Jabiru J230-C User manual

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Aircraft Service Manual
Service Schedule
Inspection Schedule
Engine Instruction & Maintenance Manual
Propeller Instruction Manual
Airworthiness Limitations
- Mandatory Replacement Times
- Structural Inspection Intervals
- Structural Inspection Procedures

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Aircraft Service Manual Jabiru J230-C
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FOREWORD
This manual contains JABIRU recommended procedures and instructions for ground
handling, servicing and maintaining the following Jabiru aircraft models:
J230-C - LSA, Factory-Built, Jabiru 3300 powered 2 Seat
J230-C - LSA, Kit-Built, Jabiru 3300 powered 2 Seat
The J230-C is an LSA acceptable aircraft. In Australia the J230-C may be registered by
CASA with a “VH” prefix as a Light Sport Aircraft (LSA) or by Recreational Aviation
Australia (RAAus) with a “24” prefix. In both categories, the J230-C has a 600kg MTOW.
There are two divisions within the LSA category – LSA Special and LSA Experimental.
Special LSAs’ are (generally) those which have been built by the factory, then maintained
in accordance with the manufacturer’s requirements (any modifications must also be
approved by the factory). Experimental LSAs’ are those built from kits or those aircraft
which have a modification which is not approved by the factory or were not
maintained to the manufacturer’s requirements. As Experimental LSAs cannot be
used for hire-and-reward operations, it is very important that owners maintain their aircraft
in an appropriate manner for their operational requirements.
It is the owner’s responsibility to become fully aware of the particular maintenance
requirements and limitations applicable to the appropriate registration. The details given
above are intended to give owners a broad appreciation of the rules for LSA – further
details can be gained by contacting CASA, the RAA or Jabiru Aircraft.
The information in this manual is based upon data available at the time of publication, and
is supplemented and kept current by Service Bulletins & Service Letters published by
JABIRU AIRCRAFT Pty Ltd. These are distributed directly to owners of J230-C aircraft in
addition to being posted on the JABIRU website. New owners of pre-owned aircraft should
ensure that the transfer of their aircraft has been advised to JABIRU AIRCRAFT Pty Ltd or
your local dealer of distributor. Existing owners should ensure that their postal address
remains current.
In addition to the information in this Service Manual, publications will periodically be
available from JABIRU which describe disassembly, overhaul and parts breakdown of
some of the various vendor equipment items. A listing of the available publications is
issued from time to time in service letters. Service Letters are also posted on the JABIRU
web site and provided to JABIRU dealers.
IMPORTANT
All maintenance should be undertaken with careful regard for the procedures
outlined in this manual. A detailed record of maintenance undertaken should be
recorded in the Aircraft Log Books.
For both kit built and factory built aircraft owners remain able to conduct maintenance on
aircraft for which they are the registered owner. If the aircraft is being used for training,

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etc, maintenance is required to be done by approved persons (L2 or LAME depending on
the registration).
In the interests of product development, we encourage owners to make suggestions
related to design improvements. However, the final decision on their adoption or otherwise
rests with JABIRU AIRCRAFT Pty Ltd.

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1Table of Contents
1TABLE OF CONTENTS ......................................................................................................................................... 4
1.1 TABLE OF FIGURES...............................................................................................................................11
1.2 LIST OF TABLES....................................................................................................................................12
2SECTION 2 – SERVICE MANUAL..................................................................................................................... 13
2.1 LIST OF EFFECTIVE PAGES ............................................................................................................13
2.2 GENERAL DESCRIPTION.................................................................................................................14
2.3 OWNER MAINTENANCE ..................................................................................................................14
2.3.1 J230-C.........................................................................................................................................14
2.4 AIRCRAFT SPECIFICATIONS ..........................................................................................................14
2.5 CENTRE OF GRAVITY LIMITATIONS...............................................................................................14
2.6 TORQUE VALUES .............................................................................................................................15
2.7 AIRCRAFT SPECIFICATIONS ...................................................................................................................15
2.8 RECOMMENDED TORQUE VALUES (IN FIBREGLASS)......................................................................17
2.9 AIRCRAFT STRUCTURE..........................................................................................................................17
3SECTION 3 - GROUND HANDLING, SERVICING, LUBRICATION & INSPECTION ............................. 18
3.1 GROUND HANDLING........................................................................................................................18
3.1.1 Towing.........................................................................................................................................18
3.1.2 Jacking ........................................................................................................................................18
3.1.3 Hoisting .......................................................................................................................................19
3.1.4 Levelling ......................................................................................................................................20
3.1.5 Parking ........................................................................................................................................20
3.1.6 Tie Down .....................................................................................................................................20
3.1.7 Flyable Storage ...........................................................................................................................20
3.1.8 Returning Aircraft to Service .......................................................................................................21
3.1.9 Temporary or Indefinite Storage .................................................................................................21
3.1.10 Inspection During Storage...........................................................................................................22
3.1.11 Returning Aircraft to Service .......................................................................................................22
3.2 WEIGHING.........................................................................................................................................23
3.2.1 Scale locations ............................................................................................................................23
3.2.2 Procedure....................................................................................................................................23
3.3 SERVICING........................................................................................................................................24
3.3.1 Engine Servicing Schedule .........................................................................................................24
3.3.2 other Servicing ............................................................................................................................25
3.3.3 Fuel .............................................................................................................................................25
3.3.4 Fuel Drain....................................................................................................................................25
3.3.5 Carburettor Air Filter....................................................................................................................25
3.3.6 Battery.........................................................................................................................................25
3.3.7 Tyres ...........................................................................................................................................25
3.3.8 Hydraulic Brakes.........................................................................................................................25
3.4 CLEANING .........................................................................................................................................26
3.4.1 Windshield and Windows............................................................................................................26
3.4.2 Interior Surfaces..........................................................................................................................26
3.4.3 Exterior Surfaces.........................................................................................................................26
3.4.4 Aluminium Surfaces ....................................................................................................................27
3.4.5 Engine and Engine Compartment ...............................................................................................27
3.4.6 Propeller......................................................................................................................................27
3.4.7 Wheels ........................................................................................................................................27
3.5 LUBRICATION ...................................................................................................................................27
3.5.1 Wheel Bearing – Mains and Nose...............................................................................................27
3.6 INSPECTION .....................................................................................................................................28
3.6.1 Inspection Intervals .....................................................................................................................28
3.6.2 Inspection Charts ........................................................................................................................28
3.6.3 INSPECTION GUIDELINES .......................................................................................................28

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3.7 MAJOR INSPECTION /REPLACEMENT ...................................................................................................32
3.7.1 MANDATORY INSPECTION ......................................................................................................32
3.7.2 INSPECTION CHART.................................................................................................................33
4SECTION 4 - FUSELAGE..................................................................................................................................... 37
4.1 FUSELAGE ........................................................................................................................................37
4.2 WINDSHIELD AND WINDOWS.........................................................................................................37
4.2.1 Description ..................................................................................................................................37
4.2.2 Cleaning ......................................................................................................................................37
4.2.3 Waxing ........................................................................................................................................37
4.2.4 Repairs........................................................................................................................................37
4.2.5 Scratches ....................................................................................................................................37
4.2.6 Cracks .........................................................................................................................................38
4.2.7 Removal ......................................................................................................................................38
4.2.8 Installation ...................................................................................................................................38
4.3 CABIN DOORS ..................................................................................................................................38
4.3.1 Removal and Installation.............................................................................................................38
4.3.2 Adjustment ..................................................................................................................................41
4.3.3 Door Seals ..................................................................................................................................41
4.3.4 Locks...........................................................................................................................................43
4.4 SEATS................................................................................................................................................43
4.4.1 Repair..........................................................................................................................................43
4.5 UPHOLSTERY ...................................................................................................................................43
4.5.1 UPHOLSTERY CLEANING – FLAME RETARDANT .................................................................43
4.6 SOUNDPROOFING .................................................................................................................................43
4.7 SAFETY PROVISIONS ......................................................................................................................43
4.7.1 Seatbelts .....................................................................................................................................43
5SECTION 5 – WINGS AND EMPENNAGE ....................................................................................................... 44
5.1 WINGS.................................................................................................................................................44
5.1.1 Removal ......................................................................................................................................44
5.1.2 Repair..........................................................................................................................................45
5.1.3 Installation ...................................................................................................................................45
5.2 WING STRUTS ..................................................................................................................................49
5.2.1 Removal and Installation.............................................................................................................49
5.2.2 REPAIR.......................................................................................................................................49
5.3 PITOT PROBE ...................................................................................................................................49
5.3.1 Description ..................................................................................................................................49
5.3.2 PITOT Removal & Installation.....................................................................................................49
5.4 LANDING LIGHT (OPTION)...............................................................................................................50
5.4.1 Description ..................................................................................................................................50
5.4.2 LANDING LIGHT Removal & Installation....................................................................................50
5.5 FIN......................................................................................................................................................51
5.5.1 Removal, Installation, Inspection and Repair..............................................................................51
5.6 HORIZONTAL STABILISER ..............................................................................................................51
5.6.1 Removal and Installation.............................................................................................................51
6SECTION 6 – LANDING GEAR AND BRAKES ............................................................................................... 52
6.1 LANDING GEAR ................................................................................................................................52
6.2 TROUBLE SHOOTING –MAIN UNDERCARRIAGE................................................................................52
6.3 MAIN GEAR .......................................................................................................................................52
6.3.1 Removal ......................................................................................................................................53
6.3.2 Installation ...................................................................................................................................53
6.3.3 Inspection and Repair .................................................................................................................53
6.3.4 Main Wheel Fairing Removal and Installation.............................................................................54
6.3.5 Main Gear Top Fairing Removal and Installation........................................................................54
6.4 MAIN WHEEL.....................................................................................................................................56
6.4.1 Main Wheel Removal ..................................................................................................................56
6.4.2 Main Wheel Disassembly............................................................................................................56

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6.4.3 Main Wheel Inspection, Assembly and Repair............................................................................56
6.4.4 Main Wheel Installation ...............................................................................................................57
6.4.5 Main Wheel Stub Axle Removal..................................................................................................57
6.4.6 Main Wheel Stub Axle Installation...............................................................................................58
6.4.7 Main Wheel Alignment ................................................................................................................58
6.4.8 Wheel Balancing .........................................................................................................................58
6.5 NOSE GEAR ......................................................................................................................................63
6.5.1 Trouble Shooting – Nose Leg .....................................................................................................63
6.5.2 Nose Gear Removal and Installation ..........................................................................................63
6.5.3 Nose Gear Inspection and Repair...............................................................................................64
6.5.4 Nose Wheel Speed Fairing Removal and Installation.................................................................64
6.6 NOSE WHEEL ...................................................................................................................................64
6.6.1 Nose Wheel Removal and Installation ........................................................................................64
6.6.2 Nose Wheel Disassembly ...........................................................................................................64
6.6.3 Nose Wheel Inspection and Repair ............................................................................................65
6.6.4 Nose Wheel Reassembly............................................................................................................65
6.6.5 Wheel Balancing .........................................................................................................................65
6.7 NOSE WHEEL STEERING SYSTEM.................................................................................................68
6.7.1 5.7.1 Steering Centring Assembly...............................................................................................68
6.7.2 Nose Wheel Steering Assembly .................................................................................................68
6.8 BRAKE SYSTEM................................................................................................................................68
6.8.1 Trouble Shooting - Brakes ..........................................................................................................68
6.8.2 Brake Master Cylinder.................................................................................................................69
6.8.3 Hydraulic Brake Lines .................................................................................................................69
6.8.4 Wheel Brake Assemblies ............................................................................................................69
6.8.5 Brake System Bleeding...............................................................................................................71
6.8.6 Brake Pad Adjustment ................................................................................................................71
6.8.7 Parking Brake..............................................................................................................................72
7SECTION 7 - AILERON CONTROL SYSTEM ................................................................................................. 75
7.1 AILERON CONTROL SYSTEM .........................................................................................................75
7.2 CONTROL COLUMN .........................................................................................................................77
7.2.1 Control Column Removal ............................................................................................................77
7.2.2 Control column inspection & repair .............................................................................................77
7.2.3 Control Column Installation .........................................................................................................77
7.3 CONTROL CABLES...........................................................................................................................79
7.3.1 Control Cable Removal ...............................................................................................................79
7.3.2 Control Cable Inspection & Repair..............................................................................................79
7.3.3 Control Cable Installation ............................................................................................................79
7.4 AILERONS .........................................................................................................................................79
7.4.1 Aileron Removal & Installation ....................................................................................................79
7.4.2 Aileron Inspection & Repair.........................................................................................................79
7.4.3 AILERON BALANCING...............................................................................................................80
7.5 CONTROL RIGGING ............................................................................................................................80
8SECTION 8 - WING FLAP CONTROL SYSTEM ............................................................................................. 82
8.1 WING FLAP CONTROL SYSTEM .....................................................................................................82
8.1.1 OPERATIONAL CHECK.............................................................................................................82
8.1.2 FLAP Switch ASSEMBLY ...........................................................................................................82
8.1.3 FLAP cross SHAFT ASSEMBLY ................................................................................................82
8.1.4 Flap Cross Shaft Removal ..........................................................................................................82
8.1.5 Flap cross shaft inspection & repair............................................................................................82
8.1.6 flap cross shaft Installation..........................................................................................................82
8.1.7 Flap Position Indicator Removal .................................................................................................83
8.1.8 flap position indicator inspection & repair....................................................................................83
8.1.9 Flap Position indicator installation...............................................................................................83
8.1.10 Flap Control Rod .........................................................................................................................83
8.2 FLAP ..................................................................................................................................................83
8.2.1 Removal and Installation.............................................................................................................83

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8.2.2 Inspection and Repair .................................................................................................................83
8.2.3 flap balancing ..............................................................................................................................83
8.2.4 flap RIGGING (as per template) .................................................................................................83
9SECTION 9 – ELEVATOR CONTROL SYSTEM............................................................................................. 90
9.1 ELEVATOR CONTROL SYSTEM ......................................................................................................90
9.2 CONTROL COLUMN DESCRIPTION................................................................................................90
9.2.1 Removal and Installation.............................................................................................................90
9.3 ELEVATOR ........................................................................................................................................90
9.3.1 Removal and Installation.............................................................................................................90
9.3.2 ELEVATOR BALANCING ...........................................................................................................90
9.3.3 Inspection and Repair .................................................................................................................91
9.4 CONTROL CABLE AND ATTACHMENTS.........................................................................................91
9.4.1 Removal and Installation.............................................................................................................91
9.5 RIGGING............................................................................................................................................91
9.6 ELEVATOR TRIM CONTROL SYSTEM ............................................................................................97
9.6.1 Operational Check ......................................................................................................................97
9.6.2 Trim Handle Assembly ................................................................................................................97
9.6.3 Control Cable and Attachments ..................................................................................................97
9.6.4 Removal and Installation.............................................................................................................97
9.6.5 Inspection and Repair .................................................................................................................97
10 SECTION 10 – RUDDER CONTROL SYSTEM .......................................................................................... 100
10.1 RUDDER PEDAL SYSTEM ............................................................................................................100
10.1.1 Removal and Installation...........................................................................................................100
10.1.2 Inspection and Repair ...............................................................................................................100
10.2 RUDDER ......................................................................................................................................102
10.2.1 Removal & Installation ..............................................................................................................102
10.2.2 Inspection & Repair...................................................................................................................102
10.3 CONTROL CABLE &ATTACHMENTS ........................................................................................102
10.3.1 Removal & Installation ..............................................................................................................102
10.4 RUDDER BALANCE.....................................................................................................................102
10.5 RIGGING ......................................................................................................................................103
11 SECTION 11 – ENGINE & ENGINE INSTALLATION.............................................................................. 106
11.1 ENGINE COWLS ..............................................................................................................................106
11.1.1 Engine Cowls – Removal & Installation ....................................................................................106
11.1.2 Cleaning and Inspection............................................................................................................109
11.1.3 Repair........................................................................................................................................109
11.2 ENGINE ........................................................................................................................................109
11.2.1 Engine Data ..............................................................................................................................109
11.2.2 Engine Trouble Shooting...........................................................................................................109
11.2.3 Engine Cleaning........................................................................................................................109
11.2.4 Engine Accessories Removal ...................................................................................................109
11.2.5 Inspection..................................................................................................................................110
11.3 COOLING AIR BAFFLES.................................................................................................................111
11.3.1 Cleaning and Inspection............................................................................................................111
11.3.2 Cooling Air Baffle Removal & Installation..................................................................................111
11.3.3 Repair........................................................................................................................................111
11.4 ENGINE MOUNT..........................................................................................................................111
11.5 ENGINE FUEL SYSTEM ..............................................................................................................111
11.5.1 Fuel System General ................................................................................................................111
11.5.2 LSA Aircraft Fuel System..........................................................................................................112
11.6 SPARK PLUGS.............................................................................................................................112
11.7 ENGINE CONTROLS ...................................................................................................................112
11.7.1 Rigging ......................................................................................................................................112
11.7.2 Throttle System.........................................................................................................................112
11.7.3 Choke........................................................................................................................................114
11.7.4 Air Intake System & Carburetor Heat........................................................................................114

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11.8 EXHAUST SYSTEM .....................................................................................................................116
11.8.1 Exhaust System Removal and Installation................................................................................116
11.8.2 Exhaust Inspection....................................................................................................................116
11.9 EXTREME CLIMATIC CONDITIONS ...........................................................................................118
11.9.1 Dust...........................................................................................................................................118
11.9.2 Seacoast and Humid Area ........................................................................................................118
12 SECTION 12 – FUEL SYSTEM...................................................................................................................... 120
12.1 DESCRIPTION .............................................................................................................................120
12.1.1 LSA Aircraft Fuel System..........................................................................................................120
12.1.2 Precautions ...............................................................................................................................120
12.1.3 Fuel System Trouble Shooting..................................................................................................122
12.2 FUEL TANK ..................................................................................................................................122
12.2.1 Description ................................................................................................................................122
12.2.2 Fuel Tank Removal & Installation .............................................................................................122
12.3 FUEL VENTS................................................................................................................................123
12.3.1 Description ................................................................................................................................123
12.3.2 Checking ...................................................................................................................................123
12.4 FUEL SHUT-OFF VALVE .............................................................................................................126
12.4.1 Description ................................................................................................................................126
12.4.2 Fuel Valve Removal & Installation ............................................................................................126
12.5 FUEL GAUGES ............................................................................................................................127
12.5.1 Description – SIGHT GLASSES ...............................................................................................127
12.5.2 Fuel SIGHT GAUGE Removal & Installation ............................................................................127
12.5.3 ELECTRIC FUEL GAUGE TROUBLESHOOTING...................................................................128
12.5.4 ELECTRIC Fuel GAUGE SENDER Removal & Installation......................................................128
12.6 HEADER TANK LOW LEVEL WARNING (OPTION) ...................................................................130
12.6.1 Description ................................................................................................................................130
12.6.2 Fuel Valve Removal & Installation ............................................................................................130
12.7 FUEL FILTERS.............................................................................................................................130
12.7.1 Fuel filter ...................................................................................................................................130
12.7.2 Fuel Filter Removal & Installation .............................................................................................131
12.8 FUEL PUMPS ...............................................................................................................................131
12.8.1 Primary Pump ...........................................................................................................................131
12.8.2 Secondary Pump.......................................................................................................................131
13 SECTION 13 – INSTRUMENTS & INSTRUMENT SYSTEMS................................................................. 132
13.1 GENERAL.....................................................................................................................................132
13.2 INSTRUMENT PANEL .................................................................................................................132
13.2.1 Instrument Panel Removal & Installation ..................................................................................132
13.2.2 INSTRUMENTS ........................................................................................................................133
13.2.3 Instrument Removal..................................................................................................................134
13.2.4 Installation .................................................................................................................................134
13.3 PITOT &STATIC SYSTEMS ........................................................................................................134
13.3.1 Pitot – Static System Maintenance ...........................................................................................135
13.3.2 Static Pressure System Inspection & Leakage Test .................................................................135
13.3.3 Pitot System Inspection & Leakage Test ..................................................................................136
13.3.4 Blowing Out Lines .....................................................................................................................136
13.3.5 Removal & Installation of Components .....................................................................................137
13.3.6 Trouble Shooting – Pitot Static System.....................................................................................137
13.3.7 Trouble Shooting – Airspeed Indicator......................................................................................138
13.3.8 Trouble Shooting – Altimeter.....................................................................................................138
13.3.9 Trouble Shooting – Vertical Speed Indicator (Option)...............................................................139
13.3.10 Pitot Tube Alignment .............................................................................................................139
13.4 TACHOMETER ............................................................................................................................143
13.5 OIL PRESSURE GAUGE..............................................................................................................144
13.6 OIL TEMPERATURE GAUGE ......................................................................................................144
13.7 CYLINDER HEAD TEMPERATURE GAUGE...............................................................................145
13.8 EXHAUST GAS TEMPERATURE GAUGE (OPTION) .................................................................145

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13.9 HOURMETER...............................................................................................................................145
13.10 MAGNETIC COMPASS................................................................................................................145
13.11 EFIS (WHERE EQUIPPED)..........................................................................................................146
13.12 EMS (WHERE EQUIPPED)..........................................................................................................146
14 SECTION 14 – ELECTRICAL SYSTEMS.................................................................................................... 147
14.1 ELECTRICAL POWER SUPPLY SYSTEM ..................................................................................147
14.2 WIRING DIAGRAM.......................................................................................................................147
14.3 BUS BARS ......................................................................................................................................150
14.3.1 Master Switch............................................................................................................................150
14.4 BATTERY POWER SYSTEM.......................................................................................................150
14.4.1 Battery.......................................................................................................................................150
14.4.2 Battery Trouble Shooting ..........................................................................................................150
14.4.3 Removal and Installation...........................................................................................................150
14.4.4 Cleaning the Battery..................................................................................................................150
14.4.5 BATTERY BOX .........................................................................................................................151
14.5 STARTER SOLENOID .................................................................................................................151
14.6 VOLTAGE REGULATOR .............................................................................................................151
14.7 STROBE SYSTEM (OPTION) ......................................................................................................151
14.8 AUXILIARY POWER SOCKET ..........................................................................................................151
14.9 ELECTRICAL LOAD ANALYSIS (ELA)..........................................................................................151
14.10 RADIO WIRING DIAGRAM (OPTION) .........................................................................................151
14.10.1 VHF ANTENNA INSTALLATION...........................................................................................151
15 SECTION 15 – PAINTING & FINISHING ................................................................................................... 153
15.1 EXTERIOR.......................................................................................................................................153
15.1.1 Painting .....................................................................................................................................153
15.1.2 Materials Recommended ..........................................................................................................153
15.1.3 Painting Equipment Required ..................................................................................................153
15.1.4 Painting Procedure:...................................................................................................................153
16 SECTION 16 - PLACARDS ........................................................................................................................... 156
16.1 J230-C DECALS...........................................................................................................................156
16.2 COCKPIT PLACARDS GENERAL ........................................................................................................158
16.3 COCKPIT CONTROL DECALS............................................................................................................158
16.4 EXTERNAL FUSELAGE .....................................................................................................................159
17 SECTION 17 - FAIRINGS............................................................................................................................... 160
17.1 WHEEL SPATS ................................................................................................................................160
17.2 WING FAIRINGS ..............................................................................................................................160
17.2.1 Removal and Installation...........................................................................................................160
17.3 REPAIR. .........................................................................................................................................160
18 APPENDIX I - JABIRU 3300 ENGINE.......................................................................................................... 161
19 APPENDIX II - JABIRU ENGINE PARTS BOOK ...................................................................................... 162
20 APPENDIX III – ENGINE INSTALLATION MANUAL ............................................................................ 163
21 APPENDIX IV – PROPELLER SERVICE MANUAL................................................................................. 164
21.1 APPROVED INSTALLATIONS .............................................................................................................164
21.2 IDENTIFICATION STAMPINGS ............................................................................................................164
21.3 DESCRIPTION .................................................................................................................................164
21.4 INSTALLATION .................................................................................................................................165
21.5 TO REMOVE EXISTING PROPELLER..................................................................................................167
21.6 TO ASSEMBLE AND REPLACE PROPELLER ASSEMBLY.......................................................................167
21.7 SERVICING AND REPAIRS ................................................................................................................168
21.8 PROPELLER BALANCING PROCEDURE ..............................................................................................169
22 APPENDIX V – AIRWORTHINESS LIMITATIONS ................................................................................. 170

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22.1 GENERAL.....................................................................................................................................170
22.2 INTERIOR FLAME RETARDANT MAINTENANCE LIMITATIONS................................................................170
22.3 COMPOSITE INSPECTION &MAINTENANCE .......................................................................................170
22.3.1 External Paint / Finishing Limitations ........................................................................................170
22.4 CONTROL SURFACE BALANCING ............................................................................................170
22.4.2 mandatory Replacement...........................................................................................................171