Jabiru J120 Technical Manual
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Jabiru J120 Technical Manual

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This Manual has been prepared as a guide to correctly maintain Jabiru Aircraft Models.
It is the owner's responsibility to regularly check the Jabiru web site at www.jabiru.net.au for
applicable Service Bulletins and have them implemented as soon as possible. Manuals are also
updated periodically with the latest revisions available from the web site. Failure to maintain the
engine or aircraft with current service information may render the aircraft un-airworthy and void
This document is controlled while it remains on the Jabiru server. Once this no longer applies
Should you have any questions or doubts about the contents of this manual, please contact
TECHNICAL MANUAL
JABIRU AIRCRAFT MODELS:
J120 Variants
J160 Variants
J170 Variants
J200/J400 Variants
J230/J430 Variants
J250/J450 Variants
DOCUMENT No. JTM001-1
DATED: 6
Jabiru's Limited, Express Warranty.
the document becomes uncontrolled.
Jabiru Aircraft Pty Ltd.
FOR
th
April 2012

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  • Page 1 Jabiru’s Limited, Express Warranty. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. Should you have any questions or doubts about the contents of this manual, please contact...

  • Page 2: Table Of Contents

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Table of Contents TABLE OF CONTENTS....................... 2 TABLE OF FIGURES ............................6 LIST OF TABLES ............................10 SECTION 2 – SERVICE MANUAL ..................11 FOREWORD / APPLICABILITY ........................11 LIST OF EFFECTIVE PAGES / ISSUE STATUS ...................14...
  • Page 3 Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants INTERIOR SURFACES ..........................57 EXTERIOR SURFACES ..........................57 ALUMINIUM SURFACES ..........................57 ENGINE AND ENGINE COMPARTMENT .....................58 PROPELLER ..............................58 WHEELS ................................58 FUSELAGE ........................59 FUSELAGE ..............................59 WINDSHIELD AND WINDOWS ........................59 J160-TYPE CABIN DOORS ...........................61...
  • Page 4 Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants 8.21 BRAKE LINING INSTALLATION .........................109 8.22 BRAKE SYSTEM BLEEDING ........................109 8.23 BRAKE PAD ADJUSTMENT ........................110 8.24 BRAKE DISC WEAR LIMIT .........................110 8.25 TROUBLE SHOOTING - BRAKES ......................111 AILERON CONTROL SYSTEM ..................
  • Page 5 Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants 14.3 FUEL TANKS ...............................182 14.4 FUEL VENTS ...............................184 14.5 FUEL SHUT-OFF VALVE ..........................185 14.6 FUEL GAUGES ............................186 14.7 FUEL FILTERS ............................189 14.8 FUEL PUMPS ..............................189 INSTRUMENTS &...

  • Page 6: Table Of Figures

    JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants TABLE OF FIGURES Figure 1 – J120-C General Arrangement ........................20 Figure 2 – J160 General Arrangement ........................21 Figure 3 – J170-C & Variants General Arrangement....................22 Figure 4 – J170-D General Arrangement ........................23 Figure 5 –...
  • Page 7 Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 47 – J230 Wing Assembly Sheet 2 (Ser 13) ....................79 Figure 48 – J230 Wing Assembly Sheet 3 (Ser 13) ....................79 Figure 49 – J250 Family Wing Assy (SP-I Type) ......................80 Figure 50 –...
  • Page 8 Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 96 – Commutator Ring Close-Up ........................127 Figure 97 – Flap Controls – Sheet 1 (Fibreglass Motor Mount) ................128 Figure 98 – Flap Controls – Sheet 1 (Aluminium Motor Mount) ................128 Figure 99 –...
  • Page 9 Figure 178 – Alternate Static Source Assy ....................... 203 Figure 179 – Hall Effect Sensor Wiring (For Tach with Jabiru Logo on Face) ............204 Figure 180 – Hall Effect Sensor Inst. (For Tach with Jabiru Logo on Face) ............205 Figure 181 –...

  • Page 10: List Of Tables

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants LIST OF TABLES Table 1 – Recommended Bolt Torque Values ......................17 Table 2 – J120-C Specifications ..........................20 Table 3 – J160 Specifications ............................. 21 Table 4 –...

  • Page 11: Section 2 - Service Manual

    J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Section 2 – Service Manual FOREWORD / APPLICABILITY  This manual contains JABIRU recommended procedures and instructions for ground handling, servicing and maintaining the following Jabiru aircraft models: J120 Kit-built J120 aircraft. J120-C...
  • Page 12 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.
  • Page 13 Jabiru harmless from any injury, loss, damage, or mishap that I, my spouse, heirs, or next of kin may suffer as a result of my use of any Jabiru product, except to the extent due to gross negligence or willful misconduct by Jabiru. I understand that proper skills and training are essential to minimize the unavoidable risks of property damage, serious bodily injury and death that arise from the use of Jabiru products.

  • Page 14: List Of Effective Pages / Issue Status

    AIRCRAFT Pty Ltd. These are distributed directly to owners of factory-built aircraft in addition to being posted on the JABIRU website or provided to your local distributor. New owners of pre-owned aircraft should ensure that the transfer of their aircraft has been advised to JABIRU AIRCRAFT Pty Ltd or your Jabiru representative so that our owner databases can be updated.

  • Page 15: Calibrations

    The steerable nose gear is a welded metal, trailing link assembly with rubber springs.  The aircraft are equipped with a JABIRU, 4 cylinder, 4 stroke engine of around 80hp or a JABIRU 6- cylinder, 4-stroke engine of around 120hp. Both engines are optimised to drive a 2-bladed, wooden, fixed pitch propeller.

  • Page 16: Owner Maintenance

    All Jabiru Aircraft, including factory-built models, have been specifically designed as 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 wherever this is allowed by the aircraft’s operating category.

  • Page 17: Standard Practices

    AIRCRAFT STRUCTURE  In all Jabiru Aircraft, due to the 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.

  • Page 18: Engines

    2.15 ENGINES  The engines used in Jabiru Aircraft are not discussed within this manual. For details of installation, maintenance and overhaul refer to the engine manuals appropriate to the engine model.  Up-to-date engine manuals are available from the Jabiru Aircraft website; www.jabiru.net.au.

  • Page 19: Aircraft Specifications

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants 2.16 AIRCRAFT SPECIFICATIONS 2.16.1 UNIVERSAL SPECIFICATIONS Item Specification  AVGAS 100LL or 100/130.  MOGAS with Octane Rating 95 RON (AKI 90) or above ...

  • Page 20: Figure 1 – J120-C General Arrangement

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants 2.16.2 J120-C Table 2 – J120-C Specifications Model J120-C Other J120 Variants 500kg 500kg Aircraft Maximum Weight (1102lb) (1102lb) Fuel Capacity 65 litres 65 litres Oil Capacity 2.3 litres...

  • Page 21: Figure 2 – J160 General Arrangement

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Table 3 – J160 Specifications Other J160 Model J160-C J160-D Variants 540kg 540kg 544kg Aircraft Maximum Weight (1190lb) (1190lb) (1190lb) Fuel Capacity 135 litres 135 litres...

  • Page 22: Figure 3 – J170-C & Variants General Arrangement

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Table 4 – J170 Specifications J170-C J170-UL Other J170 Model Variants J170-D (Europe Kit) 600kg 450kg 544kg Aircraft Maximum Weight (1320lb) (992lb) (1190lb) Fuel Capacity...

  • Page 23: Figure 4 – J170-D General Arrangement

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 4 – J170-D General Arrangement REVISION Dated: Nov 2011 Issued By: SW Page: 23 of 233...

  • Page 24: Figure 5 – J200 / J400 General Arrangement

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Table 5 – J200/J400 Specifications Model J200 J400 Number of Seats 700kg Aircraft Maximum Weight 700kg 544kg (category limitation) Fuel Capacity 135 litres 135 litres Oil Capacity 3.5 litres...

  • Page 25: Figure 6 – J230 / J430 General Arrangement

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Table 6 – J230/J430 Specifications Other J230 Model J230-C, J230-D J430 Variants Number of Seats 700kg Aircraft Maximum Weight 600kg 544kg (category 700kg limitation) Fuel Capacity...

  • Page 26: Figure 7 – J250 / J450 General Arrangement

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Table 7 – J250/J450 Specifications Model J250 J450 Number of Seats 700kg Aircraft Maximum Weight 700kg 544kg (category limitation) Fuel Capacity 135 litres 135 litres Oil Capacity 3.5 litres...

  • Page 27: Ground Handling & Storage

    J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Ground Handling & Storage TOWING  All Jabiru aircraft are relatively light and should always be moved by hand.  Moving the aircraft is accomplished by using the wing struts, prop hub or landing gear struts as push points.

  • Page 28: Hoisting

    Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Do not lift using control surfaces. Damage to the control surface or control system may result. Place a padded trestle or similar under the front of the fuselage immediately aft of the cowl outlet to ensure that the nose cannot drop down if the aircraft balance is disturbed.

  • Page 29: Storage

    CAUTION Ensure that the Master and Ignition Switches are OFF before turning motor! WARNING Do not store MOGAS or fuels containing alcohol for longer than 30 days in a Jabiru aircraft. Refer to Service Letter JSL007 for details.  Store under cover, away from direct sunlight.
  • Page 30 Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Every 7 days the propeller should be rotated through 5 revolutions without running the engine – leave propeller in the horizontal position. CAUTION Ensure that the Master and Ignition Switches are OFF before turning motor! 3.7.4 INSPECTION DURING STORAGE...

  • Page 31: Inspection & Servicing

    4.2.1 AIRFRAME  At intervals of 5000 hours the Jabiru (all models) airframe must be subject to an overall condition inspection by Jabiru Aircraft or an aircraft maintainer authorised by Jabiru Aircraft. As part of this inspection, wing struts must be disassembled, inspected for damage using appropriate NDT methods (such as dye-penetrant testing).

  • Page 32: Inspection Chart

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants INSPECTION CHART  The engine Instruction Manual also details engine inspection schedules and should be consulted in addition to this chart.  The chart below shows the recommended intervals at which items are to be inspected.
  • Page 33 Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Annual Inspection Each 200 Hours Each 100 Hours Fuel Hoses, lines, fire-sleeve & fittings SCAT Hose Condition Electrical wiring Engine controls and linkages Engine mounts, mount structure...
  • Page 34 Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Annual Inspection Each 200 Hours Each 100 Hours Main gear wheels & fairings Nose gear wheel, steering links, tension links & fairings Wheel bearings Nose gear strut Nose gear housing &...
  • Page 35 Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Annual Inspection Each 200 Hours Each 100 Hours Pitot & static system Radio, intercom & headsets Antenna & cable Door catches Stall warning Battery, battery cradle & cables...

  • Page 36: Servicing

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Annual Inspection Each 200 Hours Each 100 Hours Rigging check flight Throttle controls Control Surfaces per Section 4.17 ** Note that the control clearance inspection detailed in Section 4.17 must also be carried out at any time when the control rigging may have been altered –...

  • Page 37: Engine Pre-Inspection Run-Up

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants of exported aircraft should check with their own aviation officials to determine their individual requirements. To be displayed in the aircraft at all times: ...
  • Page 38 Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants  It is recommended that the engine compartment be visually inspected twice: once while “dirty” – i.e. fresh from operation – and again after cleaning. The “dirty” inspection allows the inspector to see patterns of leakage etc which are lost when the engine compartment is cleaned while the “clean”...

  • Page 39: Fuel System 100-Hourly

    Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants If the aircraft is using a fuel blend containing alcohol the operator must be aware that flexible fuel lines will generally age faster when exposed to alcohol. Additional care must be taken to monitor fuel system condition.

  • Page 40: Airframe 100-Hourly

    Refer to Section 8.19 for filling and bleeding of the brake system. 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.

  • Page 41: Control Systems 100-Hourly

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants  Inspect the fresh air vents for correct function and condition.  Inspect the cabin heat system for correct function and condition.  Ensure the carbon monoxide indicator (if equipped) has not expired.

  • Page 42: Special Inspections - Propeller

    6. Take the wheel weights. When the wheel weights are being taken there must be nil wind blowing on the aircraft. Due to the light nature of the Jabiru even a small breeze can cause significant weight transfer and consequentially C of G errors. In addition, door must be shut, flaps in the UP position and any items not part of the standard equipment of the aircraft removed.

  • Page 43: Figure 9 – Weighing Diagram

    JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants NOTE: The CG datum point for the J120-C is an imaginary line 1403mm forward of the right wing leading edge. Most CG calculations must be carried out relative to this datum. Figure 9 – Weighing Diagram.

  • Page 44: Special Inspections - Control Cables

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants SPECIAL INSPECTIONS – CONTROL CABLES 4.16  Inspections are required to be carried out on the primary control cables (aileron, elevator & rudder) at intervals detailed in the Airworthiness Limitations Section of this Manual (Appendix V or Section 23).

  • Page 45: Special Inspections - Control Surfaces

    4.3. In addition they must be repeated at any time when the control rigging may have been altered – i.e. if a control is removed, repaired or adjusted.  If the inspection shows that the aircraft requires adjustment Jabiru Aircraft or our local representative must be consulted for an appropriate rectification method. ...

  • Page 46: Figure 11 – Rudder Gap Cross Section

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Note the result of Inspection A and carry on to Inspection B in all cases. 4.17.2 INSPECTION B:  This inspection has two purposes: to check to see if jamming is likely due to insufficient clearance at the control’s point of overlap and to check if the control hinges are sufficiently stiff.

  • Page 47: Figure 12 – Aileron Clearance

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Control at the point of Use gauges (such as the 3mm type shown), vernier callipers or a ruler to overlap - Leading edge of aileron in line with trailing...

  • Page 48: Figure 15 – Scratches On Rudder

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants 4.17.3 INSPECTION C:  This inspection is to see if there is any travel restriction of a control at deflections other than at the control’s point of overlap.

  • Page 49: Special Inspections - Main Wheel Alignment

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants SPECIAL INSPECTIONS – MAIN WHEEL ALIGNMENT 4.18  The following process must be carried out whenever a new undercarriage leg is fitted to the aircraft or if adverse tyre wear indicates alignment outside of tolerance.

  • Page 50: Figure 18 – Alignment Measurements

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 18 – Alignment Measurements  Mark the position of the straight edge in front and behind the wheels. Positions are marked at 1.5m nominally either side of the wheel centre.

  • Page 51: Figure 19 – Camber / Toe-In Adjustment

    Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants aircraft forwards to allow the undercarriage legs to “set” to the new angles. Alternatively the wheel may be re-assembled with flock etc, left to cure and then re-checked once the resin has dried.

  • Page 52: Special Inspections - Fuel Gauge Decal Setup

    SPECIAL INSPECTIONS – FUEL GAUGE DECAL SETUP 4.19  This procedure is applicable for Jabiru Aircraft equipped with wing tanks and electronic fuel gauge senders.  This procedure must be carried out during initial assembly of a new aircraft or when a new gauge sender is fitted.

  • Page 53: Figure 21 - Fuel Gauge Calibration Decal Parts

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 21 - Fuel Gauge Calibration Decal Parts Figure 22 – 20L Indication on Sender & Decal to Match REVISION Dated: Nov 2011 Issued By: SW...

  • Page 54: Special Inspections - Fuel Sender Calibration

    SPECIAL INSPECTIONS – FUEL SENDER CALIBRATION 4.20  This procedure explains how to calibrate the inbuilt gauges in the Dynon EMS D10 unit to the Jabiru Float type gauges.  This procedure is applicable for Jabiru Aircraft equipped with wing tanks and electronic fuel gauge senders.

  • Page 55: Figure 24 – Fuel Line Clamps

    Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Remove the fuel drain from each fuel tank at a time and drain the fuel out this way. This method is faster than the previous but has the potential for spilling a lot of fuel. You also still need to drain fuel from the header tank via the engine fuel line.

  • Page 56: Figure 25 – Ems Calibration Screen #1

    Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants WARNING Before removing clamps on the fuel line make sure all fuel lines are connected. On removal of clamps check that the fuel lines are not damaged and return to their original shape Figure 25 –...

  • Page 57: Cleaning

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants CLEANING  Keeping the aircraft clean is important. Besides maintaining the appearance of the aircraft, cleaning makes inspection and maintenance easier. WINDSHIELD AND WINDOWS ...

  • Page 58: Engine And Engine Compartment

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants ENGINE AND ENGINE COMPARTMENT  The engine should be kept clean since dirty cooling fins and baffles can cause overheating of the engine. Also, cleaning is essential to minimise any danger of fire and provide easy inspection of components.

  • Page 59: 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 6.2.1 DESCRIPTION  The windshield and windows are one-piece acrylic plastic panels set in sealing strips with Epoxy Resin &...
  • Page 60 Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants 6.2.5 SCRATCHES  Scratches on clear plastic surfaces can be removed by hand buffing and polishing using Plastic Polish available from JABIRU as Part No.: NOVUS#2.

  • Page 61: J160-Type Cabin Doors

    An optional cylinder and key lock is available. When fitted, the keyed barrel lock is located in the fuselage at the rear of the Port, Starboard & Rear doors. Spare keys are available to registered owners on request to Jabiru or our local authorized representative. J160-TYPE CABIN DOOR LATCHES 6.4.1 DESCRIPTION...

  • Page 62: Figure 27 – J160-Type Door Hinge Assy

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 27 – J160-Type Door Hinge Assy Figure 28 – J160-Type Door Assembly REVISION Dated: Nov 2011 Issued By: SW Page: 62 of 233...

  • Page 63: Figure 29 – J120-Type Door Assembly

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 29 – J120-Type Door Assembly Figure 30 – J200-Type Door Assembly (J160-Type) REVISION Dated: Nov 2011 Issued By: SW Page: 63 of 233...

  • Page 64: Figure 31 – J160-Type Rear Door Assy

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 31 – J160-Type Rear Door Assy Figure 32 – J160-Type Door Latch Mechanism Assembly REVISION Dated: Nov 2011 Issued By: SW Page: 64 of 233...

  • Page 65: J200 Type Cabin Doors

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 33 – Top Door Catch Assy J200 TYPE CABIN DOORS 6.5.1 DESCRIPTION  J200-Type cabin doors are those which use the door hinge assembly shown in Figure 34 and the latch shown in Figure 37.

  • Page 66: J200-Type Cabin Door Latches

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants J200-TYPE CABIN DOOR LATCHES 6.6.1 DESCRIPTION  There is one main latch on each door of a simple spring type. This is complemented by a catch at the top front quadrant of each door.

  • Page 67: Figure 35 – J200-Type Front Door Assembly

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 35 – J200-Type Front Door Assembly Figure 36 – J200-Type Rear Door Assy REVISION Dated: Nov 2011 Issued By: SW Page: 67 of 233...

  • Page 68: Seats

    The seats are an integral part of the structure of the aircraft and must not be modified. 6.7.4 REPAIR  As seats are integral to the aircraft structure, any repair must be referred to Jabiru Aircraft Pty Ltd or our local approved representative. REVISION...

  • Page 69: Upholstery

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants UPHOLSTERY  Seat upholstery is provided through slip-on covers. These are easily removed for cleaning and inspection of the seat structures.  Optional Hood and Cabin lining is available, together with Door Pockets.

  • Page 70: Wings & Empennage

    J170 wing could be fitted to a J120 airframe without modification while the same wing has virtually all its component parts in common with the J230 wing.  Accordingly, in this section there is a degree of cross referencing – i.e. the J120 section refers to the J160 wing for details of the control system. ...

  • Page 71: J160 Wings

    Repeat Steps above to remove other wing. 7.2.3 REPAIR  All repairs must be referred to Jabiru Aircraft Pty Ltd or our approved local agent. 7.2.4 INSTALLATION Fit the lower strut attaching bolt, leaving the top end of the strut on the ground.
  • Page 72 Repeat Steps above to remove other wing. 7.3.3 REPAIR  All repairs must be referred to Jabiru Aircraft Pty Ltd or our approved local agent. 7.3.4 INSTALLATION Fit the lower strut attaching bolt, leaving the top end of the strut on the ground.

  • Page 73: Figure 38 – J160 Wing Assembly Sheet 1 (Ser X)

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 38 – J160 Wing Assembly Sheet 1 (Ser X) Figure 39 – J160 Wing Assembly Sheet 2 (Ser X) REVISION Dated: Nov 2011 Issued By: SW...

  • Page 74: Figure 40 – J160 Wing Assembly Sheet 1 (Ser Xiv)

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 40 – J160 Wing Assembly Sheet 1 (Ser XIV) Figure 41 – J160 Wing Assembly Sheet 2 (Ser XIV) REVISION Dated: Nov 2011 Issued By: SW...

  • Page 75: J170 Wings

    For these aircraft, refer to Figure 44 and Figure 45 for details. 7.4.2 REMOVAL  Refer to Section 7.3 for removal details. 7.4.3 REPAIR  All repairs must be referred to Jabiru Aircraft Pty Ltd or our approved local agent. REVISION Dated: Nov 2011 Issued By: SW Page: 75 of 233...

  • Page 76: Figure 43 – J170 Friese Aileron Installation

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants 7.4.4 INSTALLATION  Refer to Section 7.3 for installation details. Figure 43 – J170 Friese Aileron Installation Figure 44 – J170-UL Wing Assy Sheet 1 (Ser IX)

  • Page 77: J200 Wings

    7.5.2 REMOVAL  Refer to Section 7.3 for removal details. 7.5.3 REPAIR  All repairs must be referred to Jabiru Aircraft Pty Ltd or our approved local agent. 7.5.4 INSTALLATION  Refer to Section 7.3 for installation details. REVISION Dated: Nov 2011...

  • Page 78: J230 Wings

     Refer to Section 7.3 for removal details. 7.6.3 REPAIR  All repairs must be referred to Jabiru Aircraft Pty Ltd or our approved local agent. 7.6.4 INSTALLATION  Refer to Section 7.3 for installation details. Figure 46 – J230 Wing Assembly Sheet 1 (Ser 13)

  • Page 79: Figure 47 – J230 Wing Assembly Sheet 2 (Ser 13)

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 47 – J230 Wing Assembly Sheet 2 (Ser 13) Figure 48 – J230 Wing Assembly Sheet 3 (Ser 13) REVISION Dated: Nov 2011 Issued By: SW...

  • Page 80: J250 / J450 Wings

    Note that early example of this wing type used plain flaps - where the flap is similar in cross-section to the aileron and pivots on simple hinges built directly into the trailing edge of the wing (Figure 49). Later versions used slotted flaps similar in design to those used on all other Jabiru wings (Figure 50). 7.7.2 REMOVAL ...

  • Page 81: Wing Struts

    See above for the wing removal section relevant to the particular aircraft. 7.8.2 REPAIR  Wing struts are structural components and therefore all repairs must be referred to Jabiru Aircraft Pty Ltd or our approved local agent.  A dented, cracked or deformed wing strut should be replaced prior to next flight.

  • Page 82: Landing Light(S)

    LANDING LIGHT(S) 7.9.1 DESCRIPTION  Landing / taxi lights are optional equipment for Jabiru Aircraft.  Night-VFR variants have a wing-strut mounted housing on each wing strut with narrow-beam high intensity lights fitted. Smaller wide-beam lights are used in similar housings for day-VFR aircraft.

  • Page 83: Figure 52 – Night-Vfr Lighting Aim Diagram

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants 15 meters Figure 52 – Night-VFR Lighting Aim Diagram Figure 53 – Night-VFR Landing / Taxi Light Assy REVISION Dated: Nov 2011 Issued By: SW...

  • Page 84: Dynon Pitot

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 54 – Day-VFR Light Assembly 7.11 DYNON PITOT 7.11.1 DESCRIPTION  As a part of the optional Dynon instrumentation system a special pitot head can be used which allows the measurement of the angle of attack of the aircraft in flight.

  • Page 85: Wing Inspection Window

    WING INSPECTION WINDOW 7.12.1 DESCRIPTION  All Jabiru Aircraft have a small acrylic window in the underside of the wing to allow inspection of the outboard aileron clamp.  In some models this window is a simple rectangular piece of clear acrylic screwed to the wing using machine screws and anchor nuts.

  • Page 86: Fin

    7.13.1 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. 7.14 HORIZONTAL STABILISER ...

  • Page 87: Landing Gear & Brakes

     Due to space constraints not all different variations are shown herein. When ordering spare parts provide as must detail as possible – part description, aircraft model, serial number etc to Jabiru to ensure accurate part identification. MAIN UNDERCARRIAGE REMOVAL (JACKING) ...

  • Page 88: Main Wheel Fairing (Spats)

    MAIN WHEEL FAIRING (SPATS) 8.3.1 DESCRIPTION  Jabiru Aircraft are equipped with fairings for the main and nose wheel. These streamlined covers reduce the drag of the undercarriage and significantly improve the efficiency of the aircraft. 8.3.2 REMOVAL AND INSTALLATION Remove the bolt on the outside of the fairing.

  • Page 89: Main Gear Top Fairing (Speed Fairing)

    MAIN GEAR TOP FAIRING (SPEED FAIRING) 8.4.1 DESCRIPTION  Jabiru Aircraft are equipped with fairings between the main leg and the fuselage. These smooth the airflow in this area and significantly improve the efficiency of the aircraft. 8.4.2 REMOVAL AND INSTALLATION ...
  • Page 90 Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants If excessively warped or scored or worn to a thickness of 2 mm, brake discs should be replaced with a new part. Sand smooth small nicks and scratches.

  • Page 91: Figure 58 – Main Wheel To Leg Assy

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 58 – Main Wheel to Leg Assy Figure 59 – Main Wheel Assembly REVISION Dated: Nov 2011 Issued By: SW Page: 91 of 233...

  • Page 92: Main Wheel Stub Axle

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 60 – Directional Brake Disc Installation MAIN WHEEL STUB AXLE 8.6.1 DESCRIPTION  A steel stub axle is bolted to the outboard end of the undercarriage leg.

  • Page 93: Wheel Balancing

    If the flock has degraded, clean off any loose pieces. Flock the clamp to the leg (Flock made by mixing Jabiru Epoxy resin and cotton fibre flock to a gluey consistency). Do not tighten bolts while the resin is wet.

  • Page 94: Trouble Shooting - Main Undercarriage

    For the leg shown in Figure 61, inspect the outboard clamp flock bed & re-flock if damaged. WARNING Repairs to the composite undercarriage beams must be referred to JABIRU AIRCRAFT Pty Ltd or our local approved agent. TROUBLE SHOOTING – MAIN UNDERCARRIAGE Table 10 –...

  • Page 95: Figure 61 – Main Undercarriage (Type 1)

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 61 – Main Undercarriage (Type 1) Figure 62 – Main Undercarriage Assembly (Type 2) REVISION Dated: Nov 2011 Issued By: SW Page: 95 of 233...

  • Page 96: Nose Wheel Speed Fairing (Spat)

    8.10 NOSE WHEEL SPEED FAIRING (SPAT) 8.10.1 DESCRIPTION  Jabiru Aircraft are equipped with a nose wheel speed fairing (wheel spat).  This fairing smoothes the airflow around the nose wheel and significantly improves the efficiency of the aircraft. ...

  • Page 97: Figure 63 – Nose Wheel Hub Assembly

    Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants 8.11.4 NOSE WHEEL INSPECTION AND REPAIR Clean metal parts in solvent and dry thoroughly. Inspect wheel halves for cracks. Cracked wheel halves should be discarded and new parts used.

  • Page 98: Nose Wheel Steering / Centring System

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants 8.12 NOSE WHEEL STEERING / CENTRING SYSTEM 8.12.1 DESCRIPTION  For all models the nose wheel steering system consists pushrods directly connecting the rudder pedals to the nose leg assembly. The systems are shown in Section 12. For some models a “soft link”...

  • Page 99: Nose Undercarriage Leg

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 65 – Nose Leg Soft Link Assy (J200 Family) 8.13 NOSE UNDERCARRIAGE LEG 8.13.1 DESCRIPTION  The nose gear comprises a steerable nose wheel mounted on a welded steel assembly with an aluminium wheel yoke and a rubber spring system.
  • Page 100 Inspect bolts/nuts for torque – see “thick lamination” torque values in Table 1.  Repairs to the welded nose leg assembly beam must be referred to Jabiru Aircraft Pty Ltd or our approved local agent. 8.13.4 NOSE GEAR END FLOAT ADJUSTMENT ...

  • Page 101: Trouble Shooting - Nose Leg

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Nose leg Allow the resin to cure. Remove the leg and clean off any excess grease or rough edges. Apply graphite lubricant to the leg / housing. Check for full and free movement.

  • Page 102: Nose Wheel Balancing

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Trouble Probable Cause Remedy Nose strut bolts loose Tighten bolts Loose or worn steering link Tighten, replace defective parts Nose wheel shimmy Nose wheel out of balance Refer Section 8.7...

  • Page 103: Figure 68 – Nose Leg Assy

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 68 – Nose Leg Assy Figure 69 – Nose Leg Assy – Long Trail (J160 Family) REVISION Dated: Nov 2011 Issued By: SW Page: 103 of 233...

  • Page 104: Nose Leg Housing

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 70 – Fabricated Nose Wheel Yoke Assy 8.16 NOSE LEG HOUSING 8.16.1 DESCRIPTION  The nose leg housing is a structure bolted on to the lower, middle of the firewall. The nose leg tube runs in Ertalyte bushes which are bonded into this housing.

  • Page 105: Brake Master Cylinder

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants 8.16.4 INSTALLATION  Reverse procedure above for installation.  Loctite 620 must be applied to the assembly screws for the aluminium housing: Clean the threads in the aluminium parts using a ¼” UNC tap.
  • Page 106 Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants 8.17.2 BRAKE MASTER CYLINDER REMOVAL & INSTALLATION  The following procedure applies to brake cylinder installations inside the centre console, between the seats: Remove the flexible hose from one wheel brake assembly and drain the fluid from the brake system.

  • Page 107: Figure 72 – Brake Master Cylinder & Lever Assy (Type 1)

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 72 – Brake Master Cylinder & Lever Assy (Type 1) Figure 73 – Brake Master Cylinder & Lever Assy (Type 2) REVISION Dated: Nov 2011...

  • Page 108: Hydraulic Brake Lines

    HYDRAULIC BRAKE LINES 8.18.1 DESCRIPTION  Jabiru Aircraft use flexible black nylon brake hoses. On most models they are connected to the master cylinder via a tee-piece – typically located in the main undercarriage channel under the belly of the aircraft.

  • Page 109: Parking Brake

    NOTE: A replacement kit for brake pads and rivets is available from Jabiru Aircraft. Align the new lining on the pad plate and place the brake rivet in the hole with the rivet head in the lining.

  • Page 110: Brake Pad Adjustment

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants When air is fully expelled, tighten bleed nipples & check fittings for leaks. Repeat steps 1-4 for other side brake. WARNING Use only automotive brake fluid. DO NOT use aircraft hydraulic fluid or damage will result.

  • Page 111: Trouble Shooting - Brakes

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants 8.25 TROUBLE SHOOTING - BRAKES Table 12 – Trouble Shooting – Brakes Trouble Probable Cause Remedy Brake handle binding Check and adjust Worn or broken master cylinder...

  • Page 112: Figure 75 – Single Calliper Detail (Non Quick Change)

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 75 – Single Calliper Detail (Non Quick Change) Figure 76 – Single Calliper (Legacy Brake System) REVISION Dated: Nov 2011 Issued By: SW Page: 112 of 233...

  • Page 113: Aileron Control System

     Due to space constraints not all different variations are shown herein. When ordering spare parts provide as must detail as possible – part description, aircraft model, serial number etc to Jabiru to ensure accurate part identification. WARNING All spherical bearings must be fitted with a large washer on the outside of the through-bolt to prevent the bearing case and cable releasing in the event of a bearing failure.

  • Page 114: Figure 78 – Aileron System Schematic – Type 2

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 78 – Aileron System Schematic – Type 2. Figure 79 – Aileron System Schematic – Type 3. REVISION Dated: Nov 2011 Issued By: SW...

  • Page 115: Control Column

     Refer to drawings below: Figure 77, Figure 78 and Figure 79.  Jabiru Aircraft have a single control shaft running between the seats on which the control stick is mounted. 9.2.2 CONTROL COLUMN REMOVAL If required, unbolt & remove the control stick from the pivot plate.

  • Page 116: Figure 81 – Control Column Assy – Type 2

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 81 – Control Column Assy – Type 2 Figure 82 – Control Column Assy – Type 3 REVISION Dated: Nov 2011 Issued By: SW...

  • Page 117: Control Cables

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants CONTROL CABLES 9.3.1 DESCRIPTION  Control Cables are of the enclosed push-pull type, fitted with spherical bearings at both ends. To operate, the outer cover of the cable must be clamped firmly at each end.

  • Page 118: Figure 84 – Clamp Comparison & Installation (Rudder Cable)

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Trim Cable Clamp Primary Control Cable Clamp Rudder cable clamp properly installed. (note that it is larger Note seal pulled back slightly (note square corner of clamp)

  • Page 119: Figure 87 – Cable & Clamp Comparison

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Crimp visible in trim cable fitting. Clamp locking slots Figure 87 – Cable & Clamp Comparison Clamps correctly assembled. Locking Clamps incorrectly assembled. Locking tangs correctly fitted, clamp fitting...

  • Page 120: Ailerons

    Section 4.17 refers.  Repairs must be referred to Jabiru Aircraft Pty Ltd or our approved local agent. 9.4.4 AILERON BALANCING ...

  • Page 121: Figure 89 – Aileron Stops – Type 1

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants  Check UP travel on both ailerons using the Aileron Rigging Template (see Appendix 3).  Use the Aileron Control Stop adjustment on the central control shaft to adjust the total aileron movement (i.e.

  • Page 122: Figure 90 – Aileron Stops – Type 2

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 90 – Aileron Stops – Type 2 Figure 91 – Aileron Stops – Type 3 REVISION Dated: Nov 2011 Issued By: SW Page: 122 of 233...

  • Page 123: Wing Flap Control System

     Due to space constraints not all different variations are shown herein. When ordering spare parts provide as must detail as possible – part description, aircraft model, serial number etc to Jabiru to ensure accurate part identification. WARNING All spherical rod end bearings must be fitted with a large washer on the outside of the through- bolt to prevent the bearing case and cable releasing in the event of a bearing failure.

  • Page 124: Figure 93 – J200 Family Manual Flap System Sheet 1

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 93 – J200 Family Manual Flap System Sheet 1 Figure 94 – J200 Family Manual Flap System Sheet 2 REVISION Dated: Nov 2011 Issued By: SW...

  • Page 125: Manual Flap Lever Assy

    MANUAL FLAP LEVER ASSY 10.2.1 DESCRIPTION  Many Jabiru Aircraft are fitted with a manual flap system similar to that shown in Figure 92. In these systems the pilot pulls down on the lever to lower the flaps.  3 positions are available: up, first stage and second stage. The positions are controlled by the position of holes in the lever mounting plate.

  • Page 126: Figure 95 – Linear Actuator Disassembled

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants 10.3.3 INSPECTION & REPAIR  Note that while the pictures below show the motor removed, it is possible to carry out this work with the motor still fitted to the aircraft.

  • Page 127: Figure 96 – Commutator Ring Close-Up

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Gaps between segments ring must Commutator Ring. cleaned. Black material must be removed. Figure 96 – Commutator Ring Close-Up 10.3.4 INSTALLATION  Installation is the reverse of removal.

  • Page 128: Figure 97 – Flap Controls – Sheet 1 (Fibreglass Motor Mount)

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 97 – Flap Controls – Sheet 1 (Fibreglass Motor Mount) Figure 98 – Flap Controls – Sheet 1 (Aluminium Motor Mount) REVISION Dated: Nov 2011...

  • Page 129: Figure 99 – Flap Controls – Sheet 2

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 99 – Flap Controls – Sheet 2 Figure 100 – Flap Controls – Sheet 3 (Fibreglass Motor Mount) REVISION Dated: Nov 2011 Issued By: SW...

  • Page 130: Figure 101 – Flap Controls – Sheet 3 (Aluminium Motor Mount)

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 101 – Flap Controls – Sheet 3 (Aluminium Motor Mount) Figure 102 – J200 Family Electric Flap System Sheet 1 REVISION Dated: Nov 2011...

  • Page 131: Flap Cross Shaft Assembly

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 103 – J200 Family Electric Flap System Sheet 2 10.4 FLAP CROSS SHAFT ASSEMBLY 10.4.1 DESCRIPTION  As shown above the flaps are driven via a shaft which runs from one side of the fuselage to the other.

  • Page 132: Figure 104 – Flap Cross Tube Assy J160 Family

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants 10.4.4 FLAP CROSS SHAFT INSTALLATION  Installation procedure is the reverse of assembly.  After installing carry out a test run while watching the external flap drive arms. Ensure the arms do not rub against the fuselage or wing mounts.

  • Page 133: Flap Position Indicator

    FLAP POSITION INDICATOR 10.5.1 DESCRIPTION  2 different flap position indicators have been used in Jabiru Aircraft (plus the manual handle which also acts as the position indicator for manual flap variants).  Both indicators consist of a cable-driven indicator which moves inside a housing. Indicators are mounted to the windscreen / door pillars.

  • Page 134: Figure 106 – Flap Position Indicator – Type 1

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 106 – Flap Position Indicator – Type 1 Figure 107 – Flap Position Indicator – Type 2 REVISION Dated: Nov 2011 Issued By: SW...

  • Page 135: External Flap Push Rod

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 108 – Flap Position Indicator Drive Cable Assembly 10.6 EXTERNAL FLAP PUSH ROD 10.6.1 DESCRIPTION  The external flap push rods connect the flap cross shaft to the flaps.

  • Page 136: Flap Rigging (As Per Template)

    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. 10.7.4 FLAP INSTALLATION ...

  • Page 137: Elevator Control System

     Due to space constraints not all different variations are shown herein. When ordering spare parts provide as must detail as possible – part description, aircraft model, serial number etc to Jabiru to ensure accurate part identification. WARNING All spherical rod end bearings must be fitted with a large washer on the outside of the through- bolt to prevent the bearing case and cable releasing in the event of a bearing failure.

  • Page 138: Figure 110 – Elevator Control System – Type 1, Sheet 2

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 110 – Elevator Control System – Type 1, Sheet 2 Figure 111 – Elevator Control Assy Type 2 REVISION Dated: Nov 2011 Issued By: SW...

  • Page 139: Control Column

    Also refer to Section 4.17.  Repairs must be referred to Jabiru Aircraft Pty Ltd or our approved local agent. 11.3.5 INSTALLATION ...

  • Page 140: Figure 112 – J160 Models – Horizontal Tail & Elevator Assy

    Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants WARNING All spherical rod end bearings must be fitted with a large washer on the outside of the through- bolt to prevent the bearing case and cable releasing in the event of a bearing failure.

  • Page 141: Elevator Control Cables

     The 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.  Details of inspections required for control cables are given in Sections 9.3.3 and 0.

  • Page 142: Rigging

    RIGGING Refer to Figure 115. Control templates are available for all models from Jabiru Aircraft. Using the factory anchor points, make sure each end of the cable is secure. Set the full up travel first using the factory templates. Making sure both the control column and the elevator trim is hard back.

  • Page 143: Elevator Trim - Control Lever Assy

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants ELEVATOR TRIM – CONTROL LEVER ASSY 11.6 11.6.1 DESCRIPTION  The control lever for the elevator trim is mounted on the centre console.  The assembly includes friction plates so that the lever does not move once in position.

  • Page 144: Figure 116 – Trim Lever Assy – Type 1

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 116 – Trim Lever Assy – Type 1 Figure 117 – Trim Lever Assy – Type 2 REVISION Dated: Nov 2011 Issued By: SW...

  • Page 145: Elevator Trim - Aft Assembly

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 118 – Elevator Trim Handle Assy – Type 3 ELEVATOR TRIM – AFT ASSEMBLY 11.7 11.7.1 DESCRIPTION  The elevator trim control system comprises a Trim Cable connected to a lubron block, so that the cable is able to move the block fore and aft approximately 35mm.

  • Page 146: Trim Control Cables

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants 11.7.4 INSPECTION & REPAIR  Visually inspect for excess wear or contamination of the lubron block.  If required, apply fresh graphite lubricant  Inspect the pivot bearings for condition and replace if required.
  • Page 147 11.8.3 CONTROL CABLE INSPECTION  The Control Cable may not be repaired or removed without reference to Jabiru Aircraft Pty Ltd or our approved local agent.  Details of inspections required for control cables are given in Sections 9.3.3 and 0.

  • Page 148: Rudder Control System

    12.1.1 DESCRIPTION  Jabiru Aircraft use rudder pedals connect directly to the nose leg to control nose wheel steering in addition to the rudder control surface. The system is comprised of rudder pedals, two push rods, a centring mechanism and an enclosed push-pull cable.

  • Page 149: Figure 121 – Rudder Pedal - Non-Adjustable

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants 12.1.3 INSPECTION AND REPAIR Inspect nylon bearings for wear. Replace if worn. Inspect pedal bars for wear around bearing area and for distortion. Inspect pedals for distortion or loose rivets in end stops.

  • Page 150: Figure 122 – Adjustable Rudder Pedal Assy – Type 1

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 122 – Adjustable Rudder Pedal Assy – Type 1 Figure 123 – Adjustable Rudder Pedal Assy – Type 2 REVISION Dated: Nov 2011 Issued By: SW...

  • Page 151: Rudder Centring System

    RUDDER CENTRING SYSTEM 12.2.1 DESCRIPTION  In Jabiru Aircraft the rudder pedals are connected directly to the nose leg. This gives both nose wheel steering and the mechanism connecting the left and right pedals.  The drawings shown in Figure 124 through to Figure 128 show several variations of the systems used.

  • Page 152: Figure 125 – Steering/Rudder Centring Assy – Type 2

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 125 – Steering/Rudder Centring Assy – Type 2 Figure 126 – Steering/Rudder Centring Assy – Type 3 (Sheet 1) REVISION Dated: Nov 2011 Issued By: SW...

  • Page 153: Figure 127 – Steering/Rudder Assy – Type 3 (Sheet 2)

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 127 – Steering/Rudder Assy – Type 3 (Sheet 2) Figure 128 – Steering/Rudder Centring Assy – Type 3 (Includes Soft Link) REVISION Dated: Nov 2011...

  • Page 154: Rudder

    12.3 RUDDER 12.3.1 DESCRIPTION  The rudder of Jabiru Aircraft is a stressed-skin composite structure. It is connected to the rudder pedals via a self-contained push-pull cable. 12.3.2 REMOVAL & INSTALLATION Unbolt push-pull cable from rudder horn. Loosen screws in hinge pin retainers & lift retainer from hinge pin. It is not necessary to remove these parts.

  • Page 155: Rudder Control Cable

     The 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.  Details of inspections required for control cables are given in Sections 9.3.3 and 0.

  • Page 156: Rudder Balance

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants  Ensure the required inspections are carried out and the cable is clamped securely. WARNING All spherical rod end bearings must be fitted with a large washer on the outside of the through- bolt to prevent the bearing case and cable releasing in the event of a bearing failure.

  • Page 157: Engine & Engine Installation

     Due to space constraints not all different variations are shown herein. When ordering spare parts provide as must detail as possible – part description, aircraft model, serial number etc to Jabiru to ensure accurate part identification. 13.1.2 UPPER COWL REMOVAL Remove the Cam Locks from the front &...

  • Page 158: Figure 131 – Typical Upper Cowl Assy

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 131 – Typical Upper Cowl Assy Figure 132 – Typical Lower Cowl Assy REVISION Dated: Nov 2011 Issued By: SW Page: 158 of 233...

  • Page 159: Engine

    Refer to Section 5 13.2.6 ENGINE ACCESSORIES  Jabiru engines may be fitted with an accessory vacuum pump, mounted to a pad at the rear of the engine.  All Jabiru engines are fitted with a permanent magnet alternator at the rear of the engine. This is considered a part of the engine and is discussed in the engine Instruction &...

  • Page 160: Figure 133 – Fuel Hose Assy – Engine Bay

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants 13.3.2 FLEXIBLE HOSE REMOVAL  Where equipped, cut the safety wire to allow the fire sleeve to be drawn back along the hose to allow access to the hose clamp.

  • Page 161: Cooling Air Baffles

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants 13.4 COOLING AIR BAFFLES 13.4.1 DESCRIPTION  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.

  • Page 162: Engine Mount

    Engine mounts with severe corrosion must be replaced.  If cracks, dents or bends are found refer to Jabiru Aircraft or our local authorised agent. In most cases the damaged mount must be replaced. WARNING The engine mounts should not be repaired.

  • Page 163: Engine Fuel System

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants 13.5.4 INSTALLATION  For installation reverse removal procedure above.  Use the “solid laminate” torque values given in Table 1.  Ensure that the large aluminium washers (appr 40 x 40mm square) are in place on the inner side of the firewall.

  • Page 164: Figure 135 – Throttle Assy (Seat Mounted)

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants 13.7.3 THROTTLE INSPECTION, REPAIR & RIGGING 13.7.4  When adjusting any engine control, it is important to check that the control slides smoothly throughout its full range of travel and that the lever or knob moves through its full range of travel.

  • Page 165: Figure 136 – Throttle Assy (Panel Mounted)

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 136 – Throttle Assy (Panel Mounted) Figure 137 – Throttle Assy (Large Panel Mount) REVISION Dated: Nov 2011 Issued By: SW Page: 165 of 233...

  • Page 166: Choke Cable

    Installation is the reverse of the removal process above. Note that when the firewall fitting is re- fitted fireproof putty (available from Jabiru Aicraft) must be replaced to ensure a flame-proof seal. Figure 138 – Control Cable End Fitting Installation...

  • Page 167: Air Intake System & Carburetor Heat

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants 13.9 AIR INTAKE SYSTEM & CARBURETOR HEAT 13.9.1 DESCRIPTION  The engine air intake system comprises a cold air inlet in the lower cowl, a hot air muff attached to the exhaust system, a mixer assembly mounted on the firewall and connected to a carburettor.

  • Page 168: 13.10 Exhaust System

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 140 – Hot Air Duct Assy 13.10 EXHAUST SYSTEM 13.10.1 DESCRIPTION  The exhaust system consists of exhaust extractor pipes running from the cylinder heads to the muffler.

  • Page 169: Figure 141 – 2200 Exhaust System

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants 13.10.3 EXHAUST INSPECTION  As all exhaust systems are subject to burning, cracking and general deterioration from alternate thermal stress and vibration, inspection is very important and should be carried out every 100 hours of operation.

  • Page 170: Figure 142 – 3300 Exhaust System Type 1

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 142 – 3300 Exhaust System Type 1 Figure 143 – 3300 Exhaust System Type 2 REVISION Dated: Nov 2011 Issued By: SW Page: 170 of 233...

  • Page 171: 13.11 Cabin Heater System

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants 13.11 CABIN HEATER SYSTEM 13.11.1 DESCRIPTION  A cold-air inlet is fitted to the front of the engine cowls. From here the air flows through a heat exchanger installed on the exhaust tailpipe, through a control valve and into the cabin.

  • Page 172: Figure 144 – Cabin Heat Mixer Assembly

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 144 – Cabin Heat Mixer Assembly Figure 145 – Cabin Heat Exchanger Assy REVISION Dated: Nov 2011 Issued By: SW Page: 172 of 233...

  • Page 173: 13.12 Extreme Climatic Conditions

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants 13.12 EXTREME CLIMATIC CONDITIONS 13.12.1 DUST  Dust induced into the carburettor air intake system is probably the greatest single cause of early engine wear.

  • Page 174: Figure 147 – 2200 Engine Installation

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 147 – 2200 Engine Installation Figure 148 – 2200 Engine Installation, Long Engine Mount REVISION Dated: Nov 2011 Issued By: SW Page: 174 of 233...

  • Page 175: Figure 149 – J200 Family Engine Installation Type 1

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 149 – J200 Family Engine Installation Type 1 Figure 150 – J200 Family Engine Installation Type 2 REVISION Dated: Nov 2011 Issued By: SW...

  • Page 176: Fuel System

     Due to space constraints not all different variations are shown herein. When ordering spare parts provide as must detail as possible – part description, aircraft model, serial number etc to Jabiru to ensure accurate part identification. WARNING Where secondary fuel valves are fitted between wing tanks and header tanks it is recommended that they be secured in the “ON”...

  • Page 177: Figure 151 – In-Cabin Fuel System

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 151 – In-Cabin Fuel System Figure 152 – Fuel System Schematic – Type 1 REVISION Dated: Nov 2011 Issued By: SW Page: 177 of 233...

  • Page 178: Figure 153 – Fuel System Schematic – Type 2

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 153 – Fuel System Schematic – Type 2 Figure 154 – Fuel System Schematic – Type 3 REVISION Dated: Nov 2011 Issued By: SW...

  • Page 179: Figure 155 – Fuel System Schematic – Type 4

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 155 – Fuel System Schematic – Type 4 14.1.2 FUEL SYSTEM TROUBLE SHOOTING Table 13 – Trouble Shooting – Fuel System Trouble Probable Cause...

  • Page 180: Fuel Lines

    If a sharp bend is unavoidable a spring may be threaded over the line to prevent it crimping. Springs must be a snug fit on the hose & are available from Jabiru Aircraft if required. Figure 157 refers. ...

  • Page 181: Figure 157 – Sample Fuel Line Details

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Line crimped – bend too tight Fuel line clips Spring preventing line from crimping on a tight bend Figure 157 – Sample Fuel Line Details...

  • Page 182: Fuel Tanks

     Leaks can normally be found by visual inspection: AVGAS in particular will leave dye stains where leaks have occurred. If leaks are found contact Jabiru Aircraft for a repair procedure.  Visually inspect the tank and fittings for corrosion, damage and contamination.

  • Page 183: Figure 160 – Header Tank Installation – Type 1

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 160 – Header Tank Installation – Type 1 Figure 161 – Header Tank Installation – Type 2 (Sheet 1) REVISION Dated: Nov 2011 Issued By: SW...

  • Page 184: Fuel Vents

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 162 – Header Tank Installation – Type 2 (Sheet 2) 14.4 FUEL VENTS 14.4.1 DESCRIPTION  For aircraft with wing tanks ventilation is either provided by vented fuel caps or by a “sharks fin” vent fitted to the cabin roof.

  • Page 185: Fuel Shut-Off Valve

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants  To check the breather line for the header tank: Where equipped, turn off taps between the wing tanks and the header tank. Alternately fuel line clamps may be used.

  • Page 186: Fuel Gauges

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants 14.5.2 FUEL VALVE REMOVAL & INSTALLATION  Where equipped, turn OFF both taps between wing tanks and header tank. Cover both tank cap vents. Alternately removable fuel line clamps may be used.

  • Page 187: Table 14 – Trouble Shooting – Fuel Gauge

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants 14.6.2 FUEL GAUGE REMOVAL & INSTALLATION  For wing root sight gauges: Remove the fairings from between the wings and the fuselage. Disconnect the fuel lines running between the wing tanks and the sigh gauges.

  • Page 188: Figure 165 – Fuel Gauge – Electric Sender Installation

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 165 – Fuel Gauge – Electric Sender Installation Figure 166 – Fuel Gauge – Electric Sender Assembly Figure 167 – Fuel Gauge – Sight Glass...

  • Page 189: Fuel Filters

    The Primary Fuel Pump is located on the Starboard rear of the Engine. Refer to engine Maintenance & Instruction Manual for details.  A secondary, electric fuel pump is also installed in all Jabiru Aircraft to assist the primary pump, prevent vapor-lock and for redundancy. 14.8.2 SECONDARY FUEL PUMP REMOVAL & INSTALLATION ...
  • Page 190 Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants  Allow the Loctite to cure.  Reverse the preceding steps for installation. Ensure waste cloth is removed. WARNING Ensure tank vents are open (no vent covers fitted).

  • Page 191: Instruments & Instrument Systems

     Due to space constraints not all different variations are shown herein. When ordering spare parts provide as must detail as possible – part description, aircraft model, serial number etc to Jabiru to ensure accurate part identification. 15.2 INSTRUMENT PANEL 15.2.1 DESCRIPTION...

  • Page 192: Figure 168 – Instrument Panel Layout Type 1

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 168 – Instrument Panel Layout Type 1 Figure 169 – Instrument Panel Layout Type 2 Figure 170 – Instrument Panel Layout Type 3 REVISION...

  • Page 193: Instrument Panel Mount

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 171 – Instrument Panel Layout Type 4 15.3 INSTRUMENT PANEL MOUNT 15.3.1 DESCRIPTION  The instrument panel mount is a fibreglass moulding which is secured to the firewall. The instrument panel fascia secures to this mount and it also supports the panel throttle assembly (where equipped).

  • Page 194: Instruments

    INSTRUMENTS 15.4.1 DESCRIPTION  Jabiru Aircraft are equipped with a wide range of instruments depending on specification. Generally, all instruments are secured to the panel fascia with screws inserted through the panel face.  In some cases rack mounts are used where the instrument is held in a rack which, in turn, is secured to the fascia or to the fibreglass panel mount.

  • Page 195: Pitot & Static Systems

     In Jabiru Aircraft the pitot and static systems each have a water trap (or “low point”) fitted which must be checked during scheduled maintenance or after flying through rain.

  • Page 196: Figure 174 – Static Probe System Assembly

    15.5.2 PITOT-STATIC WATER TRAPS  A water trap is incorporated into both the pitot and the static systems for Jabiru Aircraft. This may take the form of the trap assembly shown below or of a “low point” where the tube is deliberately positioned in a “U-shape”...

  • Page 197: Figure 175 – Pitot / Static Water Trap

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 175 – Pitot / Static Water Trap Figure 176 – Pitot-Static System – Water Trap Locations REVISION Dated: Nov 2011 Issued By: SW Page: 197 of 233...
  • Page 198 Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants 15.5.3 STATIC PRESSURE SYSTEM INSPECTION & LEAKAGE TEST  The following procedures outline inspection and testing processes for the static pressure system.  Before testing, ensure the static system is free from entrapped moisture by checking the low points of the system as noted above.

  • Page 199: Table 15 – Trouble Shooting – Pitot-Static System

    The static probe is fixed and cannot be removed. Limited access may be available through the fin top strobe mount (where equipped) – otherwise an access hole must be cut into the fin. Consult Jabiru Aircraft or our local approved representative before making access holes. ...

  • Page 200: Table 16 – Trouble Shooting – Airspeed Indicator

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants 15.5.8 TROUBLE SHOOTING – AIRSPEED INDICATOR Table 16 – Trouble Shooting – Airspeed Indicator Trouble Probable Cause Remedy Test line and connections for Pitot pressure connection not leaks.

  • Page 201: Table 18 – Trouble Shooting – Vertical Speed Indicator

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants TROUBLE SHOOTING – VERTICAL SPEED INDICATOR 15.5.10 Table 18 – Trouble Shooting – Vertical Speed Indicator Trouble Probable Cause Remedy Check line for obstructions. Blow Static line plugged out lines.

  • Page 202: Alternate Static Source

     In the Jabiru this system consists of a section of the static tube which is exposed at the underside of the instrument at a position where the pilot can reach it in flight. Where a problem is detected the pilot reaches down and pulls on the tube, disconnecting it from the static probe in the tail.

  • Page 203: Analogue Tachometer

    ANALOGUE TACHOMETER 15.7.1 DESCRIPTION  Jabiru Aircraft may be equipped with an analogue tachometer or a digital RPM read-out as a part of an engine monitoring system.  Analogue tachometers are driven by a variety of sensors, depending on the aircraft model. In some the sensor is positioned so that the teeth of the flywheel ring gear pass close by and produce a signal.

  • Page 204: Figure 179 – Hall Effect Sensor Wiring (For Tach With Jabiru Logo On Face)

    See remedies for “incorrect Same probable causes as for Hand oscillates “Incorrect Indication” above. indication” above. Figure 179 – Hall Effect Sensor Wiring (For Tach with Jabiru Logo on Face) REVISION Dated: Nov 2011 Issued By: SW Page: 204 of 233...

  • Page 205: Analogue Engine Gauges

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 180 – Hall Effect Sensor Inst. (For Tach with Jabiru Logo on Face) 15.8 ANALOGUE ENGINE GAUGES 15.8.1 DESCRIPTION  The Oil Pressure, Oil Temperature, Voltage, Exhaust Gas Temperature (EGT, where equipped), hour meter (where equipped) and Cylinder Head Temperature (CHT) Gauges are electronic instruments.

  • Page 206: Digital Displays

     The following points reflect areas which commonly cause issues with the digital instruments used in Jabiru Aircraft. For more comprehensive installation, operation and troubleshooting data refer to the operator’s instructions. Table 21 – Trouble Shooting – Digital Instruments Gauges...

  • Page 207: 15.10 Magnetic Compass

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Trouble Probable Cause Remedy Oil pressure inaccurate / Poor quality earth connection Check connection, replace / fluctuating between display and engine improve as required. Wrong number of pulses set in Correct settings per manufacturer’s instructions.

  • Page 208: Section 14 - Electrical Systems

     Due to space constraints not all different variations are shown herein. When ordering spare parts provide as must detail as possible – part description, aircraft model, serial number etc to Jabiru to ensure accurate part identification. 16.1.1 WIRING DIAGRAMS ...

  • Page 209: Figure 181 – Wiring Diagram Sheet 1

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 181 – Wiring Diagram Sheet 1. REVISION Dated: Nov 2011 Issued By: SW Page: 209 of 233...

  • Page 210: Figure 182 – Wiring Diagram Sheet 2

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 182 – Wiring Diagram Sheet 2. Figure 183 – Night-VFR Lighting Sheet 1 REVISION Dated: Nov 2011 Issued By: SW Page: 210 of 233...

  • Page 211: Minor Electrical Equipment

     Note that the body of some starter solenoids used in Jabiru Aircraft form the earth connection. If there is excess resistance between the solenoid body and the electrical system earth then a connection will not be made and solenoid issues will result.

  • Page 212: Battery System

    Wait at least 5 minutes after turning off power before commencing any activity near the strobe light. 16.2.6 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 5 Amps. 16.3 BATTERY SYSTEM 16.3.1 DESCRIPTION...

  • Page 213: Electrical Load Analysis (Ela)

    RADIO INSTALLATION 16.5.1 DESCRIPTION  Jabiru Aircraft are equipped as standard with a VHF radio.  The main VHF radio antenna is installed within the spar at the rear of the tail fin. It consists of two sections as shown in Figure 185.

  • Page 214: Figure 186 – Second Vhf Antenna Installation (J120 / J160 Families)

    Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 186 – Second VHF Antenna Installation (J120 / J160 Families) Figure 187 – Second VHF Antenna Installation (J230 Families) REVISION Dated: Nov 2011 Issued By: SW...

  • Page 215: Transponder

    16.6.1 DESCRIPTION  A transponder is optional equipment for Jabiru Aircraft. This system consists of the transponder itself mounted to the instrument panel fascia, the encoder mounted to the firewall and the antenna fitted under the front of the aircraft.

  • Page 216: Painting & Finishing

    EXTERIOR 18.1.1 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 217 You are now ready to spray your 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.

  • Page 218: Placards

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants PLACARDS 19.1 MODEL-SPECIFIC DECALS Table 22 – Model-Specific Decals Decal Detail Preview Warning Placard J120 P/No. 5A092A0D Fitted on the rear Face of the Forward Wing Spar Carry-through Beam in the Cabin Ceiling.
  • Page 219 Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Decal Detail Preview Fit adjacent to main warning placard (LSA models, see above) Warning Placard J160 P/No. 5A011A0D Fitted above windscreen in front of wing carry through beam across to the left side.

  • Page 220: Placards General

    Fit to upper frame of DYNON EFIS if installed Baggage P/No. 5111154 J120 / J16 families: fit to inside of fuselage on right side just below rear quarter window. Locate vertical line in line with rear of baggage shelf. J200 Families: Position as noted in Flight Manual.
  • Page 221 Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Loading Limitations 500kg P/No 5118024 J120 Family Fit to inside of fuselage on right side just below rear quarter window. Loading Limitations 540kg P/No 5098854...
  • Page 222 Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Engine Oil Details. P/No. 5A008A0D 1 OFF Attach to upper cowl beside oil door or to oil door itself. Trim Position P/No. 5A031A0D (1 OFF) Fit to centre console beside of elevator fwd stop, between trim levers.
  • Page 223 Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Door String Placard PULL TO OPEN P/No5026094 Fitted on Inside of both Doors Above Door Handle. Loading Limitations P/No 5A037A0D. Fit to right side of fuselage between window and beam.
  • Page 224 Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Fuel Tap Position P/No 5023094 Where Equipped Fitted to the left-hand of the console adjacent to the fuel valve Choke Cable P/No5051094 CHOKE Where Equipped PULL ON Fitted at the base of the choke cable.

  • Page 225: Fairings

     Due to space constraints not all different variations are shown herein. When ordering spare parts provide as must detail as possible – part description, aircraft model, serial number etc to Jabiru to ensure accurate part identification. 20.1.1 REMOVAL AND INSTALLATION ...

  • Page 226: Appendix Iv - Propeller Service Manual

    22.3 IDENTIFICATION STAMPINGS  Each Jabiru propeller is marked with the particulars indicated below: The Propeller Drawing Number. The diameter and pitches in metres, preceded by the letters "D" and "P" respectively. The type of engine for which the propeller has been designed.

  • Page 227: Description

    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 In countries other than Australia, different maintenance requirements will apply. It is the owner's responsibility to become fully aware of the particular maintenance requirements and limitations applicable to the appropriate registration.

  • Page 228: Figure 189 – Propeller Installation

    Jabiru Aircraft Aircraft Service Manual Pty Ltd JTM001-1 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants Figure 189 – Propeller Installation REVISION Dated: Nov 2011 Issued By: SW Page: 228 of 233...

  • Page 229: To Remove Existing Propeller

    Check tracking of Propeller by locating a fixed object on a flat floor so that it just clears the 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.

  • Page 230: Propeller Balancing Procedure

    Refurbish with clear Epoxy paint (JABIRU Part No. PP0069N). Rebalance Propeller (see below) Reassemble and replace Propeller and Spinner (see above). Check Propeller tracking and Spinner balance (see above). Damaged urethane leading edges should be referred to Jabiru Aircraft Pty Ltd for repair. 22.9 PROPELLER BALANCING PROCEDURE ...

  • Page 231: Appendix - Airworthiness Limitations

    Jabiru Aircraft Pty Ltd CASA APPROVED SECTION Airworthiness Limitations Jabiru J160-C APPENDIX – AIRWORTHINESS LIMITATIONS THIS AIRWORTHINESS LIMITATIONS SECTION IS APPROVED BY THE CIVIL AVIATION SAFETY AUTHORITY OF AUSTRALIA. IT SPECIFIES AIRWORTHINESS LIMITATIONS REQUIRED MAINTAIN COMPLIANCE WITH CS-VLA REGULATIONS. Signature: For Civil Aviation Safety Authority.

  • Page 232: General

    Certification. Jabiru Aircraft offers training & certification for people wishing to gain Jabiru approval to inspect & maintain J160-C structures. Note: this does not include repairs. Repairs of structural parts must be referred to Jabiru Aircraft. 23.3.1 EXTERNAL PAINT / FINISHING LIMITATIONS ...

  • Page 233: Revision 1 Dated: Nov 2011 Issued By: Sw Page: 2 Of

    Jabiru Aircraft Pty Ltd CASA APPROVED SECTION Airworthiness Limitations Jabiru J160-C 23.4 CONTROL SURFACE BALANCING  The J160-C primary control surfaces are balanced during construction. In service there should be no reason to rebalance the controls. Balance checks of the controls are only required after repair or refinishing or at the 5000-hourly major airframe inspection.

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