT J160 IET Torr TETEN mes Figure 94 Throttle Assy Panel Mount 10 8 Choke CABLE Level of Certification LSA repairman inspection or maintenance 10 8 1 Description The Choke Control is normally located in the main instrument panel amp is connected to the carburettor by a control cable In some cases the Choke Control may be located on the left hand side of the firewall beside the instrument panel 10 8 2 Removal Inspection amp Installation Y Y Disconnect the choke inner amp outer cable from the carburettor remove the cable end fitting remove the cotter pin Figure 95 Note that for older aircraft the soldered end fitting must be heated with a powerful soldering iron or small gas burner and removed when the solder melts Undo the clamp nuts from the cabin end of the cable Where equipped un screw and remove the fireproof fitting on the firewall which the cable passes through Draw the cable thro
72. are installed on the correct side of the aircraft 5 Bolt the stub axle amp mount plate to the main undercarriage leg Torque to solid laminate value give in Table 2 Note that if a new leg is being fitted it will be necessary to check and adjust the angle of the stub axle This must be carried out in accordance with Section 6 18 6 Fit brake caliper to brake mount plate ra Assemble the wheel and brake assembly Fit the axle extension and adjust the brakes 8 Fasten the brake line to the undercarriage leg using zip ties 2 min per leg 7 3 8 4 INSPECTION AND REPAIR Required Tools Spanners socket wrench Parts and Material Resin with flock Replacement bolts nut washers if required Replacement Clamp if required Type of Maintenance Heavy Maintenance Level of Certification LSA repairman 1 Inspect composite beam for damage indicated by cracks or de lamination Pay particular attention to the area around the centre bend and to areas around drilled holes 2 When inspecting the legs shown in Error Reference source not found pay particular attention to the area around each bend in the leg Note that it is possible for this leg type to have internal damage which does not show to the surface In this case the best indicator of the damage is that the damaged leg will have lost stiffness compared to the other side and so the aircraft will lean in the direction of the damaged leg If required legs can be
73. assembly in the same orientation e Remove actuator WARNING Do not allow flaps to drop when disconnected from the motor or damage to the flaps wings or fuselage may result WARNING All spherical rod end bearings must be fitted with a large washer on the outside of the through bolt to prevent the bearing case and cable releasing in the event of a bearing failure 8 2 2 3 INSPECTION amp REPAIR y 4 4 e Note that while the pictures below show the motor removed it is possible to carry out this work with the motor still fitted to the aircraft e Remove the two screws then take off the motor cover as shown in Figure 64 e Figure 64 shows a close up picture of the commutator ring The unit in this picture is very dirty and badly needs cleaning e Use a rag lightly moistened with solvent such as acetone to remove as much of the black material from the ring as possible e Use a tooth brush or other similar small brush to clean between the segments of the ring as much as possible The brush may be moistened with solvent DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 120 of 223 Jabiru Aircraft Care must be taken remove the black material from the motor as it is conductive it could cause a short circuit or other problem if allowed to drip into the motor base e Allow the unit to dry fully e Re assemble taking care to line up the key slots on the motor housing e Test and repeat cleaning process if required C
74. e The fuel tanks should be filled immediately after flight to lessen condensation of moisture e Service Letter 51007 contains a great deal of detailed information on the suitability operating requirements and storage requirements of different fuels Operators and maintainers must familiarize themselves with this information and follow the guidelines given in the letter e Fuel drains must be inspected to ensure they are functioning correctly and are not leaking Fuel drains are located For J230 D aircraft with wing tanks in each of the Left amp Right hand wing fuel tanks The drains are located on the underside of the wing near the wing root For J230 D aircraft with wing tanks a third drain is located under the fuselage This drain is located just aft of the sound curtain the rear of the cabin depending on the model and configuration e Fuel filters must be checked and replaced at the intervals noted e The carburettor bowl must be removed and checked for contaminants While the bowl is removed inspect the float level and check for any foreign objects in any of the jets e Check the electronic fuel boost pump functions and produces a sufficient flow rate e Inspect fuel lines and connectors Check for hardening cracking leakage correct radius obstruction foreign matter and any other signs of deterioration e Check the condition of fire sleeves Ensure that fire sleeves are long enough to completely cover all flexible hoses
75. fluid after sealing coils and starter motor WIPE clean with brush and cloth 5 1 6 Propeller e Wash with soap and water rinse with clean water and dry with cloth or chamois CAUTION Do not use a wax based substance as this would make it almost impossible to refurbish the prop if need at a later stage 5 1 7 Wheels e The wheels should be washed periodically and examined for corrosion cracks or dents in the wheel halves or in the flanges or hubs If defects are found remove and repair in accordance with Section 7 3 Discard cracked wheel halves flanges or hubs and install new parts 5 2 Ground Handling 5 2 1 Towing e All Jabiru aircraft are relatively light and should always be moved by hand e Moving the aircraft is accomplished by using the wing struts prop hub or landing gear struts as push points CAUTION Do not use control surfaces to move the aircraft Damage to the control system may result e When pushing or moving the aircraft take care that you do not jam your fingers under the rudder or in the rudder hinge remember that it is connected to the Nose Wheel and will move whenever the nose wheel direction changes he 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 WARNING Never move the aircraft in this manner whilst the engine is hot as it may fire when the propeller
76. following criteria are met DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 48 of 223 Jabiru Aircraft tc The control clearance is less than 3mm at the control s point of overlap when tested as detailed in Inspection B Note that this clearance limit only applies to controls which are configured such that they actually have a point of overlap The control clearance changes by 5mm or more when the test load of Inspection B is applied This is irrespective of if the control has a point of overlap or not e Carry on to Inspection C in all cases Control at the point of overlap Measure the control clearance in this position while pressing on the control in the middle of the hinge Repeat the measurement when unloaded Figure 12 Rudder Gap Cross Section Use gauges such as the 3mm type shown vernier callipers or a ruler to measure the control clearance between aileron and wing Control at the point of overlap Leading edge of aileron in line with trailing edge of wing Figure 13 Aileron Clearance DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 49 of 223 Jabiru Aircraft tc a Control at the point of overlap Measure iae m the control clearance in this position _ while pressing on the control in the i f S middle of the hinge Repeat the CX measurement when unloaded x IN Press agains
77. fuel lines 11 2 Fuel Lines Type of Maintenance Level of Certification LSA repairman inspection or maintenance 11 2 1 Description e Flexible fuel lines are used tn Jabiru aircraft 11 2 2 Removal e Where required fuel lines are removed be loosening the hose clamps and pulling the line off the hose tails some cases it may be necessary to cut the lines off the hose tails due to lack of access hard tight lines etc Care must be taken that sufficient spare line remains to re connect for assembly alternately a new line must be fitted 11 2 3 Inspection e For aircraft with wing tanks Remove the header tank cover the baggage shelf for J160 J170 family aircraft and the sound curtain at the rear of the cabin for J230 family aircraft Ensure there are no U s or inverted U s in the lines Ensure line restraints are spaced at intervals no greater than 400mm In some cases fuel lines are bundled inside tubes which are Velcro ed to the aircraft this is sufficient restraint If new restraints are added plastic line clips can be bonded to the aircraft structure Figure 105 refers Fasteners such as screws which damage the structure should not be used 7 7 WII NI n 4 FUEL LINE ROUT 7 RP INVF U el NCORRECT FUEL LINE ROUTE FR dii NVERTED U FORI 7 POTENTIAL AIR LOCI Figure
78. inspection or maintenance 12 6 1 Description e Jabiru Aircraft may be equipped with an alternate static source This system is for Night VFR aircraft so that should the primary static source become blocked the pilot may switch to an alternate supply In the Jabiru this system consists of a section of the static tube which is exposed at the underside of the instrument at a position where the pilot can reach it in flight Where a problem is detected the pilot reaches down and pulls on the tube disconnecting it from the static probe in the tail The aircraft instruments will now take cabin pressure as static pressure DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 192 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 12 6 2 Removal amp Installation 77 e Drill the rivets holding the fitting to panel and remove e Disconnect static system tubes e For installation reverse removal steps listed above Parts List 6 ITEM PART NUMBER DESCRIPTION VIEW C 1 5AD43COD 1 GLASS INSTRUMENT PANEL MOULDED ISOMETRIC VIEW OF INSTALLED FITTING 4 ____ SUPPORT ASS 5 082 20 1 ALTERNATE STATIC SOURCE UN HOSE FROM OUTER END OF TUBE THRU HOLE SHOWN amp AIR INSTRUMENTS SADB2A 1D ALTERNATE STATIC SOURCE BULKHEAD FITTING BENT TUBE SUB ASSY OF PLATE amp TUBE IE P No 2 5 32 RIVET CONNECT INNER END OF TUBE LI
79. is moved and result in severe injury Always ensure that the Master and Ignitions are OFF Never approach the propeller when anyone is in the aircraft Always treat the propeller as LIVE IT KILLS 5 2 2 Jacking e Before jacking ensure that it is as light as possible by removing luggage and any unnecessary fuel DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 26 of 223 Jabiru Aircraft tc 5 2 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 2 Where equipped the fuel filler cap vent of the wing which is not being jacked may be blocked using a vent cap This is to prevent fuel leaking onto the wing while the aircraft is jacked CAUTION Where a vent cap Is used ensure that it is large and highly visible to ensure it is removed on completion of the work 3 The aircraft can be lifted on one side by a person of reasonable strength or 2 of lesser strength by lifting on the Wing Spar lift at a point in line with the wing strut and about 1m 3 feet outboard of the strut attachment Be careful lifting close to the wing tip as the wing structure in this area is quite light and can easily be damaged by misplaced jacking loads 4 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
80. iu renim Teal 5 TAL p IHIN 0 m 5 AMADA zT 1 cn 4 5 iu m an c i 2431 1 im cz s Ium Imi 5 Lk a j me porem umm Se ir 2 i p B d d 2 ae 8 at Jl 1 1 a 1 ing i I 1 3 V N 5 Jabiru Aircraft Aircraft Service Manual Odd 31925 LON 00 SJaL3nTFTIN SHOISHAREO Page 198 of 223 Wiring Diagram Sheet 1 08 May 2014 Figure 124 DOCUMENT No JTM001 0 230 D 868 Jabiru Aircraft tc CIRCUIT DIAGRAM KEY 17 CYLINDER HEAD TEMPERATURE 34 STROBE CONNECTION POINT SENSOR 35 NOISE FILTER PI4A005N 1 BATTERY 18 OVERVOLTAGE MODULE 055 36 2 STARTER 19 TACHOMETER MAGNETIC SENSOR 37 RF SUPPRESSOR LARGE 4 006 STARTER SOLENOID 20 38 RF SUPPRESSOR SMALL PI4A007N 4 STATER BUTTON PIO306N e 19 5 ON OF
81. maintenance 9 1 1 Description Jabiru Aircraft use rudder pedals connect directly to the nose leg to control nose wheel steering in addition to the rudder control surface The system is comprised of rudder pedals two push rods a Centering mechanism and an enclosed push pull cable Optional adjustable rudder pedals may be fitted These pedals are adjusted by means of a spring loaded pin that allows each pedal to be moved to one of three positions Due to space constraints not all different variations are shown herein When ordering spare parts provide as must detail as possible part description aircraft model serial number etc to Jabiru to ensure accurate part identification r a ir ins x F e FA 1 names oe Avie L RUDDER CONTROL ASSY SCHEMATIC 3An57400 1 1 m _______ sro sn E 4160 FAMILY meme UDO CABLE MOUNT 1140 1 did 1 Figure 82 Typical Rudder System Schematic 9 1 2 Removal And Installation lt Y 1 Unbolt push pull cable 2 Disconnect Centering springs 3 Unbolt both steering push rods DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 141 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 Unbolt rudder pedal bearings Remove cover plates and nylon bearings Remove both pedal bars Reverse the prec
82. metal spacers between the rubber blocks Check that the washer has been fitted at the top of the rubbers Inspect aluminium wheel yoke for damage or bending Inspect pivot bushes for wear or damage Inspect assembly bolts amp hardware replace if damaged or corroded Inspect bolts nuts for torque see thick lamination torque values in Table 2 Repairs to the welded nose leg assembly beam must be referred to Jabiru Aircraft Pty Ltd or Our approved local agent 7 3 14 4 NOSE GEAR END FLOAT ADJUSTMENT Required Tools Sanding block Parts and Material Type of Maintenance Level of Certification LSA repairman inspection or maintenance e the end float of the leg in the housing requires adjustment use the procedure below Note that this applies regardless of the type of nose leg housing fitted to the aircraft 1 The nose leg retaining collar is drilled with 3 sets of holes each at a slightly different position Depending which holes are used the distance between the upper and lower retaining collars can be increased or reduced to allow for wear 2 If there is excess float adjust 1 collar to the next smallest position If this is then too tight to fit onto the housing use a sanding block to remove a small amount of material from the top of the Ertalyte bush to allow a proper fit 3 If no smaller adjustments remain then the Ertalyte bushes must be replaced 7 3 14 5 NOSE GEAR BUSH REPLACEMENT Fine grit sand paper
83. or similar Then place the bush bolt assembly in an acetone bath to remove all oils Blow dry using clean air before installation Mix Jabiru Epoxy resin amp hardener according to the manufacturer instructions Lightly paint both the thread of the fibreglass socket and the stainless steel bush with resin Mix cotton fibre flock with the resin to a gluey consistency this mix can be left slightly wet amp thin this will aid penetration into the small voids in the threads Screw the bush into the wing Use a spanner on the small bolt to drive the bush Where an eccentric type is being fitted ensure it is oriented correctly Ensure that the bush is straight positioned centrally on the fibreglass lug and not cross threaded Leave to cure DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 66 of 223 Jabiru Aircraft tc the resin has completely set the small drive bolt can be removed from the bush Inspect the centre bore of the bush and if necessary clean out any resin using a pick or an adjustable ream Test fit the new wing attachment bolt Lightly hand polish bolt before fitting Fit the wing amp test the connection for free play as detailed in Section 6 12 Ensure a new bolt is used on the attachment which has been serviced CAUTION Do Not apply any load to the bush until it has cured Do Not use rapid set i e 5 miniute epoxy 7 Structures 7 1 Fuselage e The Fuselage is a compo
84. pass Remove the tank from the aircraft DOCUMENT No JTM001 0 230 D 868 08 May 2014 172 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 11 3 3 Fuel Tank Inspection 777 e Leaks can normally be found by visual inspection AVGAS in particular will leave dye stains where leaks have occurred If leaks are found contact Jabiru Aircraft for a repair procedure e Visually inspect the tank and fittings for corrosion damage and contamination 11 3 4 Fuel Tank Installation e For installation reverse removal procedure given above ARTEN CIMENSIONS IN MILIMETRES DO MOT SCALE PROJCTON B NOTES 1 HEADER TANK INSIDE THE FOUR POSITICNING BRIKCKETS 2 SECURE THE HEADER TANK TO THE FUSELAGE WITH THE SECURING STRAP 3 CONNECT THE FUEL FILTER AND FUEL PUMP TO THE HEADER TANK AND SECURE THE FUEL PUMP TO THE FUSELAGE 4 CONTINUE THE FUEL LINE TO THE ENGINE FUEL PUMP 5 CONNECT THE LEADS TO THE FORE AND AFT FEED OF THE WINGS ON BOTH SIDES AND ALSO THE LINE COVER THE INSTALLED HEADER TANK WITH THE CARGO FLOOR AND SECURE WITH SCREWS ALL AROUND THE FLOOR TO RIGHT SIYE FE CUT POSITICNING BRACKETS FROM TANE FIBHEGLASS ANGLE APPLY INSERTION RUBEER AT ALL CONTACT POINTS BETWEEN THE FUEL TANK AND SURROUNDING STRUCTURE APPLY NTO STRINGER MINUTE ARALDITE E
85. returned to Jabiru Aircraft for testing Inspect bolts and nuts for signs of stress bending or corrosion replace if in any doubt Inspect clamp for damage Inspect bolt seats in fuselage for signs of damage wear or perishing DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 91 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 6 For the leg shown in Error Reference source not found inspect the outboard clamp flock bed amp re flock if damaged WARNING Repairs to the composite undercarriage beams must be referred to JABIRU AIRCRAFT Pty Lid or our local approved agent 7 3 9 Trouble Shooting Main Undercarriage Table 5 Trouble Shooting Main Undercarriage Incorrect tyre inflation Inflate to pressure shown at above Aircraft leans to one side Landing gear attaching parts not Tighten loose parts Replace tight defective parts Leg de lamination Install new part s Inflate to pressure shown in Incorrect tyre inflation above Tyres wear excessively Main wheels out of alignment Align as specified above Leg de lamination Install new part s Dragging Brakes Refer to Section 7 3 Parts List ITEM PART NUMBER DESCRIPTION BARE FUSE ASSY MAIN UNDERCARRIAGE LEG 2000240 UG BACKING PLATE RAC BACKING PLATE RECT UNDERCARRIAGE WASHER UNDERCARRIAGE CLAMP J200 HQ _ A UHDERCA
86. small nicks and scratches 4 Carefully inspect bearings for damage and discolouration Note Bearings are pre packed DO NOT clean with solvents as it will remove the packing grease e If existing parts are unserviceable replace bearings 6 Apply automotive wheel rim lubricant to the bead areas of the rim halves Note that if this step is missed disassembly of the wheels in future will be very much harder 7 Position tyre and tube between wheel halves with tube inflation valve through hole in outside wheel half 8 Mate wheel halves While holding halves together assemble a washer and nut on one through bolt and tighten snugly Assemble the remaining washers and nuts on the through bolts and torque to the solid laminate value specified in Table 7 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 Note that if directional brake discs are fitted the discs must be oriented in for the correct direction of rotation Refer to Figure 70 below 10 Inflate tyre to seat tyre beads then adjust to correct tyre pressure Refer Aircraft Specifications above 7 3 5 5 MAIN WHEEL INSTALLATION Required Tools opanners socket wrench Parts and Material Anti Seize or a Water Proof grease Assembled wheel Bear
87. so that the small bolt is clamping the bush DOCUMENT No JTM001 0 230 D 868 08 May 2014 65 of 223 Jabiru Aircraft tc Clean the replacement bush bolt assembly in an acetone bath Blow dry using clean air before installation Mix Jabiru Epoxy resin amp hardener according to the manufacturer instructions Lightly paint both the thread of the fibreglass socket and the stainless steel bush with mixed resin cotton fibre flock with the resin to a gluey consistency this mix can be left slightly wet amp thin this will aid penetration into the small voids in the threads Screw the new bush into the wing Use a spanner on the small bolt to drive the bush Where an eccentric type is being fitted ensure it is oriented correctly Ensure that the bush is straight positioned centrally on the fibreglass lug and not cross threaded Leave to cure the resin has completely set the small drive bolt can be removed from the bush Inspect the centre bore of the bush and if necessary clean out any resin using a pick or an adjustable ream Test fit the new wing attachment bolt Lightly hand polish bolt before fitting If the fit is too tight an adjustable ream may be used to carefully re size the bore of the bush The ream must be adjusted to take a small cut to prevent from turning the bush Minimum material must be removed Fit the wing amp test the connection for free play as detailed
88. tanks Repeat the following steps for each tank you wish to calibrate gt Use the DOWNY or UP A buttons to select the tank that you wish to calibrate and press SEL gt Enter the approximate number of gallons or liters the tank can hold Figure 27 left In this case itis 65L Press NEXT gt Once you have confirmed that the tank you are calibrating is empty press START Figure 27 right gt Follow the on screen instructions until the completion of your fuel calibration Be aware that if you make a mistake you can only totally clear the calibration for that tank so you have to start the calibration for that tank at the beginning again DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 59 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 gt At the completion of your fuel level calibration the EMS D10 will present you with a table of values in the format pour mV gallons litres If you wish record these numbers for later reference however there is no way of entering them into the EMS 50 it is not required gt Repeat this procedure for the other fuel tank CAUTION There is often a degree of friction within the gauge sender Tap gently with a finger after adding fuel to maximise accuracy of reading WARNING Before removing clamps on the fuel line make sure all fuel lines are connected On removal of clamps check that the fuel lines are not damaged and return to their orig
89. to strain bend or damage any wires or lines DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 180 of 223 Jabiru Aircraft tc While working within the instrument panel ensure that the starter motor system or main battery is disconnected so that the motor cannot be started accidentally via a short or similar OA ED PANEL 2156 CARBON VERSION P No SADZO0BTN AL VERSION P No SAD2DBZN 174 sage 110 92 5 gn WEL GAUGES p BASIC PANEL INTERCOM CARBON VERSION P No 54020834 B AL VERSION BAD20B4N o e 7 2 Le ge s VHF Ba de Pm On 4 40 P VL DNE ais GARMIN 296 OPTION HEADER TANF LUPAN LEVEL WARNIHG OPTION THIS ORANG OOP TREAT AHG HUST BE COPIED WITHOUT THE CONSERT OF PTY LTO ACH 010 788 973 NOTE 1 ALL PANELS SUPPLIED 1TH ALL HOLES GUT PLUGS SUPPLIED HOLES 3 MATL Zmm AL SHEET OR LATUP 6 LATERI AP ABREG LASS WITH BUNDABERG 4870 Figure 113 Instrument Panel Layout Type 1 se 7 N DYNON EFIS D100 TAS E 4 eu M OO Ow 7 OLP OLT nce gt ee 9 T TARH
90. way This method is faster than the previous but has the potential for spilling a lot of fuel You also still need to drain fuel from the header tank via the engine fuel line e f the fuel has been drained out using the wing fuel drains then a small amount of fuel needs to be added to replace the unusable fuel Add 1 5L to each wing tank to replace the unusable fuel Note that this does not need to be done if the fuel was drained by method 1 Check that the fuel drains are not leaking after re installation e Next all the fuel lines from each tank need to clamped off so that fuel does not flow between tanks or to the header tank Use fuel line clamps as shown in Figure 25 DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 58 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 Figure 25 Fuel Line Clamps Before starting the fuel gauge calibration the aircraft must be laterally left right level See the Flight manual for the levelling datums e When ready to start the fuel calibration turn the EMS on and do as follows Enter the EMS menu by pressing any button below an EMS main page and pressing MORE gt SETUP gt MORE gt FUEL You are presented with the screen shown Figure 26 The menu reflects the number of fuel tanks selected in the Global Parameters Setup If you do not see the correct number of tanks here go back to the GLOBAL section of the SETUP menu and set the correct number of
91. where the rearmost edge of the aircraft is aligned with the front of the non hinged side of the control This is the critical point where a control jam becomes possible Any control which has a critical overlap of less than 2mm should also be treated as having a point of overlap as defined by this bulletin e Control clearance This is the working clearance between the control amp the aircraft e Control gap Best shown on Figure 13 left If the control passes the point of overlap a gap opens between the aircraft and the control A gap like this combined with excess flexing of the control surface hinges will lead to control surface jamming DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 47 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 Jammed control overlap rear edge of hinge deflection Aircraft in aircraft lines up with the with the control at the this case the front of the non hinged side Control in this point of overlap results wing of the control case an aileron in jamming Control at the point of Figure 11 Normal and Jammed Control Illustration 6 17 1 Inspection A e This inspection is to check if the controls are configured in such a way that there is a point of overlap as shown in Figure 11 At noted above the point of overlap is the critical point at which severe control jamming becomes possible Check each control b
92. 0 230 D 868 08 May 2014 Page 101 of 223 Jabiru Aircraft tc e Reverse procedure above for installation e Loctite 620 must be applied to the assembly screws for the aluminium housing Clean the threads in the aluminium parts using a 4 UNC tap Use compressed air or similar to blow out all blind holes to remove all debris f re using hardware thoroughly clean cap screw threads using a wire wheel or similar to remove all residual thread retaining compound If new hardware is being used thoroughly clean all threads using aerosol tool cleaner or similar Apply a bead of Loctite 620 to each screw and to each female thread Beads should be approximately the size of a match head Assemble the parts using the solid laminate torque specified in Table 2 e Ensure fresh nyloc nuts are used Pats List PART NUMBER MACHINED HOSE LEG BUSH 147 0 75 UNC CAP E SREI AT WAS SHER 14 NYLOC NUT END FLATE MACHINED HOSE LEG HOUSING 24 BOLT 5 MACHINED NOSE LEG HOUSING OUTER WASHER 1 BARGES MACHINED LEG HOLSING INNER BACKING PLATE R S 1 1 SAMIICOO BRACING 5 MACHINED NOSE LEG HOUSING 12 640036004 VERTICAL PLATE MACHINED NOSE LEG HOUSING WITH CENTREING NC OR USE IM _ FAMILY FLISEL AES UPPER SEC TION OF PED iT BE CUT OFF USE LOWER HOLE WHEN MOUNTING FIREWALL
93. 1 0 230 D 868 08 May 2014 Page 139 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 8 10 Trim Control Cables 8 10 1 Description e 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 8 10 2 Control Cable Removal y Unbolt the connections rod end bearings at either ends of the cable Unbolt the clamps at either end of the cable Where required remove any ties etc used to restrain the cables in the aircraft Tie a string or light wire to one end of the cable Draw the cable out of the aircraft leaving the string wire in place to allow installation of a replacement part 8 10 3 Control Cable Inspection e The Control Cable may not be repaired or removed without reference to Jabiru Aircraft Pty Ltd or our approved local agent e Details of inspections required for control cables are given in Sections 8 1 5 and 0 8 10 4 Control Cable Installation e Reverse the steps detailed above for installation e Ensure the required inspections are carried out and the cable is clamped securely DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 140 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 9 Rudder Control System 9 1 RUDDER Pedal SYSTEM Type of Maintenance Level of Certification LSA repairman inspection or
94. 149 9 6 149 10 ENGINE amp ENGINE 151 10 1 COW eaten 151 10 2 153 10 3 EKDE nem eee eects 154 10 4 155 10 5 ENGINE MOUN 156 10 6 sels ci 157 10 7 ENGINE THROTLE CONTBOL 157 10 8 v e V YEE OO 7 159 10 9 AIR INTAKE SYSTEM pneri ipu maps quan dut P 160 e 162 S 164 1012 EXTREME CLIMATIC CONDITIONS S 166 11 E 5 m 168 11 1 sello 168 11 2 c 170 11 3 FUEL TANK 172 11 4 alU R E E E EE 174 11 5
95. 2 Placards General Table 16 General Decals Compass Card For N 30 60 E 120 150 8 210 240 W 300 330 Steer Correction for radio on in standby mode Date 5123024 Fit in compass card holder attached to compass Baggage P No 5111154 LOAD SEA S DO LOAD AFT OF THIS REFER TG SECTION 5 OF FLIGHT MANUAL WHEN LOADING TO D 2v AIRGRA Position as noted in Flight Manual DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 208 of 223 Jabiru Aircraft Loading Limitations 600kg P No 5A073A0D J230 D Engine Oil Details P No 5A008A0D 1 OFF Attach to upper cowl beside oil door or to oil door itself Trim Position OSE DOWN RIM NOSE UP P No 5A031A0D LL 1 OFF Fit to centre console beside of elevator fwd stop between trim levers Trim Position P No5024094 NOSE DOWN NEUTRAL TRIM NOSE UP BRAKE ON lt Fitted on the Top the Beam Beside the control Brake On 5A031BOD _ Fit to centre console beside brake lever arrow pointing aft Carby Heat P No 5A030A0D Integral to Instrument Panel Face No Step 5A006A0D Qty 2 required Fit to top of main wheel spats Earth on Exhaust i i P No 5029094 Attach to the lower fuselage on the pilots side immediately above the exhaust outlet pipe DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 209 of 2
96. 23 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 5A007A0D Fit to outside of oil door in upper engine cowl Owner s Manual Door Open LHS Door Open RHS P No 5028094 Fitted to the outside of RH Door Above the Door Catch Level Loading Limitations BAGGAGE COMPARTMENT P No 5A037A0D 18KG MAXIMUM BEHIND EACH SEAT BACK TOTAL BAGGAGE CAPACITY 36KG Fit to right side of fuselage between window and beam No Smoking P No 5A035A0D Fit to instrument Fuel Contents 5A022A0D Where Equipped Fuel Tap Position P No 502319N Where Equipped Fitted on the Main Beam in front of the Fuel SELECTOR Valve Fuel Tap Position P No 5023094 Where Equipped a Fitted to the left hand of the console adjacent to the fuel valve Choke Cable P No5051094 Where Equipped PULL ON Integral to Panel Face at the base of the choke cable DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 210 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 Carb Heat P No 5026194 CARB HEAT Where Equipped PULL ON Integral to Panel at the base of the CARBY Heat Cable Static Port staric crear VENT KEEP CLEAR P No 5043094 Pe to LHS of Vertical ll In line with Static Tube Door Lean P No 5A013A0D to of doors Fuel Grade UEL
97. 3 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 Parts and Material Type of Maintenance Level of Certification following procedural steps describe how to install the leg Refer to applicable paragraphs for installation of the individual components jm Offer the beam to the fuselage and install clamp and bolts nuts 2 OFF Do not tighten at this stage 2 Locate top end bolt install and tighten nut Use the torque value given in Table 2 as guidance however do not crush the rubber bush completely Aim to compress the visible edge of the rubber to about half its unloaded thickness 3 For the curved undercarriage leg show in Figure 46 tighten outboard clamp bolts nuts 2 OFF Torque to solid laminate value give in Table 2 4 For the straight undercarriage leg shown in Error Reference source not found follow the additional steps below Check that the flock clamp bed applied to the leg is in place and fits the outboard leg clamp closely If the flock has degraded clean off any loose pieces Flock the clamp to the leg Flock made by mixing Jabiru Epoxy resin and cotton fibre flock to a gluey consistency Do not tighten bolts while the resin is wet After the resin has cured around 24 hours possibly more in cold climates fully tighten the outboard clamp bolts Torque to solid laminate value give in Table 2 Note straight legs are handed ensure the legs
98. 37 6 6 GENERAL INSPECTION GUIDELINES 37 6 7 ENGINE 38 6 8 PROPELLER 100 HOURLY ANNUAL 38 6 9 ENGINE COMPARTMENT 100 HOURLY 38 6 10 FUEL SYSTEM 100 HOURLY ANNUA 40 6 11 LANDING GEAR 100 HOURLY ett ce yt 41 6 12 AIRFRAME 100 HOURLY 42 6 13 CONTROL SYSTEMS 100 HOURLY ANNUAL sseseeereee eene netten neret nene nens 43 6 14 LUBRICA TIO M T 43 6 15 SPECIAL INSPECTIONS WEIGHING ntes rk tatnen abeat a abeo eter 43 6 16 SPECIAL INSPECTIONS CONTROL CABLES ssssseseeeeee eene neret nennen nnns 46 6 17 SPECIAL INSPECTIONS CONTROL SURFACES wesssssecssssvsssscetvascesestactusesesossecanedessssustastunsnsssuarsedavekessdueneensthnendatvennvenss 47 6 18 SPECIAL INSPECTIONS MAIN WHEEL 52 6 19 SPECIAL INSPECTIONS FUEL GAUGE DECAL SETUP 2 1 1 2 4 2 042 2 0 41 00000000 00 00 000 0 0 00000000000040000444 55 6 20 SPECIAL INSPECTIONS FUEL SENDER 57 DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page of 223 Jabiru Aircraft tc Aircraft
99. 5 100 140 8 3 11 71b ft Up to 18 Ib ft AN6 N A Up to 24 5 AN4 Propellor 72 6lb ft N A e These values relate only to steel nuts on oil free cadmium plated threads e For Engine Bolt Torque Values see Engine Maintenance Manual e The above values are recommended for all installation procedures contained in this Manual except where other values are stipulated e The above values are not to be used for checking tightness of installed parts during service DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 17 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 4 Maintainer Requirements following are recommended as the minimum requirements for someone carrying out maintenance amp inspection on Jabiru Aircraft 4 1 Facilities e An enclosed workspace with sealed floor adequate lighting compressed air amp mains electricity 4 2 Training e For engines completion of an approved instruction course specific to Jabiru Engines Approved courses include those offered by Jabiru Aircraft Australia or by local Jabiru Aircraft representatives e Airframe completion of an approved instruction course specific to Jabiru Aircraft Approved courses include those offered by Jabiru Aircraft Australia or by local Jabiru Aircraft representatives 4 3 Rating e Commercial maintainers must hold suitable ratings as required by their local Airworthiness Authority 4 4 Experience
100. 6 17 must also be carried out at any time when the control rigging may have been altered i e if a control is removed repaired adjusted 6 5 Servicing e Servicing requirements are shown in Section 6 4 below The following paragraphs supplement this table by adding details not included Note Inspection Requirements are detailed at Paragraph 3 5 6 5 1 Engine Servicing Schedule 6 5 1 1 PRE FLIGHT e Refer to Flight Manual 6 5 1 2 OTHER SERVICING e Refer to Engine Maintenance Manual 6 6 General Inspection Guidelines all possible circumstances cannot be listed here the following is provided as guidance only A critical trained eye 1 required and inspections should include but not be limited to the following e MOVING PARTS Check for 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 e METAL PARTS Check for security of attachment cracks metal distortion broken welds corrosion and any other apparent damage e WIRING Check for security chafing burning defective insulation loose or broken terminals heat deterioration and corroded terminals e BOLTS IN CRITICAL AREAS Correct torque in accordance with torque values given in the chart in Section 3 2 when installed or when visual inspection indicates the nee
101. 7 Figure 37 J230 D Wing Assembly Sheet 2 Ser 13 77 Figure 38 J230 D Wing Assembly Sheet 3 Ser 13 78 Figure 39 Light Installed Left 4 Slotted Hole In Housing 80 Figure 40 Night VFR Lighting Aim 80 Figure 41 Wing Inspection 81 Figure 42 Wheel Spat nennen nnne rni nnns nna 85 Figure 43 Main Leg 5 va Sd Tua di cama 88 Figure 44 Main Wheel 88 Figure 45 Directional Brake Disc 89 Figure 46 J230 D Main Undercarriage Assembly 2 92 DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 6 of 223 Jabiru Aircraft tc Aircraft Service Manual Figure 47 Nose Wheel Hub 95 Figure 48 Nose Leg Soft Link Assy J200 Family ccccccccccsssseseeeeeeeeeeeeeeeeeeeeeesseeeeeeeeeeeeeseuaaeeeeeeeeeesaaas 96 Figure 49 Nose Leg Housing 99 Figure 50 Nose Leg Assy Long Trail 4160 Family 100 Figure 51 Fabricated Nose Wheel Yoke 100 Figure 52
102. 8 2 5 5 FLAP BALANCING The flaps on the J160 J170 are not balanced DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 129 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 8 2 5 6 FLAP RIGGING 170 5 MODEL he J170 SP has a special requirement for its wing flap rigging To attain the required clean Stall speed the J170 SP must have its flaps rigged using a special template 8206Q5N 8 2 6 Flap RIGGING As Per Template 1 With the flap selector lever 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 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 and 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 DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 130 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 8 3 X Elevator Control System 8 3 1 Elevator Control System 8 3 1 1 DESCRIPTION e he elevator control system is comprised of a control column a
103. 868 08 May 2014 Page 196 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 13 Electrical Systems 131 Electrical Power Supply System e Electrical energy for the aircraft is supplied by a 12 volt direct current single wire negative ground electrical system e A 12 volt battery supplies power for starting and furnishes a reserve source of power in the event of electrical power system failure engine driven Alternator is the normal source of power during flight and maintains a battery charge controlled by a voltage regulator A 200 Watt alternator is fitted e he following paragraphs provide brief descriptions of the elements of the electrical system They should be read in conjunction with the Wiring Diagrams below e Due to space constraints not all different variations are shown herein When ordering spare parts provide as must detail as possible part description aircraft model serial number etc to Jabiru to ensure accurate part identification 13 1 1 Wiring Diagrams e he wiring diagram for a standard aircraft is shown in Figure 124 and Figure 125 e he wiring diagram for night VFR lighting is shown in Figure 126 and Figure 127 DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 197 of 223 EMAL oe sa sa s sa 3 pipi 34 HOO LL Bia HOMES
104. ALE PIL COPIED WITHOUT THE CONSENT OF LTO 1 1 DATE GENERAL OLERANCES WHOLE 010 7856 973 H ONE DEC 025 TOW DEC 0 05 ANGLES 0 5 TLE 3 HINKLER AIRPORT PITOT STATIC WATER TRAP ASSY 5A040A0D 4 PLASTIC SHEET 1 or 1 M Figure 120 Pitot Static Water Trap DIMENSIONS IN MILIMETRES PROJECTION STATIC amp TUBES ATTACHED TO ASI WITH WIRE TIES 50451004 2 2 5044094 assy 1048094 STATIC ASSY wem A C N 010 786 973 34 e STATIC ASSY SHEET Figure 121 Pitot Static System Water Trap Locations DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 187 of 223 5 AE io I Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 12 5 3 Static Pressure System Inspection amp Leakage Test e The following procedures outline inspection and testing processes for the static pressure system e Before testing ensure the static system is free from entrapped moisture by checking the low points of the system as noted above e Ensure the static system is free from restrictions by blowing through it Restricted flow must be rectified immediately e Ensure no alternations of airframe have been made which would affect the relationship between air pressure in the static pressure system an
105. ALVE WING INSPECTION PANEL ASSY MACHINED S BUSH FLAP HINGE INNER UL WING T6ADD 3 2 AILERON ASSY L S T JEBE u CUICK DRAIN CUT THAU WING amp TANK SKINS 4 VIEW A THOROUGHLY MIX FLOCK MIN 3 MINUTES BOND IDE DRAIN HOUSING IN PLACE WITH FLOCK NG UNDERS ENSURE NO GLASS DUST ENTERS TE SKIN BOND HINGE TO SKIN USING FLOCK MINIMUM FILLET RADIUS 10mm OVERLAY WITH 3 PIECES AF303 CLOTH EACH PIECE EX TEND 76mm MIM FWO BOTH SIDES OF HINGE DIMENSIONS DETAIL J PROJECTION de IN MILLIMETRES DO NOT SCALE WU T r i A 0 FLAP HINGE INSTALLATION i HINKLER AIRPORT Figure 37 J230 D Wing Assembly Sheet 2 Ser 13 DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 77 of 223 Jabiru Aircraft tc BOND HINGE MOUNT INSIDE TRAILING EDGE USING FLOCK 1 LAYER AF303 GLASS r POSITION HINGES TO ACHIEVE CONTROL GAP AS SHOWIN BOND HINGE MOUNT STRPTO LOWER WING SKIN USING FLOCK To lu WAN Se 5997755 pps E Moe SECTION VIEW 0 0 AILERON CABLE HINGE amp MOUNT INSTALLATION END VIEW FROM INBOARD END MEASUREMENT REFERENCES AIRFOIL SECTION s 1 r s Irr TRIM FIT M ON ASSY Te ITION FILLER AS SHOWN ON SH J m HOLE THRU SKI NS
106. ANALYSIS tnter tette ttt tte 202 13 5 eM TARNATION 202 13 6 us 204 15 PAINTING S FINISHING n iieri 206 15 1 206 16 PLACARDS 208 16 1 PI eesis 208 16 2 PLACARDS GENERAL ia E Ra aE aE EEEE 208 17 FAIRINGS e E 212 17 1 DESORPTION 9 212 18 FEEDBACK FORM 213 19 PROPELLER SERVICE 213 19 1 CERTIFIED PROPELLER 213 19 2 APPROVED ING TALULA TIONS 213 19 3 213 19 4 INSTALLING amp SERVICING 213 19 5 213 19 6 TO REMOVE EXISTING PROPELLER d eu 215 19 7 TO ASSEMBLE AND REPLACE PROPELLER ASSEMBLY 215 19 8 PROPELLER BALANCING 215 20 APPENDIX B WOHRSHEE LES erence 217 DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 5 of 223 Jabiru Aircraft tc Aircraft Service Manual 1 1 Table Of Figures Figure 1 J230 D General
107. ATS INSTALLLED ANA 1 14 FLAT WASHER WWW CASTLE NUT 5 STEERING LINK MACHINED LEG 4 SEATER 1 61910044 RETAINING COLLAR FRONT SUSPENSION FLAT WASHER 1 2 THICKNESS 30 1 ___ REBOUND RUBBER MACHINED YOKE NOSE LEG 5 MW NYLOC NUT ee Figure 50 Nose Leg Assy Long Trail 4160 Family ei ot E 3 d 12 es rome mew Jau fr pae uxr Fs eee aen Es eei mmm i EN et wem _ SUSPENSION Figure 51 Fabricated Nose Wheel Yoke Assy DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 100 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 7 3 17 Nose Leg Housing 7 3 17 1 DESCRIPTION The nose leg housing is a structure bolted on to the lower middle of the firewall The nose leg tube runs in Ertalyte bushes which are bonded into this housing e Some models use a housing moulded from fiberglass while others are fabricated from bolted aluminium 7 3 17 2 REMOVAL Required Tools Spanners Socket Wrench Screw driver Heat gun Parts and Material Type of Maintenance Level of Certif
108. CKTED OTHERMSE 05 AG C x TITLE R LATCH ASSY RS TADOT poems ASOETALED BUNDABERG A879 200 lx SHEET Pj Figure 34 J230 D Door Latch Mechanism Assembly 1 7A014B0D 1 8055 DOOR CATCH 2 7ADIACOD 2 TOP DOOR CATCH 85204 O RING 4 CIRCLIPEXTODIA 1j F DRILL 20 HOLE amp FIX BOSS INTO DOOR FRAME WITH FLOCK SECTION A A OPEN POSITION DIMENSIONS D uU SCALE 1 6052005 PROJECTION SCALE THIS DRAWING IS COPYRIGHT AND MUST BE PROJECTION MILLIMETRES COPIED WITHOUT THE CONSENT OF AVTECH PTY LTD 1 1 DATE GENERAL TOLERANCES WHOLEND SEDS f nawn 010 786 973 Fe DWG No ONE 025TWO DEC 005 ANGLES 05 OR HINKLER AIRPORT ig Um soma sap BUNDABERG 4670 DOOR CATCH ASSY INSTALLATION Figure 35 Top Door Catch DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 73 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 7 1 6 Seats Required Tools N A Parts and Material Type of Maintenance Level of Certification 7 1 6 1 DESCRIPTION e 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 pan
109. D 12 DATE GENERAL TOLERSNCES WHOLE 0 5 ONE DEC 0 25 TWO DEC 0 05 ANGLES 0 5 A C N 010 786 973 TIME DWG No ATERIAL HINKLER AIRPORT BRAKE MASTER CYLINDER amp LEVER ASSY gA0 7A0D 3 Figure 53 Brake Master Cylinder amp Lever Assy Type 2 7 3 19 Hydraulic Brake Lines Heplacement brake hoses if required LSA repairman inspection or maintenance 7 3 19 1 DESCRIPTION Jabiru Aircraft use flexible black nylon brake hoses On most models they are connected to the master cylinder via a tee piece typically located in the main undercarriage channel under the belly of the aircraft 7 3 19 1 1 Removal Repair amp Installation e Repair is limited to replacement 7 3 20 Wheel Brakes 7 3 20 1 DESCRIPTION e Wheel Brake Assemblies consist of a disc which is attached to the main wheel hub with through bolts and a floating brake caliper assembly e There is 1 calliper fitted to each wheel DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 104 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 7 3 20 2 REMOVAL Required Tools Spanners Socket wrench Container Parts and Material Type of Maintenance Level of Certification LSA repairman inspection or maintenance o remove from the wheel unbolt the brake cylinder from the backing plate remove from the aircraft disconnect the brake line Use a container to collect the brak
110. Due to space constraints not all different variations are shown herein When ordering spare parts provide as must detail as possible part description aircraft model serial number etc to Jabiru to ensure accurate part identification 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 SSH NOT 8 ELT bu l 1 a aem 4 _ Ko ial EE a Lan SS an i i 1 7A TUM aa alee N up A PE ME rs NS a ea SE See ee T y T t3 1 36 4 1 5 ner om sw REF TETTE 1180 HIGH AILERON STOP 255 1 TAE dum LS ONLY nu Eu WIR un caa tiis ae Sero Figure 55 Aileron System Schematic Type 3 8 1 2 Control Column 8 1 3 Description e Refer to drawings below Error Reference source not found Error Reference source not found and Figure 55 e Jabiru Aircraft have a single control shaft running between the seats on which the control stick is mounted DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 109 of 223 Jabiru Aircraft
111. E RESIN HALVES amp FIN CHANNELS WITH COTTON FLOCK amp LEJO EPOXY BESOIN 1 1 8 05 SECTION 155 DATE E Tu arty pem fos _____ _ __ RUDDER FIN 2A046A0D 1 as oera ee eunana J160 FAMILY Figure 88 Typical Rudder Installation Alloy Hinges DOCUMENT No JTM001 0 230 D 868 08 May 2014 147 of 223 Jabiru Aircraft tc e T E coment Ge DMENSONS wuuETES oo RUDDER OUTLINE RE HINGE GRACE FN CHANNEL Tr _ OVE HINGE RADIO ANTENMA BRACE D FIT FIN CHANNEL TO DETAL VEW B REFER TO DETAR VIEW B X 1 1 x BOMD BRACE TO CHANNEL USING COTTON FLOCK amp LC3600 EPOXY RESIN t j Le HS a d j ps 1 j j y E 1 5 HINGE PIN RETAINER A EE SS SSS f Ow HINGE il DETAIL VIEW EE HINGE BRACE DETAILS y PLACE STOPS TO LIMIT RUDOER TRAVEL FILE STOP FLAT FACE FOR RUDDER HORN 4 Lo STOP AGAINST USE TRAVEL TEMPLATES TO DETERMINE RUDOER 7 m C
112. ENGINE COMPARTMENT TO BE BODY 2072014 ASSEMBLED AS DETAILED ON DWG 4A261A0D FUEL SIGHT GAUGE OO 2 ALL FUEL LIMES TO BE SECURED BY ZIP TIES 70 ASSY 4820023 FUEL CAP SOCKET _ OTI ADIACENT STRUCTURAL ELEMENT MORE THAN Fu P Ma 2078014 77 7 400 mm PITCH WHEN RUNNING THROUGH 2 ENCLOSED SPACES x d gt 3 FUEL LINES TO ROUTED WITHOUT ANY WINKS OR F C AR TRAPS OR INVERTED U s IN THE LIMES WEHT FIT TD FUSELAGE BELLY Pa DRAIN SUMP Sigh 2080014 1 FUEL DRAIN VALVE 4 PMOO49N FINGER FILTER 4827004 C FROM a UNE FROM FINGER FILTER P Ho 4827004 REF DETAIL A FOR GASCOLATOR OPTION IN PLACE ON EACH SIDE TEE PIECE ASSY 4822023 2 TOR P Ho 49472044 aon HEADER DUAL INLET FUEL TAP 55 P No 44121 A400 DRAIN a TEE PIECE ASST 922023 2 eye HEADER TANK ASSEMBLY DETAIL amp GASCOLATOR 4A123A00 SINGLE LINE FUEL TAP ASST FALTER t 215 441720400 CARERIRRE TOR ph gt ENCGIME MOUNTED MECHANICAL FUEL PUMP PG10332N j FIREWALL FITTING PANS 4003094 IB 1 47 HOSETAL FITTING 220069 ti X
113. F TOGGLE SWITCH 22 ALTERNATOR REGULATOR 40 PIO316N 23 FLAP MOTOR 41 HEADER TANK LEVEL SENSOR OPTION PW4A01N 6 ETC SWITCH ae 42 SPARE 7 FLAP SWITCH 3A062A0D 25 WARNING LIGHT GREEN 43 VOLTAGE REDUCTION RESISTOR PI3A014A0N 8 CIRCUIT BREAKER 15A 5 44 TEST SWITCH 10092 9 CIRCUIT BREAKER 10A 26 WARNING LIGHT RED 45 WARNING L E D PISA004A0N FUSE 1 5 27 FUEL PRESSURE SWITCH ELECTROLYTIC CAPACITOR PI3A053A0N 58 OIL PRESSURE SENDER 29 4 60A BLADE FUSE HOLDER 056 30 40 STD BLADE FUSE PI3A057A0N 31 4 5 OIL TEMPERATURE SENDER 32 4 RELAY 40ADC PI3A054A0D 33 d NOTES 1 WIRING MIL SPEC M 22755 16 16 9 UNLESS SHOWN OTHER 2 STARTER CABLE 5 16mm 50 X SECTIONAL AREA SOFT LAV 3 WIRING SENSORS SUPPLIED BY MANUFACTURER AS PART OF INSTRUMENT 4 RADIO WIRING TO MANUFACTURERS SPEC 5 XPNDR WIRING TO MANUFACTURERS SPEC amp INSTRUMENTS DETAILED IN AIRCRAFT BUILD SHEET T WIRE EMS EFIS TO MANUFACTURERS INSTRUCTIONS FOR NIGHT LIGHTING WIRING SEE DRAN IAG 9 EARTH EMS DIRECT TO FIREWALL EARTH TAG WHERE EQUIPPED 10 STROBE WIRING LOOP POWER SUPPLY TO STROBE 3 TIMES THROLIGH FERRITE AS SHOWN FIT STROBE BOX FORWARD FIREWALL USE SHIELDED WIRE STROBES ENSURE SHIELD 15 CONTINUOUS BETWEEN BOX AND STROBE EARTH STROGE BOX AND STROBE CABLE SHIELD AS SHOWN
114. HES IN J E aa TOP EDGE TUBE 1 SUE OS DEEP ALL BURAS T 1 rt OM EOM y 1 T pa A EN Y 2 725484 4 1 nnd a A B l im d a ee he aa f u um gt 14 ff 40 SCREW LEADER ENDHTTNG od BETWEEN SCREW amp INSIDE e s OF FILLER SOCKET SCREW i 7 THRU TOF CLIP amp SPEED AS m aem Enero is 41 3 L 2 DIMEN SONS THE GANG 1 OPT AHD RUT NOT SCALE 4 Lb COPIED WITHOUT THE CONSENT OF A TECH PTY LTD HTS 55 GATE T rums ROM ars PROJEGTION MILLIMETRES DONOTSCAE luumsuwuEss 51 onan ACH T 1 P REFER DEAS APPR BUNDABERG 4570 Figure 110 Vented Fuel Cap Assy 11 5 Fuel Shut Off Valve Type of Maintenance TITLE ose VENT ED WING FUEL TANK ASST Level of Certification LSA repairman inspection or maintenance DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 175 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868
115. Hoist only from this point ensuring that cables ropes do not mark the top of the fuselage at corners above wing support brackets e Refer to sections below for details on procedures for fuel draining wing removal etc mad iim 5 2 4 Levelling Longitudinal Levelling e For longitudinal levelling use a spirit level on the lower door sills or For longitudinal levelling use a spirit level on the trim decal on the centre console DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 27 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 Lateral Levelling Apply spirit level to the flap drive cross shaft Apply a spirit level across the aircraft referencing the join line of the cowl top amp bottom halves 5 2 5 Parking e 115 strongly recommended that aircraft are stored in hangars wherever possible to minimise degradation caused by the elements and pests e Parking precautions depend principally on local conditions As a 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 e Whenever the aircraft is not active or being maintained it is strongly recommended that the following points are covered to prevent contamination and pest ingress Pitot tube Static vent Engine air inlet Exhaust outlet Fuel tank vent s WARN
116. ING Ensure that fuel tank vent covers are not tight fitting A tight cap can prevent fuel vapours escaping pressurising the tank and severely damaging the tank and wings for wing tanks CAUTION Equip all covers with tags or other high visibility devices to minimise the chance of inadvertent operation with covers still fitted 5 2 6 Tie Down When tying the aircraft down in the open head into the wind if possible Secure control surfaces by tying the control handle back firmly with the seat belts Then Tie ropes to the top end of each wing sirut or to the strut tie down lug if equipped Secure opposite end of the ropes to ground anchors located at approximately 30 degrees to the vertical outboard of the top wing attachment point Ensure that the ropes have sufficient slack to not strain the wing 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 5 3 Storage 5 3 1 Flyable Storage Flyable storage is defined as a maximum of 30 days non operational storage e Ensure that the engine has been stopped by turning off the fuel valve thereby not leaving any fuel in the carburettor bowl e Every 7th 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 p
117. INSTALLATION e Ensure all old epoxy resin has been removed from the fuselage sealing strips around the window frames e 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 of Epoxy 4 Flock around the outer edge of the windscreen e Place windscreen accurately over the sealing strips and locate with one screw top and bottom e Fit other screws e Take care not to crack windscreen when installing DO NOT over tighten screws cracking will result 7 1 2 ShockWatch Indicator PPM Required Tools Tools required for the checks listed Parts and Material Replacement parts if required Type of Maintenance Line Maintenance Level of Certification A amp P or LSA Repairman Maintenance LSR M Return to Service A amp P or LSA Repairman Maintenance LSR M e The installation of a 5g re settable ShockWatch indicator is recommended for all aircraft These indicators are fitted to any vertical surface of the airframe such as the seat back the wing carry through beams or whalebone The instrument panel is a suitable location in many cases however in some aircraft models resonant vibration of the panel can cause a premature trip A location in clear view of the crew is recommended for easy monitoring e When the airframe is subjected to a load of over 5g such as from a heavy landi
118. IONS cisci ixi iuto aad aaaeaii 15 3 1 UNIVERSAL FP ECIFICA MONG 15 3 2 TORQUE VALUES IN FIBREGLASS 17 4 MAINTAINER REQUIREMENTS nen roro 18 4 1 zs 18 4 2 ucdc 18 4 3 5 c 18 4 4 18 4 5 MTM ns 18 4 6 18 4 7 20 4 8 cs ee E R ee 20 4 9 SPECIAL TOOLS amp COMPOUNDS 21 5 CLEANING GROUND HANDLING amp STORAGE 24 4 4 4 244 4 4 4 4 4 25 5 1 ez NING a 25 5 2 R E E T ENEE 26 5 3 28 6 BINS EG IONS P P 31 6 1 SERVICE INTERVAL 31 6 2 getestet _____ 6____ 31 6 3 MANDATORY INSPECTIONS 4 LIFE LIMITED ITEMS eee eene 31 6 4 m 32 6 5
119. IS DRAWING IS COPYRIGHT AND MUST son agii COPIED WITHOUT THE CONSENT OF AVTECH LTD GENERAL TOLERANCES WHOLE 505 010 786 973 ONE DEC 0 25 TWO DEC 0 05 ANGLES 0 5 HINKI ER AIRPORT G No MATERIAL G 46 NOSE LEG STEERING RUBBER 6A046A0D 2 MAERA ASDETALED faper _____ 0 648 CONNECTION ASSY 1230 SERIES Figure 48 Nose Leg Soft Link Assy J200 Family 7 3 14 Nose Undercarriage Leg 7 3 14 1 DESCRIPTION e The nose gear comprises a steerable nose wheel mounted on a welded steel assembly with an aluminium wheel yoke and a rubber spring system e Several variations of the steel leg assembly have been used on different aircraft models e On earlier aircraft the wheel yoke is bolted together Figure 51 while later models use a 1 piece part e The steel tube is constrained within two Ertalite bushes mounted in a housing which is attached to the front of the firewall For some models this housing is moulded in fiberglass however for the majority an Aluminium housing is used e 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 Some models incorporate a rubber soft link between pedals and nose leg to improve ground handling nose wheel speed fairing wheel spat is standard equipment e Refer to Section 9 for views of the entire leg steeri
120. Indicator Table 10 Trouble Shooting Airspeed Indicator Pitot pressure connection not properly connected to pressure damaged line tighten Hand fails to response line from pitot tube connections Check line for obstructions Blow 99 out lines Test lines and connections for leaks Repair or replace Incorrect indication or damaged lines tighten connections hand oscillates Defective mechanism or leaking Substitute known good indicator and check reading Replace diaphragm Instrument Check panel shock mounts Replace defective shock mounts Hand vibrates Test line and connections for leaks Repair or replace Leak in pitot or static lines Check clamps and line connections for security Tighten clamps and connections replace tubing with flexible hose Excessive tubing vibration 12 5 9 Trouble Shooting Altimeter Table 11 Trouble Shooting Altimeter Static line plugged Check line for obstructions Blow out lines Substitute known good altimeter Defective mechanism and check reading Replace instrument Hands not carefully set Reset hands with knob Substitute known good altimeter Leaking diaphragm and check reading Replace instrument Compare reading with Pointers out calibration good altimeter Replace instrument Check lines for obstruction or Static pressure irregular leaks Blow out lines tighten Hand oscillat
121. Jabiru Aircraft Jabiru J230 D Variants MAINTENANCE MANUAL FOR JABIRU AIRCRAFT MODEL J230 D Serial Number XXX SAMPLE DOCUMENT No JTM001 0 230 D 858 DATED 8 May 2014 BIEU This Manual has been prepared in accordance with ASTM Standard F2483 as a guide to correctly and specifically maintain Jabiru Aircraft Model J230 D Serial 858 Other Maintenance Manuals for other configurations of the Jabiru J230 aircraft are not to be used for maintenance instructions for this aircraft It is the owner s responsibility to regularly check the Jabiru web site at www jabiru net au for applicable Service Bulletins and have them implemented as soon as possible Manuals are also updated periodically with the latest revisions available from the web site Failure to maintain the engine or aircraft with current service information may render the aircraft un airworthy and void Jabiru s Limited Express Warranty This document is controlled and kept with the aircraft compliance files at Jabiru Aircraft Pty Ltd and a copy is also kept at Jabiru USA Sport Aircraft LLC It remains controlled while in the aircraft compliance files Once this no longer applies the document becomes uncontrolled Should you have any questions or doubts about the contents of this manual please contact Jabiru Aircraft Pty Ltd 08 May 2014 Page 1 0f 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 Owner
122. LOWER LONGITUDINAL RIB Te DIMENSIONS THS DRAWING IS COPYRIGHT AND MUST BE 7 IN MILLIMETRES DONT ACME COPIER WITHOUT THE CONSENT OF LTD mrs ui ER AIRPORT DWG AS DESCRIBED iu 3A100A0D 1 Figure 129 Second VHF Antenna Installation J120 4160 Families DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 203 of 223 Jabiru Aircraft tc FLOCK FIBREGLASS ANGLE TO BULKHEAD FOR ANTENNA MOUNT IT 15 ACCEPTABLE USE BNC JOINER IN EN u NOTE VHF ANTENNA INSTALLATION 15 RUM ANTENNA COAX 90 SHOWA UHF ANTENNA IS FITTED WITH BEFORE CURVEING AROUND TO ENTER LOWER GROUND PLANE ABOVE LONGITUDINAL PROJECTION 4B 3 DIMENSIONS AVTECH PIL THIS DRAWING 18 COPYRIGHT AND MUST NOT ee 4 4 08 IN MILLIMETRES TT COPIED WITHOUT THE CONSENT OF AVTECH PTY LTD NTS DATE A C N 010 786 973 HINKLER AIRPORT E BUNDABERG SECOND VHF ANTENNA INSTALLATION J230 J430 100800 1 Figure 130 Second VHF Antenna Installation J230 Families 13 6 Transponder Type of Maintenance Level of Certification 13 6 1 Description transponder is optional equipment for Jabiru Aircraft This system consists of the transponder itself mounted to the instrument
123. LY FLOCK MOUNTING PLATE TO REAR FACE OF CENTRE CONSOLE ENSURE BEARING AXIS IS PROPERLY ALIGNED WITH CONTROL COLUMN WHILE FLOCK IS CURING APPLY 45 FLOCK BEAD AROUND THE EDGE OF THE PLATE APPLY LOCTITE 243 TO THREADS DURING FINAL ASSEMBLY ROTATE ECCENTRICS FOR ADJUST STOP POSITION U THIS DRAWING 18 COPYRIGHT MUST CON 2 WITHOLIT THE CONSENT AV TECH PIT LTD 10 786 973 AIRPORT BUNDABERG 4670 TITLE ASSY CONTROL SHAFT END HIGH AIL 5 SKF BEARING Figure 63 Aileron Stops Type 3 DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 118 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 8 2 Wing Flap Control System 8 2 1 Wing Flap Control System 8 2 1 1 DESCRIPTION For aircraft with electric flaps the control system comprises a switch mounted on the instrument panel a position indicator mounted on the windscreen door pillar and an electronic linear actuator driven common shaft assembly with pushrods connecting to the flap control surface horns e Models with manual flaps retain the same shaft assembly inside the cabin driving the flaps via pushrod however in these aircraft manual lever located above the pilots door drives the system e Refer to sections below for details on removal maintenance and installation of the various parts of the system e Due to space co
124. NE FROM STATIC SOURCE IN TAIL HOLD IN PLACE WITH LOCK WIRE B 810 HOLE DRILLED CONNECT OUTER OF TUBE PANEL MOUNT AIR INSTRUMENTS ASI ALT me NOT LOCK WIRE WELD TUBE E TOPLATE DETAIL VIEW A gid HOLE IN PLATE 20 2 PLACES o nid minia 26 5 HOLE IN PLATE TO AIR INSTRUMENTS PLACE 0 25 OD x 0 040 NOM THICK S S TUBE DIMENSIONS M THIS DRAWING iS COPYRIGHT AND MUST NOT BE in MILLIMETRES SCALE P L COPIED WITHOUT THE CONSENT OF AVTECH PTY LTD A C N 010 786 973 05 TITLE 0 DS SANT ALTERNATE STATIC SOURCE ASSY 5 082 00 1 SHEET 1 or 3 JAA Figure 123 Alternate Static Source Assy 12 7 Analogue Tachometer Type of Maintenance Level of Certification 12 7 1 Description e Jabiru Aircraft may be equipped with an analogue tachometer or a digital RPM read out as a part of an engine monitoring system e Analogue tachometers are driven by a variety of sensors depending on the aircraft model In some the sensor is positioned so that the teeth of the flywheel ring gear pass close by and produce a signal In others the same sensor reads off metal tags bolted to the flywheel Finally in some aircraft a sensor is mounted on the alternator mount plate and produces a signal from the ignition magnets e Refer to the Engine Maintenance Manual for additio
125. NERAL VIEW a y 2 7 E 17 FA n tw pe 7T 65 1 fil E f LEVER HORM OF ELEVATOR E 2 12 6 T y 15 If d 113 CR TA HE ue J are 15 Se Ww e L 4 a 9 Se t Qa e xe N 4 2 e ELEVATOR FWD CONTROL ASSEMBLY e cm s ex 3 7 ELEVATOR REAR ASST THES OOP TAHT AHO MUST RIOT SCALE Lt ROS iiie xm AVTECH COPIFTPATTHOLUT THE GORNEENT OF AVTEEH PTY ITI TES DATE HINKLER AIRPORT ELEVATOR CONTROL SYSTEM ASSY 160 3ADA2ADD 1 BUNDABERO T E KC T 7 T 1 Figure 76 Elevator Control Assy 2 8 4 Control Column 8 4 1 Description The same control panel is used for the elevator as for the ailerons Drawings of the system are given in Section 8 A central shaft is located between the crew seats The control column is mounted at the fwd end of this shaft via a pivot 8 4 2 Removal And Installation e Refer to the details given in Section 8 8 5 Elevator Type of Maintenance Level of Certification LSA repairman Inspector or Maintenance
126. NSET A OM __ j 10 _ 05 3 175 07 TS POSITIONS SMON am REGEBAT ac HNELER NIGHT VFR LIGHT WIRING Figure 127 Night VFR Lighting Sheet 2 13 2 Minor Electrical Equipment 13 2 1 Bus Bars e Electrical power for electrical equipment and installations is supplied through Bus Bars The bus bars are mounted to the circuit breakers inside the main panel Access 15 gained by removing the main instrument panel fascia 13 2 2 Master Switch e When using a key switch the Master Switch activates a relay which in turn powers the bus bars When using a toggle switch it activates the power direct from the battery e Refer to Wiring Diagram for details 13 2 3 Starter Solenoid e The starter solenoid is a sealed unit Service is limited to inspection of terminals for security and replacement of the unit e Note that the body of some starter solenoids used in Jabiru Aircraft form the earth connection If there is excess resistance between the solenoid body and the electrical system earth then a connection will not be made and solenoid issues will result e Later solenoids have a separate connector for the earth 1 they do not earth through the solenoid body determine which solenoid is which check for continuity between the earth pole and the body of the solenoid No continuity indicates the need for a separate earth connection DOCUME
127. NT No JTM001 0 230 D 868 08 May 2014 Page 200 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 13 2 4 Voltage Regulator e The voltage regulator is a sealed unit Service is limited to inspection of terminals for security and replacement of the unit 13 2 5 Strobe System Option e strobe light may be installed in the tip of the tail fin or on the wingtips e The power source for the strobe light is located in the engine bay e For best noise suppression ferrite beads must be fitted to the power amp earth wires leading to the power supply Shielded wires must be used for the connection to the lights themselves and the shielding must be electrically continuous between the light and the control box Ensure the box itself is connected to the aircraft s earth with minimum impedance Refer to Figure 124 and Figure 125 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 2 6 AUXILIARY Power Socket e The Jabiru is fitted with an auxiliary power socket that accepts a 12V cigarette lighter plug The circuit breaker for this plug is rated a 5 Amps 13 3 Battery System Type of Maintenance Level of Certification 13 3 1 Description e The battery is 12 volts and approximately 16 ampere hour capacity The battery is mounted in the
128. OCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 64 of 223 Jabiru Aircraft tc Prepare the Aluminium lugs for bonding Lightly sand bonding faces using 400 grit sandpaper to remove dirt etc from the surface After sanding wipe bonding faces with a rag moistened with Acetone to remove any oils Do not touch boding surface with bare hand after wiping with Acetone Prepare the fuselage for bonding lightly sand the bonding faces using 180 grit sandpaper After sanding wipe bonding faces with a rag moistened with Acetone to remove any oils Do not touch boding surface with bare hand after wiping with Acetone Finally roughen surface again with 180 grit sandpaper 8 blow off dust using clean dry air Mix Jabiru Epoxy resin amp hardener according to the manufacturer instructions Lightly paint both the fuselage and aluminium lug bonding surfaces with resin Mix cotton fibre flock with the resin to a gluey consistency this mix must be stiff enough to hold its shape when applied vertically Apply the resin flock mix to the fuselage and bolt the lugs in place Ensure 100 coverage of the lug Ensure the lugs are seating correctly Fit a bolt through the outboard hole to align the two lugs Do not over tighten lugs must be parallel Apply a resin flock bead around the edge of the lugs as shown in Figure 29 Wipe off excess flock clean up and allow to cure When the resin has cured re fit the upholstery Re
129. PARED OTHER SWITCHES AIRCRAFT WIRE 22 GAUGE NOTE a 7 1 HEAT SHRINK SOLDERED CONNECTIONS WHERE 05 3 8 10 8 10 POSIBLE WIRES TO INTRUMENT PANEL FLOOD LIGHT NEEDS TO NTS 1 31 5 07 BE REPLACED WITH AIRCRAFT GRADE WIFE EES DATE 3 DIMMERS NEED GET BRIGHTER WITH CLOCKWISE ms AVTECH ____ NIGHT VFR LIGHT WIRING 4 264 00 3 ROTATION Figure 126 Night VFR Lighting Sheet 1 DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 199 of 223 Jabiru Aircraft tc a 1 d m PARTS LIST ee ee ee a oe DIMENSIONS IN MILIMETRES PART NO DESC RIPTION GGL EE SWITC CN OFF DPDT INSTRUMENT LIGHT SWITCH COMPONENTS 1 ONADFF TOGGLE SWITCH FI3033A0N 2 TW 680 OHW BLUE GREY BLACK 3 RESISTOR 1W 470 OHM YELLOW VIOLET BELACH 4 3 3V 1W ZENER DIODE 337 1W LANDING LIGHT TOGGLE SWITCH ON OFF 5 ADJUSTABLE RESISOR FEN 0 1000 OHM P ORRE MANHTAS 2 PROTECTION DIODE RED BEACON ANTI COLLISION LIGHT 1 BLACK WITH SILVER PISACESO AUN WHITE LED INTERIOR LIGHT LED STREP LIGHT PRA COMBINED STROBE AND HAVIGATION POSITION LESHTS PISADAT ADH INSTRUMENT LI GHTING BEZELS PIAA I
130. PLY FIREWALL SHEET GIVEN FOR INFO ONLY Em J160 STAINLESS STEEL FIREWALL SHEET 1 3 FLAME PROOF SHEET ONLY REQUIRED ON JAR VLA COMPLIANT MODELS J160 FIREWALL TOP SHEET Le J180 C 230 J160 C FIREWALL FLAME PROOF SHEET uum 2 INSTRUMENT PANEL MOULDED 51050043 NUT UL DASH PANEL MOUNTING DRILL 3 16 HOLES THRU FIREWALL 6 PWOO58N GROMMET 3 8 X 3 4 0059 007 5 FOR MOUNTING BOLTS 7 960 10 3 16 FLAT WASHER 5 z 3 16 BOLT AIRCRAFT CENTRELINE MARKED BY CENTRAL RIVETS 285 a 785 20 20 DRILL 3 4 HOLES THRU CENTRE FLANGE ON FIREWALL FACE OF INSTRUMENT PANEL DIMENSIONS i THIS DRAWING 15 COPYRIGHT AND MUST NOT BE SC P L iR s LIN MILLIMETRES I PIED WITHOUT THE C NSENT F AVTECH PTY LTE 010786 973 h HINKLER AIRPORT BUNDABERG 4670 94670 J400 TYPE PANEL Figure 117 Instrument Panel Mount Installation 12 4 Instruments Type of Maintenance Line Maintenance Level of Certification 12 4 1 Description e Jabiru Aircraft are equipped with a wide range of instruments depending on specification Generally all instruments are secured to the panel fascia with screws inserted through the panel face e n some cases rack mounts are used where the instrument is held in a rack which in turn is secured to the fascia or to the fibreglass panel mount DOCUMENT N
131. Page 46 of223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 6 17 Special Inspections Control Surfaces 777 Required Tools Steel rule Vernier or Gauges Calibrated scales Marker w e Parts and Materia and Material of Maintenance Level of Certification A amp P or LSA Repairman Maintenance LSR M Return to Service A amp P or LSA Repairman Maintenance LSR M e The following set of inspections have been developed to address potential control surface jamming These inspections are to be carried out at the frequency defined in the inspection chart of Section 6 4 In addition they must be repeated at any time when the control rigging may have been altered i e if a control is removed repaired or adjusted f the inspection shows that the aircraft requires adjustment Jabiru Aircraft or our local representative must be consulted for an appropriate rectification method n Figure 11 several terms are defined This is provided to clarify the statements given in the remainder of this inspection Control This refers to control surfaces rudder elevator and ailerons e Aircraft This refers to the fixed part of the aircraft immediately in front of the controls In particular it refers to the point indicated in Figure 11 where the control will hit the aircraft if a jam occurs e Control at the point of overlap This is the particular point
132. RCOR he _ 4 x 500 A GPS b a 70 4 9 CHT 5 N 73 x EU CH xenon 5 i OPT F NE MM nao Anno0ooo0o0d0orrv Figure 116 Instrument Panel Layout Type 4 12 3 Instrument Panel Mount Type of Maintenance Level of Certification DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 182 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 12 3 1 Description e The instrument panel mount is a fibreglass moulding which is secured to the firewall The instrument panel fascia secures to this mount and it also supports the panel throttle assembly where equipped 12 3 2 Instrument Panel Removal amp Installation Y Y x To remove the fibreglass panel mount from the firewall Remove the fascia as noted above Remove the top engine cowl to allow access to the forward side of the firewall Where equipped disconnect the panel mount throttle If required the throttle assembly can remain inside the panel mount when it is removed full disassembly is not necessary Remove the bolts holding the panel mount to the firewall Remove the panel mount Assembly is the reverse of the above procedure Parts List NOTES 1 DETAILS FOR STAINLES STEEL FIREWALL SHEET GIVEN FOR INFO ONLY na 2 DETAILS FOR
133. RESIN SYSTEM 2 FLOCK REFERS TO GOTTON FIBRE FLOCK MIXED WITH RESIN TO GLUEY CONSISTANCTY 3 PREPARE ALL BONDING SURFACES REMOVE PEEL PLY OR SAND TO REMOVE amp OTHER SURFACE CONTAMINANTS FOR ALL BONDS AFTER INITIAL SANDING OR REMOVING PLY CLEAN WITH FINALLY SAND LIGHTLY BY HAND AND BLOW OFF DIST 4 2A121A0D LS AS SHOW 2A121BOM RS OPPOSITE THES 5 MUST MOT os HINKLER AIRPORT ae HINKLER AIRPORT S RIES 13 WING ASSY L S 1230 ser PART DESCRIPTION PART DESCRIPTION 2A122A00 1 SERIES 13 BARE WING ASSY L S 290 END 37 zAT31AQD 1 5 AILERON REMOULD AILERON PLUG MOUNTING STRIP CABLE CLAMP SHIM 1 20016543 ELEVATOR HINGE LEAF CABLE CLAMP 1 41 TLA AWET 316 0 18 0 45 GAIR _ WING FLAP ASSY LS J230 SUIT SERIES 13 42 2 131800 1 5 AILERON HINGE BACKING PLATE WING RIVET 3 16 315 2532 GRIP 26094 4 EN 46 20600 EM 20365 1032 3 46 NYLOC 49 eat FINGER FILTER DRILLED HOLES ROD END GAUGE HOLE DETAIL LOCK NUT 1 8 in E 5 022241 ORANG FINGER FILTER 2200400 010 241 COMPRESSION FITTING 1 4 TUBE 1 8 NPT 50 st 2 121600 1 WING TANK BREATHER TUBE SUIT 4462 P 53 ds m m i FUEL QUICK DRAIN V
134. RKLIAGE URETHANE STRIP 13001400 41 10 3 8 FLAT WASHER e 11 3X8 MUT 12 BOLT 1 7 MOTE A f 1 CENTRE CONSOLE DF FUSELAGE SHOWN _ 2 BOLT LENGTHS GIVEN ARE NOMINAL ENSURE 2 5 THREADS fat te PROWECT PAST LONGER BOLTS MAT BE LSED F REQUIRED 4 ot 3 Pi iy 12 Loo FL PI 42 1 4 L E 1 1 1 SUSPENSION LEG U C ASSY J400 1160 FAMILIES DRAWING 6205023 Figure 46 J230 D Main Undercarriage Assembly Type 2 DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 92 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 7 3 10 Nose Wheel Speed Fairing Spat 7 3 10 1 DESCRIPTION e Jabiru Aircraft are equipped with a nose wheel speed fairing wheel spat e This fairing smoothes the airflow around the nose wheel and significantly improves the efficiency of the aircraft n some cases the nose wheel spat is complimented by a nose leg fairing which covers the nose leg and rubber spring assembly 7 3 10 2 REMOVAL amp INSTALLATION F Required Tools Screwdrivers Spanners Socket wrench Tools as required in Section 5 2 2 2 Parts and Material N A Type of Maintenance Level of Certification Owner LSA repairman inspection or maintenance 1 Weight or tie down tail of aircraft t
135. Removal 77 Remove both top and bottom engine cowls 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 1 bar stock is ideal Remove assembly Disconnect carburettor heat pipes and if necessary remove the heat muff from the muffler If necessary remove exhaust manifolds from engine Note that loosening the screws holding the extractors to the cylinder heads will often assist in removing muffler DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 162 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 10 10 3 Exhaust Inspection Y Y Y 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 100 hours of operation e In addition an inspection of the exhaust system must be undertaken anytime exhaust fumes are noticed in the cabin Hemove engine cowlings 2 Inspect complete system 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 Remove manifolds and or muffler
136. Required Tools Parts and Material Type of Maintenance Level of Certification Owner Task instruction is helpful The alignment of lights for aircraft carrying out Night VFR operations must be checked as part of the 100 Hourly Annual inspection he lights must be aimed to focus on the ground approximately 15 meters in front of the aircraft Before this procedure is carried out ensure that the wires are connected and each light housing secure on the wing strut e Each housing must have at least one slotted light mounting hole refer Figure 39 In some cases both holes must be slotted to achieve proper targeting e Note that Figure 39 Left shows the light during a test fit the trim ring internal paint and Aluminium tape see Error Reference source not found have not been fitted yet DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 79 of 223 Jabiru Aircraft Aircraft Service Manual Jabiru J230 D Serial 868 Slot long 18mm maximum measured from the edges of the hole Figure 39 Light Installed Left amp Slotted Hole In Housing e Alignment is carried out in a dark hangar or outdoor at night Turn the lights on and mark distance 15 meters away from the wing Aim the lights at the focal points given in Figure 40 Lock the position of the lamp by tightening the screws once aiming is complete e Ensure that when the TAXI light is selected the light shown on the right o
137. SHER 15 MEMS ALK HUT 8 HOTEZ 1 CENTRE PEDAL amp PACINTS THM A VARIES BETAEEH MODELS THA A a igir JADE FAMILY THA A 15 J152 J170 Famil Di 4 Benm AS SHA 2 CEHTRE HAGE BLOCR DH FAIL T MODELS OHLY 3 1 11 12 HH CAME DALY 402 REFAENCE HE RSH OHLY TO REFERENCE DIMES SION DALY FAMILY 149 DIH 150 J170 PEDAL SPACING DIMENSIONS us THIS 18 AHO HUIT HOT BALE hee PROJECTION IN MILLIMETRES NOT SCALE WITHOUT THE COMES OF PTE LTE AR ACH OT TRE 279 Wie HINSLER RUDDER PEDAL ASSY INBUILT STOPS NO TORR S 4070 Figure 83 Rudder Pedal Non Adjustable DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 142 of 223 Jabiru Aircraft tc Aircraft Service Manual Paris Lisl JL 5 ce PEDAL P 7345 4 3b CLAMP PLATE RUDOER PEDALS 23 3 090400 2 SEE PEDE VIC AITAME SERERE Y 30 SAMADA FLIPP Y PEDAL ft Wid ADJUSTABLE SERIES 33 Tas FLIPP Y PEDAL 3 TT Wik ADASTAR ES SERIES 2 34 3A08tDUN FUPPY PEDAL 4 WIA ADJUSTABLE SERIES 2 35 AOS TA amp O 1 FLIPE cis Tieten AHG ROLL PIN 2 5 x 20 LONG
138. SIN amp MOULD DIMS ARE REF ONLY 7 RS IS OPPOSITE USING 115605N AND 115606N 8 APPLY PEEL PLY TO BONDING SURFACES LL ome o F NEN enoaan e ferrem HINGE Ls manco 1 APPLY 2 LAYERS AFSO1 TO INNER DOOR SKIN IN THIS AREA CUT SLOT IN SKINS FOR DOOR HAMDLES NOTE 1 OUTER SHIH I3 LAID UP WITH 2 LAYERS OF AF3O1 INNER SKIN ES LAID UP WITH 2 LAYERS 2 OUTER SKIN 3 LAYERS OF AF303 WHERE DOOR HINGES ATTACH 3 BEFORE JOINING DOOR FIT DOOR CATCH ASSY TADI BAON 4 DOOR INTERIOR FLOCKED ON TO DOOR SKIN amp USE LY 3500 EPOXY RESIN Beine e Jabiru J230 D Serial 868 DENSONS IN MILMETRES 00 NOT SCALE DOOR SKIN 15 JOINED DOOR INTERIOR MOULDING USING FLOCK BETWEEN MATING SURFACES SECTION VIEW FLOCK IN CATCH GUIDES AND FIT CATCH BEFORE JOINING SKINS APPLY 1 LATER AF303 OVER EACH HINGE LUG BONDING OUTER SKIN 3 m _ uses 3 aene 2 IN 772 FRONT DOOR ASSY LS J200 400 1156023 5 5 DOOR SKIN 15 JOINED DOOR INTERIOR MOULDING USING FLOCK BETWEEN MATING SURFACES REINFORCE INNER DOOR SKIN AREA SHOWN 2 ADDITIONAL LAYERS AF301 APPLY 1 tae OVER EACH HINGE LUG BONDING TO OUTER SEIN TO NNER DOOR SKIN
139. SIN IN LATUPTO CONTAIN 15 ANTIMONY EY WEIGHT RIVET ARALDITE d USE 02 36 4 TO 1 aonan LOWER COWL MOULONG 2 M5202575 ALUMINIUM PIANO 3633 8 6 212122 RETAINER 8115004 __ DUCT MOULDING ES 3 H3 10 4 524693051 5 STAINLESS SCREW 6 5 JA313501724A TINNERMAN WASHER 6 FOR ATTACHMENT DETAILS SEE DRAWNMG 9115004 NOTE 1 USE MOULD 4 1 DEFINE LAYUP SHARE AND TRIM PROFILE 2 RESIN IN LAYUP TOCONTAIN 18 ANTIMONY BY VEERSHT 3 USE 1236500 EPOXY RESIN 8 PSJED O uw ___ _ Figure 90 pex EDGE OF GLASS LAYERS MIM OVERLAP 40 180 BASIC SKIN 1 LAYER AF303 1 LAYER imm COREMAT 1 LAYER AF303 CLOTH DIRECTION AS CAMLOC 4 LOCATION 1 LAYERS REO OVER INTAKE DUCTS SPINNER CUT OUT AHD AROUND REAR EDGE 3 LAYERS ALONG EDGE WHERE HINGE GOES 40mm WIDE AMD 5 MINUTE INGE COWL i 1 10 T3 DATE L i W 160 COWL ASSY 1 042A0D 1 SHEET 1 oF Typical Upper Cowl Assy y OL COOLER SHROUD TO FITTED WITH ON AIRCRAFT POSITION SHROUD CENTRALLY AROUND COOLER TACK PLACE WITH 5 MINUTE ARALDITE
140. TE SUCH THATY LEGS ARE IN COMPRESSION DURING BRAKING BRAKE CALIPER INSTALLATION Z WHEEL ROTATION DIRECTION SAME ORIENTATION APPLIES WITH DUAL CALIPER SYSTEMS DISC LEGS MUST BE ORIENTED TO BE COMPRESSED WHEN BRAKES ARE APPLIED REPLACE WITH MK 3 BRAKE DISC PRC NECTION E DIMENSIONS DO NOT SCALE AVTECH P L THIS DRAWING IS COPYRIGHT AND MUST NOT BE MILLIMETRES N 010 768 2 COPIED WITHOUT THE CONSENT OF AVTECH PTY LTD TERT TANCES WHOLE NO 75 56 9f ONE DEC 0 2 25 TOW DEC 0 05 ANGLES 0 5 HINKLER AIRPORT LE Sele DIRECTIONAL BRAKE DISC 6A037A0D 2 BUNDABERG 4670 a INSTALLATION Figure 45 Directional Brake Disc Installation 7 3 6 Main Wheel Stub Axle 7 3 6 1 DESCRIPTION e steel stub axle is bolted to the outboard end of the undercarriage leg e Figure 43 shows a typical installation While details and part numbers vary from model to model the general arrangement shown applies to all aircraft 7 3 6 2 MAIN WHEEL STUB AXLE REMOVAL Required Tools Tools as required in Section 7 3 3 and Section 7 3 5 Parts and Material Type of Maintenance Level of Certification Owner LSA repairman inspection or maintenance Remove wheel spat in accordance with Section 7 3 3 Remove wheel in accordance with Section 7 3 5 Allow the brake calliper s to hang on the brake line ensuring that the line is not being kinked distorted or otherwise damaged If the leg mu
141. abin Some models are equipped with a low fuel pressure warning switch amp light The switch is located in the fuel line between the mechanical engine fuel pump and the carburettor e Due to space constraints not all different variations are shown herein When ordering spare parts provide as must detail as possible part description aircraft model serial number etc to Jabiru to ensure accurate part identification WARNING Where secondary fuel valves are fitted between wing tanks and header tanks it 1 recommended that they be secured in the ON position using electrical fuse wire during normal operations 11 1 1 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 defueling 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 DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 168 of 223 Jabiru Aircraft tc 3 Cap open hoses and cover connections to prevent the entrance of foreign matter E i rir C WITWOUT CONSENT OF AVTECH PTY LI DIMENSKINS IN MILIMETRES DO MOT SCALE PROJECTION E FUEL NOTE CAP 2071014 1 FUEL HOSES THE
142. ach a warning placard to the instrument panel stating that vents and breathers have been sealed and that the engine must not be started with the seals in place 12 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 before turning motor 5 3 4 Inspection During Storage 1 Generally inspect airframe and clean as necessary 2 Inspect the interior of 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 DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 29 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 5 3 5 Returning Aircraft To Service After temporary storage the procedures for returning the aircraft to service are as follows Remove aircraft from blocks and check tyres for proper inflation Check battery and install Check carburettor air filter and service if necessary Remove warning placard from propeller Remove materials used to cover openings Remove clean and gap spark plugs While spark plugs are removed rotate propeller using the starter motor for several revolutions to clear excess preservative oil from cylinders CAUTION En
143. al Jabiru 4230 1 Serial 868 Trim Cable Clamp note that it is larger Primary Control Cable Clamp Rudder cable clamp properly installed than primary control note square corner of clamp Note seal pulled back slightly cable clamp Figure 58 Clamp Comparison amp Installation Rudder Cable Aileron cable clamp properly installed viewed through inspection window Elevator cable cla Figure 59 Clamp Installations Elevator amp Aileron DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 114 of 223 Jabiru Aircraft 44 77 Aircraft Service Manual Jabiru J230 D Serial 868 HUE a E II LA Crimp visible in trim cable fitting Clamp locking slots Figure 61 Cable amp Clamp Comparison Clamps correctly assembled Locking tangs correctly fitted clamp fitting snugly around body of cable Clamps incorrectly assembled Locking tangs misaligned clamp fitting properly around body of cable Figure 62 Correct and Incorrect Clamp Installation DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 115 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 8 1 5 1 CONTROL CABLE INSTALLATION Type of Maintenance Level of Certification LSA repairman inspection or maintenance Installation procedure is the opposite of removal procedure outlined above e Ensure the cable clamps used match the cables and are properly i
144. amp TANK LL Y 4 MIX FLOCK 3 MINUTES MINIMUM amp BOND FILLER TO TANK amp WING APPLY VACUUM CLEANER TANK WHILE WORKING ec GLASS INGS RESTRAIN OUTED 1 ps D OF BREATHER IN P CLAMP AS SHOWN ORIENT WITH BREATHER HOLES FACING PWD ENSURE NO GLASS DUST ENTERS TANK SECTION FLAP INSTALLATION TRIMMING WING BOLT AXIS H _ _ DETAIL VIEW DETAIL 5 3 de STO FLAP HINGE SECTION THRU INED FLAP HINGE SPANWISE POSITIONING OF FLAP _ ATTACH WINDOW AS SHOWN AND MUE m SCALE AVTECH PIL E el SECTION H H TIED 010786973 A TALULA TION OF INSPECTION WINDOW HINKLER AIRPORT REF EMG 2A024A0D FOR DETAILS 1 BUNDABERG 4570 Figure 38 J230 D Wing Assembly Sheet 3 Ser 13 7 2 3 Wing Struts e Each wing strut is a single lift strut which transmits a part of the wing load to the lower portion of the fuselage The strut consists of a streamlined tube bolted to two end 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 7 2 3 1 REMOVAL AND INSTALLATION e See above for the wing removal section relevant to the particular aircraft 7 2 3 2 REPAIR e Wing struts are structural components and therefore all repairs must be referred to Jabiru Airc
145. and centre and to the wheel stub at the bottom e The nose gear is a welded steel trailing arm assembly with a rubber spring system The nose wheel is steerable with the rudder pedals e Nose Wheel and Main Wheel Speed Fairings wheel spats are optional equipment e Due to space constraints not all different variations are shown herein When ordering spare parts provide as must detail as possible part description aircraft model serial number etc to Jabiru to ensure accurate part identification 7 3 2 Main Undercarriage Removal Jacking Required Tools Wing stand Construct from DAR pine wood screws and a foam or thick carpet padding Temporary fuel cap should be large and brightly coloured Spanners socket wrench Jack Parts and Material Type of Maintenance Heavy Maintenance Level of Certification LSA repairman with task specific instruction e The procedure given in Section 5 2 2 is useful for wheel brake servicing or repairs but is of no value in removing the main undercarriage If the removal of the main undercarriage is necessary adopt the following procedure 1 Manufacture a wing stand A wing stand is a simple structure standing around 180cm high a frame of 90 x 45 DAR Pine assembled with screws and a diagonal brace is sufficient One end of the stand must be padded with foam thick carpet or similar this end of the stand will be supporting the underside of the wing and must be padded to spr
146. assemble the aircraft and test to ensure free play has been removed Ensure a new bolt is used on the attachment which has been serviced P FLOCK BED 7 WING LUGS Figure 29 Bond Details e f the holes in the stainless steel bushes inserted into the fibreglass wing structure have worn so that standard or close tolerance bolts have excess movement then they must be replaced as detailed below Remove the wing from the aircraft or mount it on stands as detailed above f the bush to be replaced is an eccentric type where the hole for the bolt is not in the centre of the bush make a note of the orientation of the original part Use a large soldering iron or similar to heat the bush to around 70 C This softens the resin bonding the bush in place and makes removal easier As this bush will not be re used a large drill bit or rat tailed file can be used as a screwdriver to remove the bush from the fibreglass Clean the thread cut into the wing lug fibreglass using a 5 8 UNC or 7 8 UNC tap as appropriate Take care to align the tap teeth with the old thread amp ensure tap is not cross threaded Note that there are several different styles and sizes of bush when ordering ensure the correct part is specified a bolt at least 1 size smaller than the centre hole in the bush i e for a 4 bush use a 3 16 bolt Fit the bolt to the bush and affix a washer amp nut Tighten
147. asure i Parts and Material AVGAS Fuel for filling Type of Maintenance Level of Certification A amp P or LSA Repairman Maintenance LSR M Return to Service A amp P or LSA Repairman Maintenance LSR M his procedure explains how to calibrate the inbuilt gauges in the GRT Sport SX unit to the Jabiru Capacitance type gauges e This procedure is applicable for Jabiru Aircraft equipped with wing tanks and capacitance electronic fuel gauge senders e This procedure must be carried out during initial assembly of a new aircraft or when a new gauge sender or new engine fuel monitor is fitted e The accuracy of the fuel indication system of the aircraft depends on careful and accurate completion of this process e Each fuel gauge indicator on the instrument panel or in the EMS needs to be connected to the sender on same side To achieve this on the EMS Enter the EMS menu by pressing any button below an EMS main page and pressing MORE gt SETUP gt MORE gt FUEL You are presented with the screen shown Figure 24 left Press SEL and then enter a tank size of 65 Then press NEXT Then press START You will be presented with the screen show in Figure 24 right sensor value should read around 296 as shown Disconnect a wire off the left fuel gauge sender The sensor value should increase to around 490 when wired correctly the reading does not change then disconnect a wire off the right side se
148. ated on the aircraft The aircraft complies with all safety directions issued by the manufacturer The aircraft has been maintained in accordance with the manufacturer s requirements and The continuing airworthiness functions are performed by the manufacturer or a person appointed by the Manufacturer If the aircraft no longer complies with one or more of these conditions C of A becomes void Continued operation with an invalid C of A is a criminal offence It is permissible however for the registration holder of a non compliant aircraft to apply for an Experimental Certificate Owners or Operators of Experimental Light Sport Category E LSA aircraft are authorized to maintain and inspect an E LSA Jabiru J230 D that they own or operate only upon completion of the Light Sport Repairman Inspection course 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 DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 10 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 WARNING Jabiru Aircraft Pty Ltd has devoted significant resources and testing to develop the J230 D for recreational flying and flight training Any other uses or applications not approved by Jabiru Aircraft P L may be extremely hazardous leading to property damage or inju
149. attling sound An alternative method which may be used 1 to fill the wing tanks with fuel then shake the aircraft by pushing up and down on the wingtip While small droplet leakage is normal fuel must not squirt out of the vent Check for air flow through the valve at low flow rates air should pass freely out the valve at higher rates outflow is restricted Air must be able to pass freely into the tank at all flow rates is detected disassemble the vent and replace any defective parts EARTH WIRE ASSY VENTED WING FUEL TANK CAP HOC VENTED SWIMS FUEL TAMH CAP GARING 14 075 UMC CAP SCREW Loc 6 71 SPEED NUT 6 GAUGE 1 18 SCREW AHEAD SELF TAPPING BG 1 2 E PLASTIC P CLIP SUIT 6G HARDWARE 18 O RING kg 1 ae ume 0 BODY FUEL FILLER 2 WING gt STAINLESS STEEL ROLL PIN DIA 2 x 12 LONG 5 VENTED YING FUEL TANK aon VENTED WING FUEL TANK SURGE VALVE BODY m 3 18 ACETAL BALL 1 le d gt Y LOCTITE 420 TO OF VENT TUBE amp PRESS VALVE BODY Fs BE R SURE VENTHOLES ARE ORIENTED TOWARD LOCATING ROLL PIN AND THAT VALVE BALL m 13 a ASSEMBLY 4 HITC
150. ave been recorded where a poorly fitted duct lifted from the engine and pulled the spark plug leads off the engine resulting in engine stoppage 10 5 Engine Mount Type of Maintenance Heavy Maintenance Level of Certification LSA repairman with task specific instruction 10 5 1 Description The engine mount is 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 Spacers are used to correctly align the engine Ensure that they are correctly marked removal and correctly replaced on reassembly DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 156 of 223 Jabiru Aircraft tc 10 5 2 Engine MOUNT REMOVAL 777 Remove the engine in accordance with the instructions given in the Engine Maintenance manual Cut the zip ties holding wires vents and lines to the engine mount In some cases the instrument panel covers the bolts for the engine mount Access must be secured to these bolts either from the inside of the panel or by removing or loosening the instrument panel mounting Un bolt the engine mount fasteners and remove the mount from the aircraft 10 5 3 Engine Mount Inspection Visually inspect for cracks dents bends and corrosion Mild corrosion can be treated by sanding applying etch primer then painting Engine mounts with severe corrosion must be replace
151. cal Jabiru airframe 15 1 2 Materials Recommended 15 1 2 1 PAINTS FILLERS e Coat 5 Lts MUST BE WHITE e Base Coat 4 Lts Ensure compatibility with top coat e Polyester Filler 4 kg Spot Putty 1 Ib tube Claw Glaze recommended 15 1 2 2 SANDPAPER e Note aluminium oxide type most effective stall 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 15 1 3 Painting EQUIPMENT REQUIRED Random Orbital Sander Gas Mask Compressor Spray Gun 15 1 4 Painting Procedure 1 Wash all parts to remove release agent Note Prepare all parts separately and paint separately e 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 is not cut into in the sanding process DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 206 of 223 Jabiru Aircraft tc 3 Grind excess resin from joints being careful not to grind into fibreglass 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 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 larg
152. cally have a useful life based on the type of battery fitted e Operators must ensure that where equipped the emergency beacon is within its useful life e Testing of the beacon must be carried out in accordance with the manufacturer s instructions during scheduled maintenance DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 75 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 7 2 Wings amp Empennage 7 2 1 General Note wings have a tag located inside the wing root which details the wing serial number and part number Jabiru Aircraft may request this information to ensure the correct parts are supplied CAUTION Always ensure that the correct part is specified when ordering parts Provide Jabiru with as much information about the aircraft model S No etc as possible 7 2 2 J230 D Wings 7 2 2 1 DESCRIPTION Required Tools SOpanners screw drivers etc Drill Parts and Material Type of Maintenance Level of Certification A amp P or LSA Repairman Maintenance LSR M Return to Service A amp P or LSA Repairman Maintenance LSR M e he J230 D wing is a semi cantilever stressed skin type with a main spar The wing is moulded structure with a series of ribs that are bonded through the moulding process to the fibreglass skin fuel tanks and to the spar e he forward wing attachment is an extension of the forward sub spar The rear attachment is an extension of the rea
153. ce horn with horizontal stabiliser Adjust cable rod ends to achieve UP and DOWN travel using the Elevator Rigging Template see Appendix 3 7 DO NOT move the Cable Anchors These are factory set 8 Ensure lock nut 1 tight on rod ends and that cable is visible through hole in spherical bearing DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 135 of 223 DUM Iu Jabiru Aircraft tc Aircraft Service Manual USE TESMPLATES TO MEASURE ELEVATOR TRAVEL UP amp DOWN OW Figure 79 Elevator Travel Limits DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 136 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 8 8 Elevator TRIM CONTROL LEVER ASSY 8 8 1 Description control lever for the elevator trim is mounted on the centre console e The assembly includes friction plates so that the lever does not move once in position 8 8 2 Trim Control Lever Removal 77 Type of Maintenance Level of Certification LSA repairman Inspector or Maintenance e Foratype 1 assembly Remove the cotter pin and lock nut from the lever pivot Remove the locking bolt from the front of the friction plate Remove the lever from the pivot shaft Remove the machine screw attaching the control cable to the lever Remove the assembly from the centre console Fora type 2 assembly Remove the cotter pin and lock nut from the lever pivot Remov
154. ch on the rolled rivet and hit the punch sharply with a hammer alternatively the rivet may be drilled however take care not to damage the mount plates with the drill Punch out all rivets securing the lining to the pad plate NOTE A replacement kit for brake pads and rivets 1 available from Jabiru Aircraft 4 Align the new lining on the pad plate and place the brake rivet in the hole with the rivet head in the lining Place the head against an anvil 5 Centre the rivet setting punch on the lips of the rivet While holding the pad 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 6 Realign the lining of the pad plate and install and set rivets in the remaining holes T Replace the brake pad and refix with through bolts and springs e replace inboard lining 1 On aircraft with Quick Change brakes once the calliper assembly bolts are removed the inner pad and mounting plate can be removed 2 For models without quick change brakes the calliper mount plate must be removed from the aircraft Remove wheel assembly and stub axle from undercarriage leg see Sections 7 3 5 and 7 3 6 3 Remove brake cylinder backing plate 4 Replace lining in accordance with details above D If required re fit the axle and wheel assembly as detailed in Sections 7 3 5 and 7 3 6 6 Install outboard brake pad and refix with through bolts a
155. ck of fluid in master cylinder Fill and bleed system Master cylinder defective Repair or install new parts Brake pads worn Replace with new parts 6 050 001 MACHINED DUAL PISTON HOUSING RSMK3 1 10 s 8 2 4 G OK Eme 2 3 61004 1 NPPLEBRAKEBLEEDER 1 62073044 125 BRAKECYUNDERFITTNG 1 5 3 6 FERRULE NYLON BRAKE LINE 1 O 6A0S9E10 2 CALIPER MOUNT PLATE BRAKE 1 Of GAOSOE2D 1 7 GAOSOE3D 64059 501 OUTERBRAKEPADASSYMKGBRAKE 1 mwen 2 E 5 1 26 07 2011 PROJECTION B DIMENSIONS DO NOT SCALE VT THIS DRAWING IS COPYRIGHT AND MUST NOT BE PROJECTION INMILLIMETRES AVTECH P L COPIED WITHOUT THE CONSENT OF AVTECH PTY LTD 1 2 DATE GENERAL TOLERANCES WHOLE 5 t 0 5 A C N 010 786 973 an EE rra Figure 54 Single Calliper Detail Mk III brakes DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 108 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 8 Aileron Control System 8 1 1 Aileron Control System 8 1 1 1 DESCRIPTION e The general arrangement of the aileron system used in Jabiru Aircraft is shown in drawings below Error Reference source not found and Error Reference source not found e The aileron control system is comprised of a control column and two enclosed push pull cables fitted with spherical bearings e
156. ck the tension of the propeller bolts nuts Tension if required e Check spinner and Prop Tracking e Refer to Section 19 for test procedures torque settings etc 6 9 Engine Compartment 100 Hourly Annual all possible circumstances cannot be listed here the following is provided as guidance only A critical trained eye 1 required and inspections should include but not be limited to the following e Additional details of engine maintenance are contained in the appropriate engine manual This manual must be followed in conjunction with the engine manual to ensure a proper inspection WARNING DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 38 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 Before starting work on the engine it is recommended that the engine starter be disabled via disconnecting the starter solenoid or similar to reduce the risk of injury from inadvertent engine start 15 recommended that the engine compartment be visually inspected twice once while dirty 1 fresh from operation and again after cleaning The dirty inspection allows the inspector to see patterns of leakage etc which are lost when the engine compartment is cleaned while the clean inspection may show items which were obscured by dirt previously The engine and engine compartment must be cleaned in accordance with Section 5 as a part of the inspection he Ca
157. console between the seats 1 Remove the flexible hose from one wheel brake assembly and drain the fluid from the brake system 2 Drill the rivets holding the master cylinder bracket to the centre console while it is possible to remove the cylinder from the bracket in situ it is much more difficult due to the limited access It is generally faster to drill the rivets the replace them during re installation 3i Place a rag under the cylinder to catch any drips of brake fluid 4 Disconnect flexible hose at master cylinder 5 Remove the cylinder and mounting bracket assembly from the console and unbolt the master cylinder retaining bolts 6 Plug or cap hydraulic fittings and hoses to prevent the entry of foreign material 7 Reverse the preceding steps to install brake master cylinder then fill and bleed brake system in accordance with Section 7 3 23 7 3 18 3 BRAKE MASTER CYLINDER REMOVAL amp INSTALLATION ON THE FRONT OF CENTRE CONSOLE Required Tools Screw drivers Spanners Socket Wrench Parts and Material Type of Maintenance Level of Certification LSA repairman inspection or maintenance e The following procedure applies to brake cylinder installations on the front of the centre console 8 Remove the flexible hose from one wheel brake assembly and drain the fluid from the brake system 9 Unbolt amp remove brake handle 10 Disconnect flexible hose at master cylinder 11 Unbolt master cylinder retaining b
158. ction The cable clamp inspections given below are a part of a normal 100 Hourly Annual however e Repair of control cables is limited to the installation of new parts e The Figures below show various pictures of the cable clamps and cable assemblies Points to note and which must be checked during routine maintenance include Primary cables have a green outer sheath with machined end fittings Trim cables have a black outer sheath with a visible crimp on the end fitting Primary cable clamps are smaller than trim cable clamps and have square corners Primary cable backing plates are smaller have a slotted hole and are made from aluminium The two cables are made by different manufacturers and the clamps are supplied by each manufacturer to suit The correct type of clamp must be used with each cable The rubber seal of primary control cables must be pulled back slightly to allow the clamps to be installed properly Both cables use clamps which work by the same means the clamp has a locking tang which inserts into a groove machined in the cable end fitting DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 112 of 223 Jabiru Aircraft lamp amp Backing Plate trol Cable Clamp amp e 5959 Lite 2 Figure 57 Clamp Comparison Primary Cable Clamp Upper on Right Picture DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 113 of 223 Jabiru Aircraft tc le i dii Aircraft Service Manu
159. d cracks dents or bends are found refer to Jabiru Aircraft or our local authorised agent In most cases the damaged mount must be replaced WARNING The engine mounts should not be repaired If damaged replace with a new part 10 5 4 Installation For installation reverse removal procedure above Use the solid laminate torque values given in Table 2 Ensure that the large aluminium washers appr 40 x 40mm square are in place on the inner side of the firewall WARNING The bolts on the engine mount must only be fitted with high temperature nuts DO NOT USE NYLOC NUTS as the nylon insert may melt causing failure 10 6 Engine Fuel System 10 6 1 Description engine is equipped with carburettor mounted below the engine and a fuel pump at the Starboard rear of the engine Refer to Engine Maintenance manual for carburettor jet removal idle adjustment and carburettor bowl cleaning procedures Refer to the Fuel System Section below Section 11 for details WARNING Fuel lines within the engine compartment are fitted with fireproof sleeves These sleeves must not be removed 10 7 Engine Throttle Control Level of Certification LSA repairman inspection or maintenance 10 7 1 Description Jabiru Engines use cable actuated throttle While most aircraft use a throttle control mounted on the instrument panel some are equipped with a throttle fitted to the front of the crew seat Error Re
160. d for a torque check NOTE Torque values listed are for 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 e FILTERS SCREENS and FLUIDS Cleanliness contamination and or replacement at specified intervals e AIRCRAFT FILE Various data information and licenses are part of the aircraft file Check that the following documents are up to date and in accordance with current Civil Aviation Authority Regulations Most of the items listed are required by the Australian Civil Aviation Authority DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 37 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 Regulations Since the regulations of other nations may require other documents and data owners of exported aircraft should check with their own aviation officials to determine their individual requirements To be displayed in the aircraft at all times Placards as detailed in Flight Manual 5 Manual To be carried in the aircraft at all times e Flight Manual Owner s Manual To be made available on request Aircraft Registration e Aircraft Operating Limitations e Pilot License Certificate including Medical Certificate if appropriate 67 Engine Pre Inspection Run Up e Before beginning the step by st
161. d truce ambient static air pressure for any flight configuration For example ensure that the static probe at the tip of the tail is straight and that both the static ports are clear and open e Negative Pressure Test Attach a source of suction to static pressure source opening Figure 122 shows one method of obtaining suction Slowly apply suction until the altimeter indicates a 1000 foot increase in altitude CAUTION When applying or releasing suction do not exceed the range of either the vertical speed indicator or the airspeed indicator Cut off suction source to maintain a closed system for one minute Leakage shall not exceed 100 feet altitude loss as indicated on the altimeter If leakage rate is within tolerance slowly release suction source NOTE leakage rate exceeds maximum allowable first tighten all connections then repeat leakage test If leakage rate still exceeds maximum allowable use the following procedure e Fault Location Tests Disconnect static pressure lines from airspeed indicator and vertical speed indicator Use suitable fittings to connect lines together so that the altimeter is the only instrument still connected into the static pressure system 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 pre
162. damage using appropriate NDT methods such as dye penetrant testing e Jabiru aircraft do not have an overall airframe life limitation 6 3 2 Control Cables e Control cables for all aircraft are subject to the inspection and replacement requirements detailed in Section Error Reference source not found 6 3 3 Engine Bay Flexible Hoses e 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 must be replaced immediately irrespective of age 6 3 4 Undercarriage e Main undercarriage bolts and nose leg pivot bolts shown in Figure 9 are to be changed every 500 hours TIS DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 31 of 223 Jabiru Aircraft tc Aircraft Service Manual Figure 9 Undercarriage 6 4 Inspection Chart e The Engine Maintenance Manual also details engine inspection schedules and should be consulted in addition to this chart chart below shows the recommended intervals at which items to be inspected e Additional detail of the maintenance required in each section is given in the sections below the inspection chart e As shown in the chart there are items to be inspected each 100 hours each 200 hours and Annually There are also special inspection items that require inspection or servicing at intervals other than 100 200 hours or Annually e
163. dications of impact Wings check for free play at attachments as detailed in Section 6 12 e Where a tripped indicator is found during maintenance it must be recorded in the aircraft logbook e The indicator must be re set before the aircraft is returned to service lf the indicator trips repeatedly it is recommended that the operator contact Jabiru Aircraft or our representative to determine a suitable program of additional preventative maintenance Indicator set ready to use He set tool use to re set indicator after is has tripped Indicator Tripped indicating high g force peak Note visible red dot DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 69 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 7 1 3 J230 D Cabin Doors Required Tools Spanners screw drivers etc Drill Parts and Material Weather strip if replacement is required Replacement latches if required Type of Maintenance Level of Certification A amp P or LSA Repairman Maintenance LSR M Return to Service A amp P or LSA Repairman Maintenance LSR M 7 1 3 1 DESCRIPTION J230 D cabin doors are those which use the door hinge assembly shown in Figure 31 and the latch shown in Figure 34 e The doors consist of an outer skin and an inner skin both made of fibreglass The door hinges and latch mechanism are bonded into the door and an acrylic win
164. dow is bonded in place during assembly 7 1 3 2 REMOVAL AND INSTALLATION e 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 Figure 37 below 7 1 3 3 ADJUSTMENT e Cabin doors should be adjusted so that the door skin fairs with the fuselage skin 7 1 3 4 DOOR SEALS 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 t 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 7 1 3 5 DOOR LOCKS e optional cylinder and key lock is available When fitted the keyed barrel lock is located in the fuselage at the rear of the Port Starboard amp Rear doors Spare keys are available to registered owners on request to Jabiru or our local authorized representative 7 1 4 J230 D Cabin Door Latches 7 1 4 1 DESCRIPTION e here is one main latch on each door of a simple spring type This is complemented by a catch at the top front quadrant of each door An assembly drawing of the latch mechanism is provided as Figure 42 below while the door top latch is shown as Figure 35 7 1 5 Removal And Installation e Disassembly and removal of the main latch requires cutting or drilling into the door skins to al
165. ds up an electrostatic charge which attracts dirt Oil and grease may be removed by using a soft cloth moistened with mineral turpentine CAUTION DO NOT use gasoline alcohol Buzene Acetone Carbon Tetrachloride fire extinguisher fluid de icer fluid lacquer thinner or glass window cleaning spray These solvents will soften and craze the Plastic DO NOT use a canvas cover on the windshield or windows as the cover may scratch the plastic 5 1 2 Interior Surfaces e 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 e Note that 5 1 3 Exterior Surfaces e 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 e 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 e 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 e 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 ab
166. dt Dt 50H 910 789 973 JHIHRLER ARP CIT BUHDABERS Pas List HUMBER DESCRIPTION PART NUMBER DESCRIPTION 50 FLAP ORME SHAFT ASSY Em BOLT zan33anD FLAP ASSEMBLY 2 960 518 cK __ __ 2 5 SPACER AOD EKD 3 5 _ FLAP CABLE MOUNT 7 Wasa zr ABJ ELECTRIC FLAP SERVO MOUNT PM3ACODN LINEAR ACTUATOR ELECTRIC FLAP IUD 3 SERIES 250mm STROKE 4 829305 1032 10 zB 2 BOLT 11 xanzEuu SPACER BUSH 1 4 BUNDY TUBE x jM52480 5278 COUNTERSUNK SCREW 132159 3787 FLAT WASHER 1 2 THCKNESS 13 JU FLATWASHER ee Sa NYLOC NUT D FLAP MOUNTING ARM ___ FLAP ORNE PUSH ROD SUIT END E INTERNAL DERE ASSEMBLY E Tui Siamo B ORHI AND NOTE Sce COMED WITHOUT THE CONSENT OF AVTREH PTY 010 788 LATS UNLESS OMEA S En 028 HMKLER AIRPORT Epson Figure 67 Flap Controls Sheet 1 Aluminium Motor Mount DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 123 of 223 Jabiru
167. e T Unbolt the clamps at either end of the cable 8 Where required remove any ties etc used to restrain the cables in the aircraft 9 Tie a string or light wire to one end the cable 10 Draw the cable out of the aircraft leaving the string wire in place to allow installation of a replacement part 8 6 3 Control Cable Inspection e 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 e Details of inspections required for control cables are given in Sections 8 1 5 and 0 8 6 4 Control Cable Installation e Reverse the steps detailed above for installation e Ensure the required inspections are carried out and the cable is clamped securely WARNING All spherical rod end bearings must be fitted with a large washer on the outside of the through bolt to prevent the bearing case and cable releasing in the event of a bearing failure 67 Rigging Type of Maintenance Level of Certification LSA repairman Inspector or Maintenance Refer to Figure 79 Control templates are available for all models from Jabiru Aircraft Using the factory anchor points make sure each end of the cable is secure Set the full up travel first using the factory templates Making sure both the control column and the elevator trim is hard back Adjust the female ball ends in or out if adjustment is needed To establish the neutral position align balan
168. e fluid draining from the system he brake disc is removed after the wheel is removed and disassembled 7 3 20 3 WHEEL BRAKE INSPECTION AND REPAIR Required Tools Clean cloth Spanners Socket Wrench Parts and Material Solvent Replacement O Rings Automotive brake fluid Replacement brake cylinder if required Replacement anchor bolts if required Type of Maintenance Level of Certification LSA repairman inspection or maintenance Clean all parts except brake linings in dry cleaning solvent and dry thoroughly New piston sealing O Rings should be installed each time the brakes are disassembled If re use is necessary they should be wiped with a clean cloth saturated in automotive brake fluid and inspected for damage NOTE Thorough cleaning is important Dirt and chips are the greatest single cause of malfunctions and leaks in hydraulic brake systems 3 Check brake linings for deterioration or excessive wear 4 Inspect brake cylinder bore for scoring A scored cylinder will leak or cause rapid seal 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 7 3 20 4 WHEEL BRAKE INSTALLATION Required Tools Spanners Socket Wrench Parts and Material Type of Maintenance Level of Certification LSA repairman inspection or maintenance Place brake calliper assembly in position on backing plate Install bolts sp
169. e used must stand at least 50mm high from the floor in order to touch enough of the tyre side wall DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 52 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 Figure 19 Alignment Measurements Mark the position of the straight edge in front and behind the wheels Positions are marked at 1 5m nominally either side of the wheel centre measurements from the straight edge positions to the centreline of the fuselage e Compare the measured distances to see if the wheels have toe in or toe out e Camber is the vertical angle of the wheel to the ground It is to be measured using a digital protractor or similar using the end of the axle or the brake disk as a reference The aim is to have the wheel vertical when the aircraft is fully loaded DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 53 of 223 Jabiru Aircraft tc e Toe in toe out and the wheel camber angle are related in that when the wheel has camber it behaves like a cone and wants to track in a circle around the point where the centreline of the axle hits the ground The toe of the wheel is used to compensate for this so that the wheel doesnt try and pull in or out on the leg as the plane taxis e A camber angle of 1 5 with the top of the wheel leaning slightly outboard relative to the bottom of the wheel is recommended for all models when unloaded Depending on t
170. e A minimum of 2 years experience working on aircraft under supervision is recommended for commercial maintainers before working un supervised 45 Tool amp Gauge Control e Tool amp gauge control is an important part of aviation maintenance systems Tools amp gauges must be accurate enough for the intended use i e a 12 steel ruler is not the appropriate tool to use to measure the cylinder bore diameter amp be accurately calibrated by an approved laboratory e Calibrations must be kept up to date This means a check calibration every year or more frequently for regularly used critical tooling e Even quality equipment will wear over time so items like reams and go no go gauges must periodically be checked to ensure they remain within limits 4 6 Tools Access to the following tools will be required All tools must be good quality items e Imperial Allen keys Circlip pliers e Pliers long nose regular square jaw side cutters e Ring open end spanners 5 16 3 8 7 16 1 2 9 16 10mm 17mm e Ratchet 3 8 drive breaker bar 2 extension bar 3 8 7 16 1 2 sockets 7 16 tube socket 18mm spark plug socket Screwdrivers flat blade and Phillips head in various sizes Feeler gauges metric and imperial sizes e Punch set e Torque wrench 3 8 drive name brand Snap On Warren amp Brown etc with valid calibration The wrench must have a suitable scale for use on the fasten
171. e calibrated Note that Civil Aviation Authorities generally require that the tool be calibrated in a way which is traceable to a NATA standard laboratory Crowsfoot extension as shown in Figure 4 is sometimes necessary it allows high torque settings to be used on small nuts without damaging them and access to difficult locations However when using the extension as shown in Figure 6 the extra length will throw off the torque setting of the wrench This must be corrected using the following formula Adjusted Torque Setting Required Torque Setting e 115 the distance from the middle of the grip of the handle to the centre of the wrench drive lug e 2 is the distance in the direction of the handle from the centre of the wrench drive lug to the centre of the nut socket of the adaptor e For example a nut needs to be tensioned to 30lb ft The torque wrench is 12 long and the crowsfoot extension is 2 long The extension is oriented as shown in Figure 6 This means that the torque wrench must be set to 12 mE TT MCN Adjusted Torque Setting 30 n gt Adjusted Torque Setting 30 0 857 25 716 ft f the extension is oriented at 90 to the wrench as shown in Figure 7 then no correction is needed because L2 1 zero Figure 8 Using A Crowsfoot Adaptor DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 23 of 223 Jabiru Aircraft tc 4 9 2 Torque Application Procedure e Good torque a
172. e screw while the nut is loosened inside the cabin e Disconnect the pumps electrical connections Place cloth beneath the pump to collect any fuel which may be split during removal of the filter e Disconnect the fuel lines at both ends of the pump e Remove pump e Remove the hose tail fittings from both ends of the pump Clean the thread of the fittings for re use DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 178 of 223 Jabiru Aircraft tc e Clean the threads of the hose tails and of the replacement pump using Aerostart or a volatile tool cleaner a type which does not leave a residue If cure time is an issue use Loctite 7471 Cure Accelerator on the parts before assembly e Apply Loctite 262 to the mating threads a bead the size of a match head should be applied to both the male and female threads Assemble e Allow the Loctite to cure e Reverse the preceding steps for installation Ensure waste cloth is removed WARNING Ensure tank vents are open no vent covers fitted 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 DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 179 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 12 Instruments amp Instrument Systems 12 1 General e This Section describes the typical instrument in
173. e the lever from the pivot shaft Remove the machine screw attaching the control cable to the lever If required drill the TLR rivets to remove the housing from the centre console For 2 assembly Remove the cotter pin and lock nut from the pivot shaft Remove the levers from the pivot shaft Remove the machine screw attaching the control cable to the lever f necessary drill the rivets to allow removal of the pivot housing Note that the two end pieces of the housing connect to the central spacer with a thread and will need to be un screwed for disassembly 8 8 3 Inspection amp Repair e Inspect the friction plates for excess wear galling or other damage After installation carry out the functional tests and inspections noted below 8 8 4 Installation e Reverse the removal procedure above for installation e Adjust the tension of the pivot bolt to give the required friction force e Use anew cotter pin WARNING All spherical rod end bearings must be fitted with a large washer on the outside of the through bolt to prevent the bearing case and cable releasing in the event of a bearing failure DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 137 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 DESCRIPTION BUSS FRICTION PAD FRICTION PADS FRICTION PLATE INNER DRIVE SHAFT DUAL LEVERS TRIM LEVER DUAL LEVERS
174. ead the load and to prevent scratching the paint etc WARNING When making a wing stand ensure that it is strong and stiff enough to support the aircraft with minimal distortion Remove all unnecessary equipment from the aircraft Where equipped apply a temporary cap to the fuel filler vent of the wing which will NOT be jacked as a part of this procedure This is to prevent fuel leaking out the breather onto the wing Ensure that the cap 1 large and highly visible to ensure is removed when the job 15 done Apply the hand brake or wheel chocks to the wheel which will remain on the ground Lifting from a point in line with the wing strut and around 1m 3 feet further outboard lift the main wheel off the ground More than 1 person may be required depending on the model and weight of the aircraft Place the wing stand under the wing and allow it to take the weight of the aircraft If the aircraft is to remain on the stand for more than 24 hours it is recommended that alternate supports such as trestles under the fuselage belly be used to relieve the strain on the wing and undercarriage WARNING Only jack 1 undercarriage leg at a time using this method If both legs must be removed simultaneously support the aircraft on trestles or similar supports under the fuselage belly DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 83 of 223 ol oy Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Se
175. ed Automotive wheel rim lubricant 1 Replace bearings in wheel hub 2 Apply automotive wheel rim lubricant to the tyre bead faces on the inside of the wheel rims Note that if this step is skipped disassembly of the wheel in future will be made much more difficult 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 solid lamination value specified in Table 2 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 DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 94 of 223 Jabiru Aircraft tc 5 Inflate tyre to seat the tyre beads adjust to correct tyre pressure Refer Aircraft Specifications above a sil DO NOT SCALE be lACH quent NOS WHEEL ASSY CAST BIGFOOT REFER PART DRAWING BUNDABERG 4670 WHEEL ASSY 1 392 S I TERT AI Ares Figure 47 Nose Wheel Hub Assembly 7 3 13 Nose Wheel Steering Centering System
176. ed is clean and dry before proceeding Where a reversible wrench is being used set the torque to a value slightly below the target torque and LOOSEN the fastener slightly approx 1 3 or a turn The wrench should click indicating that the fastener had maintained its set torque If the fastener torque has reduced significantly it may be an indication of damage or degradation to the assembly and should be investigated fastener is first loosened slightly to ensure that it is free to move on its threads If this step is not carried out it is possible for the fastener to corrode in place If that happens the friction of the corrosion will seize the fastener ensuring that it appears to pass torque checks but in fact has lost tension and is no longer holding the assembly correctly Tighten the fastener smoothly to the set torque Any jerks or bumps when tightening can cause the reading to be obtained prematurely The torque must be obtained while the nut is turning If you stop to reposition the torque wrench and then the required torque reading is obtained without the nut turning the nut needs to be loosened a little and then tightened again so the torque reading is obtained while turning Table 2 Recommended Bolt Torque Values Bolt Size Torque Inch Ib Torque Inch Ib Core mat or thin laminate Thick glass only laminate 20 25 1 7 2 116 Up to 4 AN4 50 70 4 2 5 8 1 Up to 8 Ib ft AN
177. eding steps for installation 91 3 Inspection And Repair 7 1 Inspect nylon bearings for wear Replace if worn 2 Inspect pedal bars for wear around bearing area and for distortion 3 Inspect pedals for distortion or loose rivets in end stops 4 Inspect bolt holes for wear and elongation 5 Inspect bolts and nuts for distortion and wear 6 Replace any distorted or worn parts the optional adjustable rudder pedals are fitted these steps must also be performed 7 Inspect adjustment pins for wear replace if required 8 Inspect adjustment pin springs and replace if required 9 Inspect adjustment pin pull rings for wear replace if required WARNING All spherical rod end bearings must be fitted with a large washer on the outside of the through bolt to prevent the bearing case and cable releasing in the event of a bearing failure Parts Lig _ PART NUMBER DE3ERFTICH 1 END STOF RUDDER 5 3 iM FLAT WASHER 520385 42 14 NYLOG NUT 1355 5 RUDDER PEGDA WWASSY INBUILT STOPS TOE BRAKES BALES RUDDER PEDLIAL Y INEUIET STIFS TOE 1 4 UNF a 24 PI e PHI238 5 Ta UMF CLAMP UDEER PEDALS CLAMP PLATE TOF RUDDER PEDALS PEDAL BEARS BLOCK X BOLT ANTEA 21 SOLT 32127 FLAT WA
178. engine compartment e The battery box is located on the firewall in the engine compartment 13 3 2 Removal And Installation 7 1 Disconnect the battery security strap 2 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 3 Disconnect the cable from the positive battery terminal 4 Lift the battery out of the battery box 5 To replace the battery reverse this procedure 13 3 3 Cleaning The Battery e For maximum efficiency the battery and connections should be kept clean at all times 1 Remove the battery and connections in accordance with the preceding paragraph 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 DOCUMENT No 001 0 230 868 08 May 2014 Page 201 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868
179. enna Installation J120 4160 5 203 Figure 130 Second VHF Antenna Installation J230 204 Figure 131 Transponder Antenna Installation 205 Figure 132 Typical Scimitar propeller 214 DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 8 of 223 Jabiru Aircraft tc Aircraft Service Manual 1 2 List Of Tables Table 1 TT T PE TE 16 Table 2 Recommended Bolt Torque Values 17 Table 3 Inspection Schedule Chart 33 Play Limi OO E 46 Table 5 Trouble Shooting Main Undercarriage nnns 92 Table 6 Trouble shooting Nose 99 Table 7 Trouble Shooting 107 Table 8 Trouble Shooting Fuel 5 169 Table 9 Trouble Shooting Pitot Static 189 Table 10 Trouble Shooting Airspeed 190 Table 11 Trouble Shooting nnn nnn nnns 190 Table 12 Trouble Shooting Vertical Speed 191 Table 13 Trouble Shooting
180. ent tyre pressure or damage to an undercarriage leg e Where equipped check the ShockWatch indicator as detailed in Section 7 1 2 Re set the indicator before returning to service e Remove the nose and main wheel fairings and inspect then for cracks fraying rubbing or other damage e While the fairings are removed inspect the wheels Visually inspect the wheel for run out which may occur due to a dent in the rim Inspect for cracks damaged hardware corrosion and any other damage e Jack the aircraft and pull the un loaded main undercarriage leg fwd and aft to check for looseness Repeat for the second leg e Inspect the nose leg steering links tension links amp fairings Check for dents bends cracks corrosion damaged or missing hardware and signs of rubbing etc Wriggle the trailing arm front suspension and check for any slop or wear in the pivot bushings of the suspension e Check for smooth rotation with no bearing rumble or slop Replace worn or damaged bearings e Inspect the nose gear housing amp bushes for wear ensure there is no excess vertical or horizontal slop in the fit of the leg to the housing e Inspect the main gear struts clamps bolts amp nuts Check for rubbing cracks corrosion missing or damaged hardware and any other damage e Replace the main gear bolts at the life indicated in Section 6 3 or earlier if the airframe is subject to rough runways taxiways or training operations e Check the ty
181. ep 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 Engine temperatures and pressures Static RPM Also refer to Engine Maintenance Manual Magneto drop Also refer to Engine Maintenance Manual Engine response to changes in power Any unusual engine noises Fuel shut off valve operate engine in ON position and in OFF position long enough to ensure shut off functions properly Idling speed After the inspection has been completed an engine run up should again be performed to determine that any discrepancies or abnormalities have been corrected 6 8 Propeller 100 Hourly Annual all possible circumstances cannot be listed here the following is provided as guidance only A critical trained eye 1 required and inspections should include but not be limited to the following e Remove the spinner and carry out a thorough visual inspection checking for cracking fraying corrosion and other damage e Check for loose missing corroded or damaged fasteners and hardware e Check for deposits and radial markings which indicate fretting between moving parts e Visually check the condition of the propeller looking for damage to the leading edge protection glass de lamination and cracks splits or crushing of the propeller blades Che
182. er mixes are necessary Use cold packs under the Body Filler board to extend setting time 6 Follow instructions carefully and experiment with setting times 7 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 IS 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 discoloured 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 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 is mandatory that exterior colour is WHITE only broken if desired by pin stripes 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 13 After filling all pinholes spray another coat of primer on the discoloured areas An all over primer coat 15 not required ove
183. ers typically found on Jabiru Aircraft for example a wrench with a scale from 20 100 is unsuitable e Adjustable reams DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 18 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 Picks probes Good quality wire strippers Terminal crimp pliers terminals heat shrink etc Safety wire pliers amp 0 032 stainless steel safety wire Inspection mirror Boroscope DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 19 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 4 7 Equipment Access to the following equipment will be required Bench vice with padded jaws Calipers must read up to 180mm Degreasing cleaning system with solvent solution containment recycling Hand press Heat gun or small butane propane torch with a soft pencil flame Multimeter or an ohmmeter Imperial thread taps UNF and UNC Adjustable wing stands Saw horses Fuel proof container with accurate volume markings Soldering iron Cable ties An accurate tyre pressure gauge Accurate scales and spirit level if the aircraft is to be weighed 4 8 General Brass drifts punches rags soft mallet hammers Greases molybdenum disulphide general purpose TorqueSeal brand security marking lacquer or similar such as coloured nail varnish 5 Minute epoxy resin Jabiru epoxy resin cotton fibre flock Q cells micro balloons c
184. es Check other instruments and Map system plumbing for leaks Blow speed indicator installations out lines tighten connections DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 190 of 223 Incorrect indication Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 12 5 10 Trouble Shooting Vertical Speed Indicator Table 12 Trouble Shooting Vertical Speed Indicator Static line pluaaed Check line for obstructions Blow ee out lines Instrument fails to Check line for damage operate connections for security Repair or replace damaged line tighten connections out lines EL Substitute known good indicator Incorrect indication Ruptured diaphragm and check reading Replace instrument Pointeroffzero off zero Reset pointer to zero Check line for obstructions Blow y 99 out lines Test lines and connections for leaks Repair or replace damaged lines tighten connections Substitute known good indicator Leak in instrument case and check reading Replace instrument defective shock mounts Hand vibrates Substitute known good indicator Defective diaphragm and check for vibration Replace instrument Static line broken Pointer oscillates DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 191 of 223 Jabiru Aircraft tc
185. ese parts 3 Remove hinge pins 4 Remove rudder 5 Reverse the preceding steps for installation 9 3 3 Inspection amp Repair 77 e Inspect rudder for any signs of delamination cracking Pay particular attention to the Control Horn and hinges and their surrounding areas e Inspect the front right hand of the rudder for any signs of rubbing against the vertical stabiliser when the rudder is at full deflection when the rudder hinge is pressed in using thumb pressure there should be clearance between the rudder and the vertical stabiliser e Details of inspections required for control surfaces are given in Section 6 17 e Repairs must be referred to Jabiru Aircraft Pty Ltd or our approved local agent DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 146 of 223 Jabiru Aircraft tc RUDDER OUTLINE REF FIT TOP HINGE BRACE TO FIN CHANNEL GRIND CORNERS OF BRACE TO ABOVE HINGE amp RADIO ANTENNA ae FIN CHANNEL REFER DETAIL B REFER TO DETAIL VIEW B BOND BRACE TO CHANNEL USING COTTON FLOCK amp 103600 RESIN PLACE HINGE RETAINER BELOW TOP HIMGE DETAIL VIEW B TOP HINGE BRACE DETAILS PLACE STOPS TO LIMIT RUDDER TRAVEL FILE STOP TO GIVE A FLAT FACE FOR RUDDER HORN STOP AGAINST USE TRAVEL TEMPLATES DETERMINE RUDDER TRAVEL amp PLACE STOPS BOND 5 IN PLACE USING COTTON FLOCK amp LC3600 EPOXY RESIN HOLD STOPS PLACE WITH SELF TAPPING SCREWS WHIL
186. ever from the cross shaft input arm 4 external flap drive arm from the end of the shaft nearest the remaining wing 5 Remove the bolts holding the input arm to the flap cross shaft fitted it will be necessary to remove any upholstery and paint from the shaft to allow it to be drawn out through the bearings on the sides of the fuselage 6 Draw the tube out of the fuselage DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 126 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 8 2 3 3 FLAP CROSS SHAFT INSPECTION amp REPAIR 7 e Repair is limited to replacing worn parts e Inspect for corrosion or damage to any parts 8 2 3 4 FLAP CROSS SHAFT INSTALLATION e Installation procedure is the reverse of assembly e After installing carry out a test run while watching the external flap drive arms Ensure the arms do not rub against the fuselage or wing mounts WARNING All spherical rod end bearings must be fitted with a large washer on the outside of the through bolt to prevent the bearing case and cable releasing in the event of a bearing failure ml ty cn co DI OMENS ONE _THS OH NG ANDIMUST i 1 04 PONOT SCALE C Acn ao Ed EHEDIWIHOUT THE CONSENT Aw TECH PTY LTD SS GATE PATE ALES SABO HEE 44 05 DEAF KLERAFFCET 160 ASSY
187. f Figure 40 illuminates i e the TAXI light is aimed to shine on the centre of the taxiway 15m in front of the aircraft The LANDING light is aimed straight ahead Figure 40 Night VFR Lighting Aim Diagram 7 2 6 DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 80 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 7 2 7 Wing Inspection Window 7 2 7 1 DESCRIPTION Jabiru Aircraft have a small acrylic window in the underside of the wing to allow inspection of the outboard aileron clamp some models this window is a simple rectangular piece of clear acrylic screwed to the wing using machine screws and anchor nuts Later variants use a machined acrylic sheet with threaded inserts 7 2 7 2 REMOVAL INSPECTION amp INSTALLATION Required Tools Parts and Material Type of Maintenance Level of Certification Owner Task instruction is helpful e Remove the screws holding the window to the wing and remove e Installation is the reverse Also refer to wing assembly drawings shown above Parts ITEM PART NUMBER DESCRIPTION 2A054A1D 2 PLATE SER WING T5ADABATD 1 IFAIRING SCREW SOCKET 4mm NAS623 22 832 BUTTON HEAD SCREW PHO219N WASHER 5 32 FLAT Z P LAP 1 4 TO SUIT INSERTS DURING ASSEMBLY DRILL ONLY DURING PLATE MANUFACTURE at rt 4 PLACES PROJECTION DONOT SCALE AVTECH P L
188. ference source not found and Error Reference source not found DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 157 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 10 7 2 Throttle Removal Loosen the lock nuts holding the cabin end of the throttle cable outer to the support bracket Disconnect the throttle cable from the output shaft of the throttle cross tube For the panel mount throttle Loosen the lock nut and un screw the throttle push rod from the rod end Withdraw the throttle push rods from the panel Undo the screws holding the throttle shaft clamp blocks Disassemble and remove the throttle shaft from inside the instrument panel f required undo the fasteners and remove the input and output arms from the throttle shaft Note that paint may need to be removed before these levers can be moved For the seat mount throttle Undo the screws holding the throttle shaft clamp blocks Disassemble and remove Remove the throttle lever from the passenger s side of the aircraft Withdraw the throttle shaft from the centre console f required undo the fasteners and remove the input and output arms from the throttle shaft Note that paint may need to be removed before these levers can be moved If required disconnect the throttle cable from the carburettor and remove the cable assembly from the aircraft 10 7 3 Throttle Inspection Repair amp Rigging 10 7 4 777 e
189. fluid DOT 3 or DOT 4 DO NOT use Aircraft hydraulic fluid mineral based or damage to the brake system will result DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 41 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 6 12 Airframe 100 Hourly Annual all possible circumstances cannot be listed here the following is provided as guidance only A critical trained eye is required and inspections should include but not be limited to the following e Inspect the aircraft exterior for cracks dents abrasions corrosion or signs of fretting or rubbing Check for missing or damaged hardware e Check for whitening of unpainted fiberglass areas an indication of damage e Check for movement of wing attachments and threaded bushes movement of undercarriage attachments loosening of firewall engine attachments e For each wing hold the tip and shake up and down and fore and aft If there is any slop in the wing or strut attachments it will be evident by feel and audibly Any slop in these connections must be addressed e Inspect windows and windshield for cracking and scratches e Inspect doors amp seals for condition Check for cracks and signs of rubbing or degradation e Inspect seatbelts amp shoulder harnesses for condition Ensure all latches function correctly and do not have excess slop Check joint pin between shoulder and lap belts and ensure it 1 secure and the connection solid
190. full travel movement Comments Elevator controls amp linkages Check all hardware ensure good condition and secure Comments Rudder pedals amp linkages Check all hardware ensure good condition and secure Comments Exterior surface of control surfaces Check for cracking fraying and other damage PP Comments Control horns hinges hinge lock tabs check condition and wear replace as required RIF Comments Aileron controls and linkages Check all hardware ensure good condition and secure LIES Comments Rigging check flight Check all system for correct function Comments Throttle controls Check smooth operation and correct adjustment of friction Comments Check control surface clearances as per section 6 17 Comments 100 hourly 100 hourly 100 hourly 100 hourly 100 hourly 100 hourly hourly NO
191. h TRAVEL amp PLACE STOPS BOND STOPS ON if IN PLACE USING COTTON FLOCK amp oad 1 3600 EPOXY RESIN HOLD STOPS ee IN PLACE WITH SELF TAPPING M SCREWS WHILE RESIN CURES a 1 Fi A _ BOND HINGE HALVES RUDDER 7 amp CHANNELS WTH COTTON FLOCK amp 23800 EPOXY RESN 2 201 nup 178 05 1 8 iss DATE BAD 20 25 AVIECH ec _ AME AS R JODER FIN ASSY 2A046AO0D 2 MEN A BUNDABERG J160 FAMIL Y Figure 89 Typical Rudder Installation Steel Hinges 9 4 Rudder Control Cable Type of Maintenance Level of Certification LSA repairman inspection or maintenance 9 4 1 Description e 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 9 4 2 Control Cable Removal 11 Unbolt the connections rod end bearings at either ends of the cable 12 Unbolt the clamps at either end of the cable 13 Where required remove any ties etc used to restrain the cables in the aircraft 14 Tie a string or light wire to one end of the cable 15 Draw the cable out of the aircraft leaving the string wire in place to allow installation of a replacement part 9 4 3 Control Cable Inspection Y Y Y e he Control Cable is a Primary Con
192. he 20L mark in the location indicated by the pointer in the fuel gauge Repeat for the second tank Make sure the decals are marked to indicate which tank they are matched with In Figure 23 left a typical sender indication with 20L added is shown Note how the needle is just slightly above 1 4 In Figure 23 right a decal assembly to match this indication is shown The 20L arrow on the outer indicates just above the 1 4 mark on the inner CAUTION There is often a degree of friction within the gauge sender Tap gently with a finger after adding fuel to maximise accuracy of reading WARNING Before removing clamps on the fuel line make sure all fuel lines are connected On removal of clamps check that the fuel lines are not damaged and return to their original shape DOCUMENT No JTMO01 0 230 D 868 08 May 2014 55 of 223 Jabiru Aircraft tc Aircraft Service Manual FUEL INDICATOR VALUES FOR LEVEL AIRCRAFT ONLY Figure 22 Fuel Gauge Calibration Decal Parts FUEL INDICATOR VALUES FOR LEVEL AIRCRAFT ONLY Figure 23 20L Indication on Sender amp Decal to Match DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 56 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 6 20 Special Inspections Fuel Sender Calibration Required Tools Clamp suitable for crimping fuel lines without damage Figure 25 Fuel container to drain fuel from wings Accurate fuel pump or me
193. he aileron hinge is pressed up using thumb pressure there should still be clearance between the aileron and the wing Section 6 17 refers e Repairs must be referred to Jabiru Aircraft Pty Ltd or our approved local agent 8 1 6 4 AILERON BALANCING Y Y Y The aileron does not have balancing weights fitted The Aileron used for the J160 C does however have limits for weight and hinge moment which are applicable to all models using the same aileron 1215mm nominal length non Friese type Weight 11509 1009 Hinge Moment 94000g mm 4000g mm e The aileron balance is checked at the factory during assembly and unless they are repaired or refinished the balance should not change e To balance the ailerons they must be removed from the aircraft Balancing is done around the hinges with the hinge pin line horizontal and on the high side of the ailerons The hinge moments can be measured by measuring the upwards force needed to maintain the flat side of the aileron horizontal Note that as this load is small a finely graduated spring balance or similar measuring instrument will be required 8 1 6 5 AILERON INSTALLATION e For aileron installation reverse the procedure detailed for removal above DOCUMENT No JTM001 0 230 D 868 08 May 2014 117 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 8 1 7 Rigging 777 Type of Maintenance Level of Certification LSA repairman
194. he aircraft Due to the light nature of the Jabiru even a small breeze can cause significant weight transfer and consequentially C of G errors In addition door must be shut flaps in the UP position and any items not part of the standard equipment of the aircraft removed 7 Using a string line or similar mark the wing leading edge on the floor under the aircraft Normally using tape to fix a string line between the points marked earlier is the best method 8 Measure the horizontal for aft distance for each wheel both sides of nose wheel to the wing leading edge Note that the two readings for the nose wheel are averaged 9 All distances aft of the datum are considered positive and all distances forward of the datum are negative See Figure 10 Note that while the arrangement shown assumes that the wing leading edge is the aircraft datum for some Jabiru models the datum is displaced a fixed amount forward of the leading edge For these models the measurements taken must be adjusted to readings relative to the datum For example The datum is 1403mm forward of the wing leading edge Measurements have found that the nose wheel is 400mm forward of the wing leading edge and the main wheels 400mm aft Corrected to reference the datum these measurements become 1003mm aft of the datum for the nose wheel and 1803mm aft for the main wheels 10 Always weigh and measure the aircraft at least twice and average the results If one weighing gives re
195. he control valve operates correctly sealing at both positions and that the heat exchanger is secure on the tailpipe e Inspect the engine cowlings fasteners and clips Check for cracks fraying signs of rubbing and other damage e Inspect the battery battery cradle amp cables for condition DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 39 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 e The Battery is a sealed type and so is not a serviceable item If electrolyte corrosion occurs Use bicarbonate of soda baking soda and clean water to neutralise electrolyte of corrosion Follow with a thorough flushing with clean water Remove battery and clean residue from aircraft Clean cable and terminal connections with a wire brush then coat with petroleum jelly before connecting cables e Replace flexible oil amp fuel line in engine compartment every 2 years or when visible deterioration cracking hardening occurs CAUTION If the aircraft is using a fuel blend containing alcohol the operator must be aware that flexible fuel lines will generally age faster when exposed to alcohol Additional care must be taken to monitor fuel system condition 6 10 Fuel System 100 Hourly Annual all possible circumstances cannot be listed here the following is provided as guidance only A critical trained eye is required and inspections should include but not be limited to the following
196. he type of operation the aircraft is normally used for the operator may alter the camber angle slightly i e if the aircraft is normally loaded heavily a slightly higher camber angle may be used for the main wheels is set at between 10mm and 0 mm This is for an empty aircraft f adjustments are required washers are used as spacers between the stub axle and the undercarriage leg e If a combined camber adjustment is required a higher stack of washers is fitted to the bolt requiring most adjustment e After packing the wheel alignment must be checked again this be done by dry assembling the wheel with packing washers but no flock and then re measuring the aircraft taking care to pull the aircraft forwards to allow the undercarriage legs to set to the new angles Alternatively the wheel may be re assembled with flock etc left to cure and then re checked once the resin has dried e wheel remains outside the given limits the alignment procedure above must be repeated Figure 20 Camber Toe In Adjustment DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 54 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 6 19 Special Inspections Fuel Gauge Decal Setup y 4 A Required Tools Clamp suitable for crimping fuel lines without damage Figure 25 Fuel container to drain fuel from wings Accurate fuel pump or measure i e Avgas bowser Parts
197. heel Alignment 777 Required Tools Marker Plumb bob String line Straight edge Steel RHS or similar at least 50mm high Digital protractor or similar Parts and Material Washers used as spacers Flock if adjustment is required Type of Maintenance Level of Certification A amp P or LSA Repairman Maintenance LSR M Return to Service A amp P or LSA Repairman Maintenance LSR M he following process must be carried out whenever a new undercarriage leg is fitted to the aircraft or if adverse tyre wear indicates alignment outside of tolerance e Before alignment the aircraft must be pulled forwards for several metres to position it in the location where the wheel alignment is going to be checked This step is very important as it sets all the wheels to the positions where they will be in normal operation e Mark a reference centreline for the aircraft on the floor Use a plumb bob from the tip of the spinner and from the tip of the ventral fin to mark points on the floor then join and mark the two points with a string line Alternatively the aircraft may be positioned accurately over a fixed line on the floor such as the join in the concrete slab used in the Figure below me Figure 17 Wheel Alignment Set Up e Place a straight edge such as a length of RHS section steel along the outside wall of the tyre Check from above to ensure that the tyre and the straight edge are parallel The straight edg
198. ibed Del mmm A Radio intercom amp headsets check correct function and condition Comments Antenna amp cables Check condition PP Comments Door catches Check condition and function Comments Stall warning Check correctly functions Comments Battery battery cradle amp cables Check condition Lad Comments Carbon monoxide detector if fitted within expiry RIF Comments Emergency beacon within useful life test in accordance with manufacturer s instructions RIF Comments Landing Taxi light alignment Night VFR equipped aircraft only P F Comments 20 1 6 Control Systems refer to section 6 13 Controls Full amp free movement correct direction of travel without interference Comments Clamps and Cables Check correct assembly indexed hardware in good condition LAESA Comments Rod ends Inspect for condition and security P Comments Trim controls and cables Check all hardware and cables ensure good condition and secure Comments Travel stops Check they are correctly adjusted and secure hourly 100 hourly 100 hourly 100 hourly 100 hourly 100 hourly 100 hourly 100 hourly Comments Decal amp labels Ensure they are in place and in good condition PP Comments Flap control amp linkages Cycle flaps ensure free amp
199. icates fail the Comments column should be used to note condition parts replaced etc INSPECTION TYPE circle 100 hourly 200 hourly Annual CARRIED OUT BY print SIQ Halle date 20 1 1 Propeller refer to section 6 8 opinner Remove and visually inspect for cracking fraying corrosion and other damage PECES Comments opinner mount plates Visually inspect for cracking fraying corrosion and other damage Comments Spinner screws Check for loose missing corroded or damaged fasteners and hardware Comments Propeller Visually check the condition of the propeller looking for damage to the leading edge protection glass de lamination and cracks splits or crushing of the propeller timber PP Comments Tracking Check propeller tracking check spinner tracking See section 19 Comments Propeller bolts nuts Check tension re tension if required See section 19 PF Comments 20 1 2 Engine Compartment refer to section 6 9 Carburettor air filter check if dirty or damaged clean with compressed air EL Comments Engine baffles and air ducts check for cracking fraying rubbing security Check rubber seals Comments 4 Oil hoses lines fire sleeve amp fittings Check for hardening cracking leakage or deterioration HE Commen
200. ication LSA repairman inspection or maintenance e Before removing the housing the nose leg steering mechanism must be disconnected Section 7 3 13 and the nose leg removed Section 7 3 14 remove remove the bolts holding the housing to the firewall required the aluminium housing be disassembled by removing the assembly screws Note that strong thread retaining compound is used on the cap screws holding the housing together To remove it may be necessary to heat the part to about 80 C using a heat gun Take care not to break screws 7 3 17 3 INSPECTION amp REPAIR Required Tools Tools as required in Section 7 3 14 5 Parts and Material Replacement hardware if required Type of Maintenance Level of Certification LSA repairman inspection or maintenance e Before removing nose leg assembly assess end float and radial wear in the nose leg bushes If necessary the bushes be replaced as detailed in Section 7 3 14 5 e Visually inspect fiberglass housing check for whitening cracks or tears e Visually inspect the flock bead of all housings check for cracking and other damage e Inspect hardware and metallic parts for wear damage or corrosion 7 3 17 4 INSTALLATION Required Tools Tools as required for Removal Air compressor Torque wrench Replacement hardware if required Type of Maintenance Level of Certification LSA repairman inspection or maintenance DOCUMENT No JTM001
201. icator tripped if fitted YES N A Comments gear wheels amp fairings Remove fairings inspect fairings and wheels for damage 100 hourly 100 hourly 100 hourly Comments Nose gear wheel steering links tension links and fairings Inspect for damage Lee Comments Wheel bearings Check for smooth rotation Comments Nose gear strut Check for rubbing cracks missing hardware etc Comments Nose gear housing amp bushes Inspect for sign of wear Comments hourly 100 hourly 100 hourly 100 hourly 100 hourly Main gear legs clamps bolts amp nuts Check for rubbing cracks corrosion missing hardware PP Comments Main gear bolts Replace as specified by intervals in section 6 3 PP Comments Tyres and tubes Check pressure examine for wear cuts bruises and slippage EAE Comments Brake fluid hoses linings discs brake assemblies amp master cylinder s LEX Comments Rod ends Check condition freedom of movement Comments Brake operational check Comments 20 1 5 Airframe refer to section 6 12 100 hourly 100 hourly 100 hourly 100 hourly 100 hourly 100 hourly Aircraft exterior Inspect exterior for cracks dents abrasions whitening of unpainted glass etc Comments Aircraft Structure Inspect as descr
202. iller Threaded Inserts some fairings are attached using threaded inserts P No 5A048A1D rather than self tapping screws The threaded insert requires a larger drilled hole and is bonded in using 5 minute Araldite This then provides a secure threaded hole for removable fairings to be attached In the case that a threaded insert has become loose or fallen out it can be repaired by bonding it back into the hole with 5 minute Araldite If the hole has suffered damage and is too large fill the hole in with Araldite and re drill then bond the insert DOCUMENT No JTMO01 0 230 D 868 08 May 2014 212 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 18 Feedback Form Any issues or corrections required of Jabiru publications are requested to be passed on to Jabiru in writing for incorporation in subsequent revisions Emails to info jabiru net au are recommended The following form template may be used if desired 19 Propeller Service Manual Heavy Maintenance Level of Certification A amp P or LSRM with task specific instruction 191 Certified Propeller Models he J230 D uses the Jabiru composite scimitar propellers 4 484 00 must maintain their propeller in accordance with the most current revision of the Jabiru propeller Maintenance Manual JPM0001 The most current manual can be found at www jabiru ne au 19 2 Approved Installations following combinations are appr
203. in Section 6 12 Ensure a new bolt is used on the attachment which has been serviced CAUTION Do Not apply any load to the bush until it has cured Do Not use rapid set i e 5 miniute epoxy 6 21 2 Attachment Point Service Movement Between Bush amp Wing e f the stainless steel bush fitted to the wing has become loose in the fibreglass lug it may be corrected as detailed below This is the most common situation causing free play in wing installations Remove the wing from the aircraft or mount it on stands as detailed above If the bush is an eccentric type where the hole for the bolt is not in the centre of the bush make a note of the orientation of the original part Use large soldering iron or similar to heat the bush to around 70 C This softens the resin bonding the bush in place and makes removal easier a bolt at least 1 size smaller than the centre hole in the bush i e for a 1 bush use a 3 16 bolt Fit the bolt to the bush and affix a washer amp nut Tighten so that the small bolt is clamping the bush This allows the technician to use the small bolt to screw the bush in and out of the fibreglass lug Remove the bush from the wing Clean the thread cut into the wing lug fibreglass using a 5 8 UNC or 7 8 UNC tap as appropriate Take care to align the tap teeth with the old thread amp ensure tap is not cross threaded Clean the bush remove all old resin amp paint using a wire wheel
204. inal shape FUEL LEVEL CALIB gt 1 LEFT gt TANK 2 RIGHT gt FULL VALUE gt PRESET VALUE gt Figure 26 EMS Calibration Screen 1 DOCUMENT No JTMO01 0 230 D 868 08 May 2014 60 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 FUEL LEVEL CALIB TANK 1 CALIBRATION gt 1 LEFT gt TANK 2 RIGHT gt SET TANK 1 SIZE FULL VALUE PRESET VALUE gt gt GALLONS _____ DEC INC a CANCEL FUEL LEVEL CALIB TANK 1 CALIBRATION gt 1 LEFT gt I rU eee gt WHEN 1 IS FULL VALUE gt FULLY EMPTY PRESS PRESET VALUE gt THE START BUTTON START BACK Figure 27 EMS Calibration Screens 2 and 3 DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 61 of 223 Jabiru Aircraft tc 6 21 Special Inspections Wing amp Strut Bush Service Required Tools Mechanic s stethoscope can be helpful Wing stands Soft hammer or similar Die grinder drill sandpaper if lug replacement necessary UNC thread tap Soldering iron or similar Parts and Material Replacement bolts if required Replacement Lug fittings if required Acetone Resin and Flock if lug replacement is necessary Etch primer corrosion inhibitor if strut lugs are replaced Stainless steel bush if replacement is required Line Maintenance Heavy Maintenance if free play detected A amp P or LSA Repairman Maintenance LSR M
205. ing spacer Type of Maintenance Level of Certification Owner LSA repairman inspection or maintenance Lightly coat axle with Anti Seize or a Water Proof grease 2 While older and lighter aircraft models use a hollow axle stub most recent aircraft use a solid version of the same part When using the solid axle an Aluminium bearing spacer ring must be fitted to the stub before the wheel assembly see Figure 43 This part is not required for hollow axles Place wheel assembly on axle Install soacer and lock bolt nut through centre of axle Wriggle the wheel along the length of the axle there should be minimal movement Movement more than 0 75mm indicates a missing spacer ring worn bearings or other issue requiring correction 5 Place outboard brake pad and springs in position and secure with bolts nuts washers 6 Install soats and speed fairing if used as outlined in Section 7 3 3 and 7 3 4 o DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 87 of 223 Jabiru Aircraft ITEM PARTNUMBER 0 DESCRIPPIN 1 80644 EXTENSION STUBAXLE 1 2 62040231 MAN UNDERCARRIAGE LEG O 1 62070233 INTEGRAL 1 25 CYLINDER BRAKE CALIPER ASSY R S 1 4 162120231 CAST WHEEL HUB ASSEMBLY 6 J 1 5 0288005 sERIS STUBAXE
206. installation WARNING Ensure the cam locks are properly engaged before starting the engine 10 1 3 Lower Cowl Removal Y Y Remove the top cowl Refer above Disconnect the engine air inlet SCAT hose and cabin heat inlet hose if fitted Remove lower cowl screws at rear of cowl Reverse the preceding steps for installation 10 1 4 Cleaning And Inspection 1 Wipe the inner surfaces of the cowlings with a cloth saturated with Mineral Turpentine 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 3 Inspect cowling camloc 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 5 Repair e Repair is limited to replacement cam locks Rivets fixing cam lock anchor lugs should be backed with washers DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 151 of 223 Jabiru Aircraft Aircraft Service Manual enero oescnenow 1 1 042 UPPER COWL MOULDING 2 MS202575 ALUMINIUMPIANO 3 3633 OINGROP RIVET 4 2600 456 CAMLOCSTUD _______ 5 20194 6 14043400 ASSY OILFILLER HOTE 1 USE MOULD TO DEFINE LAYLIP SHAPE AND TRUM PREHILE TO 2 RE
207. intenance Manual 10 2 6 Engine Accessories e Jabiru engines may be fitted with an accessory vacuum pump mounted to a pad at the rear of the engine e All Jabiru engines are fitted with a permanent magnet alternator at the rear of the engine This is considered a part of the engine and is discussed in the Engine Maintenance Manuals e Removal inspection and installation of accessories are discussed in the appropriate Engine Maintenance Manual 10 2 7 ENGINE Inspections e For specific items to be inspected and for periodic inspection details refer to Engine Maintenance Manual e Generally inspect for Loose bolts nuts cracks leaks amp cooling fin damage 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 flexible hoses in the engine compartment should be replaced at engine overhaul every 2 years whichever comes first Hoses which show visible deterioration cracking excessive hardening should be replaced immediately irrespective of age For major engine repairs refer to Jabiru Aircraft Pty Ltd or an Approved Jabiru Service Centre DOCUMENT No JTMO01 0 230 D 868 08 Ma
208. ion TE M MN E RENE et SE oi a Es X PTOL UPDATE WTH DEAL CETL B REMONED AMD ACOLD TO ATININ EE pm pe an INLET HOUSING ASSY 180 2200 4 1 6 08 mu Bilal Ee Figure 96 Carburettor Heat Box DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 161 of 223 Jabiru Aircraft tc Aircraft Service Manual Parts List ITEM PART NUMBER DESCRIPTION 14 283800 1 9 140694243 TUBE HOT AIR DUCT 2 1 4 HOSE 3 0019 187 AL POP RIVET 73 54 3 4 HOT AIR DUCT CARBY HEAT J160 C SINGLE OUTLET MUFFLER 40603244 STOP HOT AIR DUCT 010786 973 Tu COPIED WITHOUT THE CONSENT OF AVTECH LTD LES AIRPORT HOT AIR DUCT ASSY CARBY HEAT AA283AOD 1 160 SINGLE OUTLET MUFFLER Figure 97 Hot Air Duct Assy 10 10 Exhaust System Type of Maintenance Level of Certification LSA repairman inspection or maintenance 10 10 1 Description The exhaust system consists of exhaust extractor pipes running from the cylinder heads to the muffler In some cases the individual extractor pipes are connected into manifolds before reaching the muffler The muffler is attached to the extractors manifolds using springs Note that the majority of exhaust maintenance is detailed in the Engine Maintenance Manuals 10 10 2 Exhaust System
209. ion to the nose leg as shown in Figure 49 right and use it as a lever to carefully compress the rubber until the tension comes off the restraint washer Remove the restraint bolt and washer and carefully allow the rubber to expand DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 98 of 223 Jabiru Aircraft tc 6 Remove the pivot bolts and disassemble the yoke 7 If required press the pivot bushes out of the leg and yoke and replace with new parts 8 Assembly is the reverse of process above WARNING A great deal of force is required to compress the rubber Care must be taken to ensure the vice and bench are strong enough and holding the leg securely Two people are required to perform this job safely Figure 49 Nose Leg Housing amp Assembly 7 3 15 Trouble Shooting Nose Leg Table 6 Trouble shooting Nose Leg Nose strut bolts loose Tighten bolts Loose or worn steering link Tighten replace defective parts Nose wheel shimmy Nose wheel out of balance Refer Section 7 3 7 7 3 16 Nose Wheel Balancing e Refer to Section 7 3 7 for wheel balancing information DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 99 of 223 Jabiru Aircraft Aircraft Service Manual 5716 D MA OO NS LONG SAF GLYCODUR F BUSH WASMER _________________ 2035 124 Sa NYLOC NUT RETAINING COLLAR NOSE LEG RUBBER E NOSE BIGFOOT BOLT WHEN USED WITHOUT SPATS BOLT Pio 2 WHEN SP
210. iption e Where wing tanks are fitted the composite tanks are located in the left amp right hand wings A header tank is also fitted either under the passenger s seat under the baggage shelf behind the rear sound curtain Wing tanks are an integral part of the wing structure whereas header tanks are non structural and may be removed if required e sump plug is provided for each tank 11 3 2 Fuel Tank Removal wing fuel tanks are part of the wing integrity these fuel tanks cannot be removed e he header tanks may be removed if necessary to check outlet strainers etc Drain fuel from wing tanks Remove the drain plug and drain the fuel from the header tank Remove the cover from the header tank enclosure For kit built models where the tank is under the passenger s seat this may require cutting a hole into the seat pan Remove tank restraints Loosen hose clamps remove hoses amp remove tank Installation is the reverse of removal e fuel tanks installed in the cabin can be removed Drain the tank Loosen the tank restraining straps Loosen and remove the filler hose between the tank and the fuel filler on the outer skin of the fuselage Disconnect the earth wire between the tank and the fuel filler earth point Lean the tank to one side to allow access to disconnect the fuel line some cases it be necessary to disconnect the aileron cables to allow room for the tank to
211. itable Epoxy Etch Primer Once the paint has dried treat the mating surfaces of the lug and the strut with a corrosion inhibitor such as Duralac Fit the new lug to the strut while the corrosion inhibitor is wet Carefully measure the position of the lug relative to the strut to ensure the bolt hole is in the correct position Note that small errors here will have noticeable effect on the dihedral angle of the wing DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 63 of 223 Jabiru Aircraft tc Align the bolt holes of the two strut lugs This can be visually by fitting a long bolt to both the new and the old lugs and sighting along the strut to ensure they are parallel Again small errors here will cause difficulty re assembling the aircraft so care must be taken Match drill the new lug to the strut CAUTION Ensure holes in strut are not elongated oversized or otherwise damaged during drilling De burr before final assembly Fit bolts and assemble lug to the strut Apply corrosion inhibitor to the bolts amp nuts Re paint the new lug to match the aircraft colour Re assemble the aircraft and re test as detailed in Section 6 12 Ensure a new bolt is used on the attachment which has been serviced e f the holes in the wing attachment lugs of the fuselage have worn so that standard or close tolerance bolts have excess movement then the Aluminium fuselage lugs must be replaced Note that this type of wear is unusual
212. ithout fuel leakage 2 Place a cloth beneath the filter to collect any fuel which may be split during removal of the filter 3 Disconnect the fuel lines at both ends of the filter 4 Remove filter 5 Reverse the preceding steps for installation Ensure waste cloth is removed WARNING Ensure tank vents are open no vent covers fitted 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 8 Fuel Pumps Type of Maintenance Level of Certification LSA repairman inspection or maintenance 11 8 1 Description e The Primary Fuel Pump is located on the Starboard rear of the Engine Refer to Engine Maintenance Manual for details secondary electric fuel pump is also installed in all Jabiru Aircraft to assist the primary pump prevent vapor lock and for redundancy 11 8 2 Secondary Fuel Pump Removal amp Installation e Shut off the fuel on the tank side of the pump This may require the fuel tap be turned off or that the fuel system wing tanks and header tanks be drained where equipped Alternatively fuel line clamps Figure 25 may be used to close the fuel lines so that the pump can be changed without fuel leakage e Free the pump from its mounts undo the screws holding it in place Note that in several models this will require a second person outside the aircraft to hold the head of th
213. jet LEAN BONG SURFACE IT WITH RAO MCESTEHED WITH ACETONE TREN 5 SURFACE Wi TH PAPER polis EXCESS DUST WITH CLEAN RAG r APPt Y LOCTITE 820 BC D BuU SHES END PLATES TO THREADS ON ASSEMBLY USING C TTO JH FLU VA LC3G00 EPCOXY IF NECESSARY ADU WASHERS UNDER NUT OPW 5 COPE AND Pec 455 OJECTION CORED HE CONSENT OF ATES TD LIETI WALES REFER TO PART DRAWINGS MAC HINED NOSE LEG HOUSING Figure 52 Machined Nose Leg Housing DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 102 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 7 3 18 Brake Master Cylinder 7 3 18 1 DESCRIPTION e The brake master cylinder is located either inside the centre console between the seats or on the front of the main longitudinal beam In all models it is actuated by applying rearward pressure to the brake handle e Asmall reservoir is incorporated into the master cylinder for the fluid supply 7 3 18 BRAKE MASTER CYLINDER REMOVAL amp INSTALLATION INSIDE CENTRE CONSOLE Required Tools ocrew drivers Drill opanners Socket Wrench Parts and Material of Maintenance Level of Certification LSA repairman inspection or maintenance e The following procedure applies to brake cylinder installations inside the centre
214. l electrical wiring is secure Check for rubbing and damage to insulation or fittings Visually inspect for corrosion on fittings and any evidence of heat caused by a degraded connection or other issue particular the connections to the regulator and starter solenoid e Check that all engine controls and linkages work smoothly and through their full travel oecond person is required to watch the linkages move on the engine while the first person works the controls inside the cabin Ensure all stops are set correctly and that all lock nuts are Secure e Visually inspect the engine mounts mount structure and mount rubbers for cracking or other signs of degradation e Visually inspect the ignition coils and electrical connections Ensure the coils and electrical connections are secure e Verify that the carburettor heat system is functioning correctly remove the SCAT hose and verify that the flap inside the air box is moving correctly and sealing properly e Visually inspect the firewall Ensure that all firewall fittings where equipped are secure and properly filled with fireproof putty Ensure there are no screws or rivets missing and that there are no open holes through the firewall e Visually inspect the exhaust system Including Muffler Check for the condition of the restraining springs and spring tabs Check for cracks dents or other damage Particularly check for signs of leakage e Inspect the cabin heat system ensuring that t
215. l 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 and separate wheel halves removing tyre tube and wheel hub 3 Remove brake disc 4 Remove bearings from hub Note The bearings are press fit in the wheel hub and should not be removed unless a new part is to be installed 7 3 5 4 MAIN WHEEL INSPECTION ASSEMBLY AND REPAIR equired Tools Solvent Course grit sand paper Spanners socket wrench Torque wrench Parts and Material Replacement wheel halves if required Replacement Brake discs if required Replacement Wheel bearings if required Automotive wheel rim lubricant Type of Maintenance Heavy Maintenance DOCUMENT JTM001 0 230 D 868 08 May 2014 Page 86 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 Level of Certification LSA repairman inspection or maintenance e Figure 44 shows atypical wheel assembly While details and part numbers vary from model to model the general arrangement shown applies to all aircraft 1 Clean all 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 3 If excessively warped or scored or worn to a thickness of 2 mm brake discs should be replaced with a new part Sand smooth
216. lder of a CASA Weight Control Authority 2 11 Standard Practices Do not over tighten bolts Ensure a minimum of 1 full thread is clear of nuts Do not exceed 3 threads clear on nuts use extra washers Ensure nuts are not thread bound i e the thread on the nut has hit the end of the thread on the bolt e 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 i e a 7 4 washer must be fitted to 3 16 bolts or a 5 16 washer to bolts e FAA AC 43 13 or similar approved data gives guidance on accepted means for carrying out typical aircraft maintenance tasks such as safety wiring etc WARNING Thread bound nuts can carry far less load and are much more susceptible to failure WARNING DO NOT REUSE SELF LOCKING NUTS DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 14 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 2 12 Aircraft Structure In all Jabiru Aircraft due to the monocoque construction the majority of the structure is primary The components of the aircraft which are secondary structure can be identified by the fact that they are designed as fairings and are generally removable Examples of secondary structure are the engine cowls speed fairings ventral fin and wheel spats 2 13 Engines e The engines used in Jabiru Aircraft are not discussed
217. leron elevator amp rudder at intervals detailed in the Airworthiness Limitations Section of this Manual Appendix V or Section Error Reference source not found e These inspections are to be carried out as described below Measure the movement of the trailing edge of each control allowed by cable free play Disconnect both ends of the cable Move the cable by hand through its full range of movement to check freedom of movement Using a spring balance with graduations of no more than 300g measure the friction required to move the cable Repeat this step to give a minimum of 5 friction measurements in each direction of travel Reconnect one end of the cable and measure slack in the cable e hecable must be replaced if the following is found Excess friction maximum allowable force to move cable 1 9kg Excess slack in cable maximum allowable cable slack 3 5mm or tight patches of the cable travel Gritty or rough operation Significant visible damage or degradation such as corrosion scoring etc Remedial Action e Remedial action replacement or re routing of cable to reduce measured values is required if the control free play exceeds the values given in Table 4 The amount of free play in each control linkage should be within the same tolerance as the control cable itself i e 3 5mm Table 4 Control Free Play Limits Free Piay 35mm DOCUMENT No JTM001 0 230 D 868 08 May 2014
218. llation care must be taken to position the muffler correctly Carry out a test fit of the muffler to the system then stand back and check that it is positioned at the engine and is true and straight If necessary adjust the manifold or extractors Before final fit ensure that extractors manifolds are aligned well with the exhaust ports Poor alignment will result in exhaust port damage particularly for 2 bolt flanges Tighten all extractor screws amp assemble Figure 98 3300 Exhaust System 1 163 Figure 99 3300 Exhaust System Type 2 enne nnn nnn nnne nn nne nn nnne 164 Figure 100 Cabin Heat Mixer nenne nnne nnn nnn neri rrr nnne nnns 165 Figure 101 Cabin Heat Exchanger Assy 166 Figure 102 J200 Family Engine Installation Type 2 167 Figure 103 Fuel System Schematic 4 169 mie Jed EH EET EO E 170 Figure 105 Sample Fuel Line 5 171 Figure 106 Fuel Lines Showing Typical U Requiring Correction 171 Figure 107 Corrected Fuel 172 Figure 108 Header Tank Installation Type 2 Sheet 1 173 Figure 109 Header Tank Installation Type 2 Sheet 2 174 Figure T 10
219. low the removal of the locking pins DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 70 of 223 Jabiru Aircraft tc 7 1 5 1 ADJUSTMENT e Door latches or their component parts must be replaced if worn or damaged Parts List ITEM PARTNUMBER DESCRIPTION 3 16 FLAT WASHER 1160 DOOR MOCKUP SKIN BOND BUSH ARM USING EPOXY FIBRE FLOCK enau ad DIMENSIONS THIS DRAWING IS COPYRIGHT AND MUST pea 1 290144 IN MILLIMETRES 20 NOT SCALE AVTECH COPIED WITHOUT THE CONSENT OF AVTECH PTY LTD 010 786 973 LIMITS UNLESS SPECIFIED OTHERWISE 0 5 lorawN DS HINKLER AIRPORT MATERIALIREFER TO PART DRAWINGS weR BUNDABERG 4670 HE 1 Lu J160 DOOR HINGE ASSY 1 Figure 31 J230 D Door Hinge Assy DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 71 of 223 Jabiru Aircraft Aircraft Service Manual PARTS LIST Ee FRONT DOOR SKIN LS EN en _ DOORHNGEUPPERFGUESS 1 REINFORCE INNER DOOR SKIN AREA SHOWN WITH ADDITIONAL 2 LAYERS AF301 GLASS CUT SLOT IM SKINS TO FIT HANDLES an NOTE 1 OUTER SKIN IS LAID UP WITH 2 LAYERS OF AF303 FRONT DOOR SKIN INNER SKIN I5 LAID UP WITH 2 LAYER AFSO1 2 OUTER SKIN REO 5 LAYERS AF303 WHERE HINGES ATTACH 3 BEFORE JOINING DOOR FIT DOOR CATCH ASSY 4 DOOR INTERIOR 15 FLOCKED ON TO DOOR SKIN amp CIBA LY3600 EPOXY RE
220. ly without removing the damaged part from the aircraft e The procedure for repairing cracks is only recommended for low stress areas No repairs of any kind are recommended on highly stressed or compound curved areas or where repair would be likely to affect the pilot s field of vision DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 67 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 7 1 1 5 SCRATCHES e 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 7 1 1 6 CRACKS When crack appears drill a hole at the end of the crack to prevent further spreading Hole should be approximately 1 16 inch in diameter depending on length of crack and thickness of material A slightly dull unfluted drill should be used 7 1 1 7 REMOVAL 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 7 1 1 8
221. n the event of a bearing failure MITES tin 1 BOLT LENGTHS GIVEN ARE NOMINAL USE SHORTE gm IF REQUIRED EHSUR Mi OF 5 THREADS THOW THRU HUT COMMERCIAL NON JABIRU PART NUMBERS 3068064 MOUNTING PLATE TAIM ASSEMBLY _ GUANTES GIVEN ARE FOR THE COMPLETE TRIM CONTROL 3 T 1 ASSEMBLY AS SHOWN IN SHEETS 1 3 OF THIS DRAWING 59 FLAT WASHER 18 6 MSX36S 109 yie LOC NUT 184 T i2 DRIVE PLATE 1 BOLT 12 s103184 BEARING PTVOT MOUNT BLOCK ____ 1 a Praman ____ _ e 4 RODEND HE _ E E HM usi lore amwosw xeruarwasuER 2 H emo arte wae 1 m mex ____ 1_ wear O _ansies TRMCABLEASSEMSY 3 cAMLECLAMPSHM E PHIEN METALTHREAD 44525 BOLT oa 1 7 sro 35 604 6 147 FLAT WASHER 36 TRIM SPRING SOFT EH TRIM SPRING HARD NM THE DRANG DOS AND WUST HOT BE OS ind acm BUNDABERG TRIM CONTROL ASSEMBLY 200 400 3250023 2 Figure 81 Controls At Tail DOCUMENT No JTM00
222. nal details 12 7 2 Removal amp Installation Y Y Remove the instrument panel fascia as detailed above e Disconnect the instrument DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 193 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 e Undo the fasteners and remove the instrument from the fascia For installation reverse removal steps above Table 13 Trouble Shooting Tachometer Check master and avionics circuit breakers Re set Instrument fails to necessary operate Substitute known good Defective mechanism tachometer and check reading Replace instrument Sensor not positioned correctly Adjust Manual Check switch positions programming as appropriate to the tachometer Refer to engine manuals Incorrect indication Analogue Tacho Incorrectly set dip switches or tachometer programming 12 8 Digital Displays Type of Maintenance Level of Certification Digital displays are optional in Jabiru Aircraft Jabiru recommend Dynon Avionics Products Electronic Flight Information Systems EFIS and Engine Monitoring Systems EMS are used EFIS systems are a multi function flight data display The instrument shows parameters including airspeed true airspeed outside air temperature altitude heading artificial horizon turn coordinator heading markers vertical speed etc e EMS systems are multi function engine data displays The instrume
223. nd one enclosed push pull cable fitted with rod ends at both ends e Due to space constraints not all different variations are shown herein When ordering spare parts provide as must detail as possible part description aircraft model serial number etc to Jabiru to ensure accurate part identification WARNING All spherical rod end bearings must be fitted with a large washer on the outside of the through bolt to prevent the bearing case and cable releasing in the event of a bearing failure ELE EVAT JH CABLE ASSEMBLY CABLE CLAMP 5 SHIN 1 EN 1 I fh RT gt f X ELEVATOR CABLE CLAMP HBOLT TH L ED TTE pemww DS AIRPORT ELE VATOR CONTROL SYSTEM ASSY em REFE DRAWINGS APRA 4670 0 J4c 00 414 SONS Pn THIS GAMA 8 COPYRIGHT AND BE PROJECTION METRES SCALE SOPED WITHOUT THE CONSEN PTY LTD ome m M u v Figure 75 Elevator Control System Type 1 Sheet 2 DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 131 of 223 Jabiru Aircraft tc Aircraft Service Manual Parts List ITEM PART NUMBER DESCRIPTION DQWBLE CENTRE STICK ASSY 1 3 FLAT WASHER Mid 116 FEMALE ROD END 5203651082 GE
224. nd springs DOCUMENT No JTMO01 0 230 D 868 08 May 2014 106 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 7 3 23 Brake System Bleeding Required Tools Spanners Socket wrench Parts and Material Automotive brake fluid Type of Maintenance Level of Certification LSA repairman inspection or maintenance Fill the brake master cylinder with automotive brake fluid 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 tightened Release the hand brake amp repeat step 3 until all air is expelled from lines NOTE Ensure brake master cylinder remains full above the outlet hose 4 The brake callipers have been designed so that when they are in their installed position on the aircraft any air bubbles will naturally move towards the bleed nipple outlet However for dual brake systems there is potential for air bubbles to be caught at the T piece in the line near the wheel If you are having difficulty bleeding dual calliper brake system try removing both callipers from the aircraft temporarily and holding 1 calliper above the T Also ensure that the T is rotated Leave the assembly in this position for 5 10 minutes to allow any air bubbles to make their way into the high calliper then re assemble and bleed 5 When air is fully expelled tighten bleed nipple
225. nder If there is no change there is a wiring fault If it does increase then fuel gauge sender connections are reversed and must be corrected To exit press RESET and then CANCEL DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 57 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 FUEL LEVEL CALIB gt TANK 1 LEFT gt 2 RIGHT gt FULL VALUE gt PRESET VALUE v UP ajl SEL BACK 1 1 agg 5 GALLOKS TANK 2 PRES5 THE AND gt BUTTOM FULL VALUE gt UMTIL 1 15 PRESET VALUE FULL AFTER THE FIMAL POUR PRESS FULL BUTTOX gt GALLOKS 5EMSUR VALLI 253b Figure 24 EMS Fuel Calibration Screens e For this procedure the fuel tanks need to be incrementally filled from empty so first the tanks must be drained Fuel containers of sufficient volume to contain at least 10L more than the volume of fuel in the tanks are required e Drain the fuel system completely There are two ways to do this They are Disconnect the fuel line from the carburettor Using a length of fuel hose added to the fuel line pump out the fuel from the system using the auxillary electric pump and gravity Ensure the fuel tap is turned off before removing the fuel line extension and re connecting the line to the carburettor Remove the fuel drain from each fuel tank at a time and drain the fuel out this
226. ndercarriage has the same general arrangement a laminated composite spring forms the leg which is bolted to the fuselage at one end and the main wheels at the other 7 3 8 2 REMOVAL Required Tools Tools as required in Section 7 3 3 and Section 7 3 2 Parts and Material Type of Maintenance Level of Certification 1 Remove fairings to access inner and outer undercarriage leg bolts as detailed in Section Tow 2 Jack the aircraft in accordance with the details given in Section 7 3 2 3 Un bolt the axle extension and the brake calliper s to allow the removal of the wheel tyre and brake disc assembly Allow the brake calliper s to hang on the brake line ensuring that the line is not being kinked distorted or otherwise damaged If the leg must removed for an extended period it is recommended to use Zip ties or similar to support the brake calliper assembly to take the load off the brake line Cut the zip ties holding the brake line to the undercarriage leg Un bolt the stub axle from the composite leg and remove Remove bolt nut from top inboard end of undercarriage beam Remove rubber bushes 2 Remove bolts nuts 2 from the clamp at bend in undercarriage beam Remove clamp Where equipped note the orientation and remove the undercarriage leg wedge 0 Remove Undercarriage Leg Assembly m 7 3 8 3 INSTALLATION Required Tools Spanners socket wrench DOCUMENT JTM001 0 230 D 868 08 May 2014 Page 90 of 22
227. nents remove pitot mast probe remove the two rivets fastening it to the wing strut and pull it out from the strut far enough to disconnect the pitot line e For details of the Dynon pitot refer to Section Error Reference source not found e The static probe is fixed and cannot be removed Limited access may be available through the fin top strobe mount where equipped otherwise an access hole must be cut into the fin Consult Jabiru Aircraft or our local approved representative before making access holes In all cases 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 over tightening and distortion of fittings or tubing 12 5 7 Trouble Shooting Pitot Static System Table 9 Trouble Shooting Pitot Static System Low or sluggish airspeed Test pitot tube and line for leaks indication normal Pitot tube obstructed leak or or obstructions Blow out tube airspeed and vertical obstruction in pitot line and line repair or replace damaged line Incorrect or sluggish Test line for leaks and response all 3 Leaks or obstruction in static line obstructions Repair or replace instruments line blow out obstructed line DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 189 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 12 5 8 Trouble Shooting Airspeed
228. ng strong turbulence or rough round roll the indicator will trip and a red dot will appear as shown in Figure 30 e Before beginning an inspection of an airframe the indicator must be inspected If the red dot 1 visible then particular care is to be taken to inspect the parts of the aircraft which can be affected by vertical overload forces DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 68 of 223 Jabiru Aircraft tc possible circumstances cannot be listed here the following is provided as guidance only A critical trained eye is required and inspections should include but not be limited to these items undercarriage check for bent or damaged nuts bolts etc Check for damaged Spats or spat mounting hardware Nose leg check for bends cracks Check rubber has not cracked amp rubber shaft is straight Check nose wheel yoke amp nose wheel housing on firewall have not bent Main undercarriage check inboard and outboard bolts and clamps for damage and security Carefully inspect the leg for cracking or other damage Brakes check for bent discs loose or damaged hardware Check security of brake lines i e they are strapped to the undercarriage leg and not rubbing against any sharp objects such as screws etc Fuselage check structure surrounding undercarriage mount points for damage including de lamination cracking buckling etc Propeller tip check for in
229. ng assembly 7 3 14 2 NOSE GEAR REMOVAL amp INSTALLATION Required Tools Tools as required in Section 5 2 2 2 Spanners Socket Wrench Torque Wrench Parts and Material Replacement bolts and hardware if required DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 96 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 Type of Maintenance Level of Certification LSA repairman inspection or maintenance 1 Weight or tie down tail of aircraft to raise nose wheel off floor and remove the nose wheel and speed fairing as detailed in 5 2 2 Disconnect nose wheel steering pushrods and steering yoke Unbolt steering yoke from the nose leg tube Push and pull the nose leg vertically fwd aft and side side in the housing A small amount of movement is normal however any excess must be removed before it becomes excessive Refer to sections below for details on adjusting the vertical end float of the leg in the housing or replacing housing bushes 5 Remove upper collar steering yoke dependant on aircraft model from the top of the leg 6 Pull the nose wheel strut assembly down from the bushes in the fuselage 7 To install the nose gear reverse the preceding steps 7 3 14 3 NOSE GEAR GENERAL INSPECTION e Inspect steel tube and attachments for dents and straightness e Inspect rubber spring assembly for damage or perishing of the rubber or de lamination of the rubber from the
230. ning 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 Excessively hard hoses must be discarded DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 154 of 223 Jabiru Aircraft tc AND MUST CONSE EXT OF AVTECH PTY LTO AS REQUIRED L END AS REQUIRED HOSE TO FIT UP TO SHOULDER WITH MIN GAP BOTH ENDS 1 HOSE P N STAINLESS STEEL MGHTENEL HOSE ON FITTING TYP BOTH ENDS FU IEL HOSE GATES 27002 P N TO REQUIRED LEN TH FIREWALL FIRESLEEVE P N PQOO19N CUT TO LENGTH AS SHOWN amp FIT 5 NOTED WITH LOCKWIRE HOSE LENGTH 400mm LIE er x ur USE LOCKWIRE F vus AZEN TO SECURE FIRESLEEVE LENGTH 390mm WESLEEVE EITHER SIDE OF HOSE CLAMP USE LOCKWIRE P N 2 TO SECURE LENGTHS 3mm FIRESLEEVE AS CLOSE AS POSSIBLE TO HOSE CLAMP LIMIT i DETAI PURC HASED COMPONENTS iy n AL ALD MATERIAL Th pe 1C Figure 92 Fuel Hose Assy Engine Bay 10 4 Cooling Air Baffles Type of Maintenance Level of Certification 10 4 1 Description The baffles installed around the engine direct the cooling air flow to the oil cooler and to other engine components to provide optimum engine cooling The baffles
231. nstalled WARNING Failure to properly install control cables may result in loss of control of the aircraft DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 116 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 8 1 6 Ailerons Type of Maintenance Level of Certification LSA repairman inspection or maintenance 8 1 6 1 DESCRIPTION comprise a moulded and bonded monocoque structure embodying a composite drive arm While most models employ a conventional aileron some 170 variants employ a Friese aileron as shown in Error Reference source not found e Details of typical aileron installations are shown as Figures in Section 7 2 8 1 6 2 AILERON REMOVAL 1 Unbolt cable from aileron control arm 2 Loosen screws in hinge pin retainers and lift hinge pin retainer away from the hinge pin It is not necessary to completely remove these parts 3 Remove hinge pins 4 Remove aileron 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 1 6 3 AILERON INSPECTION amp REPAIR Y Y x Inspect ailerons for any signs of delamination or cracking Pay particular attention to the Drive Arm and hinges and their surrounding areas e Inspect the top front of each aileron for any signs of rubbing against the wing at full up deflection when t
232. nstraints not all different variations are shown herein When ordering spare parts provide as must detail as possible part description aircraft model serial number etc to Jabiru to ensure accurate part identification WARNING All spherical rod end bearings must be fitted with a large washer on the outside of the through bolt to prevent the bearing case and cable releasing in the event of a bearing failure 8 2 1 2 OPERATIONAL CHECK e 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 Manual Flap Lever Assy Type of Maintenance Level of Certification LSA repairman inspection or maintenance 8 2 1 3 DESCRIPTION e Many Jabiru Aircraft are fitted with a manual flap system similar to that shown in Error Reference source not found In these systems the pilot pulls down on the lever to lower the flaps positions are available up first stage and second stage The positions are controlled by the position of holes in the lever mounting plate 8 2 1 4 REMOVAL e Apply heavy duty tape or similar to both wing flaps holding them up e Remove the cotter pin and nut from the lever Remove the lever from the mount plate e Remove the screw holding the drive shaft to the handle WARNING Do not allow flaps to drop when disconnected from the handle or damage to the flaps wings or fuselage may result
233. nstrument panel shock mounts decals amp labels 9 Fresh air ventilation system 10 Cabin heat 11 Cabin upholstery trim DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 35 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 Annual Inspection Each 200 Hours Each 100 Hours 13 Pitot amp static system a 14 Radio intercom amp headsets 15 Antenna 4 cable 16 Door catches 17 Stall warning 18 Battery battery cradle amp cables 19 Carbon Monoxide Detector where equipped 20 Emergency Beacon where equipped 21 Landing Taxi Light Alignment N VFR Only Control Systems In addition to the items listed below always check for correct direction of movement particularly if controls have been disconnected and correct travel 1 Cables amp clamps 2 Rod ends 3 Trim control amp cable 4 Travel stops 5 Decals amp labels 6 Flap control amp linkages 7 Elevator control amp linkages 8 Rudder pedals amp linkages 9 Exterior surfaces of control surfaces 10 Control horns hinges amp hinge lock tabs 11 Aileron controls amp linkages 12 Rigging check flight DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 36 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 Annual Inspection Each 200 Hours Each 100 Hours 13 Throttle controls a Note that the control clearance inspection detailed in Section
234. nsure that the pitot probe on the wing strut 15 straight and that the static opening at the tip is clear and open 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 otherwise instrument may be damaged Ifthe test reveals a leak in the system check all connections for tightness 12 5 5 Blowing Out Lines e 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 e Like pitot lines static lines must be kept clear and connections tight When necessary disconnect static line at first instrument to which it is connected then blow the 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 5 6 Removal amp Installation Of Compo
235. nt shows parameters including CHT EGT oil temperature oil pressure system voltage RPM fuel level fuel flow system voltage fight timers etc Setup of these instruments must be carried out in accordance with manufacturer s instructions 12 8 1 Removal amp Installation Remove the instrument panel fascia as detailed above Disconnect the instrument Undo the fasteners and remove the instrument from the fascia For installation reverse removal steps above 12 8 2 Troubleshooting he following points reflect areas which commonly cause issues with the digital instruments used in Jabiru Aircraft For more comprehensive installation operation and troubleshooting data refer to the operator s instructions DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 194 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 Table 14 Trouble Shooting Digital Instruments Gauges Check master and avionics Circuit breaker s open circuit breakers Re set if Instrument fails to necessary operate Substitute known good instrument and check reading Replace instrument Firmware of remote compass does not match main instrument Set OAT sensor settings heading data Heading calibration not carried Perform heading calibration per Oil pressure inaccurate Poor quality earth connection Check connection replace fluctuating between display
236. nual Jabiru J230 D Serial 868 Annual Inspection Each 200 Hours Each 100 Hours Landing Gear 1 Check ShockWatch indicator where equipped 2 Main gear wheels amp fairings 8 Engine mounts mount structure 9 Starter solenoid and electrical connections 10 Coils and electrical connections 14 Carburettor heat system 12 Firewall Pf 13 Exhaust System Including Muffler Fuel pressure warning light switch where equipped 15 Cabin heat system 16 Engine cowlings and clips Fuel System 1 Fuel filters drain valves carburettor bowl 2 Electronic fuel boost pump and fittings 3 Fuel lines and connectors 4 Fire sleeves 5 Fuel line sheath inside cabin 6 Fuel tank caps amp placards 7 Fuel tank vent ball valve check Fuel Tanks 9 Fuel shut off valve amp placards DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 34 of 223 Jabiru Aircraft Aircraft Service Manual Jabiru J230 D Serial 868 Annual Inspection Each 200 Hours Each 100 Hours 3 Nose gear wheel steering links tension links amp fairings 6 Nose gear housing amp bushes Main gear bolt inspection Check life amp replace as noted in Section 6 3 2 10 Brake fluid hoses linings discs brake assemblies amp master cylinder 11 Rod ends condition freedom of movement 12 3 Windows windshield doors amp seals Pf 4 Seatbelts amp shoulder harnesses 6 Instruments amp markings TS 8 I
237. o JTM001 0 230 D 868 08 May 2014 Page 183 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 12 4 2 Instrument Removal amp Installation remove an instrument disconnect wiring or pluming to the instrument remove instrument mounting screws and take instrument out from behind or in some cases from the front of the panel n some cases due to access it may be easier to partially remove the panel fascia as noted above before attempting to remove instruments For instruments mounted a rack refer to the instrument manufacturers instructions for removal and installation procedures In 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 e 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 125 Pitot amp Static Systems Level of Certification LSA repairman inspection or maintenance 12 5 1 Description e The pitot system conveys ram air pressure to the airspeed indicator e The static system vents the
238. o JTMO01 0 230 D 868 08 May 2014 Page 84 of 223 Jabiru Aircraft tc Aircraft Service Manual Parts List MTEMI PART NUMBER DESCRIPTION 1 61020133 amp WHEEL ASSY 500 X 6 TYRE CAST HUBS 2 640384002 ONE PIECE MAIN WHEEL SPAT 500 X 6 TYRE RS 3 BOLT 96010 316 FLAT WASHER 5 ANOT0 4 WASHER 6 6527039 1 12 STRUCTURAL SCREW R S PART DRAWN P No 6A038A1D L S PART OPPOSITE P No 1 DIMENSIONS AVTECH PIL SS ome 1 IM MILLIMETRES COPIED WITHOUT THE CONSENT AVTECH PTY LTE 4 ISS DATE FA 5 010 786 9 3 e MWO DEC 0 05 ANGLES 20 HINKLER AIRPORT miin JETAILED BUNDABERG 4670 6A061A0D 1 1 CAST HUBS Figure 42 Wheel Spat Installation 7 3 4 Main Gear Top Fairing Speed Fairing 7 3 4 1 DESCRIPTION e Jabiru Aircraft are equipped with fairings between the main leg and the fuselage These smooth the airflow in this area and significantly improve the efficiency of the aircraft 7 3 4 2 REMOVAL AND INSTALLATION Required Tools Parts and Material Type of Maintenance Level of Certification Owner Task instruction is helpful e The fairing at the top of the main undercarriage leg is removed by removing the securing screws install reverse this procedure WARNING During as
239. o raise the nose wheel off the floor as detailed in Section 5 2 2 2 2 If equipped remove the screws holding the nose leg fairing together and those holding it to the wheel spat Remove the fairing 3 Remove the machine screws around the forward and rear sections of the fairing and remove the rear section 4 Loosen and withdraw the axle remove the wheel and remove the front section 5 Reverse the preceding steps for installation 7 3 11 Nose Wheel 7 3 11 1 DESCRIPTION e The nose wheel assembly consists of a cast Aluminium split rim tube and tyre The smaller half of the split rim is common with the main wheel assemblies while the larger half with integral bearing carriers is specific to the nose wheel e Figure 47 shows a typical installation While details and part numbers vary from model to model the general arrangement shown applies to all aircraft 7 3 11 2 REMOVAL AND INSTALLATION F Required Tools Tools as required in Section 5 2 2 2 Spanners Socket wrench Screwdrivers Torque wrench Parts and Material Type of Maintenance Level of Certification Owner LSA repairman inspection or maintenance 1 Weight or tie down tail of aircraft to raise the nose wheel off the floor as detailed in Section 5 2 2 2 Remove the wheel spat and the nose wheel axle bolt Pull nose wheel assembly from yoke Reverse the preceding steps to install nose wheel Tighten axle bolt to solid laminate value given in Table 2
240. ockpit baggage area This curtain is attached to the forward of the fuselage using velcro straps Its purpose 15 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 WARNING Do not stow items behind the sound curtain DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 74 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 7 1 9 Safety Provisions 7 1 9 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 Attaching parts should be replaced with equivalent parts if excessively worn or defective 7 1 9 2 CARBON MONOXIDE DETECTOR e Carbon monoxide detectors are mandatory for all aircraft fitted with a cabin heater and strongly recommended for all other aircraft e Chemical or black spot detectors are used These detectors have a life which starts from the point at which the detector is removed from its packaging e Operators must ensure that where equipped the carbon monoxide detector fitted to their aircraft is within its useful life 7 1 9 3 EMERGENCY LOCATOR TRANSMITTER e Where emergency beacons are fitted they must be maintained in accordance with their manufacturer s instructions e Beacons typi
241. olts 12 Plug or cap hydraulic fittings and hoses to prevent the entry of foreign material 13 Reverse the preceding steps to install brake master cylinder then fill and bleed brake system in accordance with Section 7 3 23 DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 103 of 223 Jabiru Aircraft tc 7 3 18 4 BRAKE MASTER CYLINDER REPAIR e 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 QTY ON 1 2 027800 MOUNT BRAKE LEVER lt 1 4 6A027C0D_ LEVER INPUT BRAKE 1 5 960 416 1 4 FLAT WASHER 4 6 ANA 11 1 9 1 5 5 16 CASTLE NUT 1 10 3031094 BRAKE KNOB SHORT 11 13032094 BRAKE KNOB LONG 12 PHo39N NUTSM BSW ____ 1 SCREW 3 16 BSW X 1 1 2 1 1 4 x1 2 UNC GRADE 8 HEX HEAD BOLT 2 2 1 15 PH3ADO7M 1 4 UNC x 3 47 GRADE 8 HEX HEAD BOLT 16 000624 BRAKE MASTER CYLINDER FITTING ASSY i 77 H A X J vt gt By 4 E FP 1 A amp x CENTER LINE MOUNTING DETAILS IN BEAM 2419106 Jw 10 8 06 DIMENSIONS _ THIS DRAWING 15 COPYRIGHT AND MUST NOT SCALE 1 1464 2005 IN MILLIMETRES SCALE AYTECH P L COPIED WITHOUT THE CONSENT OF PTY LT
242. ommutator Ring Remove screws to allow cover to be removed for motor access D ul Figure 64 Linear Actuator Disassembled DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 121 of 223 Jabiru Aircraft tc Aircraft Service Manual Gaps between segments A of the ring must be Commutator Ring cleaned Black material must be removed We Figure 65 Commutator Ring Close Up 8 2 2 4 INSTALLATION 77 Installation is the reverse of removal e Ensure the flap position indicator is positioned correctly e Ensure tape is removed from flaps and an operational test carried out before use DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 122 of 223 Jabiru Aircraft Aircraft Service Manual Jabiru J230 D Serial 868 Parts List TEM PASTNUMBER DESCRIPTON 4 34033500 1 2 BEARING BLOCK FLAP OWE d 2 A FLAT WASHER 3 Bassa 5 SaO ELECTRIC FLAP SERWO MOUNT LINEAR ACTURTOR ELECTRIG FLAP SUPER BEN Res T jew BoT l a AL EF BUSH 14 TUBE 318 FLAT WASHER 5 2 THIGRMESS TIF NYLOC MUT 2 Ba Ba fd I8 IM FLAT WASHER ____ 1 amp aaao SPACER BUSH 518 BUNDY TUBE paj IMTERNAI DRIVE j DHE AMG Pf sage Sta
243. onnection of flight controls Replacing or cleaning spark plugs and setting of spark plug gap clearance Replacing any hose connection except hydraulic connections Replacing prefabricated fuel lines Cleaning or replacing fuel and oil strainers or filter elements Replacing and servicing batteries Replacement or adjustment of nonstructural standard fasteners incidental to operations Every 100 hours if used in flight training or Annually whichever happens first a 100 hour inspection must be carried out by an Authorised Person as specified on the 100 hour inspection checklist in this manual CAUTION It is the operator s responsibility to ensure that the factory built aircraft is correctly maintained for the intended use 2 9 X Aircraft Specifications e Leading particulars of the aircraft discussed in this manual are given in Section 3 If these dimensions are used for constructing a hangar or computing clearances remember that such factors as tyre pressure tyre size and load distribution may result in some dimensions that may be somewhat different from those listed 2 10 Centre Of Gravity Limitations e All JABIRU J230 D aircraft are relatively light weight 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 or a person authorized to revise an aircraft s weight and balance information such as the ho
244. ontainers scales mixers etc Scratch removing compounds such as Novus Plastic Polish for windows DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 20 of 223 Jabiru Aircraft tc E LOCTITE LOCTITE LOGTITE LOCTITE 290 262 620 243 THREADLOCKER THREADLOCKER COMPOUND SUPER _ 1200501 THREADLOCKER H 2 SUPER 46950 62050 STUD LOCK E HighStrength SUPER PIE Super High Temp T NUT LOCK LS IGE IN Figure 2 Sealants Compounds amp Lubricants 3 e Loctite 620 is designed for the bonding of cylindrical fitting parts Typical applications include locating pins in radiator assemblies sleeves into pump housings and bearings in auto transmissions Particularly suitable for applications where temperature resistance up to 200 is required Used as a ultra strong threadlock Loctite 620 is specified in several places in the Jabiru Aircraft where a reliable bond is essential When using it follow the rules below WARNING Failure to use Loctite 620 correctly can result in bond failure Check use by dates Loctite 620 like most other compounds has a use by date Generally this is not printed on the bottle but can be found by contacting the distributor and telling them the batch number Work fast Loctite 620 can cure very quickly All screws must be torqued to final settings as quickly as practical Anything more than a minute is not recommended
245. osition liquids will drain to the lower tip resulting in an unbalanced propeller CAUTION Ensure that the Master and Ignition Switches are OFF before turning motor WARNING Do not store MOGAS or fuels containing alcohol for longer than 30 days in a Jabiru aircraft Refer to Service Letter 5 007 for details e Store under cover away from direct sunlight DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 28 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 n addition to the normal parking covers detailed in Section 5 2 5 openings in the engine cowl and other similar openings should have protective covers fitted to prevent entry of foreign materials and pests especially wasps 5 3 2 Returning Aircraft To Service e After flyable storage returning the aircraft to service is accomplished by performing a thorough pre flight inspection Ensure all protective covers are removed 5 3 3 Temporary Or Indefinite Storage e Temporary storage is defined as aircraft in non operational status for a maximum of 90 days e Treat as for flyable storage see Paragraph 3 1 7 plus For temporary storage fill fuel tank with AVGAS 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 CAUTION Do not store MOGAS or fuels containing alcohol for longer than 30 days in a Jabiru
246. otes re Shockwatch indicator 2 4 Introduction 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 distributed directly to owners of factory built aircraft in addition to being posted on the JABIRU website or provided to your local distributor IS MANDATORY that new owners of pre owned aircraft should ensure that the transfer of their aircraft has been advised to JABIRU AIRCRAFT Pty Ltd or your Jabiru representative so that our owner databases can be updated Existing owners should ensure that they update Jabiru with their new contact details when they move or details change e This Maintenance Manual is specific to the J230 D aircraft listed on the cover page and may not be appropriate to any other J230 D aircraft Before working on an aircraft the technician must be fully conversant with the Aircraft Maintenance Manual Engine Maintenance Manual Propeller Manual and any relevant Service Bulletins Service Letters or other manufacturer s data Current information is available from the Jabiru Aircraft Australia web site www jabiru net au and in the LSA Owners Info www usjabiru com e Maintenance must only be carried out by an approved person Authorized persons are noted for each procedure in the manual 2 5 Degree Of Difficulty e This manual is intended fo
247. oved Table 17 Approved Scimitar Propeller Installations Factory built Models Propeller Dia x Pitch ll Limits nd LC mage Specification J230 X Not Above 3300 19 3 19 4 Installing amp Servicing Refer to the Jabiru Propeller Manual document for installation removal maintenance and inspections 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 5 Installation Refer to Error Reference source not found and the Jabiru Composite Scimitar Propeller Manual JPM00001 DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 213 of 223 Jabiru Aircraft o 2 N 5 Aircraft Service Manual 30779 Whe ASS HITIA 0022 sana cane Lo pee t ac Le Lese Tace Td LOHN LETS E DEI ELE SUA SOL SOS MS DEC Figure 132 Typical Scimitar propeller installation Page 214 of 223 08 May 2014 DOCUMENT No JTM001 0 230 D 868 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 CAUTION 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 S
248. p push rods connect the flap cross shaft to the flaps 8 2 4 6 REMOVAL INSPECTION amp INSTALLATION e Apply heavy duty tape or similar to both wing flaps holding them up remove unbolt at both ends and remove Reverse for installation WARNING All spherical rod end bearings must be fitted with a large washer on the outside of the through bolt to prevent the bearing case and cable releasing in the event of a bearing failure 8 2 5 Flap Type of Maintenance Level of Certification LSA repairman Inspector or Maintenance 8 2 5 1 DESCRIPTION he flaps comprise a moulded and bonded monocoque structure embodying a composite control arm at the inboard end e Installation drawings for flaps are given in Section 7 2 8 2 5 2 FLAP REMOVAL 1 Unbolt rod end from flap control arm 2 Remove each flap hinge bolt and spacer 3 Remove Flap 8 2 5 3 INSPECTION AND REPAIR e Inspect flaps for any signs of delamination or cracking Pay particular attention to the Control Horn and hinges and their surrounding areas e Repairs must be referred to Jabiru Aircraft Pty Ltd or our approved local agent 8 2 5 4 FLAP INSTALLATION e Reverse the preceding steps for installation Replace all Nyloc nuts and torque in accordance with Table 2 WARNING All spherical rod end bearings must be fitted with a large washer on the outside of the through bolt to prevent the bearing case and cable releasing in the event of a bearing failure
249. panel fascia the encoder mounted to the firewall and the antenna fitted under the front of the aircraft 13 6 2 Removal amp Installation 777 e Note that transponder calibration must be carried out by CASA authorised technician All transponder maintenance must be carried out by qualified technicians remove transponder move the mounting screws holding it to the panel fascia Disconnect it from the wiring loom and draw it out under the panel In some applications it may be necessary to remove the instrument panel fascia for access remove the encoder undo the thumb screw and remove it from its bracket Disconnect the static tube and electrical loom e To remove the antenna disconnect the BNC connector loosen the lock nut and withdraw the assembly For details of electrical connection refer to the transponder manufacturer s data e For installation reverse removal steps above DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 204 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 THIS DRAWING IS COPYRIGHT AND MUST NOT BE COPIED NT WITHOUT CONEDNT OF PRY DD DIMENSIONS MILIMETRES DO NOT SCALE PROJECTION 46 MOUNT ENCODER ON F WALL BEHIND PANEL WITH 699 1 2 SCREWS TUNING SCREWS TO POINT DOWN TO ALLOW TUNING IN A C ACCESS POINT FOR TRANSPONDER ANTENNA INST BOTH SIDES NECESSARY BACKING PLATE EXTERNAL BEND TO FUSE SHAPE
250. particularly if cure accelerator spray Loctite 7471 is used Only use as much as required specified Excess compound can make it nearly impossible to disassemble the parts later Surface preparation is critical Threads must be cleaned and prepared properly To Remove Can normally be achieved by heating the screw to over 150 C using a pencil point gas burner Minimise direct heat applied to the head of the screw as this can weaken the drive socket direct heat towards the thread as must as possible e Loctite 290 is designed for the locking and sealing of threaded fasteners Because of its low viscosity and capillary action the product wicks between engaged threads and eliminates the need to disassemble prior to application The product cures when confined in the absence of air between close fitting metal surfaces and prevents loosening and leakage from shock and vibration The product can also fill porosity in welds castings and powdered metal parts e Loctite 262 is designed for the permanent locking and sealing of threaded fasteners Typical applications include the locking and sealing of large bolts and studs up to M25 A medium strength threadlock e Loctite 243 is designed for the locking and sealing of threaded fasteners which require normal disassembly with standard hand tools Particularly suitable for applications on less active substrates such as stainless steel and plated surfaces where disassembly with hand tools is
251. pinner removed 19 6 To Remove Existing Propeller 1 Remove Machine Screws and Tinnerman Washers from Spinner 2 Remove Spinner 3 Consult the Jabiru Propeller Manual for propeller removal 19 7 Assemble And Replace Propeller Assembly 1 Consult the Jabiru Propeller Manual JPMOO1 for propeller installation Servicing And Repairs 19 8 Propeller Balancing Procedure und d Propeller balance should be checked by locating a 16mm tube to firmly fit the centre mounting hole of the Propeller and balancing on knife edges e Tolerances Imbalance shall not exceed the following limit whatever the position of the Propeller in the plane of rotation 750 mm gms approximately 1 gm at the tip e The balance may only be corrected by the application of epoxy paint Any other method of securing balance is PROHIBITED e Propellers outside these limits should be rejected as unserviceable or returned to JABIRU for assessment and possible repair DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 215 of 223 20 Appendix Worksheets The worksheet provided covers all inspection tasks required for 100 hour 200 hour and annual inspections Tasks listed Annual need only be done annually 200 hourly tasks are to be completed at both annual and 200 hour inspection intervals while 100 hourly tasks are to be completed at all three inspection intervals Annual 200 hours and 100 hours P indicates pass F ind
252. pplication technique 1 essential if an accurate bolt torque reading is going to be obtained e Firstly the nut must be tightened smoothly Any jerks or bumps can cause the torque reading to be obtained prematurely e The torque must be obtained while the nut is turning If you stop to reposition the torque wrench and then the required torque reading is obtained without the nut turning the nut needs to be loosened a little and then tightened again so the torque reading is obtained while turning Unless specified otherwise all torque settings given in this manual are dry i e no special lubricant is applied to the threads or parts Where directed otherwise it is vital that the directions are followed exactly DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 24 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 5 Cleaning Ground Handling amp Storage 51 Cleaning e Keeping the aircraft clean is important Besides maintaining the appearance of the aircraft cleaning makes inspection and maintenance easier 5 1 1 Windshield And Windows e 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 mud 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 buil
253. proved local agent 8 5 5 Installation e Reverse the preceding steps for installation WARNING All spherical rod end bearings must be fitted with a large washer on the outside of the through bolt to prevent the bearing case and cable releasing in the event of a bearing failure DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 133 of 223 Jabiru Aircraft DESCRIPTION EUM ANA HORIZONTAL 2004400 _ EE i Seo 4 PHON ame POP RIVET 734548 Jel 5 20 WASHER 6 _ PHON MIE CSUNK RIVET CPiNo 48 ELEVATOR HINGELEAF a ELEVATOR HINGE LEAF 5 9 335208 245 SCREW 18 0 2001594 HINGE PIN EN cv xou HNGEPNITOD O 8 12 Ms21008108 ANCHORNUT 16 13 392 CSUNK POP RIVET 3 12 COMMERCLAL NON LABEL PART 1 2 VIEW A VIEWB TRIM TAB DETAIL HINGE DETAIL DETAIL VIEW D SCALE 1 4 SCALE 1 1 XT SRM d DIMENSIONES THIS ORANG 13 COPYRIGHT AND MUST NOT 0 j 0207 AVTECH PAL 010786973 UNITS UNLESS SPECIFED CTHERASE 1 bue us AXEPORT HORIZONTAL TAIL PLANE ASSEMBLY 20850233 ___ 20040 Parts List PART NUMBER
254. r Check that the heat exchanger is secure on the exhaust not damaged Any damaged or inoperative parts will need to replaced repair is not possible on these components 10 11 4 A Installation For installation reverse removal procedure above Parts List ITEM PART NUMBER DESCRIPTION FIREPROOF CABIN HEAT MIXER BOX MAIN BODY _ d FIREPROOF CABIN HEAT MIXER BOX BUTTERFLY _ LEVER FIREPROOF CABIN HEAT MIXER BOX SHAFT FIREPROOF CABIN HEAT MIXER BOX OUTLET THREADED SLEEVE CHOKE CABLE 5 16 UNF 5716 UNF NUT FIREPROOF CABIN HEAT MIXER BOX NUT _ 1 4 FLAT WASHER _ PH10372N 1 ROLL PIN 3 32 x 172 LONG _ 526 63284 SCREW 6 32 X 14 k E ONCE BUTTERFLY IS SCREWED TO SHAFT BURR THREADS e TO LOCK 5 11607170 70 mm JAAD 20 mm DIMENSIONS PE IN MILLIMETRES DO SCALE AVTECH CEN DEC N DEC 005 Stos DS mn DWG No ONE DEC 0 35 TOW DEC toD ANGLES 05 AIRPORT DWG REFER PARTDRAWINGS AIRPORT CABIN HEAT MIXER BOX ASSY 3A068A0D 2 FIREPROOF Figure 100 Cabin Heat Mixer Assembly DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 165 of 223 Jabiru Aircraft tc Aircraft Service Manual _Parts 1 is _ 1 PART NUMBER mM ere S 1 CABIN HEAT HEAT
255. r sub spar also known as the wing attachment lug or fork Both wing attachments are contained in a reinforced Wing End Plug and bond to the wing skins The Wing End Plug distributes load from the attachments to the main spar Both attachments are through stainless steel threaded bushes bonded into the attachment blocks e he wing internal structure is sealed and only needs to be accessed for repairs The installation of the control surfaces control cables etc for the J230 D are detailed in the drawings below Refer to Figure 36 Figure 37 and Figure 38 for details 7 2 2 2 REMOVAL e Refer to Section Error Reference source not found for removal details 7 2 2 3 REPAIR e repairs must be referred to Jabiru Aircraft Pty Ltd or our approved local agent 7 2 2 4 INSTALLATION e Refer to Section Error Reference source not found for installation details DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 76 of 223 Jabiru Aircraft 18553 NOMINAL 30 i i LLL es ee 15 Li Li 1167 r LL RR L Jo in 1215 TRIMMED AILERON INET END OF AILERON TRIM FLAP SS 4130 3186 8 TO CENTRE OF AILERON END 3180 TO OUTED OF AILERON HORN 4 wwe WINGTIP IN PLACE USING FLOCK NOTES 1 USE ONLY L 3600 EPOXY
256. r the gel coat as gel coat is a sufficient undercoat 14 The final rub is with 320 grit all over and if satisfied with the surface preparation remember paint will simply change colour 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 15 Wash down the floor of the spray area to settle dust and proceed to spray as per your selected technique 16 You are now ready to spray your 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 and ultra violet light to the aircraft structure In addition colour including stripes etc must not be applied to horizontal upper surfaces DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 207 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 16 Placards 16 1 Model Specific Decals Table 15 Model Specific Decals Decal Detail Preview Warning Placard J230 D P No 5A076A0D Fitted above windscreen in front of wing carry through beam across to the left side LSA Warning Decal J230 D Part of Instrument Panel Face Fit adjacent to main warning placard LSA models see above Nose Wheel Inflation J230 D P No 5A062A0D NFLAT Attach to left side of nose wheel spat Main Wheel Inflation J230 D P No 5A061A0D Attach to outsides of main wheel spats 16
257. r use by experienced technicians and while all processes will be explained as clearly as possible some knowledge is assumed This manual is not intended to be sufficient reference for a person with no other training to safely maintain an aircraft e In this manual we have used a spanner scale to help technicians approach a job Anyone considering undertaking a task in this manual must realistically assess themselves against this scale and not attempt any task for which they lack knowledge or the required tools The Spanner Seale Simple basic straightforward A careful layman with guidance DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 12 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 can achieve this Straightforward but with some technical bits Basic knowledge C and guidance needed Straightforward but requires special tools training and or judgement Sound basic knowledge guidance and a careful A difficult job Requires special tools solid skills good judgement Only for experts 2 6 Use By Dates amp Storage e Some products called for by this manual including thread locking compound resins and glues have a use by date Care must be taken to ensure all such compounds are within their shelf life before applying them to an aircraft Loctite products typically do not have their use by date marked on the bot
258. raft Pty Ltd or our approved local agent e dented cracked or deformed wing strut should be replaced prior to next flight DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 78 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 7 2 4 Landing Light S 7 2 4 1 DESCRIPTION e Landing taxi lights are standard equipment for Jabiru Aircraft Night VFR variants have wing leading edge mounted housing on each wing with narrow beam high intensity LED lights fitted 7 2 4 2 REMOVAL INSPECTION amp INSTALLATION otanley knife or Scalpel blade Parts and Material Silicone adhesive for reinstallation Line Maintenance Owner Task instruction is helpful e Remove the clamping screw at the trailing edge of the light housing e required carefully remove silicone adhesive between housing and strut with knife taking care not to damage the paint or the light housing e Remove the housing from the strut then disconnect the light wires e Remove light mounting screws to allow removal of the light from the housing e Visually inspect the light housing for cracks or damage Check the strut for chaffing wear corrosion Inspect the wires for damage to the insulation corrosion on the connectors etc e For installation reverse the steps given above Note that silicone adhesive or similar is required to prevent the housing chaffing on the strut 7 2 5 Landing Light Adjustment Night Vfr Models
259. rasion encountered in these areas CAUTION DO NOT use Silicon based cleaning materials as Silicon is absorbed into the composite materials and may affect reparability 5 1 4 Aluminium Surfaces e 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 DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 25 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 hose down wheels and spats after landings in mud or sand to ensure brakes wheels and spats are free of dirt build up 5 1 5 Engine And Engine Compartment e 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 e Recommended cleaning procedure is lightly spray with degreasing
260. rational Check e Movement of the Trim Lever FORE and AFT should result in movement of the Main Control FORE and AFT and movement of the Elevator UP and DOWN 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 9 3 Removal 77 e Remove the ventral fin to allow access to assembly DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 138 of 223 Jabiru Aircraft tc e Un bolt and disconnect the trim shaft from the elevator Use tape seat belts or similar to apply full aft to the control column and hold it in place This is to raise the elevator out of the work area and prevent it from dropping back down Un bolt the lubron block from the pivot plate and remove the spring loaded shaft Un bolt the control cable from the pivot arm and remove e Un bolt the pivot assembly from the fiberglass tail horn and remove from the aircraft 8 9 4 Inspection amp Repair 77 Visually inspect for excess wear or contamination of the lubron block If required apply fresh graphite lubricant Inspect the pivot bearings for condition and replace if required Inspect hardware for damage or corrosion 8 9 5 Installation e Reverse the removal procedure above for installation WARNING All spherical rod end bearings must be fitted with a large washer on the outside of the through bolt to prevent the bearing case and cable releasing i
261. rburettor 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 e The frequency with which the filter should be removed inspected and cleaned will depend on the operating conditions A good general rule however is to remove inspect and clean the filter ever 100 hours of engine operating time and more frequently if warranted by the operating conditions Clean only with compressed air and replace regularly e Engine baffles and ram air ducts must be visually inspected Check for cracking fraying and evidence of rubbing Ensure that the hold down points are in satisfactory condition and that the ram air ducts are securely attached to the engine e Inspect all sealing rubbers on the ram air ducts oil cooler openings etc and repair amp replace as required e Inspect all oil Hoses lines fire sleeve amp fittings Check for hardening cracking leakage and any other signs of deterioration e Inspect all fuel Hoses lines fire sleeve amp fittings Check for hardening cracking leakage and any other signs of deterioration Ensure that fire sleeves are long enough to completely cover all flexible hoses i e they must extend past the hose clamp to the very tip of the hose e Check SCAT hose interior and exterior condition e Ensure that al
262. re pressure and the condition of tyres amp tubes Examine tyres for wear cuts bruises and slippage e Apply the hand brake Standing in front of the aircraft pull firmly on the propeller placing hands immediately beside the spinner Rock the aircraft forward and aft left and right while observing the nose leg and both main legs Any excess movement noise or vibration which is apparent during this test can indicate deterioration in the undercarriage legs fastenings or mechanism and must be corrected e Inspect all rod ends to ensure condition freedom of movement and secure lock nuts e Visually inspect nose leg steering soft link where equipped Ensure the rubber is in good condition and that all the parts and hardware are not damaged or corroded Check brake master cylinder and refill with automotive brake fluid DOT 3 or DOT 4 Bleed the brake system of any trapped air whenever there is a spongy response on the brake lever e Check that discs are straight not excessively corroded and not worn outside of limits e Check for brake fluid leaks chafing or other damage to brake hoses Ensure that the brake linings have sufficient wear remaining to reach the next scheduled maintenance Check brake assemblies amp master cylinder for rubbing damaged or missing hardware or corrosion Carry out a brake operational check Refer to Section 7 3 20 for filling and bleeding of the brake system CAUTION The JABIRU uses automotive brake
263. rew seats a single vent line is fitted to the underside of the fuselage 11 4 2 Inspections 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 e The following procedure may be used to check the vent lines for aircraft with wing tanks Have an assistant hold a rubber glove or balloon over the vent tube on one cap 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 DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 174 of 223 Jabiru Aircraft tc Tocheck the breather line for the header tank Where equipped turn off taps between the wing tanks and the header tank Alternately fuel line clamps may be used Disconnect the fuel line from the mechanical fuel pump on the engine 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 clear Note that the fuel hose outlet must be positioned at carburetor height during this test Correct any blockage amp reassemble e check the operation of the filler cap fuel vent check valve where equipped Remove the cap and shake it The ball inside should move freely producing a r
264. rial 868 9 2 4 Rudder Centering System Installation install reverse the removal procedure given above WARNING All spherical rod end bearings must be fitted with a large washer on the outside of the through bolt to prevent the bearing case and cable releasing in the event of a bearing failure MIS M ALO RUDOE i5 ex TRUH IH Wei 4 1 LE A a meg iar i SE Lal d Eig 4 i ANC 2 ADORA Jj ML SUME BOUE LO STEER A ned LIT 5 ANCLAA 7 4 I i UAE 4 E d a Pi T L 4 a 4 L F ME ERFT rj CoU eT T ac da m Fs oa d Gr pu m LAN TER WOT SCALE FT I P EXPERCCTIIEUTITUEIPECTYTY 1 010780873 r mE gy 5E d 233 351 LL E E Ls ama wp i 1 HORE LEG STEERING RI DOE R 4 irr e E ma P T T CENTEING ASSY J160 FAMILY i T T Figure 85 Steering Rudder Centering Assy Type 3 Sheet 1 DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 144 of 223 Jabiru Aircraft m
265. rial 868 WARNING When supporting the aircraft by trestles under the belly ensure that that trestle is padded and located under the wing strut beam undercarriage channel or similar hard point on the fuselage structure Carelessly positioned trestles can easily damage the aircraft Ensure that the aircraft is stable and supported so that it cannot tip off the trestles 7 3 3 Main Wheel Fairing Spats 7 3 3 1 DESCRIPTION e Jabiru Aircraft are equipped with fairings for the main and nose wheel These streamlined covers reduce the drag of the undercarriage and significantly improve the efficiency of the aircraft 7 3 3 2 REMOVAL AND INSTALLATION Required Tools Screwdrivers Spanners Socket wrench Parts and Material Type of Maintenance Level of Certification Owner Task instruction is helpful Remove the bolt on the outside of the fairing Remove the machine screws on the inboard side of the fairing In some models the fairing is in two pieces the large outboard section and the small inboard part For these fairings the inner and outer pieces must be separated by removing all the machine screws before removal 4 Lift the fairing up and out until free of the wheel 5 Reverse the preceding steps for installation WARNING During assembly ensure that the brake line is not rubbing against the fairing or mounting screws Rubbing can lead to failure of the brake line and wheel brake failure DOCUMENT N
266. rings outboard pad and nuts washers Reconnect flexible hose Visually inspect Ensure there is clearance between the brake components and the tyre Fill master cylinder reservoir with brake fluid Bleed brakes Refer to Section 7 3 23 uio DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 105 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 7 3 21 Parking Brake 7 3 21 1 DESCRIPTION e 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 2500 adjust by one or all of the following 1 Adjust brakes as described in Section Error Reference source not found 2 Bleed air from brake system as described in Section 7 3 23 7 3 22 Brake Pad Lining Installation Solid Rivet retained pads only Required Tools Spanners Socket Wrench 1 8 punch and hammer Drill Parts and Material Replacement pads and rivets Type of Maintenance Heavy Maintenance Level of Certification LSA repairman inspection or maintenance New brake linings should be installed when the existing linings are worn to expose the rivet heads replace outboard lining 1 Remove bolts securing outboard brake pad and brake cylinder to backing plate 2 Remove outboard brake pad 3 Place brake pad on a table with lining side down flat Centre a 1 8 or slightly smaller pun
267. ry or death of persons on or in the vicinity of the vehicle Jabiru Aircraft Pty Ltd does not support the use of this aircraft in any applications which do not meet the requirements of the appropriate Pilot Operating Handbook or Flight Manual Any non compliant operation may render the aircraft un airworthy and will void any warranty issued by Jabiru Jabiru J230 D Aircraft are designed to be maintained only in strict accordance with this Maintenance Manual Any variation of any kind including alteration to any component at all whether replacement relocation modification or otherwise which is not strictly in accordance with these manuals may lead to dramatic changes in the performance of the aircraft and may cause unexpected engine stoppage loss of control or have other detrimental effects on the aircraft which may lead to injury or death Jabiru Aircraft Pty Ltd does not support any modifications to an aircraft its parts or components Any such actions may render the aircraft un airworthy and will void any warranty issued by Jabiru Maintenance and modification cannot be supervised by the manufacturer Maintenance requires extreme cleanliness exact parts precise workmanship and proper consumables It is the owner s responsibility to ensure absolute attention to detail no matter who may become involved in work on this aircraft Your safety your life and your passenger s lives rely on precise and accurate following of instructions in this man
268. s This procedure method is suitable for aircraft with dry wings no wing fuel tanks and those with a minimum of 75mm 3 free play in all connections between the wing and fuselage fuel lines aileron and electrical cables etc For aircraft equipped with fuel sight gauges inside the cabin this procedure will normally not be suitable as the short fuel hoses from the wing to the sight gauges do not have sufficient free length Two adjustable wing stands are required for this procedure Remove the wing root and wing strut fairings both top and bottom Place the two stands under the wing one located inboard close to the fuselage and the other positioned around 1m 3ft inboard from the tip Adjust the outboard stand so that it is just clear of the underside of the wing Remove the wing strut from the aircraft as detailed in Section 7 2 3 1 The strut is removed completely to clear the work area and reduce the chance of over stressing any attachment points Rest the wing on the outboard wing stand DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 62 of 223 Jabiru Aircraft tc Adjust the inboard wing stand until it is just clear of the underside of the wing Remove both the forward and aft wing attachment bolts and rest the wing on the stand The wing 1 now resting on the stands positioned close to the fuselage at the normal height so that the fuel lines and aileron cable can be left connected Ser
269. s FUEL ime AL FUEL DRAIN REAR FUSE STIFFEMER DRAN DWG N AVTECH P LIHEADER TANK INSTALLATION 4A408A0D 2 APPR BLING j230 C SHEET 1 OF 3 Figure 108 Header Tank Installation Type 2 Sheet 1 DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 173 of 223 Jabiru Aircraft tc CONS ENT i or DIMENSIONS IN MILIMETRES DO MOT SCALE PROJCTON 4B wus anro LTD P ad HEADER TANK INSTALLATION AAAQ OBAO JD 2 AS 23 0 SHEET 2 OF Figure 109 Header Tank Installation Type 2 Sheet 2 11 4 Fuel Vents Type of Maintenance Level of Certification LSA repairman inspection or maintenance 11 4 1 Description e For aircraft with wing tanks ventilation is either provided by vented fuel caps or by a sharks fin vent fitted to the cabin roof e Where vented caps are used some models incorporate a check valve to prevent excess fuel leakage when the aircraft is parked on an angle or flown out of balance e For aircraft with wing tanks and a header tank all three tanks are interconnected to ensure uniform breather pressure and even feeding from all tanks e For aircraft with a single fuel tank fitted behind the c
270. s check fittings for leaks 6 Hepeat steps 1 4 for other side brake WARNING Use only automotive brake fluid DO NOT use aircraft hydraulic fluid or damage will result WARNING The calliper mount plate can be damaged by repeated bending sharp bending or tool marks Care must be taken 7 3 23 1 BRAKE DISC WEAR LIMIT 1 Measure the thickness of the brake disc in an area where it is not being worn i e on one of the hub legs Compare this measurement to the wear face of the disc The maximum wear i e difference between the two measurements is 2 0mm 2 If brake disc is below minimum thickness install a new part For directional brake discs refer to Figure 45 for installation details 7 3 24 Trouble Shooting Brakes Table 7 Trouble Shooting Brakes Brake handle binding Check and adjust Worn or broken master cylinder Repair or install new master piston return spring cylinder Dragging brakes Drain brake line clear with compressed air If cleaning lines fails the master cylinder may be faulty and should be repaired or replaced DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 107 of 223 Restriction in hydraulic lines or in master cylinder Jabiru Aircraft Aircraft Service Manual Jabiru J230 D Serial 868 1 Brake callipers not aligned with disc Check and adjust If master cylinder wheel Leak in system cylinders are leaking repair or install new parts Brakes fail to operate La
271. s are found compete the following steps Mark the extents of the control surface travel when driven by the controls Disconnect the control from the control cable allowing it to swing freely Take not to deflect the control beyond the point where it can normally be driven by the flight controls as this will result in a false positive controls are able to move slightly beyond the normal travel limits but rubbing at these extreme deflections is not dangerous provided there is no chance of mechanical jamming Note that for the rudder and elevator DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 50 of 223 Jabiru Aircraft the fixed stops fitted at the rear of the aircraft are located approx 2mm beyond the normal travel limit Move the control through its normal travel range while pushing against each hinge in the direction that would close the control clearance with a force of approximately 5 7kg 11 150 Note if there is any travel restriction caused by the control rubbing against the aircraft Rectification work is necessary whenever any of the following criteria are met There 1 travel restriction caused by the control rubbing against the aircraft Scratches here indicate the control has rubbed against the fin illustration Figure 16 Scratches on Rudder DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 51 of 223 Jabiru Aircraft tc 6 18 Special Inspections Main W
272. s incorporate crushable foam which is essential in providing shock absorption in crash conditions The seat backs are also essential to restrain baggage in crash conditions 7 1 6 2 REMOVAL AND INSTALLATION e While the upholstery can easily be removed the actual seat structure is integral with the aircraft and cannot be removed 7 1 6 3 ADJUSTMENT Adjustment is the use of Booster cushions WARNING DO NOT MODIFY SEATS The seats are an integral part of the structure of the aircraft and must not be modified 7 1 6 4 REPAIR e As seats are integral to the aircraft structure any repair must be referred to Jabiru Aircraft Pty Ltd or our local approved representative 7 1 7 Upholstery e Seat upholstery is provided through slip on covers These are easily removed for cleaning and inspection of the seat structures e Optional Hood and Cabin lining is available together with Door Pockets e materials used in the upholstery with the exception of leather are treated with a flame retardant to meet the flammability requirements of CS VLA This treatment must be re applied after every 5 washes Accordingly whenever an item of upholstery is washed this must be recorded in the aircraft logbook Note Flame retardant must be applied by an authorized person using an approved compound Details are available from Jabiru Aircraft on request 7 1 8 Soundproofing e curtain of soundproofing material is used at the rear of the c
273. sembly ensure that the brake line is not rubbing against the fairing or mounting screws Rubbing can lead to failure of the brake line and wheel brake failure DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 85 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 7 3 5 Main Wheels 7 351 DESCRIPTION e The main wheels consist of an inner rim half also containing the bearings and brake disc mounting and an outer half e wheel rims are cast Aluminium e Figure 43 shows a typical installation While details and part numbers vary from model to model the general arrangement shown applies to all aircraft 7 3 5 2 MAIN WHEEL REMOVAL F R equired Tools Wing Stand Construct from DAR pine wood screws and a foam or thick carpet padding Jack Spanners Socket wrench Bead breaker Parts and Material Type of Maintenance Level of Certification Owner LSA repairman inspection or maintenance Jack aircraft as outlined in Section 7 3 2 above Remove the upper leg fuselage fairing and the wheel spat if equipped as detailed above Remove outboard brake pad plates Remove lock bolt nut through the axle extension Remove axle extension Pull wheel from axle Vo 7 3 5 3 MAIN WHEEL DISASSEMBLY 1 Deflate tyre and break tyre beads loose from tyre rims A bead breaker or similar may be required for this task WARNING Injury can result from attempting to separate whee
274. similar mixture The hinge moment can be measured using masses on the trailing edge by measuring the force needed to maintain the rudder for aft centreline horizontal e Weight and moment values are given below Weight 21000 1000 Hinge Moment 17500g mm 4000g mm 9 6 Rigging of Maintenance Line Maintenance L evel of Certification LSA repairman inspection or maintenance 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 3 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 Mark 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 75mm 2mm for all models bar the J200 family For the J200 family the travel must be 98mm 2mm T 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 the tail DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 149 of 223 Jabiru Aircraft
275. site monocoque self supporting structure and includes both the Horizontal Stabiliser and Vertical Fin repairs must be referred to Jabiru Aircraft Pty Ltd or approved local representative 7 1 1 Windshield And Windows 7 1 1 1 DESCRIPTION e The windshield and windows are one piece acrylic plastic panels set in sealing strips with Epoxy Resin amp Fibre Flock The windscreen and in some cases windows are also secured to the fuselage with screws nuts CAUTION In the event of a bird strike the windshield is the only protection for the crew and therefore must be maintained in excellent condition Cracks up to 25 mm in length should be stop drilled those longer than 25 mm should NOT be repaired the windshield must be replaced 7 1 1 2 CLEANING e Refer to Section 5 1 7 1 1 3 WAXING e 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 affect the reparability due to impairing bonding 7 1 1 4 REPAIRS e 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 successful
276. ssure system is at fault use the following procedure to locate the leakage gt Attach a source of positive pressure to the static source opening Figure 122 shows one method of obtaining positive pressure gt Slowly apply positive pressure until altimeter indicates a 500 foot decrease in altitude and maintain this altimeter indication while checking for leaks gt To find leaks coat line connectors and static course flange with solution of mild soap and water Watch for bubbles to locate leaks gt Tighten leaking connections Repair or replace parts found to be defective Reconnect airspeed and vertical speed indicators into static pressure systems and repeat negative pressure test detailed above CAUTION Do not apply positive pressure with airspeed indicator or vertical speed indicator connected to the static pressure system 12 5 4 Pitot System Inspection amp Leakage Test e Note that for aircraft equipped with the Dynon Angle of Attack pitot head it is necessary to remove the pitot head before leak testing the pitot system DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 188 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 e Ensure the pitot system is free from restrictions by blowing through it Restricted flow must be rectified immediately e Ensure no alternations of airframe have been made which would affect pressure present in the pitot system during flight For example e
277. st be removed for an extended period it is recommended to use zip ties or similar to Support the brake calliper assembly to take the load off the brake line 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 Remove inboard brake plate DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 89 of 223 aN Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 6 Remove axle from leg 7 3 6 3 MAIN WHEEL STUB AXLE INSTALLATION Required Tools Spanners socket wrench Parts and Material Type of Maintenance Level of Certification Owner LSA repairman inspection or maintenance 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 Section 7 3 5 7 3 7 Wheel Balancing e 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 7 3 8 Main Gear Leg 7 3 8 1 DESCRIPTION e For all models discussed in this manual the main u
278. stallation 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 e 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 troubleshooting 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 e 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 the 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 e Due to space constraints not all different variations are shown herein When ordering spare
279. sults that are significantly different from the other typically the aircraft weight should not be different by more than 2kg and the calculated CG position within 5mm then weigh the aircraft a third time to get a better match Discard the anomalous results If the third weighing is also different then there is most likely a procedure or equipment issue and the weighing must be postponed until this issue has been corrected 11 Due to the light weight of the aircraft the scales used must have an accuracy of at least 0 5kg and distances must be measured to within 1mm to ensure accurate results DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 44 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 NOSE WHEEL LEFT RIGHT MAIN MAIN NOSE WHEEL DATUM p 4 sN NN J i Figure 10 Weighing Diagram DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 45 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 6 16 Special Inspections Control Cables Required Tools Steel Ruler or similar Spring balance graduations less then 300 grams Material pe of Certification A amp P or LSA Repairman Maintenance LSR M Return to Service A amp P or LSA Repairman Maintenance LSR M e Inspections are required to be carried out on the primary control cables ai
280. sure that the Master and Ignition Switches are OFF before turning motor 8 Install spark plugs torque to 11 nm 8 ft 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 that the fuel tank breathers are clear 14 Perform a thorough pre flight inspection 15 otart and warm engine QUID Dur DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 30 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 6 Inspections 6 1 Service Interval Tolerance A tolerance of plus or minus hours is allowable on all service intervals set within this manual 6 2 Basic Inspection Procedure e Remove the engine cowlings and inspect the engine bay in dirty condition e Clean the engine bay propeller and aircraft exterior Carry out the inspections listed in e Table 3 lest and re assemble the aircraft Test fly if required 6 3 Mandatory Inspections amp Life Limited Items 6 3 1 Airframe e At intervals of 5000 hours the Jabiru all models airframe must be subject to an overall condition inspection by Jabiru Aircraft or an aircraft maintainer authorised by Jabiru Aircraft As part of this inspection wing struts must be disassembled inspected for
281. t hinge in this location within 25mm of Figure 14 Test Load Application control clearance this position while pressing on the control in the middle of the hinge Repeat the measurement when unloaded Pd Interference here at full forward stick deflection E can cause control travel restriction Figure 15 Elevator Gap Cross Section 6 17 3 Inspection C e his inspection is to see if there is any travel restriction of a control at deflections other than at the control s point of overlap e For the purposes of this inspection a travel restriction is defined as a one way jam the control cannot reach full deflection but is able to move freely in the other direction e While a control is very unlikely to completely jam due to a travel restriction the fact that the control is not achieving its full travel must be addressed e Travel restriction normally presents at the opposite control travel extreme to the control s point of overlap i e for the elevator shown above Figure 15 full stick forward deflection is the point most likely to exhibit a travel restriction as the lower surface of the elevator hits the aircraft e Inspect each control as detailed below Inspect the control for scratches and marks as shown in Figure 16 in the overlap area where the control runs inside the aircraft If no marks are found further inspection and or rectification is unnecessary However if such mark
282. t scheduled annual inspection 6 Should an owner not comply with any mandatory service requirement the aircraft shall be considered not in compliance with applicable ASTM standards and may be subject to regulatory action by the presiding aviation authority DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 2 of 223 Jabiru Aircraft tc Aircraft Service Manual OWNER OPERATOR 5 5 2 1 1 OF FIGURE 6 1 2 9 2 SECTION 2 GENERAL INFORMATION enne nnne 10 2 1 FOREWOROJ APPO CABI T M R 10 2 2 ADDITIONAL REFERENCE MANUALS 12 2 3 LST OF EFFECTIVE PAGES STATU ctn dat tute Ea aE Te tum E ERES 12 2 4 HON e 12 2 5 DIEP E E 12 2 6 DATES 13 2 7 GFNFRALE DEC CRIP TON T Q 13 2 8 es aC 13 2 9 AIRCRAFT SPECIFICATION c 14 2 10 CENTRE GRAVITY LIMITA IONS T 14 2 11 ANDARD PRACTICE 14 2 12 AIRCRAFT STRUC TUR R R N E E A EEO 15 2 13 O 15 3 AIRGRAFT SPECIFICAT
283. tion 17 1 1 Removal And Installation 77 e Remove screws holding fairing to aircraft NOTE some fairings usually the engine cowls or the ventral fin may be fitted with lead ballast Care must be taken when removing fairings containing lead to ensure that they are adequately supported while the screws are being removed to ensure no damage is inflicted to the aircraft or fairing e The fairings can be removed once these screws have been taken out When removing the wing strut fairings care should be take to avoid scratching the strut e Installation is the opposite of removal Care should be taken when tightening self tapping screws as when screwing into fibreglass it very easy to strip the hole so that it doesn t tighten 17 1 2 Repair The fairings on Jabiru Aircraft are made from 2 3 layers of 300gram m2 twill weave fibreglass and epoxy resin When damaged they may be repaired using an equivalent layup across the damage and normal fibreglass repair techniques Once repaired refer for repainting and filling techniques e Self tapper holes that become stripped may be repaired using be using the next size up self tapper from 6 gauge to 8 gauge however it is not recommended to go any larger e The hole may be filled using 5 minute Araldite and redrilled again to the original smaller size again If the hole has been exposed to oil or similar it will need to be cleaned with a solvent such as acetone prior to application of the f
284. tle For these products it is necessary to note the batch number on the bottle and contact the distributor for shelf life information e Similarly for many products the shelf life assumes a certain type of storage i e sealed temperature controlled etc Maintainers must ensure that such products are stored appropriately 2 General Description e he JABIRU aircraft described in this manual are 2 seat high wing monoplane composite aircraft of monocoque construction They are equipped with fixed tricycle landing gear of composite construction The steerable nose gear is a welded metal trailing link assembly with rubber springs he aircraft are equipped with a JABIRU 6 cylinder 4 stroke engine of around 120hp Both engines are optimised to drive a 2 bladed Jabiru composite propeller 2 8 Owner Maintenance 2 8 1 Factory Built Models Jabiru J230 D Aircraft have been specifically designed as simple aircraft which can be maintained by owners to the extent allowed 14 Part 43 3 Jabiru Aircraft allows preventive maintenance as allowed in Appendix A of Part 43 to be carried out by the owner or operator This servicing includes Removal installation and repair of landing gear tires Servicing landing gear wheel bearings such as cleaning and greasing Replacing defective safety wiring or cotter keys Lubrication not requiring disassembly other than removal of non structural items such as cover plates cowlings
285. trol and may not be repaired or removed without reference to Jabiru Aircraft Pty Ltd or our approved local agent DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 148 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 e Details of inspections required for control cables are given in Sections 8 1 5 and 0 9 4 4 Control Cable Installation e Reverse the steps detailed above for installation e Ensure the required inspections are carried out and the cable is clamped securely WARNING All spherical rod end bearings must be fitted with a large washer on the outside of the through bolt to prevent the bearing case and cable releasing in the event of a bearing failure 9 5 Rudder Balance Type of Maintenance Level of Certification LSA repairman inspection or maintenance e The J160 C rudder is balanced at the factory during assembly and unless the rudder is damaged the balance should not change If the rudder is found to be unbalanced outside the specified limits cause for this condition should be ascertained before proceeding e o balance the rudder it must be removed from the aircraft Balancing is done around the rudder hinges with the hinge pin line horizontal and on the high side of the rudder The balance weight takes the form of an epoxy resin and lead shot mixture set inside the leading edge of the rudder horn The balance should be changed by either removing lead or adding to this mass with a
286. ts 100 100 hourly 100 hourly 100 hourly 100 hourly 100 hourly 100 hourly Fuel hoses lines fire sleeves amp fittings Check for hardening cracking leakage or deterioration ts 100 omments SCAT hoses Check condition Comments Electrical wiring Check wires are secure check wires and connectors for damage degradation Comments Engine Controls and linkages Check for smooth operation through full travel RIF Comments Engine mounts and Mount structure and rubbers Inspect for cracking and other degradation Comments el Starter solenoid and electrical connections Check Insulations wires and fittings PP Comments Coils and electrical connections visually inspect ensure connections are secure Comments Carburettor heat system Remove SCAT hose check correct movement and seal Comments Firewall Ensure all fitting are secure and filled with fireproof putty ensure no missing screws rivets and ensure no holes through firewall PP Comments Exhaust System including muffler check restraining springs and tabs Check for cracks dents leakage and other damage Comments Fuel Pressure warning light if equipped Check correct function Comments Cabin heat system Check control valve sealing check heat exchanger is secure on tailpipe Comments
287. ual In exchange for the Maintenance Manual provided by Jabiru Aircraft Pty Ltd Jabiru 1 hereby agree to waive release and hold Jabiru harmless from any injury loss damage or mishap that l my spouse heirs or next of kin may suffer as a result of my use of any Jabiru product except to the extent due to gross negligence or wilful misconduct by Jabiru understand that proper skills and training are essential to minimize the unavoidable risks of property damage serious bodily injury and death that arise from the use of Jabiru products DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 11 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 2 2 Additional Reference Manuals Jabiru Engine Installation Manual JEM3302 Jabiru Engine Maintenance Manual JEMOO02 Jabiru Engine 3300 Hydraulic Lifter Parts Book JEM3303 Jabiru Engine Overhaul Manual 1 Jabiru Propeller Manual JPM0001 The latest revisions of these manuals are available online at www jabiru net au manuals Always Obtain the Latest Revision of These Manuals Before Any Maintenance 2 3 List of Effective Pages Issue Status e This manual is revised as a whole All pages retain the revision status of the overall document Issue Notes Initial Issue Add procedure for correcting free play in wing amp strut attachments As prescribed by ASTM 2483 12 Add maintainer requirements Revise logbook worksheet format Add n
288. ugh the firewall amp panel In some cases removal of the end fitting will be necessary to achieve this Installation is reverse of the removal process above Note that when the firewall fitting is re fitted fireproof putty available from Jabiru Aicraft must be replaced to ensure a flame proof seal DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 159 of 223 Jabiru Aircraft tc 42454800 gt 40288947 3 WIRE STUB 4A454COD 1 CHOKE CARBY HEAT CABLE END LUG 5 FLAT WASHER COTTER PIN BEND WIRE SHARPLY TAIL TO BE 5mm LONG MIN FROM BEND NECESSARY ADD EXTRA WASHERS TO REMOVE tee EXCESS END PLAY BEND BOTH TAILS TO SECURE THIS DRAWING IS COPYRIGHT AND MUST NOT BE COPIED WITHOUT THE CONSENT OF AVTECH PTY LTO AVTECH A C N 010 786 973 HIMKLER AIRPORT BUNDABERG 4570 TITLE CHOKE CARBY HEAT CABLE END ATTACHMENT ASSY his 54 ADD 1 Figure 95 Control Cable End Fitting Installation 10 9 Air Intake System amp Carburettor Heat Type of Maintenance Level of Certification LSA repairman inspection or maintenance 10 9 1 Description he engine air intake system comprises 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
289. val amp Installation 77 e For wing root sight gauges Remove the fairings from between the wings and the fuselage Disconnect the fuel lines running between the wing tanks and the sigh gauges It is recommended that these lines be cut and replaced on re assembly Remove the gauge from the aircraft If required remove the screws and disassemble the gauge Reverse the preceding steps for installation e For wing root electric float gauges Remove the fairings from between the wings and the fuselage Disconnect the fuel lines and remove the wings as detailed in Section 7 2 Remove the gauge assembly from the aircraft wing Calibration of the electric fuel senders is discussed in Section 12 Reverse the preceding steps for installation Parts List _ ITEM PART DESCRIPTION QTY 1 4A044BOD SIGHT GLASS BODY SP WET WING 1 2 14953224 SHORT SIGHT GLASS COVER 3 n 3 14920223 HOSETAIL SIGHT GLASS 1 _ 4 4953324 SHORT SIGHT GLASS LENS 1 5 PH0991N SHORT SIGHT GLASS RING 1 AANO 6 8 32 BUTTON HEAD SCREW 6 fi 7 PL4A000N THREADED T FITTING SP SIGHT GLASS 1 No SECURE WITH E T ff 24 LOCTITE 243 PRESS HOSETAIL FITTING WITH LOCTITE 620 FOR R S 4 044 0 1 M 6 T HOSETAIL ROTATED BY 180 sd ix 64 2 4 d 0 dO P x 2
290. vertical speed indicator if fitted altimeter and airspeed indicator to atmospheric pressure through plastic tubing connected to a static port e In Jabiru Aircraft the pitot and static systems each have a water trap or low point fitted which must be checked during scheduled maintenance or after flying through rain CAUTION 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 the principal rules for system maintenance The pitot tube and static ports MUST be kept clean and unobstructed DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 184 of 223 Jabiru Aircraft tc 230 9 A 120 TUBE BE SET PARALLEL TO AIR FLOW WHEN INSTALLED SECTION AA 2 R S WING ATTACH AT THIS END 504494 TUBE BENT ProT Pa _____ ose wes 2 LL LE Figure 118 Pitot Assembly DOCUMENT No JTM001 0 230 D 868 08 May 2014 Page 185 of 223 Jabiru Aircraft tc COTTON FLOCK amp TUBE TAIL FIN ENSURE TUBE IS ALIGNED WITH TOP OF FIN FUSELAGE WIRE TO R25 M ATTACH TUBE sent a
291. vice the attachment point as detailed in Section 6 21 1 CAUTION In this position the wing is vulnerable to being bumped or jostled off the stands This will result in significant damage to the aircraft e lfastrut attachment requires service only 1 wing stand is required Remove the wing root and wing strut fairings both top and bottom Remove the wing strut from the aircraft Rest the on a wing stand positioned approximately 1m 3ft inboard of the tip of the wing Service the attachment point as detailed below 6 21 1 Attachment Point Service Movement Between Bolt amp Lugs e Take the original bolt removed from the connection being serviced Fit it to the holes in all the mating parts i e for a wing connection fit it to the wing lug and to the Aluminium wing attachment lugs on the fuselage Wriggle the bolt in each part feeling for movement The bolt should be a transition fit there should be no movement or minimal movement when fitted in each part of the connection excess movement is detected sometimes it can be corrected by fitting new bolts n most cases the aircraft wing fuselage attachments will have been assembled using standard AN4 bolts AN5 for J250 J450 In these cases excess movement between the bolt and the lugs may be corrected by replacing these bolts with new AN174 1 4 or AN175 5 16 close tolerance bolts Similarly strut connections normally use AN5 bolts and excess movement between the bolt
292. within this manual For details of installation maintenance and overhaul refer to the latest revisions of the Jabiru Engine manuals for the 3300L model engine e Up to date engine manuals are available from the Jabiru Aircraft website www jabiru net au 3 Aircraft Specifications 3 1 Universal Specifications AVGAS 100LL or 100 130 MOGAS with Octane Rating 95 RON AKI 91 or above CAUTION Fuel Type S LSA certified models may not use fuel containing alcohol Operators who choose to use MOGAS do so at their own risk and are required to test each new batch of MOGAS for the presence of ethanol before adding it to the aircraft tanks REFER TO SERVICE LETTER JSL007 FOR DETAILS Battery Location e In Engine Compartment Jabiru 2 bladed Composite Propeller Diameter 60 dia 1524mm Target Wheel Alignment 5 at gross weight 0 Camber 0 Toe in Engine Oil Type Refer Engine Manuals DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 15 of 223 Jabiru Aircraft tc Aircraft Maximum Weight Fuel Capacity 6550 Figure 1 J230 D General Arrangement DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 16 of 223 Jabiru Aircraft tc 3 2 Torque Values In Fibreglass e Unless noted otherwise all bolt torque settings detailed within this manual are for clean dry threads e When checking fastener torque use the following procedure Ensure the fastener to be check
293. x3 Square or Plumb bob String and Tape DOCUMENT No JTMO01 0 230 D 868 08 May 2014 Page 43 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 Parts and Material Type of Maintenance Level of Certification A amp P or LSA Repairman Maintenance LSR M 6 15 1 1 SCALE LOCATIONS e For weighing three scales are used one under each main wheel and one under the nose wheel 6 15 1 2 PROCEDURE 1 Position the aircraft on the scales on a level surface preferably one that positions can be marked on to in the configuration to be weighed 2 Chock the main wheels and make sure the brake is released If the chocks are of significant weight their weight will need to be subtracted from the relevant scale readings 3 Level the aircraft using technique in Section 5 2 4 If the nose needs to be raised place packers under the nose wheel If the nose needs to be lowered pack under main wheels or deflate nose wheel Remember to re inflate to operating pressure before use 4 Using a square or a plumb bob mark the wheel centres on to the floor or scale surface Both sides of the nose wheel axle must be marked to eliminate any error if it 1511 exactly Straight 5 Again using a plumb bob or a level mark the wing leading edge onto the floor Mark these points at a position outboard of the main wheels 6 Take the wheel weights When the wheel weights are being taken there must be nil wind blowing on t
294. y 2014 Page 153 of 223 Jabiru Aircraft tc Aircraft Service Manual Jabiru J230 D Serial 868 10 3 Flexible Hoses Type of Maintenance Level of Certification LSA repairman inspection or maintenance 10 3 1 Description e Flexible rubber hoses are used within the engine bay to carry fuel and oil Vent lines for the engine and carburettor are also flexible lines 10 3 2 Flexible Hose Removal e Where equipped cut the safety wire to allow the fire sleeve to be drawn back along the hose to allow access to the hose clamp e Loosen the hose clamp e Remove the hose from the hose fitting e Note that oil cooler lines by design often become bonded or stuck to the hose barb This makes it impossible in most cases to remove these hoses without cutting them 10 3 3 Inspection Examine the exterior of hoses for evidence leakage or wetness Feel hoses to assess the hardness of the hose Excessively hard hoses must be replaced as they are likely to be subject to cracking Replace any doubtful hoses 10 3 4 Flexible Hose Installation e Hoses should not be twisted on installation Provide as large bend radius as possible Hoses should have minimum of 12mm clearance from other hoses or surrounding objects or be tie clamped to them Where fire sleeve is used ensure it is fitted per Figure 92 NOTE Rubber hoses will take a permanent set during extended use in service Straighte
295. y moving it to its maximum deflection and inspecting for a control gap as shown in the example of Figure 13 Note the result of Inspection A and carry on to Inspection B in all cases 6 17 2 Inspection B e This inspection has two purposes to check to see if jamming is likely due to insufficient clearance at the control s point of overlap and to check if the control hinges are sufficiently stiff All controls must be inspected in this way regardless of the results of Inspection A e Check the clearance between the control surface and the aircraft at the point of overlap as detailed below Set the controls so that the control being tested is at the point of overlap as shown in right picture in Figure 13 If the control being tested does not deflect to a point of overlap then place it as close as possible to the overlap point Press against the control using a thumb pushing the control in the direction that would close the control clearance Measure the control clearance while this load is applied Remove the load from the control and re measure the control clearance Controls are to be tested this way at every hinge The force to be applied in each direction is approximately 5 7kg 11 156 Inspectors can calibrate their thumbs by pushing onto a set of scales to indicate how hard they need to push See Figure 14 for details of where to push on the controls e Rectification work is necessary whenever any of the

Aircraft Service Manual - Jabiru USA Sport Aircraft

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