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

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1.1 TABLE OF FIGURES
Figure 1. J230-C General Arrangement ...........................................................................................................16
Figure 2: Weighing Diagram.............................................................................................................................24
Figure 3. Fuel Line Routing..............................................................................................................................30
Figure 3. Undercarriage....................................................................................................................................32
Figure 4. Front Door Assembly.........................................................................................................................39
Figure 5: Rear Door Assembly .........................................................................................................................40
Figure 6. Door Latch Mechanism Assembly.....................................................................................................42
Figure 7. J230 Wing Assembly Sheet 1............................................................................................................47
Figure 8. J230 Wing Assembly Sheet 2............................................................................................................48
Figure 9 – Dynon Pitot Probe Installation .........................................................................................................50
Figure 10 – Landing Light Assembly.................................................................................................................51
Figure 11. Main Undercarriage Assembly ........................................................................................................55
Figure 12. Main Wheel Alignment.....................................................................................................................59
Figure 13. Main Wheel to Leg Assy..................................................................................................................60
Figure 14. Main Wheel Assembly.....................................................................................................................61
Figure 15. Directional Brake Disc Installation ...................................................................................................62
Figure 16. Nose Leg Assy.................................................................................................................................66
Figure 17. Nose Wheel Hub Assembly.............................................................................................................67
Figure 18. Brake Calliper Assy .........................................................................................................................73
Figure 19. Brake Master Cylinder Assy ............................................................................................................74
Figure 20. Aileron System Schematic...............................................................................................................76
Figure 21. Control Column Assy.......................................................................................................................78
Figure 22. Aileron Stops ...................................................................................................................................81
Figure 23. Flap Controls – Sheet 1...................................................................................................................85
Figure 24. Flap Controls – Sheet 2...................................................................................................................86
Figure 25. Flap Cross Tube Assy .....................................................................................................................87
Figure 26. Flap Position Indicator .....................................................................................................................88
Figure 27. Flap Position Indicator Drive Cable Assembly.................................................................................89
Figure 28. Elevator Control Assy ......................................................................................................................92
Figure 29: Elevator Control Assy Rear. ............................................................................................................93
Figure 30. J230 Models - Horizontal Tail & Elevator Assy................................................................................94
Figure 31. J170 Models - Horizontal Tail & Elevator Assy................................................................................95
Figure 32. Elevator Travel Limits ......................................................................................................................96
Figure 33. Elevator Trim Handle Assy ..............................................................................................................98
Figure 34. Trim Controls – At Tail.....................................................................................................................99
Figure 35. Rudder Pedal Assy........................................................................................................................101
Figure 36. Rudder System Schematic ............................................................................................................104
Figure 37. Rudder Installation.........................................................................................................................105
Figure 38. Upper Cowl Assy ...........................................................................................................................107
Figure 39. Lower Cowl Assy ...........................................................................................................................108
Figure 40. LSA Variant Throttle (Panel Mounted)...........................................................................................113
Figure 41 – Instrument Panel & Throttle Assembly ........................................................................................114
Figure 42. Carburetor Heat Box......................................................................................................................115
Figure 43. Exhaust System.............................................................................................................................117
Figure 44. Engine Installation .........................................................................................................................119
Figure 45. Fuel System Schematic – LSA Variants........................................................................................121
Figure 46. Vented Fuel Cap Assy...................................................................................................................125
Figure 47. Single Line Fuel Tap......................................................................................................................127
Figure 48. Fuel Gauge – Electric Sender Installation .....................................................................................128
Figure 49. Fuel Gauge – Electric Sender Assembly.......................................................................................129
Figure 50. Fuel Gauge – Sight Glass .............................................................................................................129
Figure 51. Header Tank Low Level Sensor Installation ..................................................................................130
Figure 52. Instrument Panel Layout (Std Panel).............................................................................................133
Figure 53. Instrument Panel Layout – “Glass” Instrument Panel....................................................................134
Figure 54. Pitot-Statice System – Water Trap Locations................................................................................140
Figure 55. Pitot Assembly – Std Pitot .............................................................................................................141
Figure 56. Static Probe System Assembly......................................................................................................142
Figure 57. Static System Test.........................................................................................................................143

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Figure 58. Wiring Diagram Sheet 1. ...............................................................................................................148
Figure 59. Wiring Diagram Sheet 2. ...............................................................................................................149
Figure 60. VHF Antenna Installation ...............................................................................................................152
Figure 61. Propeller Installation ......................................................................................................................166
1.2 LIST OF TABLES
Table 1. J230 Specifications.............................................................................................................................15
Table 2. Recommended Bolt Torque Values....................................................................................................17
Table 3. Control Free Play Limits......................................................................................................................29
Table 4. Inspection Chart..................................................................................................................................33
Table 5. Trouble Shooting – Main Undercarriage.............................................................................................52
Table 6. Trouble Shooting – Nose Leg. ............................................................................................................63
Table 7. Trouble Shooting – Brakes .................................................................................................................68
Table 8. Trouble Shooting – Fuel System ......................................................................................................122
Table 9. Trouble Shooting – Fuel Gauge........................................................................................................128
Table 10. Trouble Shooting – Pitot-Static System ..........................................................................................137
Table 11. Trouble Shooting – Airspeed Indicator ...........................................................................................138
Table 12. Trouble Shooting – Altimeter ..........................................................................................................138
Table 13. Trouble Shooting – Vertical Speed Indicator (Option) ....................................................................139
Table 14. J230-C Decals ................................................................................................................................156
Table 15. General Cockpit Decals ..................................................................................................................158
Table 16. Cockpit Control Decals ...................................................................................................................158
Table 17. External Fuselage Decals...............................................................................................................159
Table 18. Approved Propeller Installations .....................................................................................................164
Table 19. Control Surface Balancing Limits....................................................................................................171
Table 20. Mandatory Inspection Times...........................................................................................................171
Table 21. Mandatory Replacement Times......................................................................................................171

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2Section 2 – Service Manual
2.1 LIST OF EFFECTIVE PAGES
Page Revision Date Page Revision Date Page Revision Date
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59 1 16/5/06 119 1 16/5/06 179 1 16/5/06
60 1 16/5/06 120 1 16/5/06
Revision Notes

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2.2 GENERAL DESCRIPTION
The JABIRU J230-C is a 2 seat, high-wing monoplane composite aircraft of monocoque
construction. It is equipped with fixed tricycle landing gear of composite construction. The
steerable nose gear is a welded metal, trailing link assembly with rubber springs.
The aircraft is equipped with JABIRU, 6 cylinder, 4 stroke engines driving a wooden fixed
pitch propeller.
2.3 OWNER MAINTENANCE
2.3.1 J230-C
The J230-C has been specifically designed as a simple aircraft which can be maintained
by owners to a large degree. Jabiru Aircraft allows normal maintenance up to 100-hourly
servicing to be carried out by the owner. This includes:
•Oil & oil filter changes
•Fuel filter changes
•Brake pad changes
•Tyre changes
•Spark plug changes
•Normal engine maintenance between 100-hourly maintenance (ie 33 and 66 hour
maintenance). Refer to Engine Maintenance Manual for details.
Every 100 hours or Annually (whichever happens first) a 100-hour inspection must be
inspected by an Authorised Person (such as a LAME. Refer to the RAAus Operations
Manual for RAAus aircraft Australia).
Jabiru Aircraft recommend that any aircraft being used for flight training or any other form
of hire-and-reward operation be maintained by an authorised maintenance person or
organisation.
2.4 AIRCRAFT SPECIFICATIONS
Leading particulars of this aircraft, with dimensions based on gross weight, are given in
Figure 1. If these dimensions are used for constructing a hangar or computing clearances,
remember that such factors as tyre pressure, tyre size and load distribution may result in
some dimensions that may be somewhat different from those listed.
2.5 CENTRE OF GRAVITY LIMITATIONS
The JABIRU is a very light aircraft. The installation of equipment may significantly alter the
approved CG limits of the aircraft. Therefore, all proposed fixed installations must be
approved by JABIRU AIRCRAFT Pty Ltd or an person authorized to revise an aircraft’s
weight and balance information (such as the holder of a CASA Weight Control Authority)

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2.6 TORQUE VALUES
A chart of recommended torque values is shown in Figure 1-2. These torque values are
recommended for all service procedures contained in this manual, except where other
values are stipulated. They are not to be used for checking tightness of installed parts
during service.
2.7 AIRCRAFT SPECIFICATIONS
Table 1. J230 Specifications
Model J230-C
Aircraft Maximum Weight 600kg
(1320lb)
Fuel Capacity 135 litres
Fuel Type
AVGAS 100/130.
MOGAS with Octane Rating 95 RON (AKI 90) or
above may be used if AVGAS is not available.
Fuels Containing Alcohols (Ethanol etc) will
damage the fuel tank sealant and
MUST NOT BE USED IN JABIRU AIRCRAFT
Oil Capacity 3.5 litres
Oil Type Refer Engine Manuals
Engine Model
(Refer To Appendix I For Engine Data) Jabiru 3300
Propeller Type Jabiru
2-bladed Wooden
Propeller Diameter 60” dia (1524mm)
Propeller Pitch Jabiru 53” pitch (1346mm)
Wheel Sizes Standard 500 x 6” rim
Tyres Standard 6” wide, 6 Ply
Tyre Pressures Standard - Mains 228 kpa (45 psi)
Tyre Pressures Standard - Nose 193 kpa (30 psi)
Wheel Alignment (At Gross Weight)
Camber
Toe In
0”
0”
Battery Location In Engine Compartment

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Figure 1. J230-C General Arrangement

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2.8 RECOMMENDED TORQUE VALUES (IN FIBREGLASS)
Table 2. Recommended Bolt Torque Values
Bolt Size Torque (Inch.lb)
AN3 20 - 25 (2 ft lb)
AN4 50 - 70 (4-5 ft lb)
AN5 100 –140 (8-12 ft lb)
AN4 Propellor 72 (6 ft lb)
•These values relate only to steel nuts on oil-free cadmium plated threads.
•For Engine Bolt Torque Values see Engine Instruction & Maintenance Manual.
•The above values are recommended for all installation procedures contained in this
Manual, except where other values are stipulated.
•The above values are not to be used for checking tightness of installed parts during
service.
CAUTION
GENERAL RULE: DO NOT REUSE SELF-LOCKING NUTS
2.9 AIRCRAFT STRUCTURE
In the J230 due to it’s monocoque construction the majority of the structure is primary.
The components of the aircraft which are secondary structure can be identified by the fact
that they are designed as fairings and are generally removable. Examples of secondary
structure are the engine cowls, speed fairings, ventral fin and wheel spats.

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3Section 3 - Ground Handling, Servicing, Lubrication
& nspection
3.1 GROUND HANDLING
3.1.1 TOWING
The JABIRU aircraft is very light and should always be moved by hand.
Moving the aircraft is accomplished by using the wing struts or prop hub or landing gear
struts as push points together with the solid rear fuselage join of the fin to the tail plane.
CAUTION
Do not use control surfaces to move the aircraft --Damage to the control system
may result
When pushing at the join of the fin and Tail Plane, take care that you do not jam your
fingers under the rudder or in the rudder hinge – remember that it is Connected to the
Nose Wheel.
The aircraft may also be moved by placing the propeller in the horizontal and then placing
one hand on the propeller on either side of the spinner. The aircraft can then be pulled
forward.
CAUTION
Never move the aircraft in this manner whilst the engine is hot as it may fire when
the propeller is moved and result in severe injury.
Always ensure that the Master and Ignitions are OFF.
Never approach the propeller when anyone is in the aircraft.
Always treat the propeller as LIVE! IT KILLS!
3.1.2 JACKING
JABIRU is a very light aircraft. Before jacking, ensure that it is as light as possible by
removing luggage and any unnecessary fuel.
3.1.2.1 JACKING MAIN GEAR
1. Remove main gear spat on the side to be jacked or both spats if both wheels to be
jacked.
2. The aircraft can be lifted on one side by a person of reasonable strength (or 2 of
lesser strength) by lifting on the Wing Spar, at the outboard part of the wing strut
attachment or towards the wing tip. Be careful lifting at the Wing Tip.

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3. Place a solid block (preferably wood) under the bottom of the composite glass leg
which will result in the wheel being off the ground when the aircraft is lowered. Be
careful not to interfere with brake components or Wheel Spat attachments. Chock
the opposite wheel.
4. Repeat for other side if necessary.
The above procedure is useful for wheel/brake servicing or repairs, but is of no value in
removing the main undercarriage. If the removal of the main undercarriage is necessary,
adopt the following procedure.
1. Obtain a trestle, 20ltr drum or similar object 600mm high.
2. Mount a solid foam block, sandbag, pillow or similar compliant material on top of
the trestle. (compliant material should distribute load over minimum 150 square
centimetres) Place under the lower wing strut attachment.
3. Support under both wings at the Wing Spar to prevent the aircraft from rocking.
Ensure that no fittings are strained.
3.1.2.2 JACKING NOSE GEAR
1. Push down on tail Plane (NOT THE ELEVATOR) until nose gear is off the ground.
2. Place trestle or drum under rear fuselage together with absorbent material such as
foam block, sandbags or a pillow.
CAUTION
Ensure trestle does not foul Ventral Fin.
3. Weigh down tail plane with sandbags or similar heavy absorbent (not hard – hard
items like bricks are likely to damage the aircraft) material.
CAUTION
Do not lift using control surfaces. Damage to the control surface or control system
may result.
3.1.3 HOISTING
This procedure should not be necessary for most service or maintenance procedures.
Should hoisting be necessary:
1. Drain Fuel from both wings & Remove wings. See details below
2. Fit shackles to wing support brackets (4 off).
3. Fit cables/rope to shackles and to a centre lift shackle.

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4. Hoist only from this point ensuring that cables/ropes do not mark the top of the
fuselage at corners above wing support brackets.
3.1.4 LEVELLING
Method 1
For longitudinal levelling use a spirit level on either side of the lower door sills.
For lateral leveling, use an accurate level placed against the flap drive cross tube (inside
the cabin, in the roof above the seats).
Longitudinal Method 2
Use the join line of the cowl top & bottom halves.
3.1.5 PARKING
Parking precautions depend principally on local conditions. As a general precaution,
chock the wheels and tie the control handle back firmly with a seat belt to lock the
controls. Park into the wind and tie down the aircraft as outlined in below if a hangar is not
available.
3.1.6 TIE DOWN
When mooring the aircraft in the open, head into wind if possible. Secure control surfaces
by tying the control handle back firmly with a seat belt.
Then:
1. Tie ropes to the top end of each wing strut. Secure opposite end of the ropes to
ground anchors located at approximately 30 degrees to the vertical, outboard of the
top wing attachment point. Ensure that the ropes have sufficient slack to not strain
the wing attachments should a tyre deflate while the aircraft is tied down.
2. Tie rope to the Tail Tie-down Hole in the Ventral Fin. Secure the opposite end of
rope to ground anchors.
3.1.7 FLYABLE STORAGE
Flyable storage is defined as a maximum of 30 days non-operational storage.
Ensure that the engine has been stopped by turning off the fuel valve, thereby not leaving
any fuel in the carburettor bowl.
Every 7th day the propeller should be rotated through 5 revolutions, without running the
engine. Leave the propeller in the horizontal position to ensure even distribution of liquids
in the wood. If left in the vertical position, liquids will drain to the lower tip resulting in an
unbalanced propeller.
CAUTION
Ensure that the Master and Ignition Switches are OFF!
Store under cover, away from direct sunlight.