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