Jabiru j120 User manual

TECHNICAL MANUAL
FOR
JABIRU AIRCRAFT MODELS:
J120 Variants
J160 Variants
J170 Variants
J200/J400 Variants
J230/J430 Variants
J250/J450 Variants
DOCUMENT No. JTM001-1
DATED: 6th April 2012
This Manual has been prepared as a guide to correctly maintain Jabiru Aircraft Models.
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 while it remains on the Jabiru server. 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.

Aircraft Service Manual
Jabiru Aircraft Pty Ltd
JTM001-1
J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants
REVISION
1
Dated: Nov 2011
Issued By: SW
Page: 2 of 233
1Table of Contents
1TABLE OF CONTENTS.......................................................................................................2
1.1 TABLE OF FIGURES...................................................................................................................................... 6
1.2 LIST OF TABLES...........................................................................................................................................10
2SECTION 2 –SERVICE MANUAL ....................................................................................11
2.1 FOREWORD / APPLICABILITY.....................................................................................................................11
2.2 LIST OF EFFECTIVE PAGES / ISSUE STATUS...........................................................................................14
2.3 INTRODUCTION............................................................................................................................................14
2.4 READING THIS MANUAL..............................................................................................................................14
2.5 DEGREE OF DIFFICULTY............................................................................................................................14
2.6 CALIBRATIONS.............................................................................................................................................15
2.7 USE-BY DATES & STORAGE.......................................................................................................................15
2.8 GENERAL DESCRIPTION ............................................................................................................................15
2.9 OWNER MAINTENANCE ..............................................................................................................................16
2.10 AIRCRAFT SPECIFICATIONS ......................................................................................................................16
2.11 CENTRE OF GRAVITY LIMITATIONS..........................................................................................................16
2.12 TORQUE VALUES (IN FIBREGLASS)..........................................................................................................16
2.13 STANDARD PRACTICES..............................................................................................................................17
2.14 AIRCRAFT STRUCTURE..............................................................................................................................17
2.15 ENGINES.......................................................................................................................................................18
2.16 AIRCRAFT SPECIFICATIONS ......................................................................................................................19
3GROUND HANDLING & STORAGE .................................................................................27
3.1 TOWING........................................................................................................................................................27
3.2 JACKING .......................................................................................................................................................27
3.3 HOISTING......................................................................................................................................................28
3.4 LEVELLING ...................................................................................................................................................28
3.5 PARKING.......................................................................................................................................................28
3.6 TIE DOWN.....................................................................................................................................................28
3.7 STORAGE .....................................................................................................................................................29
4INSPECTION & SERVICING.............................................................................................31
4.1 BASIC INSPECTION PROCEDURE..............................................................................................................31
4.2 MANDATORY INSPECTIONS & LIFED ITEMS ............................................................................................31
4.3 INSPECTION CHART....................................................................................................................................32
4.4 SERVICING...................................................................................................................................................36
4.5 GENERAL INSPECTION GUIDELINES ........................................................................................................36
4.6 ENGINE PRE-INSPECTION RUN-UP:..........................................................................................................37
4.7 PROPELLER 100-HOURLY ..........................................................................................................................37
4.8 ENGINE COMPARTMENT 100-HOURLY .....................................................................................................37
4.9 FUEL SYSTEM 100-HOURLY.......................................................................................................................39
4.10 LANDING GEAR 100-HOURLY.....................................................................................................................39
4.11 AIRFRAME 100-HOURLY .............................................................................................................................40
4.12 CONTROL SYSTEMS 100-HOURLY ............................................................................................................41
4.13 LUBRICATION...............................................................................................................................................41
4.14 SPECIAL INSPECTIONS –PROPELLER.....................................................................................................42
4.15 SPECIAL INSPECTIONS –WEIGHING........................................................................................................42
4.16 SPECIAL INSPECTIONS –CONTROL CABLES..........................................................................................44
4.17 SPECIAL INSPECTIONS –CONTROL SURFACES.....................................................................................45
4.18 SPECIAL INSPECTIONS –MAIN WHEEL ALIGNMENT..............................................................................49
4.19 SPECIAL INSPECTIONS –FUEL GAUGE DECAL SETUP..........................................................................52
4.20 SPECIAL INSPECTIONS –FUEL SENDER CALIBRATION.........................................................................54
5CLEANING........................................................................................................................57
5.1 WINDSHIELD AND WINDOWS.....................................................................................................................57

Aircraft Service Manual
Jabiru Aircraft Pty Ltd
JTM001-1
J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants
REVISION
1
Dated: Nov 2011
Issued By: SW
Page: 3 of 233
5.2 INTERIOR SURFACES .................................................................................................................................57
5.3 EXTERIOR SURFACES................................................................................................................................57
5.4 ALUMINIUM SURFACES ..............................................................................................................................57
5.5 ENGINE AND ENGINE COMPARTMENT.....................................................................................................58
5.6 PROPELLER .................................................................................................................................................58
5.7 WHEELS........................................................................................................................................................58
6FUSELAGE .......................................................................................................................59
6.1 FUSELAGE....................................................................................................................................................59
6.2 WINDSHIELD AND WINDOWS.....................................................................................................................59
6.3 J160-TYPE CABIN DOORS...........................................................................................................................61
6.4 J160-TYPE CABIN DOOR LATCHES............................................................................................................61
6.5 J200 TYPE CABIN DOORS...........................................................................................................................65
6.6 J200-TYPE CABIN DOOR LATCHES............................................................................................................66
6.7 SEATS...........................................................................................................................................................68
6.8 UPHOLSTERY...............................................................................................................................................69
6.9 SOUNDPROOFING.......................................................................................................................................69
6.10 SAFETY PROVISIONS..................................................................................................................................69
7WINGS & EMPENNAGE ...................................................................................................70
7.1 GENERAL......................................................................................................................................................70
7.2 J120 WINGS..................................................................................................................................................70
7.3 J160 WINGS..................................................................................................................................................71
7.4 J170 WINGS..................................................................................................................................................75
7.5 J200 WINGS..................................................................................................................................................77
7.6J230 WINGS..................................................................................................................................................78
7.7 J250 / J450 WINGS .......................................................................................................................................80
7.8 WING STRUTS..............................................................................................................................................81
7.9 LANDING LIGHT(S).......................................................................................................................................82
7.10 LANDING LIGHT ADJUSTMENT (NIGHT-VFR MODELS)............................................................................82
7.11 DYNON PITOT ..............................................................................................................................................84
7.12 WING INSPECTION WINDOW......................................................................................................................85
7.13 FIN.................................................................................................................................................................86
7.14 HORIZONTAL STABILISER..........................................................................................................................86
8LANDING GEAR & BRAKES............................................................................................87
8.1 GENERAL DESCRIPTION ............................................................................................................................87
8.2 MAIN UNDERCARRIAGE REMOVAL (JACKING) ........................................................................................87
8.3 MAIN WHEEL FAIRING (SPATS)..................................................................................................................88
8.4 MAIN GEAR TOP FAIRING (SPEED FAIRING)............................................................................................89
8.5 MAIN WHEELS..............................................................................................................................................89
8.6 MAIN WHEEL STUB AXLE............................................................................................................................92
8.7 WHEEL BALANCING.....................................................................................................................................93
8.8 MAIN GEAR LEG...........................................................................................................................................93
8.9 TROUBLE SHOOTING –MAIN UNDERCARRIAGE.....................................................................................94
8.10 NOSE WHEEL SPEED FAIRING (SPAT)......................................................................................................96
8.11 NOSE WHEEL...............................................................................................................................................96
8.12 NOSE WHEEL STEERING / CENTRING SYSTEM.......................................................................................98
8.13 NOSE UNDERCARRIAGE LEG ....................................................................................................................99
8.14 TROUBLE SHOOTING –NOSE LEG..........................................................................................................101
8.15 NOSE WHEEL BALANCING .......................................................................................................................102
8.16 NOSE LEG HOUSING.................................................................................................................................104
8.17 BRAKE MASTER CYLINDER......................................................................................................................105
8.18 HYDRAULIC BRAKE LINES........................................................................................................................108
8.19 WHEEL BRAKES.........................................................................................................................................108
8.20 PARKING BRAKE........................................................................................................................................109

Aircraft Service Manual
Jabiru Aircraft Pty Ltd
JTM001-1
J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants
REVISION
1
Dated: Nov 2011
Issued By: SW
Page: 4 of 233
8.21 BRAKE LINING INSTALLATION .................................................................................................................109
8.22 BRAKE SYSTEM BLEEDING......................................................................................................................109
8.23 BRAKE PAD ADJUSTMENT .......................................................................................................................110
8.24 BRAKE DISC WEAR LIMIT .........................................................................................................................110
8.25 TROUBLE SHOOTING - BRAKES ..............................................................................................................111
9AILERON CONTROL SYSTEM.......................................................................................113
9.1 AILERON CONTROL SYSTEM...................................................................................................................113
9.2 CONTROL COLUMN...................................................................................................................................115
9.3 CONTROL CABLES ....................................................................................................................................117
9.4 AILERONS...................................................................................................................................................120
9.5 AILERON RIGGING.....................................................................................................................................120
10 WING FLAP CONTROL SYSTEM...................................................................................123
10.1 WING FLAP CONTROL SYSTEM...............................................................................................................123
10.2 MANUAL FLAP LEVER ASSY.....................................................................................................................125
10.3 ELECTRIC FLAP DRIVE ASSEMBLY.........................................................................................................125
10.4 FLAP CROSS SHAFT ASSEMBLY .............................................................................................................131
10.5 FLAP POSITION INDICATOR .....................................................................................................................133
10.6 EXTERNAL FLAP PUSH ROD ....................................................................................................................135
10.7 FLAP............................................................................................................................................................135
10.8 FLAP RIGGING (AS PER TEMPLATE) .......................................................................................................136
11 ELEVATOR CONTROL SYSTEM ...................................................................................137
11.1 ELEVATOR CONTROL SYSTEM................................................................................................................137
11.2 CONTROL COLUMN...................................................................................................................................139
11.3 ELEVATOR..................................................................................................................................................139
11.4 ELEVATOR CONTROL CABLES ................................................................................................................141
11.5 RIGGING .....................................................................................................................................................142
11.6 ELEVATOR TRIM –CONTROL LEVER ASSY ...........................................................................................143
11.7 ELEVATOR TRIM –AFT ASSEMBLY.........................................................................................................145
11.8 TRIM CONTROL CABLES...........................................................................................................................146
12 RUDDER CONTROL SYSTEM........................................................................................148
12.1 RUDDER PEDAL SYSTEM .........................................................................................................................148
12.2 RUDDER CENTRING SYSTEM ..................................................................................................................151
12.3 RUDDER......................................................................................................................................................154
12.4 RUDDER CONTROL CABLE ......................................................................................................................155
12.5 RUDDER BALANCE....................................................................................................................................156
12.6 RIGGING .....................................................................................................................................................156
13 ENGINE & ENGINE INSTALLATION..............................................................................157
13.1 ENGINE COWLS.........................................................................................................................................157
13.2 ENGINE.......................................................................................................................................................159
13.3 FLEXIBLE HOSES.......................................................................................................................................159
13.4 COOLING AIR BAFFLES.............................................................................................................................161
13.5 ENGINE MOUNT.........................................................................................................................................162
13.6 ENGINE FUEL SYSTEM .............................................................................................................................163
13.7 ENGINE THROTTLE CONTROL.................................................................................................................163
13.8 CHOKE CABLE ...........................................................................................................................................166
13.9 AIR INTAKE SYSTEM & CARBURETOR HEAT .........................................................................................167
13.10 EXHAUST SYSTEM ....................................................................................................................................168
13.11 CABIN HEATER SYSTEM...........................................................................................................................171
13.12 EXTREME CLIMATIC CONDITIONS...........................................................................................................173
14 FUEL SYSTEM................................................................................................................176
14.1 DESCRIPTION ............................................................................................................................................176
14.2 FUEL LINES ................................................................................................................................................180

Aircraft Service Manual
Jabiru Aircraft Pty Ltd
JTM001-1
J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants
REVISION
1
Dated: Nov 2011
Issued By: SW
Page: 5 of 233
14.3 FUEL TANKS...............................................................................................................................................182
14.4 FUEL VENTS...............................................................................................................................................184
14.5 FUEL SHUT-OFF VALVE............................................................................................................................185
14.6 FUEL GAUGES ...........................................................................................................................................186
14.7 FUEL FILTERS............................................................................................................................................189
14.8 FUEL PUMPS..............................................................................................................................................189
15 INSTRUMENTS & INSTRUMENT SYSTEMS..................................................................191
15.1 GENERAL....................................................................................................................................................191
15.2 INSTRUMENT PANEL.................................................................................................................................191
15.3 INSTRUMENT PANEL MOUNT...................................................................................................................193
15.4 INSTRUMENTS...........................................................................................................................................194
15.5 PITOT & STATIC SYSTEMS .......................................................................................................................195
15.6 ALTERNATE STATIC SOURCE..................................................................................................................202
15.7 ANALOGUE TACHOMETER.......................................................................................................................203
15.8 ANALOGUE ENGINE GAUGES..................................................................................................................205
15.9 DIGITAL DISPLAYS.....................................................................................................................................206
15.10 MAGNETIC COMPASS...............................................................................................................................207
15.11 GYRO INSTRUMENT PACKAGE (OPTION)...............................................................................................207
16 SECTION 14 –ELECTRICAL SYSTEMS........................................................................208
16.1 ELECTRICAL POWER SUPPLY SYSTEM..................................................................................................208
16.2 MINOR ELECTRICAL EQUIPMENT............................................................................................................211
16.3 BATTERY SYSTEM.....................................................................................................................................212
16.4 ELECTRICAL LOAD ANALYSIS (ELA)........................................................................................................213
16.5 RADIO INSTALLATION...............................................................................................................................213
16.6 TRANSPONDER..........................................................................................................................................215
18 PAINTING & FINISHING .................................................................................................216
18.1 EXTERIOR...................................................................................................................................................216
19 PLACARDS.....................................................................................................................218
19.1 MODEL-SPECIFIC DECALS .......................................................................................................................218
19.2 PLACARDS GENERAL................................................................................................................................220
20 FAIRINGS........................................................................................................................225
20.1 DESCRIPTION ............................................................................................................................................225
22 APPENDIX IV –PROPELLER SERVICE MANUAL........................................................226
22.1 CERTIFIED PROPELLER MODELS............................................................................................................226
22.2 APPROVED INSTALLATIONS ....................................................................................................................226
22.3 IDENTIFICATION STAMPINGS...................................................................................................................226
22.4 DESCRIPTION ............................................................................................................................................227
22.5 INSTALLATION ...........................................................................................................................................227
22.6 TO REMOVE EXISTING PROPELLER .......................................................................................................229
22.7 TO ASSEMBLE AND REPLACE PROPELLER ASSEMBLY.......................................................................229
22.8 SERVICING AND REPAIRS........................................................................................................................229
22.9 PROPELLER BALANCING PROCEDURE..................................................................................................230
23 APPENDIX –AIRWORTHINESS LIMITATIONS.............................................................231
23.1 GENERAL....................................................................................................................................................232
23.2 INTERIOR FLAME RETARDANT MAINTENANCE LIMITATIONS..............................................................232
23.3 COMPOSITE INSPECTION & MAINTENANCE ..........................................................................................232
23.4 CONTROL SURFACE BALANCING............................................................................................................233

Aircraft Service Manual
Jabiru Aircraft Pty Ltd
JTM001-1
J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants
REVISION
1
Dated: Nov 2011
Issued By: SW
Page: 6 of 233
1.1 TABLE OF FIGURES
Figure 1 –J120-C General Arrangement ...................................................................................................................20
Figure 2 –J160 General Arrangement.......................................................................................................................21
Figure 3 –J170-C & Variants General Arrangement..................................................................................................22
Figure 4 –J170-D General Arrangement ...................................................................................................................23
Figure 5 –J200 / J400 General Arrangement............................................................................................................24
Figure 6 –J230 / J430 General Arrangement............................................................................................................25
Figure 7 –J250 / J450 General Arrangement............................................................................................................26
Figure 8 –Undercarriage............................................................................................................................................31
Figure 9 –Weighing Diagram.....................................................................................................................................43
Figure 10 –Normal and Jammed Control Illustration.................................................................................................45
Figure 11 –Rudder Gap Cross Section .....................................................................................................................46
Figure 12 –Aileron Clearance....................................................................................................................................47
Figure 13 –Test Load Application..............................................................................................................................47
Figure 14 –Elevator Gap Cross Section....................................................................................................................47
Figure 15 –Scratches on Rudder...............................................................................................................................48
Figure 16 –Wheel Alignment Set Up .........................................................................................................................49
Figure 17 –Alignment Straight Edge In Position........................................................................................................49
Figure 18 –Alignment Measurements........................................................................................................................50
Figure 19 –Camber / Toe-In Adjustment...................................................................................................................51
Figure 20 Max Empty (Left) and Acceptable Empty (Right) Indications.....................................................................52
Figure 21 - Fuel Gauge Calibration Decal Parts.........................................................................................................53
Figure 22 –20L Indication on Sender & Decal to Match............................................................................................53
Figure 23 –EMS Fuel Calibration Screens ................................................................................................................54
Figure 24 –Fuel Line Clamps.....................................................................................................................................55
Figure 25 –EMS Calibration Screen #1.....................................................................................................................56
Figure 26 –EMS Calibration Screens #2 and #3 .......................................................................................................56
Figure 27 –J160-Type Door Hinge Assy ...................................................................................................................62
Figure 28 –J160-Type Door Assembly......................................................................................................................62
Figure 29 –J120-Type Door Assembly......................................................................................................................63
Figure 30 –J200-Type Door Assembly (J160-Type) .................................................................................................63
Figure 31 –J160-Type Rear Door Assy.....................................................................................................................64
Figure 32 –J160-Type Door Latch Mechanism Assembly.........................................................................................64
Figure 33 –Top Door Catch Assy ..............................................................................................................................65
Figure 34 –J200-Type Door Hinge Assy ...................................................................................................................66
Figure 35 –J200-Type Front Door Assembly.............................................................................................................67
Figure 36 –J200-Type Rear Door Assy.....................................................................................................................67
Figure 37 –J200-Type Door Latch Mechanism Assembly.........................................................................................68
Figure 38 –J160 Wing Assembly Sheet 1 (Ser X).....................................................................................................73
Figure 39 –J160 Wing Assembly Sheet 2 (Ser X).....................................................................................................73
Figure 40 –J160 Wing Assembly Sheet 1 (Ser XIV) .................................................................................................74
Figure 41 –J160 Wing Assembly Sheet 2 (Ser XIV) .................................................................................................74
Figure 42 –J160 Wing Assembly Sheet 3 (Ser XIV) .................................................................................................75
Figure 43 –J170 Friese Aileron Installation ...............................................................................................................76
Figure 44 –J170-UL Wing Assy Sheet 1 (Ser IX)......................................................................................................76
Figure 45 –J170-UL Wing Assy Sheet 2 (Ser IX)......................................................................................................77
Figure 46 –J230 Wing Assembly Sheet 1 (Ser 13) ...................................................................................................78

Aircraft Service Manual
Jabiru Aircraft Pty Ltd
JTM001-1
J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants
REVISION
1
Dated: Nov 2011
Issued By: SW
Page: 7 of 233
Figure 47 –J230 Wing Assembly Sheet 2 (Ser 13) ...................................................................................................79
Figure 48 –J230 Wing Assembly Sheet 3 (Ser 13) ...................................................................................................79
Figure 49 –J250 Family Wing Assy (SP-I Type)........................................................................................................80
Figure 50 –J250 Family Wing Assy (SP-III Type)......................................................................................................81
Figure 51 –Light Installed (Left) & Slotted Hole In Housing ......................................................................................82
Figure 52 –Night-VFR Lighting Aim Diagram ............................................................................................................83
Figure 53 –Night-VFR Landing / Taxi Light Assy ......................................................................................................83
Figure 54 –Day-VFR Light Assembly ........................................................................................................................84
Figure 55 –Dynon Pitot Installation............................................................................................................................85
Figure 56 –Wing Inspection Panel.............................................................................................................................86
Figure 57 –Wheel Spat Installation............................................................................................................................88
Figure 58 –Main Wheel to Leg Assy..........................................................................................................................91
Figure 59 –Main Wheel Assembly.............................................................................................................................91
Figure 60 –Directional Brake Disc Installation...........................................................................................................92
Figure 61 –Main Undercarriage (Type 1) ..................................................................................................................95
Figure 62 –Main Undercarriage Assembly (Type 2)..................................................................................................95
Figure 63 –Nose Wheel Hub Assembly.....................................................................................................................97
Figure 64 –Nose Leg Soft Link Assy (J160 Family) ..................................................................................................98
Figure 65 –Nose Leg Soft Link Assy (J200 Family) ..................................................................................................99
Figure 66 –Nose Leg Housing & Assembly.............................................................................................................101
Figure 67 –4” Wheel Nose Leg Assy.......................................................................................................................102
Figure 68 –Nose Leg Assy ......................................................................................................................................103
Figure 69 –Nose Leg Assy –Long Trail (J160 Family) ...........................................................................................103
Figure 70 –Fabricated Nose Wheel Yoke Assy.......................................................................................................104
Figure 71 –Machined Nose Leg Housing ................................................................................................................105
Figure 72 –Brake Master Cylinder & Lever Assy (Type 1)......................................................................................107
Figure 73 –Brake Master Cylinder & Lever Assy (Type 2)......................................................................................107
Figure 74 –Dual Calliper Brake Assy (Quick Change Pads)...................................................................................111
Figure 75 –Single Calliper Detail (Non Quick Change)...........................................................................................112
Figure 76 –Single Calliper (Legacy Brake System).................................................................................................112
Figure 77 –Aileron Controls –Type 1......................................................................................................................113
Figure 78 –Aileron System Schematic –Type 2. ....................................................................................................114
Figure 79 –Aileron System Schematic –Type 3. ....................................................................................................114
Figure 80 –Control Column Assy –Type 1..............................................................................................................115
Figure 81 –Control Column Assy –Type 2..............................................................................................................116
Figure 82 –Control Column Assy –Type 3..............................................................................................................116
Figure 83 –Clamp Comparison (Primary Cable Clamp Upper on Right Picture) ....................................................117
Figure 84 –Clamp Comparison & Installation (Rudder Cable) ................................................................................118
Figure 85 –Clamp Installations (Elevator & Aileron)................................................................................................118
Figure 86 –Trim Cable Clamp Installation ...............................................................................................................118
Figure 87 –Cable & Clamp Comparison..................................................................................................................119
Figure 88 –Correct and Incorrect Clamp Installation...............................................................................................119
Figure 89 –Aileron Stops –Type 1..........................................................................................................................121
Figure 90 –Aileron Stops –Type 2..........................................................................................................................122
Figure 91 –Aileron Stops –Type 3..........................................................................................................................122
Figure 92 –Manual Flap Control System.................................................................................................................123
Figure 93 –J200 Family Manual Flap System Sheet 1............................................................................................124
Figure 94 –J200 Family Manual Flap System Sheet 2............................................................................................124
Figure 95 –Linear Actuator Disassembled ..............................................................................................................126

Aircraft Service Manual
Jabiru Aircraft Pty Ltd
JTM001-1
J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants
REVISION
1
Dated: Nov 2011
Issued By: SW
Page: 8 of 233
Figure 96 –Commutator Ring Close-Up ..................................................................................................................127
Figure 97 –Flap Controls –Sheet 1 (Fibreglass Motor Mount) ...............................................................................128
Figure 98 –Flap Controls –Sheet 1 (Aluminium Motor Mount)...............................................................................128
Figure 99 –Flap Controls –Sheet 2.........................................................................................................................129
Figure 100 –Flap Controls –Sheet 3 (Fibreglass Motor Mount).............................................................................129
Figure 101 –Flap Controls –Sheet 3 (Aluminium Motor Mount).............................................................................130
Figure 102 –J200 Family Electric Flap System Sheet 1..........................................................................................130
Figure 103 –J200 Family Electric Flap System Sheet 2..........................................................................................131
Figure 104 –Flap Cross Tube Assy J160 Family.....................................................................................................132
Figure 105 –Flap Cross Tube Assy J200 Family, Electric.......................................................................................133
Figure 106 –Flap Position Indicator –Type 1..........................................................................................................134
Figure 107 –Flap Position Indicator –Type 2..........................................................................................................134
Figure 108 –Flap Position Indicator Drive Cable Assembly....................................................................................135
Figure 109 –Elevator Control System –Type 1, Sheet 1........................................................................................137
Figure 110 –Elevator Control System –Type 1, Sheet 2........................................................................................138
Figure 111 –Elevator Control Assy Type 2..............................................................................................................138
Figure 112 –J160 Models –Horizontal Tail & Elevator Assy ..................................................................................140
Figure 113 –Wide-Span Models –Horizontal Tail & Elevator Assy –Type 1.........................................................140
Figure 114 –Wide-Span Models –Horizontal Tail & Elevator Assy Type 2 ............................................................141
Figure 115 –Elevator Travel Limits..........................................................................................................................142
Figure 116 –Trim Lever Assy –Type 1 ...................................................................................................................144
Figure 117 –Trim Lever Assy –Type 2 ...................................................................................................................144
Figure 118 –Elevator Trim Handle Assy –Type 3...................................................................................................145
Figure 119 –Trim Controls –At Tail.........................................................................................................................146
Figure 120 –Typical Rudder System Schematic .....................................................................................................148
Figure 121 –Rudder Pedal - Non-Adjustable...........................................................................................................149
Figure 122 –Adjustable Rudder Pedal Assy –Type 1.............................................................................................150
Figure 123 –Adjustable Rudder Pedal Assy –Type 2.............................................................................................150
Figure 124 –Steering/Rudder Centring Assy –Type 1............................................................................................151
Figure 125 –Steering/Rudder Centring Assy –Type 2............................................................................................152
Figure 126 –Steering/Rudder Centring Assy –Type 3 (Sheet 1)............................................................................152
Figure 127 –Steering/Rudder Assy –Type 3 (Sheet 2) ..........................................................................................153
Figure 128 –Steering/Rudder Centring Assy –Type 3 (Includes Soft Link)............................................................153
Figure 129 –Typical Rudder Installation (Alloy Hinges) ..........................................................................................154
Figure 130 –Typical Rudder Installation (Steel Hinges)..........................................................................................155
Figure 131 –Typical Upper Cowl Assy ....................................................................................................................158
Figure 132 –Typical Lower Cowl Assy ....................................................................................................................158
Figure 133 –Fuel Hose Assy –Engine Bay.............................................................................................................160
Figure 134 –Air Duct Hard Point Reinforcement.....................................................................................................162
Figure 135 –Throttle Assy (Seat Mounted)..............................................................................................................164
Figure 136 –Throttle Assy (Panel Mounted)............................................................................................................165
Figure 137 –Throttle Assy (Large Panel Mount)......................................................................................................165
Figure 138 –Control Cable End Fitting Installation..................................................................................................166
Figure 139 –Carburettor Heat Box ..........................................................................................................................167
Figure 140 –Hot Air Duct Assy ................................................................................................................................168
Figure 141 –2200 Exhaust System .........................................................................................................................169
Figure 142 –3300 Exhaust System Type 1 .............................................................................................................170
Figure 143 –3300 Exhaust System Type 2 .............................................................................................................170
Figure 144 –Cabin Heat Mixer Assembly................................................................................................................172

Aircraft Service Manual
Jabiru Aircraft Pty Ltd
JTM001-1
J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants
REVISION
1
Dated: Nov 2011
Issued By: SW
Page: 9 of 233
Figure 145 –Cabin Heat Exchanger Assy ...............................................................................................................172
Figure 146 –2200 Engine Installation......................................................................................................................173
Figure 147 –2200 Engine Installation......................................................................................................................174
Figure 148 –2200 Engine Installation, Long Engine Mount.....................................................................................174
Figure 149 –J200 Family Engine Installation Type 1...............................................................................................175
Figure 150 –J200 Family Engine Installation Type 2...............................................................................................175
Figure 151 –In-Cabin Fuel System..........................................................................................................................177
Figure 152 –Fuel System Schematic –Type 1........................................................................................................177
Figure 153 –Fuel System Schematic –Type 2........................................................................................................178
Figure 154 –Fuel System Schematic –Type 3........................................................................................................178
Figure 155 –Fuel System Schematic –Type 4........................................................................................................179
Figure 156 –Schematic............................................................................................................................................180
Figure 157 –Sample Fuel Line Details ....................................................................................................................181
Figure 158 –Fuel Lines Showing Typical “U” Requiring Correction ........................................................................181
Figure 159 –Corrected Fuel Lines...........................................................................................................................181
Figure 160 –Header Tank Installation –Type 1 ......................................................................................................183
Figure 161 –Header Tank Installation –Type 2 (Sheet 1) ......................................................................................183
Figure 162 –Header Tank Installation –Type 2 (Sheet 2) ......................................................................................184
Figure 163 –Vented Fuel Cap Assy.........................................................................................................................185
Figure 164 –Single Line Fuel Tap ...........................................................................................................................186
Figure 165 –Fuel Gauge –Electric Sender Installation...........................................................................................188
Figure 166 –Fuel Gauge –Electric Sender Assembly.............................................................................................188
Figure 167 –Fuel Gauge –Sight Glass ...................................................................................................................188
Figure 168 –Instrument Panel Layout Type 1 .........................................................................................................192
Figure 169 –Instrument Panel Layout Type 2 .........................................................................................................192
Figure 170 –Instrument Panel Layout Type 3 .........................................................................................................192
Figure 171 –Instrument Panel Layout Type 4 .........................................................................................................193
Figure 172 –Instrument Panel Mount Installation....................................................................................................194
Figure 173 –Pitot Assembly.....................................................................................................................................195
Figure 174 –Static Probe System Assembly...........................................................................................................196
Figure 175 –Pitot / Static Water Trap ......................................................................................................................197
Figure 176 –Pitot-Static System –Water Trap Locations .......................................................................................197
Figure 177 –Static System Test...............................................................................................................................202
Figure 178 –Alternate Static Source Assy...............................................................................................................203
Figure 179 –Hall Effect Sensor Wiring (For Tach with Jabiru Logo on Face).........................................................204
Figure 180 –Hall Effect Sensor Inst. (For Tach with Jabiru Logo on Face) ............................................................205
Figure 181 –Wiring Diagram Sheet 1. .....................................................................................................................209
Figure 182 –Wiring Diagram Sheet 2. .....................................................................................................................210
Figure 183 –Night-VFR Lighting Sheet 1.................................................................................................................210
Figure 184 –Night-VFR Lighting Sheet 2.................................................................................................................211
Figure 185 –VHF Antenna Installation.....................................................................................................................213
Figure 186 –Second VHF Antenna Installation (J120 / J160 Families)...................................................................214
Figure 187 –Second VHF Antenna Installation (J230 Families)..............................................................................214
Figure 188 –Transponder Antenna Installation .......................................................................................................215
Figure 189 –Propeller Installation............................................................................................................................228

Aircraft Service Manual
Jabiru Aircraft Pty Ltd
JTM001-1
J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants
REVISION
1
Dated: Nov 2011
Issued By: SW
Page: 10 of 233
1.2 LIST OF TABLES
Table 1 –Recommended Bolt Torque Values............................................................................................................17
Table 2 –J120-C Specifications.................................................................................................................................20
Table 3 –J160 Specifications.....................................................................................................................................21
Table 4 –J170 Specifications.....................................................................................................................................22
Table 5 –J200/J400 Specifications............................................................................................................................24
Table 6 –J230/J430 Specifications............................................................................................................................25
Table 7 –J250/J450 Specifications............................................................................................................................26
Table 8 –Inspection Chart..........................................................................................................................................32
Table 9 –Control Free Play Limits .............................................................................................................................44
Table 10 –Trouble Shooting –Main Undercarriage...................................................................................................94
Table 11 –Trouble shooting –Nose Leg. ................................................................................................................101
Table 12 –Trouble Shooting –Brakes.....................................................................................................................111
Table 13 –Trouble Shooting –Fuel System............................................................................................................179
Table 14 –Trouble Shooting –Fuel Gauge .............................................................................................................187
Table 15 –Trouble Shooting –Pitot-Static System..................................................................................................199
Table 16 –Trouble Shooting –Airspeed Indicator...................................................................................................200
Table 17 –Trouble Shooting –Altimeter..................................................................................................................200
Table 18 –Trouble Shooting –Vertical Speed Indicator..........................................................................................201
Table 19 –Trouble Shooting –Tachometer.............................................................................................................203
Table 20 –Trouble Shooting –Engine Gauges .......................................................................................................205
Table 21 –Trouble Shooting –Digital Instruments Gauges.....................................................................................206
Table 22 –Model-Specific Decals............................................................................................................................218
Table 23 –General Decals.......................................................................................................................................220
Table 24 –Approved Propeller Installations.............................................................................................................226
Table 25 –Control Surface Balancing Limits ...........................................................................................................233
Table 26 –Mandatory Inspection Times ..................................................................................................................233
Table 27 –Mandatory Replacement Times..............................................................................................................233