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JSA-SM230SP-A2 J230-SP/J250-SP Aircraft Service Manual

Contents

1. 6 Cz zz 6 TETRAETHYL LEAD GOOD POINTS 00000 5 1511122 6 TETRAETHYL LEAD BAD POINTS 0 0000000000000 6 THE EFFECT OF LEAD CONTENT cccecsccccececececcccececsccccucecacaucececscecsecececscauauselscseceaetecseauesetscauauaesststscsuauaeravans 6 AD CONTENT 5 2282888 8 8838838 0 6 5 WX 7 5 1 5 GOOD ee ne 7 5 2 MAS BAD POINTS nennen nennen nnne ene enel nnns 7 5 3 MOGAS USAGE RECOMMENDATIONS 2 re ride eee eee ee ese ese ese ese ese eser nera 7 5 4 DIES STORAGH 4 4 Iure Tre enne enean 7 55 MOGAS STORAGE RECOMMENDATIONS eee eI me emen ener 8 6 7 4 7 A 1 e ecc c rr rr rr re rer n e eoa e e ed n ron rune 9 6 1 GENE ek 9 6 2 PUNO GOOD POINTS eren nnne nenne 9 6 3 PIG
2. 6 3 6 3 Aileron Control Stop 0 1 m 6 6 Flap DVE Cir ___ _________ 6 10 6 5 Control Tube 6 11 6 6 Elevator Control S 6 14 6 7 Elevator Control 001 0 0 0 0 1 6 15 6 8 Tot ASSEDI 6 17 6 9 Trim Control Assembly 5 6 18 6 10 Rear lt nnn 6 19 6 11 Rudder Cable 5 2 2 2 12 1 6 23 6 12 T 6 24 6 13 Adjustable Rudder Pedals seen 6 25 zig Engine ai 7 4 2 Upper ENGINE ___ _ 6_ 6 6__ 7 8 7 2 Lower Engine acce n e acc e a 1 9 Ege M 7 11 7 15 7 6 Oil Recovery 2 1 2 11 2 66 nnn nnne 7 16 Ge et ee er ae A 7 19
3. ______1 50 6496 ONVId 9 292025 zZ 1MOO LEE FWOs ION OO S3NI3TIM SNOISNIWIA _ ONV 98300 0 wau v r J SA SM230SP A2 Cowl ine Upper Eng Figure 7 2 Page 7 8 Section 7 Engine Systems Jabiru 230 5 250 5 Aircraft Service Manual 4 30 YITANIH do ee TM PN ose i d HOALAV na sunny RON ONY 3dVvHS 3NI33CO OL LW dovSrovl GINOW ISN TlV L3Q0 dnAV T1 30 QN3 043 40 SH3AVI WNOLLIQUV dVTWiAO 3993 L33HS SSVP SOS dal 3903 L YAGYOS 10 1015 M3NNIdS OIM SH3AVT dud Old CDC4V 75309 39NIH 3HiHM da ONNOYY TN POR v1 30M OF HLOTS 3409 JO QN3 08 NOLLS3HId 3AY3M HLOTO gt J I3NHMS0 2 H3NIVI3H OOTWNVO 01 212 9 H3HSVM SS3TNIVLS MSO VrZZLOSELEV S MAYOS 56 16 ASI ISOE69PZSN 3AMdOdXSO te9xdVl ONVId WRINIWITIV s zsZ0zSW 1MOO NIVSPOVL 1 ONIOVdS uupoz
4. SIH L ASSY 091 1 pee 22696 00 _ NMVEC SSIMYSHLO 031419348 SS3INN Vd HO3 LAV 1vos LON oa S3MISWITIIN A SNOISN3WIGQ 8 190713 35813 AXOd3 SNISn WHY OL HSN ONOG WOOTHSONIHHOOG09i 08000v4 Ok ONO18X38NL 80 77 HShg839NIHMOOGd Noado00v4 6 PAIN DOTAN ZEOLSSE0ZSW 8 MHBOSONNQSHIINDOO 9Lt 856 969 064 Z aay ee 01 096 Nhas9SdvO9ONQZ LX 9ME 2 geoooowsz M3HSVMANN3d 9LE 20 0 6 Z po 600 CCC IN Ld Wall 54 Figure 3 4 Door Hinge Assembly J 160 170 230 250 Page 3 7 JSA 5 2305 1 Jabiru 230 5 250 5 Section 3 Aircraft Service Manual Fuselage Structure 7 __140 11346 26094 00 002 51 ASSY YOOd LNOUS ssi sa 22 s _ NIMS 43170 OL SNIGNO SONIH HJAO SNPS 340438 91 9 113 3909 HOLVO XOQ Y Y MIIA NOILOAS 5 NILYN N334138 MOOT 5 YOIWSLNI OL GANIOF SI NIMS 8009 31 25 LON JUIL V
5. 109 6 31 25 VV NOILO3S i NIMS YSLNO 38 OL AZNVS AXOd3 NIA G 110112 OLNI HSAW 13315 SS3JINIVIS 3903 84445 35 01 dN QN38 833445 1 01 OL NMOQ ANJE J NYld 9NION38 03395 TIYIS ANNAL AXOd3 110112 OLNI 39NVIJ NOS 8 ISOH 2 T3NNO TIVLS 0100800 s s 90 5 61900 38 ON IS 1 SI SIHI 31 25 LON OQ ing System Stall Warn 10 1 igure F Page 10 5 J SA SM230SP A0 Section 10 Jabiru 230 5 250 5 Utility Systems Aircraft Service Manual THIS PAGE INTENTIONALLY BLANK Page 10 6 J SA SM230SP A0 Jabiru 230 5 250 SP Section 11 Aircraft Service Manual Electrical System and Instruments 11 1 11 2 11 3 Section 11 Electrical System and I nstruments General Description The electrical system of the aircraft is supplied by an alternator that 15 built into the flywheel of the engine A voltage regulator converts AC from the alternator to 14 volt DC current which 15 then routed from the regulator rectifier to the battery Aircraft electrical power is conducted to the master switch breaker and then to the main and instrument buses Switch breakers and circuit breakers feed and cir
6. SLINY HLOTO NAAT 1 3309 WW HLOTO EO JV d A V1 MOS 59071 9NINSTIV MOOD dol ul I 9 NOILO3POHd 31725 LON od SSYLAWMIW SNOISNANIO Gat LEE Page 7 9 Cowl Ine Lower Engi Figure 7 3 SM230SP A2 Section 7 Engine Systems 7 5 7 6 Jabiru 230 5 250 5 Aircraft Service Manual Engine Mount 7 5 1 7 5 2 Description The engine mount 15 a welded assembly Its purpose is to support the engine and at tach the engine to the airframe The engine 15 attached to the mount with rubber lord mounts that absorb engine vibration Removal Tools Required 7 16 and 3 8 wrenches screwdriver set Parts Required New AN4 21A bolts and AN363 428 nuts for reinstallation Level of Certification Required A amp P or LSA R M M 1 Remove engine and accessories from the mount as described in 7 1 2 Spacers may be used to correctly align the engine Ensure that they are correctly marked on removal and correctly reinstalled during reassembly 3 Remove nuts and bolts attaching mount to firewall 4 Remove mount 7 5 3 Inspection Inspect engine mount for cracks and rub amp abrasion marks 7 5 4 Repair V CAUTION The engine mount should not be repaired Repair 15 limited to replacement 7 5 5 Reinstallation Use new AN4 21A bolts and AN363 428 nuts to install the engine mount Tighten to
7. 6 89 inches aft of datum MOSTAM C G EoCallOTi 13 30 inches aft of datum 1 6 Tire Inflation Pressures Standard pr 35 40 PSI Page 1 4 J SA SM230SP A1 Jabiru 230 5 250 5 Section 1 Aircraft Service Manual General Description 1 7 Equipment List The following is a list of all available equipment that affects aircraft weight and bal ance Each aircraft is equipped with one of the four instrument panel packages and may include upgrades or substitutions listed in the Panel Upgrades section of Table 1 2 S Standard on all aircraft O Optional equipment on all aircraft S O Standard on some aircraft see note in parentheses Instrument Panel Package 0 3 1 8 Airspeed Indicator 3 1 8 Altimeter 3 1 8 Vertical Speed Indicator 3 1 8 Pictorial Pilot Turn amp Bank EIS 6000 Engine Monitor Garmin 5140 Com Radio 100011 Intercom Instrument Panel Package 1 GRT Sport EFIS PFD EIS 6000 Engine Monitor Garmin CTransponder _ _ 2 1 4 Airspeed Indicator o instrument Panel Package 2 Dual GRT Sport EIS displays PFD and FD Garmin 2 1 4 Airspeed Indicator JSA SM230SP A1 Page 1 5 Section 1 Jabiru 230 5 250 5 General Description 1 7 Equipment
8. SLAN pRB pe ___ 6 J OU LINS OL JAINA 14 _ dovesove Li 0 NO 6 NS ODENY 8 pe 7 QGN3GOHN3OVdS 768000 9 ASSV S 3H L OMINOO 66 NAON VL GL M3HSVM LYT whl 98Hr096NV ZEOL SSEOZSN SS3NDOIHL H3HSVM 0LO096NV 5 430995 8 0 0 4 1 IONS 31435 5 as eiv ld 91415579 HOLVhLLOV HV3NITT NOOOVEWd INNON GANAS 9914 2151923713 _ 6 4 5 SsuaNO8SIVHMOOW pb 9 60 50 p 4fNOOIN 9H ZEOKSOEOZSA OLO9ONV 6966500 b ALD NOLLdINiOS3Q L va Figure 6 5 Flap Control Tube Assembly Page 6 11 JSA 5 2305 1 Section 6 Flight Controls Jabiru 230 5 250 5 Aircraft Service Manual 6 5 Elevator Control Sy
9. v 0zEOE LL 1 4MOHSSONMZDIVHS v60l 0E OL Al OFSNV 8 ES 1532 _ Ley ON E3 H3HSVM 1914 9 1 8WVHBlfidNIH3AJI 00022009 v 3 50 008209 z HBISVA A _ _____ oNIMVd Wall J SA 5 2305 1 4 Brake Master Cylinder Assembly Figure 5 Page 5 16 Jabiru 230 5 250 5 Aircraft Service Manual Section 5 Landing Gear and Brakes 5 8 6 Reinstallation of Master Cylinder 5 6 Tools Required Allen key set 1 2 and 7 16 wrenches Level of Certification Required A amp P LSA R M M Connect the master cylinder using the retaining bolts 2 Remove plug or cap from hydraulic fittings and hoses Reconnect the flexible hose at the master cylinder Reinstall the brake handle Reconnect the flexible hose to the wheel brake assembly Fill and bleed brake system in accordance with Paragraph 5 8 7 5 8 7 Bleeding Brake System Tools Required 1 4 wrenches brake fluid injector Parts Required Dot 4 automotive brake fluid Level of Certification Required A amp P LSA R M M V WARNING Use only automotive DOT 4 brake fluid DO NOT use JSA 5 2305 1 aircraft grade hydraulic fluid or damage will result Open the brake bleeder valve slightly to facilitate bleeding of air from the system Attach a tube from the no
10. 3 9 3 7 New Style Door 202 4 nnn nnns 3 9 3 8 Interior Door Hinge Bolts New 5 3 10 3 9 Upper Door Hinge New 3 10 4 1 Wing Assembly 250 5 4 6 5 1 Main Landing Gear 2 0 0 nnns 5 3 5 2 Assembly of Matco Wheel 5 12 5 3 55 5 13 5 4 Brake Master Cylinder 5 16 505 Nose ___ _____ _ 5 23 5 6 Nose Leg Suspension 02 0 00 0 5 24 5 7 Nose Leg 0 1 1 nnn nns 5 25 5 8 Nose Wheel 5 26 5 9 Nose Wheel Shimmy Dampener Serial 665 5 27 6 1 Control Style ER rt Credere RA 6 2 6 J SA 5 2305 1 Jabiru 230 5 250 5 Aircraft Service Manual Title of Figure Page 6 2 Control Column New
11. 7 dWSLHOIH BE ZEOL SPOLZSW OL 6 NEUEM ONT PHS ANNE w b 96 0092 9 VNZIOVPHd S 0086 LNNOW 97007 10 50 20085 7 20009 ZVXe0vO96 Z ALO AALI 5 M3HW N WALI 1811 8911 Page 7 15 Figure 7 5 Oil Cooler SM230SP A2 Section 7 Jabiru J 230 5 250 SP Engine Systems Aircraft Service Manual 7 9 Oil Recovery System 7 9 1 Description The primary purpose of the oil recovery system is to collect excess oil thrown out of the crankcase breather vent The oil line is connected to the engine crankcase filler neck and deposits excess oil into a bottle mounted on the firewall The bottle will also collect excess fuel in the event of a fuel pump failure Fluid level is visible through the side of the bottle It should be emptied at each oil change or when oil is seen dripping from the overflow tube 7 9 2 Removal Tools Required Flat head screwdriver Level of Certification Required Owner A amp P or LSA R M M 1 Loosen the clamps around the hoses on top and on the side of the oil bottle 2 Pullthe clear tube out of the top 3 Lift the bottle from the clamp on the firewall 4 Dispose of collected oil 5 Clean bottle and mount area as necessary and reinstall to firewall Be sure t
12. NOISN3IX3 931NOLLO3NNOO 130 937 1 008990 9 Z E 931350 593 NOLLdIJOS3Q WALI Figure 5 9 Nose Wheel Shimmy Dampener Serial no 665 and later Page 5 27 JSA 5 2305 1 Section 5 Jabiru J 230 SP 250 SP Landing Gear and Brakes Aircraft Service Manual THIS PAGE INTENTIONALLY BLANK Page 5 28 J SA 5 2305 1 Jabiru J 230 SP 250 SP Section 6 Aircraft Service Manual Flight Controls 6 1 Section 6 Flight Controls Control Column 6 1 1 6 1 2 6 1 3 6 1 4 Description The control column is a machined aluminum assembly mounted the center console of the cockpit that directly controls the ailerons and elevator It has a machined aluminum hand grip and lower lever arm that attaches to the elevator control cable on the front end The hand grip is hinged to move fore and aft for elevator control It rotates around a horizontal column that extends rearward through the center console and exits out the back where a mixer horn attaches to the Teleflex aileron cables between the seat backs The column rotates along the longitudinal axis of the aircraft inside a pair of nylon bushings that are epoxied and flocked permanently into the fiberglass center con sole Refer to Figure 6 1 or 6 2 Control Column Assembly Removal and Reinstallation The control column is a primary control and may not be removed or r
13. ________4 _ _ 6_ 6 __ JSA 5 2305 1 1 Section Title 2 8 2 9 2 10 General Inspection Guidelines 2 11 Cleaning LOT Inspection Intervals Section 3 Fuselage Structure 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8 3 9 DESCHOUON T 5 Baggage Seat Belt Horizontal 5 Vertical Stabilize oarre Section 4 Wing Structure 4 1 4 2 Wing 0 Section 5 Landing Gear and Brakes Page 2 5 1 5 2 5 3 5 4 5 5 5 6 5 7 5 8 5 9 General Landing Gear Troubleshooting Chart Main Wheel Fairings Main Gear Top Fairing Lower Strut Fairing Main Gear Leg Assembly Main Wheel Stub Axle Main Wheels and Brakes Master Cylinder Parking Brake Assembly Nose Wheel Jabiru 230 5 250 SP Page E 5 19 J SA 5 2305 1 Jabiru 230 5 250 5 Aircraft Service Manual Section Title Page 5 10 Nose Gear nnn se nen 5 19 NOSE WV MCC 5 21 Section 6 Flight Co
14. 3l 51708 YALYOHS ASN IVNINON SHLONATLIO 71 Jabiru 230 5 250 5 Aircraft Service Manual _____ 1 ONS 69009 9 pb HSM LVS _ SE 2 0 Vv9eotNv ee MSHSVMSSVHHIVE Zt S N69v Hd ze dos 31TvWad COH H3OVdS pO Ie sdAVIO3IEVO N68000d 0 MIHSdAVIOd318VO WiML 871004 SC PINE 22 _ ________________ __ 9 K NMHOHMiHL lXd SZ QN3QOH3TVW SVe N O00Bd vC Pp Ndao ez MSHSVMlVH B E __ 8 8096NV 22 ______ QqOMONINIVISH ONIMdS oz JOWootHliOAd3Ad3IS 2 601905 2 2 po 8i 5 n o 4 225 ta gt 2 gt n i tn E 2 lu 2 5 55 5 2 i mS am BA HWA 2 MSHSVMIVH 9LE 5 5 lt SH ODBNW E AlHW3SSV WHL ONLINCION 60890 Zz 6050 HSN vd ie
15. Comments Induction System Check the SCAT hose for damage and wear Check the carburetor heat box for blockage security cracks operation and wear Comments Cooling Baffles Check for cracks worn areas and security JSA 100HR A1 Cylinders Check cylinders and exhaust manifold for obvious leaks security and cracks Check cylinders for broken cooling fins and loose or missing base nuts Comments 100 Hour Annual Inspection Checklist Page 7 of 17 Jabiru J 230 5 250 5 and J 170 SP Aircraft Service Manual JSA 100HR A1 Crankcase Check for security of crankcase half bolts Check front seal for leaks Comments Hoses and Ducts Check all fuel oil and SCAT hose or duct for leakage cracks deterioration and damage Check fittings for security Comments I ntake and Exhaust Check for deformation security cracks leaks loose or missing nuts and clamps Check for thin wall condition which may occur due to normal internal erosion on exhaust stacks which have long service time Comments Ignition Check for proper connection security and fraying Check gap between coil and flywheel magnets should not exceed 010 Comments Distributor Caps amp Rotors Check for wear at the contact points Replace every 200 hours Comments Spark Plugs amp I gnition Leads Clean inspect regap test and replace spark plugs as necessary Tighten spark plugs to proper torque Check ignition harness condit
16. S3ML3AITIN SNOISN3HIQ WHOdHlV d HOSIAV HddY sv OL SLIWH NIMS X000 LNOYS 194 SNOIMH3LNI HOOQ 69 Ald HO3LAV 30 LN3SNOO LNOHLIM 031902 38 LON LSAW LHOIMAdOO SI SIHL 6 4 5 ONIGNOE OL Ald 133d 8 N909S11 ANY 90981 5 ALISOddO SI SH 2 AINO 43H SWIC 9 NIS3H AXOd3 COSEAT ASN S NIMS NO 03490714 SI HOOQ ASSV HOLVO HOOT HOOQ SSDNIH 3H3HM 6064 5 1 NIMS HSLNO 064 1 HLIM SI NIMS H3NNI 0 4V SHAAVT z dn NIAS HALNO 126 S3IQNVH Lid OL SNIMS 1015 LNO 046 SSvI9 LOCHAY 5 1 6 NMOHS V3 V NI NIMS X000 YANNI 39904NI2H SSV15 4 TVNH31X3 SSV 19d TVNH3 LX3 109120 2 qoa 2072 NLOOVZOd uaaanu Was 15 HOOG S1ASSV 831935 0 060 57 MOGNIM 1 0 00 0961 0961 S 1NDIS LNOH4 57 5NIC TITION HOIH3 LNI LNOHH NOI LdlHOS3Q LuVd ON LUVd Will ALO 1611 SLdVvd Door Structure Figure 3 5 J SA 5 2305 1
17. sna 30815 NT AYN SON E NOISN31X3 578 18338 24311 m1 HOLOW C EE mio amp m amp c 545 SNS SNS 7313 ans 504 1 dvd sna QNhnONO LN3ADHISNI _ 1 544 92 FT Mox 4 4 sa 7 M z LI Li 53 3 no OF 15 typ lagram ID Panel 2 Electrica Figure 11 11 Page 11 27 5 2305 1 Section 11 Jabiru 230 5 250 SP Aircraft Service Manual Electrical System and Instruments IF OIG 9180 XXXN 2904 T3NVd 9nib NIVIN NOISNSLXA SAA ay 5 Ofo 8 Lj 1 E i 5 8 1d323M ADO ix RE 8 8 WO23M31NI o o y E SHS SNS SNS d Tad Tanz S d 38085 sng IN3MPIHLISNI fos 514 ANH d Ax 9 9 o Li 3 typ lagram ID Panel 3 Electrica Figure 11 12 J SA 5 2305 1 Page 11 28 Jabiru J 230 SP 250
18. 1 1 1 200 10 3 4 J SM230SP A1 Jabiru 230 5 250 5 Aircraft Service Manual Section Title Page Section 11 Electrical System and nstruments 11 1 General c n ne c c e 11 1 11 1 e _________ ___ _________ 11 1 11 4 Switches and 11 2 INE rnc t M 11 3 11 6 Navigation Lights and 5 2 207 11 3 11 7 Recognition Landing 11 5 S PROU 11 6 11 9 Engine Information System EIS 01 0 mm 11 9 11 10 Electronic Flight Information System EFIS 11 10 11 11 Garmin Nav Com 0 40 0 0 0 0201010 11 16 11 12 Garmin 2 1 1 1 20000 11 19 11 13 Emergency Locator ees 11 20 11 14 PS Engineering nme 11 21 11 15 TruTrak DigiFlight IIG 11 21 11 16 External P
19. 2 Figure 3 Current Wedge Combustion Chamber JSL007 3 doc Page 4 of 14 JSL 007 3 oth Nov 2009 3 3 Fuel Octane Rating Requirements e All 2200B 2200C and 3300L engines may be operated using 95 Octane RON or higher MOGAS or AVGAS fuels The fuels may contain alcohol to the limits listed in Section 6 6 e Table 1 can be used to find which fuels should be used for a given engine Example 2200 engine S No 800 with no shims fitted and therefore compression ratio of 8 3 1 Section 3 Combustion chambers have been re worked to Figure 2 Read the table as marked with the arrows to the grey shaded cell the engine may use 95 Octane MOGAS Table 1 Chamber Compression Matrix Compression High Octane Modified High Chamber Octane Chamber Wedge Chamber 931 100 RONorhigher 100RONorhigher ___ ___ m 831 100 RON or __ 100 RON or 95 RON e Any of these engines may use fuels containing alcohol up to the limits given in Section 6 6 JSL007 3 doc dc id Page 5 of 14 4 2 4 3 4 4 4 5 Fuel Containing Tetraethyl Lead General As noted above worldwide AVGAS 100LL is the most common grade of aircraft fuel available The LL designation indicates that the fuel contains a Low Lead level when compared to AVGAS 100 which may also be known as AVGAS 100 130 Typically AVGAS 100LL contains less than 0 56grams litre w
20. Page 3 8 Jabiru 230 5 250 5 Aircraft Service Manual 3 3 2 Section 3 Fuselage Structure 3 3 1 3 Door Seals Weather strip is glued around all edges of the door and door sill Apart from excluding wind and water the weather strip is important in minimizing exhaust fume entry to the cabin It should be maintained in good condition and fit at all times To replace the weather strip use household door amp window EDPM rubber weather seal 7 16 thick x 3 8 wide for gaps 1 8 to 7 32 It may be found at major hardware stores Make sure surfaces are clean dry and free from oil and grease Use superglue to reinforce the bond of the self adhesive backing Door Removal Tools Required 7 16 wrenches old style or 5 32 hex new style Level of Certification Required A amp P or LSA R M M The old style door hinges are not visible from the outside of the aircraft They are simple to remove however they sag over time and are damaged easily so the hinge design was changed to create a tougher door in 2008 see Figures 3 6 and 3 7 Figure 3 6 Old style door hinge Figure 3 7 New style door hinge JSA 5 2305 1 pilot s side passenger side Page 3 9 Section 3 Jabiru 230 5 250 5 Fuselage Structure Aircraft Service Manual Removal of Old Style Door 1 Open door Have a helper support the door until hinge bolts are removed 2 Remove the hinge bolts that attach the hinges to the
21. Section 3 Jabiru 230 5 250 5 Fuselage Structure Aircraft Service Manual THIS PAGE INTENTIONALLY BLANK Page 3 14 J SA SM230SP A1 Jabiru 230 5 250 5 Section 4 Aircraft Service Manual Wing Structure 4 1 Wings 4 1 1 4 1 2 Section 4 Wing Structure Description Each composite wing 15 a semi cantilever monocoque type with a main spar The wing is a molded structure with a series of ribs that are bonded through the molding process to the fiberglass skin fuel tanks and to the spar The forward wing attachment 15 an extension of the forward sub spar The rear at tachment is a composite block heavily bonded to the reinforced wing skin and attach es to the main spar through the Wing End Plug Both attachments are through stain less steel threaded bushings bonded into the attachment blocks Removal Tools Required Screwdriver set 1 2 and 7 16 wrenches tall pad ded sawhorse or wing stand Level of Certification Required A amp P or LSA R M M The J abiru aircraft is designed with wings that are removable for storage or transport Wing removal is most easily achieved if two people are available to handle the wing 1 Remove wing root fairings 2 Drain fuel out of quick drain Note This will take some time 3 Remove wing strut fairings top and bottom 4 Disconnect pitot tube RH wing only Pitot connection is under lower strut fairing 5 Disconnect landing light wires Wire connection is under lower
22. 12 Install the ring terminal on the shield wires 13 Reinstall the ring terminals onto the antenna 14 Reinstall the rudder and control cable as outlined in Section 6 7 J SA SM230SP A1 Page 11 17 Section 11 Jabiru J 230 5 250 SP Electrical System and Instruments Aircraft Service Manual Figure 11 6 Ferrite baluns sealed onto antenna cable with heat shrink tubing left and finished antenna wiring showing double holed balun right Page 11 18 5 5 2305 1 Jabiru 230 5 250 SP Section 11 Aircraft Service Manual Electrical System and Instruments 11 12 Garmin Transponder 11 12 1 Description Both Garmin transponder options the GTX327 and GTX330 are capable of Mode C altitude encoding The GTX330 is also capable of Mode S communication which ena bles traffic information to be displayed on the EFIS within airspace supported by Traffic Information Service TIS Transponders in aircraft equipped with at least one GRT EFIS get their altitude infor mation from the EFIS and do not need a separate altitude encoder for the tran sponder If the aircraft is not equipped with a GRT EFIS or GDU 375 the encoder box is located under the panel and is plumbed into the aircraft s static system 11 12 2 Removal Tools Required 7 64 Allen key Level of Certification Required A amp P LSA R M M or Avionics Repair Station 1 Using the 7 64 Allen key loosen the retaining screw through the transponder face 2 T
23. 4 Press the unit into place Reinstall the two screws to hold it in position 5 Clean up excess silicone AeroLEDs 1 Connect wires 2 Reinstall ground on battery and test light for proper color and operation 3 Slide light unit onto mount making sure O ring is in place It may help to apply a Page 11 4 small bead of superglue to keep the O ring in place Tighten set screw J SA SM230SP A1 Jabiru 230 5 250 SP Section 11 Aircraft Service Manual Electrical System and Instruments 11 7 Recognition Landing Light 11 7 1 Description The strut mounted recognition light contains one 50W incandescent bulb Aircraft built after May 2009 had the option of an AeroLED MicroSun LED landing light mounted in the leading edge of one or both wingtips 11 7 2 Removal Tools Required Phillips screwdriver Level of Certification Required Owner A amp P or LSA R M M Strut Mounted Recognition Light 1 Disconnect ground wire from aircraft battery 2 Remove 2 screws from sides of aluminum collar 3 Slide collar off 4 Remove and disconnect light bulb Strut Mounted Recognition Light Housing 1 Disconnect ground wire from aircraft battery 2 Remove 8 screw and nut from rear of housing 3 Slide housing off wing strut AeroLED Landing Light 1 Disconnect ground wire from aircraft battery 2 Remove 6 screws from clear Lexan lens 3 Remove 4 mounting screws from LED unit 4 Slide LED unit out 5 Disconnect wires 11
24. 9 18 20 ALD Dvd Wall 8 J SA 5 2305 1 Figure 5 8 Nose Wheel Assembly Page 5 26 Section 5 Landing Gear and Brakes Jabiru 230 5 250 5 Aircraft Service Manual L GOV9v0V9 assy ONIMSSALS 931 ISON ON OMG ssi ul 8002 0122 JWI AI8W3SSY 3811 921 40 3GISNI NOM H3NHOOD dNHVHS SAOWSY OL 3114 ANNOY ISN 0297 M3 TANIH 40 S3 IONY 9070 2301 OML 92 0 23 3 26 982 0L0 60 S ON TIOHM S3ONVEHTIOL ld HO3 LAV NI divos LON SQMATTIAN 55 NO 3911 30 dOl 5 OL JM 1 14 ASN 3SV3H9 Ald HO3LAV LN3SNOO LNOHLIM Q3ldO2 38 LON LSNW ANY LHOIHAdOO SNIMVHC SIHL V V NOILOAS V Y0 6NV 0 _ 6 AT8ASSSV NO DOTAN 827 695025 8 NOLLOANNOS OL TIHA HOLVA M3HSVM 9 7 096 4 aaTima Nn 5 NOISN3 DX3 931 mm saaan 1 00570 9 9 NOLLO3NNOO ONIMSSLS 3A331S 1 0039 0 9 S NOLLO3NNOO 1 05 16 008590 9 v XNITNOLLO3NNOO 1405 WHY 16 1 002990 9
25. Section 11 Jabiru 230 5 250 SP Electrical System and Instruments Aircraft Service Manual 11 10 Electronic Flight Information System EFI S 11 10 1 Description The J abiru S LSA instrument panel features a Grand Rapids Technologies Sport EFIS unit for primary flight instrumentation and navigation The three panel options include a four pack of traditional round dial instruments one EFIS on the left side only or two EFIS units where is a primary flight display PFD and one 15 a multi function dis play MFD Single EFIS units are plumbed to the pitot static lines and a GPS antenna in addition to the 37 pin D sub connector In aircraft equipped with a second 5 as a multi function display the pitot static lines run to the PFD while the GPS is part of the MFD For detailed EFIS installation and user manuals refer to the Grand Rapids Technologies website and contact information found in the Appendix of this manual 11 10 2 Removal Tools Required 9 64 Allen key screwdriver set knife heat gun for reinstallation Level of Certification Required Owner A amp P LSA R M M or Avionics Repair Station 1 Remove the four screws at the corners of the unit 2 Pull the unit from the panel and disconnect the D sub connectors from the rear of the unit 3 If the unit is a primary flight display disconnect pitot static lines If lines cannot be pulled cut them just behind the fitting If slave multi fun
26. b JSA 5 2305 1 Page 6 19 Figure 6 10 Rear Trim Assembly Section 6 Flight Controls Jabiru 230 5 250 5 Aircraft Service Manual 6 7 Rudder Control System 6 7 1 6 7 2 6 7 3 Page 6 20 Description The rudder system 15 made up of one rudder hinged to the vertical stabilizer which 15 controlled by two sets of rudder pedals two push rods a centering mechanism and an enclosed push pull cable The rudder pedals also control the nose wheel via direct link steering pushrods The rudder consists of a molded and bonded monocoque fiberglass structure with a front spar that is attached to the rear spar of the vertical stabilizer via three hinges It incorporates a composite control horn on the lower right side The rudder control cable is of the enclosed push pull type fitted with spherical bearings at both ends as described in Section 6 2 The nose wheel steering pushrods are solid aluminum with ball link ends See Section 5 Landing Gear for more information NOTE Rudder contro cables are primary controls and may not be removed or repaired without reference to Jabiru USA Sport Aircraft LLC or our approved local agent Troubleshooting Have an assistant push the tail down until the nose wheel is off the ground Operate the rudder pedals Rudder amp steering should operate smoothly without mechanical in terference Isolate the cause of any interference The aircraft is rigged at the factory to fly
27. shield V Caution When grinding out the old epoxy and flock do not grind through the fiberglass of the Joggle Joint Window I nspection Inspect windows for scratches and cracks If cracks are greater than 25mm long re placement is necessary Cracks in the body filler along the edge of the windscreen may occur due to rapid tem perature changes and expansion of the Perspex windshield Sand and repair filler using basic bodywork paint procedures in Section 12 J SA 5 2305 1 Jabiru 230 5 250 5 Section 3 Aircraft Service Manual Fuselage Structure 3 2 6 Repair Repair is limited to scratch polishing as outlined in Paragraph 3 2 2 or crack repair out lined in Paragraph 3 2 3 Otherwise repair is limited to replacement 3 2 7 Replacement of Windscreen and Side Windows Tools Required File or small grinder drill with 1 8 unfluted drill bit 7mm socket 2 Phillips screwdriver small flat clamps sandpaper 24 hour epoxy cotton flock Parts Required Windscreen or window M4X12 countersunk screws and nuts hardware to make window clamps see Figure 3 1 Level of Certification Required A amp P or LSA R M M Windscreen 1 10 JSA 5 2305 1 Fabricate about 20 small simple clamps as shown in Figure 3 1 One small piece of sheet metal stock with one small sheet metal screw will suffice for each clamp The se will be used to hold the windshield in place while the epoxy cures Ensure all
28. 11 10 7 2 Removal Tools Required Small wire cutter Parts required None Level of Maintenance Line Level of Certification Required A amp P LSA R M M or Avionics Repair Station 1 Locate GPS antenna head Most will be located above the co pilot s door Velcroed to the upholstery as shown in Figure 11 5 2 Gently remove the door post panel cover if necessary either Velcro as shown or Small truss head screws and fish the antenna down toward the floor 3 Locate antenna cable Over door installations require cable to run alongside the snake skin wire bundle which is tied underneath the co pilot doorsill Clip zip ties as necessary 4 Follow wire up behind EFIS unit Pull connecter gently straight back out of unit 5 Remove antenna from aircraft Page 11 14 J SA SM230SP A1 Jabiru 230 5 250 SP Section 11 Aircraft Service Manual Electrical System and Instruments 11 10 7 3 Inspection Inspect wire and connector for condition 11 10 7 4 Repair Unit must be sent to Grand Rapids Technologies for repair or replacement 11 10 7 5 Reinstallation Reverse steps in 11 10 7 2 for reinstallation Replace zip ties as necessary 11 10 8 WxWorx XM Weather Module 11 10 8 1 Description EFIS equipped aircraft have the option of a WxWorx XM Weather module that can show radar METARs TAFs etc on the EFIS screens depending on sub scription level NOTE See Section 11 11 for more information on radio static caused by the WxWorx
29. 11 11 Panel 2 2 5 4 11 27 11 12 Panel 3 Electrical 11 28 12 15 Door Hinge R pa uniia 12 6 12 2 12 6 8 J SA 5 2305 1 Jabiru 230 5 250 5 Aircraft Service Manual List of Tables Title of Table Page 1 1 230 5 250 SP 6 m 1 1 1 2 Standard and Optional 0 1 nmn 1 5 1 3 List of Disposable Replacement 5 1 9 1 4 Recommended Fastener Torque 1 10 2 1 Aircraft Empty Weight and Moment 1 2 5 2 2 Aircraft Empty Weight 2 7 7 1 Replacement Flexible Hoses seen 1 21 9 1 Ground Adjustable Propeller Pitch 5 5 9 5 9 2 Approved Propeller lt 1 9 6 JSA SM230SP A1 9 Jabiru 230 5 250 5 Aircraft Service Manual Foreword This m
30. 2009 and newer 11 4 2 Removal Tools Required 1 2 deep well socket or pliers Phillips screwdriver Level of Certification Required A amp P or LSA R M M 1 Remove ground wire from aircraft battery 2 Taking care not to scratch the face of the instrument panel remove the nut on the front of the switch using the socket or the thumb screw on the front of the breaker using a pliers 3 Remove screw from bus bar Page 11 2 J SA SM230SP A1 Jabiru 230 5 250 SP Section 11 Aircraft Service Manual Electrical System and Instruments 11 5 11 6 4 Remove screw from accessory that the switch or breaker is attached to 5 Depending on location along the bus bar other switches may need to be removed to access the affected switch 11 4 3 Repair Repair of switches and breakers 15 limited to replacement 11 4 4 Reinstallation Reverse steps in 11 4 2 for reinstallation Starter 11 5 1 Description The starter is a Nippon Denso electric motor which 15 activated with the ignition key and a solenoid The starter is equipped with a standard Bendix which engages a gear with the teeth on the engine flywheel when activated 11 5 2 Removal Inspection Repair and Reinstallation Refer to the nstruction and Maintenance Manual for J abiru 3300 Aircraft Engine for information on removal inspection repair and reinstallation of the starter Navigation Lights and Strobes 11 6 1 Description Jabiru S LSA aircraft are equi
31. 7 28 129 WVU 7 29 7 10 Head Bolt 5 7 31 8 1 Fuel System Schematic s n 726 and earlier 8 9 8 2 Fuel System Schematic s n 795 and newer 8 10 PROD MOUNE DG tU UG Ub EIN TUERI 9 7 9 2 Assembly of Ground Adjustable 9 8 JSA SM230SP A1 Page 7 Jabiru 230 5 250 5 Aircraft Service Manual Title of Figure Page 10 1 Stall Warning 10 5 11 1 Pitot Static 11 7 2 Stat Vent Detail 11 8 11 3 Sport HS EFIS 11 11 11 4 Magnetometer 11 13 11 5 is 11 14 11 6 Ferrite Balun 11 18 AULODIOT SOL VOS FEE E t 11 22 11 8 External Power Receptacle 11 24 11 9 Finished External Power Receptacle Installation 11 25 11 10 Panel 1 Electrical 2 2 0 00004 0 0 n 11 26
32. Page 12 of 17 Jabiru J 230 5 250 5 and J 170 SP Aircraft Service Manual Windows and Doors Inspect windows for scratches crazing and general condition Inspect doors for security and attachment Check latching mechanism for proper engagement and ease of operation Comments Seats Seat Belts and Shoulder Harnesses nspect cabin seats seat belts and shoulder harnesses for proper operations condition and security of attachment Comments Ventilation System Check all fresh air vents for obstructions proper movement and operation Fuel System Inspect for leakage security freedom of movement and condition Inspect fuel filter and replace if necessary Check security of all fuel line hose clamps Check for proper placarding Comments Headset J acks nspect for cleanliness security and evidence of damage 4 Wings and Carry Through Structure JSA 100HR A1 Skin Check for deformation and obvious damage Check for cracks If damage is found check adjacent structure Check for indications of excessive flight loading Comments Access Panels for cracks proper fit and attachment 100 Hour Annual Inspection Checklist Page 13 of 17 Jabiru J 230 5 250 5 and J 170 SP Aircraft Service Manual Control Cables Check aileron controls for smoothness and ease of operation Check aileron cable clamps for security and proper placement Check control cable ends f
33. clear of the rudder hinge line during ground handling or pinched fingers may result V Never move the propeller when the engine is hot as it may fire unex pectedly and result in severe injury V Always ensure that the Master and Ignition switches are OFF before touching the propeller V Never approach the propeller when anyone is in the aircraft V Always treat the propeller as LI VE JSA 5 2305 1 Page 2 1 Section 2 Jabiru J 230 5 250 SP General Care amp Inspection Aircraft Service Manual NOTES 1 Approved push pull points 2 Do not push or pull on propeller tips Figure 2 1 Approved Push Pull Areas Page 2 2 5 5 2305 1 Jabiru 230 5 250 5 Section 2 Aircraft Service Manual General Care amp Inspection 2 2 Jacking the Aircraft The easiest way to jack the aircraft for access to the main wheels Is to lift up on the wing Spar just outboard of the wing strut attach point NOT at the wing tip The pro cedure used at J abiru USA is as follows 1 JSA 5 2305 1 Empty the aircraft of excess cargo to make the lift easier Shut off main fuel valves to avoid fuel cross feeding out of the wing to be jacked Find an engine hoist with enough height to raise the wing a few inches Make a flat lifting platform to fit securely to the tip of the hoist arm The platform used at J SA is made from 3 4 plywood and straddles the top of the hoist arm as shown in Figure 2 2
34. pound curves Using the paint brush press the peel ply into the fiberglass cloth No additional epoxy is needed Set up a light inside the cabin so that dry areas will be visible during the application of the glass layers Repeat steps 7 10 above to begin the interior repair Apply a generous amount of epoxy to the second layer of glass If there are any dry spots in the second layer add the amount needed to fully wet the cloth Applying too much is ok Apply the third piece of fiberglass on a bias Press it into the second piece using the paint brush Soak the third layer in the excess from the second layer Ideally there should be no need to add any additional epoxy unless all the excess is soaked up however do not leave any dry spots or air bubbles inside the layup Any areas that appear whitish will become a weak area in the repair Apply peel ply to the interior as in steps 12 and 13 Allow 24 hours to cure Remove peel ply Carefully sand any rough areas Refer to Paragraph 12 4 for prep and paint instructions If necessary reinstall the carpet that was pulled up in the first step using contact cement or upholstery glue If the carpet was destroyed during removal contact Jabiru USA for replacement pieces Page 12 3 Section 12 Jabiru 230 5 250 5 Fiberglass Repair Aircraft Service Manual 12 3 3 Damage to Wing or Horizontal Tail Damage to skin may be repaired using the procedures in this manual as long a
35. spring on the inboard side of each baffle and slide the baffles back along the spark plug wires to get them up and out of the way of all the top head bolts Remove spark plug wires from spark plugs if necessary 4 Starting with cylinder 1 remove valve cover Use rag or pan to catch oil that will drip from head 5 Refer to Figure 7 10 Head Bolt Locations Note that there are 6 head bolts Bolt Number 5 is located at the 6 o clock position of the head behind the rocker cham ber To access this bolt the plug must be removed from under the rocker arm shaft center bolt Use the 3 16 Allen key to remove the plug 6 Torque head bolts to 20 ft lbs moving in a criss cross pattern around the head see Figure 7 10 Do not loosen bolts first just apply 20 ft lbs to the head bolts as they are A 4 long 1 4 Allen key is needed for the head bolt behind the plug at the 6 o clock position JSA SM230SP A2 Jabiru 230 250 SP Section 7 Aircraft Service Manual Engine Systems 10 11 12 Reinstall rocker chamber oil plug Torque plug to 8 ft lbs DO over tighten Reinstall valve cover making sure O ring is seated in the groove on the head Repeat with all heads Reinstall spark plug leads and cooling baffles Make sure all tools are removed from engine compartment and the crankcase con tains the proper amount of oil Run the engine briefly Test both magnetos to make sure all plug wires are secure on both ends Check engin
36. unusual brake chatter Emergency Locator Transmiter Check for proper operation and ensure the ELT is armed when the airplane is returned to service Check ELT battery expiration date and replace batteries if necessary Comments Switches Circuit Breakers Check for proper operation Flight and Trim Controls Check freedom of movement and proper operation through full travel with and without flaps extended Check trim controls for proper operation 2 Powerplant Refer to nstruction amp Maintenance Manual for Jabiru 3300 Aircraft Engine Spinner and Spinner Flange Check for deformation security and cracks Propeller and mounting bolts Check tension on all propeller bolts Check propeller for condition and security Inspect blades for cracks dents nicks scratches erosion delamination in the case of fiberglass sheathed propellers security and movement in hub Comments JSA 100HR A1 100 Hour Annual Inspection Checklist Page 6 of 17 Jabiru J 230 5 250 5 and J 170 SP Aircraft Service Manual Spinner Propeller Tracking Check that propeller blade and spinner tracking is in alignment Propeller Hub Flange Check for cracks and condition Leak Check Check for oil fuel and induction leaks then clean entire engine and compartment before inspection Flywheel Screw Tension Check 24 ft lbs Induction Air Filter Check for condition cleanliness and security Replace if necessary
37. which activates a butterfly that closes the opening to ambient induction air forcing the engine to draw air through a SCAT hose connected to the heat muff NOTE Because the Bing carburetor automatically adjusts mixture with changes in air density there should be no noticeable change in RPM when carburetor heat is applied on the ground 7 15 2 Removal Tools Required Screwdriver set 3 8 and 5 8 wrenches Level of Certification Required A amp P or LSA R M M For aircraft built in 2008 or older 1 Disconnect cable from air box by removing the cotter pin from the cable ferrule and pulling ferrule from control arm 2 Remove jam nuts from cable end adjuster at the butterfly bracket 3 Remove jam nut from back side of instrument panel 4 Pull cable from the aircraft For aircraft built in 2009 or newer substitute steps 1 and 2 above with 1 Remove the nut and washer from the actuator arm 2 Slide the control wire off of the bolt 7 15 3 Inspection Inspect for cracks and loose rivets on muff Inspect valve for smooth and proper opera tion Inspect SCAT hose for damage and replace if necessary 7 15 4 Repair Repair is limited to replacement of components 7 15 5 Reinstallation Reverse the steps in 7 15 2 Page 7 24 JSA SM230SP A2 Jabiru 230 250 SP Section 7 Aircraft Service Manual Engine Systems 7 16 Ignition System Refer to Jabiru USA Service Bulletin JSA 009 for important rotor installation information 7
38. 1 Section 9 Jabiru J 230 5 250 SP Propeller amp Spinner Aircraft Service Manual 9 2 Fixed Pitch Wood Propeller 9 2 1 9 2 2 9 2 3 9 2 4 Page 9 2 Description The wood propeller is constructed from four laminations of approved species timber and is manufactured in accordance with the relevant Sensenich specifications It is a single piece two blade propeller with polyurethane leading edge protection The propeller finish is a either a clear marine polyurethane varnish or epoxy paint Pro pellers with a G suffix in the model number are covered with a layer of fiberglass for extra strength and durability Removal Level of Certification Required A amp P or LSA R M M WARNING Make sure ignition system is OFF before commencing work on propeller V WARNING Do NOT run engine with propeller disconnected or seri ous engine damage will result 1 Remove spinner as described in Section 9 1 2 Unbolt the six AN6 45A propeller bolts 3 Remove the AN960 616 washers Belleville washers two per bolt aluminum crush plate and propeller Basic nspection Before each flight and during each scheduled inspection the propeller should be looked over for damage including but not limited to nicks cracks and chips in the leading edge and blade surfaces Nicks in the paint surface are to be expected with age and if the aircraft is flown through heavy rain Nicks in the wood itself cracks splits or de
39. 17 Spark Plugs 7 17 1 Description Each magneto powers one of the two spark plugs per cylinder See Section 1 9 for re placement spark plug type 7 17 2 Removal Tools Required 18mm deep well socket 3 16 Allen key nee dle nose pliers spark plug gap tool Level of Certification Required Owner A amp P or LSA R M M 1 Remove cooling air baffles according to Section 7 4 2 Disconnect the spark plug wires from the plugs 3 Using an 18mm socket remove the spark plug and CHT probe if necessary 7 17 3 Inspection Check for cracks in the insulator or damage to the electrode Check the color of the electrode insulator Medium brown indicates correct mixture White or light gray color indicates a lean mixture Black and sooty indicates a rich mixture 7 17 4 Repair Repair is limited to cleaning and re gapping if plug is in good shape Otherwise repair is limited to replacement 7 17 5 Installation 1 Adjust plug gap to 022 inch 2 Apply nickel anti seize to threads 3 Install CHT probe on plugs where appropriate by removing the compression washer from the plug installing the probe washer and reinstalling the compression washer Be sure the washers go back on the same way they came off which is flat side to ward the top of the spark plug 4 Install the plug into the head and torque to 8 ft lbs DO NOT OVERTIGHTEN 5 Reattach spark plug leads 6 Replace engine cooling baffles SM230SP A2 Page 7 25 S
40. 19 Repeat Steps 1 18 to remove other wing if necessary Inspection Inspect wing skin for cracks breaks or delamination Check closely around flap and aileron hinges for signs of stress Look for signs of leaking fuel from the wing fuel tank or tank fittings Repair The wing is a composite monocoque structure All damage involving a break delamina tion or deformation in the wing skin must be referred to J abiru USA Sport Aircraft LLC Or an approved local agent for an appropriate repair procedure Reinstallation Tools Required Screwdriver set 1 2 and 7 16 wrenches tall pad ded sawhorse or wing stand Level of Certification Required A amp P or LSA R M M WARNING Do not tighten wing attach nuts or damage to wing at tach hardware may result Washer must be free to ro tate 1 Fitthe lower strut attach bolt leaving the top end of the strut on the ground 2 Fit wing to fuselage leaving wing tip on the saw horse and routing aileron cable fuel lines and wiring through holes in fuselage wing root 3 Install front and rear wing attach bolts nuts 4 Puttop wing strut attach bolt in your pocket J SA SM230SP A0 Jabiru J 230 SP 250 SP Section 4 Aircraft Service Manual Wing Structure 5 Lift wing tip and install wing strut to wing strut attachment with bolt from pocket 6 Install nut DO NOT tighten nut or damage to strut attach hardware may result 7 Connect all fuel and vent lines to wing making sure there ar
41. 2 for flap switch installation 3 Reverse the steps in 6 4 3 3 for flap control rod installation 4 Reverse procedure in 6 4 3 4 for flap motor assembly installation 5 Reverse procedure in 6 4 3 5 for flap position sensor installation 6 4 7 Flap Rigging 1 Ensure the flap motor is in the full UP position Park the aircraft on a level surface Hold a protractor flush on the underside of the wing airfoil and note the angle of the bottom wing surface Adjust each flap so that it sits with a 2 degree droop in the full UP position 2 Adjust flap position with the rod ends Ensure the lock nut is tight on the control ends and the thread is visible through the hole in the rod 3 Check for FULL DOWN travel using a protractor Full travel should be 30 degrees 1 5 degrees J SA SM230SP A1 Page 6 9 Jabiru 230 5 250 5 Aircraft Service Manual Flight Controls Section 6 5 5 ASSY DIN LOS Ta TAOMI LHOdMIV 26982 060 Wa HOSLAY 3O LN3SNOO JHL LNOHLIM LON LSNW ONY LHOTHAdOO SI SIH L soit Wa LNOAVT SAIC 40 HOLVOIONI NOLLISOd pe e INSWHOV LLY 9 2 m T e EQ 3SIVH OL 1 Lsnrav AdJ3S8W3SSV GOYHSNd 9 dV 51 0 di gt NOLLISOd d 14 15535405 NOLLYTTVLSNI
42. 230 5 and 250 SP Special Light Sport Aircraft Aircraft Service Manual Publication No J SA SM230SP A1 Jabiru USA Sport Aircraft LLC Jabiru Us Sport Aircraft LLC Copyright 2011 Jabiru USA Sport Aircraft LLC 2842 Highway 231 N Shelbyville Tennessee 37160 USA JSA SM230SP Record of Revisions Initial Release Jabiru USA Sport 1 3 5 9 11 Periodic Update See Original Al 16 May 2011 12 Appendix Revision Summary THIS PAGE INTENTIONALLY BLANK E s i he oe gt N e m e N oC on 2 1 2 7 2 10 9 2 11 1 2 11 3 3 8 2 3 9 2 5 7 1 5 7 5 11 6 4 7 19 8 1 8 3 gt P 1 I is Im O 8 2 11 3 3 11 10 5 11 10 6 11 10 8 11 11 W Pages Affected 1 6 1 9 2 12 2 13 2 14 3 13 3 13 5 8 5 8 to 5 10 5 21 to 5 22 5 22 6 7 to 6 9 7 30 8 9 to 8 10 11 2 11 11 to 11 12 11 13 11 15 11 16 JSA SM230SP Revision Summary s s s s s s T s s s s s s s s s i Changed head torque value to 20 ft lbs s I s Al Al Removed owner authorization for spinner removal Added spinner replacement information Added note on over tightening spinner screws Al Removed owner authorization for wood prop torque Al Removed owner authorization for carbon prop clamp bolt torque 16 2011 16 201
43. 250 5 and J 170 SP Aircraft Service Manual JSA 100HR A1 Airworthiness Responsibility abiru USA Sport Aircraft s recommended inspection program in accordance to FAR Parts 43 and 91 consists of but is not limited to inspection items listed in this Inspection Guide any applicable Service Bulletins or Air Safety Alerts issued against the airframe or any equipment installed therein The owner or operator is primarily responsible for maintaining the aircraft in an airworthy condition including compliance with all applicable Service Bulletins and Air Safety Alerts issued by the manufacturer It is further the responsibility of the owner or operator to ensure that the airplane is inspected in conformity with the requirements of Parts 43 and 91 of the Federal Aviation Regulations J abiru USA Sport Aircraft LLC has prepared this inspection guide to assist the owner or operator in meeting the foregoing responsibilities This inspection guide is not intended to be all inclusive for no such guide can replace the good judgment of a certified airframe and powerplant mechanic in the performance of his or her duties As the one pimarily responsible for the airworthiness of the airplane the owner or operator should select only qualified personnel Jabiru USA Sport Aircraft LLC issues service and safety information for the benefit of owners and operators It is the responsibility of the owner operator to review and comply with each Service Bulletin and Air
44. 3 L dovioOovZ 0 9 0917 SY ASSY 1 3 DINH men 26 982 010 NOV 0 Ald HO3LAV 30 LN3SN O 3H LNOHLIA 02905 Vd HOSLAY stvos Lon oa ce SNOISN3WId 38 LON LSNW LH9IHAdOO S SIHL 111 LLL EL E gl OSL ONINdSHOLVIHOOG 00 2 7 SLFOSENV OZ 6 0910 00 100 8 20 096 9 09 9018 HO1V13OOG GOGL00V4 ere 0917 ___ 09100 PLAN DOTAN GWE 250 59600684 Ok SS3NXOIHL 27 90 101 096 6 09 MNITONLLO3NNOO HOLVTHOOG 0001002 2 5 12202 9 JOHINOO ONIMdS H3HSVM S daO 261699250 AMIHOSONDnSHAINDnOD 9LE 8 6 MaroWdAJIHOOGd __ 122202 2 HOIV9HOOQSH ON AiD ee d J SA 5 2305 1 Door Latch Assembly Figure 3 3 Page 3 6 Section 3 Fuselage Structure Jabiru 230 5 250 5 Aircraft Service Manual Ald HO3LAV 20 1IN3SNOO JHL LNOHLIM 38 LON LSNW ONY LH9IHAdOO
45. 3NI9SN3 H3ddn WS a 2 9 9 WH 8 WN LL 30940 CT ee ASSV M 3NION3 _ e TAN Oe n Rz WH Ma 3H 96 438 92 3JlVid INNOW 3NION3 BV3H 5381 3471 SNOISN3WIG Figure 7 4 Shock Mounts Page 7 11 SM230SP A2 Section 7 Engine Systems 7 7 Jabiru 230 5 250 5 Aircraft Service Manual 7 6 2 Removal Tools Required See Engine Removal 7 1 5 Parts Required New mounts if necessary AN4 31A bolts and AN363 428 nuts for reinstallation Level of Certification Required A amp P or LSA R M M Remove engine as described in 7 1 5 then remove mounts 7 6 3 Inspection Inspect for cracking checking or deformation Check for excessive engine sag evident when spinner and cowl no longer align Replace shock mounts if indicated See Figure 7 4 7 6 4 Repair Repair 15 limited to replacement Replace worn or damaged shock mounts with new parts 7 6 5 Reinstallation Refer to Figure 7 4 Install female mounts in the rear on top and males in the rear on the bottom Lift engine into place on the mount Install the males in the front on the top and the females in the front on the bottom This arrangement is necessary to limit the sagging of the engine over time due to gravity Tighten the AN4 31A bolts with AN363 428 nuts and one washer to 8 ft lbs Oil System 7 7 1 Description Page 7 12 This manual details th
46. 43 and 91 of the Federal Aviation Regulations J abiru USA Sport Aircraft LLC has prepared this inspection guide to assist the owner or operator in meeting the foregoing responsibilities This inspection guide 15 not intended to be inclusive for no such guide can replace the good judgment of a certified airframe and powerplant mechanic in the performance of his or her duties As the one pimarily responsible for the airworthiness of the airplane the owner or operator should select only qualified personnel to maintain the aircraft Jabiru USA Sport Aircraft LLC issues service and safety information for the benefit of owners and operators It is the responsibility of the owner operator to review and comply with each Service Bulletin and Air Safety Alert While this guide may be used as an outline detailed information of the many systems and components in the airplane will be in the various section chapters of its service manual and the pertinent vendor publications It is also recommended that reference be made to the applicable airframe and engine service manuals previously issued Service Instructions abiru Service Bulletins applicable FAA regulations and publications Vendors Bulletins and specifications for torque values clearances settings tolerances and other requirements It is the responsibility of the owner or Operator to ensure that the airframe and powerplant mechanic inspecting the airplane has access to the previously noted docu
47. 5 250 5 General Description Aircraft Service Manual 1 10 Approved Oils and Capacities Oils developed and branded for use in air cooled aircraft piston engines which conform to the requirements of SAE 1899 formerly MIL L 22851D Textron Lycoming Specifi cation No 301F or Teledyne Continental Motors MHS 24B are approved Oils meeting these requirements include but are not limited to AeroShell W100 and AeroShell part synthetic 15W 50 with Aeroshell 15W 50 being the preferred oil Aeroshell 15W 50 is the recommended oil for all temperatures after the initial break in period Oil additives of any type are NOT recommended for use in J abiru aircraft engines V CAUTION DO NOT USE oil or additives containing LinKite as this Will damage the engine and void the engine warranty OI SUMP 3 7 US Quarts 1 11 Recommended Fastener Torque Values Torque inch Ib 20 25 2 ft b 50 70 4 5 ft b 100 140 8 12 ft lb AN6 Propeller 180 228 17 19 ft lb Table 1 4 Torque Values A These values relate only to steel nuts on oil free cadmium plated threads B For Engine Bolt Torque Values see Engine Instruction amp Maintenance Manual C Except where other values are specified the above values are recommended for all installation procedures contained in this manual 1 12 General Safety nformation Safety information will be maintained by J abiru USA Sport Aircraft LLC and wil
48. 7 3 Repair Repair of landing and recognition light is limited to replacement of components 11 7 4 Reinstallation Reverse steps in 11 7 2 for reinstallation J SA SM230SP A1 Page 11 5 Section 11 Jabiru J 230 5 250 SP Electrical System and Instruments Aircraft Service Manual 11 8 Pitot Static System 11 8 1 Description The pitot static system provides ram air and ambient air pressure for the Air Data Com puter within the EFIS the backup airspeed indicator and autopilot if installed The static vent is located on a probe mounted into the leading edge of the vertical sta bilizer One hole is drilled on each side of the probe just behind an aluminum bullet The bullet protects the static port from the relative wind and must be present for the static port to function The static line is safety wired and glued to the back of the probe and runs down through the vertical fin through the fiberglass tunnel on the inside of the lower fuselage skin through the center console and into the instrument panel A splice is built into the line just below the vertical stabilizer If necessary the static line may be drained of water by disconnecting it from the splice under the instrument panel and blowing through it with compressed air The pitot tube is mounted to the right wing strut The forward portion of the tube is mounted on flexible tubing to prevent damage to the tube and injury to people who bump into it The aft portion of the tube is we
49. 8 of 9 Jabiru 230 5 250 5 and J 170 SP Aircraft Service Manual 7 Rear Fuselage and Empennage Skin Check for deformation cracks and obvious damage If damage is found check adjacent structure Control Surfaces Check for deformation cracks security of hinges freedom of movement and travel limits Static Port Check for blockages Check static probe for condition 8 General Airplane cleaned and serviced Inspect all placards to assure they are easily readable and securely attached Ensure that all Service Bulletins Air Safety Alerts and previously issued Service Instructions are reviewed and complied with as required Comments JSA 50HR A1 25 50 Hour Inspection Checklist Page 9 of 9 Jabiru J 230 5 250 5 and J 170 SP Aircraft Service Manual Owner s Name Address City State Zip Annual or 100 Hour I nspection Guide For J abiru J 170 J 230 and J 250 Models A amp P or LSA Repairman with Maintenance Rating Required Registration Number Airframe Serial Number Engine Serial Number Hours Date Inspection Completed Servicing Agency Address City State Zip Phone Number A amp P Repairman Name JSA 100HR A1 I nspection I ntervals The time periods for the inspections noted in this schedule are based on normal usage under average environmental conditions Airplanes operated in humid tropics cold damp climates etc may need more frequent inspections for we
50. Add all weights to calculate Basic Empty Weight of aircraft Add all moments to find Empty Moment of aircraft To find empty Center of Gravity CG divide the Total Moment by the Basic Empty Weight Aircraft Empty Weight Record Use Table 2 2 to maintain a continuous history of changes and modifications to the air craft structure or equipment affecting weight and balance J SA SM230SP A1 Jabiru J 230 SP 250 SP Section 2 Aircraft Service Manual General Care amp Inspection Airframe Serial No Registration No Running Basic Change Weight and Moment Empty Weight and Description of Item Moment Modification or Repair MOM WT MOM Item ctr D Table 2 2 Aircraft Empty Weight Record JSA 5 2305 1 2 7 Section 2 General Care amp Inspection Aircraft Service Manual Jabiru 230 5 250 5 2 7 Parking Tie Down 2 8 Parking precautions depend principally on local conditions 1 Storage When mooring the aircraft in the open head into wind if possible and set the park ing brake The ailerons may be secured by tying the control yoke to one side with a seat belt Attach ropes to the tie down rings on each wing strut If the tie down rings are too Small for the available ropes a high quality carabineer or D ring may be installed through the ring to provide a wider opening for the rope Secure the opposite end of the ropes to ground anchors located at approxima
51. Excess epoxy and flock removed from underneath clamped area and all window windscreen edges 3 Windscreen screws countersunk below surface with no cracks 4 Window windscreen surfaces free of scratches cracks gouges and excess epoxy flock 5 See Section 12 4 for paint bodywork procedures to finish the repair 3 3 Doors 3 3 1 Description Cabin doors are composed of a fiberglass sandwich skin bonded to a molded fiberglass frame on the interior side of the skin A simple spring bolt latch system is used as a door latch and a spring ball upper latch is used to secure the upper door frame Hinges are machined aluminum or molded fiberglass A hinge stop or nylon strap is used to prevent damage from doors opening too far 3 3 1 1 Cabin Door Latches There is one main latch on each door of a simple spring bolt type This is complement ed by a spring ball latch at the top front quadrant of each door An assembly drawing of the latch mechanism 15 provided in Figure 3 3 Door Latch Mechanism Assembly Door latches or their component parts must be replaced if worn or damaged 3 3 1 2 Locks A cylinder and key lock is installed at each door The keyed barrel lock is located in the fuselage at the rear of the left right and rear doors Spare keys are available to J abiru registered owners by quoting the aircraft serial number JSA SM230SP A1 3 5 Jabiru 230 5 250 5 Aircraft Service Manual Fuselage Structure Section
52. Guidance JSL 007 3 oth Nov 2009 Do not the tank but leave MOGAS in the carburetor as the fuel evaporates from the carburetor it will tend to form varnishes which will block jets etc e Do not block the tank vents to prevent evaporation as the temperature around the aircraft rises and falls during the day and night the contents of the tank expand contract and give off gases If the vents are blocked these effects can easily rupture the tank 5 5 MOGAS Storage recommendations e Leaving the tank and carburetor full of AVGAS or e Running the carburetor dry by turning off the fuel tap and running the engine until it stops then draining all MOGAS from the tanks e Note that the storage methods currently outlined in Jabiru Technical Manuals generally presume that the aircraft is being operated on AVGAS which generally suffers far less from the problems noted above The safe amount of time that MOGAS may left in the tank depends on the exact recipe of the fuel where the aircraft is stored and ambient conditions like temperature etc e Commercial fuel additives and stabilizers are available which are designed to allow MOGAS to be stored for longer however Jabiru Aircraft have not tested their efficacy or their effects on other parts of the fuel system Jabiru Aircraft does not currently endorse or approve their use e Several different fuel blends are sold at the bowser throughout the year Winter fuel Summer f
53. HO2LAV 30 LNSSNCO LNOHUM 931602 38 LON LSNW LHOMAdGS SI 51435 TISVLSNy WIM TwOad 02 60 5 831435 WM 00 0 6 oe 31438 5 52 Saunas JTIAVLSNoy 51 dowasove zz L VIG LNI dITONIO EL INI 6 1 6200 81 digvisnrav Nid 1 0005 0 Zb _____________________ EOLSSEOZSW Sk PCCM VTE D 2 1 2079 9NhIV3H 900 8 bk 5 401 dWv19 X dOvirOve OL 5 3119 dWv1o 9 5000 8 MAYOS VEX 2 ______ __ 5 LAA dOd Tv g h N LOOHd Z dOLSQNS redre b SIN va 5171 Figure 6 13 Adjustable Rudder Pedals Page 6 25 JSA 5 2305 1 Section 6 Jabiru 230 SP 250 SP Flight Controls Aircraft Service Manual THIS PAGE INTENTIONALLY BLANK Page 6 26 J SA SM230SP A1 Jabiru 230 5 250 5 Section 7 Aircraft Serv
54. J 230 5 250 SP Electrical System and Instruments Aircraft Service Manual 11 3 3 Inspection and Repair Jabiru USA recommends replacing the battery every two years The battery is a dry cell battery therefore repair is limited to replacement NOTE If battery is drained completely down left master on its ability to hold a full charge may be compromised Perform the following procedure 1 Place battery on trickle charge for minimum of one hour 2 Start aircraft engine Jump start if necessary 3 Fly aircraft at cruise power for one hour while operating the minimum electrical equipment required for safe flight Alternator must run at cruise RPM for proper charge GROUND RUNNING WILL NOT CHARGE BATTERY 4 f voltage is not up to normal level after flight battery may need to be replaced 11 3 4 Reinstallation Reverse the steps in 11 3 2 for reinstallation 11 3 5 Trickle Charger Plug Newer J 250 and J 230 aircraft beginning in 2008 are equipped with a trickle charger lead accessible through the oil access door in the upper engine cowling Use the Bat tery Tender J unior which is delivered with each new aircraft equipped with the charg ing lead and available from Aircraft Soruce amp Specialty p n 11 05164 11 4 Switches and Breakers 11 4 1 Description Jabiru S LSA aircraft utilize 5w toggle type circuit breaker switches of different sizes Circuit breakers are either of the flush type pre 2009 models or pull type
55. List continued 2 1 4 Airspeed Indicator Instrument Panel Package G2 Garmin G3X 2 1 4 Airspeed Indicator Garmin GTX330 Mode S Transponder 2 1 4 Airspeed Indicator Garmin 5130 Nav Com replaces 5140 in Panel 0 1 or 2 Grand Rapids GRT Sport SX EFIS unit replaces GRT Sport Page 1 6 JSA 5 2305 1 Section 1 General Description Jabiru 230 5 250 5 Aircraft Service Manual Airframe Equipment Options and Upgrades Ameri King AK 450 ELT w Panel Remote 2008 and older aircraft 5 0 Kannad 406 MHz ELT w Panel Remote 2009 newer aircraft o o o S O o o S S JSA SM230SP A1 Standard Paint White base with two horizontal stripes of same color Paint Scheme 1 White base two horizontal stripes two colors Ventral Fairing rear tie down anchor Paint Scheme 2 White base up to three colors on belly and tips w accent striping Page 1 7 Section 1 Jabiru J 230 5 250 SP General Description Aircraft Service Manual Sensenich Wood Propeller painted white or varnished see Section 9 for approved diameter pitch options S O Sensenich Fiberglass Sheathed Wood Propeller standard 2010 and newer Sensenich Ground Adjustable Carbon Propeller Aluminum Spinner standard on most aircraft built after 2005 SO Spinner standard on most era bulk er 2005 Fiberglass Spinner standard on some early J 250s Tanis Engine Heater S O External Power
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57. Section 6 Flight Controls 6 2 4 Jabiru 230 5 250 5 Aircraft Service Manual Repair Repair is limited to the replacement of defective parts Because control cables are con sidered primary controls they may not be repaired without reference to J abiru USA Sport Aircraft LLC or our approved local agent for the appropriate repair procedure 6 3 Aileron Control System 6 3 1 6 3 2 6 3 3 Page 6 4 Description The aileron control system consists of one movable control surface on the trailing edge of each wing tip control cables and the control column The control surface is a molded and bonded monocoque fiberglass structure incorporating a composite control horn 10 from the inboard end The aileron control cables are of the enclosed push pull type fitted with spherical bear ings at both ends as described Section 6 2 NOTE Control column and control cables are primary controls and may not be removed or repaired without reference to Jabiru USA Sport Aircraft LLC or our approved local agent Removal of Aileron Tools Required Screwdriver set pliers 3 8 wrenches Level of Certification Required A amp P or LSA R M M For aircraft with multiple hinge pins 2008 models and older 1 Loosen screws in hinge pin retainers and lift hinge pin retainer away from the hinge pin It is not necessary to completely remove these parts 2 Unbolt cable from aileron control horn 3 With the aileron supporte
58. West Fax 61 7 4155 2669 Queensland Australia Email info jabiru net au WARNING All Jabiru aircraft manufactured SERVICE LETTER JSL 007 3 by Jabiru USA Sport Aircraft LLC are Issue 3 PROHIBITED from using any concentration of alcohol in the fuel LOOLL is recommended Date 5 Nov 2009 for all operations Subject Alcohol Lead Compression Ratio Fuel Guidance New Information Added 227 CANCELLED _ _ 3 Title changed High Lead Avgas notes added 1 AIR 257 12 e 2 2 2 2 1 5 4 2 2 2 CENE CEREREM A A a A i T O S 4 0 2 3 COMPRESSION RATIO COMBUSTION CHAMBER 5 3 3 1 COMPRESSION RATIO 1 1 3 2 COMBUSTION CHAMBER 2 1 3 3 3 FUEL OCTANE RATING REQUIREMENTS i cceccececececcecececcccececscccaeuececacauuenenecauauseducneaeuenscseauaunesevsuecnenstereuaeneness 5 4 FUEL CONTAINING
59. a minimum the cabin area should be covered with a cotton lined canvas cover Fitted 230 and 250 covers are available through J abiru USA Sport Aircraft LLC DO NOT use a tarp or unlined canvas cover as these may scratch the windows In addition the pitot tube static vent air vents openings in the engine cowl and other similar openings should have protective covers fitted to prevent entry of wa ter foreign materials and insects especially wasps Cover fuel vents for protection but do not seal completely as the system must be allowed to breathe Cowl plug and cover sets are available through J abiru USA Sport Aircraft LLC 2 8 2 Returning Aircraft to Service after Flyable Storage After flyable storage returning the aircraft to service is accomplished by performing a thorough pre flight inspection Ensure all protective covers are removed Page 2 8 J SA SM230SP A1 Jabiru J 230 SP 250 SP Section 2 Aircraft Service Manual General Care amp Inspection 2 8 3 Temporary or Indefinite Storage Temporary storage 15 defined as aircraft in non operational status for a maximum of 90 days any storage period over 90 days 15 considered indefinite storage Treat as for ble storage see Paragraph 2 8 1 plus 1 10 11 12 13 For temporary storage fill fuel tank with 10011 aviation fuel to prevent moisture accumulation DO NOT store aircraft for any length of time with auto fuel of any grade in the tanks
60. air vents and openings in engine cowl to prevent the entry of foreign material or insects especially wasps Attach a warning placard to the propeller stating that vents and breathers have been sealed The engine must not be started with the seals in place Every 7 days the propeller should be rotated CAUT OW Ensure that the Master and Ignition Switches are OFF 2 8 4 Inspection During Temporary or ndefinite Storage 1 2 JSA 5 2305 1 Generally inspect airframe and clean as necessary Inspect the interior of at least one cylinder through the spark plug hole for corro sion at least once a month At the end of an initial 90 day temporary storage period if the aircraft is to be con tinued in non operational storage repeat the process in Paragraph 2 8 2 most will only need to be checked Page 2 9 Section 2 Jabiru 230 5 250 5 General Care amp Inspection Aircraft Service Manual Page 2 10 2 8 5 Returning the Aircraft to Service after Temporary or ndefinite Storage After temporary storage the procedures for returning the aircraft to service are as follows 1 Remove aircraft from blocks and check tires for proper inflation 2 Check battery charge if needed and install 3 Check carburetor air filter and service if necessary 4 Remove materials used to cover openings 5 Remove warning placard from propeller 6 Remove clean and gap spark plugs 7 While spark plugs are removed r
61. and Reference System AHRS to determine aircraft atti tude and other data The mounting angle of the magnetometer unit and posi tion within the aircraft are critical to the functionality of the unit It is mounted to a fiberglass pad on the co pilot s side of the fuselage behind the baggage bulkhead N Figure 11 4 Magnetometer Location 11 10 6 2 Removal Level of Certification Required A amp P LSA R M M or Avionics Repair Station 1 Loosen clamp screws of D sub connector and remove from unit 2 Remove two mounting screws and remove unit from mount 11 10 6 3 Repair Magnetometer must be returned to Grand Rapids Technologies or Garmin as appropriate for repair or replacement Do not alter mounting pad If repair of mount becomes necessary contact J ab iru USA Sport Aircraft LLC for specific instructions J SA SM230SP A1 Page 11 13 Section 11 Jabiru J 230 5 250 SP Electrical System and Instruments Aircraft Service Manual 11 10 6 4 Reinstallation Reverse the steps in 11 10 6 2 for reinstallation 11 10 7 GPS Antenna 11 10 7 1 Description The GPS antenna may be located above the co pilot s door or under the instru ment panel It plugs into the rear of the EFIS MFD if in a dual EFIS panel with a simple push type connection 7 E Figure 11 5 GPS Antenna head over door location Door post er peeled back for clarity
62. as appropriate Remove unit 11 13 3 Inspection 1 2 3 Both models of ELT must be inspected according to FAR 91 207 d For inspection of Kannad 406 AF Compact refer to Installation Operation Manual for Kannad 406 AF Compact DOCO6006E Initial battery replacement timeline is found in the aircraft logbook and documents provided with the ELT DO NOT shock test Kannad ELT 11 13 4 Repair 1 2 3 Cable connections can be replaced with standard radio connection procedures Repair of batteries 5 limited to replacement Further repairs of ELT unit must be referred to ELT manufacturer 11 13 5 Reinstallation Reverse steps of Paragraph 11 13 2 for reinstallation Page 11 20 J SA 5 2305 1 Jabiru 230 5 250 SP Section 11 Aircraft Service Manual Electrical System and Instruments 11 14 PS Engineering 10001 or PM3000 Intercom 11 14 1 Description The 100011 is a four place mono intercom The PM3000 is a stereo intercom used in aircraft equipped with a Garmin MFD 11 14 2 Removal Tools Required Small Phillips screwdriver Level of Certification Required A amp P LSA R M M or Avionics Repair Station 1 Ensure the master switch is off 2 Remove the pilot and copilot knobs by gently pulling them 3 Remove the two small mounting screws from the front of the unit 4 Disconnect the 25 pin D sub plug from the rear of the unit 11 14 3 I nspection Inspection is limited to the pins and
63. basic epoxy mixing supplies fiberglass cutter Parts Required 9 07 fiberglass cloth 24 hr Aeropoxy or equiv Level of Certification Required A amp P LSA R M M Field repair of wheel fairings is authorized 1 Sand off the paint and gel coat 2 inches each side of the crack or tear with 220 grit aluminum oxide sandpaper 2 Overlay with two layers of 9 oz fiberglass cloth and wet out with 24 hour epoxy Allow to cure 3 Fill and sand until smooth See Section 12 4 for body filler information 4 Repaint See Section 12 4 for paint details J abiru USA Sport Aircraft LLC will re paint damaged wheel pants upon request J SA SM230SP A1 Section 5 Landing Gear and Brakes Jabiru 230 5 250 5 Aircraft Service Manual 60S0 9st 091 007 ASSY 931 NOISN3dShS GASN AVA 51108 HJONOT LAN 15 LOSroud S Z TVNIWON NSAID SHL NJ1 1104 2 NAAOHS LON 39V 13Sf14 JO 310SNOO SYLNAD ALON __ 9 vC9S9E0ZSW 9 819 096 OL AME S dIHLS 206044 8 0077 0027 SOVINNVOMSGNN ____ _____ 6 9 60909 S 1934 SLVId 9NDOvHO n X 609509 r
64. coat and finally a clear coat following the paint manufacturer s instructions 12 5 Door Repair Supplement The following procedure should be used in cases where the door has been overextend ed by force wind gust etc and suffered a broken door frame near the hinge points It also covers damage due to a locked door being pried open This non structural proce dure may be used to repair cracks and breaks in any portion of the door frame The hinge structures are bonded to the inside of the door frame and door skin When damage to the hinge structure or door frame occurs it is necessary to drill or cut an access hole big enough to inspect the damage and add epoxy and flock to repair the broken area The inspection hole will later be covered up with two or more layers of 10 oz glass cloth filled and painted to match 1 Remove all door upholstery and set aside to protect it from epoxy and paint Unbolt and remove restraint strap from forward edge of door to access stress cracks in that area Remove weather stripping from door edges near repair areas Remove door if necessary by following procedure in Section 3 3 2 Sand away the paint and gel coat at least 2 around the damaged area or to the edge of the structure 3 Carefully remove broken skin pieces or drill a hole into the door frame near the damaged area for inspection and application of epoxy and flock For example to repair a broken lower hinge drill near the area shown in Fi
65. cracks and deformation Check for concealed damage Comments JSA 100HR A1 Teleflex cables Check the flight control components Replace control system components that have bulges splits bends or cracks Check control cables and associated equipment for condition attachment alignment clearance and proper operation Comments 100 Hour Annual Inspection Checklist Page 11 of 17 Jabiru J 230 5 250 5 and J 170 SP Aircraft Service Manual Aileron Quadrant for condition attachment and proper operation Check for binding Flap Motor and Shafts Check for condition security and wear at all points Brake Master Cylinder Check for condition security and leaks Check lines for signs of chafing or cracks Comments Rudder Pedals Check for freedom of movement Check push pull cables for proper routing condition and security Check rudder pedal springs for condition and correct placement Check pedal extensions for security if installed Comments Control Column Check for freedom of movement Inspect rod ends for condition security and operation Trim Control Check for freedom of movement Inspect rod ends for condition security and operation Engine Controls Check for ease of operation through full travel JSA 100HR A1 Plumbing Check all plumbing and connections for security leakage and general condition Comments 100 Hour Annual Inspection Checklist
66. door frame 3 Remove the door Removal of New Style Door 1 Access the hinge bolts by gently peeling back the upholstery adjacent to the door hinge See Figure 3 8 for a view of the bolts before the fuselage is upholstered 2 Open the door Have a helper support the door until it is removed 3 Remove the cap screws that hold the hinge into position labeled 1 in Figures 3 8 and 3 9 Some filing of the fiberglass door frame or the lower fairing may be re quired to remove the hinge hardware as shown by the dashed line in Figure 3 9 Avoid filing outer fuselage skin 4 Remove door Figure 3 9 Upper door hinge new style passenger side File fiberglass as needed from dashed area to remove hinge hardware Figure 3 8 I nterior door hinge bolts new style pilot s side Page 3 10 5 5 2305 1 Jabiru J 230 SP 250 SP Section 3 Aircraft Service Manual Fuselage Structure 3 3 3 3 3 4 3 3 5 3 3 6 Seats Inspection Inspect door for cracks and latch alignment Inspect hinges for signs of cracks due to over extension Inspect upper ball latch for spring effectiveness Replace if necessary Slight inward bowing of the door skin is normal in J abiru models from early 2009 and older especially when parked in the hot sun This is due to tension on the skin from the upholstery panels It may be corrected by removing the upholstery panel and installing additional padding betwee
67. doors 2 Drain the fuel out of the header tank into an approved container by following the procedure in Paragraph 8 8 3 Mark the fuel lines upper and lower to avoid getting vent lines and fuel lines mixed up during reassembly JSA 5 2305 1 Page 8 1 Section 8 Fuel System 8 2 3 8 2 4 8 2 5 Jabiru 230 5 250 5 Aircraft Service Manual 4 Unbolt the header tank 5 When all fuel is drained from the header tank remove the hose clamps to discon nect the fuel and vent lines Inspection 1 Inspect header tank for evidence of fuel leakage Inspect fuel lines and fittings for cracks 2 Check for fuel stains on the bottom of the wing near the inboard rib If stains are evident determine whether stains come from leaking fittings or from the tank itself Repair 1 Repair of header tank is limited to replacement 2 Wing tanks can be resealed sloshed if a leak appears Contact the aircraft manu facturer for procedure and materials Reinstallation Reverse steps in 8 2 2 for reinstallation of header tank Be sure to reconnect fuel and vent lines to the correct fittings 8 3 Fuel and Vent Lines 8 3 1 8 3 2 8 2 Description The fuel and vent lines are made from 1 4 rubber hose and held in place with hose clamps There 15 a check valve in each vent line that allows air into each fuel tank The check valves are bleed valves which restrict some fuel from escaping ou
68. engine continues to run with the switch held in the past OFF position it is an indication that the magneto is still hot or ungrounded When the switch is released from the past OFF position it should automatically return to normal OFF and the engine should stop running However any ignition switch exhibiting this abnormal condition should be replaced Comments All Engine Controls With the engine running check for proper operational limits engine response and rigging Check friction locks for proper operation Comments Fuel Quantity Gauges Check for proper operation and unusual fluctuation Auxilliary Fuel Pump Check for proper operation unusual noise and fluctuations Fuel Tank Selector Valves Check for smooth operation and proper placarding Comments All Lights Check function condition attachment cracked or broken lenses Check switches knobs and circuit breakers for looseness and operation Comments Stall Warning System Check for proper operation Radio Operation Check for proper operation security of switches and knobs Comments 100 Hour Annual Inspection Checklist Page 5 of 17 Jabiru J 230 5 250 5 and J 170 SP Aircraft Service Manual Flaps check for noisy operation full travel and proper installation Flight nstruments Check for condition and proper operation Brakes Check for condition and wear ease of operation and proper release of parking brake Check for
69. ferrite baluns onto each aircraft s radio antenna to protect the avionics from radio interference This paragraph outlines the balun installation proce dure Tools Required Electrical pliers screwdriver set heat gun tools required for rudder removal Section 6 7 Parts required 20 ferrite single hole baluns 1 double hole ferrite balun 2 ring terminals 14 of 1 2 dia heat shrink tubing Level of Certification Required A amp P LSA R M M or Avionics Repair Station Refer to Figure 11 6 for more information 2 Remove the rudder as outlined in Section 6 7 3 Disconnect the antenna ground from the bottom of the antenna 4 Disconnect the antenna center conductor from the top of the antenna 5 Pull the antenna cable out of the vertical stabilizer about 18 Cut the frayed end of the antenna cable off 6 Slide the single hole baluns onto the cable Be sure they do not slide into the verti cal stabilizer 7 Slide the large heat shrink over the baluns 8 Carefully strip the end of the antenna cable to expose the shield and the center conductor DO NOT remove the clear plastic from the center conductor 9 Install the two hole balun on the center conductor 10 Install the ring terminal on the center conductor as close to the two hole balun as possible 11 Slide the single hole baluns and heat shrink up next to the two hole balun Heat the heat shrink to secure the string of baluns as shown in Figure 11 6
70. follow the man ufacturer s approved procedures may result in revocation of the S LSA air worthiness certificate 12 3 1 Fuselage Skin Repair Procedure Tools Required 220 grit aluminum oxide sandpaper epoxy brush mixing cups stir sticks adequate lighting Parts Required 9 02 fiberglass cloth System 2000 epoxy Aero poxy or other aircraft laminating epoxy Dacron peel ply Level of Certification Required A amp P or LSA R M M NOTE This procedure applies only to minor skin cracks that are further than 2 from any structural member Consult J abiru USA Sport Aircraft for proce dures to inspect and repair all other damage 1 Glass cloth must be applied to both sides of the skin for an effective repair 2 Remove paint and gel coat from the damaged area extending to an area mately three inches beyond the damaged area Take care to sand only paint and gel coat not into the glass fiber as well To prep non gel coated areas rough up the fiberglass and epoxy coat with 220 grit sandpaper to allow mechanical adhesion of the repair epoxy 3 Remove any carpet from the area affected at least six inches all directions If the carpet Is difficult to remove acetone may be used to dissolve the contact cement 4 Sand all carpet glue residue from the affected area at least three inches all direc tions Do not sand into the fiberglass structure 5 Cut two pieces of AF303 fiberglass cloth that will cover
71. hands off in level flight at 2850 RPM wings level with 200 10 pilot in the left seat If the aircraft sideslips or flies crooked in this configuration with equal amounts of fuel in each tank the rudder may be out of rig Inspect the rudder pedal springs for correct placement and or adjust the rudder control deflection as described in 6 7 7 Removal of Components 6 7 3 1 Rudder Control Surface Tools Required Screwdriver set 7 16 wrenches Level of Maintenance of Maintenance 0 Level of Certification Re A amp P or LSA R M M quired For aircraft with three rudder hinge pins models 2008 and older 1 Unbolt push pull cable from rudder horn 2 Loosen screws in hinge pin retainers amp lift retainer from hinge pin It is not necessary to remove these parts 3 Remove hinge pins and remove rudder J SA 5 2305 1 Jabiru J 230 SP 250 SP Section 6 Aircraft Service Manual Flight Controls For aircraft with a single hinge pin models 2009 and newer 1 Unbolt push pull cable from rudder horn 2 Loosen hinge pin retainer screw on top of vertical fin beneath rudder coun terbalance 3 Remove hinge pin and remove rudder 6 7 3 2 Rudder Pedals Tools Required Screwdriver set 7 16 wrenches Level of Certification Re A amp P or LSA R M M quired 1 Unbolt push pull cable 2 Unbolt both steering push rods 3 Unbolt rudder pedal bearings 4 Remove cover plates and nylon bearings 5
72. inhibit heat transfer from the combustion chamber to the head They can also cause detonation small pieces can become very hot and act like a glowing ember inside the combustion chamber This ember then ignites the fuel before the spark plug has discharged The effect of Lead Content Modern high octane MOGAS burns very cleanly a Jabiru engine It leaves no or minimal deposits inside the combustion chamber A fuel containing lead will leave deposits approximately proportional to it s lead content higher lead equals more deposits Compared to AVGAS 100 130 AVGAS 100LL produces around 25 less combustion chamber deposits This reduction in deposits can significantly improve overhaul life in certain engines by reducing valve and cylinder head deposits and well as reduce spark plug fouling Note that there is generally a maximum practical limit for the thickness of lead deposits inside a combustion chamber they do not keep on growing thicker and thicker indefinitely This means that when using AVGAS 100 the deposits reach this thickness and then stabilise more quickly than when using AVGAS 100LL Lead Content Recommendations Jabiru Aircraft have no objection to operators using AVGAS 100 130 or AVGAS 100LL JSA SM230SP A1 JSL007 3 doc Page 6 of 14 5 2 MOGAS MOGAS Good Points MOGAS 15 cheaper than AVGAS and 15 more widely available MOGAS burns cleanly and produces combustion chamber deposits at a muc
73. lamination of any composite sheath must be either rejected as unserviceable or re turned to Sensenich Wood Propeller Company for assessment and possible repair Propeller bolt tension must be periodically checked Refer to Section 9 8 for schedule amp procedure Repair Any service or repair must take account of the risk of subsequent propeller failure All propeller repairs must be referred to Sensenich Wood Propeller Company for proper repair procedure For reference the maximum size of nicks that can be approved for repair is J SA 5 2305 1 Jabiru 230 5 250 SP Section 9 Aircraft Service Manual Propeller amp Spinner 9 2 5 1 Those in leading edge 4mm deep x 20mm long 2 Those across the drive face flat sides 2mm deep x 6mm diameter or scratches not more than 0 5mm deep Repairs must also take account of changes in the balance of the propeller Therefore before return to service after any repair the propeller must be removed in accordance with the procedure described in Paragraph 9 2 2 of this section It must be checked for balance prior to reinstallation checked for tracking after reassembly and the spinner checked for balance after reassembly Reinstallation Tools Required 9 16 wrenches screwdriver set calibrated torque wrench Parts Required Six new AN365 624 nyloc nuts Level of Certification Required A amp P or LSA R M M Propeller installation must be done in accordance with Sensenich D
74. minute epoxy If small pieces were crushed be yond repair the hole may be filled using an epoxy flock mixture 8 After the epoxy has cured sand away any rough edges or excess epoxy from the repair area 9 Lay at least 2 layers of 10 oz cloth over the hole taking care to avoid sags and wrinkles Use 2 layers for cosmetic areas and 3 layers for stressed areas such as the restraint strap attach point and the area around the door lock slot Let the epoxy cure fully 10 Follow the instructions in 12 4 to fill sand and paint the affected area 11 When paint has fully cured reinstall door restraint strap upholstery panels and weather stripping as necessary Upholstery should be glued in place with contact cement See Section 3 3 for information on replacing door seals 12 Re cut the door lock slots as necessary Page 12 6 JSA SM230SP A1 Jabiru 230 5 250 5 Aircraft Service Manual Appendix Log Appendix Log The table below shows the current effective appendices and revision dates Appendices must be kept updated to ensure use of the most current inspection checklists and ser vice information A current Appendix Log with the latest change notices may be found on the manufacturer s website www usjabiru com Current instructions and maintenance documents for components such as the propeller wheels and avionics are usually available through the part vendor s website Specific components may have previously issued Ser
75. module 11 10 8 2 Removal Tools Required Tail stand screwdriver set Level of Certification Required Owner A amp P LSA R M M or Avionics Repair Station The weather module 15 located on the back of the pilot s seat or behind the baggage compartment on the floor 1 Brace the tail of the aircraft with a tail stand or padded sawhorse to allow entry of personnel into the baggage compartment 2 Remove the screws from the mounts 3 Disconnect the power wire from the unit 4 Disconnect the 9 pin connector 11 10 8 3 Inspection Inspect the wires and connections 11 10 8 4 Repair Any unit repairs should be referred to Grand Rapids Technologies See Appen dix for vendor information 11 10 8 5 Reinstallation Reverse steps in Paragraph 11 10 8 2 for reinstallation J SA SM230SP A1 Page 11 15 Section 11 Jabiru 230 5 250 5 Electrical System and Instruments Aircraft Service Manual 11 11 Garmin Nav Com Radio 11 11 1 Description Each J abiru S LSA aircraft is equipped with one Garmin communications radio either an SL 40 com only or SL 30 with built in VOR navigation capability radio antenna 15 attached to the aft face of the vertical stabilizer spar See Section 11 11 6 for information on the antenna For specific technical information about the radios refer to the Garmin website or con tact information located in the Appendix of this manual NOTE The WxWorx XM weather module may cause random i
76. not recommended 6 7 Checks When Changing to a Fuel Containing Alcohol e Fuel filter and carburettor bowl should be checked for sediment and clogging after 10 hrs or 1 month of use 115 recommended that fuel lines be renewed before switching to a fuel containing alcohol JSL007 3 doc nuoc id Page 12 of 14 Compression Ratio Fuel Guidance JSL 007 3 oth Nov 2009 7 Fuel Summary kK Ik The Perfect Fuel mythical beast does not exist ox OX operator must be aware of KKK KK AVGAS 100LL AVGAS 100 Other AVGAS Blends with Higher Lead Levels 95 Octane RON MOGAS 95 Octane RON MOGAS Containing Alcohol Lower Octane Fuels with Octane Booster Added Lower Octane fuels JSL007 3 doc UNSUITABLE for use with Jabiru Engines Availability varies Quality assurance Designed for aircraft Ease of storage Availability varies Quality assurance Designed for aircraft Ease of storage Availability varies Quality assurance Designed for aircraft Ease of storage Availability varies No lead Price Clean burn Good Octane when fresh Availability varies No lead Price Clean Burn Good octane when fresh Availability varies Price No lead Clean burn None Applicable JSA SM230SP A1 The State of the Art best fuel available for Jabiru Engines Quite Suitable A good fuel with some relatively minor negatives Con Availability vari
77. of area using hoist Engine nstallation 1 10 11 Align engine with airframe using hoist Install engine mounts and bolts as described in Section 7 6 Reinstall exhaust carburetor SCAT hose wiring and fuel lines by reversing descrip tion in 7 1 5 Rewire alternator using a soldered butt splice Reconnect all engine sensors Tie all wires neatly using cord or zip ties to avoid interference with moving or hot parts and airflow Reconnect starter and aircraft ground cables Check security of all soark plug wires on both ends Reinstall cooling baffles as described in 7 4 Reinstall propeller and spinner as described in Section 9 using all new propeller nuts and correct propeller torque values Ensure crankcase is filled with proper amount and kind of engine oil Turn main fuel valve J SA SM230SP A2 Jabiru J 230 SP 250 SP Section 7 Aircraft Service Manual Engine Systems 12 Start engine as described in POH and check for correct oil pressure oil tempera ture and other engine vital signs 13 Adjust carburetor as necessary refer to nstruction amp Maintenance Manual for J abi ru 3300 Aircraft Engine 14 Shut down engine and check for oil and fuel leaks 15 When satisfied with engine operation reinstall cowlings as described in Section 7 3 16 Consult nstruction amp Maintenance Manual for Jabiru 3300 Aircraft Engine for new or rebuilt engine break in schedule if necessary 7 1 6 Engi
78. or uneven surfaces brakes applied heavily Warped brake disc severe Inspect brake disc and replace or resurface as shimmy cases necessary Section 5 7 5 JSA 5 2305 1 Page 5 1 Section 5 Jabiru 230 5 250 5 Landing Gear and Brakes Aircraft Service Manual 5 3 Main Wheel Fairings 5 3 1 5 3 2 5 3 3 5 3 4 Page 5 2 Description The wheel fairings are single piece fiberglass finished with the same type of automo tive paint and clear coat as the rest of the airframe The main fairings are attached to the main landing gear legs using aluminum brackets screws and plastic spacers See Paragraph 5 9 2 for information regarding removal and reinstallation of the nose wheel fairing Removal Tools Required 3 2 Phillips screwdriver Level of Certification Required Owner A amp P LSA R M M 1 Remove the screw on the outboard side of the fairing 2 Remove the small machine screws 2 on the inboard side of the leg 3 Lift fairing from its mounting brackets Inspection Check for cracks or worn areas inside the fiberglass pant Check for elongation of screw holes and loose nutplates Check that clearance between wheel and pant is at least 1 inch Check security of inboard and outboard mounting brackets Check that outboard main wheel pant brackets are updated and installed as per Service Bulletin 5 004 1 Wheel Pant Bracket Replacement Repair Tools Required 220 grit aluminum oxide sandpaper
79. screwdriver 7 16 wrenches Level of Certification Required Owner A amp P or LSA R M M 1 Weight down tail of aircraft to raise the nose wheel off the floor as described in Section 2 2 Remove wheel fairing and axle bolt as described in Section 5 9 3 Pull nose wheel from yoke Take note of position of spacers 4 Reverse the preceding steps to install nose wheel 5 11 3 Disassembly Tools Required Phillips screwdriver 7 16 wrenches Level of Certification Required A amp P or LSA R M M V WARNING Do not attempt to separate wheel halves with the tire inflated or injury may result Avoid damaging wheel flanges when breaking beads loose as a scratch nick or gouge may cause wheel failure 1 Completely deflate tire and break tire beads loose at wheel rim Refer to Figure 5 8 Nose Wheel Assembly 2 Remove through bolts and separate wheel halves 3 Remove wheel hub 4 Remove tire and tube from wheel halves NOTE The bearings are press fit in the wheel hub and should not be removed unless a new part is to be installed JSA 5 2305 1 Page 5 21 Section 5 Jabiru 230 5 250 5 Landing Gear and Brakes Aircraft Service Manual 5 11 4 Nose Wheel I nspection and Repair 1 Clean metal parts in mineral spirits and dry thoroughly NOTE Bearings are pre packed Avoid cleaning with solvents as they will remove the packing 2 Inspect wheel halves for cracks Cracked wheel halves should be discarded and n
80. seal between the heads and the cylinders New engines require a head bolt tension check at after each 5 hour interval for the first 15 hours of operation then again at 25 hours After the 25 hour inspection Jabiru USA Sport Aircraft LLC recommends that head bolts are torqued to 20 ft lbs every 50 hours usually during the 50 hour inspection NOTE Engine must be at room temperature or colder to achieve proper head bolt ten sion 7 19 2 Procedure Page 7 30 Tools Required Calibrated torque wrench with 4 long 1 4 hex driver and 1 2 deep well socket 3 16 Allen key screwdriver set Level of Certification Required A amp P or LSA R M Owner Operators of S LSA aircraft that hold at least a Sport Pilot or Private Pilot Certif icate may only perform maintenance items listed in FAR Part 43 Appendix A Mainte nance Preventive Maintenance Rebuilding and Alteration Section C Owners of E LSA aircraft that hold an LSA Repairman with Inspection Rating 16 hr course may perform head torques and other maintenance tasks on their own aircraft 1 Allow engine to cool to room temperature oil temp less than 100 degrees Fahren heit or colder Plan ahead as this may take 6 to 8 hours after an engine run 2 Remove top and bottom engine cowls Refer to Section 7 3 3 Remove engine cooling baffles Note The bolts that hold the engine cooling baffles in place are also valve cover bolts Unbolt the cooling baffles unhook the tension
81. standard torque V WARNING The bolts on the engine mount must only be fitted with high temperature nuts DO NOT USE NYLOC NUTS as the nylon insert may melt causing failure Shock Mounts 7 6 1 Description Page 7 10 The engine is mounted to the welded engine mount using rubber lord mounts for re ducing engine vibration Each shock mount consists of one male and one female part J SA SM230SP A2 Section 7 Engine Systems Jabiru 230 5 250 5 Aircraft Service Manual l3VHOMIV NOILVTIVLSNI NOILVYEIA ava 755 604100 LAVUDUIY NI SNOLLVTTVISNI ANION 0055 0022 nuigvr 3189VOrTddV z LNNOW 3NISN3 N3M01 Vp S CEN z ee Zu E ASSV M INNOW 3NION3 31719 LNNOW 3NI9N3 NV3H LEE 10N 00 2 7 434 92 a Ta od a A 1 oa w a XD _ 3 31VW34 INNON NOIHSND z 31VW INNON NOIHSQO INTIOW 3NION3 33HSVM 9506 3 o 006 O DNI B qn 8 YN LL 300501 Zi UAN I KY 338 x1 334 09 LIVUIMIY NI SNOLLVTTVLISNI 3NIS9N3 0055 0022 NOLLV IDI9IHNOO LNNOW
82. strut fairing 6 Making sure the flap is supported unbolt flap control rods 1 each wing 7 Remove flap from wing so it does not crush the fuselage when lowering down 8 Unbolt aileron control cables 2 from rear of control stick horn inside cabin 9 Remove clamp block or cable clamps from aileron control cable clamps at rear of seat 1 each seat 10 Loosen hose clamps from fuel lines and vent lines If removing the left wing re move stall warning reed bell 11 Disconnect wiring to strobes and wingtip lighting 12 With one person supporting wing tip unbolt top wing strut bolt and lower the wing strut to the ground J SA SM230SP A0 Page 4 1 Section 4 Wing Structure 4 1 3 4 1 4 4 1 5 Page 4 2 Jabiru 230 5 250 5 Aircraft Service Manual 13 Lower wing tip toward the ground making sure you do not crush the underside of the wing on the fuselage wing root Rest the wing tip on a sawhorse or other suita ble stand 14 Unbolt and remove front wing attachment bolt 15 Unbolt and remove rear wing attachment bolt MOTE It may be necessary to rock the wing slightly while pulling attaching bolt or carefully use a long drift punch to drive out attaching bolt 16 Carefully remove wing by moving it outward to clear the aileron cable from the fu selage 17 Place wing on cushioned structure to avoid damage to wing skin and strut attach ment 18 Unbolt lower wing strut bolt and remove wing strut
83. the affected exterior area plus 2 inches in all directions on a bias Cut three pieces of AF303 on a bias to cov er the affected interior area by two inches in all directions 6 Mix an amount of 24 hour epoxy sufficient to wet out the fiberglass cloth 7 Using a 1 paint brush apply a thin coat of 24 hour epoxy on the affected area of the exterior 8 Lay the first piece of cloth on the area 9 Finish wetting out the first piece of fiberglass cloth with a generous amount of epoxy Page 12 2 J SA 5 2305 1 Jabiru J 230 SP 250 SP Section 12 Aircraft Service Manual Fiberglass Repair 10 11 12 13 14 15 16 17 18 19 20 21 22 J SA 5 2305 1 Apply the second piece of fiberglass cloth over the first on a bias Using the paint brush press the second piece of fiberglass into the first Don t add any additional epoxy until the excess from the first application has been soaked into the second layer If there are any dry spots in the second layer add only the amount needed to fully wet the cloth Ideally there should be no need to add any additional epoxy unless all the excess is soaked up however do not leave any dry spots or air bubbles inside the layup Any areas that appear whitish will become a weak area in the repair Cut a piece of Dacron peel ply to cover the entire affected area Peel ply will make the finishing and paint process easier Multiple pieces may be used to cover com
84. through full travel with and without flaps extended Check trim controls for proper operation Comments 2 Powerplant Refer to nstruction amp Maintenance Manual for Jabiru 3300 Aircraft Engine Spinner and Spinner Flange Check for deformation security and cracks Propeller and mounting bolts Check tension on all propeller bolts Check propeller for condition and security Inspect blades for cracks dents nicks scratches erosion delamination in the case of fiberglass sheathed propellers security and movement in hub JSA 50HR A1 25 50 Hour Inspection Checklist Page 4 of 9 Jabiru J 230 5 250 5 and J 170 SP Aircraft Service Manual Induction Air Filter Check for condition cleanliness and security Replace if necessary Induction System Check the SCAT hose for damage and wear Check the carburetor heat box for blockage security cracks operation and wear Comments Cooling Baffles Check for cracks worn areas and security Cylinders Check cylinders and exhaust manifold for obvious leaks security and cracks Check cylinders for broken cooling fins and loose or missing base nuts Comments Exhaust Check for deformation security cracks leaks loose or missing nuts springs and clamps Check for thin wall condition which may occur due to nromal internal erosion on stacks which have long service time Comments Ignition System Clean inspect regap test and replace spark p
85. to replacement 3 Fittings are standard AN flare fittings Reinstallation 1 See Figure 7 5 Reinstall fittings into radiator using Permatex 2 gasket sealant 2 Reinstall radiator onto sump 3 Reconnect braided hoses to cooler and adapter 4 Run engine for at least 30 seconds verifying that it has at least the minimum pressure in the system Shut down and inspect for leaks J SA SM230SP A2 eyl Section 7 Engine Systems ssi 911 Ald HO3LAV 30 8 931969 J LON LSM 8 BIHL z wa Jabiru 230 5 250 5 Aircraft Service Manual oo ee Nawa 500 J30 940 5050 INQ 60 SON TOL Td HO3LAV TVOS LON NI SNGOISN3MIG 2 00 522 8 0066 ASSY LNNOW 431009 10 HOaLISOd 22 ON 46 904 010 NOV NOLLVTIVLSNI LNNOW lt Mf dNNS OL NOLLYTIVLSNI 7 6 1 3915110 SNIJ GNOCOAS ANY 15 13 SQV3HHL 1108 OS N323M138 305 OL Z 9NO1S48MJOVdS 431005 TIOHOALISOd NO3SZZVb EL 1 MAYIS YNNSHALNNOD SLE 920566964 21 sie
86. 0 SP 250 SP Section 7 Aircraft Service Manual Engine Systems 1 Be prepared to catch oil that may leak from the valve covers when removing bolts 2 Remove the necessary valve cover bolts from the engine and the tension spring from the inboard side 3 Carefully lift the baffle off the cylinders 4 Move the baffle back along the spark plug wires to get it out of the way for head torque or other maintenance To remove baffle entirely thread spark plug wires through the grommet hole and remove 7 4 3 Inspection and Cleaning Engine baffles should be cleaned with detergent and water or a suitable solvent mineral spirits to remove dirt and oil Inspect baffles for wear marks cracks splits or other damage 7 4 4 Repair 1 3 Rubber seals may be replaced by removing the existing rubber seals sanding back the bonding face of the fiberglass baffles to bare glass using 80 grit sandpaper or similar and bonding new rubber strips in place with 5 Minute epoxy Repair of cracks or tears can be made using the general fiberglass repair procedure Outlined in Section 12 Replace defective parts if worn beyond reasonable repair 7 4 5 Reinstallation 1 SM230SP A2 Reinstall the spark plug leads through the grommet in the aft portion of the baffle Slide the baffle forward along the spark plug leads Reinstall or check security of all soark plug leads Set the baffle down on top of the cylinder heads taking care to inst
87. 1 1005 918 SAMOA gor owaavanna ASSY T33HM 931 3SON 4 TWIHS _ soa nacre auu ez6982010 Now SQ 3S MEHHIO 31412445 SS IND NMOHS LON SHA8ENY ALISV TO 04 Ald 30 LNASNGO JHL 031909 38 LON LSNW ONY SI Jabiru 230 5 250 5 Aircraft Service Manual Landing Gear and Brakes Section 5 719134 ASSY NOISNAdSNS 8 8 NOILOAS N J SA 5 2305 1 Figure 5 6 Nose Leg Suspension Detail Page 5 24 Section 5 Landing Gear and Brakes Jabiru 230 5 250 5 Aircraft Service Manual 0489 981 JSON GSNIHDVW O11 Ald HOSLAY 30 JHL LNOHLIM LON LSNW LHOIHAdOO _ NIS3 AXOd3 Page 5 25 SONIMVUC 345 vn Tu 226 982 00 NOW 8 SSTINN SLANT LON SHELSNITIIW NI m d Vid 009691 X90714 ONISN ATSINSSSY 5 1 OL 5 OL 5 5 ONOG 029 311L001 12 HUM LSNA 88 2 3 330 HSfH8 H3dVd AHW3 SNISHIN32 SNISNOH 937 ISON C3NIHOVW 1
88. 1 16 2011 16 2011 16 2011 16 2011 16 2011 16 2011 16 2011 16 2011 16 2011 16 2011 16 2011 16 2011 16 2011 16 2011 16 2011 16 2011 16 2011 16 2011 16 2011 16 2011 16 2011 16 2011 16 2011 16 2011 16 2011 16 2011 16 2011 Section Pages Affected Description 11 14 111 21 Al Added PM3000 to intercom description 16 May 2011 11 15 1 11 21 1 Added autopilot pitch cable note 16 May 2011 12 1 12 1 Al Added note about structural repair authorization 16 May 2011 16 May 2011 Added paint codes for base white 16 May 2011 Added reference to rotor service bulletin JSA 009 28 Feb 2013 12 3 12 4 12 2 Al Revised structural fiberglass repair section 12 4 to 12 6 Al 7 16 7 25 A2 J SA SM230SP A1 List of Effective Sections The table below shows the effective sections and dates for the most current revision of this manual Appendices are issued and controlled separately by the Appendix Log The revision number is found in the footer of each page after the document number For example Revision Al would look like J SA SM230SP A1 A list of affected pages is found in the Revision Summary in the front of this manual THIS PAGE INTENTIONALLY BLANK Jabiru 230 5 250 5 Aircraft Service Manual Table of
89. 14 TVOLLH3A 0008009 ONISNOH 9313SON Q3NIHOVW S19NIOvHB TVNH31NI d OED0v9 0 53 9NDIOVE HINNI ONISNOH 931380N 03600 9 W3HSVA ONISNOH 93138O0N Q3NIHOVW 038000 8 ee DAI 9313SON s pO v dVOONN SLOX ___ Z 237 5 GSNIHOVA ___ 569 BNN Will ALS cer Figure 5 7 Nose Leg Housing OL SNILLNNOW 3 OH 1108 3SN 420 119 38 LSNIW 30 NOILOSS S3ov ASN 091 NI ASN 303 3 LON JSA 5 2305 1 Jabiru 230 5 250 5 Aircraft Service Manual Landing Gear and Brakes Section 5 0 169 Wid 1005919 1570 ASSY TASHM 3SON ON 0 0297 TA SONIMVHC LYYd OL 2 H3 DINIH Bere suval ssil Ald HO31AV JO LNSSNO9 1 409 LON NI 3 t LON SMW LHDIMAdOO S SIHL HO31AV sNoiSNawig K a l Cot 1 p UNE T INN JOTAN 80 9960484 9 9 N6 z00dd 9 WIM T33HM 1572 8201129 2
90. 2 When installing the torque arm on the roll servo use Loctite 242 on the mounting screw JSA 5 2305 1 11 23 Section 11 Jabiru 230 5 250 SP 11 16 External Power Booster Cable 11 16 1 Description An External Power booster cable comes standard with new J 250 and J 230 aircraft It enables the operator to use an external battery to start the engine without removing the cowlings The following describes the installation procedure for retro fit kits availa ble through J abiru USA Sport Aircraft LLC for aircraft built before the plug became standard 11 16 2 Installation Page 11 24 Tools Required Ruler marker 3 16 drill 3 8 and 10mm wrenches Parts required Booster plug kit part no J U 46 Level of Certification Required A amp P LSA R M M or Avionics Repair Station 1 Remove upper and lower engine cowlings 2 Make sure receptacle mounting area see Figure 11 6 15 free of grease and dirt 3 The receptacle must be mounted slightly off center so the bolts clear the rudder pedal assembly inside the cabin To find the proper location for the receptacle A Using a ruler make a mark in the center of the recessed area under the passenger side of the firewall B From the center mark measure 1 toward the pilot s side of the aircraft and make another mark C Draw a line from that mark aft 3 or 4 and parallel to the centerline of the aircraft 4 Hold the receptacle in place centered on t
91. 3 8 1 Page 3 12 Description The horizontal stabilizer is a molded monocoque structure of rigid cellular polystyrene bonded to a fiberglass skin and rear spar The stabilizer is bonded into a flange and slot molded into the aft fuselage with epoxy and cotton flock The bond joint is overlaid J SA 5 2305 1 Jabiru J 230 SP 250 SP Section 3 Aircraft Service Manual Fuselage Structure 3 9 3 8 2 3 8 3 3 8 4 with multiple layers of fiberglass extending several inches either side of the joint Hing es attach the rear horizontal spar to the elevator Removal and I nstallation The horizontal stabilizer is permanently bonded to the fuselage and 15 an integral part of the fuselage If the stabilizer structure is damaged the entire stabilizer may be re moved and replaced Contact J abiru USA Sport Aircraft for further instructions Inspection Check for cracks or breaks in the skin Look carefully at the joint area between fuse lage and horizontal for cracks or delamination If cracks in paint are found sand into the paint and body filler to determine whether the crack penetrates a layer of fiberglass or just through the body filler Cracks only involving body filler may be repaired using paint and finishing procedures in Section 12 Repair The horizontal stabilizer is a composite monocoque structure All damage involving a break or deformation in the skin or damage to the spar must be referred to J ABIRU USA SPORT AIRC
92. 8VON H MddV OL 1951402 WIL 3 13 Id WOO NSAID SSLLILNYND E ETDINIH nma SSIMUSHLO Gaidi0ade SSTINA SLAN SYSEWNN NON TVI2H3AWOO 72 46 982 0 0 NIY LAN MOHL S Z JO IW 31 81108 LON oq 39311 YELYOHS ASN TVNIWON NSAID SHLON3TL108 Vid HOALAY SNOISN3MIC A18A3SSV TOHLINOO WIH L 55 ALd INSSNCO 031800 Jabiru 230 5 250 5 Aircraft Service Manual Section 6 Flight Controls uen SIL Figure 6 9 Trim Control Assembly Side J SA 5 2305 1 Page 6 18 Section 6 Flight Controls SS DINIHT nmaa SSIMUSHLO SETIN SLIAN Ald 1 LNOHLIM awos LON S3U LSNITIIN 38 LON 1 SI ONIMVMC Vd SIHL 30 SLASHS NI NMOHS SY TIOHLNOO 3L318ANO2 IHL JHAY NSAID 76 5 Dvd NON TvION3WIAOO 72 LON MOHL 472 3O HOSN3
93. BAD POINTS 1 eere nnnm denne nnn 9 6 4 INDIVIDUAL ITEMS 0000000 10 6 5 TESTING FOR 1 1440 0 caca 10 6 6 ALCOHOL USAGE RECOMMENDATIONS 11 6 6 1 IIT 11 062 JAUfOROLHNVO 11 6 6 5 Use of Automotive Gasoline Containing Up to 10 Alcohol 11 6 6 4 Use of Automotive Gasoline Containing Between 10 and 2096 1 1 00001 12 6 6 5 Use of Automotive Gasoline Containing More Than 20 1 1 12 6 7 CHECKS WHEN CHANGING A FUEL CONTAINING 5 4 12 7 gU 13 8 CONTACT INFORMATION creer err 14 JSA SM230SP A1 Compression Ratio Fuel Guidance JSL 007 3 oth Nov 2009 1 Applicability All Jabiru Aircraft and Engines Note for LSA category aircraft this Letter is equivalent to a Manufacturer s Safety Direction 2 Background 2 1 Issue Notes e Originally this Service Letter was inte
94. Booster Plug all 2305 some late 2505 Odyssey PC625 Sealed Dry Cell Battery Fuel Pressure Sender discontinued in 2009 5 0 Fuel Flow Sender 2009 and newer Replaces Fuel Pressure Sender Table 1 2 Standard and Optional Equipment Page 1 8 JSA SM230SP A1 Jabiru 230 5 250 5 Section 1 Aircraft Service Manual General Description 1 8 Sources to Purchase Parts All airframe and engine parts are available from any J abiru USA full service distributor As of this printing those distributors are Jabiru USA Sport Aircraft LLC 2842 Highway 231 Shelbyville TN 37160 931 680 2800 www usjabiru com Jabiru Pacific LLC 255 W Fallbrook Ste 202B Fresno CA 93711 559 431 1701 www jabirupacific com 1 9 Disposable Replacement Parts Some disposable airframe and engine parts can be sourced from automotive parts and other local retail stores Items marked with an asterisk may be difficult to find local ly but are readily available from J abiru USA Sport Aircraft LLC Pat Manufacturer Pat amp 6016 oo S dina 5 00 x 5 Ribbed Tre Various Six Ply Aircraft T ires equivalent 092 308 0 Michelin Inner Tube Main 500 5 TR67A 90 valve Michelin or equivalent 9 stem Inner Tube Toptyres or 13x5 00 6 TR87 90 valve Nose equivalent stem short Table 1 3 List of Disposable Replacement Parts JSA SM230SP A1 Page 1 9 Section 1 Jabiru 230
95. Contents Section Title Foreword Section 1 General Description 1 1 Aircraft 2 1 2 Aircraft 153 VIEW Drawing S rti ep corner 1 4 Engine 5 5 1 5 Weight amp Balance 22 mmm 1 6 Tire Inflation 1 8 0 7 Eguipment UEM 1 8 Sources to Purchase 1 9 Disposable Replacement 5 1 10 Approved Oils mnn 1 11 Recommended Fastener Torque 1 12 General Safety 2 1 13 Reporting Safety of Flight or Service 1 14 Extreme Climactic Conditions emm VCO Ul T Section 2 General Care and I nspection Zk Ground TOTIS 2 2 Jacking 2 3 Jacking Nose ___ _ _ __ MIU 2 6 Weighing the emen
96. Control Surface Throw Templates J SA SM230SP A0 Jabiru J 230 5 250 SP Aircraft Service Manual Appendix THIS PAGE INTENTIONALLY BLANK J SA 5 2305 0 Control Surface Throw Templates Page 2 of 2 Jabiru 230 5 250 5 Aircraft Service Manual Appendix Vendor Contact nformation Aircraft Manufacturer Jabiru USA Sport Aircraft LLC 2842 Highway 231 Shelbyville TN 37160 Phone 931 680 2800 Fax 931 680 1817 http www usjabiru com Engine nformation For all correspondence regarding Jabiru S LSA aircraft engines please contact Jabiru USA Sport Aircraft LLC All engine manuals are available for free download from J abiru Aircraft PTY LTD at their web site http www jabiru net au Propeller nformation Sensenich Wood Propeller Co Inc 2008 Wood Court Plant City FL 33563 Phone 813 752 3711 Fax 813 752 2818 http www sensenichprop com Wood Propellers Installation Operation amp Maintenance Available for free download in PDF format http www sensenichprop com sen html aircraft cet install cf a pdf Wheels and Brakes Matco Manufacturing 2361 South 1560 West Woods Cross UT 84087 Phone 801 335 0582 Fax 801 335 0581 www matcomfg com MHE51 Technical Manual available for free download in PDF format http www matcomfg com TechnicalManualsServiceBulletins tp2 23 html JSA SM230SP A1 Vendor Information Page 1 of 4 Jabiru 230 5 250 5 Appendix Aircraft Se
97. I 1108 SILON YIHSYM LY 14 OSENW SZ ha 8 1 EN NidN31lOO 7 38 267 N loHd zz 2015 ALICTWHY mu TWHNLONYLS 21660784 AN 9NISP __ 9004 02 eee E WIHS _____ 68 gt YJ TE ES ATGWASSY WiML GL MIYOS MNNSHALNNOD 9 2 966972 21 9 8i NV CON 31VW3 LAN DOIN ZEOLSSE0ZSW FL NUN 2 44 L MAHSYM LYH 9UE OL 098NV 2 1108 95 WOI ENY 9 8 370502 5 ONIS FIOSNOO OL Wv3HNIVWN3OVvdS 0 80 LANSUSVO ___ 8 2 8 MH3HSVM LV TA t h 8H 086NV 9 E WNL gH 0 WRINIWIYITV ET YANNI peogeoe ES HalnOalvid NOLLORIJ Z Go O a V AID NOLLdlHOS3G 1 WALI De Par Figure 6 8 Trim Control Assembly old Page 6 17 JSA 5 2305 1 i 30 E SLSSHS NI NMOHS SV ATaWSSsS 048v Su3
98. IAIS ________________ VOLENV Ob 68000 ____________ 9 ATQWASSY 31HVO HOIVA3T3 ____ 2 PINE ___ 09 SHSM LTS 5 OL 096NV 2 NOON DIE 2207 59 025 7610089 SHSM ___ 81 096 SEWN Lived ee reefer J SA 5 2305 1 Figure 6 6 Elevator Control System Page 6 14 Section 6 Flight Controls Jabiru 230 5 250 5 Aircraft Service Manual I3AVML HOIVATI3 AYNSVAWN OL S3lVidWSil ASN 46 31 25 LON 00 S3HI3ATIIW SNOISN3MIG p wk mete iW m 2 MO Figure 6 7 Elevator Control Rigging Page 6 15 JSA 5 2305 1 Section 6 Flight Controls Jabiru 230 5 250 5 Aircraft Service Manual 6 6 Elevator Trim Control System 6 6 1 6 6 2 6 6 3 6 6 4 6 6 5 6 6 6 Page 6 16 Description Refer to Figures 6 8 6 9 and 6 10 for illustrations of the trim system The elevator trim control system consists of a covered cable running from the trim han dle in the cockpit to a spring mechanism in the tail that is connected to the elevator The ca
99. ING BEWARE OF PROPELLER AT ALL TI MES 1 Run engine until warmed to operating temperature 2 Turn idle limit screw until an idle rpm of 800 850 is achieved with throttle closed Page 7 18 J SA SM230SP A2 ct HIM E30 5 AREY ONISOOH LAIN 1 2 DNI 1 1 n 3310N VW ar itr e LLI Tot H Ba eli 0 5 OFL SIE dle L A ANS 12925 Warnes 1 SEA SUP ed WI ar ____ 6 J O c LO ag YY 0 MET 4 E or Figure 7 7 Air Mixer Page 7 19 SM230SP A2 Section 7 Jabiru J 230 5 250 SP Engine Systems Aircraft Service Manual 7 11 Induction Air System 7 11 1 Description The engine air intake system includes a cold air inlet in the lower cowl a hot air muff attached to the exhaust system and a mixer assembly mounted on the firewall and connected to the carburetor The mixer box incorporates the air filter and a pressure relief dump valve For information on the carburetor heat system see Section 7 13 The air filter should be cleaned every 100 hours or more regularly if the engine is oper ated in dusty conditions Refer to Paragraph 7 11 2 and Figure 7 7 7 11 2 Removal and Replacement of Air Filter Tools Required Screwdriver set compressed air blower Parts Requ
100. Jabiru J 230 5 250 SP Propeller amp Spinner Aircraft Service Manual gt A ME Figure 9 2 Assembly of Ground Adjustable Propeller Page 9 8 J SA SM230SP A1 Jabiru 230 5 250 SP Section 9 Aircraft Service Manual Propeller amp Spinner 9 8 Propeller Bolt Tension Check 9 8 1 9 8 2 Description Because of natural expansion and contraction due to normal use and environmental conditions the hub bolt tension of wood propellers MUST be periodically checked ac cording to the propeller manufacturer s timetable which is outlined in this paragraph For detailed information regarding torque procedure and propeller maintenance refer to Section 9 8 and Sensenich Propeller Co Wood Propeller Installation Operation and Maintenance Guide Doc WOOD CF REVC A doc in the Appendix of this manual Check the Sensenich website www sensenichprop com for the latest revision of wood propeller installation and maintenance instructions Sensenich Required Propeller Bolt Torque Schedule 1 After First Flight After the first flight using a new propeller recheck the bolt torque 2 After First 25 Hours After the first 25 hours recheck the propeller bolt torque 3 Every 50 Hours After the first 25 hour recheck it is MANDATORY that the propel ler bolt torque be rechecked every 50 hours 4 Environmental changes Should the operating environment change significantly in temperature and or humidity fo
101. Jabiru J 230 SP 250 SP Section 2 Aircraft Service Manual General Care amp Inspection Section 2 General Care amp Inspection 2 1 Ground Handling The J abiru aircraft is very light and should always be moved by hand Press down lightly on the joint between the rear fuselage and the horizontal and vertical stabilizers to raise the nose wheel When the nose wheel is not touching the ground the aircraft may be pivoted on the main wheels and pushed any direction Use the wing struts prop hub or inboard leading edge of the horizontal stabilizer as push points The aircraft may be moved from the front by placing the propeller in the horizontal position and then plac ing one hand on the propeller on either side of the spinner The aircraft can then be pulled forward and nose wheel lifted off the ground if necessary See figure 2 1 for ap proved push pull points Jabiru USA offers a towbar kit which utilizes a Bogi Bar towbar and pins that screw into the existing nose pant nose fork hold down screws on most Jabiru aircraft Contact ab iru USA for more information WARNING V Do not use control surfaces to move the aircraft as damage to the con trol system may result V Do not push the tips of the propeller as damage may result V When moving the aircraft never turn the nose wheel more than 15 de grees either side of center or nose gear may be damaged V Always remember the rudder is connected to the nose gear Keep hands
102. LSA R M M with J abiru USA Engine Seminar Task Specific Training or A amp P 1 Support tail of aircraft with a sturdy tail stand or padded sawhorse set just forward of the ventral fin 2 Remove engine cowling as described in Section 7 3 3 Remove cooling air ducts from engine as described in Section 7 4 4 Remove spinner and propeller as described in Section 9 5 Disconnect main ground cable from battery SM230SP A2 Page 7 1 Section 7 Engine Systems 7 1 6 Page 7 2 10 11 12 13 14 15 16 Jabiru 230 5 250 5 Aircraft Service Manual Shut main fuel valve off Drain fuel from carburetor bowl and main fuel line Disconnect fuel line from mechanical fuel pump Loosen carburetor coupling clamp and remove carburetor from intake manifold Disconnect oil temperature oil pressure CHT and EGT sender wires starter ground cable and starter wire off starter contactor Clip cable ties as necessary to move wiring out of the way Cut alternator wires at one of the connections Remove all SCAT hoses Remove muffler by disconnecting springs Use flat screwdriver and take care not to gouge or damage exhaust Attach engine hoist to the engine by running a cargo strap around rearmost intake and exhaust pipes up to the hook on the engine hoist and back down around the crankshaft Support engine with hoist Remove two LOWER engine mount bolts Remove two upper engine mount bolts Pull engine out
103. N RIGGING INSTRUCTIONS Figure 6 3 Aileron Control Stop and Rigging Page 6 6 J SA SM230SP A1 Jabiru J 230 SP 250 SP Section 6 Aircraft Service Manual Flight Controls 6 4 Wing Flap Control System 6 4 1 6 4 2 6 4 3 Description The electric wing flap control system consists of one fiberglass control surface on each wing driven by a single linear actuator The flaps are operated by one pre 2010 or two manual toggle switches on the instrument panel Position is indicated with a flap posi tion sensor in the left wing root and an LED position indicator mounted on the instru ment panel GRT and analog panels or a display on the primary EFIS G3X The linear actuator 15 12 volt DC with a 2 inch stroke and drives a common shaft assembly with pushrods connecting the shaft to the flap surface control horns Each flap control sur face is a molded and bonded monocoque fiberglass structure incorporating a composite control horn at the inboard end Operational Check Make sure baggage door 15 closed and latched Operate flaps through their full range of travel observing for uneven or jumpy motion or binding in the system Ensure flaps move together through their full range of travel and do not interfere with wing fairings or fuselage structure Removal of Flap Components 6 4 3 1 Flap Control Surface Tools Required Screwdriver set 3 8 wrenches Level of Certification Required A amp P or LSA R M M Remove wing root fairing
104. Olympic White Fleet White Aircraft s n 702 and later Matrix MT 84 pure white toner 12 4 2 Repair Repair procedures are similar to those used in auto body shops 12 4 3 Paint Repair Paint repairs are the done the same way whether over a fresh fiberglass repair or simp ly over a scrape or mar Sand off existing clear coat and base color coat over and around the repair area Ex tend the surface prep about 2 inches from the damage Sand off the sealer primer as well Be careful to not remove the underlying gel coat and use extreme caution to avoid sanding into or cutting any fiberglass strands Fill and smooth the area with Evercoat Lightweight Fiberglass body filler or equivalent Apply a coat of automotive primer sealer primer over the damage area When dry fol Page 12 4 JSA SM230SP A1 Jabiru J 230 SP 250 SP Section 12 Aircraft Service Manual Fiberglass Repair low with a base color coat and clear coat Jabiru USA uses PPG or Matrix brand but any compatible automotive base coat clear coat 15 acceptable After paint cures use a buffer to blend the repair area into the rest of the paint 12 4 4 Complete Repaint For a complete repaint of the airframe the clear coat and most of the base coat and primer sealer should be removed Wet sanding is the preferred method to remove paint Take care not to sand through gel coat or fiberglass strands Repaint with a quality brand of primer sealer that includes a UV barrier base color
105. QIVHalVid SNDOVHO Dn ___ v60 E09 9 00 00 937 20089 i a MINN Led ee Figure 5 1 Main Landing Gear Assembly Page 5 3 JSA 5 2305 1 Section 5 Jabiru J 230 5 250 SP Landing Gear and Brakes Aircraft Service Manual 5 3 5 Reinstallation Reverse the steps in 5 3 2 for reinstallation of main wheel fairings 5 4 Main Gear Top Fairing Lower Strut Fairing 5 4 1 Description The main gear leg top fairing is a molded fiberglass part laminated from three layers of 9 oz fiberglass cloth It also functions as the lower strut fairing There is one fairing on each side of the aircraft 5 4 2 Removal and Installation Tools Required Phillips screwdriver Level of Certification Required Owner A amp P LSA R M M 1 Remove the screws 2 Remove the fairing carefully so the paint is not cracked or the edges damaged 3 reinstall the fairing carefully work the fairing around the gear leg and strut mount until it is back in place Take care not to pinch any wires brake lines or tot static lines that may run underneath the fairing 4 Reinstall the screws 5 4 3 Inspection Check for cracks tears or delamination in the fiberglass 5 4 4 Repair Repair cracks or tears by overlaying with fiberglass as in the procedure for wheel fair ing repair See Paragraph 5 3 4 5 5 Main Gear Leg As
106. RAFT LLC for an appropriate repair procedure Repair must be made be fore the next flight Dents crush damage or tears the fiberglass end caps of the stabilizer are a non structural area and can be repaired using the standard fiberglass repair procedures Section 12 Vertical Stabilizer 3 9 1 3 9 2 3 9 3 3 9 4 Description The vertical stabilizer is a molded composite structure supported by ribs and a rear spar The vertical stabilizer is bonded to a raised ridge on the aft fuselage with epoxy and cotton flock The bond joint is overlaid with three layers of fiberglass extending two inches either side of the joint Hinges attach the rear vertical spar to the rudder Removal and I nstallation The vertical stabilizer is permanently bonded to the fuselage and Is an integral part of the fuselage structure If the vertical stabilizer structure is damaged beyond repair the entire stabilizer may be removed and replaced Contact J abiru USA Sport aircraft for further instructions Inspection Inspection is limited to inspection of the stabilizer skin for cracks or delamination and inspection of the vertical spar for cracking or delamination or other damage Repair All damage involving a break or deformation in the skin or damage to the spar or ribs must be referred to J ABIRU USA SPORT AIRCRAFT LLC for an appropriate repair proce dure Repair must be made before the next flight JSA 5 2305 1 3 13
107. RM ITSELF to normal operating oil temperature and CHT with not more than 1200 rpm Installation and use of a Tanis amp engine heater is recommended for frequent operation in cold weather They are available through abiru USA Sport Aircraft V CAUTION Use caution when preheating engine to avoid directing extremely hot air onto SCAT hoses cowling skins or other materials that may be damaged by heat JSA SM230SP A1 Page 1 11 Section 1 Jabiru J 230 SP 250 SP General Description Aircraft Service Manual 1 15 Approved Fuels The recommended fuel for J abiru S LSA aircraft is 100LL Approved fuels are limited to 100LL aviation gasoline or fresh automotive gasoline MOGAS of 93 octane and higher The Jabiru is a high compression engine which may be damaged by detonation of low octane or degraded fuel Jabiru has not tested and does not recommend use of any fuel additives including octane boost or stabilizers Use of ethanol or other alcohol based additives is prohibited in all J abiru aircraft manufactured by Jabiru USA Sport Aircraft See Service Bulletin SA 006 for more information V WARNING Gasoline with an octane rating of less than 91 may cause engine damage due to detonation WARNING Auto fuel degrades quickly with age Use of auto fuel more than 60 days old may damage engine and fuel system CAUTION Use of any unauthorized fuel additives will void the engine and aircraft warranty Page 1 12 J SA SM230SP A1
108. Remove both pedal bars 6 Reverse the preceding steps for installation 6 7 4 Inspection of Components 6 7 4 1 Rudder Control Surface Inspect rudder for any signs of delamination cracking or warping Pay particu lar attention to the control horn and hinges and their surrounding areas 1 spect hinge pin anchor s and pushrod connections for security 6 7 4 2 Rudder Pedals 1 Inspect nylon bearings for wear Replace if worn 2 Inspect pedal bars for wear around bearing area and for distortion 3 Inspect pedals for distortion or loose rivets in end stops 4 Inspect bolt holes for wear and elongation 5 Inspect bolts and nuts for distortion and wear 6 7 4 3 Rudder Cables See Section 6 2 for inspection of control cables JSA 5 2305 1 Page 6 21 Section 6 Flight Controls Jabiru 230 5 250 5 Aircraft Service Manual 6 7 5 Repair of Components 1 All damage involving cracking warping or delamination of the rudder control sur face or hinge damage must be referred to J abiru USA Sport Aircraft LLC or our ap proved local agent for an appropriate repair procedure 2 Replace any distorted or worn parts of the rudder pedal assembly 6 7 6 Reinstallation of Components WARNING All spherical bearings on control cable ends must be fitt ed 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 1 Reverse the steps of Paragrap
109. SP Section 12 Aircraft Service Manual Fiberglass Repair Section 12 Fiberglass Repair 12 1 Description Structural repairs beyond those listed in this manual are not authorized without the consent of the manufacturer J abiru USA will provide specific procedures for repair or replacement of damaged airframe components after receipt of full details of the extent of the damage Structural repairs that do not exactly follow the man ufacturer s approved procedures may result in revocation of the S LSA air worthiness certificate Non structural repairs or minor structural repairs described in this section are au thorized if completed according to the procedures in this section 12 2 General Non Structural Fiberglass Repair Tools Required 220 grit aluminum oxide sandpaper NOT silicon based epoxy brush mixing cups stir sticks Parts Required 9 07 fiberglass cloth System 2000 epoxy Aero poxy or other aircraft laminating epoxy Level of Certification Required A amp P or LSA R M M Most non structural fiberglass 15 in wing tips horizontal stabilizer end caps cowls fairings or wheel pants These parts are generally made from three layers of 9 02 fiberglass or from a sandwich of two layers glass one layer of Cormat and another two layers of glass Repair of breaks delaminations or tears can easily be made by applying fiberglass cloth to one or both sides of the damaged area The epoxy used J abiru aircraft manufacture is
110. Safety Alert While this guide may be used as an outline detailed information of the many systems and components in the airplane will be in the various section chapters of its service manual and the pertinent vendor publications It is also recommended that reference be made to the applicable airframe and engine service manuals previously issued Service Instructions J abiru Service Bulletins applicable FAA regulations and publications Vendors Bulletins and specifications for torque values clearances settings tolerances and other requirements It is the responsibility of the owner or operator to ensure that the airframe and powerplant mechanic inspecting the airplane has access to the previously noted documents as well as this inspection guide These documents may be downloaded from the manufactuer s website www usjabiru com 100 Hour Annual Inspection Checklist Page 2 of 17 Jabiru J 230 5 250 5 and J 170 SP Aircraft Service Manual 1 Operational I nspection Starter Check for proper operation unusual noises and dragging Fuel Pressure or Flow Check within normal limits if installed Cylinder Head Temperature Check for proper operation temperature and fluctuations Alternator Check for proper output and unusual noises Propeller Check for smoothness of operation CH 2 Oil Pressure and Temperature Check for proper pressure temperature limits and unusual fluctuations 4 Magnetos Check the pe
111. System 2000 from Fiberglast Devel opments Inc System 2000 is the preferred repair epoxy Other laminating epoxy resins can be used if they have similar properties Procedure 1 Remove paint and gel coat from the damaged area extending to an area approx imately two inches beyond the damage area Take care to sand only paint and gel coat not into the glass fiber 2 prep gel coated areas rough up the fiberglass and epoxy coat with 220 grit sandpaper to allow mechanical adhesion of the repair epoxy 3 After sanding clean with acetone or water to remove all dust DO NOT use soap or silicone based cleaners 4 Apply light coat of epoxy to the repair area Align the broken parts Apply two layers of 9 oz fiberglass cloth to the area and wet out Apply two layers of cloth to the other side if necessary 5 Allow to cure Finish as described in 12 4 J SA 5 2305 1 Page 12 1 Section 12 Jabiru 230 5 250 5 Fiberglass Repair Aircraft Service Manual 12 3 Structural Fiberglass Repair Structural fiberglass repair should only be attempted by personnel with previous fiber glass experience Structural repairs beyond those listed in this manual are not authorized without the con sent of the manufacturer J abiru USA will provide specific procedures for inspection repair or replacement of damaged airframe components after receipt of full details of the extent of the damage Structural repairs that do not exactly
112. The platform should be wide enough to distribute the weight of the aircraft across about 2 square feet of wing surface Pad the platform with a folded shipping blanket piece of carpet or other soft mate rial Place the hoist into position under the wing tip and raise it so the platform lifts the wing underneath the spar just outboard of the wing strut attach point The hoist needs to point toward the fuselage as shown in Figure 2 3 so the platform can remain squarely under the wing and pivot with the wing undersurface as it tilts up ward Raise the aircraft up as necessary for the job to be performed For longer term re pairs involving removal of the main gear legs the fuselage may be blocked up with a padded sawhorse or crate minimum 24 square inches of surface area under the lower wing strut carry through beam and under the tail boom Lower the hoist to lower the aircraft back down Figure 2 2 Plywood J acking Platform on Engine Hoist Page 2 3 Section 2 Jabiru J 230 5 250 SP General Care amp Inspection Aircraft Service Manual Figure 2 3 J acking Aircraft with Engine Hoist 2 3 Jacking Nose Gear 1 Place a cushion on the floor under the ventral fin 2 Press down on the root of the horizontal stabilizer until nose gear is off the ground and set the rear fuselage down gently on the cushion 3 Weigh down the inboard half of the horizontal stabilizer with a sandbag or similarly heavy and cushioned material The airc
113. a mild acid solution effectively vinegar the effect is the same as when the seal fails on a bottle of wine which can attack fuel system fittings e Long term exposure to Ethanol damages some types of plastics The flexible fuel lines used by Jabiru Aircraft have been chosen with Ethanol use in mind and are designed to be safe when replaced at the intervals specified in the aircraft Maintenance Manuals However increased monitoring during servicing is recommended when using an Ethanol blend e Note that flexible fuel lines are available in a wide range of colours Generally the colour of the line is a dye only and has no bearing on the line s ability to operate in contact with alcohol though some fuel line manufacturers use different colours to designate different products Jabiru Aircraft have used blue fuel lines and at the time of writing orange lines Both are acceptable for use with fuels containing alcohol Some fuel testers including the type supplied by Jabiru Aircraft at the time of writing have a scale on their side which allows the Ethanol content of a fuel to be checked amp assessed e Several Australian Civil Aviation Safety Authority CASA documents discuss Ethanol use in aircraft Jabiru Aircraft strongly recommend that owners considering using an Ethanol fuel JSL007 3 doc Page 9 of 14 Compression Ratio Fuel Guidance JSL 007 3 oth Nov 2009 blend read and understand this information before using a f
114. ach blade and ensure they are the same Very slight varia tions in pitch between blades will cause significant vibration J SA 5 2305 1 Jabiru 230 5 250 SP Section 9 Aircraft Service Manual Propeller amp Spinner 9 3 4 Reinstallation Parts Required New Nyloc propeller hardware Tools Required 9 16 wrenches screwdriver set torque wrench propeller protractor 1 JSA 5 2305 1 Level of Certification Required A amp P or LSA R M M Refer to Figure 9 2 With the Sensenich prop drive bushings place position the spinner backplate rear hub half on the prop flange and install the six AN5 bolts Torque to 20 ft lbs Make sure to align the spinner backplate correctly as the spinner cone only fits one Way Position the center nylon block and the two blades in place while setting the front hub half into position Install the six prop hub bolts with the stepped washers and tighten until just snug Using the propeller protractor set each blade to the same angle as they were be fore disassembly or adjust using Table 9 1 Be precise as a small difference in an gle will result in propeller vibration Place protractor on a line measured 12 inboard from tip of propeller blade and perpendicular to blade centerline Move protractor to top of engine crankcase to check relative pitch angle Pitch angle must not exceed limits in Table 9 1 Slowly and evenly tighten the hub bolts to avoid changing the blade ang
115. acting in their fuel system maintenance e 15 recommended that after the first 200hrs or 6 months of operation on fuel containing alcohol the carburettor be disassembled for a one off inspection Components must be checked for damage excessively soft or hard rubber parts swelling of rubber components corrosion of metal components Replace parts if damaged or in doubt 6 6 4 Use of Automotive Gasoline Containing Between 10 and 20 Alcohol e Jabiru Aircraft does not recommend that operators use any fuel containing between 10 and 20 alcohol in Jabiru Aircraft or Jabiru Engines e Operational experience has shown that operating Jabiru Aircraft and Engines with a fuel containing 10 20 alcohol is safe and does not introduce excessive maintenance requirements However formal testing has not been carried out and this level of alcohol content exceeds the maximum safe recommendations for some fuel system components e Operators using such fuel must understand that they operate entirely at their own risk Clearly such operations occur in categories such as the Experimental category where all aircraft occupants amp operators fly at their own risk e Only those Jabiru Aircraft with white coloured fuel tank sealant can use fuel containing alcohol No modifications are required for Jabiru Engines run using fuel with 10 20 alcohol e Where a Jabiru Engine is installed in a non Jabiru airframe the operator must
116. actory set J SA 5 2305 1 Jabiru 230 5 250 5 Aircraft Service Manual DIMENSIONS IN JSA 5 2305 1 SCALE 1 1 SECTION BB SECTION CC SCALE 1 1 Figure 6 11 Rudder Cable Schematic Section 6 Flight Controls M wo57Anp _ a RUDDER CABLE MOUNT 160 1 DESCRIPTION NL STEERING CENTRING J160 1 11 sum cime __ 2 10 ___ CLAMP __ 2 por 2 1 aosan PART No 12 1404 CABLE RUDDER DRIVE UL Page 6 23 Section 6 Jabiru 230 5 250 5 Flight Controls Aircraft Service Manual B F g 2 ak Heg 7 y 16 ttre 2000 Nl A 5 5 i 5 3 i 200 4409 FAMILY THM 340 SHER PEDE IASS 7 78 771 f See LANS La p ie 0 I 9 J 9 1 CENTRE DA SPACING DIM VARTS BETATEN MODELS AS OWS 2 NT UL SP ETC SP UL PEDAL SPACING SHOWN Figure 6 12 Rudder Pedals Page 6 24 J SA SM230SP A1 Section 6 Flight Controls Jabiru 230 5 250 5 Aircraft Service Manual ev 13995 Ald
117. akes 5 7 1 5 7 2 Page 5 8 For more detailed information on Matco components refer to the Matco Mfg Technical Service Bulletin for MHE51 Series wheels and brakes which can be found on the Matco website A link to the website is located in the Appendix of this manual Description All Jabiru LSA aircraft utilize Matco MHE51J E series 5 aluminum alloy wheels single piston external caliper brakes for ease of maintenance and availability of parts The master brake cylinder is a J abiru product See Section 5 8 for information on the master cylinder and brake bleeding procedures CAUTION When replacing a brake caliper assembly the brake pis ton BUNA N O ring MUST be replaced with a VITON O ring compatible with DOT 4 fluid p n 1201T71 Removal and Disassembly 5 7 2 1 Wheel Removal Tools Required Wire cutter Phillips screwdriver needle nose pliers 7 16 wrenches Level of Certification Required A amp P or LSA R M M 1 Remove wheel pant as described in Section 5 3 2 Remove outer wheel pant bracket by cutting the safety wire and removing the two bolts 3 Remove the brake caliper bolts by cutting the safety wire and removing the two bolts 4 Support the airframe using the jacking procedure in Section 2 2 5 Remove cotter pin from axle nut 6 Remove axle nut 7 Support wheel as it comes off 5 7 2 2 Wheel Disassembly V WARNING Do not attempt to separate wheel halves with tire in flat
118. all the edge of the fiberglass without crossing over one or more cooling fins Reinstall spring and bolts Page 7 7 Jabiru 230 5 250 5 Aircraft Service Manual Engine Systems Section 7 4 140 1136 Saas ouaavaNnne CALON SSJINO vnr3i vw YOdaly ATANI SH3AVI Z eS 02 Add w wwe ON SMO 20 darsd OL aya SSI NIS3H AXOd3 009597 ISN Z v0 8 9c x p INOW OL WIH L 3dVHS df1AV 13NI330 OL ta TINON ISN M3AVI lVN 3402 CO dV 3903 Hv38 dNA 019 INO LND H3NNIdS 7 SLONG 3 VLNI M3AO O JV 5 21 TYI 1235 A TddV IYW 3803 30 QN3 OL OF 595 00 NIN 55322 3NION3 D 1 1 404 31950 d33d ier I Ov dVTM3AO 1 559 15 dO 3503 14 40 OL E IVA 3803 40 ONG NOMJ 40 SHSAVI 9 AXOd3 HUM HOLLY O88 OL 096 435 38 AVW QOVLBOVI ASSY 000 309 3903 OlM 0 JV SHJAVI MOO OL ALIGIVYY S L13AlM rey Z L _ Assy 00 aoverovi 9 5 e 997 0092
119. anced NOTE Takeoff technique also affects nose wheel shimmy See 230 Flight Training Sup plement available in the LSA Owners section of www usjabiru com for more infor mation J SA 5 2305 1 Section 5 Landing Gear and Brakes Jabiru 230 5 250 5 Aircraft Service Manual 11 Ald 30 LN3SNO9 INCHLIA 031605 38 LON LSNW S SIHL OL O96NV 1709 20 JOA dO L LIVHS 937 SSON 04200 9 po NidM3liOO LON 3118 VO 90 6 SOLENV 6 82 596006 4 4 9 096 8 GATTIVLSNI SLVdS ZANY 1 ASN LNOHLIM G4SN N3HM 1108 ZEOL SSE0ZSA e 5 4 lt v 8 S 5 931 ISON 4V T109 ONINIVISY 7701909 Po ONON vES SSEOZSM pS SOREN d 2 05 9 S 90820099 v 1004 918 GSNIHOVW 9313SON ASSY goozo0v9 1005 918 NIH LSY ASSY TIJAHM ISON 5 9 zZ 1009 919 34O0A CIHNIHOVW 9313SON ___ GOv OOv9 b ALD WALI 3811 SHEd Gh Ob ib H3 DINIH FUL 626 987 010 NOV Nose Leg Assembly Figure 5 5 Page 5 23 JSA 5 2305
120. anks or free water While very small amounts of water can be absorbed without significantly affecting combustion at higher levels the mixture will not be combustible In addition because this incombustible fuel is formed from a mixture of the Ethanol in the fuel and the water it can have a large volume so a small amount of water will result in a much larger amount of incombustible Ethanol water mix This may give false readings in the fuel tank sumps or exceed the volume of the sump altogether e As noted above Ethanol is an Octane booster and can be absorbed by water Because of this mixing a fuel with water can effectively wash the Ethanol out of the fuel resulting in a significant drop to the remaining fuel s Octane rating e f an Octane Booster containing alcohol is used the operator must ensure that the maximum alcohol content of the resulting fuel booster mix does not exceed the limits given below Due to the fact that their composition varies widely between brands Jabiru Aircraft recommend avoiding the use of octane boosters wherever possible e The engine will use slightly more fuel as the percentage of added alcohol increases As an approximate rule of thumb the engine must burn 3 more fuel to give the same power output if the fuel contains 10 Ethanol e Ethanol mixed with water is somewhat corrosive and may attack parts of the fuel system e In long term storage Ethanol may oxidise with exposure to air This process produces
121. anual contains recommended procedures and instructions for ground handling servicing and maintaining the Jabiru 230 5 and J 250 SP Special Light Sport Aircraft S LSA This man ual is provided by J abiru USA Sport Aircraft LLC to owners operators and maintenance techni cians as required by the applicable ASTM standards The Jabiru 230 5 and 250 SP comply with the following ASTM standards for design con struction and continued airworthiness F2245 Standard Specification for Design and Performance of a Light Sport Airplane e F2279 Standard Practice for Quality Assurance in the Manufacture of Fixed Wing Light Sport Aircraft F2295 Standard Practice for Continued Operational Safety Monitoring of Light Sport Air craft F2483 Standard Practice for Maintenance and the Development of Maintenance Manuals for Light Sport Aircraft Should certification documentation need to be recovered for this aircraft please contact the manufacturer This handbook includes the material required to be furnished to the owner operator by ASTM Standard F2483 The information in this manual is based upon data available at the time of pub lication and is supplemented and kept current by Service Bulletins and Air Safety Alerts pub lished by J abiru USA Sport Aircraft LLC These are posted on the J abiru USA website www usjabiru com and are available through local authorized Jabiru dealers addition to the information in th
122. ar corrosion lubrication and or lack of maintenance Under these adverse conditions perform periodic inspections in compliance with this guide at more frequent intervals undil the owner or operator can set his or her own inspection periods based on the contingencies of experience The 100 hour inspection is required ONLY for aircraft used in commercial operations Airplanes operated commercially less than 100 hours per year must have a 100 hour inspection performed no later than 12 months following the date of the preceeding 100 hour inspection The 100 hour interval between performances of the procedures specified herein should NEVER be exceeded by more than 10 hours which can be used only if the additional time is required to reach a place where the inspection can be satisfactorily accomplished However any extension of the 100 hour interval must be subtracted from the following 100 hour interval with no time extension permitted For example if an inspection is done at 110 hours the next In addition to the inspections prescribed by this schedule the ATC transponder must be tested and inspected at 24 month intervals in compliance with the requirements specified in FAR Part 91 Placards Ensure that all placards are in place and legible whenever the airplane has been repainted or touched up after repairs Replace any placards that have been inadvertently defaced or removed 100 Hour Annual Inspection Checklist Page 1 of 17 Jabiru J 230 5
123. arbon propellers require a check of blade clamp bolt tension every 25 hours in accord ance with Sensenich Document 1 EZ Pitch Composite Aircraft Pro peller Installation and Operation Instructions A copy of this document dated 11 26 08 found in the Appendix of this manual Check the Sensenich website for the latest revi sion Removal Tools Required 1 2 wrenches screwdriver set ruler pencil propeller protractor Level of Certification Required A amp P or LSA R M M Lay ruler on the rear face of one blade Mark 12 from the tip on the trailing edge of the blade Repeat for the other blade Use a propeller protractor to note the prop angle relative to the top of the crankcase when the blades are in a horizontal posi tion 2 Remove machine screws and fiber or plastic washers from spinner 3 Remove spinner cone 4 Remove the six hub bolts from the front half of the hub Take care to support the prop blades when the bolts are loosened 5 Remove front half of prop hub Support the blades when removing the hub half 6 Remove the center positioning nylon block 7 Remove the six hub retaining bolts in the rear hub half to completely remove prop hub and spinner lockplate Inspection 1 Check for nicks and cracks the leading edge and faces of the blades 2 Make sure clamping bolts in propeller hub are torqued to correct specifications See Section 9 8 3 3 Measure pitch angle of e
124. as fuel degradation may occur causing engine damage when aircraft is removed from storage For indefinite storage drain fuel tanks and ensure carburetor bowl is empty by run ning engine with fuel valve off until it stops or by draining carburetor bowl Clean aircraft thoroughly Clean any dirt oil or grease from tires and coat tires with a tire preservative Cover tires to protect against dirt and oil Either block up undercarriage fuselage to relieve pressure on tires or rotate wheels every 30 days to prevent flat spotting the tires Remove battery and store in a cool dry place Charge as required or place on a battery maintainer NOTE It is recommended that a battery which is not used should be charged every 30 days Disconnect spark plug leads and remove spark plugs from each cylinder Using an oil can or spray atomizer spray preservative oil through a spark plug hole of each cylinder with the piston in the down position NOTE Use AeroShell fluid 2UN MIL C 6529C Type 1 or similar engine corrosion inhibitor CAUTION Ensure that the Master and Ignition Switches are OFF Rotate the propel ler 10 12 times leaving it in the horizontal position Install spark plugs and connect leads Seal exhaust pipes Attach a red streamer to each DO NOT seal fuel tank vents Cover the vents to prevent bugs and dirt from accumulating but still allow the sys tem to breathe Place protective covers over pitot tube static source vents
125. as permitted in the Aircraft Service Manual on E LSA aircraft that they own and make the logbook endorsement for return to service as specified by FAR 43 9 JSA SM230SP A1 Page 1 of 1 THIS PAGE INTENTIONALLY BLANK Jabiru J 230 5 250 5 and J 170 SP Aircraft Service Manual 25 and 50 Hour I nspection Guide For J abiru J 170 J 230 and J 250 Models The 25 hour service and inspection is done only one time at the end of the engine break in period at 25 hours total time The break in oil and filter must be removed and replaced head bolts torqued to proper tension cold engine and a general inspection logged At each 50 hour interval after the initial 25 hour inspection the oil must be changed and the 50 hour inspection must be completed and logged Owner Operators of S LSA aircraft that hold at least a Sport Pilot or Private Pilot Certificate may perform maintenance items listed in FAR Part 43 Appendix A Maintenance Preventive Maintenance Rebuilding and Alteration Section C Owner operators performing preventive maintenance must return the aircraft to service by endorsing the aircraft or engine logbook as specified in FAR 43 9 All other S LSA maintenance tasks must be performed by an A amp P LSA Repairman with Maintenance Rating or FAA certified repair station Owner operators of E LSA aircraft that hold a minimum maintenance certification of LSA Repairman with Inspection Rating are authorized under FAR 43 1 b 2 to perform main
126. ble anchor points make sure each end of the cable is se cure 2 Setthe full up travel first using the factory templates Make sure the control column is hard back Adjust the female ball ends in or out if adjustment is needed Refer to Figure 6 2 for an illustration of the elevator cable control stick connection 3 To establish the neutral position align elevator counterbalance with horizontal sta bilizer 4 Adjust cable rod ends to achieve UP and DOWN travel using the Elevator Rigging Template see Appendix If template not available set up travel to a minimum 18 degrees from neutral and down travel to at least 7 degrees from neutral 5 DO NOT move the cable anchors These are factory set 6 Ensure lock nut is tight on rod ends and that cable is visible through hole in spheri cal bearing JSA 5 2305 1 Page 6 13 Jabiru 230 5 250 5 Aircraft Service Manual Flight Controls Section 6 eal ASSY W31SAS YOLYATTI o que zun tz6987010 __50 SEINA BLATT ALd HO3LAV LN3SNOO 031 00 TVd HO3LAV 31926 LON Od S3M L3NITIIM NI gk 38 LON LENN ONY LHOIHAdOO ONIMVHCO SIHL SNOISNaWig 334 51108 HOVLLY TO 3 18YO SIHL 30 9 SL33HS I3 TIV L3G SY A T8ASSSY 7OHLNOO 313 1d NOS HOS N
127. ble is connected to a lubron block so that the cable can move the block fore and aft approximately 35mm An aluminum rod is free to slide through this lubron block and is centered by 2 compression springs The output end of the rod is connected to the elevator horn To operate outer covers of the cable must be clamped firmly at both ends NOTE Control cables may not be removed or repaired without reference to J abiru USA Sport Aircraft LLC or our approved local agent for an approved repair procedure Operational Check Movement of the trim control lever FORE and AFT should result in movement of the control column FORE and AFT and movement of the Elevator DOWN and UP respec tively V WARNING This operational check MUST be performed whenever the trim cable has been disconnected to ensure it has been correctly installed Removal The trim control cable is a primary control and may not be removed or repaired without reference to J abiru USA Sport Aircraft LLC or our approved local agent for an approved repair procedure I nspection The trim mechanism must be kept clean and periodically lubricated with graphite See Annual Inspection Checklist in the Appendix for more information Inspect trim system generally for security and any signs of wear Pay particular atten tion to the bearing blocks friction plates bearing springs cable and attachments The spring rod can be lubricated with a graphite lubricant if any friction is obser
128. comply with the airframe manufacturer s approved fuel recommendations e The ongoing maintenance requirements of a Jabiru aircraft or engine using this level of alcohol are currently unknown The following points are recommended however they are intended as a basic guide for operators and may not address all issues found when operating on these fuels Operators must develop their own ongoing maintenance and Inspection scheme suitable to their fuel and useage i Clear fuel hose should be monitored for hardness brittleness and loss of colour Lines must be inspected regularly and renewed if any sign of deterioration Such as brittleness or cracking is found It is recommended that all flexible fuel lines be replaced at 1 year intervals when using fuels containing 10 20 alcohol li At every 200hrs or 6 months of operation the carburettor be disassembled and all components checked for damage excessively soft or hard rubber parts swelling of rubber components corrosion of metal components Replace component if in damaged or in doubt At every 200 hours 6 months of operation the mechanical fuel pump be disassembled all components checked for damage excessively soft or hard rubber parts swelling of rubber components corrosion of metal components Replace component if in damaged or in doubt 6 6 5 Use of Automotive Gasoline Containing More Than 2096 Alcohol e Use of fuel containing more than 20 alcohol is
129. ction display unit dis connect GPS antenna 11 10 3 Inspection and Repair Inspection is limited to checking the cables and D sub connectors for damage or bad pins and checking upgrading software See 11 10 5 for software upgrade instructions All repairs must be done by Grand Rapids Technologies at their facility 11 10 4 Reinstallation Page 11 10 1 Cut away any remaining pitot static line material from the fittings at the back of the unit Heat the end of the pitot line until it is soft then press it onto the fitting Re peat process for the static line 2 Reconnect D sub connector 3 Reconnect GPS antenna if necessary 4 Power up unit and check for proper operation The magnetometer may need to be recalibrated and certain parameters may have to be reset Consult the GRT Sport installation manual for guidance J SA 5 2305 1 Jabiru 230 5 250 SP Section 11 Aircraft Service Manual Electrical System and Instruments 11 10 5 Grand Rapids Software amp Database Upgrade Tools Required Computer with USB port and Internet access USB flash drive with at least 256MB Level of Certification Required Owner A amp P LSA R M M or Avionics Repair Station Note For Garmin G3X updates see www garmin com for subscription information 1 If not already known determine unit model EFIS software version and navigation database date by turning on the MASTER and INST switches and waiting for the unit to power up Th
130. ctions to steel tubes Page 11 6 J SA SM230SP A1 Section 11 Electrical System and Instruments Jabiru 230 5 250 SP Aircraft Service Manual IVIYUVY 4 L 000 NOV ON Id HOSLAV AG 3i IE NES 31 25 NUS ASSY lOlld OllVIS 608701 E ASSY LOLId 7607506 PEA 1 20514 ASSY dVML M3lVM doVOrovs 39 13503 ACISNI OL 3801 39913513 3015100 OL NAHL 3 135 4 OLNI 31O0H NYHL 380 9NIMIVJ ATI38 03395 334 IVMIN3A 9 531 914 5 9 SINSANNYLSNI OL Q3HOVLIV 4 53901 2115 10 Pitot Static System Figure 11 1 11 7 JSA 5 2305 1 Jabiru 230 5 250 SP Aircraft Service Manual dO 133 7609 0 ASSY 10 OILVLS ON OMG HOALAV SLINAWNYLSN OL 3871 58 gzi Eo EB jani OL 91 38IM 30 39 135054 30 901 SI 3801 3 Nid IYL OL 1 AXOd3 9011 NOLLOO _ sv ayeaiw Vent Detail Static Figure 11 2 J SA SM230SP A1 Electrical System and Instruments Section 11 011 Ald 40 LNASNOO LNOHLIM 9 NOILO3PO d JIWOS LON Od SNOISNAWIC 035035 38 LON LHOINAdOS SI SIHL Page 11 8 Jabi
131. ctor for corrosion cracks or frays Replace connector if necessary Repair Electric fuel pump repair 5 limited to replacement Reinstallation 1 Zi Reverse the steps in 8 4 2 for installation To test pump function turn master switch ON engine not running and then turn fuel pump ON There should be an audible tapping sound The frequency of the taps will change slightly when the carburetor bowl is filled with fuel WARNING All fuel line firesleeve removed during maintenance must be reinstalled before the aircraft is returned to service 8 5 Fuel Filters 8 5 1 Description There is one removable brass finger filter in each fuel tank exit line two in each main tank and one in the header tank to filter large particles exiting the fuel tanks There 15 automotive type main fuel filter located between the center console shutoff valve and the firewall between the rudder pedal units 8 5 2 Removal of Finger Filters Page 8 4 Level of Certification Required A amp P or LSA R M M Drain fuel from the affected fuel tank using procedure outlined in Paragraph 8 8 Remove wing root fairings or header tank as necessary see Paragraph 8 2 of this section for removal of header tank Remove hose clamp and fuel line Remove finger filter using deep well socket J SA SM230SP A1 Jabiru 230 5 250 5 Section 8 Aircraft Service Manual Fuel System 8 5 3 Removal of Main Fuel Filter Tools Required 7 16 deep
132. cuit protect the electrical appliances in the aircraft Electrical circuit diagrams are provided for the three available Grand Rapids panel layouts and other standard and optional electrical devices in this section Contact J abiru USA Sport Aircraft LLC for wiring and electrical information for the Garmin G3X panel option Consult the Engine Instruction amp Maintenance Manual for Jabiru 3300 Aircraft Engine for guidance on removal inspection and reinstallation of the electrical generating system Alternator 11 2 1 Description Electrical power is generated by 20 amp permanent magnet alternator that 15 inte gral to the flywheel AC current is rectified to DC current and is regulated to 14 volt DC by a solid state regulator mounted on the firewall 11 2 2 Removal Inspection Repair and Reinstallation Refer to the nstruction and Maintenance Manual for Jabiru 3300 Aircraft Engine for information on removal inspection repair and reinstallation of the alternator volt age regulator and their components Battery 11 3 1 Description The Odyssey PC625 battery is a 12 volt drycell which is mounted on the firewall 11 3 2 Removal Tools Required 10mm wrench or socket Level of Certification Required Owner A amp P or LSA R M M 1 Remove battery ground cable and undo strap buckle 2 Disconnect the battery positive cable 3 Remove the battery strap 4 Remove the battery J SA SM230SP A1 Page 11 1 Section 11 Jabiru
133. d remove hinge pins For aircraft with a single hinge pin 2009 models and newer 1 Remove hinge pin retaining screw 2 Unbolt cable from aileron control horn 3 With the aileron supported remove hinge pin Inspection Inspect ailerons for any signs of delamination or cracking Pay particular attention to the control horn and hinges and their surrounding fiberglass areas See Section 6 2 for inspection of control cables J SA SM230SP A1 Jabiru J 230 SP 250 SP Section 6 Aircraft Service Manual Flight Controls 6 3 4 Repair All damage involving cracking delamination or hinge damage must be referred to J abi ru USA Sport Aircraft LLC or approved local agent for an appropriate repair procedure 6 3 5 Reinstallation Reverse the removal processes of Paragraph 6 3 2 for reinstallation V WARNING All spherical bearings on control cable ends 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 6 3 6 Aileron Rigging Tools Required Screwdriver set 7 16 and 3 8 wrenches 36 straightedge Aileron Rigging Template see Ap pendix or angle finder Level of Certification Required A amp P or LSA R M M Park aircraft on a level surface With the control stick in the neutral position use a straightedge not less than 1 meter long Hold the straightedge flush on the under side of the wing airfoil and adjust aileron to sit on the
134. d in Section 7 4 Using the oil filter wrench turn the filter counter clockwise to remove the oil filter Oil Filter nspection optional Using an oil filter cutter open the filter can and remove the filter paper Carefully wash the paper in gasoline or similar solvent Inspect the filter media for metal debris Some amount of non magnetic aluminum particles is to be expected Fine rusty bronze colored particles that look the size of squashed sugar grains indicate rocker bushing wear Larger copper or bronze colored particles indicate main or rod bearing wear Ex cessive amounts and or size of these particles may indicate need for further engine in spection or repair Reinstallation of Oil and Filter 1 2 J SA SM230SP A2 Lubricate the rubber seal of the new filter with engine oil Screw the filter onto the threaded adapter and turn clockwise until the filter con tacts the cooler adapter Continue clockwise for 2 3 turn There is no need to lock wire the filter in place Reinstall cooling baffle Refill crankcase with appropriate amount and type of oil Total oil capacity is 3 7 quarts but 3 5 quarts is typically the amount added during an oil change To check oil quantity screw dipstick cap all the way into the case then unscrew lift out and check Normal oil level range is depicted by the cross hatched area on the dipstick Do not overfill Clean all excess oil from exterior surfaces of engine especially around t
135. de owners and operators on some of the effects of using a fuel containing alcohol in a Jabiru Aircraft or Engine An automotive fuel s anti detonation performance is usually measured in Australia using RON Research Octane Number MON Motor Octane Number or AKI Anti Knock Index are sometimes also used RON is always a higher number than both MON and AKI As a general rule RON can be estimated by adding 5 a fuel s AKI i e a fuel with an AKI of 89 will have a RON of approximately 94 and so must not be used recommendations given in this letter are applicable for Jabiru Aircraft and Engines as noted including older variants While older Jabiru Engines have a different combustion chamber shape which demands the use of a fuel with 100 Octane RON or higher the presence of alcohol in the fuel within the limits noted is not a problem for these engines JSL007 3 doc dc id Page 2 of 14 3 3 1 3 2 Compression Ratio Combustion Chamber Shape Compression Ratio At Manufacture the compression ratios of Jabiru Engines were as listed 1600 All S No 9 3 1 2200 S No 1 106 9 3 1 2200 S No 107 127 9 3 1 2200 S No 128 831 7 8 1 or 8 3 1 2200 S No 832 1003 7 8 1 or 8 3 1 2200 S No 1004 Onwards 8 1 3300 S No 1 223 7 81 or 8 3 1 3300 S No 224 Onwards 8 1 5100 All S No 8 5 1 Where two ratios are listed those engines fitted with shims between the cylinder barrel and the c
136. e Power Up page in Figure 11 3 will display on the PFD and MFD screen if installed Write down any information needed from both screens and shut off master switch 2 Insert USB stick into computer Go to www grtavionics com click Support then Software Click the link to load the software appropriate to the EFIS in the aircraft It will be either the SWS older version wide screen SHS most 2305 later 2505 taller high res screen or SX 2010 and newer 230s Save the dat file to the main root directory of the USB drive not in a separate folder BIEFIS Sport HS Power Up DEFIS software integrity check PASS EFIS software version Date 2009 07 13 AHRS software version 0 28 Navigation database integrity check PASS Navigation database date 2009 11 19 AHRS Communication OK EIS Communication OK Inter Display Communication OK Primary Speed Distance units Knots nautical miles 77 Feedback Report Generated Push FEED BACK for options Figure 11 3 Sport HS EFI S unit power up page 3 Save the newest Navigation Database NAV DB file to the main root directory of the USB drive 4 Power up the EFIS units by turning on the MASTER and INST switches Accept the power up screen 5 the PFD or default screen press the NEXT soft key until SET MENU ap pears over one of the soft keys Press that key J SA SM230SP A1 Page 11 11 Section 11 Jabiru 230 5 250 SP Elec
137. e appearance of the air craft cleaning makes inspection and maintenance easier 2 11 1 Exterior The exterior finish used on J abiru aircraft is a two part automotive type paint system that utilizes a base clear coat For optimum performance and aesthetics the exteri or surfaces of the aircraft should be kept clean and free of bugs and grease The painted surfaces and windows of J abiru USA factory demonstrator airplanes are routinely cleaned and polished with Turtle Wax Express Shine a spray type cleaner that leaves a thin protective coating This coating aids in removal of dirt and bugs if kept up regularly It is applied directly to the surface with the spray bottle and simply wiped dry with a clean microfiber cloth When cleaning windows always use a new clean cloth and avoid swirling motions Heavy accumulation of bugs and grease on painted surfaces should be removed with a light mixture of soap and water and then rinsed The TurtleWax may then be applied for a smooth protective shine Specialty plastic cleaners such as Plexus will also work on the windows which are acrylic based Perspex If tape or sticker residue gets on the windows GooGone citrus stain remover dabbed onto a soft microfiber cloth will remove it without harming the windows Light scratches and swirl marks may be buffed out using a Plexiglas window buffing system such as Scratch Off available through Aircraft Spruce and Specialty V CAUTION Use onl
138. e compartment for oil leaks Complete 50 hour service and inspection as necessary When satisfied rein stall engine cowlings On a new engine if head bolt tension continues to change after the 10 hour check investigate whether the heads are receiving enough cooling Overheated heads will cause head bolt tension to change as the heads expand beyond engineered limits and then contract Correct the cooling problem ASAP or contact J abiru USA for as sistance Figure 7 10 Head Bolt Locations Number 5 15 hidden behind rocker chamber oil plug SM230SP A2 Page 7 31 Section 7 Jabiru J 230 5 250 SP Engine Systems Aircraft Service Manual THIS PAGE INTENTIONALLY BLANK Page 7 32 J SA SM230SP A2 Jabiru 230 5 250 5 Section 8 Aircraft Service Manual Fuel System Section 8 Fuel System 8 1 General Description The engine is equipped with a carburetor see Section 7 10 mounted behind the en gine and a fuel pump at the starboard rear of the engine There Is one fiberglass main fuel tank in each wing Fuel is routed in automotive ethanol resistant fuel lines from each wing through a shutoff valve on each side of the cockpit interior mounted aft of the cockpit doors It then flows into a header tank located behind or under the passen ger seat Fuel is fed from the header tank to the engine through a filter located be tween the two sets of rudder pedals As long as there is fuel inside the wing tanks there 15 e
139. e inner surfaces of the cowlings with a cloth saturated with mineral spirits 2 Wash with a solution of mild soap and water and rinse thoroughly After cleaning inspect for dents burns rubbing marks cracks and any signs of delamination Repair Repair of cracks or tears can be made using the general fiberglass repair procedure out lined in Section 12 Replace damaged or worn cam locks and anchor lugs with new parts Repair is limited to replacement cam locks Rivets fixing cam lock anchor lugs must be backed with washers Reinstallation 1 Install the lower cowl before the upper Reverse the removal steps for reinstalla tion 2 Do not fully tighten the lower cowl screws until after the top cowl has been installed V WARNING Ensure the cam locks are properly engaged before starting engine 7 4 Cooling Air Baffles 7 4 1 7 4 2 Page 7 6 Description The fiberglass baffles installed on top of the engine direct the cooling air flow to the cylinder heads and to other engine components to provide optimum engine cooling V Caution The baffles air inlets outlets and scoops are accurately posi tioned to maintain engine cooling efficiency Their removal or modification may cause improper air circulation and engine overheating Removal Tools Required 3 16 Allen key needle nose pliers rag or con tainer to catch Level of Certification Required Owner A amp P or LSA R M M J SA SM230SP A2 Jabiru J 23
140. e it has a higher compression ratio the Jabiru 5100 engine must be operated using AVGAS or other fuel with a RON of 100 or higher e Where a Jabiru Engine is installed in a non Jabiru airframe the operator must comply with the airframe manufacturer s approved fuel recommendations 6 6 2 Automotive Gasoline e Jabiru Aircraft has no objection to operators using automotive gasoline in Jabiru Aircraft or Jabiru Engines For most engines the use of fuel with RON of 95 or above is adequate however older engines must use fuel which meets the Octane rating requirements of their combustion chamber See Section 3 above e Note that different Jabiru Airframes can have different maintenance requirements example the CASA Certified J160 C must be operated and maintained in accordance with the CASA Approved procedures given in it s Flight and Maintenance manuals which do not allow the use of fuels containing alcohol but do approve the use of suitable MOGAS e Operators wishing to use automotive gasoline but wishing to avoid using alcohol should obtain Technical Data Sheets for the Gasoline they are using Regular testing as detailed above should also be carried out to ensure the fuel does not contain alcohol e Operators using Octane Boosters and wishing to avoid introducing alcohol to their fuel systems must ensure that their chosen octane booster does not contain alcohol e Maintenance for the engine and airframe is to be carried out in acco
141. e no lines that have kinked Reinstall stall warning reed bell 8 Reconnect electrical wires to strobes and wingtip lights 9 Put about 3 gallons of fuel in each tank amp check for any leaks 10 Attach flap to wing ensuring all bushings are in place 11 Install bolt nut in flap control rod 12 Install bolt nut in aileron control cable on main control stick horn 13 Install clamp on aileron control cable clamp between the seats 14 For RH wing reconnect pitot tube 15 For LH wing reconnect recognition light 16 Replace wing strut fairings top and bottom 17 Replace wing root fairings 18 Perform a fuel flow test Disconnect the fuel line from the mechanical fuel pump in the engine compartment Have a second person catch any fuel that flows out of the line in a container with accurate volume marks Turn electric fuel pump on and pump fuel through the lines into container Ensure there is a minimum of 0 25 gal lon per minute flow rate 19 After carrying out the fuel flow test check that both wing tanks are feeding fuel SM230SP A0 Turn off both of the doorpost fuel valves pump about a quart out of the header tank and then turn the left wing valve on The wing tank will gravity feed to the header tank and it should re fill within approximately 1 2 minutes This must be repeated for the right wing If a wing is not flowing correctly check lines for kinks blockages amp airlocks Page 4 3 Section 4 Wi
142. e oil cooler and oil recovery systems because their installation is unique to Jabiru S LSA aircraft Refer to nstruction amp Maintenance Manual for J abiru 3300 Aircraft Engine for other oil system details The engine oil pump is located at the end of the cam shaft Oil is pumped out the side of the crankcase through an oil cooler adapter and oil cooler radiator and then through the oil filter Oil is then fed under pressure to the interior of the engine and returns to a wet sump at the bottom of the engine Oil pressure is monitored just before the oil leaves the crankcase on the way to the cooler Oil temperature is measured in the sump A pressure regulating valve is under the oil cooler adapter SM230SP A2 Jabiru 230 5 250 5 Section 7 Aircraft Service Manual Engine Systems 7 7 2 and Filter Change 5 6 Tools Required Phillips screwdriver oil filter wrench oil collec tion pan of at least 1 gal capacity Parts Required 4 quarts oil and new filter see Section 1 9 Level of Certification Required Owner A amp P or LSA R M M If possible run engine until oil is up to normal operating temperature Remove upper and lower engine cowl as described in Section 7 3 Open quick drain valve if installed in bottom of oil sump and let oil drain If no quick drain valve is installed remove plug Empty oil breather vent collector bottle as described in Section 7 9 Remove left side cooling baffle as describe
143. e rivets or deformation e TT Head Bolt Tension Torque head bolts to proper tension 3 Cabin and Baggage Compartment Rudder Pedals Check for freedom of movement Check push pull cables for proper routing condition and security Check rudder pedal springs for condition and correct placement Check pedal extensions for security if installed Comments Instruments and I nstrument Panel nspect instrument panel placards and instruments for condition and attachment Check all knobs for security JSA 50HR A1 25 50 Hour Inspection Checklist Page 7 of 9 Jabiru J 230 5 250 5 and J 170 SP Aircraft Service Manual 4 Wings and Carry Through Structure Skin Check for deformation and obvious damage Check for cracks If damage is found check adjacent structure Check for indications of excessive flight loading Wing Bolts Check wing bolts for security DO NOT overtighten Fuel Vents Pitot Tube and Stall Warning Check for condition and obstructions 5 Nose Gear Wheel and Tire Check wheel for cracks and tire for wear damage condition and proper inflation Check wheel bearings for condition and wear 6 Main Gear and Brakes Wheels and Tires Check wheels for cracks and tires for wear damage condition and proper inflation Check and repack wheel bearings Landing Gear Legs nspect legs for cracks overextension signs of delamination JSA 50HR A1 25 50 Hour Inspection Checklist Page
144. e wheel is mounted an aluminum yoke which 15 bolted to the steerable welded steel tube nose leg Two aluminum brackets and Delrin bush ings form a housing which attaches the steel tube nose leg to the firewall Nose wheel steering is achieved by connecting the rudder pedal assembly to the nose wheel steering link by push rods The nose wheel 15 centered by springs attached to the pedals and a bracket on the center console inside the cockpit The springs extend and contract as the nose leg is moved left and right and are critical to the rudder rig ging and handling characteristics of the aircraft JSA 5 2305 1 Page 5 19 Section 5 Jabiru 230 5 250 5 Landing Gear and Brakes Aircraft Service Manual 5 10 2 Removal Tools Required Screwdriver set 7 16 wrenches and or sock ets pliers Level of Certification Required A amp P or LSA R M M Refer to Figures 5 5 to 5 8 1 2 6 Remove engine cowlings as described in Section 7 Weigh down tail of aircraft to raise nose wheel off floor as described in Section 2 Disconnect nose wheel steering pushrods from steering cross beam Unbolt steering cross beam Remove upper collar steering yoke dependant on aircraft serial number from the top of the leg Pull the nose wheel strut assembly down from the bushings in the fuselage 5 10 3 Inspection and Repair 1 Inspect steel tube and attachments for dents and straightness If bent or dented replace ste
145. ection 7 Engine Systems Jabiru 230 5 250 5 Aircraft Service Manual 7 18 Exhaust System 7 18 1 Description The exhaust system consists of individual exhaust manifolds attached to the cylinder heads and a muffler assembly that is attached to the bottoms of the manifolds with springs Refer to Figure 7 8 for more information 7 18 2 Removal Tools Required Screwdriver set 3 16 hex driver Level of Certification Required A amp P or LSA R M M V WARNING Never remove coupling spring with a sharp object or 3 4 one which can mark the spring material A rounded screwdriver shank or a hook fashioned from 34 bar Stock 15 ideal Disconnect the carb heat and cabin heat SCAT hoses Remove muffler springs Remove muffler assembly If necessary loosen exhaust manifold bolts Remove individual exhaust manifolds as needed 7 18 3 Inspection Page 7 26 As all exhaust systems are subject to burning cracking and general deterioration from alternate thermal stress and vibration inspection 15 very important and should be car ried out every 50 hours of operation addition an inspection of the exhaust system must be undertaken anytime exhaust fumes are noticed in the cabin Inspect complete system starting at the connection to the head Inspect the securing bolts and move outwards looking for cracks Especially check areas adjacent to welds Look for exhaust gas deposits in surrounding areas indicating that exhaust
146. ed as injury may result Avoid damaging wheel flanges when breaking beads loose as a scratch nick or gouge may cause wheel failure 1 Deflate tire and break tire beads loose from tire rims 2 Remove brake disc 3 Remove through bolts nuts and separate wheel halves removing tire tube and wheel hub J SA SM230SP A1 Jabiru J 230 SP 250 SP Section 5 Aircraft Service Manual Landing Gear and Brakes 5 7 3 Wheel I nspection 1 2 Clean all metal parts in solvent and dry thoroughly Inspect wheel halves for cracks Cracked wheel halves should be discarded and new parts used Sand out nicks gouges and corroded areas Carefully inspect bearings for damage and discoloration Repack bearings as needed NOTE Bearing cleaning solvents will remove the pack ing grease therefore bearings must be repacked after cleaning 5 7 4 Brake Inspection 1 2 Check assembly and fittings for evidence of leaks Check safety wire and security of caliper bolts Look for the half moon shaped wear mark on the fore and aft faces of the brake pads If the mark is not visible the pads are worn beyond service limits and must be replaced Check disks for wear grooves deep scratches pitting or coning Isolated grooves up to 0 030 inch deep are acceptable but any grooving will reduce service life of the pads Coning beyond 0 015 in in either direction requires disk replacement Minimum serviceable disk thickness 15 0 167 inches Excessi
147. ed from the wing tank NOTE The capacity of each wing tank Is approx 18 U S gallons Page 8 8 SM230SP A1 Section 8 Fuel System Jabiru 230 5 250 5 Aircraft Service Manual 2 Jue 497 03 eur 3u9A 03 JBPUSS en4 ueAuq euibu3 dund 21u329 3 9Ur 9Ur Poor 493 duns JO nus gt A3 Figure 8 1 Fuel System Schematic Drawing aircraft s n 726 and earlier Page 8 9 JSA 5 2305 1 Section 8 Jabiru 230 5 250 5 Aircraft Service Manual Fuel System ue 2 03 03 SULT ue JopeoH Jopues Mo J N4 dund jen4 dund jen 4 2u329 3 SUI oul 423 duns SAIEA HO ANYS 9 EA 32945 AD v r gt lt gt gt pei e zue L 1497 03 eur Figure 8 2 Fuel System Schematic Drawing 230 5 795 and newer J SA SM230SP A1 Page 8 10 Jabiru 230 5 250 SP Section 9 Aircraft Service Manual Propeller amp Spinner Section 9 Propeller 9 1 Spinner Assembly 9 1 1 Description Each J abiru S LSA airc
148. eel Bearings Nose Gear Leg Housing Control Stick Housing Trim Spring Assembly 2 10 8 Aircraft Documents To be displayed in the aircraft at all times a Placards as detailed in Pilot s Operating Handbook b Airworthiness Certificate c Aircraft Registration To be carried in the aircraft at all times a Current version of Pilot s Operating Handbook b Operating Limitations c Weight and Balance 2 10 9 Engine Run Up Page 2 12 Before beginning the step by step inspection start warm run up and shut down the engine in accordance with instructions in the Pilot s Operating Handbook During the run up observe the following making note of any discrepancies or abnormalities DE Gn e ey Engine temperatures and pressures Static RPM also refer to Engine Instruction Manual Magneto drop also refer to Engine Instruction Manual Engine response to changes in power Any unusual engine noises Idle RPM Fuel shut off valve operate engine in ON position and in OFF position long enough to ensure shut off functions properly After the inspection has been completed an engine run up should again be performed to determine that any discrepancies or abnormalities have been corrected and to check engine for oil leaks J SA 5 2305 1 Jabiru J 230 SP 250 SP Section 2 Aircraft Service Manual General Care amp Inspection 2 11 Cleaning Keeping the aircraft clean is important Besides maintaining th
149. eft New style roll servo viewed from front between seats top right New style roll servo installation from rear bottom right Old style roll servo installation bottom left Page 11 22 5 5 2305 1 Jabiru J 230 SP 250 SP Section 11 Aircraft Service Manual Electrical System and Instruments 11 15 2 Removal Programmer Autopilot Head 1 Disconnect battery ground 2 Remove the four mounting screws 3 Disconnect the pitot and static lines at the rear of the unit 4 Disconnect the 25 pin sub d plug from the rear of the unit Roll servo 1 Disconnect battery ground 2 Remove the control rod from the servo and aileron mixer 3 Disconnect the 15 pin sub d plug from the rear of the servo 4 Remove the servo mounting bolts Pitch servo 1 Disconnect battery ground 2 Support the tail of the aircraft with a tail stand to allow entry into tail of aircraft 3 Loosen the jam nut on the control cable 4 Remove the screw at the center of the torque arm and remove the arm 5 Remove the four nuts from the servo mount base and lift the servo 6 Remove the 15 pin sub d plug from the servo 11 15 3 Inspection 1 Inspect pins and wiring 2 Inspect servo mounts and brackets for cracking or looseness 3 Inspect servo arms for condition 11 15 4 Repair Refer to TruTrack Flight Systems for any repairs to the programmer or servos 11 15 5 Reinstallation 1 Reverse applicable steps in Section 11 15 2 for reinstallation of components
150. el nose leg assembly Repair 15 limited to replacement Inspect rubber suspension assembly for damage or cracking of the rubber or de lamination of the rubber from the aluminum spacers between the rubber blocks If weather checked cracked or otherwise damaged replace rubber suspension spring assembly Inspect aluminum wheel yoke for damage or bending If cracked bent or other wise damaged replace the yoke Check bolt nut tension on entire assembly see Table 1 4 Torque Values Inspect steering rod connections and rudder springs for security and condition Re placed if bent sprung or otherwise damaged Check for bending or deformation of nose leg housing assembly Check Delrin bush es for wear or breakage Repair of nose leg housing 15 limited to straightening or replacement of aluminum brackets and replacement of Delrin bushes 5 10 4 Reinstallation 1 2 5 20 Reverse the steps Paragraph 5 10 2 for reinstallation When replacing Delrin bushings install with a mixture of epoxy and cotton flock and bed in place J SA 5 2305 1 Jabiru 230 5 250 5 Section 5 Aircraft Service Manual Landing Gear and Brakes 5 11 Nose Wheel 5 11 1 Description The nose wheel is a J abiru cast aluminum wheel with sealed bearings The wheel is in two halves which are joined by through bolts to the wheel hub as shown in Figure 5 8 Nose Wheel Assembly 5 11 2 Removal and Installation Tools Required Phillips
151. epaired without reference to Jabiru USA Sport Aircraft LLC or a local approved agent Inspection Check for worn nylon bushings Replace as needed Repair Replace all worn or damaged parts Control Cables 6 2 1 Description All control cables used in J abiru aircraft are of the enclosed push pull type with the ca ble bolted directly to the control surface horn at one end and to the pilot control at the other end To operate correctly outer covers of the cable must be clamped firmly at both ends V WARNING All spherical bearings on control cable ends must be fit ted 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 6 2 2 Removal The control cables are primary controls and may not be repaired or removed without reference to J abiru USA Sport Aircraft LLC or our approved local agent for an appropri ate procedure 6 2 3 Inspection Check for broken sheaths broken or frayed cables and loose fittings Make sure the cable sheath is clamped securely in the correct position at each end JSA 5 2305 1 6 1 Section 6 Jabiru 230 5 250 5 Flight Controls Aircraft Service Manual ate AS DETAILED IN SHEETS 1 gt Ah Figure 6 1 Control Column Old Style Page 6 2 J SA SM230SP A1 Section 6 Flight Controls Jabiru 230 5 250 5 Aircraft Service Manual 029 Su3g8
152. er 8130 2F Each 100 Hour Interval 100 Hour Inspection JSA 100HR A amp P or LSA R M M Commercial Operators Change 3 Section 126 Replacement of Engine Each 200 Hour Interval Ignition Wires Caps and 3300 Installation age LSA All Recommended and Instruction Manual aircraft manufacturer Rotors Landing Gear Bolt Each 500 Hour nterval JSA 003 1 A amp P or LSA R M M All Aircraft manufacturer Replacement Each 1000 Hour Interval Engine Top Overhaul Jabiru 3300 Overhaul or LSA R M M All Recommended oy Manual engine manufacturer Each 2000 Hour I nterval Engine Complete Overhaul Japru A amp P or LSA R M M All Recommended by Manual engine manufacturer Significant temp humidity Aircraft Service Manual All aircraft except those change over several weeks Propeller Hub Bolt Tension or Sensenich Doc A amp P or LSA R M M equipped with ground Propeller Check WOOD CF REV A DOC 5 adjustable carbon manufacturer or months 20 04 propeller FAA Order 8130 2F Change 3 Section 126 Carbon Propeller Clamp Bolt Propeller Each 25 Hour nterval Tension Check manufacturer Every 12 Calendar Months Annual Inspection JSA 100HR A amp P LSA R M M or ELT Inspection ELT operation manual aed aone fach All FAR 91 207 d Transponder operation A amp P LSA R M M Every 24 Calendar Months Transponder Inspection All FAR 91 413 a Recom
153. eral Description Aircraft Service Manual 1 4 Engine Specifications Manufacture Jabiru Aircraft Pty Ltd Aero Engines Division TYDE e c Ra nd 3300A Air Cooled sciret 112 hp 2850 RPM ER 120 hp 3300 RPM ip E 228 ft Ib 2500 RPM 3300 202 cu in Clockwise when viewed from aft of engine Prop Hub wood SAE 1 4 375 inch radius bolt pattern Prop Hub carbon propeller 4 0 inch radius bolt pattern 1 5 Weight amp Balance I nformation The J ABIRU is a very light aircraft The installation of equipment may significantly alter the center of gravity of the aircraft Therefore all proposed fixed installations must be approved by Jabiru USA Sport Aircraft LLC Refer to Section 2 of this man ual for weighing procedure and Section 4 of the Pilot s Operating Handbook for cen ter of gravity calculation instructions and limitations J230 SP ERE Leading Edge of Wing Most Forward 3 89 inches aft of datum Most Aft C G EOCOlloD 11 10 inches aft of datum 250 5 Leading Edge of Wing Most Forward
154. ervice Manual 5 7 6 Wheel Reassembly Refer to the Matco Service Instructions located in the Appendix of this manual for addi tional information regarding wheel assembly Tools Required 7 16 wrenches tire pressure gauge Parts Required Wheel rim lubricant new inner tube if neces Sary Level of Certification Required A amp P or LSA R M M 1 Apply automotive tire mounting lubricant to the tire bead areas of the rim halves 2 Position tire and tube between wheel halves with tube inflation valve through hole in outside wheel half 3 Mate wheel halves While holding halves together assemble a washer and nut on one through bolt and tighten snugly 4 Assemble the remaining washers and nuts on the through bolts and torque to 16 ft lbs V CAUTION Ensure tube 15 not pinched between wheel halves dur ing assembly Uneven or improper torque of through bolt nuts can cause bolt failure and subsequent wheel failure 5 Insert through bolts through brake disc and position disc on the inner wheel hub flange 6 Inflate tire to seat tire beads then adjust to correct tire pressure Refer to Para graph 1 6 5 7 7 Reinstallation of Wheel Brake onto Axle Tools Required Screwdriver 7 16 wrenches safety wire pliers adjustable wrench Parts Required New 1 8 by 2 cotter pin if necessary 032 safety wire Level of Certification Required A amp P or LSA R M M Refer to the Matco Service Instructions located in the Appendix of th
155. es Lead content Price Availability varies Lead content Price ouitable A good fuel but which has operational maintenance and legal requirements the Marginal Should only be used when the operator has no other suitable choice Maintenance may be higher Availability varies Lead content Price Maintenance may be higher Availability varies Does not store well Lower quality controls Not designed for aircraft Availability varies Does not store well Lower quality controls Extra alcohol related maintenance required Not designed for aircraft Availability varies Unknown octane rating Lower quality controls Does not store well Unknown octane booster content Extra alcohol related maintenance required Not designed for aircraft Unsuitable Will damage engines May write engine off completely Page 13 of 14 JSL 007 3 oth Nov 2009 8 Contact Information Preferred Method of Contact email info jabiru net au Postal Address Jabiru Aircraft P L PO Box 5186 Bundaberg West 4670 QLD Australia JSL007 3 doc Page 14 of 14 Appendix Jabiru 230 5 250 SP Aircraft Service Manual ooro S3ML3SNFIIN SNOISN3NIO GLT Abo LDORLM CX ICH SDN ONF SD NI NADG S S dvi Ost VV OPERUM us TO ER MGT Sn CSPI Cer yan ssw Tot t NOESY Page 1 of 2
156. ew parts used Sand out nicks gouges and corroded areas Clean thoroughly Inspect bearings for damage and discoloration 3 Refit bearings or replace if necessary 5 11 5 Nose Wheel Reassembly 5 9 5 Page 5 22 1 Ensure bearings are properly reinstalled in wheel hub 2 Apply automotive tire mounting lubricant to the tire bead faces on the inside of the wheel rims 3 Position tire and tube between wheel halves with tube inflation valve through hole in outside wheel half 4 Mate wheel halves While maintaining a light force assemble a washer and nut on one through bolt and tighten snugly Assemble the remaining washers and nuts on the through bolts and torque to the value specified in Table 1 4 Torque Values WARNING Ensure tube 5 not pinched between wheel halves dur ing assembly Uneven or improper torque of through bolt nuts can cause failure of bolts with resultant wheel failure 5 Inflate tire to seat the tire beads Adjust to correct tire pressure Refer to Section 1 6 Nose Wheel Balancing Tools Required Phillips screwdriver 7 16 wrenches Parts Required Wheel weights various sizes Level of Certification Required A amp P or LSA R M M Since uneven tire wear 15 usually the cause of tire imbalance replacing the tire will probably correct this condition Slight shimmy felt after takeoff is usually a result of tire imbalance If a wheel shows evidence of imbalance during service it may be statically bal
157. formance Conditioning removes high spots and creates a layer of glazed material at the lining surface Normal braking will produce enough heat to maintain glazing during the life of the lining Glazing can be worn off during light use such as taxiing 1 After the linings have been installed apply brake pressure during high throttle static run up Note RPM at creep if any occurs Perform two or three high speed taxi runs Apply firm braking at 30 40 mph down to 5 mph to generate the necessary 300 400 degree temperatures at the brake pads DO NOT bring the aircraft to a complete stop during taxi runs and continue to roll aircraft until reaching the tie down area Release brake pressure at tie down area 5 soon as practical and park with brake pressure released Allow brakes to cool for 10 15 minutes Repeat step one and note RPM at creep if any occurs There should be a noticeable increase holding torque If properly conditioned the pads will have a uniform shiny appearance glaze the surface Repeat steps 1 3 if necessary to produce glaze NOTE Forward movement of the aircraft during static run up could be caused by the wheels skidding not brake malfunction J SA 5 2305 1 Jabiru 230 5 250 5 Section 5 Aircraft Service Manual Landing Gear and Brakes 5 9 Nose Wheel Fairing 5 9 1 Description Wheel fairings pants are standard equipment on Jabiru J 230 and J 250 aircraft The nose wheel fairing is c
158. ft with main gear still installed 2 f movement beyond normal flexing of the leg is observed A Tighten clamp bolts 2 evenly to take beam movement out Do not over tighten Add washers if necessary max 4 until between 3 and 5 threads show the bolt If more washers are necessary use a shorter bolt B Over tightening AND failure to tighten both bolts adequately can cause bolt failure See Table 1 4 Torque Values for proper bolt torque 3 Inspect composite beam for damage indicated by cracks or delamination Pay par ticular attention to the area around the center bend and to areas around drilled holes 4 nspect main gear mounting hardware for wear bending and signs of damage Replace hardware if necessary 5 Inspect bolt seats in fuselage for signs of damage or wear JSA SM230SP A1 Page 5 5 Section 5 Jabiru 230 5 250 5 Landing Gear and Brakes Aircraft Service Manual 5 5 4 Repair All damage involving cracking or delamination must be referred to J abiru USA Sport Air craft LLC or an approved local agent for an appropriate repair procedure Repair is generally restricted to replacement of the gear leg 5 5 5 Reinstallation Tools Required Screwdriver set 7 16 1 2 and 9 16 wrenches Parts Required New AN bolts and nuts as required length varies with thickness of fiberglass mounting areas Level of Certification Required A amp P LSA R M M The following procedural steps install the
159. gas Is es through a hole or crack For a more thorough inspection the following procedure Is recommended 1 2 Remove manifolds and or Use rubber expansion plugs to seal openings Using a manometer or gauge apply approximately 1 1 2 psi 3 inches of mercury of air pressure while the manifold and or muffler are submerged in water All leaks will appear as bubbles and can be readily detected It is recommended that any exhaust system component found to be defective is repaired or replaced with a new part before the next flight J SA SM230SP A2 Jabiru J 230 SP 250 SP Section 7 Aircraft Service Manual Engine Systems 7 18 4 Repair 1 Cracks or leaks can be welded by a technician skilled welding of stainless exhaust pipes 2 Cracks not suitable for welding require replacement of the exhaust component 7 18 5 Reinstallation 1 Reverse the steps in 7 16 2 for installation 2 If reinstalling the exhaust manifold pipes install bolts hand tight to allow wiggle room until the muffler is in place then tighten them the rest of the way 3 Run engine until it reaches normal operating temperature Shut it down and while it is still warm torque exhaust manifold bolts to final torque value See nstruction amp Maintenance Manual for J abiru 3300 Aircraft Engine for specific torque values SM230SP A2 Page 7 27 Section 7 Jabiru J 230 5 250 SP Engine Systems Aircraft Service Manua
160. ground cable and nut 9 Make sure the cables do not contact any part of the exhaust system Tie the two jumper cables together using zip ties or other acceptable wire tie method to finish up the installation 10 Reinstall the cowls 11 16 3 Removal Reverse steps in 11 16 2 for removal 11 16 4 Repair Repair 15 limited to replacement of components Figure 11 9 Finished Installation J SA SM230SP A1 Page 11 25 Section 11 Jabiru 230 5 250 SP Aircraft Service Manual Electrical System and Instruments 80 61 80 3 0 XXXN d ANVNIIATT3Sd T3NVd OML 578 MOISN31X3 578 5718 5 dieta Sw 5153 513 x00 0 OHE io ooo E E 1 1 8 gu 8 E SH N FN dr AYN AYN 1d323M 4 1 SON Ao FE 5 m m ie DI i 17 INOOM o 3 OF 15 36 dS sna typ lagram ID Panel 1 Electrica Figure 11 10 J SA 5 2305 1 Page 11 26 Section 11 Electrical System and Instruments Jabiru 230 5 250 SP Aircraft Service Manual pe HG HEY dew 1304 TQ XXXN 1291014 13NVd 9nLL
161. gure 12 1 Use a step drill or file to enlarge the hole big enough to inspect and repair the damage 4 Thoroughly inspect the damage and determine amount of epoxy and flock needed to repair the joint Mix up a batch of 24 hour epoxy and cotton flock to the con sistency of mayonnaise 5 Using a popsicle stick or other application tool thoroughly coat the cracked surfac es Cover as much of the cracked surface as possible and be generous with the epoxy mixture Fillet the flock into the inside of the door frame and skin to add rein forcement to the broken areas Clean up all epoxy that drips on the outside surfac es of the door with acetone 6 When satisfied with an internal hinge repair shut the door latch it and let it sit untouched overnight inside a heated hangar or with an external heat source that will heat the repaired area to at least 609F With the door shut proper hinge align ment will be assured J SA SM230SP A1 Page 12 5 Section 12 Jabiru J 230 5 250 5 Fiberglass Repair Aircraft Service Manual Lay 10 oz cloth over the door lock area ideally covering at least 2 from the ed cracks ES straint strap stress cra drill into door frame sary for access pe with epoxy flock Figure 12 1 Hinge repair Figure 12 2 Door lock slot repair 7 If door frame pieces were removed during inspection and internal repair carefully glue them back into place with 5
162. h 6 7 3 1 for reinstallation of the rudder Be sure rud der cable is attached to TOP of rudder horn otherwise rudder will be out of rig 2 Reverse the steps of Paragraph 6 7 3 2 for reinstallation of the rudder pedal assem bly 6 7 7 Rigging the Rudder Page 6 22 1 To establish the neutral position raise the nose wheel off the ground by having a helper press down on the rear fuselage near the joint of the verti cal and horizontal stabilizers Allow the nose wheel and therefore the rudder pedals to neutralize Align the rudder 5mm to the right of center Adjust the rod ends on the cable so that the hole in the rear rod end aligns with the hole in the control horn Fit bolt nut and washers Mark or tape a line from the center of the rudder trailing edge onto the fu selage Displace the right rudder pedal to the rudder pedal stop Measure the rudder displacement at the rudder trailing edge with reference to the previously marked line It should be 98mm 2mm Repeat Step 6 for left pedal and adjust rudder pedal stops as required Test fly the aircraft noting any slip or skid tendencies in level flight as de scribed in 6 7 2 Adjust length of the rudder control cable in 1 2 turn incre ments to achieve coordinated wings level flight WARNI NG The rudder pedal stops must engage BEFORE the control surface stops on the tail WARNI NG DO NOT move the cable anchor points or adjust control surface stops These are f
163. h slower rate than AVGAS Fresh MOGAS of the correct octane rating produces the same engine performance as AVGAS MOGAS Bad Points The single biggest drawback with MOGAS is Quality Control quality control for MOGAS is very much poorer than for AVGAS Fuel sold from automotive service stations may often be stale contaminated or diluted The busiest service station in town is most likely to have fresh clean fuel and getting to know the station operators is also a good idea Many automotive MOGAS blends rely on highly volatile components to produce the proper power etc During storage these volatiles be lost rapidly and the fuel s performance can degrade significantly in a relatively short period of time Always using fresh fuel is strongly recommended This needs to be stressed to operators as it is entirely possible for MOGAS loose several points from it s Octane rating while stored leaving the engine vulnerable to detonation In addition long term storage of MOGAS in an open vented fuel system like a Jabiru s can encourage the formation of gums and other varnishes or solids which can then block the lines or filters Automotive fuels are generally more prone to vapour lock than AVGAS Testing has shown that Jabiru Aircraft meet certification requirements for the prevention of vapour lock when using MOGAS however issues can be provoked by poor operational procedures The following are recommended when operating on MOGAS i Avoid run
164. he bolts Snug lightly into posi tion 6 Use torque wrench to tighten bolts to between 15 and 17 ft lbs of torque moving in a criss cross pattern around the hub see Figure 9 1 for torque pattern 7 Check propeller tracking as described in Section 9 5 8 Reinstall spinner as described in Section 9 1 9 8 3 Ground Adjustable Carbon Propeller Bolt Tension Check Required Tools Calibrated torque wrench with 1 2 socket screw driver set propeller protractor Level of Certification Required A amp P LSA R M Ensure ignition switch is in the OFF position and set parking brake 2 Remove spinner using procedure in Section 9 1 3 Set torque wrench to 20 ft lbs and check tension on the six propeller blade clamp bolts Do not loosen bolts just apply tightening pressure to the bolts in a criss cross pattern similar to that shown in Figure 9 1 4 f any movement in bolts is noted recheck propeller blade pitch angles as described in Section 9 3 NOTE Owners are NOT AUTHORI ZED to change propeller blade pitch If blade angles are outside of limits or do not match an A amp P or LSA RM M must recalibrate the propeller to proper pitch Page 9 10 J SA 5 2305 1 Jabiru 230 5 250 5 Section 10 Aircraft Service Manual Utility Systems Section 10 Utility Systems 10 1 Cabin Heat 10 1 1 Description Cabin heat 15 provided by air from a cowl intake that is warmed over the muffler and delivered to a firewa
165. he filter ar ea and quick drain Run engine for at least 30 seconds to check oil pressure and other engine vitals Page 7 13 Section 7 Engine Systems Jabiru 230 5 250 5 Aircraft Service Manual 8 Shut engine down and check for oil leaks Investigate source of any leaks and cor rect 9 Reinstall engine cowls as described in Section 7 3 7 8 Cooling System 7 8 1 7 8 2 7 8 3 7 8 4 7 8 5 Page 7 14 Description An oil cooling radiator is mounted at the bottom front of the oil sump Hoses route the oil from the oil cooler adapter under the filter to the cooler and back See Figure 7 5 Removal 1 Disconnect braided hoses from oil cooler and oil cooler adapter 2 Remove cooler from engine by removing attachment bolts See Figure 7 5 Inspection Tools Required 3 8 7 16 11 16 wrenches Phillips 2 screw driver Parts Required Permatex No 2 gasket sealant for reinstallation Level of Certification Required A amp P or LSA R M M 1 Inspect hoses for kinks leaks cracks or loose fittings 2 Inspect radiator for leaks bent fins impacted debris damaged fittings or damaged attachment brackets Repair 1 Repair of hoses is limited to replacement of the stainless braided hose The AN fittings are removable and can be reused if not damaged 2 Repair of radiator should be referred to a qualified radiator repair facility for inspec tion testing and repair Repair is usually limited
166. he line with its flat side against the fuse lage skin and its forward edge about 1 1 4 inches aft of the lower edge of the fire wall The exact placement is not critical but the receptacle should sit as flat as pos sible on the surface of the fuselage and be far enough forward that the bolts are accessible from behind the rudder pedal assembly See Figure 11 6 5 Carefully drill through one of the bolt holes in the receptacle into the bottom skin of the fuse lage be prepared to stop the drill as soon as it breaks through so that it does not tear up the inte X rior carpet Place one bolt through the hole square the receptacle into final position and drill the second hole Figure 11 8 Booster Receptacle Position J SA 5 2305 1 Jabiru 230 5 250 5 Section 11 Aircraft Service Manual Electrical System and Instruments 6 Attach the nuts to the bolts inside the cabin under the rudder pedal assembly 7 Plug the lower portion of each cable into the receptacle Black goes to the negative terminal and red goes to the positive terminal 8 Ensure Master switch is OFF Using the 10mm wrench disconnect the aircraft ground cable black from the battery followed by the power cable red Install the red jumper cable end to the positive terminal of the battery followed by the power cable and nut Last install the black jumper cable end to the negative termi nal of the battery followed by the aircraft
167. hile AVGAS 100 contains less than 0 85g L AVGAS 100LL is dyed blue while AVGAS 100 is dyed green Generally AVGAS blends store well and do not tend to degrade to a lower octane value over time Tetraethyl Lead Good Points Tetraethyl Lead is an additive which is included in fuels to help suppress knock or detonation Generally detonation is the name given to a process where the fuel air mix in the cylinder ignites too early It produces very high pressures inside the engine which can easily cause severe damage Aircraft engines are particularly vulnerable knock because they operate at higher power settings and temperatures than most other types of engine Tetraethyl Lead also has some lubrication properties which helps to reduce wear to valve guides etc The combination of benefits given by tetraethyl lead have proven to be hard to produce any other way which has made it difficult to develop a replacement fuel which will operate correctly in aircraft engines particularly older types or high powered turbo types Tetraethyl Lead Bad Points By products produced when a fuel containing tetraethyl lead is burnt are well known pollutants Because of this automotive fuels etc are now unleaded types AVGAS is the only fuel containing lead still available in most parts of the world High tetraethyl lead levels in a fuel can produce combustion chamber deposits These deposits can affect piston ring sealing and valve sealing and also
168. hose longer than 25 mm should NOT be repaired the windshield must be replaced General Upkeep 3 2 2 1 Waxing Waxing will fill in minor scratches in clear plastic and help protect the surface from further abrasion Use a good grade of commercial wax NOT SILICON BASED applied in a thin even coat Bring wax to a high polish by rubbing lightly with a clean dry flannel cloth See Section 2 for more information on cleaning and maintaining windows V CAUTION Silicon based waxes and polishes are not rec ommended as silicon may be absorbed into the glass fiber laminate around the windows and affect reparability due to impairing bonding 3 2 2 2 Scratches JSA 5 2305 1 Scratches on clear plastic surfaces can be removed by buffing and polishing using plastic polish available from most aircraft supply companies NOTE Rubbing plastic surface with a dry cloth will build up an electrostatic charge which will attract dirt particles and may eventually cause scratching of the surface After applying polish dissipate this charge by rubbing surface with a slightly damp chamois This will also remove dust particles which have collected while wax Is hardening Page 3 1 Section 3 Jabiru 230 5 250 5 Fuselage Structure Aircraft Service Manual 3 2 3 3 2 4 3 2 5 Page 3 2 Window Crack Repair Tools Required 1 16 drill Level of Certification Required A amp P or LSA R M M Damaged window panels and windshield
169. ice Manual Engine Systems Section 7 Engine Systems 7 1 Engine 7 1 1 7 1 2 7 1 3 7 1 4 7 1 5 Description Both the 230 5 and J 250 5 are powered by the Jabiru 3300A engine equipped with hydraulic lifters It is a 6 cylinder 4 stroke direct drive air cooled engine driving a fixed pitch wood or ground adjustable carbon propeller When viewing the engine tractor configuration from the pilot s seat cylinders 1 3 and 5 are on the right side of the case and cylinders 2 4 and 6 are on the left Cylinders 1 and 2 are the closest to the propeller flange 3 and 4 are in the middle and 5 and 6 are at the accessory end The firing order 15 1 4 5 2 3 6 For repair amp overhaul of the engine refer to nstruction amp Maintenance Manual for J abi ru 3300 Aircraft Engine Engine Data Refer to nstruction amp Maintenance Manual for J abiru 3300 Aircraft Engine Engine Troubleshooting Refer to nstruction amp Maintenance Manual for J abiru 3300 Aircraft Engine Engine Cleaning See Section 2 of this manual for cleaning instructions Engine Removal Tools Required Phillips screwdriver straight screwdriver 3 16 Allen key 3 8 7 16 9 16 amp 10mm wrenches 3 8 amp 9 16 regular socket 7 16 deep well 1 4 drive socket with ratchet wire cutter pliers engine hoist with lifting strap Level of Maintenance of Maintenance Level of Maintenance 00000000000 Level of Certification Required
170. if the additional time is required to reach a place where the inspection can be satisfactorily accomplished However any extension of the 100 hour interval must be subtracted from the following 100 hour interval with no time extension permitted For example if an inspection is done at 110 hours the next inspection is due 90 hours later with no extension allowed addition to the inspections prescribed by this schedule the altimeter static system and ATC transponder MUST be tested and inspected at 24 month intervals in compliance with the requirements specified in FAR Part 91 Placards Ensure that all placards are in place and legible whenever the airplane has been repainted or touched up after repairs Replace any placards that have been inadvertently defaced or removed Airworthiness Responsibility Jabiru USA Sport Aircraft s recommended inspection program in accordance to FAR Parts 43 and 91 consists of but is not limited to inspection items listed in this Inspection Guide any applicable Service Bulletins or Air Safety Alerts issued against the airframe or any equipment installed therein The owner or operator is primarily responsible for maintaining the aircraft in an airworthy condition including compliance with all applicable Service Bulletins and Air Safety Alerts issued by the manufacturer It is further the responsibility of the owner or operator to ensure that the airplane is inspected in conformity with the requirements of Parts
171. ing after performance of any preventive maintenance tasks not listed under FAR Part 43 A Maintenance Preventive Maintenance Rebuilding and Alteration Section C J SA SM230SP A1 Quick Ref Guide Appendix Page 1 of 2 Jabiru J230 SP J250 SP Appendix Aircraft Service Manual THIS PAGE INTENTIONALLY BLANK J SA SM230SP A1 Quick Ref Guide Page 2 of 2 OPER Control No Ss 8 Comments Describe the malfunction or defect and the circumstances under which it Jabi ru USA Sport Aircraft LLC OPER Control No occurred State probable cause and recommendations to prevent recurrence MALFUNCTION OR DEFECT REPORT N MANUFACTURER MODEL SERIES SERIAL NUMBER 2 3 4 5 SPECIFIC PART of component CAUSING TROUBLE MFG Model or Part No Part Defect Location 6 APPLIANCE COMPONENT Assembly that Includes part Name Model or Part No Serial Number Check a box below if this report is related to an aircraft JSA 501 Use this space for continuation of Block 8 if required Return this form with any additional information to Jabiru USA Sport Aircraft LLC 2842 Highway 231 North Shelbyville TN 37160 931 680 2800 Accident Date Incident Date OPERATOR DESIGNATIO SUBMITTED BY TELEPHONE NUMBER REP STA OPER MECH B FAA OTHER DISTRICT OFFICE JABIRU AIRCRAFT 5792 61 7 4155 1778 Bundaberg
172. ing care to keep all glue and debris out of the aluminum funnel The divider plate should pro trude out of the leading edge approximately 1 2 and a 30 angle down from the chord line of the wing 2 After the epoxy cures touch up the edges of the screen as necessary with body filler and paint Keep the screen clear of dust and paint 10 3 6 Calibration of Stall Horn The default angle of the plate is 30 down from the wing chord line Bending the divider plate upward will make the stall horn sound at a faster airspeed lower angle of attack Bending it downward will make it sound at a slower airspeed higher angle of attack 1 Fly the aircraft to a safe altitude and enter slow flight Note the speed at which the stall horn sounds 2 Bend the plate up or down as necessary to adjust the warning speed angle of at tack Page 10 4 J SA SM230SP A0 Section 10 Utility Systems Jabiru 230 5 250 SP Aircraft Service Manual ON 38VUNPIH 1 0 83 DINIH 216 982 010 LyV JO 1 HS 1 5 201 602 ONIM Al 541445 ASSY ONINSVM TIVIS ON ora 14345 TIYIS 15 01 M3IVI Q3AWIMI 38 39Nv13 Q3NIn038 3l uum OL 39NV1J SNIM 40 3NITJHIN39 01 0 SNINHVM TIVIS 404 0 29 3119130 SV 1008 SLZL 3HIN3O 5 4 OL ASN NIAS NYHL 6L
173. inside the windscreen as the tape may become Page 3 3 Section 3 Jabiru 230 5 250 5 Fuselage Structure Aircraft Service Manual Figure 3 1 Window clamps made from 0 125 aluminum stock and sheet metal screws left Clamp in position holding upper portion of windshield to fuselage right Figure 3 2 Window clamps in position nstall following the pattern shown working from the center outward and checking alignment frequently Page 3 4 J SA 5 2305 1 Jabiru J 230 SP 250 SP Section 3 Aircraft Service Manual Fuselage Structure permanently bonded and visible from outside the aircraft when the installation is finished 11 Carefully drill holes for M4x12 countersunk mounting screws with dull drill or Permagrit 1 8 bit Holes should be 3 4 apart centered on the joggle Countersink holes so screw heads are slightly below surface 12 DO NOT over tighten screws cracking will result Tighten until snug only 13 See Section 12 4 for paint bodywork procedures to finish the repair Side Windows 1 Install side windows in the same manner as the windshield except that no screws will be driven through the plastic The simple clamps are screwed to the door frame alongside the window plastic to hold it in place while the epoxy cures 2 After epoxy cures see Section 12 4 for paint bodywork procedures to finish the repair Inspection of Finished Window Windscreen nstallation 1 All clamps removed 2
174. ion and for proper attachment Comments 100 Hour Annual Inspection Checklist Page 8 of 17 Jabiru J 230 5 250 5 and J 170 SP Aircraft Service Manual Electrical Wiring and Equipment nspect electrical wiring and associated equipment and accessories for fraying and attachment Comments Battery nspect clean and tighten connections Check for security and proper attachment Check for corrosion Make certain battery is clean Water or dirt on battery surfaces can cause battery to discharge Comments Fuel Pump Inspect fittings and pump for leaks Engine Controls and Linkages Check controls and associated equipment for condition attachment alignment and rigging Check control operation Comments Engine Mounts Check for cracks corrosion and security Inspect rubber cushions mount bolts and nuts and grounding straps for condition and security Comments Starter and Solenoid Check for condition attachment and chafed or loose wires Alternator and Electrical Connections Check for condition and attachment Check wiring for proper attachment and possible chafing Check for unsusual noise Comments Carburetor Heat System Check for blockage security operation and wear JSA 100HR A1 100 Hour Annual Inspection Checklist Page 9 of 17 Jabiru J 230 5 250 5 and J 170 SP Aircraft Service Manual Carburetor Check overall condition Inspect for leaks Remove b
175. ion is provided through aluminum vents bolted to NACA inlets in the cabin side walls 10 2 2 Removal Tools Required Screwdriver set 11 32 wrench Level of Certification Required A amp P or LSA R M M 1 Remove the vents by unbolting them from the cabin side wall 10 2 3 Inspection and Repair 1 Check the vents for smooth operation and proper closure 2 Repair is limited to replacement 10 2 4 Reinstallation Reverse steps in 10 2 2 for reinstallation 10 3 Stall Warning System 10 3 1 Description The stall warning system 5 of the suction reed type It consists of a screened opening in the leading edge of the left wing an airflow divider plate an air line that runs to the cabin and a reed with an amplifier bell mounted inside the cockpit The airflow divider plate is calibrated to match the critical angle of attack of the wing When the wing ap proaches the critical angle of attack the divider plate disturbs the airflow in front of the screen creating a low pressure area that sucks air from inside the cabin through the reed and out the screen The reed is mounted inside the left doorpost so that it 15 easi ly audible from the left seat 10 3 2 Removal Page 10 2 The reed bell assembly is easily accessible by removing the pilot s side door post cover The bell is held to the air line with small safety wire 032 The screen and divider plate are epoxied into the leading edge of the wing before the wing
176. ion of the seat structures Upholstery is available in automotive cloth vinyl or leather Cabin lining is standard together with door pockets 3 6 Baggage Area The baggage area 15 the floor directly behind the front seats All baggage must 5 cured before flight Tiedown rings are installed in the floor of the baggage area and may be used with cargo nets or straps as appropriate The rear baggage bulkhead is velcroed to the fuselage frame and may be pulled forward and removed for access to controls and electronics in the rear fuselage 3 7 Seat Belts 3 7 1 3 7 2 3 7 3 3 7 4 3 7 5 Description One aircraft grade seatbelt and shoulder harness is provided for each occupant and is bolted to the fuselage structure Belts are rated to 9G and have metal to metal buck les Removal Tools Required 3 8 wrenches Level of Certification Required A amp P or LSA R M Belts are attached in three places and can be removed by removing the AN3 attach bolts at the belt anchor locations Inspection Belts should be replaced if frayed or cut latches are defective or stitching 15 broken Repair Repair 15 limited to replacement Belts should be replaced if frayed or cut latches are defective or stitching is broken Attachment parts should be replaced with equivalent grade parts if excessively worn or defective Reinstallation Reinstall belts as described in 3 7 2 using all new AN hardware 3 8 Horizontal Stabilizer
177. ired Replacement air filter See Section 1 9 Level of Certification Required Owner A amp P or LSA R M M 1 Disconnect SCAT hose from airbox outlet 2 Remove screws 4 from corners of filter box 3 Remove filter 7 11 3 Inspection and Repair 1 Inspect for breaks in the filter medium by shining a light through Repair 15 limited to replacement 2 Inspect for dirt clean by blowing air back through the filter Replace if dirt does not blow away 7 11 4 Reinstallation 1 Place new filter into airbox base 2 Position cover in place over the filter 3 Install screws 4 4 Reconnect SCAT hose to airbox cover and tighten clamp 7 12 Flexible Hoses 7 12 1 Description Fuel lines and SCAT hoses run throughout the engine compartment and should be checked periodically Replacement of all engine compartment flexible hoses is recom mended every 24 calendar months Page 7 20 J SA SM230SP A2 Jabiru 230 5 250 5 Section 7 Aircraft Service Manual Engine Systems 7 12 2 Removal Parts Required Replacement hoses if necessary Level of Certification Required Owner A amp P or LSA R M M V WARNING DO NOT substitute SCEET hose for SCAT hose as the inner lining may pull away from the hose structure and block carburetor or air inlets 1 Shut off fuel valves before removing any fuel lines 2 Loosen clamps and pull to remove lines and hoses from fittings 7 12 3 Inspection 1 After each 50 hours of operation flexible ho
178. ires to 35 40 psi one side on lev el ground with Landing gear attaching hard Check and tighten Section 5 5 5 replace hard equal amounts Ware not tight ware if damaged or beyond 500 hours of life J SA of fuel in each Service Bulletin SA 003 1 Undercarriage Bolt tank Replacement Stretched or cracked fiberglass Inspect gear leg for cracks replace a cracked or gear leg hard landing delaminated leg before next flight Bent axle stub Replace axle stub Section 5 6 Main tires wear Incorrect tire inflation Inflate or deflate main tires to 35 40 psi excessively It is normal for Main wheels out of alignment Install axle shims to realign wheels see Section 5 tires to wear on 6 outboard side regular rotation Bent axle stub Replace axle stub Section 5 6 is recommend ed Dragging or skidding tires with Avoid locking brakes on taxi and landing use less brakes on engine rpm during run up Nose wheel Improper takeoff technique See 230 Flight Training Supplement for normal shimmy after holding nose wheel on runway takeoff technique description rotation liftoff too long Loose nose strut bolts or steer Inspect nose strut assembly for loose worn or ing link defective parts Section 5 10 Wheel out of balance Balance nose wheel tire assembly 5 9 5 Worn wheel bearings Replace nose wheel bearings 5 9 3 Main gear legs Uneven runway surface Some brake shimmy is normal during heavy brak shimmy when ing on rough
179. is attached from carb throttle arm to a cross rod supported in acetal blocks attached to the cabin side of the firewall Control input is fed to the cross rod from a knob and push pull rod through the panel face 7 13 2 Removal Tools Required Screwdriver set 7 16 3 8 wrenches Level of Certification Required A amp P or LSA R M M For aircraft built in 2008 or older 4 Disconnect throttle cable from carb and from throttle cross rod Remove the bolts through the firewall that hold the acetal blocks Disconnect push pull rods from cross rod by loosening jam nut and unscrewing push pull rods Remove cross rod For aircraft built in 2009 or newer substitute steps 1 and 2 above with 1 2 Remove the nut and washer from the actuator arm Slide the control wire off of the bolt 7 13 3 Inspection Inspect all parts for damage or wear When adjusting any engine control it is im portant to check that the control slides smoothly throughout its full range of travel amp that the lever or knob moves through its full range of travel 7 13 4 Repair Repair is limited to replacement Page 7 22 J SA SM230SP A2 Jabiru 230 250 SP Section 7 Aircraft Service Manual Engine Systems 7 13 5 Reinstallation Reverse steps in 7 13 2 7 13 6 Adjustment 1 Adjust cable end connection at firewall and at carb so that the throttle arm at the carb rests against the full throttle stop when throttle is open and against firewal
180. is manual for more information regarding wheel and bearing installation 1 Lightly coat axle with Anti Seize or a waterproof grease 2 Install the inboard tapered bearing to the axle Page 5 10 J SA 5 2305 1 Jabiru J 230 SP 250 SP Section 5 Aircraft Service Manual Landing Gear and Brakes 3 Place wheel assembly on axle 4 Install outboard tapered bearing to the axle 5 Install washer and axle nut Tighten until the outer part of the bearing does not spin but everything else does Some drag force is normal for the roller bearings to work properly 6 Install cotter pin to axle nut 7 Place outboard brake pad plate and spacer in position and secure with bolts Re place safety wire Vote Newer 230 SP models use lock washers in lieu of safety wire on the brake pad plates 8 Install wheel pant if used as outlined in Paragraph 5 3 JSA 5 2305 1 Page 5 11 Section 5 Jabiru 230 5 250 5 Landing Gear and Brakes Aircraft Service Manual sa 4 A 2 2 dimple up amp Nut gt Stem into Valve Hole in Valve Half amp Align I Figure 5 2 Assembly of Matco Wheel Halves Page 5 12 J SA SM230SP A1 Section 5 Landing Gear and Brakes Jans 1N332 Fi SHOT OSL TM 1 T3 31 HLOONS 61 331108 61 HIM OF SNOT 002 H38MIL 9355350 97 40 3owduns SIH ONIONYS isiro T
181. is painted To remove them file away the paint and body filler from around the J SA SM230SP A0 Jabiru 230 5 250 SP Section 10 Aircraft Service Manual Utility Systems Opening until the edges of the screen are visible Pry the screen and divider plate away from the opening The aluminum funnel may then be removed allowing access to the air line inside the wing 10 3 3 Inspection To check function of the stall warning system on the ground remove any foreign mate rial from the screen bugs dirt etc and then place a suction source mouth or vacu um over the opening Have a helper listen inside the cabin for the stall warning tone If no tone 5 observed remove the reed bell housing from the air line and check to make sure the line is not blocked or kinked If air flows freely through the line then the reed Should be replaced If the stall warning operates on the ground but fails to operate in the air the airflow divider plate needs to be calibrated See Paragraph 10 3 6 for calibration instructions 10 3 4 Repair Repair of the stall horn is limited to cleaning of the screen calibrating the divider plate as detailed above or replacement of the affected part s 10 3 5 Reinstallation To reinstall or replace the reed bell housing 1 Attach the reed bell housing firmly to the air line using safety wire and superglue The reed bell housing 15 simply tucked under the support for the door post cover Reinstall the door pos
182. is service manual installation and maintenance publications are available from component manufacturers which describe disassembly overhaul and parts breakdown of some of the various vendor equipment items A listing of vendors their contact information and available user documentation is published in the Appendix of this manual Owner Operator Responsibility Page 10 To maintain compliance with ASTM Standard F2295 the owner or operator of this aircraft must follow six rules that are listed below and specified in Section 5 4 of F2295 Failure to comply with these responsibilities could result in an aircraft that may be out of compliance with the ASTM standards and could lead to revocation of the aircraft airworthiness certificate It is the owner s responsibility to become fully aware of the particular maintenance requirements limitations applicable to the LSA airworthiness certification 1 Each owner operator of this aircraft shall read and comply with the maintenance and con tinued airworthiness information and instructions provided by the manufacturer 2 Each owner operator of this aircraft shall be responsible for providing the manufacturer with current contact information where the manufacturer may send the owner operator supple mental notification bulletins 3 The owner operator of this aircraft shall be responsible for notifying the manufacturer of any safety of flight issue or significant service difficulty upon discover
183. l ow OPTIONAL FRONT RET MOUNT 387 Figure 7 8 Exhaust System Page 7 28 5 SM230SP A2 Section 7 Engine Systems Jabiru 230 5 250 5 Aircraft Service Manual Laoviglvr ON BAN 59 QL1 Ald JO LN35NOO IHL LNOHLIM 031909 SLIN 50 0 FARS LON LENN LHOMAdOS SI SNIMVHU SIH L 3814 L31 00 4 aarSd OL 5 515 70 LLVIN 54 SNISN INOA 38 OL Z SNOISNSWIG SINIJA Sir S LLON 4L E MEHJDWISUINI ATMWY4OO0P 3did JUNO 2 EA 51371110 O M ASSY M3 434A GOVSZIVP b NOLdBOS3G M3EWON u a ae 4 HddV SONIMWHO LHYd O1 H3 J3H 279 TV 507 RT WIL oe JU NO 90 SIOHM S3ONYH3101 LON SAAMIIN NI ae LITNI 007 002 ASSY NATASNW 1 3uu 22699 000 sa 9 7 29 Figure 7 9 Muffler Detail SM230SP A2 Section 7 Engine Systems Jabiru J230 SP J250 SP Aircraft Service Manual 7 19 Head Bolt Tension Check Head Torque Procedure 7 19 1 Description All Jabiru engines require periodic check of head bolt tension to maintain a proper
184. l 2 Adjust tension on the bolts holding the acetal blocks to the firewall to provide prop er throttle friction to hold throttle setting at idle 7 14 Choke 7 14 1 Description The choke control is located in the center of the main instrument panel amp is connected to the carburetor by a solid wire control cable 7 14 2 Removal Tools Required Screwdriver set 3 8 and 5 8 wrenches Level of Certification Required A amp P or LSA R M M For aircraft built in 2008 or older 1 Disconnect choke from carburetor by removing the cotter pin from the cable ferrule and pulling ferrule from choke arm 2 Remove jam nuts from cable end adjuster at the carb bracket 3 Remove jam nut from back side of instrument panel 4 Pull cable from the aircraft For aircraft built in 2009 or newer substitute steps 1 and 2 above with 1 Remove the nut and washer from the actuator arm 2 Slide the control wire off of the bolt 7 14 3 Inspection 1 Check for kinks or breaks in the cable sheath 2 Check for smooth operation 7 14 4 Repair Repair is limited to replacement SM230SP A2 Page 7 23 Section 7 Jabiru J 230 5 250 SP Engine Systems Aircraft Service Manual 7 14 5 Reinstallation Reverse steps in section 7 14 2 7 15 Carburetor Heat 7 15 1 Description The carburetor heat unit consists of an stainless steel heat muff riveted to the cabin heat muff Carburetor heat is activated by a push pull knob on the instrument panel
185. l be made available to interested parties 1 13 Reporting Safety of Flight or Service Difficulties Page 1 10 Report any maintenance difficulty or safety of flight concerns to J abiru USA Sport Air craft LLC on form JSA501 Ma function or Defect Report found in the Appendix of this manual The form may be downloaded online at www usjabiru com in the LSA Owners Info section J SA 5 2305 1 Jabiru J 230 SP 250 SP Section 1 Aircraft Service Manual General Description 1 14 Extreme Climatic Conditions A Dust inducted into the carburetor air intake system 15 probably the greatest single cause of early engine wear When operating under high dust conditions the carbu retor air filters should be serviced daily as outlined in Section 7 11 B saltwater areas special care should be taken to keep the engine and accessories clean to prevent oxidization C In humid areas fuel should be checked frequently and drained of condensed mois ture D The maximum ambient outside air temperature for aircraft operation is 104 F 1 14 1 Cold Weather Engine Operation Before starting engine in temperatures below 32 F preheating is recommended A warm air source should be directed through the rear opening in the lower cowling to warm the carburetor intake manifold and engine oil sump Once the intake area is sufficiently warm start engine using the Cold Engine Start pro cedure found in the Pilot s Operating Handbook LET ENGINE WA
186. landing gear as a complete assembly Refer to applicable paragraphs for installation of the individual components With aircraft jacked 6 Position the main gear leg under the fuselage and install clamp rubber cushion and bolts nuts 2 OFF Do not tighten at this stage Locate inboard bolt install and tighten nut See Table 1 4 Torque Values Tighten the two clamp bolts nuts See Table 1 4 Torque Values Connect flexible brake line Fill brake master cylinder with fresh brake fluid and bleed brakes see Paragraph 5 8 7 Lower aircraft to the ground 5 6 Main Wheel Stub Axle 5 6 1 Description The main stub axle Matco part number WHLA3A is a machined aluminum axle 1 25 inches in diameter It is designed to accept the Matco wheel amp brake system and fea tures machined bearing stops to ensure brake caliper alignment 5 6 2 Removal Tools Required Screwdriver set 7 16 1 2 and 9 16 wrench es Level of Certification Required A amp P or LSA R M M J SA SM230SP A1 Page 5 6 Jabiru 230 5 250 5 Section 5 Aircraft Service Manual Landing Gear and Brakes 5 6 3 5 6 4 5 6 5 5 6 6 1 Remove speed fairing if installed in accordance with Paragraph 5 3 2 2 Remove wheel in accordance with Paragraph 5 7 2 3 Note number and position of the wheel alignment shims if any between the axle flange and composite leg If shims are not epoxied in place mark them or tape them together carefull
187. lded to a bracket that is pop riveted to the wing strut The pitot line runs through the lower half of the strut into the belly of the fuselage in front of the main gear legs up through the center console and into the instrument panel The line is concealed by the lower wing strut fairing 11 8 2 Removal and Repair Tools Required 3 16 drill wire cutter safety wire pliers Parts required Superglue 032 safety wire Level of Certification Required A amp P or LSA R M M The static probe is bonded permanently to the vertical stabilizer Contact J abiru USA Sport Aircraft LLC for instructions on removal or repair of the static probe and line within the vertical stabilizer structure Repair of pitot static lines and probes is limited to replacement If replacing pitot or static lines attach string to one end of the old line prior to removal to aid in re threading the new lines The forward portion of the pitot tube may be re moved from the strut by pulling it from hose that connects it to the aft portion To re move the aft portion 1 Drill out the 3 16 pop rivets that hold the bracket in place 2 Remove the bracket 3 If preserving the pitot line tape it to the outside of the strut so it will not fall back inside Clip the safety wire that holds the pitot line to the probe 11 8 3 Reinstallation Reverse the steps in Paragraph 11 7 2 for reinstallation of pitot static lines Superglue and safety wire must be used on all conne
188. le Recheck the blade angle often When the bolts are tight enough that the blades no longer wiggle and both blade angles are correct torque the front half hub bolts to 20 ft los Recheck blade angle to make sure there was no change Install spinner on spinner flange and attach with machine screws through fiber washers Check propeller tracking as outlined in Paragraph 9 5 of this section Suggested Pitch Minimum Pitch Maximum Pitch NOTE Any change made to propeller pitch will likely require carburetor jetting adjustment Table 9 1 Ground Adjustable propeller blade pitch settings in degrees Page 9 5 Section 9 Propeller amp Spinner Jabiru J 230 5 250 SP Aircraft Service Manual 9 4 Balancing Procedure After any repair work is done to a wood or carbon propeller it must be rebalanced Re fer to Sensenich Wood Propeller Company for approved balancing procedures 9 5 Propeller Tracking Procedure Required Tools Ruler with mm increments Level of Certification Required Owner A amp P LSA R M After removing and reinstalling any propeller the blade tracking must be measured be fore the aircraft is returned to service V WARNING Before handling any propeller ensure the ignition and master switches are in the OFF position 1 Check tracking of propeller by placing a fixed object on the floor in front of the air craft so that it just clears the propeller tips when rotating the propeller by hand Ensure
189. level is full 4 Inflate tires to recommended operating pressures 5 Raise flaps to the fully retracted position 6 Place all control surfaces in neutral position Scale Reading Net B Total As Weighed Table 2 1 Aircraft Empty Weight and Moment Determination JSA SM230SP A1 Page 2 5 Section 2 Jabiru J 230 5 250 SP General Care amp Inspection Aircraft Service Manual Dat um Wing Leading Edge Eh Ic 2 6 2 2 6 4 2 6 5 Page 2 6 Figure 2 4 Aircraft Moment Arm Measurements Weighing Aircraft 1 2 3 Place scales under each wheel Level aircraft as described in Section 2 5 With the airplane level and brakes released record the weight shown on each scale in the appropriate places on Table 2 1 Deduct the tare if any from each reading Determine Moment Arms Refer to Figure 2 4 To find empty moment of aircraft measure distance from datum wing leading edge to center of wheel axles while the aircraft is level 1 Measure from the center of each main wheel axle to plumb bob dropped from the wing leading edge to obtain Distance A Measurement must be parallel to aircraft centerline Measure from the plumb bob to the center of the nose wheel axle to obtain Dis tance B keeping measurement parallel to aircraft centerline Record the measurements in Table 2 1 To find the moments of the weighing points multiply net weight by the arm of each weighing point
190. ll fuel flow shutoff 8 3 4 Repair 1 Fuel line repair is limited to replacement 2 Fuel valve and check valve repair is limited to replacement 8 3 5 Reinstallation 1 Follow steps in 8 3 2 for reinstallation of fuel lines Make sure they are reconnected to the correct fittings 2 Reinstall the interior door post covers and the nut on each shut off valve 3 Reinstall the wing root fairings bottom fairing first 8 4 Fuel Pumps 8 4 1 Description The mechanical fuel pump is mounted to the passenger side of the engine See nstruc tion and Maintenance Manual for J abiru 3300 Aircraft for information about servicing the mechanical fuel pump The electric fuel pump is mounted in series with the mechanical pump It is bolted to the firewall inside the engine compartment 8 4 2 Removal Tools Required 3 8 wrench wire cutter screwdriver set Level of Certification Required A amp P or LSA R M M 1 If possible run engine Shut off by turning fuel valve in the center console to OFF position and waiting for engine to quit from fuel starvation J SA SM230SP A1 Page 8 3 Section 8 Fuel System 8 4 3 8 4 4 8 4 5 Jabiru 230 5 250 5 Aircraft Service Manual 2 Make sure master and ignition switches are OFF 3 Disconnect electrical wire 4 Unbolt pump from firewall 5 Remove safety wire and pull back firesleeve to access fuel pump fittings 6 Remove fuel lines from pump Inspection Check electrical conne
191. ll mounted mixer box Hot air 15 introduced to the cabin through use of a push pull knob on the instrument panel 10 1 2 Removal Level of Certification Required A amp P or LSA R M M Disconnect SCAT intake hose from muff and from cowl intake Disconnect SCAT duct from muff and firewall mixer box Loosen strap clamps from muffler to remove heat muff Firewall mixer box 15 riveted to firewall and can be removed only by drilling out the blind rivets 10 1 3 Inspection and Repair 1 2 J SA SM230SP A0 Check the SCAT for cracks or breaks Replace if damage found Check the aluminum muff for cracks or deformation Small cracks can be repaired by riveting a 025 aluminum patch over the crack Otherwise repair is limited to replacement Inspect the firewall mixer box for cracks or damage Replace mixer box if damage found Check push pull cable for smooth operation Replace cable if damage found or smooth operation cannot be achieved When heat muff is removed from muffler inspect muffler for cracks or signs of exhaust leaks WARNI NG Cracks in exhaust system underneath heat muff may lead to carbon monoxide poisoning See Section 7 18 for information on exhaust system inspection and re pair Page 10 1 Section 10 Utility Systems Jabiru 230 5 250 5 Aircraft Service Manual 10 1 4 Reinstallation Reverse steps in 10 1 2 for reinstallation 10 2 Cabin Ventilation 10 2 1 Description Cabin ventilat
192. lugs as necessary Tighten spark plugs to proper torque Check condition and attachment of all ignition leads at plug and distributor Battery nspect clean and tighten connections Check for security and proper attachment Check for corrosion Make certain battery is clean Water or dirt on battery surfaces can cause battery to discharge Comments JSA 50HR A1 25 50 Hour Inspection Checklist Page 5 of 9 Jabiru J 230 5 250 5 and J 170 SP Aircraft Service Manual Engine Controls and Linkages Check controls and associated equipment for condition attachment alignment and igging Check control operation Carburetor Check overall condition Inspect for leaks 2 Engine Sump Check for cracks leaks proper fluid level and security Oil Service Remove and replace oil filter Drain and replace engine oil Empty the oil overflow bottle Comments Oil Cooler Check oil cooler lines and fittings for condition security chafing and leaks Comments JSA 50HR A1 25 50 Hour Inspection Checklist Page 6 of 9 Jabiru J 230 5 250 5 and J 170 SP Aircraft Service Manual All Drains and Plugs Check for condition cleanliness and security Check for leaks and correct tension Cowling skin Check for deformation delamination and obvious damage or cracks Check for rub points on the interior surfaces Cowling structure Check for cracks and delamination Check hinge pin structure for loos
193. m Emergency Locator Transmitter Aircraft manufactured before 2009 AK 450 121 5 243 MHz ELT Ameri King Corporation 17881 Sampson Lane Huntington Beach CA 92648 Phone 714 842 8555 Fax 714 842 4235 Email ameriking9 aol com http www ameri king com Free manual in PDF format available for download in Manuals section of website Aircraft manufactured in 2009 and newer Kannad 406 AF Compact KANNAD 2 1 des 5 Chemins BP 23 56520 GUI DEL France Phone 433 2 97 02 49 49 Fax 33 2 97 65 00 20 http www kannad com index php Free manual available in PDF format for download http www kannad com upload contenu fichier 78fichier2 pdf J SA SM230SP A1 Vendor Information Page 3 of 4 Appendix Jabiru 230 5 250 5 Aircraft Service Manual Navigation Anti collision Lights Aircraft manufactured prior to June 2009 GS AI R A Division of GS Developments LLC 130 Cheval LN NE Rochester MN 55906 USA E mail support ogs air com WWW gs air com Aircraft manufactured J une 2009 and newer Page 4 of 4 AeroLEDs 967 East Park Center Boulevard Suite 381 Boise ID 83706 6700 Phone 208 850 3294 Fax 208 246 0552 http www aeroleds com home aspx Free manual available in PDF format for download http www aeroleds com resources installationmanuals aspx Vendor Information J SA SM230SP A1
194. may be removed and replaced if damage 15 substantial However certain minor repairs as prescribed in the following paragraphs can be made successfully without removing the damaged part from the aircraft The procedure for repairing cracks is only recommended for low stress areas No re pairs of any kind are recommended on highly stressed or compound curved areas or where repair would be likely to affect the pilot s field of vision NOTE Cracks up to 25 mm in length should be stop drilled those longer than 25 mm should NOT be repaired the windshield or window must be replaced If a crack appears drill a hole at the end of the crack to prevent further spreading Hole should be approximately 1 16 inch in diameter depending on length of crack and thickness of material An unfluted drill should be used Window Removal Tools Required Small grinder 7mm socket 2 Phillips screwdriver Level of Certification Required A amp P or LSA R M M As the windscreen and windows are bonded into the fuselage it is not possible to re move them without destroying them Use the grinder to score the window near the paint line Once the window has been broken out any screws used in the original instal lation screws in windscreen only should be removed and old epoxy removed by grind ing it out of the joggle After removing the nuts from the screws the screw may have to be heated with a soldering iron to soften any epoxy that might hold it in the wind
195. mended by aircraft manufacturer or Engine Aircraft Service Manual amp or LSA R M M Compartment Flexible Hoses aircraft manufacturer Every 24 Calendar Months 1 800 212 SAVE or Title 47 Parts 80 Aircraft equipped with 87 and 95 of U S and at change of ELT Registration Renewal www beaconregistration Owner Operator 406 MHz satellite ELT of Federal ownership noaa gov Regulations Aircraft Battery Replacement Aircraft Service Manual Owner Operator 406 MHz ELT Six Year Kannad ELT Every 72 Calendar Months Inspection and Battery Installation Operation Replacement Manual DOCO6006E FAR Part 145 Repair Aircraft equipped with Station 406 MHz satellite ELT 91 207 Owner Operators of S LSA aircraft that hold at least a Sport Pilot or Private Pilot Certificate may only perform maintenance items listed in FAR Part 43 Appendix A Maintenance Preventive Maintenance Rebuilding and Alteration Section C Owner operators performing preventive maintenance must return the aircraft to service by endorsing the aircraft or engine logbook as specified in FAR 43 9 All other maintenance tasks must be performed by an A amp P LSA Repairman with Maintenance Rating or FAA certified repair station Owner operators of E LSA aircraft that hold a minimum maintenance certification of LSA Repairman with Inspection Rating are authorized under FAR 43 1 b 2 to perform maintenance
196. ments as well as this inspection guide These documents may be downloaded from the manufactuer s website www usjabiru com JSA 50HR A1 25 50 Hour Inspection Checklist Page 2 of 9 Jabiru 230 5 250 5 and J 170 SP Aircraft Service Manual 1 Operational Inspection Starter Check for proper operation unusual noises and dragging Fuel Pressure Fuel Flow Check within normal limits if installed Cylinder Head Temperature Check for proper operation temperatures and fluctuations Alternator Check for proper output Propeller Check for smoothness of operation Oil Pressure and Temperature Check for proper pressure temperature limits and unusual fluctuations JSA 50HR A1 25 50 Hour Inspection Checklist Page 3 of 9 Jabiru J 230 5 250 5 and J 170 SP Aircraft Service Manual Magnetos Check the performance of the magneto as outlined under the heading NORMAL PROCEDURES in the appropriate Pilot s Operating Handbook Auxilliary Fuel Pump Check for proper operation unusual noise and fluctuations Comments All Lights Check function condition attachment cracked or broken lenses Check switches knobs and circuit breakers for looseness and operation Brakes Check for condition and wear ease of operation and proper release of parking brake Check for unusual brake chatter Comments Flight and Trim Controls Check freedom of movement and proper operation
197. mount of Loctite 242 Reinstall wing and fairings as described in Section 4 Page 8 7 Section 8 Jabiru J 230 5 250 SP Fuel System Aircraft Service Manual 8 8 Fuel Draining Procedure From time to time it may be necessary to drain fuel from the aircraft for disassembly or inspection and repair of fuel system components Fuel should be drained from the wing tanks before the wings are removed for any reason Tools Required Screwdriver set long piece of 1 4 ID fuel hose gasoline approved amp clean fuel contain ers with enough capacity to hold contents of tank to be drained plus header tank Level of Certification Required Owner A amp P or LSA R M M To drain fuel from the header tank 1 Close both left and right fuel valves Make sure main fuel valve is ON 2 Disconnect fuel line between the electric and the mechanical fuel pump 3 Connect a long fuel line from the output fitting on the electric pump to a container approved to hold gasoline 4 Turn on master switch Turn on electric fuel pump Run fuel pump until all fuel is pumped from the header tank NOTE The capacity of the header tank 15 approx 1 5 U S gallon Allow extra room for fuel in the lines To drain fuel from a wing tank 1 Make sure the fuel valve appropriate to the tank being drained left or right is switched ON and turn the other one OFF Make sure the main fuel valve is turned ON 2 Follow steps 2 through 4 above until fuel is drain
198. n deformation sealing and tension 2 10 2 Fluid Lines and Hoses Check for leaks cracks kinks chafing proper radius security corrosion deteriora tion obstruction and foreign matter 2 10 3 Metal Parts Check for security of attachment cracks metal distortion broken welds corrosion and any other apparent damage 2 10 4 Wiring Check for security chafing burning defective insulation loose or broken terminals heat deterioration and corroded terminals 2 10 5 Bolts in Critical Areas Correct torque in accordance with torque values given in the chart in Table 1 4 Torque Values when installed or when visual inspection indicates the need for a torque check NOTE Torque values listed in Table 1 4 are derived from oil free cadmium plated threads and are recommended for all installation procedures contained in this manual except where other values are stipulated They are not to be used for checking tight ness of installed parts during service 2 10 6 Filters Screens and Fluids Check for contamination and condition Replace at specified intervals or when condi tion warrants JSA 5 2305 1 Page 2 11 Section 2 Jabiru 230 5 250 5 General Care amp Inspection Aircraft Service Manual 2 10 7 Lubrication There are no special lubrication requirements for J abiru aircraft other than those listed below Reference Undercarriage and Controls sections for lubricating instructions a cp ar Wh
199. n data is being copied The light will blink slow er when the operation is complete When the EFIS has completed copying files from the USB drive the display unit will reboot After reboot verify the power up page displays the new EFIS software ver sion Repeat software and or nav database update for the if installed Add Map Features Roads Lakes State Lines etc 1 5i Load each of the map features database files onto your USB drive Install drive in back of EFIS unit as described above In the SET MENU Display Unit Maintenance scroll to Load Navigation Database and select the additional database files from the list You can load all the map fea tures files as a batch Push LOAD to start copying the database into the display unit The display will reboot when the database has finished copying After loading all the map features files go to the Moving Map page in the Set Menu Scroll down to the heading for the database that you want to display Select it and change to Show On All Maps The default setting will show them on the North UP screen only Repeat for other EFIS if desired J SA 5 2305 1 Jabiru 230 5 250 SP Section 11 Aircraft Service Manual Electrical System and Instruments 11 10 6 Magnetometer 11 10 6 1 Description The Grand Rapids Sport and Garmin G3X systems utilize an external magne tometer to sense information about aircraft heading This information enables the Attitude Heading
200. n the skin and the upholstery Repair Repair of fiberglass cracks or delamination in the doors can be done by following the general fiberglass repair procedures or door hinge and lock slot repair supplement Section 12 For repairs to windows see Section 3 2 Reinstallation Reverse the steps in Paragraph 3 3 2 Follow the steps in 3 3 6 for adjustment if neces sary after reinstallation Adjustment Cabin doors should be adjusted by shims at the hinge attach points so that the door skin fairs with the fuselage skin and the door latch pin lines up with the hole in the door frame 3 4 1 Description 3 4 2 3 4 3 3 4 4 3 4 5 The J abiru seats an integral part of the structure of the aircraft they are therefore fixed in position V WARNING DO NOT MODIFY SEATS Removal Seats may not be removed Inspection Inspect fiberglass layups in the seat structure for cracking and delamination Repair Seats are a structural element in the fuselage and the manufacturer must approve all repairs to the seats Adjustment Forward and upward adjustment can be achieved by placing a cushion behind and or under the occupant Rudder pedal extensions may be installed as an option JSA 5 2305 1 3 11 Section 3 Jabiru 230 5 250 5 Fuselage Structure Aircraft Service Manual 3 5 Upholstery Seat upholstery is provided through removable cushions These are easily removed for cleaning and inspect
201. nd strut for straightness and security Actuating Linkages Check for wear at attach points Check for cracks and security Nose Gear Steering Linkage nspect linkages for tightness condition and security Comments Nose Gear Operation Check for condition smooth operation and security JSA 100HR A1 100 Hour Annual Inspection Checklist Page 15 of 17 Jabiru J 230 5 250 5 and J 170 SP Aircraft Service Manual 6 Main Gear and Brakes Brakes Lines Lining and Discs Check for condition wear and security Check lines for chafing and signs of leakage and cracks Check brake discs for cracks Comments Wheels and Tires Check wheels for cracks and tires for wear damage condition and proper inflation Check and repack wheel bearings Comments Landing Gear Legs Inspect legs for cracks overextension or signs of delamination Comments 7 Rear Fuselage and Empennage Skin Check for deformation cracks and obvious damage If damage is found check adjacent structure Internal Fuselage Structure Check for cracks and deformation Check bulkheads door posts and center tunnel for cracks or delamination Control Cables Check elevator and rudder push pull cables for condition attachment alignment clearance and proper operation Check cable clamps on both ends for proper attachment and placement Check rod ends for security and freedom of motion Comments Control Surface
202. nded to provide operators with basic guidance information for operating their aircraft and engines on fuels containing alcohol Issue 2 was produced to include additional information about the combustion chamber compression ratio and suitable fuels Issue includes operating information on fuels with a higher lead content At the same time the technical content of the letter has now moved so far beyond alcohol limits that the title of the Service Letter has been changed to better reflect it s content 2 2 General e Current Jabiru 2200 and 3300 engines are designed to use Australian Aviation Gasoline AVGAS or Australian Premium Unleaded Motor Spirit 5 of at least 95 octane RON e Over time Jabiru Engines have used several different compression ratios and combustion chamber arrangements Section 3 gives details on the different combinations produced and discusses suitable fuels for each e Worldwide the most common type of AVGAS is 100LL where LL means Low Lead In some areas AVGAS 100 which contains significantly more tetraethyl lead is also available Section 4 gives details of the different fuels and discusses their different operating and maintenance effects Recently it has become common for automotive fuels to contain alcohol Many automotive fuels now contain 5 10 or higher percentages of alcohol typically Ethanol Octane boosters also often contain alcohol Section 5 has been prepared to gui
203. ne Accessories Removal Removal of engine accessories for inspection involves stripping the engine of parts ac cessories amp components as appropriate During removal of all parts carefully examine amp tag defective parts for repair or replacement with a new part NOTE All openings exposed by the removal of an item should be closed by installing a suitable cover or cap over the opening This will prevent the entry of foreign particles 17 suitable covers are not available tape be used to cover the opening 7 2 Basic Engine Compartment Inspection For specific items to be inspected and for periodic inspection details refer to nstruction amp Maintenance Manual for J abiru 3300 Aircraft Engine 1 Visually inspect the engine for loose bolts nuts cracks leaks amp cooling fin damage Blis tered paint around the base of the cylinders may indicate an overheating issue Inspect baffles baffle seals amp brackets for cracks deterioration or damage Inspect all control linkages for security and operation Inspect wiring for chafed areas and security Inspect hoses for internal swelling chafing cuts breaks stiffness or loose connections Excessive heat on hoses will cause them to become brittle amp easily broken Hoses are most likely to crack or break near the ends amp at support points Check fire sleeves on fuel lines within the engine compartment Avoid excessive flexing amp sharp bends when exam ini
204. ng Structure Jabiru 230 5 250 5 Aircraft Service Manual 4 2 Wing Struts 4 2 1 4 2 2 Page 4 4 Description Each wing strut is a single lift strut which transmits a part of the wing load to the lower portion of the fuselage The strut consists of a streamlined tube bolted to two end fit tings which attach to the fuselage and wing V WARNING Do Not Tighten Strut Attachment Bolts Damage to wing attach hardware may result Bolt must be free to rotate Removal Tools Required Screwdriver set 1 2 wrenches tall padded saw horse or wing stand Level of Certification Required A amp P or LSA R M M 1 Remove wing root fairings 2 If planning to leave the wing blocked up more than a few minutes drain fuel out of the wing tank to lighten it up Note This will take some time 3 Remove wing strut fairings top and bottom 4 Disconnect pitot tube RH wing only Pitot connection is underneath lower strut fairing 5 Disconnect the recognition light wires LH wing Rec light connection is under neath lower strut fairing 6 Making sure the flap is supported disconnect flap control rods 1 each wing Flap may be supported by using generous amounts of masking tape to hold in the up position 7 Support the wing using a padded sawhorse or brace structure just outside the strut attach point with the lowest amount of wing tip droop as possible 8 Remove the bolts from the top attachment and the bot
205. ng hoses for stiffness All flexible hoses in the engine compartment should be replaced at engine overhaul or every 2 years whichever comes first Hoses which show visible deterioration cracking excessive hardening should be replaced immediately regardless of age JSA SM230SP A2 7 3 Section 7 Jabiru J 230 5 250 SP Engine Systems Aircraft Service Manual ETE 55 DY 3 thu 000509 2 os 3 am i ECALE NTS now THE OFAN 15 COPYRIGHT MUST Ar mou HE CONSENT OI AVILUR DU BUNDABERG 4670 A C N 010 758973 HINKLER AIRPORT ENGINE ASSY JABIRU 3300A DONOT SEALE avrecnen 3 o 2 f z RED MOUNT MOP NONAL FRONI PROJECTION 710 Figure 7 1 Engine Dimensions Page 7 4 J SA SM230SP A2 Jabiru 230 250 SP Section 7 Aircraft Service Manual Engine Systems 7 3 Engine Cowls 7 3 1 7 3 2 Description The engine cowls consist of one upper and one lower composite structure The upper cowl is fitted with three cam locks in the rear and two machine screws in the front one inside each air inlet The lower cowl is attached to the fuselage with 10 machine screws mounting into anchor nuts with Tinnerman washers One long hinge pin connects the two cowls together along each side with the hinge pin entering and exiting the hinge through
206. ning the engine for extended periods on the ground this causes heat soak into the engine bay which increases vapour lock risk li Use the back up electric fuel pump for all critical modes of flight generally any time the aircraft is on the ground or within 1500 feet of the ground Jabiru Aircraft have no objection to operators running the electric boost pump continuously MOGAS Usage Recommendations Use fuel which is as fresh as possible Be aware of the potential issues arising from using MOGAS Follow the storage recommendations given below MOGAS Storage Do not leave small amounts of MOGAS in the tank as will be relatively highly exposed to air and may form gums varnishes or other solids Gum formation is caused by a chemical reaction within the fuel The reaction speeds up as temperature increases so it is a particular problem in warmer climates Aside from gum formation the fuel s octane rating will also drop with time Do not leave a tank full of MOGAS as it will loose volatiles over time reducing it s octane rating A full tank is somewhat less prone to forming solids than a nearly empty one because a smaller percentage of the fuel is exposed to the air but after a month or two the entire contents may have lost so many octane points that it should not be used in the aircraft Disposing of a large quantity of stale fuel then becomes a major problem JSA SM230SP A1 JSL007 3 doc Page 7 of 14 Compression Ratio Fuel
207. nough pressure to force fuel from the header tank through the firewall An engine driven mechanical fuel pump helps provide pressure to feed the carburetor An electric boost pump is available to fill the carburetor bowl with fuel prior to engine start and also to function as a backup in case the mechanical pump fails There is one main fuel shutoff valve located on the center console between the control stick and the brake handle A vent line for each tank runs to the wing tip where it exits the leading edge of the winglet in the 230 or the trailing edge of the wing tip in the 250 The header tank is vented into both main tanks on aircraft before s n 795 It vents to the wingtip in s n 795 and later aircraft Check valves reduce the amount of fuel allowed to back out of the vents Three fuel sumps allow sampling of fuel for water and sediment There is one sump at the root end of each wing tank and one in the header tank that protrudes out the belly of the fuselage 8 2 Fuel Tanks 8 2 1 Description Each fuel tank consists of a fiberglass shell that is internally coated with sealant There is one main tank the root end of each wing and one header tank behind or under the passenger seat The main tanks are an integral part of the wing structure and may not be removed 8 2 2 Removal of Header Tank Level of Certification Required A amp P or LSA R M M 1 Shut off the Left and Right fuel valves located on the doorposts aft of the cabin
208. ntermittent radio static on isolated frequencies in the SL30 or SL40 To troubleshoot pull the WX circuit breaker or disconnect power from the WxWorx module and see if the static disappears A WxWorx hardware upgrade is available to fix this problem Contact Grand Rapids Technologies for more information 11 11 2 Removal Tools Required 7 64 Allen key screwdriver set Level of Certification Required A amp P LSA R M M or Avionics Repair Station 1 Using the 7 64 Allen key loosen the retaining screw through the radio face 2 Turn counterclockwise until it stops 3 Pull radio from tray 11 11 3 Inspection 1 Check pin connections at rear of radio for damage 2 Inspect tray for bent pins or loose connections 3 Inspect antenna coax for damage 11 11 4 Repair 1 Repair of bent pins can be made by standard radio repair procedures 2 Repair of the radio itself is limited to sending the radio to an approved repair cen ter 11 11 5 Reinstallation Reverse steps in Paragraph 11 11 2 for reinstallation Page 11 16 J SA SM230SP A1 Jabiru 230 5 250 5 Section 11 Aircraft Service Manual Electrical System and Instruments 11 11 6 Radio Antenna Balance Balun Installation Some J abiru aircraft exhibit pitch changes when the autopilot is engaged and the push to talk switch is pressed The manufacturer of the autopilot has determined this is due to interference from the communications radio antenna Jabiru USA now installs
209. ntrols 6 1 GOON KE o RENT T MM 6 1 6 3 Alleron Gohlrol SY ___ 6 4 6 4 Wing Flap Control 2 6 7 6 5 Elevator Control xia Rec qua i ea E CRGO 6 12 6 6 Elevator Trim Control 6 16 6 7 Rudder Control 6 20 Section 7 Engine Systems Po UU TT 7 1 7 2 Basic Engine Compartment 1 01 7 2 158 COWS UN 7 5 7 6 7 5 ENGIN EEE HORE 7 10 7 10 ES 7 12 7 8 Oil Cooling 7 14 7 9 Recovery 7 16 TENG CAPO Ol e 7 17 7 11 7 20 7 20 7519 CORO ett 7 22 urgeri H 1 23 PEMD Oc pog i is Marc 7 24 JSA SM230SP A1 3 Jabiru 230 5 250 5 Aircraft Service Manual Section Title Page Tonton y 7 25 7417 Spark _____ _____ __ _ 7 25 7 18 Exhaust SVSLEOFPI eae
210. nual is in question JSA 5 2305 1 Page 11 Jabiru 230 5 250 5 THIS PAGE INTENTIONALLY BLANK Page 12 J SA SM230SP A1 Jabiru 230 5 250 5 Section 1 Aircraft Service Manual General Description Section 1 General Description 1 1 Aircraft Description The Jabiru 230 SP and 250 SP aircraft described in this manual are 2 seat high wing aircraft of fiberglass composite monocoque construction Each model is equipped with fixed tricycle landing gear The main gear is composite construction The steerable nose gear is a welded metal trailing link assembly with rubber springs Each aircraft is equipped with one Jabiru 6 cylinder 4 stroke engine driving a Sensenich wooden fixed pitch propeller or a Sensenich carbon fiber ground adjustable propeller 1 2 Aircraft Specifications 12305 2505 Fuel Consumption 4 5 5 5 gallons hour Table 1 1 J230 SP J250 SP Specifications J SA SM230SP A1 Page 1 1 Section 1 Jabiru J 230 5 250 SP General Description Aircraft Service Manual 1 3 Three View Drawings 371 542 A T 13 p 6550 257 8 Figure 1 1 Three View Drawing J 230 SP Page 1 2 J SA SM230SP A1 Jabiru 230 5 250 5 Section 1 Aircraft Service Manual General Description 1820 96 72 5550 257 8 Figure 1 2 Three View Drawing 250 5 JSA 5 2305 1 Page 1 3 Section 1 Jabiru J 230 SP 250 SP Gen
211. num surfaces require a minimum of care but should not be neglected Wash and clean as detailed in paragraph 2 11 1 above Scratches in the spinner may be re moved using an aluminum polishing compound such as Flitz or Nuvite Jabiru aircraft are designed for minimum maintenance However special attention should be applied when the aircraft has been used in extremely corrosive conditions e g beach landings with sand and salt Always ensure the aircraft is thoroughly hosed and washed immediately after such use Pay particular attention to wheels and exter nal controls Always hose down wheels and wheel fairings after landings in mud or sand to ensure brakes wheels and fairings are free of dirt build up For regular landings on soft conditions removal of wheel fairings is recommended 2 11 5 Engine and Engine Compartment The engine should be kept clean since dirty cooling fins and baffles can cause overheat ing of the engine Also cleaning is essential to minimize any danger of fire and provide easy inspection of components Recommended cleaning procedure is spray lightly with degreasing fluid after sealing coils and starter motor WIPE clean with brush and cloth V CAUTION DO NOT hose engine Electrical components may be damaged by moisture Ensure electrical components are protected against moisture Caustic cleaning solu tions should not be used 2 11 6 Propeller Wash with soap and water rinse with clean water and dry with cloth
212. o reconnect breather hose and fuel pump vent line 7 9 3 Inspection Clean bottle and mounting area if nec essary Look the bottle over for cracks or blockages Check for kinks in the lines The oil breather vent line may become saturated after one or two years or several hundred hours of operation and weep oil Replacement of a weepy oil breather line is recommend ed every 24 calendar months or as needed to keep a clean engine com partment 7 9 4 Repair Figure 7 6 Oil Recovery Bottle Repair is limited to replacement of components See Table 7 1 for re placement hose information Page 7 16 J SA SM230SP A2 Jabiru 230 250 SP Section 7 Aircraft Service Manual Engine Systems 7 9 5 Reinstallation 1 Secure the bottle inside the firewall clamp 2 Reconnect the hoses 7 10 Carburetor 7 10 1 Description The J abiru 3300 utilizes a Bing 64 altitude compensating carburetor Refer to the n struction amp Maintenance Manual for J abiru 3300 Aircraft Engine for detailed carburetor data See Section 7 13 of this manual for information on the carburetor heat system 7 10 2 Removal Tools Required 5 16 wrenches screwdriver set needle nose pliers Level of Certification Required A amp P or LSA R M M V WARNING Fuel lines within the engine compartment are fitted with fireproof sleeves f removed the sleeves must be reinstalled before the aircraft ts returned to service 1 Disconnect fuel line from ca
213. oc WOOD CF REV A DOC Wood Propellers Installation Operation amp Maintenance found in the Appen dix of this manual Check the Sensenich website for latest revision to this document 1 Ensure the propeller drive bushings are in place in the crankshaft propeller flange 2 Insert the AN6 45A bolts from the rear 3 Position the spinner back plate on the crankshaft propeller flange with the back plate flange facing aft Insert the prop drive bushings through the back plate 4 Install prop over back plate and drive bushings Make sure the prop and spinner back plate are in the correct position for spinner cone installation 5 Install crush plate over the bolts 6 Install two Belleville washers on each prop bolt as shown in Figure 9 1 7 Install one AN960 616 washer on each bolt 8 Install AN365 624 nuts on bolts Use new nuts 9 Torque to 15 17 ft lbs in the sequence indicated in Figure 9 1 10 Check propeller tracking as outlined in Paragraph 9 5 of this section J SA SM230SP A1 Page 9 3 Section 9 Propeller amp Spinner Jabiru J 230 5 250 SP Aircraft Service Manual 9 3 Ground Adjustable Carbon Propeller 9 3 1 Description 9 3 2 9 3 3 Page 9 4 The ground adjustable carbon propeller consists of a two piece machined anodized alu minum hub and two carbon fiber composite blades A nickel steel leading edge protec tor is bonded to the leading edge of each blade Each blade 15 finished in epoxy paint C
214. old epoxy resin has been removed from the fuselage sealing strips around the window frames Peel away the plastic coating on the inside of the windscreen only about 2 back from the edge Check new windscreen for fit inside the joggle File or grind away any excess windscreen material to ensure a close fit Do not attempt to cut with any type of saw file only Fit windscreen in the joggle Trace the edge of the fiberglass with a marker then tape 1 8 inside the line on both outside and inside with painter s tape to protect the windscreen from glue Be sure all surfaces of windscreen inside the line are cov ered Rough up the edge about 4 inch wide of the windscreen with 220 grit sandpaper then again with 80 grit Wet the window frame joggle and the outer edge of the windscreen with a light coat of epoxy Mix cotton flock with epoxy to the consistency of soft peanut butter Apply a bed of epoxy amp flock in the joggle to form a bed for the windscreen about 1 8 thick Place windscreen accurately onto the joggle Secure in place with the clamps shown in Figure 3 1 Install the first clamp above the top center of the windscreen and the second bottom center Install all clamps in a zig zag pattern radiating out from the center so the windscreen does not get pushed to one side or the other see Figure 3 2 Clean up excess epoxy flock and allow it to cure for 24 hours Be sure to clean off all epoxy that overlaps the tape
215. older 4 Loosen screws in hinge pin retainers and lift hinge pin retainers from hinge pins It is not necessary to remove these parts 5 Remove hinge pins 6 Remove elevator For aircraft with two elevator hinge pins 2009 models and newer 4 Remove hinge pin retaining screws 5 Supporting elevator remove hinge pins 6 Remove elevator J SA 5 2305 1 Jabiru J 230 SP 250 SP Section 6 Aircraft Service Manual Flight Controls 6 5 4 6 5 5 6 5 6 6 5 7 Inspection Inspect elevator for any signs of delamination or cracking Pay particular attention to the control horn and hinges and their surrounding areas See Section 6 1 for inspection of control column and 6 2 for inspection of control cable Repair All damage involving cracking delamination or hinge damage must be referred to J abi ru USA Sport Aircraft LLC or an approved local agent for an appropriate repair proce dure Reinstallation Reinstall by reversing steps in Paragraph 6 5 3 WARNING All spherical bearings on control cable ends must be fit ted with a large washer on the outside of the through bolt to prevent the bearing case and cable from release ing in the event of a bearing failure Rigging the Elevator Control Tools Required Screwdriver set 3 8 wrenches Elevator Rigging Template see Appendix or angle finder Level of Certification Required A amp P or LSA R M M Refer to Figure 6 7 1 Using the factory set ca
216. olt master cylinder retaining bolts 2 5 8 4 Inspection Inspect for leaks at fittings Check for damage to brake piston and diaphragm 5 8 5 Repair Hydraulic Brake Lines Repair is limited to replacement Master Cylinder JSA 5 2305 1 Figure 5 4 Brake Master Cylinder Assembly may be used as guide during disassembly repair and reassembly of the brake master cylinder Repair is limited to installation of new parts cleaning and adjustment Master cylinder replacement may be the least expensive method of repair Re place with Wilwood Master Cylinder model 950 260 1304 V WARNING Use only automotive DOT 4 brake fluid DO NOT use aircraft grade hydraulic fluid or damage will result Page 5 15 Jabiru 230 5 250 5 Aircraft Service Manual Landing Gear and Brakes Section 5 22079 STONY 500 9300 j O30 3NO 90 SON 8 TVH3N3O ALVd 551 Ald HO3LAV 40 LNASNOO LNOHLIM 9409 SOOZ rO FL 38 LON LSNW ONY LHSIMAdOD SI ONIMVHO SIHL SNOISN3MIG someon 2 Mr ASSY ONLLLIS H3QNITAO YALSYW 290004 9 X ONDLP L NZOOVEHd SL L108 GWSH 8 N900VEHd vL ie LX MSE MIYOS N6zPOHd L ___ Zl _
217. omposed of two pieces for easy installation and removal 5 9 2 Removal and Installation Tools Required Phillips screwdriver 7 16 wrenches Parts Required Loctite 242 for installation Level of Certification Required Owner A amp P or LSA R M M 1 Weight down tail of aircraft to raise nose wheel off floor as described in Section 2 2 Remove the machine screws that join the forward and rear sections of the fairing and remove the rear section 3 Use a set of 7 16 wrenches to remove the nose wheel axle bolt Support the nose wheel as it falls from the nose fork and take care that it does not catch on the edge of the fairing 4 Remove the upper screw and washer from each side of the forward half of the wheel fairing and nose gear fork and remove the front half of the fairing 5 If returning the aircraft to service without the nose wheel fairing reinstall wheel and axle bolt Add spacers to each side of the nose wheel yoke to take up the extra space 6 Reverse the preceding steps for installation using Loctite 242 on the screws that attach to the aluminum nose wheel fork to keep them from coming loose 5 9 3 Inspection and Repair See Section 5 3 for information regarding inspection and repair of nose wheel fairing The procedure 15 the same as for the main wheel fairings 5 10 Nose Gear Leg 5 10 1 Description The nose gear 15 a welded steel and aluminum trailing arm assembly with a rubber spring cushion system The nos
218. or broken master Repair or install new mas cylinder piston return ter cylinder spring Restriction in brake lines or Drain brake line clear with in master cylinder compressed air If cleaning lines fails inspect and re pair or replace master cyl inder Brakes fail to operate Worn brake pads Replace with new parts Leak in system Check for leaks and repair or install new parts Lack of fluid in master cyl Fill and bleed system inder check for leaks Defective master cylinder Repair or install new parts Shimmy or chatter when Rough or uneven runway Some main gear chatter 15 brakes applied heavily surface normal during heavy brak ing on rough surface Warped or worn brake Inspect disks for wear disks severe chatter resurface or replace as necessary Page 5 14 JSA SM230SP A1 Jabiru 230 5 250 5 Section 5 Aircraft Service Manual Landing Gear and Brakes 5 8 3 Removal Tools Required Allen key set 1 2 and 7 16 wrenches Level of Certification Required A amp P or LSA R M M Refer to Figure 5 4 Brake Master Cylinder Assembly Take care to avoid dripping brake fluid onto interior surfaces of cabin as this may damage the finish 1 4 5 Remove the flexible hose from one wheel brake assembly and drain the hydraulic fluid from the brake system Remove brake handle Disconnect flexible hose at master cylinder Plug or cap hydraulic fittings and hoses to prevent the entry of foreign material Unb
219. or chamois Wax the propeller with automotive wax for best results use a paste wax as opposed to a spray wax to help preserve the finish Empty the spinner of all water 2 11 7 Wheels The wheels should be washed at least annually more frequently if used in harsh envi ronments and examined for corrosion cracks or dents in the wheel halves or in the flanges or hubs If defects are found remove and repair in accordance with Section 5 Discard cracked wheel halves flanges or hubs and install new parts Page 2 14 JSA SM230SP A1 Jabiru J 230 5 Aircraft Service Manual 250 SP Section 3 Fuselage Structure Section 3 Fuselage Structure 3 1 Description The fuselage Is a composite monocoque self supporting structure and includes both the horizontal stabilizer and vertical fin All repairs to structural components must be approved by J abiru USA Sport Aircraft LLC or approved local representative 3 2 Windows 3 2 1 3 2 2 Description The windshield is a one piece acrylic plastic Perspex amp panel bonded into a joggle with epoxy resin amp fiber flock and secured to the fuselage with screws and nuts Windows are one piece acrylic plastic Perspex amp panels bonded into a joggle with epoxy resin amp fiber flock NOTE the event of a bird strike the windshield 15 the only protection for the crew and therefore must be maintained in excellent condition Cracks up to 25 mm in length should be stop drilled t
220. or security alignment corrosion and binding Comments Ailerons Check control surfaces for proper clearance and freedom of movement Check hinges and hinge pins for security Check aileron skin and visible structure for cracks Comments Fuel Tanks Caps and Vents nspect bottom of wing for evidence of fuel tank leakage Inspect vents for blockages Check filler caps for ease of operation Plumbing Check for leakage chafing condition and security Electrical Wiring and Equipment nspect for chafing damage security and attachment Comments Flaps and Actuators Check for condition security binding or chafing of actuator rods Check flap skin and visible structure for cracks Comments Flap Position I ndicator Check for security and operation Wing Bolts Check wing bolts for security DO NOT overtighten JSA 100HR A1 100 Hour Annual Inspection Checklist Page 14 of 17 Jabiru J 230 5 250 5 and J 170 SP Aircraft Service Manual Fuel Vents Pitot Tube and Stall Warning Check for condition and obstructions Drain Ports Check drain holes in wing and surfaces to assure they are free of obstructions 5 Nose Gear Wheel and Tire Check wheel for cracks and tire for wear damage condition and proper inflation Check sealed bearings for condition and wear Landing gear strut nspect rubber shock strut and components for cracks wear and attachment Inspect wheel yoke a
221. osen the nut slightly until the washer will rotate The wash er must be free to rotate 4 Install the outboard end or the strut onto the wing spar strut fitting Attach lug and line up the hole 5 Install the AN5 NAS bolt washer and nut 6 Tighten the nut in the same manner as the lower strut attach bolt making sure the bolt is just free enough for the washer to rotate 7 Reconnect the flaps and remove supporting tape 8 Reconnect recognition light wires and or pitot tube 9 Reinstall upper and lower strut fairings by installing the self tapping screws 10 Look over the fuel lines and stall warning tube LH wing only in the wing root to check for kinks or pinches 11 Reinstall upper and lower wing root fairings SM230SP A0 Page 4 5 Section 4 Jabiru 230 5 250 SP Wing Structure Aircraft Service Manual Figure 4 1 Wing Assembly J 250 SP Page 4 6 J SA SM230SP A0 Jabiru 230 5 250 5 Section 5 Aircraft Service Manual Landing Gear and Brakes Section 5 Landing Gear and Brakes 5 1 General Description The main landing gear legs consist of two separate composite beams which are bolted to the fuselage at the top and center and to the wheel stub axle at the bottom The main wheels are Matco aircraft wheels and brakes are Matco aircraft hydraulic brakes Wheel pants are standard equipment 5 2 Landing Gear Troubleshooting Chart Aircraft leans to Incorrect tire inflation Inflate or deflate main t
222. otate propeller several revolutions to clear excess preservative oil from cylinders 8 Install spark plugs torque to 8 ft lbs or 96 in Ibs 9 Check fuel filter replace if necessary 10 Check brake fluid level 11 If returning to service after indefinite storage fill fuel tanks with correct grade of fresh fuel 12 Check fuel tank and fuel lines for moisture and sediment Drain enough fuel to eliminate any moisture and sediment 13 Check fuel tank vents are clear 14 Perform a thorough pre flight inspection 15 Start and warm engine J SA 5 2305 1 Jabiru J 230 SP 250 SP Section 2 Aircraft Service Manual General Care amp Inspection 2 9 Inspection Intervals Refer to J abiru 230 5 250 SP S LSA Maintenance Schedule found in the Appendix of this manual for detailed schedule of service and inspections All 25 50 hour 100 hour and Annual inspections must follow the guidelines set in the appropriate mainte nance checklists Doc 5 5 JSA 100HR also found the Appendix of this manual The Engine Instruction Manual also details engine inspection schedules and should be consulted in addition to this manual 2 10 General nspection Guidelines 2 10 1 Moveable Parts Inspect for adequate lubrication security of attachments binding excessive wear Safety proper operation proper adjustment correct travel cracked fittings security of hinges defective bearings cleanliness corrosio
223. ower Booster 11 24 Section 12 Fiberglass Repair UE VEO DERE E 12 1 12 2 General Non Structural Fiberglass 12 1 12 3 Structural Fiberglass 1 1 1 111 12 2 4 ________ 12 4 12 5 Door Repair 11 01 111 nnne 12 5 Follows Section 12 JSA 5 2305 1 Page 5 List of Figures Jabiru 230 5 250 5 Aircraft Service Manual Title of Illustration Page 1 1 Three View Drawing 230 5 1 2 1 2 Three View Drawing 250 5 1 3 2 1 Approved Push Pull 2 2 2 2 Plywood Jacking Platform on Engine 5 2 3 2 3 Jacking Aircraft with Engine 15 0 0 ms 2 4 FE ____ ________ gt 3 4 3 2 Window Clamps 3 4 3 3 Door 3 6 3 4 Door Hinge 3 7 259 RESTE 3 5 Fo DIG DCE DOO
224. owl and check for sediment Check condition of floats Plumbing nspectall hoses lines and clamps for condition and attachment Check plumbing clearance secure against possible chafing Comments Engine Sump Check for cracks leaks proper fluid level and security Oil Service Remove oil filter Inspect oil sump drain and install new filter Drain and replace crankcase oil Empty oil overflow bottle Comments Oil Cooler Check oil cooler lines and fittings for condition security chafing and leaks Engine Accessories Check for condition security and leaks Check wiring hoses and tubes for chafing security and leaks Cabin Heat System Check for cracks distortion corrosion leaks and obstructions JSA 100HR A1 100 Hour Annual Inspection Checklist Page 10 of 17 Jabiru J 230 5 250 5 and J 170 SP Aircraft Service Manual All Drains and Plugs Check for condition cleanliness and security Check for leaks and correct tension Cowling skin Check for deformation delamination and obvious damage or cracks Check for rub points on the interior surfaces Comments Cowling structure Check for cracks and delamination Check hinge pin structure for loose rivets or deformation Head Bolt Tension Torque head bolts to proper tension Comments 3 Cabin and Baggage Compartment Skin Inspect skins for deformation or cracks If damage is found check adjacent structure Structure Check for
225. pINOZISOH OL Piy H38mvo NOSNad SoS 931 HOISN3d5n S INJNMHOFT T33HM SHL JOO Addo 01 eH OL LAJH 01901 MJA Zk 3725 MGMHDOITY OW T33HM 88 5 JM T 0191 X OF X ANIMAL TY H2w3 SIGN 91 2 HUM T3NNYHO 631 40 SMIONYS AB JNOl 99 ISAM X GE X OF AMMAN T _ 38 01 gnis LON 00 Jabiru 230 5 250 5 Aircraft Service Manual Figure 5 3 Axle Alignment Page 5 13 Note Drawing refers to Jabiru UL model but alignment procedure 15 the same JSA 5 2305 1 Section 5 Jabiru 230 5 250 5 Landing Gear and Brakes Aircraft Service Manual 5 8 Master Cylinder Parking Brake Assembly 5 8 1 Description The brake master cylinder located between the seats on the front of the main longitu dinal beam 15 actuated by applying rearward pressure to the brake handle A small res 5 incorporated into the master cylinder for the fluid supply The parking brake consists of an over center cam on the brake handle Flexible lines carry fluid from the master cylinder through the belly of the aircraft inside the trailing edges of the main landing gear legs and into the Matco wheel cylinders 5 8 2 Troubleshooting Dragging brakes Brake handle binding Check and adjust Worn
226. pped with external navigation and strobe wingtip lighting Each wingtip light unit consists of one red or green navigation light in the front one white navigation light in the rear and one strobe anti collision light the center craft built after May 2009 have either the GS Air unit or an AeroLEDs Pulsar unit 11 6 2 Removal Tools Required 10mm wrench Phillips screwdriver razor knife Level of Certification Required Owner A amp P or LSA R M M GS Air 1 Remove ground cable from aircraft battery 2 Remove the two screws from lens 3 Cut silicone bead around lens 4 Pull unit from wingtip and disconnect wires J SA SM230SP A1 Page 11 3 Section 11 Jabiru 230 5 250 5 Electrical System and Instruments Aircraft Service Manual AeroLED 1 Remove ground cable from aircraft battery 2 Loosen set screw at rear of light assembly 3 Slide unit forward on its mounting track Light tapping on the set screw may be re quired 4 Remove unit from wing and disconnect wires 11 6 3 Repair Repair of wingtip lighting 15 limited to replacement of the unit 11 6 4 Reinstallation Tools Required Phillips screwdriver RTV silicone Level of Certification Required Owner A amp P or LSA R M M GS Air Connect wires Reinstall ground on battery and test light for proper color and operation 3 Apply a small bead of silicone around the edge of the light unit to form a gasket between the unit and the wingtip
227. pre a EE C xc laca aaan 1 26 7 19 Head Bolt Tension Check Head Torque Procedure 1 30 Section 8 Fuel System General OM anrasin 8 1 922 8 1 8 3 Fuel and m 8 2 TUS PUI _____ 8 3 EE feces 8 4 8 6 Fuel Sump E MO E d Es 8 5 Ord 8 6 8 8 Fuel Draining 8 8 Section 9 Propeller amp Spinner 9 1 ASS SOY 0 1 9 2 Fixed Pitch Wood 9 2 9 3 Ground Adjustable Carbon Propeller enn 9 4 9 4 Balan iNO Nm 9 6 9 5 Propeller Tracking 20 0 1 1 9 6 9 6 Approved lt 9 6 9 7 Identification 065 9 6 9 8 Propeller Bolt Tension 1 a 9 9 Section 10 Utility Systems 10 1 Pret ord M nee eoe rre air 10 1 1022 Cabin V SMOG COM se 10 2 10 3 Stall Warning 5
228. r a long period of time i e seasonal changes the propeller bolt torque must be rechecked Sensenich Ground Adjustable Carbon Propellers require a tension check of the blade clamp bolts every 25 hours See Section 9 8 3 for procedure Jabiru S LSA aircraft use nyloc nuts to attach wood propeller bolts to the hub No safety wire is needed however if the nuts are removed they MUST be replaced with new hardware Wood Propeller Bolt Tension Check Procedure Required Tools Calibrated torque wrench with 9 16 socket 9 16 wrench screwdriver set Required Parts 6 new AN365 624 nyloc nuts Level of Certification Re A amp P LSA R M quired Ensure ignition switch is in the OFF position and set parking brake 2 Remove spinner using procedure in Section 9 1 3 Set torque wrench to 15 17 ft lbs Check tension of nuts by moving in a criss cross pattern around the hub see Figure 9 1 for torque pattern Use box end wrench to hold bolt heads secure 4 f nuts move during the procedure this means the propeller has contracted Finish J SA SM230SP A1 Page 9 9 Section 9 Jabiru J 230 5 250 SP Propeller amp Spinner Aircraft Service Manual tightening nuts to 15 17 ft lbs of torque and move onto Step 7 If nuts do not move during the procedure the propeller has expanded To achieve proper tension the nuts must be removed and replaced with new hardware Move on to Step 6 5 Remove propeller nuts and thread new nuts onto t
229. r use with fuels containing alcohol Maintenance amp inspection requirements increased for fuel containing more than 1096 alcohol White Coloured Fuel Tank Sealant Suitable for use with fuels containing alcohol Caramel Coloured Fuel Tank Sealant Unsuitable for use with fuels containing alcohol Combustion Chamber Shape All combustion chamber shapes are compatible with fuels containing alcohol However the Octane rating of the fuel used must be selected to suit the combustion chamber design 6 5 Testing for Alcohol Using a clear jar of about 100 200 ml capacity ideally a long and narrow jar add about 10 by volume of water and mark the level of the water on the jar Add a sample of the fuel to be tested to the jar so that the relative volumes are about 10 water 90 fuel Details applicable for OEM parts from Jabiru Aircraft Australia only JSA SM230SP A1 JSL007 3 doc Page 10 of 14 e Shake the sample vigorously and then allow the sample to settle e Check the level of the water e lf the level is the same as previously marked on the jar no alcohol is present in the fuel e fthe level of water increases alcohol is present in the fuel 6 6 Alcohol Usage Recommendations 6 6 1 General e Where possible Jabiru Aircraft recommend using AVGAS This is a fuel specifically designed for aircraft use and is subject to very strict documentation and quality assurance This is simply the safest fuel available e Becaus
230. raft is equipped with a spinner to protect the propeller hub area and help direct cooling air into the cowling inlets Early models were equipped with a fiberglass spinner while later models are delivered standard with a Cummins polished aluminum spinner 9 1 2 Removal Level of Certification Required A amp P or LSA R M M 1 Remove machine screws and nylon washers from spinner 2 Remove spinner cone 3 Remove the nuts from the six propeller bolts 4 Remove the AN960 616 washers Belleville washers two per bolt aluminum crush plate and propeller 5 Remove spinner backing plate 9 1 2 Inspection 1 Inspect spinner for cracks and dents 2 Inspect spinner back plate for cracks warps or bends and loose nutplates 9 1 3 Repair 1 Dented and or cracked spinners and damaged back plates must be replaced Spin ner cones and backplates come match drilled and must be replaced as a Set 2 Replace loose 8 nutplates using solid AD countersunk aluminum rivets 3 Scratches may be polished from spinner with Flitz Nuvite or other similar aluminum polishing compounds 9 1 4 Reinstallation 1 Reverse steps in 9 1 2 for reinstallation of spinner components using propeller stallation procedure 9 3 5 2 Reinstall spinner cone Tighten screws JUST UNTIL SNUG or until the plastic wash ers begin to compress slightly DO NOT OVERTIGHTEN as this may cause the spin ner cone to crack over time JSA 5 2305 1 Page 9
231. raft should remain in a three point stance without much added weight V CAUTION Do not press or lift on the control surfaces Damage to the control surface or control system may result 2 4 Hoisting This procedure should not be necessary for most service or maintenance procedures Should hoisting be necessary Drain fuel from both wings amp remove wings See Sections 8 8 and 4 1 Fit shackles to the four wing support brackets Fit cables rope to shackles and to a center lift shackle xx Ew e p Hoist only from this point ensuring that cables ropes do not damage the top of the fuselage at corners above wing support brackets Page 2 4 J SA SM230SP A1 Jabiru J 230 SP 250 SP Section 2 Aircraft Service Manual General Care amp Inspection 2 5 Leveling 1 Place a spirit level on the trim control lever decal and make adjustments as neces sary to level the aircraft in the longitudinal direction 2 Place a spirit level across the fuselage between the door sills use blocking of equal height on each side to clear seats and obstructions and make adjustments as nec essary to level the aircraft in the lateral direction 2 6 Weighing the Aircraft Tools Required 3 aircraft weighing scales spirit level plumb bob tape measure Level of Certification Required Owner A amp P LSA R M 2 6 1 Preparation 1 Thoroughly clean aircraft and remove all baggage tools and personal items 2 Drain all fuel 3 Confirm that oil
232. rankcase have the lower ratio engines without shims the higher Note that the details given above apply to each engine as was produced As many the older engines are now more than 10 years old and have been overhauled in the meantime operators must be aware that the engine s current configuration may be different from that given here Combustion Chamber Shape Older Jabiru Engines had a combustion chamber shape which demands the use of AVGAS or 100 Octane RON fuel Details are given below Note that the details given above apply to each engine as it was produced As many of the older engines are now more than 10 years old and have been overhauled in the meantime operators must be aware that the engine s current configuration may be different from that given here The following engines were manufactured with combustion chamber as shown in Figure 1 2200 S No 1 1003 3300 S No 1 223 All Jabiru 1600 engines Figure 1 Early High Octane Combustion Chamber JSA SM230SP A1 JSL007 3 doc Page 3 of 14 Jabiru Service Letter Alcohol Lead Compression Ratio Fuel Guidance JSL 007 3 oth Nov 2009 e The High Octane chamber can be modified as shown in Figure 2 Combustion chamber edges re shaped Figure 2 Re Worked High Octane Combustion Chamber Engines with Serial Numbers higher than the range listed above were manufactured using variations of the SUL chamber shown in Figure 3
233. rb 2 Disconnect throttle cable from carb 3 Disconnect choke cable from carb 4 Disconnect ground strap from carb 5 Loosen clamp on rubber carb adapter 6 Pull the carb to the rear and down to remove 7 10 3 Inspection and Repair 1 Inspect rubber carb connector for cracks or deformation Repair is limited to re placement 2 Remove carb dome and inspect diaphragm for cracks or breaks Replace if damage 15 observed 3 Inspect the needle for damage or deformation Repair is limited to replacement 4 Inspect floats for damage or fuel saturation Repair 15 limited to replacement 5 Inspect float valve for rubber tip damage or deformation Repair 15 limited to re placement 6 Inspect all o rings and seals for evidence of leaking or damage Repair is limited to replacement SM230SP A2 Page 7 17 Jabiru 230 5 250 5 Section 7 Aircraft Service Manual Engine Systems 7 10 4 Reinstallation Follow the instructions in section 7 10 2 in reverse order for reinstallation 7 10 5 Idle Speed Adjustment Tools Required 2 foot long flat head screwdriver or 5 16 wrench Level of Certification Required A amp P or LSA R M M Refer to nstruction amp Maintenance Manual for Jabiru 3300 Aircraft Engine for detailed carburetor jet removal idle adjustment and carburetor bowl cleaning procedures V WARNING A qualified person must be in the cockpit of the aircraft at all times the engine 15 running V WARN
234. rdance with the standard schedules detailed in the Instruction and Maintenance Manuals of the engine and airframe manufacturers 6 6 3 Use of Automotive Gasoline Containing Up to 10 Alcohol e Jabiru Aircraft has no objection to operators using gasoline containing up to 10 alcohol in Jabiru Aircraft or Jabiru Engines except as limited by the aircraft s certification basis For most engines the use of fuel with RON of 95 or above is adequate however older engines must use a fuel which meets the Octane rating requirements of their combustion chamber See Section 3 above e Only those Jabiru Aircraft with white coloured fuel tank sealant can use fuel containing alcohol e No modifications are required for Jabiru Engines to use fuel containing 10 alcohol e Where a Jabiru Engine is installed in a non Jabiru airframe the operator must comply with the airframe manufacturer s approved fuel recommendations e Clear fuel hose should be monitored for hardness brittleness and loss of colour Lines must be inspected regularly and renewed if any sign of deterioration such as brittleness or cracking is found In addition at the time of writing Jabiru Aircraft recommend that all flexible fuel lines be replaced at 2 year intervals While this is considered adequate while JSL007 3 doc Edo id Page 11 of 14 JSL 007 3 oth Nov 2009 using a fuel containing alcohol operators choosing to use these fuels are encouraged to be especially pro active and ex
235. rformance of the magneto as outlined under the heading NORMAL PROCEDURES in the appropriate Pilot s Operating Handbook JSA 100HR A1 100 Hour Annual Inspection Checklist Page 3 of 17 Jabiru J 230 5 250 5 and J 170 SP Aircraft Service Manual Power Check Refer to NORMAL PROCEDURES in the appropriate Pilot s Operating Handbook JSA 100HR A1 Voltmeter Check for proper indication and unusual fluctuations Comments Heating and Ventilating System Check for proper operation heat and airflow output Check controls for freedom of operation Comments Front Console Main Fuel Shutoff Valve Check for proper operation and freedom of movement Comments I nduction Airbox Valve Doors and Controls Remove air filter and inspect hinges doors seals and attaching parts for wear and security Check operation Comments Oil Cooler Check for obstructions leaks and security of attachment Doors Check latches hinges and seals for condition operation and security of attachment Idle RPM and Mixture Settings Check for both proper RPM and mixture settings Check controls for freedom of operation Comments 100 Hour Annual Inspection Checklist Page 4 of 17 Jabiru J 230 5 250 5 and J 170 SP Aircraft Service Manual JSA 100HR A1 Ignition switch Rotate the ignition switch through the OFF position to the extreme limit of switch travel If the engine stops firing the switch is normal If the
236. ru 230 5 250 SP Section 11 Aircraft Service Manual Electrical System and Instruments 11 9 Engine Information System El S 11 9 1 Description The Grand Rapids Technologies Engine Information System EIS Model 6000 is used to monitor all engine parameters The instrument monitors RPM OAT CHT 6 EGT 6 Oil Pressure Oil Temp Voltmeter Flight Timer and Hobbs Meter High and low limits are programmed into the unit for all measurable parameters A warning light and the EIS screen flashes to highlight information sets that are outside of programmed limits 11 9 2 Removal Tools Required 9 64 Allen key screwdriver set Parts required None Level of Maintenance Line Level of Certification Required A amp P LSA R M M or Avionics Repair Station 1 Remove the four screws at the corners of the unit 2 Pullthe unit from the panel and disconnect the D sub connectors from the rear of the unit 11 9 3 I nspection and Repair Inspection is limited to checking the cables and D sub connectors for damage or bad pins Any other repair must be done by Grand Rapids Technologies at their facility 11 9 4 Reinstallation 1 Reverse steps in 11 9 2 for reinstallation 2 Run engine and check EIS unit for proper operation 11 9 5 Reprogramming nstructions 1 If default settings in the EIS become corrupted and reprogramming is necessary contact J abiru USA Sport Aircraft LLC for further instructions J SA SM230SP A1 Page 11 9
237. rvice Manual Electronic Flight Information System EFI S and Engine nformation Sys tem EIS Grand Rapids Technologies Inc 3133 Madison Ave Wyoming 49548 1211 Phone 616 245 7700 Fax 616 245 7707 Free user manuals available for download in PDF format http www grtavionics com XM Weather WxWorx receiver provided and supported by Grand Rapids Technologies Inc Free manual available in PDF format for download http www grtavionics com default aspx id 4 Radio and Transponder Garmin Aviation Support USA Phone 913 397 8200 USA Toll Free 1 866 739 5687 Canada 1 866 429 9296 http www garmin com Free user manuals are available for download in PDF format http www8 garmin com support userManual sp Intercom PS ENGINEERING Inc 9800 Martel Rd Lenoir City TN 37772 Technical Support 865 988 9800 Fax 865 988 6619 E Mail contact ps engineering com http www ps engineering com Free user manuals available for download in PDF format http www ps engineering com downloads shtml Page 2 of 4 Vendor Information J SA SM230SP A1 Jabiru 230 5 250 5 Aircraft Service Manual Appendix Autopilot TruTrak Flight Systems Inc 1500 South Old Missouri Road Springdale AR 72764 Phone 1 866 TRUTRAK or 479 751 0250 Fax 479 751 3397 http www trutrakflightsystems com Free user manuals available for download in PDF format http www trutrakflightsystems com docs2 ht
238. s 2 Support the flap so it will not fall against the fuselage 3 Unbolt rod end from flap control arm 4 Remove each flap hinge bolt and spacer bushing 5 Remove flap 6 4 3 2 Flap Switch Assembly Tools Required Screwdriver set 7 16 wrenches Level of Certification Required A amp P or LSA R M M 1 Remove switch jam nut 2 Disconnect wires 3 Remove switch assembly JSA 5 2305 1 Page 6 7 Section 6 Jabiru J 230 SP 250 SP Flight Controls Aircraft Service Manual 6 4 3 3 Flap Control Rod Tools Required Screwdriver set 3 8 wrenches Level of Certification Required or LSA R M M 1 To remove clamp flaps in position so they do not fall against the fuselage 2 Unbolt control rod at both ends and remove 6 4 3 4 Flap Motor Assembly Tools Required Screwdriver set 7 16 wrenches Level of Certification Required A amp P or LSA R M M Remove wing root fairings 2 Support the flaps in the UP position so they do not fall against the fuselage 3 Disconnect electrical wires 4 Remove the bolt in each end of the flap motor 5 Reverse procedure to install 6 4 3 5 Flap Position Sensor Level of Certification Required A amp P or LSA R M M 1 Remove upper wing root fairing from left wing 2 Disconnect pushrod clevis and electrical connector from sensor 3 Remove mounting screws from nutplate bracket and remove sensor 6 4 4 Inspection of Flap Components 1 Inspect flaps for an
239. s Check for deformation cracks security of hinges freedom of movement and travel limits JSA 100HR A1 100 Hour Annual Inspection Checklist Page 16 of 17 Jabiru J 230 5 250 5 and J 170 SP Aircraft Service Manual Fixed Trim Tabs Check for security and obvious damage Static Port Check for blockages Check static probe for condition RR Antennas Check for condition and security 8 General Airplane cleaned and serviced I nspect all placards to assure they are easily readable and securely attached Ensure that all Service Bulletins Air Safety Alerts and previously issued Service Instructions are reviewed and complied with as required Comments For a complete annual or 100 hour inspection of the airplane all items on the airplane that are noted in this guide must be inspected JSA 100HR A1 100 Hour Annual Inspection Checklist Page 17 of 17 THIS PAGE INTENTIONALLY BLANK Jabiru J230 SP J250 SP Aircraft Service Manual Jabiru J 230 5 amp J 250 SP Quick Reference Maintenance Guide uel Filter ir Filter NAPA 6116 or K amp N 33 2031 2 park Plug park Plug Gap park Plug Tension gnition Coil Gap ead Bolt Tension rop Bolt Tension 17 19 ft lbs Main Tire Pressure ose Tire Pressure After initial 25 hour engine break in period Main Tire Pressure NOTE All S LSA aircraft must have a logbook endorsement for return to service by an A amp P or LSA Repairman with Maintenance Rat
240. s Individual pages affected by revisions are listed in the Revision Summary at the front of this manual and are available for download as a batch PDF file at www usjabiru com Each page of the manual lists the document number with an issue letter and change indicator suffix For example SA 5 2305 is the original release of a section in Issue A of JSA SM230SP J SA SM230SP B3 is the third revision of a section in Issue B of J SA SM230SP Section revisions are listed on the List of Effective Sections page near the front of the manual Appendix documents are controlled separately by the Appendix Log located immediately after the last section of the manual Owners are responsible for keeping the List of Effective Sections Appendix Log and the Record of Revisions updated when handbook revisions are issued A cur rent List of Effective Sections and the Appendix Log may be found at the J abiru USA website www usjabiru com Revisions to this Aircraft Service Manual are available for download on the J abiru USA website Revisions on paper or CD are available for a fee upon request Distribution will include new pag es for the sections that have changed a new List of Effective Sections or Appendix Log and any necessary instructions Revisions should be examined immediately upon receipt and incorpo rated into this handbook per the instruction provided Owners should contact J abiru USA when ever the revision status of their service ma
241. s described in Paragraph 8 8 JSA SM230SP A1 8 5 Section 8 Fuel System 8 7 8 6 3 8 6 4 8 6 5 Jabiru 230 5 250 5 Aircraft Service Manual 2 Turn sump drains out of the bottom of the tank with the wrench Inspection Inspect sump drains for proper seating If a sump drain sticks or drips fuel there is probably debris in the seat that needs to be washed away Repair Repair of sump drains Is limited to cleaning or replacement Reinstallation Reverse the steps in 8 6 2 for installation Add a small amount of fuel to tank then check drain for leaks Fuel Gauges 8 7 1 8 6 Description There 5 one resistive float type fuel quantity sender in the root end of each main wing tank Each sender is wired to its own set of LED fuel gauge indicator lights on the in strument panel EIS equipped aircraft Garmin G3X aircraft the gauges are programmed into the EFIS and the LED lights are omitted Each fuel gauge consists of a group of four green LEDs and one red LED Each LED rep resents approximately two gallons of fuel When the corresponding tank contains two gallons or less the red LED will light and the four greens will be dark Because of the shape of the fuel tank the wing dihedral and the placement of the sender anything over 10 gallons will register as four green LEDs For the same reasons the G3X fuel level indicator will not read completely full when the tanks are f
242. s there is no delamination or damage to underlying structures Damage to leading edge skin 1 Cut out damaged area Prep area as described in Paragraph 12 3 1 1 2 Carve a Styrofoam block insert to fit the contour of the leading edge Insert Styrofoam into leading edge area to maintain shape Cover with four layers of 9 oz cloth as detailed in Paragraph 12 3 1 Overlap damaged area by two inches Apply peel ply Finish and repaint according to Section 12 4 Paint and Refinishing 12 3 4 Damage to Underlying Structure Damage of any kind to structures that support the skin of any of the aircraft structural components must be reported to the manufacturer The manufacturer must evaluate the damage and in consultation with J abiru Aircraft Pty Ltd will make a determination of whether the damage is repairable The manufacturer will then issue an appropriate repair procedure or will specify that components must be replaced The integrity of the underlying structure is critical to the structural integrity of the air craft Any damage to any of the underlying structure is considered major damage and careful application of specific repair procedures provided by the manufacturer is re quired 12 4 Paint and Finishing 12 4 1 Description The paint finish is an automotive base coat clear coat system similar to modern auto mobiles using either PPG or Matrix systems Paint codes for the base white are Aircraft s n prior to 702 PPG WA8624 GM
243. sembly 5 5 1 Description The main gear leg is a molded fiberglass lamination of 10 oz unidirectional fiberglass Figure 5 1 Main Undercarriage Assembly illustrates the main landing gear Page 5 4 JSA SM230SP A1 Jabiru 230 5 250 5 Section 5 Aircraft Service Manual Landing Gear and Brakes 5 5 2 Removal Tools Required Screwdriver set 7 16 1 2 and 9 16 wrench es Level of Certification Required A amp P or LSA R M M The following procedural steps involve removal of one side of the landing gear as a complete assembly Refer to applicable paragraphs for removal of the individual com ponents 1 Peel back the carpet in the baggage area to reveal the main landing gear mounting bolts 2 Jack the aircraft in accordance with the details given in Section 2 3 Disconnect the top end of flexible brake hose catching brake fluid in a container Take care to avoid dripping brake fluid onto the center console as it will damage the finish 4 Remove bolt and nut from top inboard end of undercarriage beam Remove rubber bushings 2 5 Remove bolts nuts 2 from the clamp at the bend in undercarriage beam 6 Remove clamp and main landing gear leg assembly 5 5 3 Inspection NOTE Gear leg attach bolts must be replaced every 500 hours total time Re fer to abiru USA Service Bulletin J SA 003 1 for more information 1 Check for looseness of main gear legs by lifting each wing and trying to move gear legs fore and a
244. ses should be checked for leaks 2 Remove fire sleeve from fuel hoses Examine the exterior of hoses for evidence of leakage or wetness 3 Replace any worn or cracked hoses 7 12 4 Repair Repair of hoses is limited to replacement 2 Aeroduct SCAT hose 2 1 4 Aeroduct SCAT hose 1 4 ID 1 2 OD 50 PSI Oil breather line 1 2 ID marine fuel line or automotive heater hose Fuel pump overflow line General purpose clear PVC tubing 3 16 ID 3 8 OD 3 32 wall Table 7 1 Replacement Flexible Hoses 7 12 5 Reinstallation NOTE Rubber hoses will take a permanent set during extended use in service Straightening a hose with a bend having a permanent set will result in hose crack ing Care should be taken during removal so that hose is not bent excessively and during reinstallation to assure hose is returned to its original position SM230SP A2 Page 7 21 Section 7 Engine Systems Jabiru 230 5 250 5 Aircraft Service Manual Lines and hoses must not be twisted on installation Provide as large a bend radius as possible Lines and hoses must have a minimum of 12mm clearance from other hoses or surrounding objects or be tie clamped to them to minimize chafing WARNI NG Fuel lines within the engine compartment are fitted with fireproof sleeves If removed the sleeves must be reinstalled before aircraft is returned to service 7 13 Throttle Control 7 13 1 Description A stiff stranded wire throttle cable
245. stem 6 5 1 6 5 2 6 5 3 Page 6 12 Description The elevator control system is comprised of the elevator control surface the control column described in Section 6 1 and one enclosed push pull cable fitted with rod bear ings at both ends as described in Section 6 2 The elevator control surface consists of a rigid cellular polystyrene core molded and bonded to a composite skin incorporating a composite control horn at the center An elevator trim system 15 attached and de scribed in Section 6 6 NOTE Control column and control cables are primary controls and may not be removed or repaired without reference to Jabiru USA Sport Aircraft LLC or our approved local agent Troubleshooting Operate the elevator control while observing for friction and interference The trim spring mechanism places some tension on the control however the elevator should move stop to stop with no rubbing scraping or other mechanical interference inter ference is detected isolate problem and correct Sudden onset of friction or strange interference in the elevator control may be due to a damaged autopilot servo Removal of Elevator Tools Required Screwdriver set 7 16 wrenches Level of Certification Required A amp P or LSA R M M 1 Remove ventral fairing from lower rear fuselage 2 Unbolt elevator cable from control horn 3 Unbolt trim linkage from control horn For aircraft with six hinge pins the elevator 2008 models and
246. straightedge Make this ad justment with the cable rod ends ensuring that on completion the locknut is tight on the rod ends and the cable is visible through the inspection hole in the rod end 2 Check UP travel on both ailerons Up travel should be 18 20 degrees Down trav el should equal 10 degrees or more 3 Usethe aileron control stop adjustment see Figure 6 3 Aileron Rigging to adjust the total aileron movement i e UP travel and use cable adjustment as previously described to proportion UP and DOWN travel The aileron control stop should en gage before the aileron arm hits the UP travel stop at the wing tip DO NOT move the cable anchors these positions have been set using a jig V WARNING Aileron cable must be connected to the same side of the control column bell crank as the wing to which the aileron is fitted otherwise control surface reversal Will result DO NOT CROSS CABLES JSA SM230SP A1 Page 6 5 Section 6 Jabiru 230 5 250 5 Flight Controls Aircraft Service Manual GO 2 a 1 4 2 Drawing 5011094 2 AILERON CONTROL STOP ASSEMBLY LOCATE TEMPLATE ON TOP OF WING AND ADJUST AILERON UP 2 amp DOWN TRAVEL NOTE THIS WASHER 13 LARGER TO COVER ROD END BALL ADJUST STOP STUDS amp CABLES TO ACHIEVE AILERON TRAVEL USE TEMPLATE TO MEASURE amp ENSURE BOTH AILERONS ARE ADJUSTED TO TEMPLATE ANGLE Drawing 9014093 1 AILERO
247. t cover To reinstall or replace the aluminum funnel 1 Attach the aluminum funnel to the air line in the same manner as the reed bell housing Make sure there is enough extra air line to provide easy access to either end but not so much that it will kink inside the wing 2 Prepare the area of the funnel that will contact the wing skin A new funnel should be scuffed for proper adhesion to the epoxy Clean up a reused funnel so that it fits nicely within the hole in the wing skin Recess the surface of the funnel enough that the screen can be laid over the top of it and be flush with the outer surface of the wing skin 3 When satisfied with the fit attach the funnel securely to the wing skin using 5 minute epoxy To reinstall or replace the air line 1 Remove the both the reed bell end and the aluminum funnel from the air line but DO NOT pull the line out of the wing 2 Thread a long flexible piece of cord or wire through the air line so that it extends out of both ends of the line 3 Firmly attach one end of the cord to the new air line Carefully pull the cord and old line out threading the new line through the wing J SA SM230SP A0 Page 10 3 Section 10 Jabiru 230 5 250 5 Utility Systems Aircraft Service Manual To reinstall the screen and divider plate 1 Clean up the edges of the hole and slot for the divider plate as necessary Mix a batch of 5 minute epoxy and glue screen and divider plate in place tak
248. t of the vent but allow for the release of air pressure inside the tanks therefore it is normal for small amounts of fuel to reach the fuel tank vents The header tank vent Is inde pendent of the main tanks exiting the right wing tip beginning with aircraft serial num ber 795 Removal Level of Certification Required A amp P or LSA R M M Consult J abiru USA Sport Aircraft LLC for any necessary removal of vent lines as they are built into the wing structure V WARNING Make sure all fuel 15 drained from system before remov ing fuel lines To remove or inspect fuel lines and check valves 1 Remove the top and bottom wing root fairings to access the fuel lines and check valves in the wing roots J SA SM230SP A1 Jabiru 230 5 250 5 Section 8 Aircraft Service Manual Fuel System 2 access fuel lines and valves inside the cabin doorposts remove the nut from each doorpost fuel valve Carefully pull the upholstery panel from the doorpost around the valve Some aircraft utilize screws and Velcro to keep the upholstery in place while others use only Velcro 3 Remove lines or valves as necessary by loosening hose clamps 8 3 3 Inspection 1 Remove the caps from the wing root check valves to avoid building pressure in the tanks Then blow air through the vent lines to make sure they are clear Replace the caps 2 Inspect the fuel lines for cracks or leaks 3 Inspect all three fuel valves for smooth operation and fu
249. tely 30 degrees to the vertical outboard of the top wing attachment point Ensure that the ropes have sufficient Slack to not strain the wing attachments should a tire deflate while the aircraft is tied down Tie a third rope to the tail tie down hole in the ventral fin and secure to ground an chor To keep rain water animals and curious onlookers out of the aircraft always use a Jabiru USA Bruce s Custom Covers aircraft cabin cover and close all fresh air vents when parking the aircraft outside Make sure the 5 under wing straps are snugged up tight to seal the wing roots from rainwater entry Cowl pitot static and fuel vent plug cover sets are also available from J abiru USA and recommended for outdoor tie down 2 8 1 Placing Aircraft in Flyable Storage Flyable storage is defined as a maximum of 30 days non operational storage 1 Ensure that the engine has been stopped by turning off the fuel valve and running the engine until it quits to remove the fuel from the carburetor bowl Remember to turn OFF the Master and gnition switches Every 7th day the propeller should be rotated through 5 revolutions without run ning the engine Leave the propeller in the horizontal position to ensure even dis tribution of moisture in the wood If left in the vertical position moisture will drain to the lower tip resulting in an unbalanced propeller In ideal conditions the aircraft should be stored away from direct sunlight At
250. tenance as permitted in the Aircraft Service Manual JSA SM170SP on E LSA aircraft that they own and make the logbook endorsement for return to service as specified by FAR 43 9 Owner s Name Address City State Zip Registration Number Airframe Serial Number Engine Serial Number Hours ________________________________________________ Date Inspection Completed Servicing Agency Address City State Zip Phone Number Name of Repairman JSA 50HR A1 25 50 Hour Inspection Checklist Page 1 of 9 Jabiru 230 5 250 5 and J 170 SP Aircraft Service Manual Inspection ntervals The time periods for the inspections noted in this schedule are based on normal usage under average environmental conditions Airplanes operated in humid tropics cold damp climates etc may need more frequent inspections for wear corrosion lubrication and or lack of maintenance Under these adverse conditions perform periodic inspections in compliance with this guide at more frequent intervals undil the owner or operator can set his or her own inspection periods based on the contingencies of experience Airplanes operated commercially less than 100 hours per year must have a 100 hour inspection performed no later than 12 months following the date of the preceeding 100 hour inspection The 100 hour interval between performances of the procedures specified herein should NEVER be exceeded by more than 10 hours which can be used only
251. the cabin door frame Removal Tools Required Phillips 32 screwdriver Level of Certification Required Owner A amp P or LSA R M M Upper Cowl 1 Remove the three cam locks from the rear of the top cowling and the two screws from the nose cone of the cowl 2 Remove hinge pin located in the door frame on each side 3 From the side of the aircraft grasp the front edge of the cowl with one hand and slide fingers of the other hand under the rear edge Pull carefully upward until the lower edge of the cowl clears the upper edge of the spinner then lift the cowl off 4 Replace the cam locks in the cowling to ensure they are not misplaced NOTE Always ensure that the cowl is placed in a position where it cannot be damaged by people walking around the aircraft or by wind Lower Cowl 1 Remove the upper cowl 2 Disconnect the engine air inlet SCAT hose and cabin heat inlet hose 3 Remove screws at rear of cowl Support the lower cowl as screws are being re moved It helps to have an assistant while removing lower cowl JSA SM230SP A2 Page 7 5 Section 7 Engine Systems 7 3 3 7 3 4 7 3 5 Jabiru 230 5 250 5 Aircraft Service Manual Inspection and Cleaning Inspect upper and lower cowls for cracks tears in the fiberglass or delamination In spect cowling camloc mounts for rigidity bonding and wear Inspect locking pins for damage Inspect rubber grommets firewall for wear or damage 1 Wipe th
252. the floor is a level surface 2 Check that each blade clears the object by the same amount Maximum tracking error tolerance is 2mm If the propeller is outside the approved tolerance refer to Sensenich Wood Propeller Company or Jabiru USA Sport Aircraft for service 9 6 Approved Installations for J 230 SP and 250 SP SENSENI CH W64Z7K 49 SENSENI CH W60ZK 53 SENSENICH W60ZK 55G SENSENICH 2 0 5R64Z N NOTE Any change in propeller pitch or diameter will likely require carburetor jet ting adjustment ich ind onstruction _ 53 WOOD FIBERGLASS 55 WOOD FIBERGLASS GROUND AD USTABLE Table 9 2 Approved Propeller nstallations 9 7 Identification Stampings Each wood propeller is marked with the model number the diameter and pitch inch es part of model number and manufacturer s serial number the propeller hub Page 9 6 J SA 5 2305 1 Jabiru 230 5 250 SP Section 9 Aircraft Service Manual Propeller amp Spinner FOR CORRECT TORQUE DETAIL BELLEVILLE WASHER ASSY SEQUENCE FOR TIGHTENING PROPELLER BOLTS 1 4 6 2 5 2 3 5 7 2 5 INSTALLATION SEE DETAIL E D FOR ANCHOR 1 2 Figure 9 1 Prop Mount Detail Note Spinner mount screw 4 in diagram has been replaced with 8 truss head machine screw Washer 3 in diagram has been replaced with one flat Nylon washer JSA 5 2305 1 Page 9 7 Section 9
253. tom attachment These are NAS close tolerance bolts and may be difficult to remove Pull strut away from the fuselage attachment while moving the strut up and down WARNING DO NOT put fore and aft pressure on the strut or strut attachment while removing as this may damage strut attach points J SA SM230SP A0 Jabiru J 230 SP 250 SP Section 4 Aircraft Service Manual Wing Structure 4 2 3 4 2 4 4 2 5 Inspection Check for any loose or damaged bolts at each end of the strut Check for nicks cracks or dents in the strut body Check to see that struts are straight and not twisted Repair Wing struts are structural components and repairs are mostly limited to replacement The strut bolts that attach the ends to the main body of the strut may be replaced if the strut itself shows no signs of other damage Nicks cracks and other damage must be referred to J abiru USA Sport Aircraft LLC for determination of reparability and issuance of repair instructions A dented cracked or deformed wing strut must be replaced prior to next flight Reinstallation V WARNING Do not apply any fore and aft force to the strut during the installation as this may damage strut attach points 1 Place inboard end of strut onto the fuselage strut attachment lug 2 Insert new AN5 NAS bolt through the strut and the lug bushing 3 Install the washer and nut and tighten carefully to the point where the washer can not be rotated Then lo
254. trical System and Instruments Aircraft Service Manual Page 11 12 6 10 11 12 Turn the right knob to move the cursor over Display Unit Maintenance then press the knob to activate Use the right knob to move the cursor over Load EFIS Software and press the knob to activate Rotate the same knob clockwise to activate the EFIS upgrade page Insert the USB drive into the USB port in the back of the unit on the upper co pilot s side corner The back of the unit is accessible through the access opening in the bottom of the instrument panel Wait for the EFIS to detect the USB drive and download the files The EFIS may take up to one minute to detect the USB drive The light on the USB drive should blink faster when detected and when data is being copied The light will blink slow er when the operation is complete When the EFIS has completed copying files from the USB drive the display unit will reboot After reboot verify the power up page displays the new EFIS software ver sion Repeat for the MFD OR load navigation database into the PFD as described below Update Navigation Database 1 2 5 Repeat steps 4 6 above Use the right knob to move the cursor over Load Navigation Database and press the knob to activate Wait for the EFIS to detect the USB drive and download the files The EFIS may take up to one minute to detect the USB drive The light on the USB drive should blink faster when detected and whe
255. uel and Alpine fuel and many other sub divisions are sold depending on the time of year and the location of the fuel station These fuels all have slightly different recipes designed to provide the right vaporization octane number etc for an engine operating in the given environment Fuel bought at the top of a snow covered mountain in winter is not suitable for use sea level during a summer heat wave This is another reason why long term storage of MOGAS for aircraft use is not recommended JSL007 3 doc dc id Page 8 of 14 Compression Ratio Fuel Guidance JSL 007 3 5th Nov 2009 WARNING Use of alcohol in any J abiru aircraft manufactured by J abiru USA 6 Alcohol Sport Aircraft LLC is PROHIBITED See Service Bulletin J SA 006 for more 6 1 General information available on www usjabiru com e Worldwide debate on using Ethanol as an aircraft fuel continues The problem is that while it is a good fuel while the engine is running it becomes a significant maintenance and storage issue whenever the aircraft is parked These issues must be addressed if an aircraft is to operate safely on a fuel containing alcohol 6 2 Alcohol Good Points e Alcohol is a renewable fuel which arguably produces less carbon dioxide than fossil fuel e Alcohol burns cleanly and has an octane boosting effect 6 3 Alcohol Bad Points e Ethanol is hygroscopic i e it will mix with water This can be water vapour from the air condensation inside t
256. uel of this type The following CASA document is current at the time of writing Airworthiness Bulletin AWB 2828 003003 Important Note For Jabiru Aircraft Only aircraft with white coloured fuel tank sealant can use fuel containing alcohol Earlier tanks use a caramel coloured sealant this sealant is soluble in alcohol amp must not be used with an alcohol blend fuel Fuel tanks with caramel coloured sealant may be re sealed with white sealant contact Jabiru Aircraft or our local representative for details Figure 4 shows the sealant colour as seen through the filler Figure 4 Fuel Tank Sealant Colours White on Left 6 4 Individual Items Carburettor Suitable for use with fuels containing alcohol Carburettor inspection recommended after 200hrs or 6 months using fuel containing alcohol Mechanical Fuel Pump Suitable for use with fuels containing alcohol No additional maintenance required for up to 1096 alcohol The pump manufacturer does not recommended using fuels containing more than 10 Operational experience with fuels containing higher percentages has shown that the mechanical fuel pump is tolerant of higher levels of alcohol Carburettor Connection Suitable for use with fuels containing alcohol Electronic Fuel Pump Suitable for use with fuels containing alcohol O Rings Suitable for use with fuels containing alcohol Black Fuel Hose Suitable for use with fuels containing alcohol Blue Fuel Hose Suitable fo
257. ull NOTE When the aircraft 15 flown in an uncoordinated condition the fuel gauges may temporarily read inaccurately due to float position and sloshing of fuel in the tanks The fuel quantity reading should return to normal within several seconds of aircraft stabiliza tion Pilots are strongly encouraged to visually check fuel quantity before each flight using a calibrated fuel dipstick Fuel dipsticks are available through J abiru USA Sport Aircraft LLC Gauge Reading Fuel Quantity 4 GREEN 8 17 gal 3 GREEN 6 8 gal 2 GREEN 4 6 gal 1 GREEN 2 4 gal RED Less than 2 gal J SA SM230SP A1 Jabiru 230 5 250 5 Section 8 Aircraft Service Manual Fuel System 8 7 2 Removal of Float Senders Level of Certification Required A amp P or LSA R M M 1 Drain fuel from fuel tank as described in Paragraph 8 8 2 Remove wing root fairings 3 Remove wing as described in Section 4 1 4 Remove the 4 screws that mount the sender in the tank 5 Remove sender 8 7 3 Inspection Inspection is limited to checking the float for pin holes or leaks 8 7 4 Repair Repair is limited to replacement of the float sender 8 7 5 Reinstallation 1 2 JSA 5 2305 1 Prior to reinstallation clean all sealant from the mounting surfaces Apply a small amount of Permatex 2 gasket sealant to the mating surface of the sender Install the sender in the wing Install the four 8 truss head machine screws with a small a
258. urn counterclockwise until screw stops turning 3 Pull transponder from tray 11 12 3 Inspection 1 Check pin connections at rear of transponder for damage 2 Inspect tray for bent pins or loose connections 3 Inspect antenna coax for damage 4 The transponder must be tested as required by FAR 91 413 11 12 4 Repair 1 Repair of bent pins can be made by standard radio repair procedures 2 Repair of the transponder itself is limited to sending it to an approved repair center 11 12 5 Reinstallation Reverse the steps in Paragraph 11 12 2 for reinstallation J SA SM230SP A1 Page 11 19 Section 11 Jabiru 230 5 250 SP Electrical System and Instruments Aircraft Service Manual 11 13 Emergency Locator Transmitter 11 13 1 Description All Jabiru S LSA aircraft are equipped with an Emergency Locator Transmitter The unit is located on the floor of the fuselage behind the baggage area A remote switch is lo cated in the instrument panel for testing the unit Aircraft built prior to 2009 are equipped with an AmeriKing AK 450 VHF radio based ELT Aircraft built in 2009 and newer are equipped with a Kannad AF Compact 406 MHz satellite based ELT 11 13 2 Removal Tools Required 7 64 Allen key screwdriver set Level of Certification Required A amp P LSA R M M or Avionics Repair Station 4 5 Turn off the ELT Disconnect remote cable Disconnect antenna coax cable Loosen hold down clamp or undo the Velcro strap
259. vaNrna T LH Vd OL 3H 3H Ha DINIH 280 330 MOI SZ Full 6 98 010 0 TOHM B39NVH3701 Ald HO2LAY JO LNOHUM 031800 x 38 LON LHOTHAdOO SI SNIMVHO Md HO3LAV 00 NI He rr HBHERSN H6 MS 544015 TIY 1 1 2 55 00 80 OZ SdOLS 6 A0S2Z WL ASZL VE NO ANVINSWOW 1545 HOLMS 1 NZ6O0ld 8 ASSY MOLLS 3HIN3O 5 90 920 Sk 2 5 t 2 4 OMT 1913 M Ob 8 PETE ENV 8 S 8 260 5960086 2 6 X 0OLO96NV H3OVdS 55982006 5 LON GO 52 01 Z PBOLLLE L ALY id LOAld 5 3HIN3O 218100 0039209 wu AIO LOAld XOLLS 3HLIN3O 008 809 z 5 WILI 1041405 b Page 6 3 FIN Figure 6 2 Control Column New Style JSA 5 2305 1
260. ve rust not removable by normal braking should be cleaned using a wire brush followed by 220 grit sandpaper Take care not to remove plating from areas not contacted by brake pads 5 7 5 Replacement of Brake Pads Contact Matco Mfg for replacement brake shoes with pads already installed for a fast replacement Follow instructions below to replace the pads linings on the existing shoes From Matco Mfg Technical Service Bulletin for MHE51 Series Wheels and Brakes Revi sion D J une2007 1 JSA 5 2305 1 Remove the caliper from the wheel by removing the two MSCAN4H9 16A bolts that hold it on Remove old linings by drilling the crimped side of the rivet Do not use a punch amp hammer Using a 25 drill 0 1495 diameter drill through rivet taking care to avoid damaging the rivet hole After drilling crimped edge off rivets lift old lining and remaining rivet pieces from the brake shoe Inspect the brake shoe for any bending or other damage that may have occurred during service A shoe with more than 0 010 bend should be replaced Inspect rivet holes to ensure that no damage has occurred during removal Using a brake relining tool recommends a Threaded Screw Action such as the W404 from Aircraft Tool Supply Co or pneumatic press replace the lining us ing the brass rivets shown on the illustrated parts list and install the hub Page 5 9 Section 5 Jabiru J 230 5 250 SP Landing Gear and Brakes Aircraft S
261. ved during operation of trim or elevator Repair Repair is limited to the replacement of defective parts As the trim control cable is a primary control it may not be repaired without reference to J abiru USA Sport Aircraft LLC or our approved local agent for the appropriate repair procedure Reinstallation Trim cable reinstallation requires a special procedure from the manufacturer There fore it may not be reinstalled without reference to J abiru USA Sport Aircraft LLC or our approved local agent for the appropriate reinstallation procedure J SA 5 2305 1 Section 6 Flight Controls Jabiru 230 5 250 5 Aircraft Service Manual Z EZ00SZE 005770027 ATEWASSVTOULNOO oerousavanna YIDNIH sq SSTINN 8 Ald HOBLAY 30 LN3SNOO LNOHLIM 091800 NI p 38 LON ISIN LHEFYAcOO SI ONIMVMC SIH L Vd FWOSLONOD Joo 4 wa d 39014 9 ILIO TYY SIHL JO 6 SLASHS NI NMOHS SY ATHASSSY ONISN TOULNOS 3 3 1dWOO IHL HOS NSAID H3H13901 SW3ll LYVd niuravr NON Z NHHL S Z 40 IN 5 Casinos 1108 H31MOHS ISN 3HY NSAID SHL NT
262. vice Bulletins that are not published in this manual or on J abiru USA s website It is the responsibility of the mechanic and owner operator to ensure that all documents used during maintenance are current and that all applicable Service Bulletins and Air Safety Alerts are complied with 230 SP 250 SP S LSA All Al 16 May 2011 Service Schedule 25 and 50 Hour Inspection Guide 16 May 2011 100 Hour Annual Inspection Guide 16 May 2011 Jabiru 230 5 amp 250 5 All Al 16 May 2011 Quick Reference Maintenance Guide 5 501 1 Malfunction or Defect Report 1 April 2010 Service Letter J SL 007 3 1 and 9 Al 16 May 2011 Fuel Guidance Ethanol Warning Control Surface Throw Templates 1 April 2010 Vendor Contact Information 1 Al 16 May 2011 Jabiru PTY LTD website added J SA SM230SP A1 Page 1 of 2 Jabiru 230 5 250 5 Aircraft Service Manual Appendix Log THIS PAGE INTENTIONALLY BLANK JSA SM230SP A1 2 2 Jabiru J230 SP J250 SP Aircraft Service Manual J abiru J 230 SP 250 SP S LSA Maintenance Schedule 1 Reference Min Qualification Aircraft Affected Required By 25 Hours Total Time JSA 50HR A amp P or LSA R M M Engine manufacturer Aircraft Service Manual or Only aircraft equipped Sensenich Doc COMP A amp P or LSA R M M with Sensenich Ground AC CF Adjustable Carbon Prop Each 50 Hour nterval JSA 50HR A amp P or LSA R M M manufacturer Inspection FAA Ord
263. well socket flat screwdriver fuel line pliers Level of Certification Required A amp P or LSA R M M Run engine if possible Empty fuel from the main fuel line by turning the main fuel valve to the OFF position and letting the engine quit due to fuel starvation Turn master and ignition switches to the OFF position after the engine quits 2 Remove fuel filter by loosening the hose clamps and pulling the lines off of the filter fittings 8 5 4 Inspection 1 Inspect finger filters by looking for blockages Clean if necessary 2 Ifthe main fuel filter is housed in clear plastic visually inspect by checking for dirt particles or blockages 8 5 5 Repair 1 Repair of finger filters is limited to cleaning 2 Repair of main fuel filter is limited to replacement See Section 1 9 for part number 8 5 6 Reinstallation 1 Reverse instructions in 8 5 2 for finger filters or 8 5 3 for main fuel filter 2 Reinstall wing root fairings according to the appropriate section of this manual Fuel Sump Drains 8 6 1 Description Three spring loaded fuel sump drains allow pilot or mechanic to drain fuel from the tanks for daily sample or fuel removal There is one sump drain in the rear root end of each wing tank and one in the bottom of the header tank which protrudes from the bel ly of the aircraft 8 6 2 Removal Tools Required 5 8 wrench Level of Certification Required A amp P or LSA R M M 1 Drain fuel from the affected fuel tank a
264. wiring 11 14 4 Repair Repairs to the intercom must be referred to PS Engineering 11 14 5 Reinstallation Reverse the steps in Paragraph 11 14 2 for reinstallation 11 15 TruTrak DigiFlight Autopilot 11 15 1 Description The DigiFlight IIG autopilot is two axis autopilot with an altitude hold heading hold and GPS steering capabilities The pitch servo is mounted behind the baggage bulkhead on the pilot s side floor It is attached to the elevator through the use of a captured cable system NOTE Most air craft have the pitch control cable installed at the factory regardless of whether the air craft is ordered with an autopilot This makes retrofit of a new autopilot much easier For retrofit instructions please contact J abiru USA Sport Aircraft LLC In airplanes with the new style center console generally 2008 and newer the aileron servo is mounted to the plate between the seats used to anchor the aileron cables and is connected to the aileron system via a control rod directly to the aileron mixer at the rear of the control stick In aircraft with the old style center console the roll servo was mounted on the floor behind the passenger seat and connected to the aileron mixer using a push pull rod JSA 5 2305 1 Page 11 21 Section 11 Jabiru J 230 5 250 SP Electrical System and Instruments Aircraft Service Manual Figure 11 7 Autopilot servos Pitch servo installation all years top l
265. y J SA 5 2305 1 Jabiru 230 5 250 5 Aircraft Service Manual 4 The owner operator of this aircraft shall be responsible for complying with all manufacturer notices of corrective action and for complying with all applicable aviation authority regula tions in regard to maintaining the airworthiness of this aircraft 5 The owner operator of this aircraft shall ensure that any needed corrective action be com pleted as specified in a notice or by the next scheduled annual inspection 6 Should an owner not comply with any mandatory service requirement the aircraft shall be considered not in compliance with applicable ASTM standards and may be subject to regula tory action by the presiding aviation authority Handbook Revisions It is the responsibility of the owner to maintain this manual in a current status when it is being used for maintenance purposes For the convenience of owner operators and mechanics the most current version of the manual is now available for download in the LSA Owners section of the Jabiru USA website www usjabiru com A major release of the handbook is called an Issue while a section release is called a Revision This manual utilizes section level revision control revision indicators are consistent throughout an entire section but may vary among sections as they are revised Owner operators and mechanics may replace the entire section or only the affected pages when updat ing printed manual
266. y cleansers approved for acrylic based plastics on and near the windows V CAUTION Do not use silicone based cleansers as these may soak through the finish and into the fiberglass and af fect future reparability of the components V CAUTION DO NOT use glass window cleaning spray gasoline alcohol benzene acetone carbon tetrachloride fire extinguisher fluid de icer fluid or lacquer thinner These solvents will soften and craze the plastic V CAUTION DO NOT use a canvas cover on the windshield or win dows as the cover may scratch the plastic Factory Issued aircraft covers have a cotton inner layer to pro tect the windows 2 11 2 Interior Surfaces and Upholstery The interior may be cleaned using standard automotive upholstery cleaners made for the particular type of covering carpet leather vinyl or cloth EFIS screens and instruments may be cleaned using a soft cloth and a cleanser made for LCD screens V CAUTION Do not use silicone based cleansers as these may soak through the carpet and into the fiberglass affecting fu ture reparability of the components JSA 5 2305 1 2 13 Section 2 Jabiru J 230 SP 250 SP General Care amp Inspection Aircraft Service Manual Volatile substances such as those mentioned in Paragraph 2 11 1 must never be used Interior painted surfaces may be cleaned using the same automotive cleaning materials as the exterior surfaces 2 11 3 Aluminum Surfaces The alumi
267. y signs of delamination or cracking Pay particular at tention to the control horn and hinges and their surrounding areas 2 Check for continuity in all switch positions and proper flap angle indication Page 6 8 SM230SP A1 Jabiru J 230 SP 250 SP Section 6 Aircraft Service Manual Flight Controls 3 Check for cracks and twists in the control rods Check for oblong bolt holes 4 Check for chafed wires near motor switch and position sensor 5 Check position sensor clevis for binding wear and proper connection 6 4 5 Repair of Flap Components 1 All control surface damage involving cracking delamination or hinge dam age must be referred to J abiru USA Sport Aircraft LLC or approved local agent for an appropriate repair procedure 2 Repair of switch motor indicator or potentiometer is limited to replace ment 3 Replace worn or damaged control rods and fittings 6 4 6 Reinstallation of Flap Components Tools Required Angle finder 3 8 or 7 16 wrenches Level of Certification Required A amp P or LSA R M M V WARNING All spherical rod end bearings must be fitted with a large washer on the outside of the through bolt to pre vent the bearing case and cable from releasing in the event of a bearing failure 1 Reverse the steps in 6 4 3 1 for installation of flap control surface Replace all four nyloc nuts Torque only until the flap hinge begins to bind then loosen slightly 2 Reverse the steps in 6 4 3
268. y so that they can be installed in exactly the same position to ensure that wheel alignment is not disturbed 4 Remove 4 bolts nuts washers securing axle to main gear leg Inspection 1 Check to see if axle is bent or cracked 2 Check for gouges or scratches in bearing seat areas Repair Repair is limited to replacement with new part Reinstallation 1 Secure axle and brake assembly to composite leg with the proper AN4 bolts mak ing sure that any wheel alignment shims are installed in their original position 2 Install wheel assembly on axle in accordance with Paragraph 5 7 7 Main Wheel Realignment Tools Required 7 16 wrenches Parts Required AN washers 5 min epoxy and cotton flock Level of Certification Required A amp P LSA R M M 1 Main wheel axles must be aligned for proper ground tracking Refer to Figure 5 3 2 Axles must be parallel with no toe in or toe out Positive camber is acceptable amount of camber is not critical to handling but may affect tire wear 3 Very small adjustments can be made by sanding the fiberglass gear leg as shown Figure 5 3 Adjustments more than 1 32 must be accomplished using shims 4 Shim with AN 4 washers on bolts between gear leg and axle as necessary Epoxy and flock washers into place when proper alignment 15 established JSA 5 2305 1 Page 5 7 Section 5 Jabiru 230 5 250 5 Landing Gear and Brakes Aircraft Service Manual 5 7 Main Wheels and Br
269. zzle of a squirt can of brake fluid to the top of the brake bleeder valve Pump the handle until fluid flows bubble free from service hose be fore attaching Make sure that the master cylinder shaft is fully extended to open up the internal bypass valve Inject brake fluid DOT 4 or equivalent into the puck housing and continue inject ing until the fluid travels through the system in to the master cylinder Air in the system will be pushed up and out in to the master cylinder ONLY IF the master cylinder or remote reservoir is at the highest point in the system and there are no loops in the brake lines Fluid should be pushed through the system until it reaches approximately 24 inch from the top of the master cylinder Close the brake bleeder valve and remove the service hose Page 5 17 Section 5 Jabiru 230 5 250 5 Landing Gear and Brakes Aircraft Service Manual 5 8 8 Page 5 18 8 10 If the brake system is free of air the brake lever should feel firm and not spongy If not repeat steps 1 through 7 until the system is free of trapped air Fluid leakage from the top of the master cylinder during operation indicates too high a fluid level Ensure that all drilled bolts are properly safety wired NOTE The Master Cylinder is NOT approved for inverted flight Matco Mfg Brake Conditioning Procedure It is important to condition the new linings after installation to obtain maximum service life and per

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