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Manuals and User Guides for Jabiru J230-C. We have
1
Jabiru J230-C manual available for free PDF download: Service Manual
Jabiru J230-C Service Manual (171 pages)
Brand:
Jabiru
| Category:
Aircrafts
| Size: 15 MB
Table of Contents
L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc
2
L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc
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1 Table of Contents
4
L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc
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Table of Figure
11
List of Tables
12
2 Section 2 - Service Manual
13
List of Effective
13
General Description
14
Owner Maintenance
14
J230-C
14
Aircraft Specifications
14
Centre of Gravity Limitations
14
Torque Values
15
Aircraft Specifications
15
L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc
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Figure 1. J230-C General Arrangement
16
Recommended Torque Values (in Fibreglass)
17
Aircraft Structure
17
3 Section 3 - Ground Handling, Servicing, Lubrication & Inspection
18
Ground Handling
18
Towing
18
Jacking
18
Hoisting
19
Levelling
20
Parking
20
Tie down
20
Flyable Storage
20
Returning Aircraft to Service
21
Temporary or Indefinite Storage
21
Inspection During Storage
22
Returning Aircraft to Service
22
Weighing
23
Scale Locations
23
Procedure
23
Servicing
24
Engine Servicing Schedule
24
Figure 2: Weighing Diagram
24
Other Servicing
25
Fuel
25
Fuel Drain
25
Carburettor Air Filter
25
Battery
25
Tyres
25
Hydraulic Brakes
25
Cleaning
26
Windshield and Windows
26
Interior Surfaces
26
Exterior Surfaces
26
Aluminium Surfaces
27
Engine and Engine Compartment
27
Propeller
27
Wheels
27
Lubrication
27
Wheel Bearing - Mains and Nose
27
Inspection
28
Inspection Intervals
28
Inspection Charts
28
Inspection Guidelines
28
Table 3. Control Free Play Limits
29
Figure 3. Fuel Line Routing
30
L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc
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Major Inspection / Replacement
32
Mandatory Inspection
32
Figure 3. Undercarriage
32
Inspection Chart
33
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4 Section 4 - Fuselage
37
Fuselage
37
Windshield and Windows
37
Description
37
Cleaning
37
Waxing
37
Repairs
37
Scratches
37
Cracks
38
Removal
38
Installation
38
Cabin Doors
38
Removal and Installation
38
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Figure 4. Front Door Assembly
39
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Figure 5: Rear Door Assembly
40
Adjustment
41
Door Seals
41
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Figure 6. Door Latch Mechanism Assembly
42
Locks
43
Seats
43
Repair
43
Upholstery
43
Upholstery Cleaning - Flame Retardant
43
Soundproofing
43
Safety Provisions
43
Seatbelts
43
5 Section 5 - Wings and Empennage
44
Wings
44
Removal
44
Repair
45
Installation
45
L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc
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Figure 7. J230 Wing Assembly Sheet 1
47
L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc
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Figure 8. J230 Wing Assembly Sheet 2
48
L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc
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Wing Struts
49
Removal and Installation
49
Repair
49
Pitot Probe
49
Description
49
PITOT Removal & Installation
49
Landing Light (Option)
50
Description
50
LANDING LIGHT Removal & Installation
50
Figure 9 - Dynon Pitot Probe Installation
50
Fin
51
Removal, Installation, Inspection and Repair
51
Horizontal Stabiliser
51
Removal and Installation
51
Figure 10 - Landing Light Assembly
51
6 Section 6 - Landing Gear and Brakes
52
Landing Gear
52
Trouble Shooting - Main Undercarriage
52
Main Gear
52
Removal
53
Installation
53
Inspection and Repair
53
Main Wheel Fairing Removal and Installation
54
Main Gear Top Fairing Removal and Installation
54
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Figure 11. Main Undercarriage Assembly
55
Main Wheel
56
Main Wheel Removal
56
Main Wheel Disassembly
56
Main Wheel Inspection, Assembly and Repair
56
Main Wheel Installation
57
Main Wheel Stub Axle Removal
57
Main Wheel Stub Axle Installation
58
Main Wheel Alignment
58
Wheel Balancing
58
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Figure 12. Main Wheel Alignment
59
Figure 13. Main Wheel to Leg Assy
60
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Figure 14. Main Wheel Assembly
61
L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc
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Figure 15. Directional Brake Disc Installation
62
L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc
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Nose Gear
63
Trouble Shooting - Nose Leg
63
Nose Gear Removal and Installation
63
Nose Gear Inspection and Repair
64
Nose Wheel Speed Fairing Removal and Installation
64
Nose Wheel
64
Nose Wheel Removal and Installation
64
Nose Wheel Disassembly
64
Nose Wheel Inspection and Repair
65
Nose Wheel Reassembly
65
Wheel Balancing
65
Figure 16. Nose Leg Assy
66
L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc
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Figure 17. Nose Wheel Hub Assembly
67
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Nose Wheel Steering System
68
Steering Centring Assembly
68
Nose Wheel Steering Assembly
68
Brake System
68
Trouble Shooting - Brakes
68
Brake Master Cylinder
69
Hydraulic Brake Lines
69
Wheel Brake Assemblies
69
L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc
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Brake System Bleeding
71
Brake Pad Adjustment
71
Parking Brake
72
Figure 18. Brake Calliper Assy
73
L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc
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Figure 19. Brake Master Cylinder Assy
74
L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc
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7 Section 7 - Aileron Control System
75
Aileron Control System
75
Figure 20. Aileron System Schematic
76
L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc
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Control Column
77
Control Column Removal
77
Control Column Inspection & Repair
77
Control Column Installation
77
Figure 21. Control Column Assy
78
L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc
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Control Cables
79
Control Cable Removal
79
Control Cable Inspection & Repair
79
Control Cable Installation
79
Ailerons
79
Aileron Removal & Installation
79
Aileron Inspection & Repair
79
Aileron Balancing
80
Control Rigging
80
Figure 22. Aileron Stops
81
L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc
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8 Section 8 - Wing Flap Control System
82
Wing Flap Control System
82
Operational Check
82
FLAP Switch ASSEMBLY
82
FLAP Cross SHAFT ASSEMBLY
82
Flap Cross Shaft Removal
82
Flap Cross Shaft Inspection & Repair
82
Flap Cross Shaft Installation
82
Flap Position Indicator Removal
83
Flap Position Indicator Inspection & Repair
83
Flap Position Indicator Installation
83
Flap Control Rod
83
Flap
83
Removal and Installation
83
Inspection and Repair
83
Flap Balancing
83
Flap RIGGING (as Per Template)
83
L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc
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Figure 23. Flap Controls - Sheet 1
85
L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc
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Figure 24. Flap Controls - Sheet 2
86
L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc
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Figure 25. Flap Cross Tube Assy
87
L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc
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Figure 26. Flap Position Indicator
88
L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc
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Figure 27. Flap Position Indicator Drive Cable Assembly
89
L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc
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9 Section 9 - Elevator Control System
90
Elevator Control System
90
Control Column Description
90
Removal and Installation
90
Elevator
90
Elevator Balancing
90
Inspection and Repair
91
Control Cable and Attachments
91
Removal and Installation
91
Rigging
91
Figure 28. Elevator Control Assy
92
L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc
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Figure 29: Elevator Control Assy Rear
93
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Figure 30. J230 Models - Horizontal Tail & Elevator Assy
94
L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc
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Figure 31. J170 Models - Horizontal Tail & Elevator Assy
95
L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc
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Figure 32. Elevator Travel Limits
96
L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc
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Elevator Trim Control System
97
Operational Check
97
Trim Handle Assembly
97
Control Cable and Attachments
97
Removal and Installation
97
Inspection and Repair
97
Figure 33. Elevator Trim Handle Assy
98
L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc
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Figure 34. Trim Controls - at Tail
99
10 Section 10 - Rudder Control System
100
Rudder Pedal System
100
Removal and Installation
100
Inspection and Repair
100
Figure 35. Rudder Pedal Assy
101
L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc
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Rudder
102
Removal & Installation
102
Inspection & Repair
102
Control Cable & Attachments
102
Rudder Balance
102
Rigging
103
Figure 36. Rudder System Schematic
104
L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc
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Figure 37. Rudder Installation
105
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11 Section 11 - Engine & Engine Installation
106
Engine Cowls
106
Engine Cowls - Removal & Installation
106
Figure 38. Upper Cowl Assy
107
L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc
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Figure 39. Lower Cowl Assy
108
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Cleaning and Inspection
109
Repair
109
Engine
109
Engine Data
109
Engine Trouble Shooting
109
Engine Cleaning
109
Engine Accessories Removal
109
Inspection
110
Cooling Air Baffles
111
Cleaning and Inspection
111
Cooling Air Baffle Removal & Installation
111
Repair
111
Engine Mount
111
Engine Fuel System
111
Fuel System General
111
LSA Aircraft Fuel System
112
Spark Plugs
112
Engine Controls
112
Rigging
112
Throttle System
112
Figure 40. LSA Variant Throttle (Panel Mounted)
113
L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc
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Choke
114
Air Intake System & Carburetor Heat
114
Figure 41 - Instrument Panel & Throttle Assembly
114
Figure 42. Carburetor Heat Box
115
L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc
115
Exhaust System
116
Exhaust System Removal and Installation
116
Exhaust Inspection
116
Figure 43. Exhaust System
117
L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc
117
Extreme Climatic Conditions
118
Dust
118
Seacoast and Humid Area
118
Figure 44. Engine Installation
119
L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc
119
12 Section 12 - Fuel System
120
Description
120
LSA Aircraft Fuel System
120
Precautions
120
Figure 45. Fuel System Schematic - LSA Variants
121
L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc
121
Fuel System Trouble Shooting
122
Fuel Tank
122
Description
122
Fuel Tank Removal & Installation
122
Fuel Vents
123
Description
123
Checking
123
L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc
124
Figure 46. Vented Fuel Cap Assy
125
L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc
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Fuel Shut-Off Valve
126
Description
126
Fuel Valve Removal & Installation
126
Fuel Gauges
127
Description - SIGHT GLASSES
127
Fuel SIGHT GAUGE Removal & Installation
127
Figure 47. Single Line Fuel Tap
127
Electric Fuel Gauge Troubleshooting
128
ELECTRIC Fuel GAUGE SENDER Removal & Installation
128
Figure 48. Fuel Gauge - Electric Sender Installation
128
Figure 49. Fuel Gauge - Electric Sender Assembly
129
Figure 50. Fuel Gauge - Sight Glass
129
L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc
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Header Tank Low Level Warning (Option)
130
Description
130
Fuel Valve Removal & Installation
130
Fuel Filters
130
Fuel Filter
130
Figure 51. Header Tank Low Level Sensor Installation
130
Fuel Filter Removal & Installation
131
Fuel Pumps
131
Primary Pump
131
Secondary Pump
131
13 Section 13 - Instruments & Instrument Systems
132
General
132
Instrument Panel
132
Instrument Panel Removal & Installation
132
Instruments
133
Figure 52. Instrument Panel Layout (Std Panel)
133
Instrument Removal
134
Installation
134
Pitot & Static Systems
134
Figure 53. Instrument Panel Layout - "Glass" Instrument Panel
134
Pitot - Static System Maintenance
135
Static Pressure System Inspection & Leakage Test
135
Blowing out Lines
136
Pitot System Inspection & Leakage Test
136
Removal & Installation of Components
137
Trouble Shooting - Pitot Static System
137
Trouble Shooting - Airspeed Indicator
138
Trouble Shooting - Altimeter
138
Pitot Tube Alignment
139
Trouble Shooting - Vertical Speed Indicator (Option)
139
Figure 54. Pitot-Statice System - Water Trap Locations
140
L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc
140
Figure 55. Pitot Assembly - Std Pitot
141
L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc
141
Figure 56. Static Probe System Assembly
142
L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc
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Tachometer
143
Figure 57. Static System Test
143
Oil Pressure Gauge
144
Oil Temperature Gauge
144
Cylinder Head Temperature Gauge
145
Exhaust Gas Temperature Gauge (Option)
145
Hourmeter
145
13.10 Magnetic Compass
145
Efis (Where Equipped)
146
Ems (Where Equipped)
146
14 Section 14 - Electrical Systems
147
Electrical Power Supply System
147
Wiring Diagram
147
L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc
148
L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc
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Bus Bars
150
Master Switch
150
Battery Power System
150
Battery
150
Battery Trouble Shooting
150
Removal and Installation
150
Cleaning the Battery
150
Battery Box
151
Starter Solenoid
151
Voltage Regulator
151
Strobe System (Option)
151
Auxiliary Power Socket
151
Electrical Load Analysis (Ela)
151
Radio Wiring Diagram (Option)
151
Vhf Antenna Installation
151
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152
15 Section 15 - Painting & Finishing
153
Exterior
153
Painting
153
Materials Recommended
153
Painting Equipment Required
153
Painting Procedure
153
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154
L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc
155
16 Section 16 - Placards
156
J230-C Decals
156
L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc
157
Cockpit Placards General
158
Cockpit Control Decals
158
External Fuselage
159
17 Section 17 - Fairings
160
Wheel Spats
160
Wing Fairings
160
Removal and Installation
160
Repair
160
18 Appendix I - Jabiru 3300 Engine
161
19 Appendix II - Jabiru Engine Parts Book
162
20 Appendix III - Engine Installation Manual
163
21 Appendix IV - Propeller Service Manual
164
Approved Installations
164
Identification Stampings
164
Description
164
Installation
165
L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc
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To Remove Existing Propeller
167
To Assemble and Replace Propeller Assembly
167
Servicing and Repairs
168
Propeller Balancing Procedure
169
22 Appendix V - Airworthiness Limitations
170
General
170
Interior Flame Retardant Maintenance Limitations
170
Composite Inspection & Maintenance
170
External Paint / Finishing Limitations
170
Control Surface Balancing
170
L:\Files\Technical_Manuals\J230_J430\J230.J430_Work_Files\J230-C_Tech_Rev_1.Doc
170
REVISION Dated : Feb 2006 Issued By: RAS Page: 4 of
171
REVISION Dated : Feb 2006 Issued By: RAS Page: 9 of
171
Mandatory Replacement
171
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