1. Manuals
  2. Brands
  3. Jabiru Manuals
  4. Aircrafts
  5. J230-C
  6. Service manual

Jabiru J230-C Service Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Service Schedule
Inspection Schedule
Engine Instruction & Maintenance Manual
Propeller Instruction Manual
Airworthiness Limitations
0
REVISION
L:\files\Technical_manuals\J230_J430\J230.J430_Work_files\J230-C_Tech_Rev_1.doc
Print Date: 14/01/2009 4:41:00 PM
Aircraft Service Manual
-
-
-
Dated : May 2006
Mandatory Replacement Times
Structural Inspection Intervals
Structural Inspection Procedures
Issued By: RAS
Page: 1 of 171

Advertisement

Table of Contents
loading

Related Manuals for Jabiru J230-C

Summary of Contents for Jabiru J230-C

  • Page 1 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 Dated : May 2006 Issued By: RAS Page: 1 of 171 REVISION L:\files\Technical_manuals\J230_J430\J230.J430_Work_files\J230-C_Tech_Rev_1.doc Print Date: 14/01/2009 4:41:00 PM...

  • Page 2: L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc

    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.

  • Page 3: L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc

    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. Dated : Feb 2006 Issued By: RAS...

  • Page 4: Table Of Contents

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Table of Contents TABLE OF CONTENTS ............................4 ..........................11 ABLE OF IGURES ............................12 IST OF ABLES SECTION 2 – SERVICE MANUAL........................13 LIST OF EFFECTIVE PAGES ......................13 GENERAL DESCRIPTION.........................14 OWNER MAINTENANCE ........................14 2.3.1...
  • Page 5 Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C MAJOR ....................32 INSPECTION EPLACEMENT 3.7.1 MANDATORY INSPECTION ......................32 3.7.2 INSPECTION CHART.........................33 SECTION 4 - FUSELAGE............................. 37 FUSELAGE ............................37 WINDSHIELD AND WINDOWS......................37 4.2.1 Description ..........................37 4.2.2 Cleaning ............................37 4.2.3 Waxing ............................37 4.2.4 Repairs............................37...
  • Page 6 Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C 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 NOSE GEAR ............................63...
  • Page 7 Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C 8.2.2 Inspection and Repair .........................83 8.2.3 flap balancing ..........................83 8.2.4 flap RIGGING (as per template) ....................83 SECTION 9 – ELEVATOR CONTROL SYSTEM ..................... 90 ELEVATOR CONTROL SYSTEM ......................90 CONTROL COLUMN DESCRIPTION....................90 9.2.1...
  • Page 8 Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C 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 SECTION 12 – FUEL SYSTEM........................120 12.1...
  • Page 9 Removal and Installation......................160 17.3 ............................160 EPAIR APPENDIX I - JABIRU 3300 ENGINE......................161 APPENDIX II - JABIRU ENGINE PARTS BOOK ..................162 APPENDIX III – ENGINE INSTALLATION MANUAL ................163 APPENDIX IV – PROPELLER SERVICE MANUAL................. 164 21.1 ......................164...

  • Page 10: L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C 22.1 GENERAL.............................170 22.2 ..............170 NTERIOR LAME ETARDANT AINTENANCE IMITATIONS 22.3 & M ..................170 OMPOSITE NSPECTION AINTENANCE 22.3.1 External Paint / Finishing Limitations ..................170 22.4 CONTROL SURFACE BALANCING ....................170 22.4.2 mandatory Replacement ......................171...

  • Page 11: Table Of Figure

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C 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.

  • Page 12: List Of Tables

    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.

  • Page 13: Section 2 - Service Manual

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Section 2 – Service Manual LIST OF EFFECTIVE PAGES Page Revision Date Page Revision Date Page Revision Date 16/5/06 16/5/06 16/5/06 16/5/06 16/5/06 16/5/06 16/5/06 16/5/06 16/5/06 16/5/06 16/5/06 16/5/06 16/5/06...

  • Page 14: General Description

    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.

  • Page 15: Torque Values

    MOGAS with Octane Rating 95 RON (AKI 90) or above may be used if AVGAS is not available. Fuel Type 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...

  • Page 16: L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Figure 1. J230-C General Arrangement Dated : Feb 2006 Issued By: RAS Page: 16 of 171 REVISION L:\files\Technical_manuals\J230_J430\J230.J430_Work_files\J230-C_Tech_Rev_1.doc Print Date: 14/01/2009 4:41:00 PM...

  • Page 17: Recommended Torque Values (In Fibreglass)

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C RECOMMENDED TORQUE VALUES (IN FIBREGLASS) Table 2. Recommended Bolt Torque Values Bolt Size Torque (Inch.lb) 20 - 25 (2 ft lb) 50 - 70 (4-5 ft lb) 100 –140 (8-12 ft lb)

  • Page 18: Section 3 - Ground Handling, Servicing, Lubrication & Inspection

    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 Remove main gear spat on the side to be jacked or both spats if both wheels to be jacked.

  • Page 19: Hoisting

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C 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.

  • Page 20: Levelling

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C 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.

  • Page 21: Returning Aircraft To Service

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C In addition, the Pitot tube, static air vent, air vents, openings in the engine cowl and other similar openings should have protective covers fitted to prevent entry of foreign materials and beings (especially wasps).

  • Page 22: Inspection During Storage

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Ensure that the Master and Ignition Switches are OFF! Install spark plugs and connect leads. Seal exhaust pipes. Attach a red streamer to each. DO NOT seal fuel tank breathers. Place protective covers over Pitot tube, static source vents, air vents and openings in engine cowl to prevent the entry of foreign material or beings (especially wasps).

  • Page 23: Weighing

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Install spark plugs – torque to 20 Nm (180 inch/lbs). Check fuel filter – replace if necessary. Check brake fluid level. If returning to service after indefinite storage, fill fuel tanks with correct grade of fuel.

  • Page 24: Servicing

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C 7. Repeat steps 5 and 6 again to avoid errors. 8. Due to the light weight of this aircraft measurements must have an accuracy of at least +/-0.5kg and +/-1mm. 9. Average of the measurements taken for each quantity and the average of the two nose wheel distances are now used to calculate the aircrafts C.G.

  • Page 25: Other Servicing

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C 3.3.2 OTHER SERVICING • Replace flexible oil & fuel line in engine compartment every 2 years or when visible deterioration (cracking, hardening) occurs. 3.3.3 FUEL The fuel tanks should be filled immediately after flight to lessen condensation of moisture.

  • Page 26: Cleaning

    Aircraft Service Manual Jabiru J230-C CAUTION The JABIRU uses automotive brake fluid (DOT 3 or DOT 4). DO NOT use Aircraft hydraulic fluid (mineral based) or damage to the brake system will result. CLEANING Keeping the aircraft clean is important.

  • Page 27: Aluminium Surfaces

    If defects are found, remove and repair in accordance with Section 6. Discard cracked wheel halves, flanges or hubs and install new parts. LUBRICATION There are no lubrication requirements for the JABIRU other than those detailed in Appendix 1. 3.5.1 WHEEL BEARING – MAINS AND NOSE At each 100 hour inspection, jack the wheel, spin the wheel and check for free running and any play on the shaft.

  • Page 28: Inspection

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C INSPECTION 3.6.1 INSPECTION INTERVALS A tolerance of plus or minus 3 hours is allowable on all of the service intervals given within this manual – i.e. a 100-hourly inspection may be carried out at any time between 97 and 103 hours of operation.

  • Page 29: Table 3. Control Free Play Limits

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C The cable must be replaced if the following is found: • Excess friction – maximum allowable force to move cable 1.9kg. • Excess slack in cable – maximum allowable cable slack 3.5mm •...

  • Page 30: Figure 3. Fuel Line Routing

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Figure 3. Fuel Line Routing 3.6.3.6 ELECTRIC FUEL PUMP • Ensure the fuel tanks are low (Less than 40L total). • Turn master switch ON and confirm that the fuel pressure light is illuminated. If it does not light, turn the master switch OFF and remove residual pressure from the lines.

  • Page 31: L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc

    Before beginning the step-by-step inspection, start, run-up and shut-down the engine in accordance with instructions in the Flight Manual and Section 18 (APPENDIX I - JABIRU 3300 ENGINE) of this manual. During the run-up, observe the following, making note of any discrepancies or abnormalities: 1.

  • Page 32: Major Inspection / Replacement

    MAJOR INSPECTION / REPLACEMENT 3.7.1 MANDATORY INSPECTION 3.7.1.1 AIRFRAME The J230-C does not have an overall airframe life limitation. 3.7.1.2 UNDERCARRIAGE Main undercarriage bolts and nose leg pivot bolts shown in Figure 4 are to be changed every 500 hours TIS.

  • Page 33: Inspection Chart

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C 3.7.2 INSPECTION CHART IMPORTANT READ ALL INSPECTION RQUIREMENTS PRIOR TO USING THESE CHARTS. Table 4. Inspection Chart Annual Inspection Each 200 Hours Each 100 Hours PROPELLER Spinner Spinner Flange Spinner screws...

  • Page 34: L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Annual Inspection Each 200 Hours Each 100 Hours Starter, solenoid and electrical connections Coils and electrical connections Carburettor heat system Firewall Exhaust System (Including Muffler) Fuel pressure warning light switch Cabin heat system...

  • Page 35: L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Annual Inspection Each 200 Hours Each 100 Hours Wheel bearings Nose gear strut Nose gear housing & bushes Main gear struts, clamps, bolts & nuts Tyres & tubes Brake fluid, hoses, linings, discs, brake assemblies &...

  • Page 36: L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Annual Inspection Each 200 Hours Each 100 Hours Radio, intercom & headsets Antenna & cable Door catches Stall warning Battery, battery cradle & cables Control Systems In addition to the items listed below, always...

  • Page 37: Section 4 - Fuselage

    Section 4 - Fuselage FUSELAGE The Fuselage is a composite monocoque (self-supporting) structure and includes both the Horizontal Stabiliser and Vertical Fin. All repairs must be referred to Jabiru Aircraft Pty Ltd or approved local representative. WINDSHIELD AND WINDOWS 4.2.1 DESCRIPTION The windshield and windows are one-piece acrylic plastic panels set in sealing strips with Epoxy Resin &...

  • Page 38: Cracks

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C surface. After applying polish, dissipate this charge by rubbing surface with a slightly damp chamois. This will also remove dust particles which have collected while wax is hardening. 4.2.6 CRACKS When a crack appears, drill a hole at the end of the crack to prevent further spreading.

  • Page 39: L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Figure 5. Front Door Assembly Dated : Feb 2006 Issued By: RAS Page: 39 of 171 REVISION L:\files\Technical_manuals\J230_J430\J230.J430_Work_files\J230-C_Tech_Rev_1.doc Print Date: 14/01/2009 4:41:00 PM...

  • Page 40: L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Figure 6: Rear Door Assembly Dated : Feb 2006 Issued By: RAS Page: 40 of 171 REVISION L:\files\Technical_manuals\J230_J430\J230.J430_Work_files\J230-C_Tech_Rev_1.doc Print Date: 14/01/2009 4:41:00 PM...

  • Page 41: Adjustment

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C 4.3.2 ADJUSTMENT Cabin doors should be adjusted so that the door skin fairs with the fuselage skin. 4.3.3 DOOR SEALS A weather strip is glued around all edges of the door. Apart from excluding wind and water, the weather strip is important in minimising exhaust fume entry to the cabin.

  • Page 42: L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Figure 7. Door Latch Mechanism Assembly Dated : Feb 2006 Issued By: RAS Page: 42 of 171 REVISION L:\files\Technical_manuals\J230_J430\J230.J430_Work_files\J230-C_Tech_Rev_1.doc Print Date: 14/01/2009 4:41:00 PM...

  • Page 43: Locks

    4.5.1 UPHOLSTERY CLEANING – FLAME RETARDANT The upholstery used in the J230-C has been treated with a flame retardant to meet the flammability requirements of LSA. This treatment will withstand 5 washes or dry cleans before requiring re-application. The washing of cabin upholstery must be noted in the aircraft’s maintenance log book and the flame retardant re-applied by an authorized...

  • Page 44: Section 5 - Wings And Empennage

    5.1.1 REMOVAL The JABIRU aircraft is designed with wings which are removable for storage or transport. Wing removal is most easily achieved if two persons are available to handle the wing. Remove wing root fairings. Drain Fuel out of Quick Drain ( Note: This will take some time) Remove wing strut fairings –...

  • Page 45: Repair

    Unbolt lower wing strut bolt and remove wing strut. Repeat Steps 5 – 16 to remove other wing. 5.1.2 REPAIR The wing is a composite monocoque structure. All repairs must be referred to JABIRU AIRCRAFT Pty Ltd or our approved local agent. 5.1.3 INSTALLATION Fit the lower strut attaching bolt, leaving the top end of the strut on the ground.

  • Page 46: L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Install clamp block and pin in aileron control cable clamp at rear of seat. On RH wing, reconnect Pitot tube. Replace wing strut fairings – top and bottom. Replace wing root fairings.

  • Page 47: Figure 7. J230 Wing Assembly Sheet 1

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Figure 8. J230 Wing Assembly Sheet 1 Dated : Feb 2006 Issued By: RAS Page: 47 of 171 REVISION L:\files\Technical_manuals\J230_J430\J230.J430_Work_files\J230-C_Tech_Rev_1.doc Print Date: 14/01/2009 4:41:00 PM...

  • Page 48: Figure 8. J230 Wing Assembly Sheet 2

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Figure 9. J230 Wing Assembly Sheet 2 Dated : Feb 2006 Issued By: RAS Page: 48 of 171 REVISION L:\files\Technical_manuals\J230_J430\J230.J430_Work_files\J230-C_Tech_Rev_1.doc Print Date: 14/01/2009 4:41:00 PM...

  • Page 49: Wing Struts

    The probe is mounted on a special mount rather than off the wing strut as normal for the J230-C. Details of the probe’s installation are given in Figure 10 below. Note that this probe incorporates water drain holes for flying in rain and must be removed before leak testing the pitot system.

  • Page 50: Landing Light (Option)

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Figure 10 – Dynon Pitot Probe Installation LANDING LIGHT (OPTION) 5.4.1 DESCRIPTION A landing light may be fitted to the wing strut as an option (refer to Figure 11). 5.4.2 LANDING LIGHT REMOVAL & INSTALLATION 1.

  • Page 51: Fin

    REMOVAL, INSTALLATION, INSPECTION AND REPAIR The fin is an integral part of the fuselage structure and cannot be removed. All repairs must be referred to JABIRU AIRCRAFT Pty Ltd or our approved local agent. HORIZONTAL STABILISER The horizontal stabiliser is a moulded monocoque structure of rigid cellular polystyrene bonded to a fibreglass skin and rear spar.

  • Page 52: Section 6 - Landing Gear And Brakes

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C SECTION 6 – LANDING GEAR and BRAKES LANDING GEAR Main gear comprises two separate composite beams which are bolted to the fuselage at the top and centre and to the wheel stub at the bottom.

  • Page 53: Removal

    Inspect bolts and nuts for signs of stress or bending – replace if in any doubt. Inspect clamp for damage. Inspect bolt seats in fuselage for signs of damage, wear or perishing. Repairs to the composite undercarriage beams must be referred to JABIRU AIRCRAFT Pty Ltd or our local approved agent. Dated : Feb 2006...

  • Page 54: Main Wheel Fairing Removal And Installation

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C 6.3.4 MAIN WHEEL FAIRING REMOVAL AND INSTALLATION Remove the machine screws around the join of the inner and outer sections of the fairing. Remove the bolt on the outside of the fairing.

  • Page 55: L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Figure 12. Main Undercarriage Assembly Dated : Feb 2006 Issued By: RAS Page: 55 of 171 REVISION L:\files\Technical_manuals\J230_J430\J230.J430_Work_files\J230-C_Tech_Rev_1.doc Print Date: 14/01/2009 4:41:00 PM...

  • Page 56: Main Wheel

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C MAIN WHEEL Refer to Figure 14 6.4.1 MAIN WHEEL REMOVAL Jack aircraft as outlined in Section 3.1.2 above. Remove speed fairing, if installed, in accordance with paragraph 6.3.4. Remove outboard brake pad plate.

  • Page 57: Main Wheel Installation

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Bearings are pre-packed. DO NOT clean with solvents as it will remove the packing. Replace bearings. Apply automotive wheel rim lubricant to the bead areas of the rim halves. Note that If this step is missed, disassembly of the wheels in future will be very much harder.

  • Page 58: Main Wheel Stub Axle Installation

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Disconnect flexible brake hose and drain brake fluid. Remove 4 bolts/nuts/washers securing axle to leg. NOTE: When removing axle from leg, note number and position of the wheel alignment shims (if any) between the axle flange and composite leg. Mark these shims or...

  • Page 59: L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Figure 13. Main Wheel Alignment Dated : Feb 2006 Issued By: RAS Page: 59 of 171 REVISION L:\files\Technical_manuals\J230_J430\J230.J430_Work_files\J230-C_Tech_Rev_1.doc Print Date: 14/01/2009 4:41:00 PM...

  • Page 60: Figure 13. Main Wheel To Leg Assy

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Figure 14. Main Wheel to Leg Assy Dated : Feb 2006 Issued By: RAS Page: 60 of 171 REVISION L:\files\Technical_manuals\J230_J430\J230.J430_Work_files\J230-C_Tech_Rev_1.doc Print Date: 14/01/2009 4:41:00 PM...

  • Page 61: Figure 14. Main Wheel Assembly

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Figure 15. Main Wheel Assembly Dated : Feb 2006 Issued By: RAS Page: 61 of 171 REVISION L:\files\Technical_manuals\J230_J430\J230.J430_Work_files\J230-C_Tech_Rev_1.doc Print Date: 14/01/2009 4:41:00 PM...

  • Page 62: Figure 15. Directional Brake Disc Installation

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Figure 16. Directional Brake Disc Installation Dated : Feb 2006 Issued By: RAS Page: 62 of 171 REVISION L:\files\Technical_manuals\J230_J430\J230.J430_Work_files\J230-C_Tech_Rev_1.doc Print Date: 14/01/2009 4:41:00 PM...

  • Page 63: Nose Gear

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C NOSE GEAR The nose gear comprises a steerable nose wheel mounted on a welded steel assembly with an aluminium wheel yoke and a rubber spring system. The steel tube is constrained within two Ertalite bushes mounted in an aluminium housing which is attached to the front of the firewall.

  • Page 64: Nose Gear Inspection And Repair

    Inspect aluminium wheel yoke for damage or bending. Inspect bolts/nuts for torque – see torque values Table 2. Repairs to the welded nose leg assembly beam must be referred to JABIRU AIRCRAFT Pty Ltd or our approved local agent. 6.5.4...

  • Page 65: Nose Wheel Inspection And Repair

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C NOTE: The bearings are “press-fit” in the wheel hub and should not be removed unless a new part is to be installed. 6.6.3 NOSE WHEEL INSPECTION AND REPAIR Clean metal parts in solvent and dry thoroughly.

  • Page 66: Figure 16. Nose Leg Assy

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Figure 17. Nose Leg Assy Dated : Feb 2006 Issued By: RAS Page: 66 of 171 REVISION L:\files\Technical_manuals\J230_J430\J230.J430_Work_files\J230-C_Tech_Rev_1.doc Print Date: 14/01/2009 4:41:00 PM...

  • Page 67: Figure 17. Nose Wheel Hub Assembly

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Figure 18. Nose Wheel Hub Assembly Dated : Feb 2006 Issued By: RAS Page: 67 of 171 REVISION L:\files\Technical_manuals\J230_J430\J230.J430_Work_files\J230-C_Tech_Rev_1.doc Print Date: 14/01/2009 4:41:00 PM...

  • Page 68: Nose Wheel Steering System

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C NOSE WHEEL STEERING SYSTEM 6.7.1 5.7.1 STEERING CENTRING ASSEMBLY The Nosewheel Centring Assembly consists of springs which are stretched when the nose leg is moved to the left or the right. Repair is limited to replacement of parts.

  • Page 69: Brake Master Cylinder

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C 6.8.2 BRAKE MASTER CYLINDER The brake master cylinder, located on the front of the main longitudinal beam, is actuated by applying rearward pressure to the brake handle. A small reservoir is incorporated into the master cylinder for the fluid supply.

  • Page 70: L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc

    Punch out all rivets securing the lining to the pad plate. NOTE: A replacement kit for brake pads and rivets is available from JABIRU Clamp the flat side of an anvil in a vice. Dated : Feb 2006...

  • Page 71: Brake System Bleeding

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Align the new lining on the pad plate and place the brake rivet in the hole with the rivet head in the lining. Place the head against the anvil. Centre the rivet setting punch on the lips of the rivet. While holding the pad plate down firmly against the lining, hit punch with hammer to set the rivet.

  • Page 72: Parking Brake

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C 6.8.7 PARKING BRAKE The Parking Brake consists of an over centre cam on the brake handle. Should the cam have insufficient travel for the brakes to hold the aircraft with a propeller thrust of 2500rpm, adjust by one or all of the following: Adjust brakes as described in Paragraph 6.8.6.

  • Page 73: Figure 18. Brake Calliper Assy

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Figure 19. Brake Calliper Assy Dated : Feb 2006 Issued By: RAS Page: 73 of 171 REVISION L:\files\Technical_manuals\J230_J430\J230.J430_Work_files\J230-C_Tech_Rev_1.doc Print Date: 14/01/2009 4:41:00 PM...

  • Page 74: Figure 19. Brake Master Cylinder Assy

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Figure 20. Brake Master Cylinder Assy Dated : Feb 2006 Issued By: RAS Page: 74 of 171 REVISION L:\files\Technical_manuals\J230_J430\J230.J430_Work_files\J230-C_Tech_Rev_1.doc Print Date: 14/01/2009 4:41:00 PM...

  • Page 75: Section 7 - Aileron Control System

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C SECTION 7 - AILERON CONTROL SYSTEM AILERON CONTROL SYSTEM Refer to Figure 21. The aileron control system is comprised of a control column and two enclosed push-pull cables fitted with spherical bearings.

  • Page 76: Figure 20. Aileron System Schematic

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Figure 21. Aileron System Schematic Dated : Feb 2006 Issued By: RAS Page: 76 of 171 REVISION L:\files\Technical_manuals\J230_J430\J230.J430_Work_files\J230-C_Tech_Rev_1.doc Print Date: 14/01/2009 4:41:00 PM...

  • Page 77: Control Column

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C CONTROL COLUMN Refer to Figure 22. 7.2.1 CONTROL COLUMN REMOVAL If required, unbolt & remove the control stick from the pivot plate. Unbolt and remove the aileron cable ends from the aileron drive arms at the lower end of the control column.

  • Page 78: Figure 21. Control Column Assy

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Figure 22. Control Column Assy Dated : Feb 2006 Issued By: RAS Page: 78 of 171 REVISION L:\files\Technical_manuals\J230_J430\J230.J430_Work_files\J230-C_Tech_Rev_1.doc Print Date: 14/01/2009 4:41:00 PM...

  • Page 79: Control Cables

    Inspect ailerons for any signs of delamination or cracking. Pay particular attention to the Control Horn and hinges and their surrounding areas. Repairs must be referred to JABIRU AIRCRAFT Pty Ltd or our approved local agent. Dated : Feb 2006...

  • Page 80: Aileron Balancing

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C 7.4.3 AILERON BALANCING The aileron does not have balancing weights fitted. The control does however have limits for weight and hinge moment: Weight 1150g +/- 100g Hinge Moment 94000g.mm +/- 4000g.mm The aileron balance is checked at the factory during assembly and unless they are repaired or refinished the balance should not change.

  • Page 81: Figure 22. Aileron Stops

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Figure 23. Aileron Stops Dated : Feb 2006 Issued By: RAS Page: 81 of 171 REVISION L:\files\Technical_manuals\J230_J430\J230.J430_Work_files\J230-C_Tech_Rev_1.doc Print Date: 14/01/2009 4:41:00 PM...

  • Page 82: Section 8 - Wing Flap Control System

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C SECTION 8 - WING FLAP CONTROL SYSTEM WING FLAP CONTROL SYSTEM Refer to Figures 24 to 26. The wing flap control system comprises a switch & position indicator mounted on the instrument panel, and a electronic linear actuator-driven common shaft assembly, with pushrods connecting to the flap control surface horns.

  • Page 83: Flap Position Indicator Removal

    INSPECTION AND REPAIR Inspect flaps for any signs of delamination or cracking. Pay particular attention to the Control Horn and hinges and their surrounding areas. Repairs must be referred to JABIRU AIRCRAFT Pty Ltd or our approved local agent. 8.2.3 FLAP BALANCING The flaps on the J230 are not balanced.

  • Page 84: L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Adjust with the rod ends. Ensure that the lock nut is tight on the control ends and that the thread is visible through the hole in the rod. Check for FULL DOWN travel using the Flap Rigging Template (see Appendix 3).

  • Page 85: Figure 23. Flap Controls - Sheet 1

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Figure 24. Flap Controls – Sheet 1 Dated : Feb 2006 Issued By: RAS Page: 85 of 171 REVISION L:\files\Technical_manuals\J230_J430\J230.J430_Work_files\J230-C_Tech_Rev_1.doc Print Date: 14/01/2009 4:41:00 PM...

  • Page 86: Figure 24. Flap Controls - Sheet 2

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Figure 25. Flap Controls – Sheet 2 Dated : Feb 2006 Issued By: RAS Page: 86 of 171 REVISION L:\files\Technical_manuals\J230_J430\J230.J430_Work_files\J230-C_Tech_Rev_1.doc Print Date: 14/01/2009 4:41:00 PM...

  • Page 87: Figure 25. Flap Cross Tube Assy

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Figure 26. Flap Cross Tube Assy Dated : Feb 2006 Issued By: RAS Page: 87 of 171 REVISION L:\files\Technical_manuals\J230_J430\J230.J430_Work_files\J230-C_Tech_Rev_1.doc Print Date: 14/01/2009 4:41:00 PM...

  • Page 88: Figure 26. Flap Position Indicator

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Figure 27. Flap Position Indicator Dated : Feb 2006 Issued By: RAS Page: 88 of 171 REVISION L:\files\Technical_manuals\J230_J430\J230.J430_Work_files\J230-C_Tech_Rev_1.doc Print Date: 14/01/2009 4:41:00 PM...

  • Page 89: Figure 27. Flap Position Indicator Drive Cable Assembly

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Figure 28. Flap Position Indicator Drive Cable Assembly Dated : Feb 2006 Issued By: RAS Page: 89 of 171 REVISION L:\files\Technical_manuals\J230_J430\J230.J430_Work_files\J230-C_Tech_Rev_1.doc Print Date: 14/01/2009 4:41:00 PM...

  • Page 90: Section 9 - Elevator Control System

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C SECTION 9 – ELEVATOR CONTROL SYSTEM ELEVATOR CONTROL SYSTEM See Figures 29, 31 and Figure 32. The elevator control system is comprised of a control column and one enclosed push-pull cable fitted with rod ends at both ends.

  • Page 91: Inspection And Repair

    Inspect elevator for any signs of delamination or cracking. Pay particular attention to the Control Horn and hinges and their surrounding areas. Repairs must be referred to JABIRU AIRCRAFT Pty Ltd or our approved local agent. CONTROL CABLE AND ATTACHMENTS 9.4.1...

  • Page 92: Figure 28. Elevator Control Assy

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Figure 29. Elevator Control Assy Dated : Feb 2006 Issued By: RAS Page: 92 of 171 REVISION L:\files\Technical_manuals\J230_J430\J230.J430_Work_files\J230-C_Tech_Rev_1.doc Print Date: 14/01/2009 4:41:00 PM...

  • Page 93: Figure 29: Elevator Control Assy Rear

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Figure 30: Elevator Control Assy Rear. Dated : Feb 2006 Issued By: RAS Page: 93 of 171 REVISION L:\files\Technical_manuals\J230_J430\J230.J430_Work_files\J230-C_Tech_Rev_1.doc Print Date: 14/01/2009 4:41:00 PM...

  • Page 94: Figure 30. J230 Models - Horizontal Tail & Elevator Assy

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C 127.0 76.2 280 GAP BETWEEN VG 2350 2205 2210 1900 1560 Figure 31. J230 Models - Horizontal Tail & Elevator Assy Dated : Feb 2006 Issued By: RAS Page: 94 of 171 REVISION L:\files\Technical_manuals\J230_J430\J230.J430_Work_files\J230-C_Tech_Rev_1.doc...

  • Page 95: Figure 31. J170 Models - Horizontal Tail & Elevator Assy

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Figure 32. J170 Models - Horizontal Tail & Elevator Assy Dated : Feb 2006 Issued By: RAS Page: 95 of 171 REVISION L:\files\Technical_manuals\J230_J430\J230.J430_Work_files\J230-C_Tech_Rev_1.doc Print Date: 14/01/2009 4:41:00 PM...

  • Page 96: Figure 32. Elevator Travel Limits

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Figure 33. Elevator Travel Limits Dated : Feb 2006 Issued By: RAS Page: 96 of 171 REVISION L:\files\Technical_manuals\J230_J430\J230.J430_Work_files\J230-C_Tech_Rev_1.doc Print Date: 14/01/2009 4:41:00 PM...

  • Page 97: Elevator Trim Control System

    9.6.4 REMOVAL AND INSTALLATION The Trim Control Cable is a Primary Control and may not be repaired or removed without reference to JABIRU AIRCRAFT Pty Ltd or our approved local agent. 9.6.5 INSPECTION AND REPAIR Inspect Trim system generally for security and any signs of wear. Pay particular attention to the bearing blocks, friction plates, bearing, springs, cable and attachments.

  • Page 98: Figure 33. Elevator Trim Handle Assy

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Figure 34. Elevator Trim Handle Assy Dated : Feb 2006 Issued By: RAS Page: 98 of 171 REVISION L:\files\Technical_manuals\J230_J430\J230.J430_Work_files\J230-C_Tech_Rev_1.doc Print Date: 14/01/2009 4:41:00 PM...

  • Page 99: Figure 34. Trim Controls - At Tail

    2085023 ELEVATOR ASSY NUT. 3065094 MOUNTING PLATE TRIM ASSEMBLY 2. CPNo. = COMMERCIAL (NON JABIRU) PART NUMBERS AN960-416 1/4" FLAT WASHER 3. QUANTITIES GIVEN ARE FOR THE COMPLETE TRIM CONTROL ASSEMBLY AS SHOWN IN SHEETS 1-3 OF THIS DRRAWING. AN3-10A 3/16"...

  • Page 100: Section 10 - Rudder Control System

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C 10 SECTION SECTION 10 10 – – – – RUDDER CONTROL SYSTEM SECTION SECTION 10.1 RUDDER PEDAL SYSTEM Refer to Figure 36. Rudder control is maintained through the use of rudder pedals which also control nose wheel steering.

  • Page 101: Figure 35. Rudder Pedal Assy

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Figure 36. Rudder Pedal Assy Dated : Feb 2006 Issued By: RAS Page: 101 of 171 REVISION L:\files\Technical_manuals\J230_J430\J230.J430_Work_files\J230-C_Tech_Rev_1.doc Print Date: 14/01/2009 4:41:00 PM...

  • Page 102: Rudder

    Inspect rudder for any signs of delamination or cracking. Pay particular attention to the Control Horn and hinges and their surrounding areas. Repairs must be referred to JABIRU AIRCRAFT Pty Ltd or our approved local agent. 10.3 CONTROL CABLE & ATTACHMENTS The control cable is of the push-pull type fitted with spherical bearings at both ends.

  • Page 103: Rigging

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C 10.5 RIGGING To establish the neutral position, raise the nose wheel off the ground by leaning down on the horizontal stabiliser. Allow the nose wheel (and therefore the rudder pedals) to centralise.

  • Page 104: Figure 36. Rudder System Schematic

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Figure 37. Rudder System Schematic Dated : Feb 2006 Issued By: RAS Page: 104 of 171 REVISION L:\files\Technical_manuals\J230_J430\J230.J430_Work_files\J230-C_Tech_Rev_1.doc Print Date: 14/01/2009 4:41:00 PM...

  • Page 105: Figure 37. Rudder Installation

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Figure 38. Rudder Installation Dated : Feb 2006 Issued By: RAS Page: 105 of 171 REVISION L:\files\Technical_manuals\J230_J430\J230.J430_Work_files\J230-C_Tech_Rev_1.doc Print Date: 14/01/2009 4:41:00 PM...

  • Page 106: 11 Section 11 - Engine & Engine Installation

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C 11 Section 11 – Engine & Engine Installation 11.1 ENGINE COWLS The engine cowls comprise both an Upper and Lower composite structure. The Upper Cowl is fitted with five locating Cam Locks, two at the front & three at the rear of the cowlings.

  • Page 107: Figure 38. Upper Cowl Assy

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Figure 39. Upper Cowl Assy Dated : Feb 2006 Issued By: RAS Page: 107 of 171 REVISION L:\files\Technical_manuals\J230_J430\J230.J430_Work_files\J230-C_Tech_Rev_1.doc Print Date: 14/01/2009 4:41:00 PM...

  • Page 108: Figure 39. Lower Cowl Assy

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Figure 40. Lower Cowl Assy Dated : Feb 2006 Issued By: RAS Page: 108 of 171 REVISION L:\files\Technical_manuals\J230_J430\J230.J430_Work_files\J230-C_Tech_Rev_1.doc Print Date: 14/01/2009 4:41:00 PM...

  • Page 109: Cleaning And Inspection

    5 and the rear Port cylinder is numbered 6. Refer to Engine Instruction & Maintenance Manual for detailed engine data. For repair & overhaul of the engine, refer to the applicable publication issued by Jabiru Aircraft Pty Ltd. 11.2.1 ENGINE DATA Refer Engine Instruction &...

  • Page 110: Inspection

    2 years whichever comes first. Hoses which show visible deterioration (cracking, excessive hardening) should be replaced immediately, irrespective of age. For major engine repairs, refer to JABIRU AIRCRAFT Pty Ltd or an Approved Jabiru Service Centre. 11.2.5.1 FLEXIBLE HOSES Leak Test After each 100 hours of operation, flexible hoses should be checked for leaks.

  • Page 111: Cooling Air Baffles

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C 11.3 COOLING AIR BAFFLES The baffles installed around the engine direct the cooling air flow to the oil cooler and to other engine components to provide optimum engine cooling. The baffles, air inlets and outlets and air scoops are accurately positioned to maintain engine cooling efficiency and their removal will cause improper air circulation and engine overheating.

  • Page 112: Lsa Aircraft Fuel System

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C 11.5.2 LSA AIRCRAFT FUEL SYSTEM A schematic drawing of the system is shown as Figure 46 The fuel filter and auxiliary electronic fuel pump are mounted inside the header tank enclosure.

  • Page 113: Figure 40. Lsa Variant Throttle (Panel Mounted)

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Figure 41. LSA Variant Throttle (Panel Mounted) Dated : Feb 2006 Issued By: RAS Page: 113 of 171 REVISION L:\files\Technical_manuals\J230_J430\J230.J430_Work_files\J230-C_Tech_Rev_1.doc Print Date: 14/01/2009 4:41:00 PM...

  • Page 114: Choke

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Figure 42 – Instrument Panel & Throttle Assembly 11.7.3 CHOKE The Choke Control is located in the main instrument panel & is connected to the carburettor by a control cable. 11.7.4 AIR INTAKE SYSTEM &...

  • Page 115: Figure 42. Carburetor Heat Box

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Figure 43. Carburetor Heat Box Dated : Feb 2006 Issued By: RAS Page: 115 of 171 REVISION L:\files\Technical_manuals\J230_J430\J230.J430_Work_files\J230-C_Tech_Rev_1.doc Print Date: 14/01/2009 4:41:00 PM...

  • Page 116: Exhaust System

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C 11.8 EXHAUST SYSTEM The exhaust system consists of front and rear exhaust manifolds attached to the engine block and a muffler assembly and springs which attach the muffler to the manifolds. Refer to Figure 44 11.8.1...

  • Page 117: Figure 43. Exhaust System

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Figure 44. Exhaust System Dated : Feb 2006 Issued By: RAS Page: 117 of 171 REVISION L:\files\Technical_manuals\J230_J430\J230.J430_Work_files\J230-C_Tech_Rev_1.doc Print Date: 14/01/2009 4:41:00 PM...

  • Page 118: Extreme Climatic Conditions

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C 11.9 EXTREME CLIMATIC CONDITIONS 11.9.1 DUST Dust induced into the carburettor air intake system is probably the greatest single cause of early engine wear. When operating under high dust conditions, the carburettor air filters should be serviced regularly as outlined in Paragraph 11.7.4.

  • Page 119: Figure 44. Engine Installation

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Figure 45. Engine Installation Dated : Feb 2006 Issued By: RAS Page: 119 of 171 REVISION L:\files\Technical_manuals\J230_J430\J230.J430_Work_files\J230-C_Tech_Rev_1.doc Print Date: 14/01/2009 4:41:00 PM...

  • Page 120: 12 Section 12 - Fuel System

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C 12 SECTION 12 – FUEL SYSTEM 12.1 DESCRIPTION Refer to Figures 46 and !Undefined Bookmark, NONCSVLAF for system schematic details. Fuel is pump-fed from two composite fuel tanks inside the wings, through a header tank, fuel filter &...

  • Page 121: Figure 45. Fuel System Schematic - Lsa Variants

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Figure 46. Fuel System Schematic – LSA Variants Dated : Feb 2006 Issued By: RAS Page: 121 of 171 REVISION L:\files\Technical_manuals\J230_J430\J230.J430_Work_files\J230-C_Tech_Rev_1.doc Print Date: 14/01/2009 4:41:00 PM...

  • Page 122: Fuel System Trouble Shooting

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C 12.1.3 FUEL SYSTEM TROUBLE SHOOTING Table 8. Trouble Shooting – Fuel System Trouble Probable Cause Remedy Fuel shut-off valve not turned Turn valve ON Service with proper grade and Fuel tank empty...

  • Page 123: Fuel Vents

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Remove tank restraints. Loosen hose clamps, remove hoses & remove tank. Installation is the reverse of removal. 12.3 FUEL VENTS 12.3.1 DESCRIPTION Refer to Figure 47. Positive ventilation is provided by vented fuel caps. The caps incorporate a check valve to prevent excess fuel leakage when the aircraft is parked on an angle or flown out of balance.

  • Page 124: L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C An alternative method which may be used is to fill the wing tanks with fuel, then shake the aircraft by pushing up and down on the wingtip. While small droplet leakage is normal, fuel must not squirt out of the vent.

  • Page 125: Figure 46. Vented Fuel Cap Assy

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Figure 47. Vented Fuel Cap Assy Dated : Feb 2006 Issued By: RAS Page: 125 of 171 REVISION L:\files\Technical_manuals\J230_J430\J230.J430_Work_files\J230-C_Tech_Rev_1.doc Print Date: 14/01/2009 4:41:00 PM...

  • Page 126: Fuel Shut-Off Valve

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C 12.4 FUEL SHUT-OFF VALVE See Figure 46 or !Undefined Bookmark, NONCSVLAF & 48, depending on model variant. 12.4.1 DESCRIPTION The fuel shut-off valve is a two-position ON – OFF valve which is located in front of the main longitudinal beam.

  • Page 127: Fuel Gauges

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Figure 48. Single Line Fuel Tap 12.5 FUEL GAUGES Two different fuel gauge systems are used in the J230 family. The first uses sight gauges located in the wing roots while the second uses senders in the tanks to drive electronic (LCD) gauges fitted in the instrument panel.

  • Page 128: Electric Fuel Gauge Troubleshooting

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C 12.5.3 ELECTRIC FUEL GAUGE TROUBLESHOOTING Table 9. Trouble Shooting – Fuel Gauge Trouble Probable Cause Remedy Bad connection between Fix connection Gauge on panel reads sender & gauge full, tanks low Sender has lost calibration Remove sender &...

  • Page 129: Figure 49. Fuel Gauge - Electric Sender Assembly

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Figure 50. Fuel Gauge – Electric Sender Assembly Figure 51. Fuel Gauge – Sight Glass Dated : Feb 2006 Issued By: RAS Page: 129 of 171 REVISION L:\files\Technical_manuals\J230_J430\J230.J430_Work_files\J230-C_Tech_Rev_1.doc Print Date: 14/01/2009 4:41:00 PM...

  • Page 130: Header Tank Low Level Warning (Option)

    Aircraft Service Manual Jabiru J230-C 12.6 HEADER TANK LOW LEVEL WARNING (OPTION) The J230-C may be fitted with a low level warning light in the header tank as an option. See Figure 52. 12.6.1 DESCRIPTION The sensor is a solid-state LED which illuminates a red warning light on the instrument panel if the fuel level in the header tank falls below approximately 3 litres.

  • Page 131: Fuel Filter Removal & Installation

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C 12.7.2 FUEL FILTER REMOVAL & INSTALLATION Drain fuel system, wing tanks and header tanks. Place a cloth beneath the filter to collect any fuel which may be split during removal of the filter.

  • Page 132: Section 13 - Instruments & Instrument Systems

    Malfunctioning instruments should be either returned to JABIRU AIRCRAFT Pty Ltd or sent to an approved instrument overhaul and repair station for servicing.

  • Page 133: Instruments

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C 13.2.2 INSTRUMENTS Refer to Figure 53 & Figure 54. Figure 53. Instrument Panel Layout (Std Panel) Dated : Feb 2006 Issued By: RAS Page: 133 of 171 REVISION L:\files\Technical_manuals\J230_J430\J230.J430_Work_files\J230-C_Tech_Rev_1.doc Print Date: 14/01/2009 4:41:00 PM...

  • Page 134: Instrument Removal

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Figure 54. Instrument Panel Layout – “Glass” Instrument Panel 13.2.3 INSTRUMENT REMOVAL Most instruments are secured to the panel with screws inserted through the panel face. To remove an instrument, disconnect wiring or pluming to the instrument, remove mounting screws and take instrument out from behind, or in some cases, from the front of the panel.

  • Page 135: Pitot - Static System Maintenance

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C 13.3.1 PITOT – STATIC SYSTEM MAINTENANCE Proper maintenance of pitot and static system is essential for proper operation of the altimeter, airspeed indicator and vertical speed indicator (if fitted). Leaks, moisture and obstructions in the pitot system will result in false airspeed indications, while static system malfunctions will affect readings of all three instruments.

  • Page 136: Pitot System Inspection & Leakage Test

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Use suitable fittings to connect lines together so that the altimeter is the only instrument still connected into the static pressure system. Repeat leakage test to check whether static pressure system or the bypassed instruments are the cause of the leakage.

  • Page 137: Removal & Installation Of Components

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C 13.3.5 REMOVAL & INSTALLATION OF COMPONENTS To remove pitot mast, remove the two rivets fastening it to the wing strut and pull it out from the strut far enough to disconnect the pitot line.

  • Page 138: Trouble Shooting - Airspeed Indicator

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C 13.3.7 TROUBLE SHOOTING – AIRSPEED INDICATOR Table 11. Trouble Shooting – Airspeed Indicator Trouble Probable Cause Remedy Test line and connections for Pitot pressure connection not leaks. Repair or replace properly connected to...

  • Page 139: Trouble Shooting - Vertical Speed Indicator (Option)

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Trouble Probable Cause Remedy Check other instruments and Leak in airspeed or vertical system plumbing for leaks. speed indicator installations Blow out lines, tighten connections 13.3.9 TROUBLE SHOOTING – VERTICAL SPEED INDICATOR (OPTION) Table 13.

  • Page 140: Figure 54. Pitot-Statice System - Water Trap Locations

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Figure 55. Pitot-Statice System – Water Trap Locations Dated : Feb 2006 Issued By: RAS Page: 140 of 171 REVISION L:\files\Technical_manuals\J230_J430\J230.J430_Work_files\J230-C_Tech_Rev_1.doc Print Date: 14/01/2009 4:41:00 PM...

  • Page 141: Figure 55. Pitot Assembly - Std Pitot

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Figure 56. Pitot Assembly – Std Pitot Dated : Feb 2006 Issued By: RAS Page: 141 of 171 REVISION L:\files\Technical_manuals\J230_J430\J230.J430_Work_files\J230-C_Tech_Rev_1.doc Print Date: 14/01/2009 4:41:00 PM...

  • Page 142: Figure 56. Static Probe System Assembly

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Figure 57. Static Probe System Assembly Dated : Feb 2006 Issued By: RAS Page: 142 of 171 REVISION L:\files\Technical_manuals\J230_J430\J230.J430_Work_files\J230-C_Tech_Rev_1.doc Print Date: 14/01/2009 4:41:00 PM...

  • Page 143: Tachometer

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Figure 58. Static System Test 13.4 TACHOMETER The tachometer is electronic and driven from a magnetic pick up. Should the tachometer fail to operate: Check 10amp instrument circuit breaker and re-set if necessary.

  • Page 144: Oil Pressure Gauge

    Check correct installation of magnetic sensor on engine (Refer to engine Instruction & Maintenance Manual) Refer to an Authorised Service Centre to have Alternator and Regulator checked. Refer instrument to VDO Service Centre or JABIRU AIRCRAFT Pty Ltd for inspection and possible repair. 13.5 OIL PRESSURE GAUGE The Oil Pressure Gauge is an electronic instrument.

  • Page 145: Cylinder Head Temperature Gauge

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Check wiring at Sender for security. Replace Sender. Replace Gauge. 13.7 CYLINDER HEAD TEMPERATURE GAUGE The Cylinder Head Temperature Gauge is a Thermo-couple instrument and is not connected to the aircraft electrical system. See Wiring Diagram Figure 59. Should the instrument fail to operate: Check for loose terminal connections and damage to wiring.

  • Page 146: Efis (Where Equipped)

    A detailed description of the instrument, it’s installation and operation can be found in the appropriate Dynon User & Installation manuals. In brief, the EMS is an electric instrument which in the J230-C generates a digital display of: • RPM •...

  • Page 147: 14 Section 14 - Electrical Systems

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C 14 SECTION 14 – ELECTRICAL SYSTEMS 14.1 ELECTRICAL POWER SUPPLY SYSTEM Electrical energy for the aircraft is supplied by a 12 volt, direct-current, single-wire, negative ground electrical system. A 12-volt battery supplies power for starting and furnishes a reserve source of power in the event of electrical power system failure.

  • Page 148: L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Figure 59. Wiring Diagram Sheet 1. Dated : Feb 2006 Issued By: RAS Page: 148 of 171 REVISION L:\files\Technical_manuals\J230_J430\J230.J430_Work_files\J230-C_Tech_Rev_1.doc Print Date: 14/01/2009 4:41:00 PM...

  • Page 149: L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Figure 60. Wiring Diagram Sheet 2. Dated : Feb 2006 Issued By: RAS Page: 149 of 171 REVISION L:\files\Technical_manuals\J230_J430\J230.J430_Work_files\J230-C_Tech_Rev_1.doc Print Date: 14/01/2009 4:41:00 PM...

  • Page 150: Bus Bars

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C 14.3 BUS BARS Electrical power for electrical equipment and installations is supplied through Bus Bars. The bus bars are mounted at the rear of the lower instrument panel. Access is gained by removing the main instrument panel (see Paragraph 13.2.1).

  • Page 151: Battery Box

    14.8 AUXILIARY POWER SOCKET The jabiru is fitted with an auxiliary power socket that accepts a 12V cigarette lighter plug. The circuit breaker for this plug is rated a 10 Amps. However it should be noted that the maximum continuous alternator output is also 10 Amps.

  • Page 152: L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Figure 61. VHF Antenna Installation Dated : Feb 2006 Issued By: RAS Page: 152 of 171 REVISION L:\files\Technical_manuals\J230_J430\J230.J430_Work_files\J230-C_Tech_Rev_1.doc Print Date: 14/01/2009 4:41:00 PM...

  • Page 153: 15 Section 15 - Painting & Finishing

    EXTERIOR 15.1.1 PAINTING The following painting procedure, as used at the Jabiru factory, had proven successful in ensuring good presentation of the aircraft. 2-part paint should be used for best results. Due to the variation between different paints, we recommend carefully following the pack recommendations relating to surface preparation and safety.

  • Page 154: L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Note: Prepare all parts separately and paint separately. Completely sand all outside surface area with 150 grit to give paint adhesion. The factory uses a Random Orbital Sander and 150mm Stickit discs.

  • Page 155: L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc

    You are now ready to spray final coat. GOOD LUCK! WARNING The Jabiru aircraft is only approved to be painted in basic White colour, so as to minimise the effects of heat and ultra-violet light to the aircraft structure. In addition, colour (including stripes etc) must not be applied to horizontal, upper surfaces.

  • Page 156: 16 Section 16 - Placards

    Pty Ptd Aircraft Service Manual Jabiru J230-C 16 SECTION 16 - PLACARDS 16.1 J230-C DECALS Table 14. J230-C Decals Decal Detail Preview Warning Placard P/No. 5A051A0D Fitted above windscreen in front of wing carry through beam across to the left side.

  • Page 157: L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Decal Detail Preview Loading Limitations P/No 5A056A0D Fitted on inside of fuselage of RHS of cabin below Rear Window. Engine Oil Details. P/No. 5A008A0D 1 OFF Attach to upper cowl beside oil door or to oil door itself.

  • Page 158: Cockpit Placards General

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C 16.2 COCKPIT PLACARDS GENERAL Table 15. General Cockpit Decals Decal Detail Preview LSA Warning decal P/No 5A060A0D To be fitted above the windscreen to the right of the Warning Placard Owners Manual...

  • Page 159: External Fuselage

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Decal Detail Preview Trim Position NOSE DOWN NEUTRAL TRIM NOSE UP BRAKE ON P/No5024094 Fitted on the Top of the Main Beam Beside the trim control Fuel Tap Position P/No 502319N...

  • Page 160: 17 Section 17 - Fairings

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Decal Detail Preview No Step P/No 5A006A0D Qty 2 Required Attach one to the top of each main wheel spat. Wing Bolt Tightening DANGER DO NOT TIGHTEN P/No 5039094 Qty 8 Required Attach to the fuselage and wings beside each wing, and lift strut attachment fitting.

  • Page 161: 18 Appendix I - Jabiru 3300 Engine

    Aircraft Service Manual Jabiru J230-C 18 APPENDIX I - JABIRU 3300 ENGINE Appendix 1 of this Manual is the Instruction and Maintenance Manual for the Jabiru 3300 engine. Please insert your copy of the INSTRUCTION AND MAINTENANCE MANUAL that comes with your engine into this section if you are printing this out.

  • Page 162: 19 Appendix Ii - Jabiru Engine Parts Book

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C 19 APPENDIX II - JABIRU ENGINE PARTS BOOK Please insert your copy of the INSTRUCTION AND MAINTENANCE MANUAL that comes with your engine into this section. THIS PAGE IS INTENTIALLY LEFT BLANK...

  • Page 163: 20 Appendix Iii - Engine Installation Manual

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C 20 APPENDIX III – ENGINE INSTALLATION MANUAL Please insert your copy of the INSTALLATION MANUAL that comes with your engine into this section. THIS PAGE IS INTENTIALLY LEFT BLANK Dated : Feb 2006...

  • Page 164: 21 Appendix Iv - Propeller Service Manual

    The Propellers are constructed from 4 laminations of approved species timber and are manufactured in accordance with the relevant approved Drawing. They are single piece 2 blade propellers with an inlaid leading edge (urethane). The propeller finish is a composite sheath, and clear epoxy paint (JABIRU Part No. PP0039N). WARNING ENSURE IGNITION SYSTEM IS "OFF"...

  • Page 165: Installation

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C DO NOT RUN ENGINE WITH PROPELLER DISCONNECTED OR ENGINE DAMAGE WILL RESULT. 21.4 INSTALLATION Refer to Figure 62. The Propeller is bolted to the Propeller Drive Flange with 6 x AN4 aircraft grade bolts attaching to Nyloc Nuts.

  • Page 166: L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc

    Jabiru Aircraft Pty Ptd Aircraft Service Manual Jabiru J230-C Figure 62. Propeller Installation Dated : May 2006 Issued By: RAS Page: 166 of 171 REVISION L:\files\Technical_manuals\J230_J430\J230.J430_Work_files\J230-C_Tech_Rev_1.doc Print Date: 14/01/2009 4:41:00 PM...

  • Page 167: To Remove Existing Propeller

    Propeller tips when rotating the Propeller by hand. Check that each blade clears the object by the same amount. If the Propeller is outside the approved tolerance, refer to JABIRU Aircraft Pty Ltd or a JABIRU Approved Service Centre. Maximum Tracking Error Tolerance is +/- 2mm.

  • Page 168: Servicing And Repairs

    Only nicks within the size tolerances described above may be repaired. All propellers with cracks or splits (or any delamination of the composite sheath in the case of sheathed Propellers) must be either Rejected as unserviceable or returned to JABIRU Aircraft Pty Ltd or our local approved agent for assessment and possible repair.

  • Page 169: Propeller Balancing Procedure

    The balance may only be corrected by the application of epoxy paint. Any other method of securing balance is PROHIBITED. Propellers outside these limits should be rejected as unserviceable or returned to JABIRU for assessment and possible repair. Dated : May 2006...

  • Page 170: 22 Appendix V - Airworthiness Limitations

    22.2 INTERIOR FLAME RETARDANT MAINTENANCE LIMITATIONS Most materials used in the interior upholstery of the J230-C have been treated with a flame retardant to meet the flammability requirements of LSA. This treatment must be renewed after an article has been washed 5 times.

  • Page 171: Revision Dated : Feb 2006 Issued By: Ras Page: 4 Of

    Jabiru Aircraft Pty Ptd Jabiru J230-C Airworthiness Limitations Table 19. Control Surface Balancing Limits Control Hinge Moment Limits Weight Limits Manual Section 56300g.mm 2200g 10.4 RUDDER BALANCE Rudder +/- 4000g.mm +/- 100g 94000g.mm 1150g 7.4.3 AILERON Aileron +/- 4000g.mm +/- 100g BALANCING 323300g.mm...

Table of Contents