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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. JTM001-5
th
DATED: 29
Jabiru's Limited, Express Warranty.
the document becomes uncontrolled.
Jabiru Aircraft Pty Ltd.
FOR
October 2014
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Table of Contents
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Summarization of Contents
SECTION 2 – GENERAL INFORMATION
2.1 FOREWORD / APPLICABILITY
Manual covers ground handling, servicing, and maintenance for Jabiru aircraft models.
2.2 LIST OF EFFECTIVE PAGES / ISSUE STATUS
Lists all pages and their revision status within the manual.
2.3 INTRODUCTION
Overview of manual content, based on data and supplemented by bulletins.
2.4 READING THIS MANUAL
Guidance on how to effectively read and navigate the manual, including hyperlinks.
2.5 DEGREE OF DIFFICULTY
Explains the "Spanner Scale" for assessing task difficulty and required skill.
2.6 USE-BY DATES & STORAGE
Notes on product shelf life, use-by dates, and proper storage conditions.
2.7 GENERAL DESCRIPTION
Describes the Jabiru aircraft as 2-seat, high-wing monoplanes of monocoque construction.
2.8 OWNER MAINTENANCE
Details owner responsibilities and allowed maintenance tasks for factory-built models.
2.9 AIRCRAFT SPECIFICATIONS
Provides leading particulars and dimensions for the aircraft models covered.
2.10 CENTRE OF GRAVITY LIMITATIONS
Discusses CG limitations and the impact of equipment installation on limits.
2.11 STANDARD PRACTICES
Outlines standard practices for bolt tightening and thread clearance.
2.12 AIRCRAFT STRUCTURE
Explains the primary and secondary structure of the Jabiru aircraft.
2.13 ENGINES
Notes that engine details are in separate manuals, not this one.
2.14 EQUIPMENT LIST
Lists typical equipment found in Jabiru J-series aircraft across different models.
2.15 SOURCE OF PURCHASE PARTS
Provides contact details for sourcing replacement parts from Jabiru Aircraft P/L.
2.16 LIST OF DISPOSABLE REPLACEMENT PARTS
Lists common disposable replacement parts with part numbers and manufacturers.
2.17 AIRCRAFT SPECIFICATIONS
Details universal specifications for all J-Series aircraft, including fuel type and battery.
2.18 TORQUE VALUES (IN FIBREGLASS)
Provides recommended bolt torque values for clean, dry threads in fiberglass structures.
3 MAINTAINER REQUIREMENTS
3.1 FACILITIES
Recommends an enclosed workspace with sealed floor, lighting, and utilities.
3.2 TRAINING
Recommends approved instruction courses for engines and airframes.
3.3 RATING
States commercial maintainers must hold suitable ratings per Airworthiness Authority.
3.4 EXPERIENCE
Recommends a minimum of 2 years supervised aircraft experience for unsupervised work.
3.5 TOOL & GAUGE CONTROL
Emphasizes accurate, calibrated tools and regular calibration checks for aviation maintenance.
3.6 TOOLS:
Lists required tools for maintenance, emphasizing good quality items.
3.7 EQUIPMENT:
Lists essential equipment required for aircraft maintenance tasks.
3.8 GENERAL:
Lists general items like greases, compounds, and cleaning agents needed for maintenance.
3.9 SPECIAL TOOLS & COMPOUNDS
Details specific Loctite products and their applications for bonding and sealing.
4 CLEANING, GROUND HANDLING & STORAGE
4.1 CLEANING
Provides detailed instructions for cleaning aircraft exterior and interior surfaces.
4.2 GROUND HANDLING
Covers procedures for towing, jacking, and parking the aircraft safely.
4.3 STORAGE
Outlines procedures for flyable, temporary, and indefinite aircraft storage.
5 INSPECTION & SERVICING
5.1 SERVICE INTERVAL TOLERANCE
Specifies a tolerance of plus or minus 3 hours for all service intervals.
5.2 BASIC INSPECTION PROCEDURE
Outlines the general steps for performing a basic aircraft inspection.
5.3 MANDATORY INSPECTIONS & LIFED ITEMS
Details mandatory airframe, control cable, and engine bay hose replacement intervals.
5.4 INSPECTION CHART
Provides a chart detailing inspection intervals (Annual, 200 Hrs, 100 Hrs) for various aircraft systems.
5.5 SERVICING
Refers to Section 5.4 for servicing requirements and provides supplementary details.
5.6 GENERAL INSPECTION GUIDELINES
Offers guidance for critical inspections, covering moving parts, metal parts, wiring, and bolts.
5.7 ENGINE PRE-INSPECTION RUN-UP:
Details steps for engine run-up before inspection, focusing on observation.
5.8 PROPELLER 100-HOURLY
Outlines visual inspection procedures for the propeller and spinner at 100-hour intervals.
5.9 ENGINE COMPARTMENT 100-HOURLY
Provides guidance for 100-hourly inspection of the engine compartment and its components.
5.10 FUEL SYSTEM 100-HOURLY
Details 100-hourly inspection procedures for the aircraft's fuel system components.
5.11 LANDING GEAR 100-HOURLY
Outlines 100-hourly inspection procedures for the landing gear and brake systems.
5.12 AIRFRAME 100-HOURLY
Details 100-hourly inspection procedures for the aircraft's airframe and associated systems.
5.13 CONTROL SYSTEMS 100-HOURLY
Covers 100-hourly inspection procedures for all primary and secondary control systems.
5.14 LUBRICATION
Refers to engine manuals for lubrication requirements and lists specific pivot points.
5.15 SPECIAL INSPECTIONS – PROPELLER
Refers to Service Bulletin JSB014 for inspections of non-approved propeller types.
5.16 SPECIAL INSPECTIONS – WEIGHING
Details the procedure for weighing the aircraft and calculating the Center of Gravity.
5.17 SPECIAL INSPECTIONS – CONTROL CABLES
Outlines inspection procedures for primary control cables, checking free play and friction.
5.18 SPECIAL INSPECTIONS – CONTROL SURFACES
Details inspections to prevent control surface jamming, focusing on clearance and hinge stiffness.
5.19 SPECIAL INSPECTIONS – MAIN WHEEL ALIGNMENT
Describes the process for checking and adjusting main wheel alignment.
5.20 SPECIAL INSPECTIONS – FUEL GAUGE DECAL SETUP
Provides instructions for setting up fuel gauge decals for accurate indication.
5.21 SPECIAL INSPECTIONS – FUEL SENDER CALIBRATION
Explains how to calibrate the inbuilt Dynon EMS fuel gauges to Jabiru float type senders.
5.22 SPECIAL INSPECTIONS – WING & STRUT BUSH SERVICE
Details procedures for correcting free-play in wing and strut attachment points.
6 STRUCTURES
6A FUSELAGE
Describes the composite monocoque fuselage structure and windshield/window care.
6B WINGS & EMPENNAGE
Discusses Jabiru wing design, interchangeability, and specific model variations.
6C LANDING GEAR & BRAKES
Covers general description, removal, installation, and inspection of landing gear and brakes.
6D AILERON CONTROL SYSTEM
Details the arrangement and components of the aileron control system.
6E WING FLAP CONTROL SYSTEM
Explains the flap control system, including manual and electric drive assemblies.
6F ELEVATOR CONTROL SYSTEM
Covers the elevator control system, including removal, installation, and balancing.
6G RUDDER CONTROL SYSTEM
Details the rudder pedal system, including steering and centring mechanisms.
7 ENGINE & ENGINE INSTALLATION
7.1 Engine Cowls
Describes the upper and lower composite engine cowls and their removal/installation.
7.2 Engine
Provides an overview of Jabiru engines, referring to separate maintenance manuals.
7.3 Flexible Hoses
Covers the removal, inspection, and installation of flexible rubber hoses in the engine bay.
7.4 Cooling Air Baffles
Explains the function of cooling air baffles and procedures for their removal and inspection.
7.5 Engine Mount
Describes the engine mount's purpose and procedures for its removal, inspection, and installation.
7.6 Engine Fuel System
Notes the carburettor and fuel pump setup, referring to the Fuel System section.
7.7 Engine Throttle Control
Details the cable-actuated throttle system, including removal and inspection.
7.8 Choke CABLE
Covers the removal, inspection, and installation of the choke control cable.
7.9 Air Intake System & Carburettor Heat
Explains the air intake system, mixer box, and carburettor heat activation.
7.10 Exhaust System
Describes the exhaust system and provides procedures for removal, inspection, and installation.
7.11 Cabin Heater System
Details the cabin heater system, including removal, inspection, and installation.
7.12 Extreme Climatic Conditions
Discusses effects of dust and salt water on the engine and maintenance precautions.
9 PROPELLER SERVICE MANUAL
9.1 Certified Propeller Models
Lists certified propeller models and refers to specific technical manuals for maintenance.
9.2 Approved Installations
Provides tables of approved propeller and engine combinations for J-Series aircraft.
9.3 Identification Stampings
Explains the markings found on Jabiru propellers, including drawing number and serial number.
9.4 Description
Describes propeller construction from timber laminations with composite sheath and epoxy paint.
9.5 Installation
Details the procedure for installing the propeller assembly, including torque values.
9.6 To Remove Existing Propeller
Provides step-by-step instructions for removing the existing propeller assembly.
9.7 To Assemble And Replace Propeller Assembly
Outlines the procedure for assembling and replacing the propeller assembly.
9.8 Servicing And Repairs
Details service and repair procedures, focusing on filling small nicks in the propeller.
9.9 Propeller Balancing Procedure
Describes the method for checking and correcting propeller balance using specific tools.
11 INSTRUMENTS & INSTRUMENT SYSTEMS
11.1 GENERAL
Emphasizes troubleshooting, corrective measures, and referring to specialists for instrument repair.
11.2 INSTRUMENT PANEL
Describes the instrument panel fascia and provides removal/installation procedures.
11.3 INSTRUMENT PANEL MOUNT
Details the instrument panel mount, secured to the firewall, and its removal/installation.
11.4 INSTRUMENTS
Covers general instrument securing, removal, and installation, emphasizing protection of lines.
11.5 PITOT & STATIC SYSTEMS
Explains the pitot and static systems, including water traps and proper maintenance.
11.6 ALTERNATE STATIC SOURCE
Describes the alternate static source system for Night-VFR aircraft to use cabin pressure.
11.7 ANALOGUE TACHOMETER
Discusses analogue tachometers, their sensors, and refers to the Engine Maintenance Manual.
11.8 ANALOGUE ENGINE GAUGES
Covers analogue engine gauges (oil pressure, temp, CHT, EGT) and their electrical connections.
11.9 DIGITAL DISPLAYS
Details optional digital displays like EFIS and EMS, and their setup procedures.
11.10 MAGNETIC COMPASS
Describes the liquid-filled magnetic compass and its minimal maintenance requirements.
11.11 GYRO INSTRUMENT PACKAGE (OPTION)
Mentions optional vacuum pump driven gyros and electric turn coordinator.
12 ELECTRICAL SYSTEMS
12.1 ELECTRICAL POWER SUPPLY SYSTEM
Details the aircraft's 12-volt DC electrical system, battery, and alternator.
12.2 MINOR ELECTRICAL EQUIPMENT
Covers bus bars, master switch, and starter solenoid details.
12.3 BATTERY SYSTEM
Explains the 12-volt battery, its location, removal/installation, and cleaning procedures.
12.4 ELECTRICAL LOAD ANALYSIS (ELA)
Discusses ELA requirements for factory-built variants and operational considerations.
12.5 RADIO INSTALLATION
Mentions standard VHF radio installation and optional second VHF antennas.
12.6 TRANSPONDER
Covers transponder installation, removal, and calibration requirements.
15 PAINTING & FINISHING
15.1 EXTERIOR
Provides factory-recommended painting procedures, materials, and equipment.
16 PLACARDS
16.1 MODEL-SPECIFIC DECALS
Lists model-specific warning placards and their locations on the aircraft.
16.2 PLACARDS GENERAL
Lists general decals such as compass card, EFIS warning, and baggage placards.
17 FAIRINGS
17.1 DESCRIPTION
Describes fairings attached by screws, self-tappers, or threaded inserts, and their repair.
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