J200-J400 Technical Manual Part 1
Contents
1. 11 Switches FUSES sc iere ia E ERES u i 12 Pitot and static systemslips i l 13 Radio intercom and headsets 14 Antenna and cable p 15 Battery battery cradle and cables sa 16 Battery electrolyte If Applicable Page 2 14 Issue 1 Date 220801 CONTROL SYSTEMS In addition to the items listed below always check for correct direction of movement particularly if controls have been disconnected and correct travel Annual Inspection Each 200 Hours Each 100 Hours Each 50 Hours 1 Cables and cla iris o e xA ee ki 2 KOU CHAS EE x 3 Trim control and cable k 4 Travel STOPE aeo Ee A paquete ee se 5 Decals and labels 6 Flap controls and linkages 7 Elevator control and linkages k 8 Rudder pedals and linkages sa 9 Exterior surfaces of control surfaces Ga 10 Control horns hinges and hinge lock tabs Page 2 15 Issue 1 Date 220801 SECTION 3 FUSELAGE Table of Contents Paragraph BUS CLA BS P ae 3 1 Windshield2. 3 Cylmd rs sus ca ien RO EN EENS 4 Crankcase and front crankcase seal de Hoses lines and fittings 6 Intake and exhaust systems 7 Ignition are eege ya cent ieee andes T ka 8 Spark plugsu ov ced cee id 9 Compression check ka TO Blectrical Wining oo sousye Ere s t vave pies AN Ii pune eod ee 12 Engine controls and linkages T ki 13 Engine mounts mount structure 14 Starter solenoid and electrical connections i 15 Coils and electrical connections 16 Carburettor heat system 17 Throttle and linkage 18 o ET a 5 19 Oil system tubes and hoses ki 20 Hrewalls San das di wae see t kaa bte do ud t sa 21 Engine cowlings and clipsS Page 2 13 Issue 1 Date 220801 Annual Inspection Each 200 Hours Each 100 Hours Each 50 Hours FUEL SYSTEM 1 Fuel filters drain valves bowls 2 Fuel tank vents caps and placards T T 3 Fuel tanks fs O e a de vast 4 Fuel shut off valve and placards T 5 Elec
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4. ene 6 4 MEIN on Rm 6 5 Wing Flap Control System 7 1 Operational Check EE 7 2 Flap Handle Assembly etta ea etaed eta ea vo Eee tuas 7 3 Flap Common Shaft Assembly eee 7 4 jur mem et TER ERUNT ES ita ada dos ba pas enki 7 6 Page 0 3 Issue 1 Date 280801 Table of Contents Continued Paragraph Elevator Control System 8 1 Control Coll Mises 8 2 E td 8 3 Control Cable and Attachments 8 4 A UM 8 5 Elevator Trim Control System 8 6 Rudder Control System 9 1 Rudder Pedal Ass cm ii 9 2 RUC Qa aaa A a 9 3 Control Cable and Attachments 9 4 BRU DANN L Uu sua meats eeu E u ded a ua 9 5 Engine See also Appendix 1 10 0 Engine CoWlings iiie nennt esse ga data ied ee vae pde Conus be i 10 1 EXISTE un pat si n e decay Ro NI unda edel mid esu ae um 10 2 Bafflesnu g is 10 3 Ensine Montu un s a S SP e aS S SSL 10 4 Engine Fuel System See also Section 11 10 5 Spark PLUGS e 10 6 Engine EE
5. 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 5 Unbolt flap control rods 1 each wing 6 Remove flap from wing so 1t does not crush the fuselage when lowering down 7 Unbolt aileron control cables 2 from rear of control stick horn inside cabin 8 Remove pin and clamp block from aileron control cable clamps at rear of seat 1 each seat 9 Loosen hose clamps from Fuel lines from Breather tubes Gascolator amp Fuel Gauge 10 With one person supporting wing tip unbolt top wing strut bolt and lower wind strut to the ground 11 Lower wing tip to towards the ground making sure you do not crush the under side of the wing on the fuselage wing root 12 Unbolt and remove front wing attachment bolt 13 Unbolt and remove rear wing attachment bolt Note 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 14 Carefully remove wing by moving it out to clear the aileron cable from the fuselage 15 Place wing on cushioned structure to avoid damage to wing strut attachment 16 Unbolt lower wing strut bolt and remove wing strut 17 Repeat Steps 5 16 to remove other wing 4 2 2 Repair The wing is a composite monocoque structure All repairs must be referred to JABIRU AIRCRAFT Pty Ltd Page 4 2 Issue 1 Date 280801 4
6. 5 Replace bearings Page 5 4 Issue 1 Date 280801 6 Position tyre and tube between wheel halves with tube inflation valve through hole in outside wheel half Le Mate with wheel hub 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 Figure 1 2 CAUTION Ensure tube is not pinched between wheel halves during assembly Uneven or improper torque of through bolt nuts can cause failure of bolts with resultant wheel failure 8 Insert through bolts through brake disc and position disc on the inner wheel hub flange 9 Inflate tyre to seat tyre beads then adjust to correct tyre pressure Refer Figure 1 1 5 4 4 Main Wheel Installation 1 Lightly coat axle with Anti Sieze or a Water Proof grease 2 Place wheel assembly on axle 3 Install spacer and lock bolt nut through centre of axle 4 Place outboard brake pad plate and springs in position and secure with bolts nuts washers 5 Reconnect flexible brake line 6 Refill brake master cylinder with fresh brake fluid 7 Bleed brakes Refer to Section 5 8 5 8 Install speed fairing if used as outlined in Paragraph 5 3 4 5 4 5 Main Wheel Stub Axle Removal Remove speed fairing if installed in accordance with Paragraph 5 3 4 Remove wheel in accordance with Paragraph 5 4 1 Disconnect flexible brake hose and d
7. It is not necessary to completely remove these parts 3 Remove hinge pins 4 Remove aileron Reverse the preceding steps for installation 6 4 2 Inspection and Repair Inspect ailerons for any signs of delamination or cracking Pay particular attention to the Control Horn and hinges and their surrounding areas Repairs must be referred to JABIRU AIRCRAFT Pty Ltd mm 65 RIGGING With the control stick in the neutral position use a straight edge not less than 1 metre long Hold the straight edge flush on the underside of the wing aerofoil and adjust aileron to sit on the straight edge Make this adjustment with the cable rod ends ensuring that on completion the locknut is tight on the rod ends and that cable is visible through the inspection hole in the rod end Then check UP travel on both ailerons using the Aileron Rigging Template see Appendix 3 as shown in Figure 6 5 Use the Aileron Control Stop adjustment see Figure 6 5 1 to adjust the total aileron movement ie UP travel and use cable adjustment as previously described to proportion UP and DOWN travel The Aileron Control Stop should engage 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 WARNING The control cable must be connected to the same side of the control column bellcrank as the wing to which the aileron is fitted otherwise control surface reversal will result DO NO
8. Option 13 9 UHF Antenna Installation 13 10 Patin s acta u eo Porte Y DOE ror MA Rn Re has IR FORMEN UNS 14 0 A Pe UC ECC EIU EMO 14 1 ee 14 2 PAC Ar Siac datei id coa 15 Appendices Jabiru Engine Instruction and Maintenance Manual Appendix 1 Jabiri Engin Parts Books su u reet Er Edge Appendix 2 Jabiru Engine Installation Manual Appendix 3 Jabiru Propeller Service Manual Appendix 4 Airworthiness Limitations eese enne Appendix 5 1 General 2 Mandatory Replacement Times 3 Structural Inspection Intervals 4 Structural Inspection Procedures Page 0 5 Issue 1 Date 280801 JABIRU AIRCRAFT PTY LTD SERVICE MANUAL LIST OF EFFECTIVE PAGES The following pages are current Original Effective Date Latest Amendment Date Page No Effective Date Issue Page 0 6 Issue 1 Date 220801 THIS PAGE IS INTENTIONALLY LEFT BLANK Page 0 7 Issue 1 Date 220801 SECTION 1 GENERAL DESCRIPTION Table of Contents Paragraph General Desc A opes cea mk alae wake se d a RUE aces 1 1 ATEGFAT E EE 1 2 Centre of Gravity Limitations 1 3 Torque Valesi e ilden eee RSR TR EU RUE Y e COPI RA Sh 1 4 E 1 1 GENERAL DESCRIPTION The JABIRU J200 400 aircraft described in this manual a
9. 1 4 B 2 I 5011194 PLATE AILERON CONTROL 1 3 NUT HEX NYLOC 1 4 B mm 4 5011294 STUD AILERON CONTROL 2 N Drawing 5011094 2 AILERON CONTROL STOP Figure 6 5 1 Page 6 5 Issue 1 Date 280801
10. 10 7 Exhaust SY SUC ti Zn au nimun aa as 10 8 Extreme Climatic Conditions 10 9 Dor SV SCG a c C EE 11 0 DESTA DUO EE 11 1 Fuel E ta aaa 11 2 NA kka 11 3 Fuel Shut off Valve oae veste ete te eI le EU PNE eR ER RES RENE 11 4 L ge Herbs eoe uut Gane ate BM tees ese M Ee 11 5 elt GR cones cette din tbe eee Ad 11 6 Instruments and Instrument System s 12 0 General yan kaye et iq RUNS ON Du a a qut ui u ski 12 1 Instrument Patel ost r a een pa a sr ue 12 2 TEST Na aT VES pa a 12 3 Pitot and Static Systems estos dest eed ras sei teta o SEC des dan d devon 12 4 E EE 12 5 OU PTGS SUT Gase ecco tiet aos N eet ep Nue M 12 6 Oil Temperature GAUP s souci eina cis 12 7 Cylinder Head Temperature Gauge 12 8 Exhaust Gas Temperature Gauge Option 12 9 A A ENS 12 10 Magneto COMPASS EE eege 12 11 GYRO Instrument Package 12 12 Page 0 4 Issue 1 Date 280801 Table of Contents Continued Paragraph Electrical Systems india 13 0 Electrical Power Supply System 13 1 Battery mee eege eege 13 2 Battery Bokaro e E 13 3 Starter Solenoid iion ee Ae Ne 13 4 Voltage Relation 13 5 O AAA A east eae e 13 6 Electrical Load EE 13 7 W TTD CAA ie EC S 13 8 Radio Wiring Diagram
11. 2 3 Installation 1 Fit wing and its lower attaching bolt leaving the top end of the strut on the ground WARNING Do Not Tighten nut or metal fatigue may result Washer must be free to rotate 2 Fit wing to fuselage leaving wing tip on the ground and routing aileron cable through hole in fuselage wing root Install front and rear wing attaching bolts nuts Put top wing strut attaching bolt in your pocket Lift wing tip and install wing strut to wing strut attachment with bolt from pocket Install nut WARNING Do Not Tighten nut or metal fatigue may result washer must be free to rotate KJE Attached flap to wing ensuring all bushes are in place Install bolt nut in flap control rod Install bolt nut in aileron control cable on main control stick horn Install clamp block and pin in aileron control cable clamp at rear of seat On RH wing reconnect Pitot tube Connect all fuel lines to wing fuel gauge amp gascolator making sure there are no lines that have kinked 12 Put about 10lts of fuel in each tank amp check for any leaks ri OUO c ON roe 13 Replace wing strut fairings top and bottom 14 Replace wing root fairings 15 Preform a fuel flow test taking the fuel line of the mechanical fuel pump in the engine compartment Using a second person to catch any fuel that flows out of the line Turn Electric fuel pump on amp by selecting on take at a time pump fuel through the lines into catchment conta
12. Gravity Limitations esee 1 3 Torque Values aste ote ioi E 1 4 Ground Handling Servicing Lubrication and TAS POCO AAA 2 0 Ground Eatdlmgs susto onec de eee Doe ub User a Dudes 2 1 Servicing incl Servicing Schedule 2 2 OLA A eoe ED u LO 2 3 Lubtigatibil 3456 anu Lecta E 2 4 9 Inspection incl Inspection Schedule 2 5 O O CEDENS 3 1 Windshield and Windows 3 2 Ee 3 3 io 3 4 Cabin Upholstery E 3 5 SO DdpDEPOOHNBSr carte la e ce is Sa 3 6 Safety PFOVISIONUS id 3 7 Wings and Empennaee 4 1 WAN ES sata ay 4 2 Wine Sits AA GAL TE 4 3 ert E 4 4 Horizontal STADE 4 5 Landing Gear and Brakes S 0 E E 5 1 Trouble SAOOUN Oo wii a a anne 3 2 Main Gear a dsi L 5 3 Mat What tu ipit i ades 5 4 Nose EE 3 5 Nose Wheels cba l dE 5 6 Nose Wheel Steering System 5 7 Brake Ys id tido 5 8 Aileron Control System 6 1 Control Cot s taste ke adopt k konne abo ae ke da 6 2 Control Cables ise Uie abd e RURALES gg ege 6 3 Ailere Su st Sun
13. MAIN WHEEL 5 4 4 Main Wheel Removal Jack aircraft as outlined in Paragraph 2 1 2 Remove speed fairing if installed in accordance with paragraph 5 3 4 Remove outboard brake pad plate Remove lock bolt nut through centre of axle and spacer Remove lock spacer Pull wheel from axle gud oem E 5 4 2 Main Wheel Disassembly 1 Deflate tyre and break tyre beads loose from tyre rims WARNING Injury can result from attempting to separate wheel halves with the tyre inflated Avoid damaging wheel flanges when breaking beads loose as a scratch nick or gouge may cause wheel failure 2 Remove through bolts nuts and separate wheel halves removing tyre and tube and wheel hub 3 Remove brake disc 4 Remove bearings from hub NOTE The bearing are press fit in the wheel hub and should not be removed unless a new part is to be installed 5 4 5 Main Wheel Inspection Assembly and Repair 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 Clean thoroughly and paint with silver paint 3 If excessively warped or scored or worn to a thickness of 2 mm brake discs should be replaced with a new part Sand smooth small nicks and scratches 4 Carefully inspect bearings for damage and discolouration NOTE Bearings are pre packed DO NOT clean with solvents as it will removed the packing DAS
14. a table with lining side down flat Centre a 1 8 or slightly smaller punch on the rolled rivet and hit the punch sharply with a hammer Punch out all rivets securing the lining to the pad plate NOTE A replacement kit for brake pads and rivets is available from JABIRU 4 Clamp the flat side of an anvil in a vice 5 Align the new lining on the pad plate and place the brake rivet in the hole with the rivet head in the lining Place the head against the anvil 6 Centre the rivet setting punch on the lips of the rivet While holding the pad plate down firmly against the lining hit punch with hammer to set the rivet Repeat blows on the punch until the lining is firmly against the pad plate 7 Realign the lining of the pad plate and install and set rivets in the remaining holes 8 Replace the brake pad and refix with through bolts and springs To replace inboard lining it is necessary to Remove wheel assembly see Paragraph 5 4 1 Remove stub axle see Paragraph 5 4 5 Remove brake cylinder backing plate Replace lining in accordance with steps 3 7 above Install axle and wheel assembly see Paragraph 5 4 6 Install outboard brake pad and refix with through bolts and springs OV Oi da ups Page 5 11 Issue 1 Date 280801 5 8 5 Brake System Bleeding 1 Fill the brake master cylinder with automotive brake fluid 2 Loosen the bleed nipple at the brake cylinder 3 Pull the handbrake back to the rear stop amp h
15. an electrostatic charge which attracts dirt Oil and grease may be removed by using a soft cloth moistened with mineral turpentine CAUTION gt DO NOT use gasoline alcohol buzene acetone carbon tetrachloride fire extinguisher fluid de icer fluid lacquer thinner or glass window cleaning spray These solvents will soften and craze the Plastic DO NOT use a canvas cover on the windshield or windows as the cover may scratch the plastic 2 3 2 Interior Surfaces Interior surfaces should be cleaned with a soft cloth fresh water and a mild detergent Volatile substances such as those mentioned in the previous section must never be used Page 2 8 Issue 1 Date 220801 2 3 3 Exterior Surfaces The exterior surfaces under normal conditions require a minimum of polishing and buffing CAUTION gt DO NOT polish or buff the aircraft within the first 2 weeks after delivery from the factory as surface treatments take up to 14 days to properly cure Generally the exterior surfaces can be kept bright by washing with water and a mild soap or detergent followed by a rinse with water and drying with a cloth or a chamois Remove stubborn oil and grease with a cloth moistened with mineral turpentine then wash with water and a mild soap rinse and dry as stated before After the curing period the aircraft may be waxed with a good quality automobile wax A heavier coating of wax on the leading edges of the wing tail and on the engine n
16. as necessary to ensure continuous airworthiness Page 2 10 Issue 1 Date 220801 e Ateach 100 hours the 50 hours items would be completed in addition to the items marked under EACH 100 HOURS as necessary to insure continuous airworthiness e An inspection conducted at 200 hours would likewise include the 50 hour items and 100 hour items in addition to those at EACH 200 HOURS Acomplete aircraft inspection includes all 50 100 and 200 hour items together with those shown in the Engine Instruction Manual 2 5 1 INSPECTION GUIDELINES MOVEABLE PARTS for FLUID LINES AND HOSES for METAL PARTS for WIRING for lubrication servicing security of attachments binding excessive wear safety proper operation proper adjustment correct travel cracked fittings security of hinges defective bearings cleanliness corrosion deformation sealing and tension leaks cracks kinks chafing proper radius security corrosion deterioration obstruction and foreign matter security of attachment cracks metal distortion broken welds corrosion and any other apparent damage security chafing burning defective insulation loose or broken terminals heat deterioration and corroded terminals BOLTS IN CRITICAL AREAS for correct torque in accordance with torque values NOTE given in the chart in Section 1 when installed or when visual inspection indicates the need for a torque check Torque valu
17. contaminants are not present 2 2 4 Carburettor Air Filter The Carburettor air filter keeps dust and dirt from entering the induction system The value of maintaining the air filter in a good clean condition cannot be overstressed More engine wear is caused through the use of a dirty or damaged air filter than is generally believed The frequency with which the filter should be removed inspected and cleaned will depend on the operating conditions A good general rule however is to remove inspect and clean the filter ever 50 hours of engine operating time and more frequently if warranted by the operating conditions Clean only with compressed air Under extreme operating conditions daily servicing of the filter is recommended 2 2 5 Battery The Battery is not a serviceable item as it is a gel Use bicarbonate of soda baking soda and clean water to neutralise electrolyte of corrosion Follow with a thorough flushing with clean water Do not allow bicarbonate of soda to enter the battery Remove battery and clean residue from aircraft Tighten cable and terminal connections with a wire brush then coat with petroleum jelly before connecting cables Check the battery every 50 hours or at least every 30 days more often in hot weather If you are not using a gel sell battery add only distilled water not acid or rejuvenators to maintain electrolyte level in the battery Inspect the Battery Box and attachments and clean and remove any
18. of publication and is supplemented and kept current by Service Bulletins amp Service Letters published by JABIRU AIRCRAFT Pty Ltd These are sent to all JABIRU owners or your local dealer of Distributor as recorded by JABIRU so that they have the latest authorised recommendations for servicing the aircraft New owners of pre owned aircraft should ensure that the transfer of their aircraft has been advised to JABIRU AIRCRAFT Pty Ltd or your local dealer of distributor Existing owners should ensure that their postal address remains current In addition to the information in this Service Manual vendor publications will periodically be available from JABIRU which describe disassembly overhaul and parts breakdown of some of the various vendor equipment items A listing of the available publications is issued from time to time in service letters IMPORTANT All maintenance should be undertaken with careful regard for the procedures outlined in this manual A detailed record of maintenance undertaken should be recorded in the Aircraft Log Books In the interests of product development we encourage owners to make suggestions related to design improvements However the final decision on their adoption or otherwise rests with JABIRU AIRCRAFT Pty Ltd Page 0 2 Issue 1 Date 280801 SERVICE MANUAL Table of Contents Paragraph General D s riDtfi m a v eo in oou von no on eran ueneno 1 1 Aircraft Specifications id 1 2 Centre of
19. sao daras 6 3 Removal and Installapon no dias a iy a gi 6 3 1 AUTOM 5285 3 C PT 6 4 Removal and Installapon eene enne eene 6 4 1 reen 6 4 2 RISIN Sus H 6 5 61 AILERON CONTROL SYSTEM Refer to Figure 6 5 The aileron control system is comprised of a control column and two enclosed push pull cables fitted with spherical bearings WARNING All spherical bearings must be fitted with a large washer on the outside of the through bolt to prevent the bearing case and cable releasing in the event of a bearing failure See Figure 6 5 6 2 CONTROL COLUMN Refer to Figure 6 2 6 2 1 Removal and Installation The Control Column is a Primary Control and may not be removed or repaired without reference to JABIRU AIRCRAFT Pty Ltd 63 CONTROL CABLES Control Cables are of the enclosed push pull type fitted with spherical bearings at both ends To operate the outer cover of the cable must be clamped firmly at each end 6 3 1 Removal and Installation Control Cables are Primary Control and may not be removed or repaired without reference to JABIRU AIRCRAFT Pty Ltd Page 6 1 Issue 1 Date 280801 amp 64 AILERONS Ailerons comprise a moulded and bonded monocoque structure embodying a composite control horn at the outboard end 6 4 1 Removal and Installation Unbolt cable from aileron control arm 2 Loosen screws in hinge pin retainers and lift hinge pin retainer away from the hinge pin
20. signs of spillage or corrosion 2 2 6 Tyres Page 2 7 Issue 1 Date 220801 Maintain tyre pressure at the air pressure specified in Figure 1 1 When checking tyre pressure examine tyres for wear cuts bruises and slippage Remove oil grease and mud from tyres with soap and water NOTE Recommended tyre pressures should be maintained especially in cold weather Remember that any drop in temperature of the air inside the tyre causes a corresponding drop in tyre pressure 2 2 7 Hydraulic Brakes Check brake master cylinder and refill with automotive brake fluid 3 4 Bleed the brake system of any trapped air whenever there is a spongy response on the brake lever Refer to paragraph 5 8 for filling and bleeding of the brake system CAUTION gt The JABIRU uses automotive brake fluid 3 4 DO NOT use Aircraft hydraulic fluid mineral based or damage to the brake system will result 2 5 CLEANING Keeping the aircraft clean is important Besides maintaining the appearance of the aircraft cleaning makes inspection and maintenance easier 2 3 1 Windshield and Windows These should be cleaned carefully with plenty of fresh water and a mild detergent using the palm of the hand to feel and dislodge any caked dirt or mud A sponge soft cloth or chamois may be used but only as a means of carrying water to the plastic Rinse thoroughly then dry with a clean moist chamois DO NOT rub the plastic with a dry cloth as this builds up
21. 1 Clean all parts except brake linings and cylinder buckets in dry cleaning solvent and dry thoroughly 2 New cylinder buckets should be installed each time they are removed If reuse is necessary they should be wiped with a clean cloth saturated in automotive brake fluid and inspected for damage NOTE Thorough cleaning is important Dirt and chips are the greatest single cause of malfunctions and leaks in hydraulic brake systems Page 5 10 Issue 1 Date 280801 3 Check brake linings for deterioration or excessive wear 4 Inspect brake cylinder bore for scoring A scored cylinder will leak or cause rapid bucket wear If wear is evident install a new brake cylinder 5 Ifthe anchor bolts on the brake assembly are nicked or gouged replace with new bolts 6 Inspect wheel brake disc for a minimum thickness of 2mm If brake disc is below minimum thickness install a new part Wheel Brake Installation Place brake cylinder assembly in position on backing plate Install bolts springs outboard pad and nuts washers Reconnect flexible hose Fill master cylinder reservoir with brake fluid Bleed brakes Refer to Paragraph 5 8 5 Bee W Brake Lining Installation New brake linings should be installed when the existing linings are worn to expose the rivet heads To replace outboard lining 1 Remove bolts securing outboard brake pad and brake cylinder to backing plate 2 Remove outboard brake pad 3 Place brake pad on
22. Aircraft Service Manual Service Schedule gt Inspection Schedule gt Engine Instruction and Maintenance Manual gt Propeller Instruction Manual gt Airworthiness Limitations Mandatory Replacement Times Structural Inspection Intervals Structural Inspection Procedures Page 0 1 Issue 1 Date 280801 FOREWORD This manual contains JABIRU recommended procedures and instructions for ground handling servicing and maintaining The following Jabiru aircraft models J200 400 Jabiru 3300 powered J200 The Jabiru model J200 is the Amateur Built or Experimental Kit aircraft with only two seats In Australia it may either be registered by CASA in the general aviation category as a VH prefix amp have a MTOW of 700kg or the AUF in the Ultralight category as a 19 prefix amp have a MTOW of 544kg In countries other than Australia other registration requirements will apply J400 The Jabiru model J400 is also Amateur Built or Experimental Kit aircraft with four seats In Australia it may either be registered by CASA or a body who representative CASA This is a VH prefix with a MTOW of 700kg In countries other than Australia other registration requirements will apply It is the owner s responsibility to become fully aware of the particular maintenance requirements and limitations applicable to the appropriate registration The information in this manual is based upon data available at the time
23. Compartment LOCATION Figure 1 1 Aircraft Specifications Page 1 2 Issue 1 Date 220801 RECOMMENDED TORQUE VALUES in fibreglass Bolt Size Inch lbs AN3 ee tesa ak tte yp Fk take Md hs tA TOR Mn dde de P ie aa 20 25 2 ft Ib EE 50 70 4 5 ft lb PAIN e dd 100 140 8 12 ft Ib AN4 Prop EE 72 6 ft Ib Table 1 1 These values relate only to steel nuts on oil free cadmium plated threads For Engine Bolt Torque Values see Engine Instruction amp Maintenance Manual at Appendix 1 The above values are recommended for all installation procedures contained in this Manual except where other values are stipulated The above values are not to be used for checking tightness of installed parts during service CAUTION DO NOT REUSE SELF LOCKING NUTS Figure 1 2 Recommended Torque Values Page 1 3 Issue 1 Date 220801 SECTION 2 GROUND HANDLING SERVICING LUBRICATION AND INSPECTION Table of Contents Paragraph GROUND HANDLING seti teste dau gba ote bet kase pankat 2 1 TOWING E kad Sdk 2 1 1 Ek 2 1 2 TEE hc Nt ala a i tut t e 2 1 3 E np 2 1 4 A o eeu aa oa mitte ciis eege 2 1 5 RE EE 2 1 6 TPAD SLOT AGE s a ny E ree edd sasa 217 Returning Aircraft to Servico iussi vea it editt etus ti elas pann teeta totes kaka asasen 2 1 8 Temporary or Indefinite Storage ta osskas ek O
24. ON Java WALI wad qauoads sun L 931 IAN ANT 9NIS331S l 8 g n S Wo NOUDSE 931 I W AYTO 9NINI13H 9 1004 318 I W 931 NOISN3ASNS L aagana NO S 38ni 8 wT NINIV 1334 6 o 135 M3ovds gr LI D er z gl 9 z SI 9 LI 9 2 OLENV 6l Z Z OBENY OZ N604t09 LZ 1109 SH GNY zz HH 3404 133 NvO 909 Z HI 3404 TAIHA Ua 9 Xx 1 ASSY NIH c 39 Ds KS H YL ENY L SINOA ml 9 x n DA dsns AJAYNJ YIHS v80 809 No Loarodd S3313N W SIHL 5 16 Page Figure 5 7 2 Steering assembly Page 5 17 Issue 1 Date 280801 YY Q31w130 SV ayaa BO Y39 NIVW OL NOB 4 NOLLO3S 5 8 2 Figure L L b Ll L C JIS e L c L G 3MVMa y L aay L e 6 L LYOHS 8ON 3 vua ON Ld WALI ALO NOlLdlJOS30 Odd JWS od Sul SIHL 280801 Date 1 Issue 5 18 o on 3 A SECTION 6 AILERON CONTROL SYSTEM Table of Contents Paragraph Aileron Control System inside 6 1 Control Collie 6 2 Removal and Installapon ennemis 6 2 1 Control Cables iaa
25. T CROSS CABLES Page 6 2 Issue 1 Date 280801 NANA VJ TOUIN Ud E Ou We Nsv NSv j3H Or aa NDIL23S NOI123 STFALII SNOISNII ON SNOldIHOSIO SY INAN Los ON HLM S JGNAN WALI LON ALD ON l lval wan ALO NOLLIIOS3Q ON Leva Du L qNvH Yadanal N6 00Nld L HOI 30A 1ndlno l L 1109 bl 4 Y SL 1108 L ED 3801 WNC OH 7 LL e 8L g 1108 4 6L 9 YIHSY L l a3Dvas oz 3lv d NANI L N3 do Z O 31QNvH 38N1 N80r01 l H3HSVM AA l L ana gc LI E HJIIVdS ve eL 6 2 Figure 040401 Date 3 Issue 6 3 Page LOCATE TEMPLATE ON n R TOP OF WING AND ES A VLERON UP JA SURE BOTH A ONS AR ADJUSTED TO TEMPLATE ANG AILERON RIGGING INSTRUCTIONS Figure 6 5 EC A dg ITEM PART No DESCRIPTION QTY D H 4 l 3 an g wey TA 3 NUT HEX
26. WINGS and EMPENNAGE Table of Contents Paragraph Wings and Biripennage visir E e AAT RES ANE S MAN asas Fsk Nee HE UR gaan 4 1 WINS S L pin kan eet a DEE 4 2 TRC AMS oad E 4 2 1 RG All un eio eM PN ANIME kot d s aasma Medis SIUE Re dM Dd LL 4 2 2 Installation eos ka E DM As ON apiu 4 2 3 Wing SITUS oc ces e 4 3 Removal and Installaltofi d n D i 4 3 1 EE PAL sk EM Pp 4 3 2 FA ivan dav 4 4 Removal Installation and Repair 4 4 1 Horizontal Sa 4 5 Removal Installation and Repair 4 5 1 Page 4 1 Issue 1 Date 280801 mi 4 1 WINGS and EMPENNAGE 4 2 Wings Refer to Figure 4 2 Each composite wing is a semi cantilever monocoque type with a main spar The wing is a moulded structure with a serious of Ribs that is bonded through the moulding process to a fibreglass skin and to the spars The forward wing attachment is an extension of the forward sub spar The rear attachment is a composite block heavily bonded to the reinforced wing skin and attaching the main spar through the Wing End Plug Both attachments are through stainless steel threaded bushes bonded into the attachment blocks 4 2 1 Removal The JABIRU aircraft is designed with wings which are removable for storage or transport Wing removal is most easily achieved if two persons are available to handle the wing 1 Remove wing root fairings
27. ail Plane Watch that you do not jam your fingers under the Rudder or in the rudder hinge Remember that it is Connected to the Nose Wheel gt CAUTION When moving the aircraft never turn the Nose Wheel more than 15 degrees either side of centre or Nose Gear may be damaged The aircraft may also be moved by placing the propeller in the horizontal and then placing 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 CAUTION Never move the aircraft in this manner whilst the engine is hot as it may fire when the propeller is moved and result in severe injury Always ensure that the Master and Ignitions are OFF Never approach the propeller when anyone is in the aircraft Always treat the propeller as LIVE IT KILLS 2 1 2 Jacking JABIRU is a very light aircraft Before jacking ensure that it is as light as possible by removing luggage and any unnecessary fuel Jacking Main Gear 1 Remove main gear spat on the side to be jacked or both spats 1f both wheels to be jacked 2 The aircraft can be lifted on one side by a person of reasonable strength or 2 of lesser strength by lifting on the Wing Spar at the outboard part of the wing strut attachment or towards the wing tip Be careful lifting at the Wing Tip Page 2 2 Issue 1 Date 220801 3 Place a solid block preferably wood under the bottom of the composite glass leg w
28. and Windows scccccccccccesssssssececesececsessnseceeececeesenessaecececeeseeenssseaeeesees 3 2 DESTAPE 3 2 1 EE eege 3 22 A EE 3 2 3 LEE 3 2 4 EE 3 2 5 See cp CE 3 2 6 Removal csi diablo dep dans nes 3 2 7 DETENER TP 3 2 8 Cabin DOOts2 aaa e Deed nC a 3 3 Removal and installation enne enne 3 3 1 Adj stment ts sra 3 3 2 Door seals sua na ias ESI Dan eye adan da gin ta si ko 3 3 3 Cabin door latches arenae B EHE ets 3 3 4 LOCKS asya tito ae ea CRI isd oe e 3 3 5 a EE ee ts o a tossed 3 4 IRE PAUL GM M SR 3 4 1 EIpliplstery ios a Tt DRE Ruta ehe Ne 3 5 SOUNAPLOONN e nsa al asar 3 6 EE 3 7 Eelere EE ee ted baa naat qayaq 3 7 1 Page 3 1 Issue 1 Date 220801 31 FUSELAGE The Fuselage is a composite monocoque self supporting structure and includes both the Horizontal Stabiliser and Vertical Fin All repairs must be referred to Jabiru Aircraft Pty Ltd gt 32 WINDSHIELD and WINDOWS 3 2 1 Description The windshield and windows are one piece acrylic plastic panels set in sealing strips with Epoxy Resin amp Fibre Flock and secured to the fuselage with screws nuts IMPORTANT The Windshield is a structural element of the Fuselage and therefore must be Maintained in excellent condition Cracks up to 25 mm in length should be stop drilled those longer than 25 mm should NOT be repaired and the windshield should be replaced 3 2 2 Cleaning Refe
29. aph 2 1 7 plus For temporary storage fill fuel tank with correct grade of gasoline to prevent moisture accumulation For indefinite storage drain fuel tank ensure carburettor bowl is empty by running engine with fuel valve off until it stops or by draining bowl Then 1 Clean aircraft thoroughly Clean any dirt oil or grease from tyres and coat tyres with a tyre preservative Cover tyres to protect against dirt and oil 3 Either block up undercarriage fuselage to relieve pressure on tyres or rotate wheels every 30 days to prevent flat spotting the tyres 4 Seal or cover all openings 5 Remove battery and store in a cool dry place Service the battery periodically and charge as required NOTE 1 It is recommended that a battery which is not used should be charged every 30 days 6 Disconnect spark plug leads and remove spark plugs from each cylinder 7 Using an oll can or spray atomiser spray preservative oil through a spark plug hole of each cylinder with the piston in the down position NOTE Use shell ENSIS Engine Oil 30 or similar engine preservative 8 Rotate the propeller 10 12 times leaving it in the horizontal position CAUTION Ensure that the Master and Ignition Switches are OFF 9 Install spark plugs and connect leads 10 Seal exhaust pipes Attach a red streamer to each DO NOT seal fuel tank breathers Page 2 5 Issue 1 Date 220801 11 12 13 2 1 10 py 2 1 11 Place pr
30. ate 280801 SECTION 5 LANDING GEAR and BRAKES Table of Contents Paragraph PP ma h oc Msi shulka a casse kiya ke 5 1 Trouble tee 5 2 Mati Gir op DET cc 5 3 Removal sassa n 5 3 1 WS al A ie Da Rum amara Daqu Clas dioc ties 3 32 Inspection and REPA eeu soe ote eso sat Eege 5 3 3 Main Wheel Fairing Removal and Installation 5 3 4 Main Gear Top Fairing Removal and Installation 5 3 5 Mam Wheel yy s es Ba re e dcum EE Ee 5 4 Din DM an dou sida il sida dols aa kitte bi tonton EEAEE 5 4 1 Da an addu t i d 5 42 Inspection Assembly and Repalr eerie ioe ls 5 4 3 TOSCO A ee metus 5 4 4 Stub Ale Removal cases tivi ld 5 4 5 Wheel Installation script da iud edis 5 4 6 A ers n 5 4 7 BO A anam apas a eases ae aa dot een ea Ma ie 5 4 8 Nose GAL t boat ke eit A hae ai 5 5 Trouble EE 5 5 1 Removal and Installation ape A kee a a u Sa 3 5 2 Oe Ee 5 5 3 Nose Wheel Fairing Removal and Installation 5 5 4 Nose Wheel ananassa aina yaaa ea HP 5 6 Removal and Installation es ade e to si fane et 5 6 1 DU SASSE TINO Yoho dice dln sic Ga ben l aes 5 6 2 Inspection and Rent 5 cc e E E aldea end 5 6 3 A E une its kuq Ert asua 5 6 4 Balaretib EE 5 6 5 Nose Wheel Steermg E 5 7 Steering Cable Asset 5 7 1 Nose Wheel Steering Assembly esses e
31. e the aircraft is tied down 2 Tie rope to the Tail Tie down Hole in the Ventral Fin Secure the opposite end of rope to ground anchors 2 1 7 Flyable Storage Flyable storage is defined as a maximum of 30 days non operational storage Ensure that the engine has been stopped by turning off the fuel valve on both tanks thereby not leaving any fuel in the carburettor bowl Every i day the propeller should be rotated through 5 revolutions without running the engine Leave the propeller in the horizontal position to ensure even distribution of liquids in the wood If left in the vertical position liquids will drain to the lower tip resulting in an unbalanced propeller CAUTION Ensure that the Master and Ignition Switches are OFF Store under cover away from direct sunlight as ultra violet rays damage composite structures Page 2 4 Issue 1 Date 220801 In addition the pitot tube static air vent air vents openings in the engine cowl and other similar openings should have protective covers fitted to prevent entry of foreign materials and beings especially wasps 2 1 7 Returning Aircraft to Service After flyable storage returning the aircraft to service is accomplished by performing a thorough pre flight inspection Ensure all protective covers are removed 2 1 9 Temporary or Indefinite Storage Temporary storage is defined as aircraft in non operational status for a maximum of 90 days Treat as for flyable storage see Paragr
32. ene 5 7 2 Brake SM kaa 5 8 Trouble SHOES tle so pe dele eae 5 8 1 Er de din M M 5 8 2 Removal and Installation Repair Hydr lie Brake LE i T pe an ka ius 5 8 3 Wheel Brake Assemblies uoc ioa ee Ee 5 8 4 Removal Inspection and Repair Installation Brake Lining Installation Brake System BISedimg uo st och eases een Sa testo Vae eiue R ko ee eina b li 5 8 5 Brake Pad dus HO icicles velle udo us Facete oia be Deed des ci ue 5 8 6 PATE Bra nf sa 5 8 7 Page 5 1 Issue 1 Date 280801 gt 5 1 LANDING GEAR Main gear comprises two separate composite beams which are bolted to the fuselage at the top and centre and to the wheel stub at the bottom The nose gear is a welded steel trailing arm assembly with a rubber spring system The nose wheel is steerable with the rudder pedals Nose Wheel and Main Wheel Speed Fairings are optional equipment gt 52 TROUBLE SHOOTING Aircraft leans to one side Incorrect tyre inflation Inflate to pressure shown at Fig 1 1 Landing gear attaching parts not tight Tighten loose parts Replace defective parts Tyres wear excessively Incorrect tyre inflation Main wheels out of alignment Inflate to pressure shown in Figure 1 1 Align as specified in Figure 1 1 5 3 MAIN GEAR Figure 5 3 illustrates the main landing gear The illustrations should be used in conjunction with the following procedures during removal and installation of compo
33. es listed in section 1 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 tightness of installed parts during service FILTERS SCREENS and FLUIDS for cleanliness contamination and or Page 2 11 replacement at specified intervals Issue 1 Date 220801 ATRCRAFT FILE Various data information and licenses are part of the aircraft file Check that the following documents are up to date and in accordance with current Civil Aviation Authority Regulations Most of the items listed are required by the Australian Civil Aviation Authority Regulations Since the regulations of other nations may require other documents and data owners of exported aircraft should check with their own aviation officials to determine their individual requirements To be displayed in the aircraft at all times Placards as detailed in Flight Manual Paragraph 2 9 To be carried in the aircraft at all times Flight Manual To be made available on request Aircraft Registration Radio Station License Pilot License Certificate including Medical Certificate if appropriate ENGINE RUN UP Before beginning the step by step inspection start run up and shut down the engine in accordance with instructions in the Flight Manual and Appendix 1 of this manual During the run up observe the follow
34. fing material is normally used in the Firewall In addition a curtain of soundproofing material can be used at the rear of the cockpit baggage area This curtain is attached to composite struts in the fuselage with velcro straps Its purpose is to minimise drumming of the fuselage as well as restricting material falling aft of the curtain and resulting in a severe aft centre of gravity condition The curtain should be in place for all flights mb 37 SAFETY PROVISIONS 3 7 1 Seatbelts Aircraft grade Seatbelts bolted to the fuselage structure are provided for both seats Belts should be replaced if frayed or cut latches are defective of stitching is broken Attaching parts should be replaced with equivalent grade parts if excessively worn or defective Page 3 5 Issue 1 Date 220801 YddV NMVMHO WALI N S 3d S1 JAISNI EEN ro Nid Hl o Ald HOAIAY 40 INJ 38 LON ASAW ON 1H l 3 3 4 Door Latch Assembly Figure 220801 Date 1 Issue 316 Page SECTION 4
35. gs See Paragraph 4 2 1 Fit shackles to wing support brackets 4 off Fit cables rope to shackles and to a centre lift shackle Hoist only from this point ensuring that cables ropes do not mark the top of the fuselage at corners above wing support brackets ARE 2 1 4 Levelling Page 2 3 Issue 1 Date 220801 Method 1 For both lateral and longitudinal levelling use a spirit level on either side of the lower door sills or the fuselage cowl flange line Method 2 Use the join line of the cowl top amp bottom cowl as one point As the second measuring point use the join where the top amp bottom fuse meets which should be the leading edge of the horizontal stabiliser 2 1 5 Parking Parking precautions depend principally on local conditions As a general precaution check the wheels and tie the control handle back firmly with a seat belt to lock the controls Park into the wind and tie down the aircraft as outlined in Paragraph 2 1 6 if a hangar is not available 2 1 6 Tie Down When mooring the aircraft in the open head into wind if possible Secure control surfaces by tying the control handle back firmly with a seat belt Then 1 Tie ropes to the top end of each wing strut Secure opposite end of the ropes to ground anchors located at approximately 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 tyre deflate whil
36. hich have collected while wax is hardening 3 2 6 Cracks When 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 3 2 7 Removal Unscrew all M4 machined screws and remove carefully with a small chisel 3 2 8 Installation 1 Ensure all old epoxy resin has been removed from the fuselage sealing strips and from a used windscreen which is being replaced 2 Check new windscreen for fit File or grind away any excess material to ensure a close fit 3 Squeeze a bead of Epoxy amp Flock around the outer edge of the windscreen 4 Place windscreen accurately over the sealing strips and locate with one screw top and bottom 5 Fit other screws 6 Take care not to crack windscreen when installing DO NOT over tighten screws cracking will result 3 3 CABIN DOORS 3 3 1 Removal and Installation Removal of doors is achieved by removing the hinge bolts or removing the machined screws that attach the hinges to the door frame Page 3 3 Issue 1 Date 220801 3 3 2 Adjustment Cabin doors should be adjusted so that the door skin fairs with the fuselage skin 3 3 3 Door Seals A weather strip is glued around all edges of the door Apart from excluding wind and water the weather strip is important in minimising exhaust fume entry to the cabin It should be maintai
37. hich will result in the wheel being off the ground when the aircraft is lowered Be careful not to Interfere with brake components or Wheel Spat attachments 4 Repeat for other side if necessary The above procedure is useful for wheel brake servicing or repairs but is of no value in removing the main undercarriage If the removal of the main undercarriage is necessary adopt the following procedure 1 Obtain a trestle 20ltr drum or similar object 600mm high 2 Mount a solid foam block sandbag pillow or similar compliant material on top of the trestle compliant material should distribute load over minimum 150 square centimetres Place under the lower wing strut attachment 3 Support under both wings at the Wing Spar to prevent the aircraft from rocking Ensure that no fittings are strained Jacking Nose Gear 1 Push down on tail Plane NOT THE ELEVATOR until nose gear is off the ground 2 Place tressel or drum under rear fuselage together with absorbent material such as foam block sandbags or a pillow gt CAUTION Ensure tressel does not foul Ventral Fin 3 Weigh down tail plane with sandbags or similar heavy absorbent material gt CAUTION Do not lift using control surfaces Damage to the control surface or control system may result 2 1 5 Hoisting This procedure should not be necessary for most service or maintenance procedures Should hoisting be necessary Drain Fuel from both wings amp Remove win
38. iner to ensure there is about 1 litre per minute 4 3 WING STRUTS 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 riveted to two end fittings which attach to the fuselage and wing WARNING Do Not Tighten Strut Attachment Bolts Metal fatigue may result Bolt must be free to rotate 4 3 1 Removal and Installation See Wing Removal Paragraph 4 2 1 and Wing Installation Paragraph 4 2 3 4 3 2 REPAIR Page 4 3 Issue 1 Date 280801 Wing struts are structural components and therefore all repairs must be referred to JABIRU AIRCRAFT Pty Ltd A dented cracked or deformed wing strut should be replaced prior to next flight 4 4 FIN The Fin is a moulded composite structure supported by a rib and a rear spar Hinges attached to the rear spar attach the rudder 4 4 1 Removal Installation Inspection and Repair The fin is an integral part of the fuselage structure and cannot be removed All repairs must be referred to JABIRU AIRCRAFT Pty Ltd 45 HORIZONTAL STABILISER The horizontal stabiliser is a moulded monocoque structure of rigid cellular polystyrene bonded to a fibreglass skin and rear spar 4 5 1 Removal and Installation The horizontal stabiliser is an integral part of the fuselage to which it is bonded It cannot be removed All repairs must be referred to JABIRU AIRCRAFT Pty Ltd Page 4 4 Issue 1 D
39. ing making note of any discrepancies or abnormalities E Engine temperatures and pressures 2 Static RPM Also refer to Engine Instruction Manual 3 Magnito drop Also refer to Engine Instruction Manual 4 Engine response to changes in power 5 Any unusual engine noises 6 Fuel shut off valve operate engine in ON position and in OFF position long enough to ensure shut off functions properly 7 Idling speed After the inspection has been completed an engine run up should again be performed to determine that any discrepancies or abnormalities have been corrected Page 2 12 Issue 1 Date 220801 D 2 52 INSPECTION CHART IMPORTANT READ ALL INSPECTION RQUIREMENTS PARAGRAPHS PRIOR TO USING THESE CHARTS Annual Inspection Each 200 Hours PROPELLER Each 100 Hours Each 50 Hours 1 SPINNE ss Sk s sasa ksa a 2 Sprinter Mane occus reso aps eris kok ee e Pd SENER S 3 Spinner SCLeWS ceres ee eri ie a 4 Propellers va a kak pate snieni kaye seksion enna eee ki 5 Propeller bolts nuts B 6 Leading Edge Tape if fitted ENGINE COMPARTMENT Check for evidence of oil and fuel leaks then clean entire engine and compartment if needed prior to inspection See notes in Paragraph 2 3 5 re engine cleaning 1 Carburettor air filter 2 Engine baffles and air ducts
40. kg 1540 Ib GROSS WEIGHT FUEL CAPACITY 100 or 140 litres 100 or 140 litres 100 or 140 litres OIL CAPACITY 3 3 litres 3 3 litres 3 3 litres ENGINE MODEL Refer to Appendix I Jabiru 3300 Jabiru 3300 Jabiru 3300 for Engine Data PROPELLER Jabiru 60 dia 1524mm Jabiru 60 dia 1524mm 60 dia 1524mm Diameter PROPELLOR Pitch Jabiru 53 pitch 1346mm Jabiru 53 pitch 53 pitch 1346mm 1346mm MAIN WHEEL TYRES STANDARD 500 x 6 rim 500 x 6 rim 500 x 6 rim MAIN WHEEL 6 wide 6 wide 6 wide TYRES STANDARD 6 Ply Rating 6 Ply Rating 6 Ply Rating NOSE WHEEL TYRE 500 x 6 rim 500 x 6 rim 500 x 6 rim STANDARD 6 Ply Rating 6 Ply Rating 6 Ply Rating TYRE PRESSURES 170 kpa 20 psi 170 kpa 20 psi 170 kpa 20 psi STANDARD Mains TYRE PRESSURES 82 kpa 20 psi 82 kpa 20 psi 82 kpa 20 psi STANDARD Nose WHEEL ALIGNMENT at Gross Weight Camber 0 0 0 Toe In 0 0 0 PRINCIPAL DIMENSIONS Wing Span 8100 mm 318 8 8100 mm 318 8 8100 mm 318 8 Length 6550 mm 257 8 6550 mm 257 8 6550 mm 257 8 Height 2200 mm 86 6 2200 mm 86 6 2200 mm 86 6 Cabin Width 1120 mm 44 09 1120 mm 44 09 1120 mm 44 09 Height 1090mm 42 9 1090mm 42 9 1090mm 42 9 Tail Span 2660mm 104 7 2660mm 104 7 2660mm 104 7 Wing Area 8 0 sqm 86 1 sq ft 8 0 sqm 86 1 sq ft 8 0 sqm 86 1 sq ft BATTERY In Engine Compartment In Engine Compartment In Engine
41. limited to replacement of both or either part 5 7 2 Nose Wheel Steering Assembly Refer to Figure 5 7 2 The Nosewheel Steering Assembly comprises of two Steering push rods attaching the Rudder Pedals and the Steering Link Repair is limited to the replacement of serviced parts 5 8 BRAKE SYSTEM The hydraulic brake system consists of one master cylinder located between the seats in the main longitudinal beam flexible hoses connecting the master cylinder to each wheel brake cylinder and the single disc floating cylinder type brake assembly located at each main landing gear wheel 5 8 1 Trouble Shooting A AA A A A E a la tee a AS A Dragging brakes Brake handle binding Worn or broken piston return spring Restriction in hydraulic lines or in master cylinder Repair or install new master cylinder AA EOS ARA A Drain brake line clear with compressed air If cleaning lines fails the master cylinder may be faulty and should be E repaired or replaced If master cylinder or wheel cylinders are leaking repair or install new parts Lack of fluid in master cylinder 5 8 2 Brake Master Cylinder The brake master cylinder located between the seats in the main longitudinal beam is actuated by applying rearward pressure to the brake handle A small reservoir is incorporated into the master cylinder for the fluid supply Issue 1 Date 280801 Brake Master Cylinder Removal and Installations 1 Remo
42. lts nuts 2 Do not tighten at this stage 25 Locate top end bolt install and tighten nut See Torque Value Figure 1 2 3 Tighten clamp bolts nuts 2 See Torque Value Figure 1 2 4 Connect flexible brake line 5 Top up brake master cylinder with fresh brake fluid and bleed brakes see Paragraph 5 8 5 6 Lower aircraft 5 3 3 Inspection and Repair 1 Inspect composite beam for damage indicated by cracks or delamination Pay particular attention to the area around the centre bend and to areas around drilled holes 2 Inspect bolts and nuts for signs of stress or bending replace if in any doubt 3 Inspect clamp for damage 4 Inspect bolt seats in fuselage for signs of damage wear or perishing Repairs to the composite undercarriage beams must be referred to JABIRU AIRCRAFT Pty Ltd 4 3 4 Main Wheel Fairing Removal and Installation 1 Remove the machine screws around the join of the forward and rear sections of the fairing 2 Remove the bolt on the outside of the rear section of the fairing 3 Remove the machine screws 2 in the leg attachment fitting 4 Remove the machine screws 3 in the inside of the rear section of the fairing 5 Reverse the preceding steps for installation Page 5 3 Issue 1 Date 280801 5 3 5 Main Gear Top Fairing Removal and Installation The fairing at the top of the main undercarriage leg is removed by removing the securing screws To install reverse this procedure 5 4
43. ned in good condition and fit at all times New weather strip may be applied after mating surfaces of weather strip and door are clean dry and free from oil and grease 3 3 4 Cabin Door Latches There is one main latch on each door of a simple spring type This is complemented by two Aluminium catches at the top front quadrant of each door Door latches or their component parts must be replaced if worn or damaged 3 3 5 Locks An optional cylinder and key lock is available When fitted the keyed barrel lock is located in the fuselage at the rear of the Port amp Starboard amp Rear doors Spare keys are available to JABIRU registered owners by quoting the aircraft Serial Number 3 4 SEATS The JABIRU seats are an integral part of the structure of the aircraft they are therefore fixed in position Forward and upward adjustment can be achieved by placing a cushion behind and or under the occupant The seat pans incorporate crushable foam which is essential in providing shock absorption in crash conditions WARNING DO NO MODIFY SEATS 3 4 1 Repair As seats are integral to the aircraft structure any repair must be referred to JABIRU AIRCRAFT Pty Ltd 35 UPHOLSTERY Seat upholstery is provided through slip on covers These are easily removed for cleaning and inspection of the seat structures Optional Hood and Cabin lining is available together with Door Pockets Page 3 4 Issue 1 Date 220801 m 3 6 SOUNDPROOFING Soundproo
44. nent parts The wheels comprise two wheel halves which are attached to the wheel hub by through bolts and nuts as shown in Figure 5 3 1 During assembly of the main wheels the through bolts nuts should be tightened to the value specified in Figure 1 2 WARNING Check looseness of main u c beams by lifting each wing and trying to move beam back and forth If movement tighten clamp bolts 2 evenly to take beam movement out Do not over tighten or exceed 3 threads clear on the nuts use extra washers Over tightening can cause bolt fracture and failure to tighten both can also cause bolt failure See Torque Value Figure 1 2 Issue 1 Date 280801 5 3 1 Removal The following procedural steps remove one side of the landing gear as a complete assembly Refer to applicable paragraphs for removal of the individual components Li Jack the aircraft in accordance with Paragraph 2 1 2 2 Unbolt wheel end of flexible brake hose catching brake fluid in a container 3 Remove bolt nut from top inboard end of undercarriage beam Remove rubber bushes 2 4 Remove bolts nuts 2 from the clamp at bend in undercarriage beam 5 Remove clamp 6 Remove Undercarriage Leg Assembly 5 3 2 Installation The following procedural steps install the landing gear as a complete assembly Refer to applicable paragraphs for installation of the individual components With aircraft Jacked 1 Offer the beam to the fuselage and install clamp and bo
45. nt A nose wheel speed fairing is optional equipment Disassembly inspection repair and reassembly of the nose wheel assembly are described in separate paragraphs The wheel is in two halves which are joined by through bolts to the wheel hub as shown in Figure 5 5 During assembly of the nose wheel the through bolts must be tightened evenly and torqued to the value specified in Figure 1 2 5 5 1 Trouble Shooting GE Trouble _________________Probable Cause Remedy amp Nose wheel shimmy Nose strut bolts loose Tighten bolts Loose or worn steering link Tighten replace defective i novo CELA te ea TIMER parts Nose wheel out of balance Refer Paragraph 5 6 5 Wheel bearings loose Replace Page 5 6 Issue 1 Date 280801 5 5 Nose Gear Removal and Installation See Figure 5 5 Weight or tie down tail of aircraft to raise nose wheel off floor Disconnect nose wheel steering pushrods and steering cross beam Unbolt steering cross beam Slide steering cross beam from nose leg assemble from the top Pull the nose wheel strut assembly down from the bushes in the fuselage IS To install the nose gear reverse the preceding steps 5 5 3 Nose Gear Inspection and Repair 1 Inspect steel tube and attachments for dents and straightness 2 Inspect rubber spring assembly for damage or perishing of the rubber or delamination of the rubber from the aluminium spacers between the rubber blocks 3 Inspect alumini
46. old in same position until nipple has been re torque Release the hand brake amp repeat step 3 until all air is expelled from lines NOTE Ensure brake master cylinder remains full above the outlet hose 4 When air is fully expelled tighten bleed nipples amp check fittings for leaks 5 Repeat steps 1 4 for other side brake CAUTION TM Use only automotive brake fluid DO NOT use aircraft hydraulic fluid or damage will result 5 8 6 Brake Pad Adjustment Brake Pads may be adjusted by remove the Main Wheel Spats and tightening the brake pad attaching bolts and nuts until the wheel just rotates freely 5 8 7 Parking Brake The Parking Brake consists of an over centre cam on the brake handle Should the cam have insufficient travel for the brakes to hold the aircraft with a propeller thrust of 2500rpm adjust by one or all of the following 1 Adjust brakes as described in Paragraph 5 8 6 2 Bleed air from brake system as described in Paragraph 5 8 5 3 Adjust length of Master Cylinder Drive Rod at the Rod End attaching to the Brake Handle making sure you still have free play in handle to allow the master cylinder to breath NOTE Items 1 and 2 above should correct the adjustment Item 3 should only be necessary with replacement of Master Cylinder Page 5 12 Issue 1 Date 280801 UTZ e
47. or cracks Cracked wheel halves should be discarded and new parts used Sand out nicks gouges and corroded areas Clean thoroughly and paint with silver paint 3 Carefully inspect bearings for damage and discolouration NOTE Bearings are pre packed DO NOT clean with solvents as it will remove the packing 4 Refit bearings 5 6 4 Nose Wheel Reassembly 1 Replace bearings in wheel hub 2 Position tyre and tube between wheel halves with tube inflation valve through hole in outside wheel half 3 Mate with wheel hub 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 Figure 1 2 CAUTION TM Ensure tube is not pinched between wheel halves during assembly Uneven or improper torque of through bolt nuts can cause failure of bolts with resultant wheel failure 4 Insert through bolts through brake disc and position disc on the inner wheel hub flange 5 Inflate tyre to seat the tyre beads adjust to correct tyre pressure Refer Figure 1 1 5 6 5 Wheel Balancing Refer to Paragraph 5 4 8 for wheel balancing information Page 5 8 Issue 1 Date 280801 5 7 NOSE WHEEL STEERING SYSTEM 5 7 1 Steering Centring Assembly The Nosewheel Centring Assembly consists of springs which are compressed with two nylon machined bushes when the nose leg is moved to the left or the right Repair is
48. ose cap will help reduce abrasion encountered in these areas CAUTION DO NOT use Silicon based cleaning materials as Silicon is absorbed into the composite Materials and may affect reparability 2 3 4 Aluminium Surfaces The aluminium surfaces require a minimum of care but should not be neglected Wash and clean as detailed in paragraph 2 3 3 above gt CAUTION 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 external controls Always hose down wheels and spats after landings in mud or sand to ensure brakes wheels and spats are free of dirt build up 2 3 5 Engine and Engine Compartment The engine should be kept clean since dirty cooling fins and baffles can cause overheating of the engine Also cleaning is essential to minimise any danger of fire and provide easy inspection of components Page 2 9 Issue 1 Date 220801 gt CAUTION DO NOT hose engine Electrical components may be damaged by moisture Ensure electrical components are protected against moisture Caustic cleaning solutions should not be used Recommended cleaning procedure is lightly spray with degreasing fluid after sealing coils and starter motor WIPE clean with br
49. otective covers over pitot tube static source vents air vents and openings in engine cowl to prevent the entry of foreign material or beings especially wasps 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 through 5 revolutions without running the engine leave propeller in the horizontal position CAUTION Ensure that the Master and Ignition Switches are OFF Inspection During Storage Generally inspect airframe and clean as necessary Inspect the interior of at least one cylinder through the spark plug hole for corrosion at least once a month If at the end of the 90 day period the aircraft is to be continued in non operational storage repeat Steps 1 13 above most will only need to be checked Returning Aircraft to Service After temporary storage the procedures for returning the aircraft to service are as follows e One A NO D o o Remove aircraft from blocks and check tyres for proper inflation Check battery and install Check carburettor air filter and service if necessary Remove warning placard from propeller Remove materials used to cover openings Remove clean and gap spark plugs While spark plugs are removed rotate propeller several revolutions to clear excess preservative oil from cylinders CAUTION Ensure that the Master and Ignition S
50. r to Section 2 3 2 3 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 IMPORTANT Silicon based waxes and polish are not recommended as silicon may be absorbed into the glass fibre laminate and effect the reparability due to impairing bonding 3 2 4 Repairs Damaged window panels and windshield may be removed and replaced if damage is 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 repairs 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 Page 3 2 Issue 1 Date 220801 3 2 5 Scratches Scratches on clear plastic surfaces can be removed by hand buffing and polishing using Plastic Polish available from JABIRU as Part No NOVUS 2 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 w
51. rain brake fluid Remove 4 bolts nuts washers securing axle to leg qo DOE NOTE When removing axle from leg note number and position of the wheel alignment shims if any between the axle flange and composite leg Mark these shims or tape them together carefully so that they can be installed in exactly the same position to ensure that wheel alignment is not disturbed 5 Remove inboard brake plate Page 5 5 Issue 1 Date 280801 5 4 6 Main Wheel Stub Axle Installation 1 Secure axle and inboard brake plate to composite leg making sure that any wheel alignment shims are installed in their original position 2 Install wheel assembly on axle in accordance with Paragraph 5 4 4 5 4 7 Main Wheel Alignment Refer to Figure 5 4 7 5 4 8 Wheel Balancing Since uneven tyre wear is usually the cause of tyre imbalance replacing the tyre will probably correct this condition If a wheel shows evidence of imbalance during service it may be statically balanced 5 5 NOSE GEAR The nose gear comprises a steerable nose wheel mounted on a welded steel assembly with aluminium trailing arms and a rubber spring system The steel tube is constrained within two Ertalite bushes mounted in the fuselage main horizontal beam Nose wheel steering is achieved by connecting the rudder pedal assembly to the nose wheel steering link by a push rod The nosewheel is centred by two springs against the firewall amp steering link in the engine compartme
52. re 2 seat or 4 seat version high wing monoplane composite aircraft of monocoque construction They are equipped with fixed tricycle landing gear of composite construction The steerable nose gear is a welded metal trailing link assembly with rubber springs The aircraft is equipped with JABIRU 6 cylinder 4 stroke engines driving a wooden fixed pitch propeller I 1 2 AIRCRAFT SPECIFICATIONS Leading particulars of this aircraft with dimensions based on gross weight are given in Figure 1 1 If these dimensions are used for constructing a hangar or computing clearances remember that such factors as tyre pressure tyre size and load distribution may result in some dimensions that may be somewhat different from those listed BP 1 3 CENTRE OF GRAVITY LIMITATIONS The JABIRU is a very light aircraft The installation of equipment may significantly alter the approved CG limits of the aircraft Therefore all proposed fixed installations must be approved by JABIRU AIRCRAFT Pty Ltd I 1 4 TORQUE VALUES A chart of recommended torque values is shown in Figure 1 2 These torque values are recommended for all service procedures contained in this manual except where other values are stipulated They are not to be used for checking tightness of installed parts during service Page 1 1 Issue 1 Date 220801 MODEL J200A J200B J400 AIRCRAFT SPECIFICATIONS 700 kg 1540 Ib 544 kg 1197 Ib 700
53. rge de E 2 1 9 Inspection During Storage siir E sil 2 1 10 Returning Gate Eeer eh 2 1 11 SERVICING A bek PERI RO 2 2 DET WIG MES Schedule io dos 2 2 1 FWON e at ka kn k s aaa kan t ed Da ae s 2 2 2 Fuel Drs o de dti e i iq 2 2 3 Carburettor Arr Filter M Rt T E 2 2 4 Battery nna is 2 2 9 jul M PE EUR E TR 2 2 6 Le EE 22g CLEANING illar l RENE RISE ERIS SS SSS 2 3 Windshield and WIN WS petentis is 2 3 1 Interior Surfaces EE 2 3 2 Exterior SUT ACES P la skara Bilal a Taal skan Oasan ia M 2 3 3 Al mint m SULT ACES pto 2 3 4 Engine and Engine Compartmetnt aeta eara rueda adn 23 3 POPC TEE ue Fasha ee op oe oH US asap MORI a e kan a an AR Re eM ID 2 3 6 KEE EE 2 3 7 BDCT LAN NA RE 2 4 Wheel Bearings Mains and Nose sess enne enne nennen 2 4 1 INSPECTION eer 2 9 Inspection Guidelines sed iee n s S SSSR Mua paqa aQ alus Ta 2 5 1 Inspection Chart na 2 5 2 Page 2 1 Issue 1 Date 220801 W 2 1 GROUND HANDLING BP 2 1 1 Towing The JABIRU aircraft is very light and should always be moved by hand Moving the aircraft is accomplished by using the wing struts or prop hub or landing gear struts as push points together with the solid rear fuselage join of the fin to the tail plane gt CAUTION Do not use control surfaces to move the aircraft Damage to the control system may result When pushing at the join of the fin and T
54. tronic fuel boost pump and fittings d ki 6 Fuel lines and connectors S 2d T Fire SlCGVES oi iii ea da ka k 8 E A 2 LANDING GEAR 1 Main gear wheels and fairings 5 2 Nose gear wheel steering links tension links and TIE gs u ttp O si SS 3 Wheel bearings A sa 4 Nose gear SICUL fey esse oak De akay ae eure AREE ERR EINER XT aga a 3 Nose gear housing and bushes 6 Main gear struts clamps and bolts nuts a EA Tyres and tubes reee 8 Brake fluid hoses linings discs brake assemblies and master cylinder ricas tilda T 9 Brake operational check m d AIRFRAME 1 AIrOraft exterior ai ki paye Mises ak sk a Ha ki ke pa dS aA Res l a 2 a AA sa Ede tasa RECS D eai gt 3 Windows windshield doors and seals i ki 4 Seatbelts and shoulder harnesses Font amp Rear T xa 5 Seat structure Front amp Rear 6 Instruments and markings s e T Instrument plumbing and wiring Y 8 Instrument panel shockmounts decals and labels 9 Ventilation system ki T 10 Cabin upholstery trim
55. um trailing arms for damage or bending 4 Inspect bolts nuts for torque see torque values Figure 1 2 Repairs to the welded nose leg assembly beam must be referred to JABIRU AIRCRAFT Pty Ltd 5 5 4 Nose Wheel Speed Fairing Removal and Installation 1 Remove the machine screws around the forward and rear sections of the fairing and remove the front section 2 Loosen the axle nuts and remove the rear section 3 Reverse the preceding steps for installation 5 6 NOSE WHEEL 5 6 1 Nose Wheel Removal and Installation 1 Weight or tie down tail of aircraft to raise the nose wheel off the floor 2 Remove nose wheel axle bolt 3 Pull nose wheel assembly from yolk Reverse the preceding steps to install nose wheel Tighten axle bolt 5 6 2 Nose Wheel Disassembly 1 Completely deflate tyre and break tyre beads loose at wheel rim WARNING Injury can result from attempting to separate wheel halves with the tyre inflated Avoid damaging wheel flanges when breaking beads loose as a scratch nick or gouge may cause wheel failure Page 5 7 Issue 1 Date 280801 Remove through bolts and separate wheel halves Remove wheel hub Remove tyre and tube from wheel halves Remove bearings See tS NOTE The bearings are press fit in the wheel hub and should not be removed unless a new part is to be installed 5 6 3 Nose Wheel Inspection and Repair 1 Clean metal parts in solvent and dry thoroughly 2 Inspect wheel halves f
56. ush and cloth 2 3 6 Propeller Wash with soap and water rinse with clean water and dry with cloth or chamois Do not use a wax based substance as it make is almost impossible to refurbish the prop if need at a later stage 2 3 7 Wheels The wheels should be washed periodically 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 2 4 LUBRICATION There are no lubrication requirements for the JABIRU other than those detailed in Appendix 1 2 4 1 Wheel Bearing Mains and Nose At each 100 hour inspection jack the wheel spin the wheel and check for free running and any play on the shaft Remove and replace if there is any sign of binding or wear 2 5 INSPECTION Inspection Charts The chart at Paragraph 2 5 2 shows the recommended intervals at which items are to be inspected As shown in the chart there are items to be inspected each 50 hours each 100 hours and each 200 hours There are also special inspection items which require inspection of servicing at intervals other than 50 100 and 200 hours The engine Instruction Manual also details engine inspection schedules and should be consulted in addition to this chart e When conducting an inspection at 50 hours all items marked under EACH 50 HOURS would be inspected serviced or otherwise completed
57. ve the flexible hose from one wheel brake assembly and drain the hydraulic fluid from the brake system Remove cover over main longitudinal beam between seats Unbolt pushrod at brake handle and remove pushrod Disconnect flexible hose at master cylinder Unbolt master cylinder retaining bolts 2 Plug or cap hydraulic fittings and hoses to prevent the entry of foreign material Dt Reverse the preceding steps to install brake master cylinder then fill and bleed brake system in accordance with Paragraph 5 8 5 Brake Master Cylinder Repair Figure 5 8 2 may be used as a guide during disassembly repair and reassembly of the brake master cylinder Repair is limited to installation of new parts cleaning and adjustment Use only automotive brake fluid DO NOT use aircraft grade hydraulic fluid or damage will result 5 8 5 Hydraulic Brake Lines These lines are flexible hoses connected through a tee piece Repair is limited to replacement 5 8 4 Wheel Brake Assemblies The Wheel Brake Assemblies use a disc which is attached to the main wheel hub with through bolts and a floating brake assembly Refer to Figure 5 3 1 Removal The Wheel brake assemblies can be removed by disconnecting the brake hose and unbolting the brake cylinder from the backing plate The brake disc is removed after the wheel is removed and disassembled Refer to Figure 5 3 1 for disassembly of either wheel brake assembly Wheel Brake Inspection and Repair
58. witches are OFF Install spark plugs torque to 20 nm 180 inch lbs Check fuel filter replace if necessary Check brake fluid level If returning to service after indefinite storage fill fuel tanks with correct grade of fuel Check fuel tank and fuel lines for moisture and sediment Drain enough fuel to eliminate any moisture and sediment Check fuel tank breather is clear Perform a thorough pre flight inspection Start and warm engine 22 SERVICING Servicing requirements are shown at Paragraph 2 2 1 The following paragraphs supplement this table by adding details not included Page 2 6 Issue 1 Date 220801 Note that Inspection Requirements are detailed at Paragraph 2 5 2 2 1 Servicing Schedule Pre Flight Refer to Flight Manual 25 Hour Service Refer to Engine Instruction amp Maintenance Manual 50 Hour Service Refer to Engine Instruction amp Maintenance Manual 100 Hour Service Refer to Eng Instruction amp Maintenance Manual Other Inspection amp Maintenance Procedures Refer to Engine Instruction amp Maintenance Manual Replace flexible oil amp fuel line in engine compartment every 2 years 2 2 2 Fuel The fuel tanks should be filled immediately after flight to lessen condensation of moisture The tank capacity is listed in Section 1 2 2 3 Fuel Drain A fuel drain is located in the Left amp Right hand fuel tanks near the wing root Drain fuel after each refuelling to ensure moisture and
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