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Aircraft Service Manual

1. enne eene ener ens 3 3 1 Adj stment tro 3 3 2 Door seals estt huu IO ESI eet Ds 3 3 3 Cabin door l tehes arenae B EHE ets 3 3 4 LOCKS AAA es 3 3 5 a EE ee ts o A eae ase 3 4 Door JM MP UR 3 4 1 E Gaun soci lo Ts Aa QURE SSS ska Sa Qusa asus 3 5 ee EE 3 6 Safety PrOVISIOS O 3 7 SEVEL St tan ae pn EE ahua au EE 3 7 1 Page 3 1 Issue 3 Date 040401 mj 3 1 FUSELAGE The Fuselage is a composite monocoque self supporting structure and includes both the Horizontal Stabiliser and Vertical Fin All repairs must be referred to Jabiru Aircraft Pty Ltd 3 2 WINDSHIELD and WINDOWS 3 2 1 Description The windshield and windows are one piece acrylic plastic panels set in sealing strips with Sikaflex 291 or silicon and secured to the fuselage with screws nuts IMPORTANT The Windshield is a structural element of the Fuselage 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 and the windshield should be replaced 3 2 2 Cleaning Refer to Section 2 3 2 3 Waxing Waxing will fill in minor scratches in clear plastic and help protect the surface from further abrasion Use a good grade of commercial wax NOT SILICON BASED applied in a thin even coat Bring wax to a high polish by rubbing lightly with a clean dry flannel cloth IMPORTANT Silicon based waxes and polish are not
2. 8 Fite SICEV Edge LANDING GEAR 1 Main gear wheels and Tamngs sees ee eee 2 Nose gear wheel steering links tension links and PAITINGSS O p SU ES NO 3 Wheel bearings 4 INGSE Sear TEE 5 Nose gear housing and bushes 6 Main gear struts clamps and bolts nuts d Tyres ANG UD ato 8 Brake fluid hoses linings discs brake assemblies and master cyH idet as eege 9 Brake operational check AIRFRAME l Aircraft exterior ww dy vw osi seek aer an ena VP kasse 2 E svcuientpersivextersvarstaoenssaceenee 3 Windows windshield doors and seals 4 Seatbelts and shoulder hamesses 5 SeatSETrUCtUre os 6 Instruments and markings 7 Instrument plumbing and wiring 8 Instrument panel shockmounts decals and labels 9 Ventilation system 10 Cabin upholstery trim 11 Switches fuses m 12 Pitot and static systemslips 13 Radio intercom and headsets 14 Antenna and cable 15 Battery battery cradle and cables 16 Battery electrolyte
3. Date a T MENS rur ds Add 03 71IV130 Sv EI 9 93 1 NOISNddS M SLAIT 2 L ALO Wall ALO WAL yas l a gt NSW L c Q L Sy L L 6 L L d LI IVIJAVIYJJONN HS id jivld 9NIMO a LAN 9 5 3 Figure 3 Issue 5 13 Page an a31409 39 L 193 034 4WIS LON OU SJALINEIN NO RED ASSY 133 EJES CEI E san Kees m Y gt ALL 33Id02 3H LON JSN OLT Ald HOJJAY 30 IN3SNO3 Ji ONY JH9RAdOD SI ON Y0 SIHL EN N Sie P d EE i l 03378 HUN AC l S1 09318 HU 9c l avid 9 sz v e A b e E l G WOH3 3A0N334 DI l OlSld AWE oz E DA 6 4 l NOUSId 60 L09 8 A 11 V9 L vNV s 4 9 0 l div ld SNILNC S y l anis 3 k690009 pl ALO NOUiMOS3q ON tava Wall ALO NOlLAINOS30 ON lavd au Date 040401 3 Issue 5
4. an Ald Q3d09 38 LON 15 v 30 ONY 1HOhHAdOO SI Al S3313M 1 NOTE THIS S LARGER ROD END ULL J ACHIEV RON JSE TEMPLATE TO MEAS JRE BOTH AILERON ADJUSTED TO TEMPLATE Drawing AILERON RIGGING INSTRUCTIONS Figure 6 5 1 NUT HEX 1 4 2 5011194 PLATE AILERON CONTROL 1 NUT HEX NYLOC 1 4 B 2 4 5011294 STUD AILERON CONTROL 2 ERON CONTROL SIOP Figure 6 5 1 Page 6 5 Issue 3 Date 040401
5. 13 9 UHF Antenna Installation 13 10 NEE 14 0 A A ee 14 1 EXI RR 14 2 PASAN AS iaces ka ki coral 15 Appendices Jabiru Engine Instruction and Maintenance Manual Appendix 1 Jabiru Propeller Instruction Manual Appendix 2 Airworthiness Limitations Appendix 3 1 General 2 Mandatory Replacement Times 3 Structural Inspection Intervals 4 Structural Inspection Procedures Jabiru Parts EE Appendix 4 Jabiru Engine Parts Catalogue Appendix 5 Page 0 6 Issue 3 Date 040401 JABIRU AIRCRAFT PTY LTD SERVICE MANUAL LIST OF EFFECTIVE PAGES The following pages are current Original Effective Date 010493 Latest Amendment Date 130302 Page No Effective Date 0 1 0 6 040401 0 7 0 8 040401 1 1 1 4 040401 2 1 2 16 040401 3 1 3 6 040401 4 1 4 4 040401 5 1 5 22 040401 6 1 6 5 040401 7 1 7 6 040401 8 1 8 8 040401 9 9 7 040401 10 1 10 12 040401 11 1 11 6 040401 12 1 12 14 040401 13 1 13 7 040401 14 1 040401 15 1 040401 App 1 1 040401 App 2 1 040401 App 3 1 040401 2 14 2 16 130302 0 7 0 8 130302 Page 0 7 Issue 4 Issue 52 Q0 O Q2 Q Y Q2 Y UY YY Q Y Q Q YU WW uy Date 130302 THIS PAGE IS INTENTIONALLY LEFT
6. Page 2 15 Issue 3 XXX X XK X X X X X Xo X X X X Date 130302 Xo X X X X X X X Xo X X X X X XK X 0X E X X SZ X X SZ SZ KK 0X XXX CONTROL SYSTEMS In addition to the items listed below always check for correct direction of movement particularly 1f controls have been disconnected and correct travel Annual Inspection Each 200 Hours Each 100 Hours Each 50 Hours Cables and cla iris o Y EXE XE ENEE ee AAA O Trim control and cable eee eeeeeeee enna Travel SstoBS as coi E oe Decals and labels Flap controls and linkages Elevator control and linkages Rudder pedals and linkages Exterior surfaces of control surfaces 0 Control horns hinges and hinge lock tabs Es 1p oO ON res opp s XK X X X X X X X X X XK X X x X X X X X X Page 2 16 Issue 3 Date 130302 SECTION 3 FUSELAGE Table of Contents Paragraph FUSELAGE ui iii 3 1 Windshield and Windows ccccccccccccesssssssecececccecsesenseceeecececeeeessaeeeeeeecsesensnseaeeesecs 3 2 EEN ee 3 2 1 EE 25 2 i ro sg cc EN 3 2 3 LEE 3 2 4 BOTS 8 116 Dek ERP RRS ere ANA PE MOU E 3 2 5 E ee 3 2 6 R emevali tec eh nebst dep dann es 3 2 7 Installation us TP 3 2 8 Cabin OOS 2 eee Tte nC RE a 3 3 Removal and installation
7. ot Lon Page 5 3 Issue 3 Date 040401 5 3 5 Main Gear Top Fairing Removal and Installation The fairing at the top of the main undercarriage leg is removed by removing the securing screws To install reverse this procedure 5 4 MAIN WHEEL 5 4 1 Main Wheel Removal Jack aircraft as outlined in Paragraph 2 1 2 Remove speed fairing 1f installed in accordance with paragraph 5 3 4 Remove outboard brake pad plate Remove lock bolt nut through centre of axle and spacer Remove lock spacer Pull wheel from axle EAR E 5 4 2 Main Wheel Disassembly 1 Deflate tyre and break tyre beads loose from tyre rims WARNING Injury can result from attempting to separate wheel halves with the tyre inflated Avoid damaging wheel flanges when breaking beads loose as a scratch nick or gouge may cause wheel failure 2 Remove through bolts nuts and separate wheel halves removing tyre and tube and wheel hub 3 Remove brake disc 4 Remove bearings from hub NOTE The bearing are press fit in the wheel hub and should not be removed unless a new part is to be installed 5 4 3 Main Wheel Inspection Assembly and Repair Clean all metal parts in solvent and dry thoroughly Inspect wheel halves for cracks Cracked wheel halves should be discarded and new parts used Sand out nicks gouges and corroded areas Clean thoroughly and paint with silver paint 3 If excessively warped or scored or worn to a thickness of 2 mm brake dis
8. D ring Storage adios 2 1 10 Re et rnIne Aircraft tO Ser vite espe cea tudinis iude sedie edu ditus 2 1 11 JA ASI I oossoo rosis UN ARS Sau CHUA 2 2 Servicing Schedule 5o ee eb dT Ee 2 2 1 A cqa da d ako al eki pa asa asqa edd ee 2 2 2 ENEE ee 2 2 3 Carburettor Ao 2 2 4 LEE 2 2 5 Hur S259 ai I 2 2 6 Hydraulic Brakes TH RH 2 2 7 LNBD SH EE 2 3 Windshield and WAIBdOWS EE 2 3 1 ve E 2 3 2 e ae e 2 3 3 ALU SULEACES ras 2 3 4 Engine and Engine Compartiment ido cie petiere edd 2 3 5 Eeer 2 3 6 WV TG Mu bade ba Dol at eer Deene eege 2 3 7 BUBB RICA N L8 NEE 2 4 Wheel Bearings Mains and Noe 2 4 1 INSPECTION A OO 2 5 Inspection tr EI 2 5 1 Inspection Chart anna 2 5 2 Page 2 1 Issue 3 Date 130302 W 21 GROUND HANDLING ED 2 1 1 Towing The JABIRU aircraft is very light and should always be moved by hand Moving the aircraft is accomplished by using the wing struts or prop hub or landing gear struts as push points together with the solid rear fuselage join of the fin to the tail plane CAUTION Do not use control surfaces to move the aircraft Damage to the control system may result When pushing at the join of the fin and Tail Plane Watch that you do not jam your fingers under the Rudder or in the rudder hinge Remember that it is Connected to the Nose Wheel gt CAUTION When moving the aircraft never
9. Inspect the Battery Box and attachments and clean and remove any signs of spillage or corrosion 2 2 6 Tyres Maintain tyre pressure at the air pressure specified in Figure 1 1 When checking tyre pressure examine tyres for wear cuts bruises and slippage Remove oil grease and mud from tyres with soap and water NOTE Recommended tyre pressures should be maintained especially in cold weather Remember that any drop in temperature of the air inside the tyre causes a corresponding drop in tyre pressure 2 2 7 Hydraulic Brakes Check brake master cylinder and refill with automotive brake fluid 3 4 Bleed the brake system of any trapped air whenever there is a spongy response on the brake lever Refer to paragraph 5 8 for filling and bleeding of the brake system CAUTION The JABIRU uses automotive brake fluid 3 4 DO NOT use Aircraft hydraulic fluid mineral based or damage to the brake system will result 2 3 CLEANING Keeping the aircraft clean is important Besides maintaining the appearance of the aircraft cleaning makes inspection and maintenance easier 2 3 1 Windshield and Windows These should be cleaned carefully with plenty of fresh water and a mild detergent using the palm of the hand to feel and dislodge any caked dirt or 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 dr
10. L o CS l s1 03418 HUN A008 NOLSId 808809 9c H3HS e l 3lvid SNILNnO E Sc 1108 l d LAA vo L osia ve 0l dvd vea ec G LAN 6 l CH ONIO olz SH 44 L FIXY ANIS N31X3 8 l 9 x 33A1 LC L 1108 L gt L OlSld FDAvAA c ONIH 9 a e 1348 Ola 6l L NH DH S l Way AdOS8 NOISId 8l DL YIHSYI V 4 1109 LI 4 ONIYdS 91 b 110 4 l 3lV1d 9 SI L l123r02 d gt GE AD KIEREN ON Laval Du HI unce TAAT H INA isn 38 5 4 7 Figure 040401 Date 3 Issue 5 17 Page Seravawna si C Sy IEREEK au Ki Een AD 46 984 NOV F A A q Py 931 3 Vd HOSIAY I Y rA DANA S3HSh8 HIM ASSY 931 I N HYTIOD ON l3MOvHH N 9 ra Y 9 d 431105 NadSNS Hsna 1109 HY 30A T33H H1 34304 33H 1733H a HH NOULIS EE Qr A SNOIS JWOS LON od aaid00 38 10
11. The wheels comprise two wheel halves which are attached to the wheel hub by through bolts and nuts as shown in Figure 5 3 1 During assembly of the main wheels the through bolts nuts should be tightened to the value specified in Figure 1 2 NOTE The Main Undercarriage Legs are Left and Right handed as denoted by Part Nos 6003093 and 602409N respectively They are NOT interchangeable WARNING Check looseness of main u c beams by lifting each wing and trying to move beam back and forth If movement tighten clamp bolts 2 evenly to take beam movement out Do not over tighten or exceed 3 threads clear on the nuts use extra washers Models with wide 65 t tanks must have tank attachments and hoses loosened and rocked to obtain clearance on rear main saddle bolt Over tightening can cause bolt fracture and failure to tighten both can also cause bolt failure Page 5 2 Issue 3 Date 040401 5 3 1 Removal The following procedural steps remove one side of the landing gear as a complete assembly Refer to applicable paragraphs for removal of the individual components Li Jack the aircraft in accordance with Paragraph 2 1 2 2 Unbolt wheel end of flexible brake hose catching brake fluid in a container 3 Remove bolt nut from top inboard end of undercarriage beam Remove rubber bushes 2 4 Remove bolts nuts 2 from the clamp at bend in undercarriage beam 5 Remove clamp 6 Remove Undercarriage Leg Assembly 5 3 2 Installation
12. Wie EE 3 5 ee Meed 5 6 Nose Wheel Steering System 5 7 Brake SYSf M EE 5 8 Aileron Control System 6 1 CONTO COTUBID EE 6 2 Control Cables r a N E ass TERR MER 6 3 A ec 6 4 RIN RUE 6 5 Wing Flap Control System 7 1 Operational Check aptas 7 2 Flap Handle Assembly 2 2 eire tete bra eR noire tare ene eap 7 3 Flap Common Shaft Assembly a 7 4 inier Met d T REPE ES LE EE 7 6 Page 0 4 Issue 3 Date 040401 Table of Contents Continued Paragraph Elevator Control System 8 1 Control TE 8 2 SE 8 3 Control Cable and Attachments 8 4 RIg8IDS aaa eae aces laurie aie ea ee Nea ei M 8 5 Elevator Trim Control System 8 6 Rudder Control System 9 1 Rudder Pedal Assembly a isa 9 2 Te E EE 9 3 Control Cable and Attachments 9 4 habuic MEE 9 5 Engine See also Appendix 1 10 0 Engine Cowles wissen eibi stet ct dee dai 10 1 EE 10 2 A En 10 3 Engine Mount z
13. 040401 Date 5 5 3 Issue Figure 5 18 Page DEVIN El 1 NS ie amWwiad sy Wiss Odi H3DINIH 98L 010 NOW d HO3IAY q3uo34s SSINN S O EH AID NOLLAIIDS30 ON Laval val 931 I W ANN SNIPH33IS d 10N A 4 1109 MVTIOO ONIN 9 O A 931 NoISN3dsns L YIBINY NOISN3ASAS 38N1 8 2171109 SNINI713 l 6 LIFYE NOISN3L NO e 9 4 ANK 9Nlav38 YAV SL TIJHA 1NO34 ANK 9 Y 1109 9 LAN JAN TUSVO 6 Nid 331105 oz N3dshs HSNA 4 1109 e HH 340A 133 Ir02909 YA H1 30A 133 u v dHAL v X OOP ASSY N sz 4 SMZ yv009 ONI N6 Z008d gz 31Xv NOMA bbOS909 La 108 VCY YNV b 1109 6c S330A T33HM Ae Og X OOF 3HAL NOLLON LE X NOZLONd Le 104 VLL ENV ZE JH dsns aJAYnJ W3HSv e HOU 22004 SFALINNMI daldoo SIHL 6 16 aa O 040401 Date 3 Issue 5 19 Page L 30 13s old 931 ASC E ANMA Sv tient wad QAJADIIS SS3INM S O su 1123
14. 14 Page S3MAL 9 X Jud amu HH NOLLOAS 040401 Date 3 Issue 5 15 Page SH 03318 HLM A009 NOLSId 8c L gnis IXY ui S 03318 HLI L V gl 9c v Zl al SC v LI g tala b ol 4 EZ S J 44 L IXY gnis NOISN31X3 8 311 L L106 L oz e 9 g 51 S Hv AdOd NOLSId el 0 V e 110 LI 0 e SNIHdS 9l V 4 3lv1d NILNNO SI ONIDYOJNIFY OM 9 l AD dra maul ALO WAL Ze L 3o mmus NSY dck aaa sy Jive auu 1 200 GOUL FIM NOILO3S 931 NOISNIASAS 040401 Date 5 3 1 3 Issue Figure 5 16 Page Hi Y d L anis av rl A C NN EE l Sy 03318 HU A008 NOLSId LI 1108
15. 60 60 1524mm 1524mm 1524mm 1524mm PROPELLOR Fixed Pitch 42 48 42 48 1066 8mm 1219 2mm 1040mm 1040mm MAIN WHEEL TYRES STANDARD Options Available 11 dia x 4 rim 11 dia x 4 rim 11 dia x 4 rim 11 dia x 4 rim MAIN WHEEL TYRES STANDARD 4 wide 4 wide 4 wide 4 wide Options Available 4 Ply Rating 4 Ply Rating 4 Ply Rating 4 Ply Rating NOSE WHEEL TYRE STANDARD Options Available 10 25 dia x 4 10 25 dia x 4 10 25 dia x 4 10 25 dia x 4 rim rim rim rim NOSE WHEEL TYRE STANDARD 4 wide 4 wide 4 wide 4 wide Options Available 4 Ply Rating 4 Ply Rating 4 Ply Rating 4 Ply Rating TYRE PRESSURES STANDARD Mains 170 kpa 25 psi 170 kpa 25 psi 170 kpa 25 psi 170 kpa 25 psi TYRE PRESSURES STANDARD 82 kpa 12 psi 82 kpa 12 psi 82 kpa 12 psi 82 kpa 12 psi Nose WHEEL ALIGNMENT at Gross Weight 0 0 0 0 Camber 0 0 0 0 Toe In PRINCIPAL DIMENSIONS Wing Span 8034 mm 26 4 8034 mm 26 4 8034 mm 26 4 9398mm 30 10 Length 5040 mm 165 5040 mm 165 5040 mm 16 5 5640mm 18 6 Fin Height 2013 mm 67 2013 mm 67 2013 mm 67 2013 mm 67 Track Width Wheel Centres 1600 mm 53 1600 mm 53 1600 mm 53 1600 mm 53 Tail Span 2350 mm 78 2350 mm 7 8 2350 mm 7 8 2350 mm 7
16. BLANK Page 0 8 Issue 4 Date 130302 SECTION 1 GENERAL DESCRIPTION Table of Contents Paragraph General Desconocida 1 1 ee E EE 1 2 Centre of Gravity Lmmtatnons eene 1 3 Torque VAS AA AA EENS 1 4 E 1 1 GENERAL DESCRIPTION The 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 The aircraft is equipped with JABIRU 4 cylinder 4 stroke engines driving a wooden fixed pitch propeller MP 1 2 AIRCRAFT SPECIFICATIONS Leading particulars of this aircraft with dimensions based on gross weight are given in Figure 1 1 If these dimensions are used for constructing a hangar or computing clearances remember that such factors as tyre pressure tyre size and load distribution may result in some dimensions that may be somewhat different from those listed m 1 3 CENTRE OF GRAVITY LIMITATIONS The JABIRU is a very light aircraft The installation of equipment may significantly alter the approved CG limits of the aircraft Therefore all proposed fixed installations must be approved by JABIRU AIRCRAFT Pty Ltd MP 1 4 TORQUE VALUES A chart of recommended torque values is shown in Figure 1 2 These torque values are recommended for all service procedures contained in this manual except where other values are stipu
17. Ensure that the engine has been stopped by turning off the fuel valve thereby not leaving any fuel in the carburettor bowl Every 7 day the propeller should be rotated through 5 revolutions without running the engine Leave the propeller in the horizontal position to ensure even distribution of liquids in the wood If left in the vertical position liquids will drain to the lower tip resulting in an unbalanced propeller CAUTION Ensure that the Master and Ignition Switches are OFF Store under cover away from direct sunlight as ultra violet rays damage composite structures Page 2 4 Issue 3 Date 130302 In addition the pitot tube static air vent air vents openings in the engine cowl and other similar openings should have protective covers fitted to prevent entry of foreign materials and beings especially wasps 2 1 7 Returning Aircraft to Service After flyable storage returning the aircraft to service is accomplished by performing a thorough pre flight inspection Ensure all protective covers are removed 2 1 9 Temporary or Indefinite Storage Temporary storage is defined as aircraft in non operational status for a maximum of 90 days Treat as for flyable storage see Paragraph 2 1 7 plus For temporary storage fill fuel tank with correct grade of gasoline to prevent moisture accumulation For indefinite storage drain fuel tank ensure carburettor bowl is empty by running engine with fuel valve off until it
18. Lining Installation New brake linings should be installed when the existing linings are worn to expose the rivet heads To replace outboard lining 1 Ze 3 A Ce Remove bolts securing outboard brake pad and brake cylinder to backing plate Remove outboard brake pad Place brake pad on a table with lining side down flat Centre a 1 8 or slightly smaller punch on the rolled rivet and hit the punch sharply with a hammer Punch out all rivets securing the lining to the pad plate NOTE A replacement kit for brake pads and rivets is available from JABIRU as Part No 6000994 Clamp the flat side of an anvil in a vice Align the new lining on the pad plate and place the brake rivet in the hole with the rivet head in the lining Place the head against the anvil Centre the rivet setting punch on the lips of the rivet While holding the pad plate down firmly against the lining hit punch with hammer to set the rivet Repeat blows on the punch until the lining is firmly against the pad plate Realign the lining of the pad plate and install and set rivets in the remaining holes Replace the brake pad and refix with through bolts and springs To replace inboard lining it is necessary to SA AE Remove wheel assembly see Paragraph 5 4 1 Remove stub axle see Paragraph 5 4 5 Remove brake cylinder backing plate Replace lining in accordance with steps 3 7 above Install axle and wheel assembly see Paragraph 5 4 6 I
19. The Jabiru UL has been developed to meet the FAI Microlight definition In countries other than Australia other registration requirements will apply It is the owner s responsibility to become fully aware of the particular maintenance requirements and limitations applicable to the appropriate registration The information in this manual is based upon data available at the time of publication and is supplemented and kept current by Service Bulletins amp Service Letters published by JABIRU AIRCRAFT Pty Ltd These are sent to all JABIRU owners as recorded by JABIRU so that they have the latest authorised recommendations for servicing the aircraft New owners of pre owned aircraft should ensure that the transfer of their aircraft has been advised to JABIRU AIRCRAFT Pty Ltd Existing owners should ensure that their postal address remains current In addition to the information in this Service Manual vendor publications will periodically be available from JABIRU which describe disassembly overhaul and parts breakdown of some of the various vendor equipment items A listing of the available publications is issued from time to time in service letters Page 0 2 Issue 3 Date 040401 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 The JABIRU isa CAO 101 55 Type Certified Aircraft In a
20. The following procedural steps install the landing gear as a complete assembly Refer to applicable paragraphs for installation of the individual components With aircraft Jacked 1 Offer the beam to the fuselage and install clamp and bolts nuts 2 Do not tighten at this stage 25 Locate top end bolt install and tighten nut See Torque Value Figure 1 2 3 Tighten clamp bolts nuts 2 See Torque Value Figure 1 2 4 Connect flexible brake line 5 Top up brake master cylinder with fresh brake fluid and bleed brakes see Paragraph 5 8 5 6 Lower aircraft 5 3 3 Inspection and Repair 1 Inspect composite beam for damage indicated by cracks or delamination Pay particular attention to the area around the centre bend and to areas around drilled holes 2 Inspect bolts and nuts for signs of stress or bending replace if in any doubt 3 Inspect clamp for damage 4 Inspect bolt seats in fuselage for signs of damage wear or perishing Repairs to the composite undercarriage beams must be referred to JABIRU AIRCRAFT Pty Ltd 4 3 4 Main Wheel Fairing Removal and Installation l Remove the machine screws around the join of the forward and rear sections of the fairing Remove the bolt on the outside of the rear section of the fairing Remove the machine screws 2 in the leg attachment fitting Remove the machine screws 3 in the inside of the rear section of the fairing Reverse the preceding steps for installation
21. control cable clamp at rear of seat On RH wing reconnect pitot tube 0 Replace wing strut fairings top and bottom 1 Replace wing root fairings ION 4 3 WING STRUTS Each wing strut is a single lift strut which transmits a part of the wing load to the lower portion of the fuselage The strut consists of a streamlined tube riveted to two end fittings which attach to the fuselage and wing WARNING gt Do Not Tighten Strut Attachment Bolts Metal fatigue may result Bolt must be free to rotate 4 3 1 Removal and Installation See Wing Removal Paragraph 4 2 1 and Wing Installation Paragraph 4 2 3 4 3 2 REPAIR Wing struts are structural components and therefore all repairs must be referred to JABIRU AIRCRAFT Pty Ltd A dented cracked or deformed wing strut should be replaced prior to next flight 4 4 FIN The Fin is a moulded composite structure supported by a rib and a rear spar Hinges attached to the rear spar attach the rudder 4 4 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 Page 4 3 Issue 3 Date 040401 m 45 HORIZONTAL STABILISER The horizontal stabiliser is a moulded monocoque structure of rigid cellular polystyrene bonded to a fibreglass skin and rear spar 4 5 1 Removal and Installation The horizontal stabiliser is an integral part of the fuselage to which it i
22. eg 4 3 2 FA ii a EE 4 4 Removal Installation and Repair esee 4 4 1 FION e ET 4 5 Removal Installation and Repair esee 4 5 1 Page 4 1 Issue 3 Date 040401 E 41 WINGS and EMPENNAGE m 42 Wings Refer to Figure 4 2 Each composite wing is a semi cantilever monocoque type with a main spar The wing is a moulded structure of rigid cellular polystyrene which is bonded through a moulding process to a fibreglass skin and to the spars The forward wing attachment is an extension of the forward sub spar The rear attachment is a composite block heavily bonded to the reinforced wing skin and attaching the main spar through the Wing End Plug Both attachments are through stainless steel threaded bushes bonded into the attachment blocks 4 2 1 Removal The JABIRU aircraft is designed with wings which are removable for storage or transport Wing removal is most easily achieved if two persons are available to handle the wing Remove wing root fairings Remove wing strut fairings top and bottom Disconnect Pitot tube RH wing only Unbolt flap control rods 1 each wing Unbolt aileron control cables 2 from rear of control stick horn inside cabin Remove pin and clamp block from aileron control cable clamps at rear of seat 1 each seat 7 With one person supporting wing tip unbolt top wing strut bolt and lower wind strut to the ground Lower wing tip to ground Unb
23. exhaust pipes Attach a red streamer to each DO NOT seal fuel tank breathers Place protective covers over pitot tube static source vents air vents and openings in engine cowl to prevent the entry of foreign material or beings especially wasps Attach a warning placard to the propeller stating that vents and breathers have been sealed The engine must not be started with the seals in place Every 7 days the propeller should be rotated through 5 revolutions without running the engine leave propeller in the horizontal position CAUTION Ensure that the Master and Ignition Switches are OFF Inspection During Storage Generally inspect airframe and clean as necessary Inspect the interior of at least one cylinder through the spark plug hole for corrosion at least once a month 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 Returning Aircraft to Service After temporary storage the procedures for returning the aircraft to service are as follows SLO SA d pesti 8 9 1 10 1 12 13 14 15 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 sever
24. listed in section 1 are derived from oil free cadmium plated threads and are recommended for all installation procedures contained in this manual except where other values are stipulated They are not to be used for checking tightness of installed parts during service FILTERS SCREENS and FLUIDS for cleanliness contamination and or AIRCRAFT FILE replacement at specified intervals 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 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 Paragraph 2 9 To be carried in the aircraft at all times Flight Manual To be made available on request Aircraft Registration Radio Station License Pilot License Certificate including Medical Certificate if appropriate ENGINE RUN UP Page 2 12 Before beginning the step by step inspection start run up and shut down the engine in accordance with instructions in the Flight Manual and Appendix 1 of this manual During the run up observe the following making note o
25. necessary to ensure continuous airworthiness e Ateach 100 hours the 50 hours items would be completed in addition to the items marked under EACH 100 HOURS as necessary to insure continuous airworthiness e An inspection conducted at 200 hours would likewise include the 50 hour items and 100 hour items in addition to those at EACH 200 HOURS e A complete aircraft inspection includes all 50 100 and 200 hour items together with those shown in the Engine Instruction Manual 2 5 1 INSPECTION GUIDELINES MOVEABLE PARTS for FLUID LINES AND HOSES for METAL PARTS for WIRING for Page 2 11 lubrication servicing security of attachments binding excessive wear safetying proper operation proper adjustment correct travel cracked fittings security of hinges defective bearings cleanliness corrosion deformation sealing and tension leaks cracks kinks chafing proper radius security corrosion deterioration obstruction and foreign matter security of attachment cracks metal distortion broken welds corrosion and any other apparent damage security chafing burning defective insulation loose or broken terminals heat deterioration and corroded terminals Issue 3 Date 130302 BOLTS IN CRITICAL AREAS for correct torque in accordance with torque values NOTE given in the chart in Section 1 when installed or when visual inspection indicates the need for a torque check Torque values
26. recommended as silicon may be absorbed into the glass fibre laminate and effect the repairablity due to impairing bonding 3 2 4 Repairs Damaged window panels and windshield may be removed and replaced if damage is substantial However certain minor repairs as prescribed in the following paragraphs can be made successfully without removing the damaged part from the aircraft 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 Page 3 2 Issue 3 Date 040401 3 2 5 Scratches Scratches on clear plastic surfaces can be removed by hand buffing and polishing using Plastic Polish available from JABIRU as Part No NOVUS 2 NOTE Rubbing plastic surface with a dry cloth will build up an electrostatic charge which will attract dirt particles and may eventually cause scratching of the surface After applying polish dissipate this charge by rubbing surface with a slightly damp chamois This will also remove dust particles which have collected while wax is hardening 3 2 6 Cracks When a crack appears drill a hole at the end of the crack to prevent further spreading Hole should be approximately 1 16 inch in diameter depending on length of crack and thickness of material An unfluted drill should be used 3 2 7 Removal Unscrew and remove carefully with a small
27. stops or by draining bowl Then l Clean aircraft thoroughly 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 5 Remove battery and store in a cool dry place Service the battery periodically and charge as required NOTE 1 It is recommended that a battery which is not used should be charged every 30 days NOTE 2 The battery serial number is recorded in the aircraft equipment list To assure accurate warranty records the battery should be reinstalled in the same aircraft from which it was removed If the battery is returned to service in another aircraft appropriate changes must be made and JABIRU AIRCRAFT Pty Ltd must be notified es Disconnect spark plug leads and remove spark plugs from each cylinder 7 Using an oil can or spray atomiser spray preservative oil through a spark plug hole of each cylinder with the piston in the down position NOTE Use shell ENSIS Engine Oil 30 or similar engine preservative 8 Rotate the propeller 10 12 times leaving it in the horizontal position 5 CAUTION Page 2 5 Issue 3 Date 130302 11 12 13 2 1 10 Su 2 1 11 Ensure that the Master and Ignition Switches are OFF Install spark plugs and connect leads Seal
28. tail and on the engine nose cap will help reduce abrasion encountered in these areas gt CAUTION DO NOT use Silicon based cleaning materials as Silicon is absorbed into the composite materials and may affect repairability 2 3 4 Aluminium Surfaces The aluminium surfaces require a minimum of care but should not be neglected Wash and clean as detailed in paragraph 2 3 3 above gt CAUTION JABIRU aircraft are designed for minimum maintenance However special attention should be applied when the aircraft has been used in extremely corrosive conditions e g beach landings with sand and salt Always ensure the aircraft is thoroughly hosed and washed immediately after such use Pay particular attention to wheels and external controls Always hose down wheels and spats after landings in mud or sand to ensure brakes wheels and spats are free of dirt Page 2 9 Issue 3 Date 130302 build up 2 3 5 Engine and Engine Compartment The engine should be kept clean since dirty cooling fins and baffles can cause overheating of the engine Also cleaning is essential to minimise any danger of fire and provide easy inspection of components gt CAUTION DO NOT hose engine Electrical components may be damaged by moisture Ensure electrical components are protected against moisture Caustic cleaning solutions should not be used Recommended cleaning procedure is lightly spray with degreasing fluid after sealing coils and sta
29. the rubber or delamination of the rubber from the aluminium spacers between the rubber blocks 3 Inspect aluminium trailing arms for damage or bending 4 Inspect bolts nuts for torque see torque values Figure 1 2 Repairs to the welded nose leg assembly beam must be referred to JABIRU AIRCRAFT Pty Ltd 5 5 4 Nose Wheel Speed Fairing Removal and Installation 1 Remove the machine screws around the forward and rear sections of the fairing and remove the front section 2 Loosen the axle nuts and remove the rear section 3 Reverse the preceding steps for installation 5 6 NOSE WHEEL 5 6 1 Nose Wheel Removal and Installation 1 Weight or tie down tail of aircraft to raise the nose wheel off the floor 2 Remove nose wheel axle bolt 3 Pull nose wheel assembly from yolk Reverse the preceding steps to install nose wheel Tighten axle bolt 5 6 2 Nose Wheel Disassembly 1 Completely deflate tyre and break tyre beads loose at wheel rim 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 Page 5 7 Issue 3 Date 040401 Remove through bolts and separate wheel halves Remove wheel hub Remove tyre and tube from wheel halves Remove bearings OS NOTE The bearings are press fit in the wheel hub and should not be removed unless a new part is to be installed 5 6
30. turn the Nose Wheel more than 15 degrees either side of centre or Nose Gear may be damaged The aircraft may also be moved by placing the propeller in the horizontal and then placing one hand on the propeller on either side of the spinner The aircraft can then be pulled forward and nose wheel lifted off the ground if necessary CAUTION Never move the aircraft in this manner whilst the engine is hot as it may fire when the propeller is moved and result in severe injury Always ensure that the Master and Ignitions are OFF Never approach the propeller when anyone is in the aircraft Always treat the propeller as LIVE IT KILLS 2 1 2 Jacking JABIRU is a very light aircraft Before jacking ensure that it is as light as possible by removing luggage and any unnecessary fuel Jacking Main Gear 1 Remove main gear spat on the side to be jacked or both spats 1f both wheels to be jacked 2 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 around the outboard part of the wing strut attachment Be careful lifting at the Wing Tip Page 2 2 Issue 3 Date 130302 3 Place a solid block preferably wood under the bottom of the composite glass leg which will result in the wheel being off the ground when the aircraft is lowered Be careful not to Interfere with brake components or Wheel Spat attachments 4 Repeat for other side if necessary The above pro
31. 3 Nose Wheel Inspection and Repair 1 Clean metal parts in solvent and dry thoroughly 2 Inspect wheel halves for cracks Cracked wheel halves should be discarded and new parts used Sand out nicks gouges and corroded areas Clean thoroughly and paint with silver paint 3 Carefully inspect bearings for damage and discolouration NOTE Bearings are pre packed DO NOT clean with solvents as 1t will remove the packing 4 Refit bearings 5 6 4 Nose Wheel Reassembly 1 Replace bearings in wheel hub 2 Position tyre and tube between wheel halves with tube inflation valve through hole in outside wheel half 3 Mate with wheel hub While maintaining a light force assemble a washer and nut on one through bolt and tighten snugly Assemble the remaining washers and nuts on the through bolts and torque to the value specified in Figure 1 2 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 4 Insert through bolts through brake disc and position disc on the inner wheel hub flange 5 Inflate tyre to seat the tyre beads then adjust to correct tyre pressure Refer Figure 1 1 5 6 5 Wheel Balancing Refer to Paragraph 5 4 8 for wheel balancing information Page 5 8 Issue 3 Date 040401 5 7 NOSE WHEEL STEERING SYSTEM 5 7 1 Steering Centring Cable Assembly The Nosewheel Centring Cable Assembly consis
32. 5 21 Page BEIEN agnivisa sv TVIYILYN JAJI AVY FL XOc 3 MOOls 20012 v3H NI k y SC z GG Oc TO M31SVIN 8l MVE Y d3OvdS A J O OONN 3v A 43H WILI ALO NOlLdlY9S30 YOS 53413 JA NI 040401 Date 5 8 2 3 Issue Figure 5 22 Page SECTION 6 AILERON CONTROL SYSTEM Table of Contents Paragraph Aileron Control System eurer sasa bornas 6 1 Control Colt isis 6 2 Removal and Installapon no nnne enne nnns 6 2 1 Control ee EE 6 3 Removal and Installapon no EAR 6 3 1 O EE 6 4 Removal and Installapon r enne nns 6 4 1 Inspection amp A Re a h um eum m ua Qa gua 6 4 2 RIANT oa sae a A R R R R a RE 6 5 6 1 AILERON CONTROL SYSTEM Refer to Figure 6 5 The aileron control system is comprised of a control column and two enclosed push pull cables fitted with spherical bearings WARNING All spherical bearings must be fitted with a large washer on the outside of the through bolt to prevent the bearing case and cable releasing in the event of a bearing failure See Figure 6 5 6 2 CONTROL COLUMN Refer to Figure 6 2 6 2 1 Removal and Installation The Control Column is a Primary C
33. 8 OLLDJNOAA ERD JON 00 Sul WH SN a Ald HOBLAY 30 31402 38 LON Is IN3SNO9 1nOHll SIHL NOL n au 93113 10N 1004 38 9 M 931 NOISN3dSnS a 3gan Jan NINISL3H IO 13S d3ovds 3gana LIN l JAN FUSY l Nid 31105 D l YA l e l L be L 9 4 9c L TX NOUA LI L N 108 VL ENY 6z l SIMOA 133 3dvIS 0g l 9 3 2011 le l 108 L Dida dshs G3A3809 AYIKSYI D ga Nol93s 040401 Date 3 Issue 5 20 Page Iv 311140 VIS LVN d 318000 ASSY ANVAHI 1138 ET Wa 040401 Date 7 2 5 3 Issue igure F OL UJNSJ ALO HOU A2 RER 31Wld AA H3O0VdS C Jlvld l e 011 Ald HO3IAV 30 IN d3ldOO 3H LON ISNA ANY 1HE 103704 FWIS SIHL
34. 8 1 2 1 2 1 2 1 2 BATTERY LOCATION In Engine In Engine In Engine In Engine Compartment Compartment Compartment Compartment Figure 1 1 Aircraft Specifications Page 1 3 Issue 1 Date 040401 RECOMMENDED TORQUE VALUES in fibreglass Bolt Size Inch lbs AN Yok kt an tp a erat Hu ead dan eta E RON rere ree den n let 20 25 2ftlb LON EE 50 70 4 5 ft lb ANS Vs tO A A DAL 100 140 8 12 ft Ib AN4 ee 84 7 ft Ib Table 1 1 These values relate only to steel nuts on oil free cadmium plated threads For Engine Bolt Torque Values see Engine Instruction amp Maintenance Manual at Appendix 1 The above values are recommended for all installation procedures contained in this Manual except where other values are stipulated The above values are not to be used for checking tightness of installed parts during service CAUTION DO NOT REUSE SELF LOCKING NUTS Figure 1 2 Recommended Torque Values Page 1 4 Issue 1 Date 040401 SECTION 2 GROUND HANDLING SERVICING LUBRICATION AND INSPECTION Table of Contents Paragraph VGROUND HANDEING sheds 2 1 dun 2 1 1 E asa te an aqa n a kn as nt oid aa s aneh nka ga 2 1 2 HOISUHE EE 2 1 3 E aT A E EE EE BORN E Sa a ASS CS 2 1 4 Pasados 2 1 5 iab E 2 1 6 PASO diodos 2515 Returning Aircraft to Ser viles Eeler 2 1 8 Temporary or Indefinite Storage necia is 2 1 9 Inspection
35. Aircraft Service Manual gt Service Schedule gt Inspection Schedule gt Engine Instruction and Maintenance Manual gt Propeller Instruction Manual gt Airworthiness Limitations Mandatory Replacement Times Structural Inspection Intervals u Structural Inspection Procedures Page 0 1 Issue 3 Date 040401 FOREWORD This manual contains JABIRU recommended procedures and instructions for ground handling servicing and maintaining The following Jabiru aircraft models LSA 55 2J Jabiru 1600 powered LSA 55 3J Jabiru 2200 powered Jabiru ST Jabiru 1600 powered Jabiru ST3 Jabiru 2200 powered SK Either Jabiru 1600 or 2200 powered UL450C Jabiru 2200 powered SP Jabiru 2200 powered UL6 Jabiru 3300 powered SP6 Jabiru 3300 powered SP4 Jabiru 2200 powered SP T Jabiru 2200 powered SP T Jabiru 3300 powered The Jabiru models LSA 55 2J Jabiru 2200 powered LSA 55 3J Jabiru 2200 powered Jabiru ST Jabiru 2200 powered Jabiru ST3 Jabiru 2200 powered UL450C Jabiru 2200 powered are Type Certificated by the Australian Civil Aviation Safety Authority CASA under Civil Aviation Order CAO 101 55 In Australia the LSA 55 23 and LSA 55 33 models may be registered with the Australian Ultralight Federation AUF Models Jabiru ST and Jabiru ST3 are registered with CASA The Jabiru model SK is the Amateur Built or Experimental Kit aircraft In Australia it may either be registered by CASA or the AUF
36. EE 5 8 Trouble Shooting eye Ee GE 5 8 1 Master Cilindrada 5 8 2 Removal and Installation Repair Echter 5 8 3 Wheel Brake Assemblies uoc ioa ee Ee 5 8 4 Removal Inspection and Repair Installation Brake Lining Installation Brake Sy Stemi EE 5 8 5 Brake Pad AdjJustiment2u sassa sana h aQ un apupa ed e ie 5 8 6 Parkina Brake ma p eee ua oe a ted se aS Su S Yok asa 5 8 7 Page 5 1 Issue 3 Date 040401 m 5 1 LANDING GEAR Main gear comprises two separate composite beams which are bolted to the fuselage at the top and centre and to the wheel stub at the bottom The nose gear is a welded steel trailing arm assembly with a rubber spring system The nose wheel is steerable with the rudder pedals Nose Wheel and Main Wheel Speed Fairings are optional equipment m 52 TROUBLE SHOOTING Trouble Probable Cause Remedy Aircraft leans to Incorrect tyre Inflate to pressure one side inflation shown at Fig 1 1 Landing gear Tighten loose parts attaching parts Replace defective not tight parts Bent axle stubs Install new part s Tyres wear Incorrect tyre Inflate to pressure excessively inflation shown in Figure 1 1 Main wheels out Align as specified of alignment in Figure 1 1 Bent axle stubs Install new part s Dragging Brakes Refer to Para 5 8 m 53 MAIN GEAR Figure 5 3 illustrates the main landing gear The illustrations should be used in conjunction with the following procedures during removal and installation of component parts
37. ake assemblies can be removed by disconnecting the brake hose and unbolting the brake cylinder from the backing plate The brake disc is removed after the wheel is removed and disassembled Refer to Figure 5 3 1 for disassembly of either wheel brake assembly Wheel Brake Inspection and Repair 1 Clean all parts except brake linings and cylinder buckets in dry cleaning solvent and dry thoroughly 2 New cylinder buckets should be installed each time they are removed If reuse 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 Page 5 10 Issue 3 Date 040401 Check brake linings for deterioration or excessive wear Inspect brake cylinder bore for scoring A scored cylinder will leak or cause rapid bucket wear If wear is evident install a new brake cylinder If the anchor bolts on the brake assembly are nicked or gouged replace with new bolts Inspect wheel brake disc for a minimum thickness of 2mm If brake disc is below minimum thickness install a new part Wheel Brake Installation MAIS Place brake cylinder assembly in position on backing plate Install bolts springs outboard pad and nuts washers Reconnect flexible hose Fill master cylinder reservoir with brake fluid Bleed brakes Refer to Paragraph 5 8 5 Brake
38. al revolutions to clear excess preservative oil from cylinders CAUTION Ensure that the Master and Ignition Switches are OFF Install spark plugs torque to 20 nm 180 inch lbs Check fuel filter replace if necessary Check brake fluid level If returning to service after indefinite storage fill fuel tank with correct grade of fuel Check fuel tank and fuel lines for moisture and sediment Drain enough fuel to eliminate any moisture and sediment Check fuel tank breather is clear Perform a thorough pre flight inspection Start and warm engine Page 2 6 Issue 3 Date 130302 We 22 SERVICING Servicing requirements are shown at Paragraph 2 2 1 The following paragraphs supplement this table by adding details not included Note that Inspection Requirements are detailed at Paragraph 2 5 2 2 1 Servicing Schedule Pre Flight Refer to Flight Manual 25 Hour Service Refer to Engine Instruction amp Maintenance Manual 50 Hour Service Refer to Engine Instruction amp Maintenance Manual 100 Hour Service Refer to Eng Instruction amp Maintenance Manual Other Inspection amp Maintenance Procedures Refer to Engine Instruction amp Maintenance Manual Replace flexible oil amp fuel line in engine compartment every 2 years 2 2 2 Fuel The fuel tank should be filled immediately after flight to lessen condensation of moisture The tank capacity is listed in Section 1 2 2 3 Fuel Drain A fuel drain is located in
39. as a aS duo u Supa ag 10 4 Engine Fuel System See also Section 11 10 5 Spark PLUGS cosida dada sais anana 10 6 Engme Controls at is ad ii 10 7 Exhaust System a nu qia ee ee 10 8 Extreme Climatic Condtons 10 9 A EE 11 0 IR EH 11 1 TWE Kn 11 2 Euel Vent O 11 3 Fuel Shut off Valeria tio 11 4 A os quitus bead utu ie uit 11 5 Puel PUDO 2 it A h e ya h pa be 11 6 Instruments and Instrument System s 12 0 Ela e e os de dl da e 12 1 Instrument Panels renee exe YE aga ie a ed E AS 12 2 A o de ien 12 3 Pitot and Static Systems resi e estes beet ai 12 4 Ee 12 5 OU EE 12 6 Oil Temperature CrauPeu anda ici 12 7 Cylinder Head Temperature Gauge 12 8 Exhaust Gas Temperature Gauge Option 12 9 ee ul 12 10 KEE C ONA PAS a E pie ap A ks 12 11 GYRO Instrument Package 12 12 Page 0 5 Issue 3 Date 040401 Table of Contents Continued Paragraph MEA e 13 0 Electrical Power Supply System 13 1 Battery POWer y eege Eege 13 2 Battery EE 13 3 Starter Solenoid iii 13 4 Voltage Result todas 13 5 Strobe System IS 13 6 Electrical Load ASS iet kas tease ia ate ai I stad ese aa san s r n 13 7 Winne DIA CS 13 8 Radio Wiring Diagram Option
40. ccordance with Civil Aviation Regulations and Orders and the Australian Ultralight Federation Operations Manual NO MODIFICATIONS ARE PERMITTED 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 Page 0 3 Issue 3 Date 040401 SERVICE MANUAL Table of Contents Paragraph General D s riDfi m a a aa von no ean ivo 1 1 Aircraft E e 1 2 Centre of Gravity Limitations iii 1 3 Torque VALUES iii ias 1 4 Ground Handling Servicing Lubrication and PRS POCO AAA 2 0 Ground Handling n os cts see eege Ee oia 2 1 D Servicing incl Servicing Schedule 2 2 TEEN 2 3 Lubtie 3B ODE o cus EE 2 4 9 Inspection incl Inspection Schedule 2 5 A OO 3 1 Windshield and Windows 3 2 Cabim Eiter 3 3 SEALS EE 3 4 Cabin Upholstery asnos e ii EEGEN pei kas E 3 5 SOUMGPEOO LG u ko asa usan sS di 3 6 SEELEN 3 7 Wings and Empennaee 4 1 TE 4 2 WIDE Dee ee 4 3 er 4 4 Horizontal Sad indi 4 5 Landing Gear and Brakes S 0 Landing AA ei a ei ea 5 1 Trouble SIONES AA AA meta AAA 5 2 EC A O 5 3 M in EE 5 4
41. cedure is useful for wheel brake servicing or repairs but is of no value in removing the main undercarriage If the removal of the main undercarriage is necessary adopt the following procedure 1 Obtain a tressel 20ltr drum or similar object 600mm metre high 2 Mount a solid foam block sandbag pillow or similar compliant material on top of the tressel compliant material should distribute load over minimum 150 square centimetres Place under the lower wing strut attachment 3 Support under both wings at the Wing Spar to prevent the aircraft from rocking Ensure that no fittings are strained Jacking Nose Gear 1 Push down on tail Plane NOT THE ELEVATOR until nose gear is off the ground 2 Place tressel or drum under rear fuselage together with absorbent material such as foam block sandbags or a pillow CAUTION Ensure tressel does not foul Ventral Fin 3 Weigh down tail plane with sandbags or similar heavy absorbent material gt CAUTION Do not lift using control surfaces Damage to the control surface or control system may result 2 1 3 Hoisting This procedure should not be necessary for most service or maintenance procedures Should hoisting be necessary Remove wings See Paragraph 4 2 1 Fit shackles to wing support brackets 4 off Fit cables rope to shackles and to a centre lift shackle Hoist only from this point ensuring that cables ropes do not mark the top of the fuselage at corners above wing
42. chisel 3 2 8 Installation 1 Ensure all old Silastic Sikaflex 291 sealant has been removed from the fuselage sealing strips and from a used windscreen which is being replaced 2 Check new windscreen for fit File or grind away any excess material to ensure a close fit 3 Squeeze a bead of Silastic Sikaflex 219 around the outer edge of the windscreen 4 Place windscreen accurately over the sealing strips and locate with one screw top and bottom 5 Fit other screws 6 Take care not to crack windscreen when installing DO NOT over tighten screws cracking will result 3 3 CABIN DOORS 3 3 1 Removal and Installation Removal of doors is achieved by removing the hinge pins or removing the screws which attach the hinges Page 3 3 Issue 3 Date 040401 3 3 2 Adjustment Cabin doors should be adjusted so that the door skin fairs with the fuselage skin 3 3 3 Door Seals A weather strip is glued around all edges of the door Apart from excluding wind and water the weather strip is important in minimising exhaust fume entry to the cabin It should be maintained in good condition and fit at all times New weather strip may be applied after mating surfaces of weather strip and door are clean dry and free from oil and grease 3 3 4 Cabin Door Latches There is one main latch on each door of a simple spring type This is complemented by two wedge catches at the top of each door Door latches or their component parts must be re
43. cs should be replaced with a new part Sand smooth small nicks and scratches 4 Carefully inspect bearings for damage and discolouration NOTE Bearings are pre packed DO NOT clean with solvents as 1t will removed the packing DAS 5 Replace bearings Page 5 4 Issue 3 Date 040401 Position tyre and tube between wheel halves with tube inflation valve through hole in outside wheel half Mate with wheel hub While maintaining a light force assemble a washer and nut on one through bolt and tighten snugly Assemble the remaining washers and nuts on the through bolts and torque to the value specified in Figure 1 2 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 Insert through bolts through brake disc and position disc on the inner wheel hub flange Inflate tyre to seat tyre beads then adjust to correct tyre pressure Refer Figure 1 1 5 4 4 Main Wheel Installation AOS e CH Lightly coat axle with Anti Sieze or a Water Proof grease Place wheel assembly on axle Install spacer and lock bolt nut through centre of axle Place outboard brake pad plate and springs in position and secure with bolts nuts washers Reconnect flexible brake line Refill brake master cylinder with fresh brake fluid Bleed brakes Refer to Section 5 8 5 Install speed fairing if used as outlin
44. ed in Paragraph 5 3 4 5 4 5 Main Wheel Stub Axle Removal To E Remove speed fairing if installed in accordance with Paragraph 5 3 4 Remove wheel in accordance with Paragraph 5 4 1 Disconnect flexible brake hose and drain brake fluid 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 Page 5 5 Issue 3 Date 040401 5 4 6 Main Wheel Stub Axle Installation 1 Secure axle and inboard brake plate to composite leg making sure that any wheel alignment shims are installed in their original position 2 Install wheel assembly on axle in accordance with Paragraph 5 4 4 5 4 7 Main Wheel Alignment Refer to Figure 5 4 7 5 4 8 Wheel Balancing Since uneven tyre wear is usually the cause of tyre imbalance replacing the tyre will probably correct this condition If a wheel shows evidence of imbalance during service it may be statically balanced 5 5 NOSE GEAR The nose gear comprises a steerable nose wheel mounted on a welded steel assembly with aluminium trailing arms and a rubber spring system The steel tube is constrained within two lubron bushes mounted in the fuselage main horizontal beam Nose wh
45. eel steering is achieved by connecting the rudder pedal assembly to the nose wheel steering link by a push rod The nosewheel is centred by a sprung steel cable A nose wheel speed fairing is optional equipment Disassembly inspection repair and reassembly of the nose wheel assembly are described in separate paragraphs The wheel is in two halves which are joined by through bolts to the wheel hub as shown in Figure 5 5 During assembly of the nose wheel the through bolts must be tightened evenly and torqued to the value specified in Figure 1 2 5 5 1 Trouble Shooting Trouble Probable Cause Remedy Nose wheel shimmy Nose strut bolts loose Tighten bolts Loose or worn steering link Tighten replace defective parts Nose wheel out of balance Refer Paragraph 5 6 5 Wheel bearings loose Replace Page 5 6 Issue 3 Date 040401 5 5 2 Nose Gear Removal and Installation See Figure 5 5 1 Weight or tie down tail of aircraft to raise nose wheel off floor 2 Disconnect nose wheel steering cables and centring cable from steering cross beam 3 Unbolt steering cross beam 4 Slide steering cross beam from position in top of front aluminium beam 5 Pull the nose wheel strut assembly down from the bushes in the fuselage To install the nose gear reverse the preceding steps 5 5 3 Nose Gear Inspection and Repair 1 Inspect steel tube and attachments for dents and straightness 2 Inspect rubber spring assembly for damage or perishing of
46. f any discrepancies or abnormalities 1 Engine temperatures and pressures Static RPM Also refer to Engine Instruction Manual 3 Magnito drop Also refer to Engine Instruction Manual 4 Engine response to changes in power 5 Any unusual engine noises Issue 3 Date 130302 Page 2 13 6 Fuel shut off valve operate engine in ON position and in OFF position long enough to ensure shut off functions properly 7 Idling speed After the inspection has been completed an engine run up should again be performed to determine that any discrepancies or abnormalities have been corrected Issue 3 Date 130302 D 2 52 INSPECTION CHART IMPORTANT READ ALL INSPECTION RQUIREMENTS PARAGRAPHS PRIOR TO USING THESE CHARTS Annual Inspection Each 200 Hours PROPELLER Each 100 Hours Each 50 Hours l SPINNE e co a ieee oo pake e kn eee ka 2 Springer Mange i as o eee S m 3 e EIER 4 Propeller 2 poin sro vip aaa kaskad UE rasis ki 5 Propeller bolts nuts ld ki 6 Leading Edge Tape if fitted ENGINE COMPARTMENT Check for evidence of oil and fuel leaks then clean entire engine and compartment if needed prior to inspection See notes in Paragraph 2 3 5 re engine cleaning 1 Carburettor air filter di 2 Engine baffles and air ducts 3 Cyl ers sas ca ien ood
47. ght on the rod ends and that cable is visible through the inspection hole in the rod end Then check UP travel on both ailerons using the Aileron Rigging Template see Appendix 3 as shown in Figure 6 5 Use the Aileron Control Stop adjustment see Figure 6 5 1 to adjust the total aileron movement ie UP travel and use cable adjustment as previously described to proportion UP and DOWN travel The Aileron Control Stop should engage before the Aileron Arm hits the UP travel stop at the Wing Tip DO NOT move the Cable Anchors these positions are factory set 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 Page 6 2 Issue 3 Date 040401 lel vv NULIO3S 338 ay 88 NOILOSS 5438 S438 Wan 21 ASSY IN3He Levy 040401 Date 3 Issue oudiyosaa ON l va au lavd ALO NOLIdINOS30 ATI 3 Andino dis a vH M 6 2 6 3 L 3 a Figure Page
48. l falling aft of the curtain and resulting in a severe aft centre of gravity condition The curtain should be in place for all flights mb 37 SAFETY PROVISIONS 3 7 1 Seatbelts Aircraft grade Seatbelts bolted to the fuselage structure are provided for both seats Belts should be replaced if frayed or cut latches are defective of stitching is broken Attaching parts should be replaced with equivalent grade parts if excessively worn or defective Page 3 5 Issue 3 Date 040401 Door Latch Assembly ITEM gt N DESCRIPTION QTY DOOR LATCH ASSY PLUNGER DOOR LATCH BLOCK NYLON DOO LEVER DOOR LATCH ROLL PIN SPRING wal LATCH 3 X 1 2 6 PLATE ALUMINIUM 7 SELF TAP 6gg X 10 2 SECTION AA Drawing 7012093 3 DOOR LATCH AS Figure 3 3 4 Page 3 6 Issue 3 Date 040401 SECTION 4 WINGS and EMPENNAGE Table of Contents Paragraph Wings and EMpenMage visir isso 4 1 WM 4 2 Lee 4 2 1 A ai rete a tn pe suan pa Pe dis a es EE An A 4 2 2 Ir ue EE 4 2 3 WINE SOUS gege 4 3 Removal and A io ia 4 3 1 Een Ee
49. lated They are not to be used for checking tightness of installed parts during service Page 1 1 Issue 1 Date 040401 MODEL LSA 55 2J amp LSA 55 3J amp SK UL450C UL6 Jabiru ST Jabiru ST3 AIRCRAFT SPECIFICATIONS 430 kg 946 Ib 430 kg 946 lb 430 kg 946 lb 450 kg 990 lb 500 kg 1100 Ib GROSS WEIGHT FUEL CAPACITY 50 litres 65 litres 50 or 65 litres 50 litres 85 litres OIL CAPACITY 2 3 litres 2 3 litres 2 3 litres 2 3 litres 3 4 litres ENGINE MODEL Refer to Appendix Jabiru 1600 Jabiru 2200 Jabiru 2200 Jabiru 2200 Jabiru 3300 I for Engine Data PROPELLOR Jabiru 54 dia 60 60 60 60 Fixed Pitch 1371mm 1524mm 1524mm 1524mm 1524mm PROPELLOR Jabiru 38 pitch 42 42 42 48 Fixed Pitch 965mm 1040mm 1040mm 1040mm 1040mm MAIN WHEEL TYRES 11 dia x 4 rim 11 dia x 4 rim 11 dia x 4 rim 11 dia x 4 rim 11 dia x 4 rim STANDARD Options Available MAIN WHEEL 4 wide 4 wide 4 wide 4 wide 4 wide TYRES 4 Ply Rating 4 Ply Rating 4 Ply Rating 4 Ply Rating 4 Ply Rating STANDARD Options Available NOSE WHEEL TYRE 10 25 dia x 4 rim 10 25 dia x 4 rim 10 25 dia x 4 rim 10 25 dia x 4 rim 10 25 dia x 4 rim STANDARD Options Available NOSE WHEEL 4 wide 4 wide 4 wide 4 wide 4 wide TYRE 4 Ply Rating 4 Ply Rating 4 Ply Rating 4 Ply Rating 4 Ply Rati
50. ng STANDARD Options Available TYRE 170 kpa 25 psi 170 kpa 25 psi 170 kpa 25 psi 170 kpa 25 psi 170 kpa 25 psi PRESSURES STANDARD Mains TYRE 82 kpa 12 psi 82 kpa 12 psi 82 kpa 12 psi 82 kpa 12 psi 82 kpa 12 psi PRESSURES STANDARD Nose WHEEL ALIGNMENT at Gross Weight Camber 0 0 0 0 0 Toe In 0 0 0 0 0 PRINCIPAL DIMENSIONS Wing Span 8034 mm 26 4 8034 mm 26 4 8034 mm 26 4 9398mm 30 10 9398mm 30 10 Length 5040 mm 16 5 5040 mm 16 5 5040 mm 16 5 5640mm 18 6 5640mm 18 6 Fin Height 2013 mm 67 2013 mm 67 2013 mm 67 2013 mm 67 2013 mm 67 Track Width 1600 mm 53 1600 mm 53 1600 mm 53 1600 mm 53 1600 mm 53 Wheel Centres 2350 mm 7 8 2350 mm 7 8 2350 mm 7 8 2350 mm 7 8 2350 mm 7 8 Tail Span 1 2 1 2 1 2 1 2 1 2 BATTERY In Engine In Engine In Engine In Engine In Engine LOCATION Compartment Compartment Compartment Compartment Compartment Page 1 2 Issue 1 Date 040401 MODEL SP SP6 SP T SP T6 AIRCRAFT SPECIFICATIONS GROSS WEIGHT 430 kg 946 Ib 430 kg 946 lb 430 kg 946 lb 430 kg 946 Ib FUEL CAPACITY 50 litres 65 litres 50 or 65 litres 65 litres OIL CAPACITY 2 3 litres 2 3 litres 2 3 litres 2 3 litres ENGINE MODEL Refer to Appendix I for Engine Data Jabiru 2200 Jabiru 3300 Jabiru 2200 Jabiru 3300 PROPELLOR Fixed Pitch 60 60
51. nie nee sade ANEN 4 Crankcase and front crankcase seal a de Hoses lines and fittings 6 Intake and exhaust systems eeessssesese esseere eee ki k 7 Ignition liatnessc c4 ioa rea D AE T ka 8 Spark PUES vcd di 9 Compression check i a 10 Electrical EE l Il P ebphipa ei ian kako ke Opec he a san T 12 Engine controls and linkages T ki 13 Engine mounts mount structure 5 14 Starter solenoid and electrical connections i 15 Coils and electrical connections a 16 Carburettor heat system 17 Throttle and linkage LOW Q ee 2 5 19 Oil system tubes and hoses cece sees eee eee ees ki 20 reelle ee EE EEN o 21 Engine cowlings and clips Page 2 14 Issue 3 Date 130302 Annual Inspection Each 200 Hours Each 100 Hours Each 50 Hours FUEL SYSTEM 1 Fuel filter drain valve bowl Ze Fuel tank vent cap and placards 3 a KH 4 Check tank attachments 5 Fuel shut off valve and placards 6 Electronic fuel boost pump and fittings 7 Fuel lines and connectors
52. nstall outboard brake pad and refix with through bolts and springs Page 5 11 Issue 3 Date 040401 5 8 5 Brake System Bleeding 1 Fill the brake master cylinder with automotive brake fluid 2 Loosen the flexible hose fitting at the brake cylinder 3 Pump the handbrake until air is expelled from lines NOTE Ensure brake master cylinder remains full above the outlet hose 4 When air is fully expelled tighten flexible hose fitting 5 Repeat steps 1 4 for other side brake CAUTION Use only automotive brake fluid DO NOT use aircraft hydraulic fluid or damage will result 5 8 6 Brake Pad Adjustment Brake Pads may be adjusted by remove the Main Wheel Spats and tightening the brake pad attaching bolts and nuts until the wheel just rotates freely 5 8 7 Parking Brake The Parking Brake consists of an over centre cam on the brake handle Should the cam have insufficient travel for the brakes to hold the aircraft with a propeller thrust of 2500rpm adjust by one or all of the following 1 Adjust brakes as described in Paragraph 5 8 6 2 Bleed air from brake system as described in Paragraph 5 8 5 3 Adjust length of Master Cylinder Drive Rod at the Rod End attaching to the Brake Handle NOTE Items 1 and 2 above should correct the adjustment Item 3 should only be necessary with replacement Of Master Cylinder Page 5 12 Issue 3 Date 040401 040401
53. ocated between the seats in the main longitudinal beam 1s actuated by applying rearward pressure to the brake handle A small reservoir is incorporated into the master cylinder for the fluid supply Date 040401 Page 5 9 Issue 3 Brake Master Cylinder Removal and Installations 1 Remove the flexible hose from one wheel brake assembly and drain the hydraulic fluid from the brake system Remove cover over main longitudinal beam between seats Unbolt pushrod at brake handle and remove pushrod Disconnect flexible hose at master cylinder Unbolt master cylinder retaining bolts 2 Plug or cap hydraulic fittings and hoses to prevent the entry of foreign material AE to Reverse the preceding steps to install brake master cylinder then fill and bleed brake system in accordance with Paragraph 5 8 5 Brake Master Cylinder Repair Figure 5 8 2 may be used as a guide during disassembly repair and reassembly of the brake master cylinder Repair is limited to installation of new parts cleaning and adjustment Use only automotive brake fluid DO NOT use aircraft grade hydraulic fluid or damage will result 5 8 3 Hydraulic Brake Lines These lines are flexible hoses connected through a tee piece Repair is limited to replacement 5 8 4 Wheel Brake Assemblies The Wheel Brake Assemblies use a disc which is attached to the main wheel hub with through bolts and a floating brake assembly Refer to Figure 5 3 1 Removal The Wheel br
54. olt and remove front wing attachment bolt 10 Unbolt and remove rear wing attachment bolt Note It may be necessary to rock the wing slightly while pulling attaching bolt or carefully use a long drift punch to drive out attaching bolt DEAD HE SE 11 Carefully remove wing by moving it out to clear the aileron cable from the fuselage 12 Place wing on cushioned structure to avoid damage to wing strut attachment 13 Unbolt lower wing strut bolt and remove wing strut 14 Repeat Steps 6 12 to remove other wing 42 2 Repair The wing is a composite monocoque structure All repairs must be referred to JABIRU AIRCRAFT Pty Ltd 4 2 3 Installation l Fit wing and its lower attaching bolt leaving the top end of the strut on the ground Page 4 2 Issue 3 Date 040401 WARNING gt Do Not Tighten nut or metal fatigue may result washer must be free to rotate 2 Fit wing to fuselage leaving wing tip on the ground and routing aileron cable through hole in fuselage wing root Install front and rear wing attaching bolts nuts Put top wing strut attaching bolt in your pocket Lift wing tip and install wing strut to wing strut attachment with bolt from pocket Install nut WARNING D Do Not Tighten nut or metal fatigue may result a z washer must be free to rotate Install bolt nut in flap control rod Install bolt nut in aileron control cable on main control stick horn Install clamp block and pin in aileron
55. ontrol and may not be removed or repaired without reference to JABIRU AIRCRAFT Pty Ltd 6 3 CONTROL CABLES Control Cables are of the enclosed push pull type fitted with spherical bearings at both ends To operate the outer cover of the cable must be clamped firmly at each end 6 3 1 Removal and Installation Control Cables are Primary Control and may not be removed or repaired without reference to JABIRU AIRCRAFT Pty Ltd Page 6 1 Issue Date 040401 amm 6 4 AILERONS Ailerons comprise a moulded and bonded monocoque structure embodying a composite control horn at the outboard end 6 4 1 Removal and Installation 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 Reverse the preceding steps for installation 6 4 2 Inspection and Repair Inspect ailerons for any signs of delamination or cracking Pay particular attention to the Control Horn and hinges and their surrounding areas Repairs must be referred to JABIRU AIRCRAFT Pty Ltd mm 65 RIGGING 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 ti
56. placed if worn or damaged 3 3 5 Locks An optional cylinder and key lock is available When fitted the keyed barrel lock is located in the fuselage at the rear of the Port side door An internal toggle catch located in the fuselage at the rear of the Starboard door locks the Starboard door Spare keys are available to JABIRU registered owners by quoting the aircraft Serial Number 34 SEATS The JABIRU seats are an integral part of the structure of the aircraft they are therefore fixed in position Forward and upward adjustment can be achieved by placing a cushion behind and or under the occupant The seat pans incorporate crushable foam which is essential in providing shock absorption in crash conditions WARNING DO NO MODIFY SEATS 3 4 1 Repair As seats are integral to the aircraft structure any repair must be referred to JABIRU AIRCRAFT Pty Ltd 3 5 UPHOLSTERY Seat upholstery is provided through slip on covers These are easily removed for cleaning and inspection of the seat structures Optional Hood and Cabin lining is available together with Door Pockets Page 3 4 Issue 3 Date 040401 m 36 SOUNDPROOFING Soundproofing material is included in the Firewall In addition a curtain of soundproofing material is provided at the rear of the cockpit baggage area This curtain is attached to composite struts in the fuselage with velcro straps Its purpose is to minimise drumming of the fuselage as well as restricting materia
57. rter motor WIPE clean with brush and cloth 2 3 6 Propeller Wash with soap and water rinse with clean water and dry with cloth or chamois Lightly wax using automotive wax 2 3 7 Wheels The wheels should be washed periodically and examined for corrosion cracks or dents in the wheel halves or in the flanges or hubs If defects are found remove and repair in accordance with Section 5 Discard cracked wheel halves flanges or hubs and install new parts 2 4 LUBRICATION There are no lubrication requirements for the JABIRU other than those detailed in Appendix 1 2 4 1 Wheel Bearing Mains and Nose At each 100 hour inspection jack the wheel spin the wheel and check for free running and any play on the shaft Remove and replace if there is any sign of binding or wear Page 2 10 Issue 3 Date 130302 2 5 INSPECTION Inspection Charts The chart at Paragraph 2 5 2 shows the recommended intervals at which items are to be inspected As shown in the chart there are items to be inspected each 50 hours each 100 hours and each 200 hours There are also special inspection items which require inspection of servicing at intervals other than 50 100 and 200 hours The engine Instruction Manual also details engine inspection schedules and should be consulted in addition to this chart e When conducting an inspection at 50 hours all items marked under EACH 50 HOURS would be inspected serviced or otherwise completed as
58. s bonded It cannot be removed All repairs must be referred to JABIRU AIRCRAFT Pty Ltd Page 4 4 Issue 3 Date 040401 SECTION 5 LANDING GEAR and BRAKES Table of Contents Paragraph kanding E EE 5 1 Trouble Shooting 0 s 5 2 ENEE 5 3 Removal yu aw an n 5 3 1 KAS Ca nees Eege ee 5 3 2 inspection abu AA sawas A eka t ka 5 3 3 Main Wheel Fairing Removal and Installation eese 5 3 4 Main Gear Top Fairing Removal and Installation 5 3 5 Mam EE 5 4 Removal orinando M 5 4 1 a oo tl 5 4 2 Inspection Assembly and Repair iii deen ioe ate 5 4 3 T stallati on a enini e n e QO a ae S m Qs ua GSS 5 4 4 Stub Ale REMOV EE 5 4 5 Wheel Installation viii ad lid 5 4 6 AJISBImenta re do crio de 5 4 7 Bal3netng 422 ga eae nae ea aie atu defecit ia een 5 4 8 Nose Gears wi tib ba koub ba ty eit S 5 5 Ree EE 5 5 1 Removal and Installation iS A E 3 5 2 Inspection and Repas obo do en cba 5 5 3 Nose Wheel Fairing Removal and Installation sese 5 5 4 Nose EE 5 6 Removal and Installation A n nunus 5 6 1 KE 5 6 2 Inspection and R pait aiii e E E pdi saa AA oak yanasa 5 6 3 Reassembly oc io pe susunka aca a be sus t US kuq su aaa 5 6 4 EE 5 6 5 Nose EE EE 5 7 Steering Cable ASSembINs gedet eat sede e EISES 5 7 1 Nose Wheel Steering Assembly nein o estie ide sen pee etie ceu 5 7 2 Le
59. support brackets Tu eS Page 2 3 Issue 3 Date 130302 2 1 4 Levelling Method 1 For both lateral and longitudinal levelling use a spirit level on either side of the lower door sills or the fuselage cowl flange line Method 2 Use the join line of the cowl top amp bottom cowl as one point As the second measuring point use the join where the top amp bottom fuse meets which should be the leading edge of the horizontal stabiliser 2 1 5 Parking 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 Paragraph 2 1 6 if a hangar is not available 2 1 6 Tie Down When mooring the aircraft in the open head into wind if possible Secure control surfaces by tying the control handle back firmly with a seat belt Then 1 Tie ropes to the top end of each wing strut Secure opposite end of the ropes to ground anchors located at approximately 30 degrees to the vertical outboard of the top wing attachment point Ensure that the ropes have sufficient slack to not strain the wing 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 2 1 7 Flyable Storage Flyable storage is defined as a maximum of 30 days non operational storage
60. the fuel tank Drain fuel after each refueling to ensure moisture and contaminants are not present 2 2 4 Carburettor Air Filter The Carburettor air filter keeps dust and dirt from entering the induction system The value of maintaining the air filter in a good clean condition cannot be overstressed More engine wear is caused through the use of a dirty or damaged air filter than is generally believed The frequency with which the filter should be removed inspected and cleaned will depend on the operating conditions A good general rule however is to remove inspect and clean the filter ever 50 hours of engine operating time and more frequently if warranted by the operating conditions Clean only with compressed air Under extreme operating conditions daily servicing of the filter is recommended 2 2 5 Battery The Battery is not a serviceable item as it is a gel Use bicarbonate of soda baking soda and clean water to neutralise electrolyte of corrosion Follow with a thorough flushing with clean water Do not allow bicarbonate of soda to enter the battery Remove battery and clean residue from aircraft Tighten cable and terminal connections with a wire brush then coat with petroleum jelly before connecting cables Check the battery every 50 hours or at least every 30 days more Page 2 7 Issue 3 Date 130302 often in hot weather Add only distilled water not acid or rejuvenators to maintain electrolyte level in the battery
61. ts of a manufactured cable assembly and a spring Repair is limited to replacement of both or either part 5 7 2 Nose Wheel Steering Assembly Refer to Figure 5 7 2 The Nosewheel Steering Assembly comprises a Steering Bellcrank Assembly which is bolted to the Main Beam and push rods attaching the Rudder Pedals and the Steering Link Repair is limited to the replacement of serviced parts 58 BRAKE SYSTEM The hydraulic brake system consists of one master cylinder located between the seats in the main longitudinal beam flexible hoses connecting the master cylinder to each wheel brake cylinder and the single disc floating cylinder type brake assembly located at each main landing gear wheel 5 8 1 Trouble Shooting Probable Cause Brake handle binding Trouble Dragging brakes Remedy Check and adjust Worn or broken piston return spring Restriction in hydraulic lines or in master cylinder Brakes fail to operate Leak in system Air in system Lack of fluid in master cylinder Master cylinder defective Brake pads worn Repair or install new master cylinder Drain brake line clear with compressed air If cleaning lines fails the master cylinder may be faulty and should be repaired or replaced If master cylinder or wheel cylinders are leaking repair or install new parts Bleed system Fill and bleed system Repair or install new parts Replace with new parts 5 8 2 Brake Master Cylinder The brake master cylinder l
62. y cloth as this builds up an electrostatic charge which attracts dirt Oil and grease may be removed by using a soft cloth moistened with mineral turpentine CAUTION DO NOT use gasoline alcohol buzene acetone carbon tetrachloride fire extinguisher fluid de icer fluid lacquer thinner or glass window cleaning spray These solvents will soften and craze the Plastic DO NOT use a canvas cover on the windshield Page 2 8 Issue 3 Date 130302 or windows as the cover may scratch the plastic 2 3 2 Interior Surfaces Interior surfaces should be cleaned with a soft cloth fresh water and a mild detergent Volatile substances such as those mentioned in the previous section must never be used 2 3 3 Exterior Surfaces The exterior surfaces under normal conditions require a minimum of polishing and buffing CAUTION DO NOT polish or buff the aircraft within the first 2 weeks after delivery from the factory as surface treatments take up to 14 days to properly cure Generally the exterior surfaces can be kept bright by washing with water and a mild soap or detergent followed by a rinse with water and drying with a cloth or a chamois Remove stubborn oil and grease with a cloth moistened with mineral turpentine then wash with water and a mild soap rinse and dry as stated before After the curing period the aircraft may be waxed with a good quality automobile wax A heavier coating of wax on the leading edges of the wing

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