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Aircraft Service Manual - Jabiru Aircraft & Engines Australia

1. 63 6 5 1 Trouble Shooting Nose Leg 63 6 5 2 Nose Gear Removal and Installation sess esent 63 6 5 3 Nose Gear Inspection and denen enhn nnns 64 6 5 4 Nose Wheel Speed Fairing Removal and Installation sess 64 66 NOSE WHEEL ere ED inert eee 64 6 6 1 Nose Wheel Removal and Installation esses deessent nnne 64 6 6 2 Nose Wheel Disassembly edens nenne erinnern nint narii nnn intern 64 6 6 3 Nose Wheel Inspection and Repair 65 6 6 4 Nose Wheel 65 6 6 5 Wheel Balancing ient ctr er intente 65 67 NOSE WHEEL STEERING 5 68 6 71 5 7 1 Steering Centring Assembly sss deseen nna 68 6 72 Nose Wheel Steering Assembly irte stint 68 68 BRAKESYSTEML Neue ie ierat ere ena iive rete er 68 6 8 1 Trouble Shooting Brakes Ngee e 68 6 8 2 Brake Master OV IPOS sa e e ee ea 69 6 8 3 Hydraulic Brake LINES LDL ea
2. denen 59 Figure 13 Main Wheel to Leg 55 60 Figure 14 Main Wheel Assembly eese 61 Figure 15 Directional Brake Disc Installation 62 Figure 16 Nose Leg 66 Figure 17 Nose Wheel Hub Assembly 67 Figure 18 Brake Calliper ASSY 73 Figure 19 Brake Master Cylinder 5 74 Figure 20 Aileron System 76 Figure 21 Control Column 5 1 4 6 6 sess eene nnne 78 Figure 22 Allerom Stops Ee eii ila cete e a ode 81 Figure 23 Flap Controls Sheet 1 Salles e ee e 85 Figure 24 Flap Controls Sheet 2 86 Figure 25 Flap Cross Tube ASSY a 87 Figure 26 Flap Position eterne ene tret 88 Figure 27 Flap Position Indicator Drive Cable AssemblY sss 89 Figure 28 Elevator Control ASSY 92 Figure 29 Elevator Control Assy Rear 93 Figure 30
3. 5 A lt tc T a 2 o 40 co e N LL LMiles Technical manuals J230 24301 230 430 Work filesJ230 C Tech Rev 1 doc REVISION Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft Shaun un Aircraft Service Manual Jabiru J230 C 10 2 RUDDER See Figures 37 and 38 10 2 1 REMOVAL amp INSTALLATION 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 4 Remove rudder 5 Reverse the preceding steps for installation 10 2 2 INSPECTION amp REPAIR Inspect rudder for any signs of delamination or cracking Pay particular attention to the Control Horn and hinges and their surrounding areas Repairs must be referred to JABIRU AIRCRAFT Pty Ltd or our approved local agent 10 3 CONTROL CABLE amp ATTACHMENTS The control cable is of the 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 10 3 1 REMOVAL amp INSTALLATION The Control Cable is a Primary Control and may not be repaired or removed without reference to JABIRU AIRCRAFT Pty Ltd or our approved local agent 10 4 RUDDER BALANCE The rudder is balanced at the factory during assembly and unless the rudder is damaged the balance shoul
4. 170 22 3 1 External Paint Finishing Limitations sessi eee 170 22 4 CONTROL SURFACE BALANCING 170 22 4 mandatory Replacement soosiana iii Aeara aE E AENEA perenni nnns 171 Revision Dated Feb 2006 Issued By RAS Page 10 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft Mm un Aircraft Service Manual Jabiru J230 C 11 TABLE OF FIGURES Figure 1 J230 C General Arrangement 16 Figure 2 Weighing Diagram anaa nennen nennen nnne ener ener 24 Foues Fuel Line ire rei 30 Foures Dm 32 Figure 4 Front Door Assembly secta teen 39 Figure 5 Rear Door doas ee 40 Figure 6 Door Latch Mechanism Assembly denen denen nennen 42 Figure 7 J230 Wing Assembly Sheet 1 47 Figure 8 J230 Wing Assembly Sheet 2 48 Figure 9 Dynon Pitot Probe Installation a 50 Figure 10 Landing Light 5 51 Figure 11 Main Undercarriage Assembly 55 Figure 12 Main Wheel
5. n ro tuvo 20 3 1 8 Returning Aircraft to Service innate sitate 21 3 1 9 Temporary or Indefinite Storage sss 21 3 1 10 Inspection During 22 3 1 11 Returning Aircraft to Service sisse essen 22 3 2 Cc M 23 3 2 1 Scale ae aaa n 23 FOCUS 23 39 ecmm as 24 3 3 1 Engine Servicing Schedule dps nantes 24 33 2 other SERVICING ivi visi oe ee teed 25 3 3 3 Fel iu Leere S eo elles 25 3 8 4 Fuel Drain fJ eo mne 25 3 3 5 Carburettor Alir Filtegi v uiis sssssss sensere nani 25 3 0 6 10 14 2 LEE E 25 BBL E 1E eaae ere Mega p n e 25 3 3 8 Hydraulic 2 egt rtp eg oet go ne e aie 25 cc ensem S 26 3 4 1 Windshield and WINDOWS sass eens 26 3 4 2 Interior Surfaces udi eerta Lamar nne n na 26 343 Exterior ui REL erecto rap 26 3 4 4 Aluminium Surfaces sss
6. LAN DOTAN 92 ZEOL SIEOZSIN ZL 133HM LNNOW 509 09 bL v ALAN DOTAN SZirG9EOZGNN OL 8 H3HSVAA LYT vll SLt 096NV amp v 1108 til 8 SSANMOIHL 2 1 N3HSVA 1914 918 70L 096Nv 1 1708 91 9 ANLS NOISN31X3 1650009 9 A18 3SSV SNH 133HM NIVW 15 2 9 v 0879 ASSY 190 HONA 52 WHOSLNI 8202029 8013 31 1690008 0 002 93139VvliuuvOH3ONf 6207009 ALO 199 4811 sped gt o l o 5 LL n lt e 2 o 2 e e N LL a a z 9 rtc Print Date 14 01 2009 4 41 00 PM LMiles Technical manuals J230 J430230 J430 Work filesJ230 C Tech Rev 1 doc ft Pty Pia ircra A Aircraft Service Manual iru Jab Jabiru J230 C 1 2202 129 Ag 0497 SY38 YONNE 9 ATAWSSSV ANH 133HM LSVO 37926 LON OLI Ald HOSLAY 30 LN3SNOO JHL LAOHLIM 031909 ION ISNAN IHOIHAdOO SI 16 984 OLO Vd HO31AV SONIANHO 15 OL 3438 1 931312348 SS NN SLINIT JYAL OVSd OLNO SIAL 3 18AJS
7. 3HOW ON IN3AW313 WHNLOINYLsS lN3OvrOv 01 S3lL diz A8 0340035 38 OL SINN 304 TW v Q Ovi9cvy NO Sv I31BW3SSv 38 OL IN3MUNVdWOO 3NISN3 JHL NI 5350 IINA dvi OL TWM 4 3SIMY3HLO GALON 3H3HM 1430 3 QOvOSZve SA NO N Sv Q318W3SSv 38 OL YAYY lld 209 NI S3SOH 1304 Z HIV3HS 40 510130 804 40909277 OMA 335 TMAH OL dvl OL JYNSOTONS 1303 TANA NI 3102434 OL 3913503 3015100 WOYS NZOOvvld N d NI Q3HIV3HS 38 OL 209 NI SINIJA Wand ONY SASOH 7304 11 ALON 31725 LON 00 09100924 ON d L NOILOJ OY d 5 SNOISN3WIQ CZOZZ6v ON d ASSY 30819 331 JANM 55082 30 Lv 3913504 NI 308 v6v100v ON d YINI N6POOWd ON d TANA 10080 oN d dNNS 00 NI 51130 8 55 ISOH HO4 2 310N 335 NI 5711130 AT8W3SSv HIY3HS 350 304 310N 335 1005 ON d Yad BIN4 N d HUM 3SOH OL ALAYI 1004 ONIA OLNI 53015 HLOS NO 301713573 COL NIN HIY3HS HUM N d HIN3HS 1305 5 23114 ISOH SONIA N33A38 JAMU INIA 55080 7 AID 0078 2 ON d ASSY ASSY M3aNas 390 9 TINA Qovesovr OMG 3434 AlgW3ssv 730
8. 1600019 370129433 908 Nz900Qd ONILLIJ ASSY Q3ONOB 8 aovel ove ALO 5 Liva jer Sed gt o lt o o T 3 oO A lt tc a 2 e 0 co e N LL a z o o 2 rc Print Date 14 01 2009 4 41 00 PM LMiles Technical manuals J230 J430230 J430 Work filesJ230 C Tech Rev 1 doc ft Pty Pia ircra A Aircraft Service Manual iru Jab Jabiru J230 C 40 133Hs 4 600702 9 NYBY OL 311201 350 88 NOILO3S ASSY 40 J3ISVW 33Vu8 anu 180489 31Ni30 Sv WIL 26 98 010 NOY Wd HO3LAY AXOd3 P MOO14 3984 NIYAN OL _ Se VV NDILO3S 6 SA3NOS LINS OL S310H Z XNIS 2 O NIV NL LBA SNA 29 InN P DLENY ZL v IBA 9 SVEL vZ 2 InNEE OL G9 0ZSN N3ONIIAO WILS W 00 000 9 z MIYOS 05 2 2725 lt 69 25 OL WYO 60090 lt ZZ 0 9 S3HSVM 01 096 6 3A331S
9. TIYA VLI WOE 8 490 TANS GSLNSA 00650 8 WNVL Tans ONIM GALNSA 09590996 SL SNO VIO 1108 13318 SS3TNIVIS NZZOVPHd ft AAT 1903 008 106102 Eb ONIY AvLOSS IL SHVAAOHVH 99 LINS 410 d OILSV Id NOO0VZHd OL Naess X 999 4138 QV3H d MIYOS PINJA 01028 3111201 Alda 9 LINN 03345 8 25 520 X 4 Svz 80ze SIN 9 72258 NLOOVP Dd 5 13 3 ONIA Q31N3A Qoaesovr t AQOH dv2 1802 JIJLNIA Q025S0Vt ASSY dul A Hlava N6SLecOF L Iva Wall 157 sued Figure 47 Vented Fuel Cap Assy N A lt tc T a 2 o 40 co e N LL LMiles Technical 51 230 24301 230 430 Work filesJ230 C Tech Rev 1 doc REVISION Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft un Aircraft Service Manual Jabiru J230 C 12 4 FUEL SHUT OFF VALVE See Figure 46 or Undefined Bookmark NONCSVLAF amp 48 depending on model variant 12 4 1 DESCRIPTION The fuel shut off valve is a two position ON OFF valve which is located in front of th
10. 52 6 3 IMAINIGEAR siiis bre cer exer Venn oer a 52 6 3 1 um 53 6 3 2 53 6 33 Inspection and Repair osi seen aaa 53 6 3 4 Main Wheel Fairing Removal and Installation eese 54 6 3 5 Main Gear Top Fairing Removal and Installation sisse 54 64 esses 56 6 4 1 Main Wheel Fiemoval cte tasto rdg 56 6 42 Wheel 56 Revision Dated Feb 2006 Issued By RAS Page 5 01171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft un Aircraft Service Manual Jabiru J230 C 6 4 8 Main Wheel Inspection Assembly 56 6 44 Main Wheel SANSOM seacoast ea lax eee a 57 645 Main Wheel Stub Axle 57 6 4 6 Main Wheel Stub Axle Installation sessi esee 58 6 47 Wheel Alignment cst esee nnnm 58 6 4 8 AMET IN P 58 6 5
11. ASSY TOULNOS A 1 l V 0927 15 IN DowssovE 6 A innon yaaani vVLO ENV 21 InN proi secozsm M3HSvM 91 096 5 o INI doy 9 Oo 98 2 8 2 1108 Y90 ENY Davo N68009d OL 318 0 WHS 660099 11 9 1n 3 0 HEN 0 1024 ZL lt e 2 S g 92 o E 5 e 0 N gt LL m 9 3 N e i 5 LL 31 25 22 NOU23S z 9 2 tc Print Date 14 01 2009 4 41 00 PM ft Pity Pta ircra A Aircraft Service Manual iru Jab Jabiru J230 C lL 40 13385 0 500 95 M3OQQM 9 ON OM SY vig3LvW aiva 7551 94 0 0 um 3was 5 15 WLNOZIYOH 30 37308 HOLVW OL T3NNYHO 40 WIL 6 31 25 NOILO3S 39773513 LINS OL 3dvHS 225 39v13snd OL ASSY NO 14 TE INVIdTIVL NO TIY 30 LYVLS 9NO1 75 9NO1 OSZ 002 082 f xf T 9NO1 08 085 OLE SNO 08S 08 541915 SNIOHOJNI3H WL Wel 39NIH 401 M0138 M3NIVL3H 39719
12. 5 2 2 o LL lt e 2 o 2 e N LL a a REVISION Print Date 14 01 2009 4 41 00 PM LMiles Technical manuals J230 J430230 J430 Work filesJ230 C Tech Rev 1 doc Wd 00 Le 6002 10 71 ereq OOP uoe 9 WOM jeoruuoe z m o 2 U T m o c w 2 gt 0 2 9 M 1 2 8 5 o 1 E D 6 5 4 WV 3 2 1 Parts List NOTES ITEM PART NUMBER DESCRIPTION USE AN960 416L 1 BOLT LENGTHS GIVEN ARE NOMINAL USE SHORTER 1 12085023 ELEVATOR ASSY i 1 2 THICKNESS WASHER BOLTS IF REQUIRED ENSUR MI OF 2 5 THREADS THOW THRU 2065094 MOUNTING PEATE TRIM ASSEMBLY l Be ARE ues 2 CPNo COMMERCIAL NON JABIRU PART NUMBERS 9 960 416 1 4 FLAT WASHER 10 SA 3 QUANTITIES GIVEN ARE FOR THE COMPLETE TRIM CONTROL 14 3 10 3 16 BOLT 2 4 ASSEMBLY AS SHOWN IN SHEETS 1 3 OF THIS DRRAWING 15 960 10 3 16 FLAT WASHER 10 17 820365 1032 3 16 NYLOC NUT 8 18 3102284 SPACER DRIVE PLATE
13. 4 eeeeee seres eene eene estas senso data sta petas staat tastes sess ease ease tassa senate 147 14 1 ELECTRICAL POWER SUPPLY SYSTEM sene 147 14 2 WIRING DIAGRAM retenue ru retten REESE 147 14 3 BUS BARS MEE 150 14 3 1 Master SWIICh kr ke ra E RARE 150 14 4 BATTERY POWER SYSTEM inneren itr dee etate nto ese bn Eee eges 150 144 1 BONY bases etie ute bentes eee tet Pa ten 150 14 4 2 Battery Trouble Shooting eee 150 14 4 3 Removal and 150 14 4 4 Cleaning the ae 150 1445 BATTERY BOX e tede ees lena 151 14 5 STARTER SOLENOID e 151 14 6 VOLTAGE REGULATOR ee 151 14 7 STROBE SYSTEM enne 151 14 8 AUXILIARY POWER SOCKET er Neteco hnnc reru meto e teen ie zn re epa na dun 151 14 9 ELECTRICAL LOAD ANALYSIS 151 14 10 RADIO WIRING DIAGRAM 4 0 1 00000 00 151 14 10 1 VHF ANTENNA 5 2222 4 00000 000000000000 99 9 dnte 9 151 15 SECTION 15 PAINTING amp FINISHING
14. H3HSVM dO L 937 ISON Godeoov9 Gc D 191 8 01 096 vz 1108 9 VLO ENV z 340A GANIHOVW dO LJVHS Y3ggNY 9313S0N 004200 9 cc HALLOO 261 9995 12 D LAN 3118 VO 91 6 S OLENV 02 1108 91 6 eySNV 6l 5 LAN OOTAN ll 8 7 99 025 0 81 c YAHSVM 9 096 21 Q3TTIVISNI 33V S1VdS NAHM 2 ON d 1708 ISN SIVAS LNOHLIM CASN 1108 9l LAN DOTAN ZEOL S9E0ZSW Gl 1108 9V V90 ENV vl L 031 ISON YY1109 SNINIV L3H vvOL909 l LAN 94 9 VZS S9 07SW 2 v H3HSVM QLS O96NV 1108 91 9 VSL SNV OL o L HSN AAS 8 QO 8 AI 91 9 Nooovodd 6 1003 918 31XV LNOMH 9 H3OVdS 07909 8 L 1004 918 3TXV LNOYS 909 2 GOA H3HSVM H3MOTH38SnH 931 ISON godzoovs 9 330A GANIHOVW 3SV8 1JVHS 9371 3SON 00820079 6 L 1003 919 340A T33HM ISON Qgovioovo L 710041 919 AMOA Q3NIHOVMW 931 ISON ASSY Y394NY goocoov9o lt x 1009 918 WIN LSVO ASSY 133HM ISON 8208129 c 1005 918 340A Q3NIHOVM ASSY 931 ISON Qovroovo ALD MASON 1894 NALI 1511 sued SHLONAT 1108 ASSV 9310 HVTIOO 8 SAMOA t INSSI G3ISIGOW QN38 MIN SMOHS 3155
15. J3ovds 64000 6 L LNNOW dv 14 Q0HSSOVE 8 COY LINS OL OOY dv14 1 21412313 YOLYNLOY HY3NIT NOOOVEWd 9 Y LAN 91 6 VS OLENV t LAN OLE ANN 91 6 31840 MOH 15 005226 8 83100 31899 TOHLINOO 0 9 YANNI 31890 1 1 02 c00veod L ALO NOlldldOSad YASWAN LIYA Wall 38 sued lt e 2 o 2 e e N LL a a z 9 rtc Print Date 14 01 2009 4 41 00 PM LMiles Technical manuals J230 J430230 J430 Work filesJ230 C Tech Rev 1 doc Jabiru Aircraft me un Aircraft Service Manual Jabiru J230 C 9 SECTION 9 ELEVATOR CONTROL SYSTEM 9 1 ELEVATOR CONTROL SYSTEM See Figures 29 31 and Figure 32 The elevator control system is comprised of a control column and one enclosed push pull cable fitted with rod ends at both ends 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 9 2 CONTROL COLUMN DESCRIPTION Refer to Figure 22 9 2 1 REMOVAL AND INSTALLATION Refer to Paragraph 7 2 1 9 3 ELEVATOR The elevator comprises a Rigid Cellular Polystyrene core moulded and bonded to a composite
16. a z 9 o 2 tc Print Date 14 01 2009 4 41 00 PM LMiles Technical manuals 230 J430M230 J430 Work filesJ230 C Tech Rev 1 doc Jabiru Aircraft Shaun un Aircraft Service Manual Jabiru J230 C 64 MAIN WHEEL Refer to Figure 14 6 4 1 MAIN WHEEL REMOVAL 1 Jack aircraft as outlined in Section 3 1 2 above 2 Remove speed fairing if installed in accordance with paragraph 6 3 4 3 Remove outboard brake pad plate 4 Remove lock bolt nut through centre of axle and spacer 5 Remove lock spacer 6 Pull wheel from axle 6 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 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 6 4 3 MAIN WHEEL INSPECTION ASSEMBLY AND REPAIR 1 Clean all metal parts in solvent and dry thoroughly 2 Inspect wheel halves for cracks Cracked wheel halves should be discarded and new parts used Sand out nicks gouges and corroded areas 3 If excessively warped or scored or worn to a thickness of 2 mm brake dis
17. un Aircraft Service Manual Jabiru J230 C 4 3 2 ADJUSTMENT Cabin doors should be adjusted so that the door skin fairs with the fuselage skin 4 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 should be maintained 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 1 1 Cabin Door Latches There is one main latch on each door of a simple spring type This is complemented by a catch at the top front quadrant of each door An assembly drawing of the latch mechanism is provided as Figure 7 below Door latches or their component parts must be replaced if worn or damaged Revision Dated Feb 2006 Issued By RAS Page 41 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM ft Pty Pia ircra A Aircraft Service Manual iru Jab Jabiru J230 C 1 OL H3J3H wae 2 x 87 ee 04204 631436 f 5711 0 44 ASSY HOLVO yooq ey aay TSW 031412345 SOTIN 31Vd ssi ONT Al HOAIAW HO INISNOS NOH IHAA 91900
18. 53871 911715 10 NOILOJ OYd d EP 21 25 LON OQ 5 SNOISN3MIQ Ald HO3IAY 40 LIN3SNOO LNOHLIM 931909 LON 5 ONY SI SIHL Figure 55 Pitot Statice System Water Trap Locations E A lt tc T a 2 o 40 c e e N LL 9 2 rc Print Date 14 01 2009 4 41 00 PM LMiles Technical manuals J230 J430230 J430 Work filesJ230 C Tech Rev 1 doc Jabiru Aircraft _ N Aircraft Service Manual Jabiru J230 C Jr EL UBE TO BE SET PARALLEL AIR OW WHEN INSTALLED SECTION 9 50449 TUBE BENT PITOT 8 OSE CLAMP MS8242 2 7 504439N HOSE COUPLING 6 PVOO29N PVC TUBE 1 4 ID RIVET MOUNT PLATE PITOT TUBE TUBE STRAIGHT PITOT 093 WING STRUT ASSY ITEM PART No DESC gt RIPTION QTY Drawing 9024094 2 PITOT ASSEMBLY Figure 56 Pitot Assembly Std Pitot Revision Dated Feb 2006 Issued By RAS Page 141 of 171 LMi
19. ALO gt a o d 5 N N co 5 A lt E a 2 40 e N LL wee Jo Print Date 14 01 2009 4 41 00 PM LMiles Technical manuals 230 J430M230 J430 Work filesJ230 C Tech Rev 1 doc Jabiru Aircraft me un Aircraft Service Manual Jabiru J230 C 11 1 2 CLEANING AND INSPECTION 1 Wipe the inner surfaces of the cowlings with a cloth saturated with Mineral Turpentine 2 Wash with a solution of mild soap and water and rinse thoroughly After cleaning inspect for dents burns rubbing marks cracks and signs of delamination 3 Inspect cowling camloc mounts for rigidity amp bonding amp for wear Inspect locking pins for damage Inspect rubber grommets in firewall for wear or damage 4 Replace any damaged or worn parts with new parts 11 1 3 REPAIR Repair is limited to replacement cam locks Rivets fixing cam lock anchor lugs should be backed with washers 11 2 ENGINE The engine is a JABIRU 6 cylinder 4 stroke air cooled driving a fixed pitch wooden propeller The front Starboard cylinder is numbered 1 the front Port is numbered 2 the centre Starboard is numbered 3 the centre Port is numbered 4 the rear Starboard is numbered 5 and the rear Port cylinder is n
20. un Aircraft Service Manual Jabiru J230 C 10 SECTION 10 RUDDER CONTROL SYSTEM 10 1 RUDDER PEDAL SYSTEM Refer to Figure 36 Rudder control is maintained through the use of rudder pedals which also control nose wheel steering The system is comprised of rudder pedals two push rods a centering mechanism and an enclosed push pull cable 10 1 1 REMOVAL AND INSTALLATION 1 Unbolt push pull cable 2 Unbolt both steering push rods Unbolt rudder pedal bearings 4 Remove cover plates and nylon bearings 5 Remove both pedal bars 6 Reverse the preceding steps for installation 10 1 2 INSPECTION AND REPAIR Ts 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 Replace any distorted or worn parts revision 0 Dated Feb 2006 Issued By RAS Page 100 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM ft Pity Pta ircra A Aircraft Service Manual iru Jab Jabiru J230 C Ald HOSLAY 40 LN38NOO JHL LNOHLIM 931902 38 LSNM ONY LHSIYAdOS SI NWA SIHL 26 982 010 sa Nava 38 AH3HLO 031319396 SSSTI
21. eee etee eese eene testa een seins ta 153 15 1 EXTERIOR 5 tse gy 153 o E 153 15 1 2 Materials Recommended 153 15 1 3 Painting Equipment Required 153 15 1 4 Painting 153 16 SECTION 16 PLACARDS 44 eere eese etae tene inet paetos eroe eno thee Eee 156 16 1 J230 G DECALS Pete edet 156 16 2 COCKPIT PLACARDS GENERAL a etie Festes exe eue TE ERROR TRE Ee 158 16 3 COCKPIT CONTROL DECALS eet eder ee Pete Re cues 158 16 4 EXTERNAL FUSELAGE sacs ese 159 17 SECTION 17 FAIRINGS 160 17 1 WHEEL SPATS M aa e E 160 17 2 WING FAIRINGS rte eae 160 17 2 1 Removal 1 160 17 3 REPAIR E m 160 18 APPENDIX I JABIRU 3300 161 19 APPENDIX II JABIRU ENGINE PARTS 162 20 APPENDIX
22. 8 gt a 0 d 2 o 5 N c c CU lt cc en 2 2 c e LL jrevsion j Print Date 14 01 2009 4 41 00 PM LMiles Technical manuals 230 J430M230 J430 Work filesJ230 C Tech Rev 1 doc Jabiru J230 C Jabiru Aircraft Aircraft Service Manual 208129 1005918 LSvO ASSY 133HA END gro E 3 THNIH sa uama 9 031519345 SS3INN SLIWR 26 982 OLO 017 Ald HO3LAV 40 LNSSNOD LNOHLIM 00 S3u L3INETTIALNIT gh ION 5 IHOIHAdOO SI DNIMYHC SIH Vd HO3lAV 3V9810NOGd t 9 Sct S9c0cSW e 0 lt N6z008d 4 2011 28 6216129 gt jr E Figure 18 Nose Wheel Hub Assembly o n lt e 2 o 2 e e N LL a z o o rtc Print Date 14 01 2009 4 41 00 PM LMiles Technical manuals J230 J430230 J430 Work filesJ230 C Tech Rev 1 doc Jabiru Aircraft un Aircraft Service Manual Jabiru J230 C 6 7 NOSE WHEEL STEERING SYSTEM 6 7 1 5 7 1 STEERI
23. Dated Feb 2006 Issued By RAS Page 12 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft un Aircraft Service Manual Jabiru J230 C 2 Section 2 Service Manual 2 1 LIST OF EFFECTIVE PAGES Page Revision Date Page Revision Date Page Revision Date 1 1 16 5 06 61 1 16 5 06 121 1 16 5 06 2 1 16 5 06 62 1 16 5 06 122 1 16 5 06 3 1 16 5 06 63 1 16 5 06 123 1 16 5 06 4 1 16 5 06 64 1 16 5 06 124 1 16 5 06 5 1 16 5 06 65 1 16 5 06 125 1 16 5 06 6 1 16 5 06 66 1 16 5 06 126 1 16 5 06 7 1 16 5 06 67 1 16 5 06 127 1 16 5 06 8 1 16 5 06 68 1 16 5 06 128 1 16 5 06 9 1 16 5 06 69 1 16 5 06 129 1 16 5 06 10 1 16 5 06 70 1 16 5 06 130 1 16 5 06 11 1 16 5 06 71 1 16 5 06 131 1 16 5 06 12 1 16 5 06 72 1 16 5 06 132 1 16 5 06 13 1 16 5 06 73 1 16 5 06 133 1 16 5 06 14 1 16 5 06 74 1 16 5 06 134 1 16 5 06 15 1 16 5 06 75 1 16 5 06 135 1 16 5 06 16 1 16 5 06 76 1 16 5 06 136 1 16 5 06 17 1 16 5 06 77 1 16 5 06 137 1 16 5 06 18 1 16 5 06 78 1 16 5 06 138 1 16 5 06 19 1 16 5 06 79 1 16 5 06 139 1 16 5 06 20 1 16 5 06 80 1 16 5 06 140 1 16 5 06 21 1 16 5 06 81 1 16 5 06 141 1 16 5 06 22 1 16 5 06 82 1 16 5 06 142 1 16 5 06 23 1 16 5 06 83 1 16 5 06 143 1 16 5 06 24 1 16 5 06 84 1 16 5 06 144 1 16 5 06 25 1 16 5 06 85 1 16 5 06 145 1 16 5 06 26 1 16 5 06 86 1 16 5 06 146 1 16 5 0
24. MOHI S ASS ONISNOH ITIN YN 02162 GCt S9 OcSW OIONSOS 819 096Nv ETETEN 2 alvid ONINO 85 ASSY IN3A 1300 2530 5 31 26 LON 00 53 NI SNOISN3HIQ FE eden 2309 38 LON LENN ANY HOliAgO SI QNIN SIHL LMiles Technical manuals J230 J430230 J430 Work filesJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft un Aircraft Service Manual Jabiru J230 C 12 SECTION 12 FUEL SYSTEM 121 DESCRIPTION Refer to Figures 46 and Undefined Bookmark NONCSVLAF for system schematic details Fuel is pump fed from two composite fuel tanks inside the wings through a header tank fuel filter amp shut off valves and through a bulkhead in the firewall to the carburettor The primary fuel pump is attached to the engine A secondary electronic pump is mounted in the cabin refer details below Positive ventilation is provided by vented fuel caps The airspaces of all tanks are connected to ensure even feeding 12 1 1 LSA AIRCRAFT FUEL SYSTEM 1 A schematic drawing of the system is shown as Figure 46 2 The 5 Litre header tank is housed in an enclosure behind the rear cockpit bulkhead This enclosure is sealed from the cabin amp vented overboard 3 The fuel filter and au
25. i E ns ca HES Y ff A 6 i put T Y 9 2 N N 14 i fee 1 1 boy 11 1 la Figure 43 Carburetor Heat Box Revision Dated Feb 2006 Issued By RAS Page 115 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft me un Aircraft Service Manual Jabiru J230 C 11 8 EXHAUST SYSTEM The exhaust system consists of front and rear exhaust manifolds attached to the engine block and a muffler assembly and springs which attach the muffler to the manifolds Refer to Figure 44 11 8 1 EXHAUST SYSTEM REMOVAL AND INSTALLATION 1 Remove both top and bottom engine cowls 2 Remove springs WARNING Never remove coupling spring with a sharp object or one which can mark the spring material A rounded screwdriver shank or a hook fashioned from bar stock is ideal 3 Remove muffler assembly 4 If necessary remove exhaust manifolds from engine 5 Reverse the preceding steps for installation 11 8 2 EXHAUST INSPECTION As all exhaust systems are subject to burning cracking and general deterioration from alternate thermal stress and vibration inspection is very important and should be carried out every 100 hours of operation In addition an insp
26. 2 An alternative method which may be used is to fill the wing tanks with fuel then shake the aircraft by pushing up and down on the wingtip While small droplet leakage is normal fuel must not squirt out of the vent 3 If a fault is detected disassemble the vent and replace any defective parts Revision Dated Feb 2006 Issued By RAS 124 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM ft Pity Pta ircra A Aircraft Service Manual iru Jab Jabiru J230 C 079v ASSY MNVL TANS 93 NIH au 26 982 OLO NOV may 15 OL 5 F SSWHSHLO 031 SSIINN OLT HOALAW JO INISNOD LNOHLIM 031402 Vid HO3LAV SSHEWITIW 38 LON LSM ONY 4 9 SI SIHL SNOISNSWIC Eu TY SAOWSY WW L XOYddy 3903 JOL t A THI ISSSV 30338 5 SI SATWAIWHL ONY Nid ONUV3071 SOYVMOL O3ENSIHO SSTOH LNSA SYNS MYA AGO 68339 9 8 1 OL 029 31011207 NAAOHS SV dl 19 d OL NYHL 134208 HATTA 30 MINIS N33A 38 30V31
27. N Dated Feb 2006 Issued By RAS Page 159 of 171 LMilesVTechnical manuals 230 J430230 J430 Work 1 5 230 Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft me un Aircraft Service Manual Jabiru J230 C Decal Detail Preview No Step P No 5A006A0D Qty 2 Required Attach one to the top of each main wheel spat PING 5039094 ELSE Qty 8 Required Attach to the fuselage and wings beside each wing and lift strut attachment fitting 17 SECTION 17 FAIRINGS The J230 is fitted with fairings around the wing roots wing struts under the fuselage and wheel spats 171 WHEEL SPATS Removal and installation of wheel spats is covered under 6 3 4Main Wheel Fairing Removal and Installation and 6 5 4Nose Wheel Speed Fairing Removal and Installation 17 2 WING FAIRINGS 17 2 1 REMOVAL AND INSTALLATION These fairings are attached using self tapping screws The fairing can be removed once these screws have been taken out When removing the wing strut fairings care should be take to avoid scratching the strut Installation is the opposite of removal Care should be take when tightening self tapping screws as when screwing into fibreglass it very easy to strip the hole so that it doesn t not tighten 17 3 REPAIR The fairings on the J230 are made from 2 layers of 300gram m twill weave fibre glass and epoxy resin When damaged they may be repaired using an eq
28. lt oc en 2 o 2 e e N LL O o a z 9 o 2 tc Print Date 14 01 2009 4 41 00 PM LMiles Technical manuals J230 J430230 J430 Work filesJ230 C Tech Rev 1 doc Jabiru J230 C ft Pty Pia ircra A Aircraft Service Manual iru Jab 9 ASSY OIMIOSTS E cena m 5 Ji ON 26 982 OLO W 35WSHIO 031910995 SEINN SLINN 31V 561 Ald HO3LAV 4O LN3SNOO 031900 Vd HO3 LAV S3913NI77IIA NI iF pom 38 LON LSMH ONY 1H9I4dO9 SI NWO SIHL SNOISNSWIG pode 5 S ATSWSSSV GOYHSNd 3dis ino h e 2 o 2 2 0 E MOLVOIONI NOLLISOd m LN3HHOV LLV 19 S 5 2 21 72 I e o 3SIvH S Q QON 18 0 a NOLLISOd 193802 iL NOLLVTIVISNI 38 2 NWS 14 A TIVOLLHSA ite Q AINNOW OAY3S 30 NOWISOd N 5 5 D AGuos N gioHd SL 1 318 0 dvd i goHssove 2 LAN 201 S OLENV EL 1108 9U L
29. 79 43 AILERON BALANCING Ses aes a aa 80 7 5 CONTROL RIGGING itched Motte ee e eret te e ert eee lela 80 8 SECTION 8 WING FLAP CONTROL 5 8 442 4 t tasa 82 8 31 WING FLAP CONTROL 5 5 82 8 1 1 OPERATIONAL CHEGK orb el erint 82 8 42 FLAP Switch ASSEMBLY odd ea aA co e RR 82 81 3 FLAP cross SHAFT 82 8 1 4 Flap Cross Shaft 82 8 1 5 cross shaft inspection amp 82 8 1 6 cross Shaft 82 8 1 7 Position Indicator Removal 83 8 1 8 flap position indicator inspection amp 83 8 1 9 X Flap Position indicator installation eene denen nnn ntn nennen nter 83 8 14 10 Flap Control Bod iio eid toda ten pt a extant det OA 83 82 JE aaa 83 8 2 1 Removal and INSTA AON 83 Revision Dated Feb 2006 Issued By RAS Page 6 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft u
30. DIMENSIONS CALE THIS DRAWING COPYRIGHT AND MUST NOT prouection INHILLIMETFES DO NOT SCALE AVTECH PIL COPIED WITHOUT THE CONSENT OF AYTECH PTY LTO GENERAL TOLERANCES WHOLE NO S 305 ONE DEC 0 25 TNO DEC 1005 ANGLES 05 DRAWN Jw ACN 010786973 TILE HINKLER AIRPORT FUEL GAUGE ASSY BUNDABERG 4670 Figure 50 Fuel Gauge Electric Sender Assembly Parts List ITEM PART No DESCRIPTION QTY 1 4 044800 SIGHT GLASS BODY SP WET WING 1 2 4953224 SHORT SIGHT GLASS COVER 1 3 4920223 HOSETAIL SIGHT GLASS 1 4 4953324 SHORT SIGHT GLASS LENS 1 5 PH0991N SHORT SIGHT GLASS O RING 1 6 8 32 BUTTON HEAD SCREW 6 7 PL4A000N THREADED T FITTING SP SIGHT GLASS 1 SECURE WITH LOCTITE 243 PRESS FIT HOSETAIL FITTING WITH LOCTITE ZDN FOR R S 4A044CON Cc D HOSETAIL ROTATED BY 180 SIND SECURE _ M A LOCTITE 243 G NOTE ASSY P No 4A044A0D SHOWN 4A044CON OPPOSITE Jw 2 041005 DIMENSIONS THIS DRAWING IS COPYRIGHT AND MUST NOT BE SCALE 1 6 6 03 PROJECTION IN MILLIMETRES DO NOT SCALE AvTECH P L COPIED WITHOUT THE CONSENT OF AVTECH PTY LTD 74 155 DATE LIMITS UNLESS SPECIFIED OTHERWISE 0 5 08 dere A E TITLE DWG No IMATERIAL
31. Dated Feb 2006 Issued By RAS Page 30 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft me un Aircraft Service Manual Jabiru J230 C 3 6 3 11 AIRCRAFT 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 To be displayed in the aircraft at all times e Placards as detailed in Flight Manual Owner s Manual To be carried in the aircraft at all times e Flight Manual Owner s Manual To be made available on request Aircraft Registration e Radio Station License Pilot License Certificate including Medical Certificate if appropriate 3 6 3 12 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 Section 18 APPENDIX JABIRU 3300 ENGINE of this manual During the run up observe the following making note of any discrepancies or abnormalities 1 Engine temperatures and pressures 2 Static RPM Also refer to Engine Instruction Manual 3 Magneto drop Also refer to Engine Instruction Manual 4 Engine response to changes in power 5 Any unusual engine no
32. ENGINE INSTALLATION MANUAL eese eese enero soto senos 163 21 APPENDIX IV PROPELLER SERVICE 2 1 164 21 1 APPROVED INSTALLATIONS 164 21 2 IDENTIFICATION STAMPINGS x vai oh te ee 164 21 3 DESCRIPTION M 164 21 4 INSTALLATION M c XM Ee 165 21 5 TO REMOVE EXISTING 167 21 6 TO ASSEMBLE AND REPLACE PROPELLER 558 167 21 7 izrcuieles Word cd c 168 21 8 PROPELLER BALANCING PROCEDURE 000000sseeeeeeeeeseeeeseeeseseseeeeeeeseesblesseeeeeeeeeseseeeeeseeeeeeeeeeeees 169 22 APPENDIX V AIRWORTHINESS 200 170 Revision Dated Feb 2006 Issued By RAS Page 9 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft un Aircraft Service Manual Jabiru J230 C 22 1 170 22 2 INTERIOR FLAME RETARDANT MAINTENANCE 8 2 0 nnn nnn nnn 170 22 3 COMPOSITE INSPECTION amp MAINTENANCE
33. JO L33HS 2 00 9 TWILA HAA na 31 0 S0 e vl V o0 Uve e JINN HLO HO SLINN HO NIA H3HLI3 SNAM HOLY INDY 15 Nid SNG OL JOHLNOO 39v110A MOTTAL SNINHVM 3OVLIOA MOT OL LINN NaS FOULS Nid 5 Z MOLVNH3LT WOW 3ma Wd l YOLYNYALTY 3079 3ivd AM3lLVH OL o18 JA LINN ASOULS diL ONIM Jp HOLLAHNEHVD 3805 M3ldvOVv LNNOW 31872 38015 411 ONIM 1391 a 00 FOVLIOA SNIUIAA 39nvo9 3 NOVP OOVEId Q 31 ONINHVA 260014 HO LIMS 1831 NOY LOYE ld HOLSISSH NOILONGSY NLOWPAAd T 3HVdS NOILdO HOSN3S 13A31 MNV L H3QV3H NOLLdO 13n43 NOILdO LINN a3envo 1914 TIVI S HOSSSHYddNS JH ADYV1 HOSSSYddNS JH NOILdO SI33 NONAG H3 L1l3 3SION LNIOd NOILO3NNOO 380H1S OP LP OF 6 BE LE 796 756 pe 5 MNoll34nguvo OL 3NISN3
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36. nouoaroud 6 1 a1vos 1 1 31 25 1 IIOS 11 130 39NIH 11130 AVL NMOHS LON NIMS HOLVA3T3 NMOHS SV OL ANN AX 962 Lave iran NON TWIIHIWNWNOD ILON 43 40 LIAI dOd ANNSO 26 6 N66 0Hd El 9 LAN HOHONV 801 6901 ZS 9 Nid PEHLOOE 9 Nid 6910064 OL 9 MIYOS SvZ 902G SlIN 5 9 JV3139NIH HOLIvA313 7891002 8 9 3931 HO1VA373 6 1002 9 9 1 ON dD LAA dOd ANNS ILE N6500Hd 8 9 H3HSV A TWD 1914 OZ X X 5 9 9 vSv 2 ON dO LAA dOd N6 00Hd t WIL NOISN3LX3 FO6NLOOZ E L AISWYSSV HOLvA313 89800 L 009 0027 ATSWASSY TYL Tv LNOZIHOH 1580 ALO NOILdIHoS30 H38 ADN Led 3 3811 sued Figure 32 J170 Models Horizontal Tail amp Elevator Assy e LO lt e 2 o 2 e e N LL a a z 9 rtc Print Date 14 01 2009 4 41 00 PM LMiles Technical manuals J230 J430230 J430 Work filesJ230 C Tech Rev 1 doc Jabiru Aircraft 25 2 N Aircr
37. 27 3 4 5 Engine and Engine Compartment esses seien 27 3446 Propeller sias Aer aere ME aa pe 27 c INED Emu 27 3 5 NEI IIe Spleen m 27 3 5 1 Wheel Bearing Mains and 27 3 6 INSPECTION T Y 28 3 6 1 Inspeccion eal taca ahnen a e Rosle e 28 3 6 2 Inspection Charts ssa aaa ae an aa a an 28 3 6 3 INSPECTION GUIDELINES 28 Revision Dated Feb 2006 Issued By RAS Page 4 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft Mn un Aircraft Service Manual Jabiru J230 C 37 MAJOR INSPECTION REPLACEMENT cceeeeeeeneneeenenene nennen mene n enn ne nennen nnne nennen nee nennen nnne eren nnne nennen 32 3 7 1 MANDATORY INSPECTION a 32 3 7 2 INSPECTION CHARE SRSA 33 4 SECTION 4 FUSELA GR oc m m 37 4 1 FUSELAGE rt en e a v er ur 37 4 2 WINDSHIELD AND 37 4 2 1 IB edo m 37 422 Cleaning aae tt re fen 37 4 2 3 e E
38. A NCORRZCT FUEL LINE ROJTE AM Us Ak INVERTED U FORM 7 POTENTIAL AIR LOCKS LJ INES TO BE ROUTED WITHOUT ANY KINKS Al TRAPS 176 VERTED Us INI Figure 3 Fuel Line Routing 3 6 3 6 ELECTRIC FUEL PUMP e Ensure the fuel tanks are low Less than 40L total Turn master switch ON and confirm that the fuel pressure light is illuminated If it does not light turn the master switch OFF and remove residual pressure from the lines Turn the electric fuel pump ON e Confirm that the pump is audible and that the pressure warning light turns off 3 6 3 7 METAL PARTS security of attachment cracks metal distortion broken welds corrosion and any other apparent damage 3 6 3 8 WIRING security chafing burning defective insulation loose or broken terminals heat deterioration and corroded terminals 3 6 3 9 BOLTS IN CRITICAL AREAS correct torque in accordance with torque values given in the chart in Section 2 when installed or when visual inspection indicates the need for a torque check NOTE Torque values listed in section 2 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 3 6 3 10 FILTERS SCREENS AND FLUIDS cleanliness contamination and or replacement at specified intervals RESON
39. Jabiru J230 C Aircraft Service Manual 53 035 ASSY SAMO 01410314 1 0 0 wo Wa Q11A1d AV 40 IHISHOO LA 090400 39 LON 15 ONY LI OTHAdOO SI ONAYA SII LL Vd HOSLAV 6 SAR 13 3ri313130 93NNI 06 N6810Hd ANDON 318Vv2 L coHssove LAN 3201 i 1108 9L QOY LINS OL QOY 3AIH Tovesove 1AN 3NN 0 ASSV S TONLNOS dv14 GOY JIV JOTAN H3HSVM DOTAN 80 SSANYOIHL 21 H3HSVM 1v 14 SLE t l HSN N39V4S SYOULS SIIS dvd 21412313 YOLVNLIV HV3NIET ANnOH OAH3S 14 12313 SH INOA 3 1VHA Otr EET S O dO HSfld N dvd 30018 ALO NOlidid3S30 YSEWNN Lavd PN sued T 9 o 2 o i Lud c Ta A o 3 2 iL N T
40. NOILdO Sd H30 NOdSNVH L 2IH 10313 NOLLdO SHA SHA HOLIMS 3unssaud 13n3 NOVPOOVEld LHDIT NOWSOOVEld N3349 LH917 1970205 XNY HOLOW HOLVINDSY HOLVNH3 LTV 1303 ILIN LIOA HOSN3S OIL3NOVIA HILIWOHOYL H313ll HALSWOHOVL HOSN3S 3univH3dWal H3ONI1AO JYS LON 04 5 SNOISN3WIQ Ald HOSLAY JO LN3SNOO LAOHLM 031909 38 LON LSOW ONY 0 SI 5 43 LE 08 80 40 92 GS 0 10 61 81 p OWS 3onvo 1 110 1 110 aunssaud 110 110 ISNA H3 V3ua LINDHIO 791 S Ek bh OL VOL HINVIHA LINOHIO 6 yst HSMWSHE LINOHIO 8 HOLIMS 4 HOLIMS 213 9 N9L Old HOLIMS 316050 33O NO S N90 0ld NOLLn8 HALVLS GION31OS H31HVIS 76 H31HVIlS 72 AH3ILVS 1 Wvuovid o E o S a e 5 iL we A lt T a 2 o 40 N LL 9
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42. 2 rc Print Date 14 01 2009 4 41 00 PM LMiles Technical manuals 230 J430M230 J430 Work filesJ230 C Tech Rev 1 doc Jabiru Aircraft me un Aircraft Service Manual Jabiru J230 C 14 3 BUS BARS Electrical power for electrical equipment and installations is supplied through Bus Bars The bus bars are mounted at the rear of the lower instrument panel Access is gained by removing the main instrument panel see Paragraph 13 2 1 14 3 1 MASTER SWITCH When using a key switch the Master Switch activates a relay which in turn powers the bus bars When using a toggle switch it activates the power direct from the battery Refer to Wiring Diagram at Figure 59 14 4 BATTERY POWER SYSTEM Refer also to Wiring Diagram at Figure 59 14 4 1 BATTERY The battery is 12 volts and approximately 16 ampere hour capacity The battery is mounted in the engine compartment 14 4 2 BATTERY TROUBLE SHOOTING Trouble Shooting is limited to inspection of wiring and terminals battery charge condition and battery solenoid 14 4 3 REMOVAL AND INSTALLATION Disconnect the battery security strap 2 Disconnect the ground cable from the negative battery terminal black insulation WARNING When installing or removing battery always observe the proper polarity with the aircraft electrical system negative to ground Reversing the polarity even momentarily may result in failure of semi conductor devices a
43. AS DETALED AVTECH PIL ACN 010 786973 IHINKLER AIRPORT BUNDABERG 4670 THS DRAWING IS COPYRIGHT AND WUST NOT BE SCALE 1_200 COPIED WITHOUT THE CONSENT OF AVTECH PTY LTD ss DWG No TITLE FUEL GAUGE ASSY 4 278 00 1 1 2 Figure 49 Fuel Gauge Electric Sender Installation revision LMiles Technical manuals 230 J430M230 J430 Work filesJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Dated Feb 2006 Issued By RAS Page 128 of 171 Jabiru Aircraft Aircraft Service Manual Jabiru J230 C PART No DESCRIPTION PISAO17GON 1 FUEL GAUGE SENDER GEAR 8 PIVOT HOLDER SIDEK 1 FUEL GAUGE SENDER FLOAT SIDEK p 017 0 1 FUEL GAUGE SENDER FLOAT GEAR SIDEK cc 01700 1 FUEL GAUGE SENDER FLOAT ARM SIDEK 17 0 FUEL GAUGE SENDER FLOAT SIDEK PI3A017FON FUEL GAUGE SENDER SHAFT GEAR SIDEK PISAO17HON 1 FUEL GAUGE SENDER MAGNETS SIDEK 4A278D0D 1 FUEL GAUGE SENDER DRIVE SHAFT 1 87 9 Y 8 STAINLESS MAGNET CAN BE TWISTED ON 5 SHAFT ONCE FITTED TO CALIBRATE FUEL GAUGE AADTBADD ASSY SEE SHEET 1 DRILL ON CENTRELINE NO MORE THAN 25MM DEEP ROUGHEN OR KNURL BEFORE BONDING BENT AS SHOWN FOR LS TANK EXPLODED VIEW OF PI3ADITADN ASSEMBLY BEND SO FLOAT ON OPPOSITE SIDE FOR RS TANK CUT 66MM LONG
44. eee E 11 1 2 HISTOR TABLES 12 2 SECTION 2 SERVICE MANUAL sessesesseesossescoscesossoesoesososscosoesossossossolassoosoecsosobeossossssoosoessesoesocsssssssosssesesosso 13 21 LISTOF EFFECTIVE PAGES 2 13 2 2 GENERAL DESCRIPTION 14 2 3 14 2 13 17 2806 ette deer e ee te de ener dos eer tote 14 2 4 AIRCRAFT SPECIFICATIONS 14 2 5 CENTRE OF GRAVITY 6 0 2 0 400000 0000000 14 26 TORQUE VALUES nire eer xe E e een 15 27 AIRCRAFT SPECIFICATIONS 15 2 8 RECOMMENDED TORQUE VALUES FIBREGLASS nennen nennen 17 2 9 AIRCRAFT STRUCTURE tiet coe tue ed xa A eee 17 3 SECTION 3 GROUND HANDLING SERVICING LUBRICATION amp INSPECTION 18 3 1 GROUND 18 3 1 1 Viale PUER eer te A 18 J 2 SACKING auo E inten ane 18 ala osse atte eae eite touc ix 19 NE EEUU MEE E rm 20 lS FOO E 20 3 1 6 HE 20 3 7 Flyable SIOT ge u
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46. Figure 41 LSA Variant Throttle Panel Mounted N bs t A lt 5 2 e e N LL z o o iu rtc Print Date 14 01 2009 4 41 00 PM LMiles Technical manuals J230 J430230 J430 Work filesJ230 C Tech Rev 1 doc Jabiru Aircraft 2 ad Aircraft Service Manual Jabiru J230 C Parts List Parts List ITEM PART NUMBER DESCRIPTION ITEM PART NUMBER DESCRIPTION QTY 5 MS20365 1032 3 16 NYLOC NUT 11 1 5 043 00 1 INSTRUMENT PANEL FASCIA GLASS COCKPIT J160 1 6 3A005C1D 1 THROTTLE CROSS SHAFT PANEL 5A043 1 2 PZ0059N 1 TUBE CLAMP 4 7 3 005000 2 THROTTLE LEVER INPUT INSIDE PANEL 2 3 AN3 13A E BOLT 4 8 AN3 11A 3 16 BOLT 5 4 AN970 1032 3 16 PENNY WASHER 6 9 AN960 10 3 16 FLAT WASHER 7 10 3067134 7 OUTPUT LEVER THROTTLE JABIRU 1 11 3A005E0D 4 PUSH ROD SHAFT HIGH MOUNT THROTTLE 2 12 2 KNOB RS COMP 771 730 2 13 0009 3 16 MALE ROD END 2 14 316 3 LOCK NUT 2 18 AN960 416 1 4 FLAT WASHER 2 17 3A005F0D 2 PIVOT BLOCK HIGH MOUNT THROTTLE 2 18 3 005 00 2 SPACER PIVOT BLOCK MOUNT 2 19 ANS 224 3 16 BOLT 2 20 3A005J0N SPACER BUNDY TUBE PIVOT 17 LG X 1 4 OD 2 21 3 16 POP RIVET 6 22 5A043COD 1 GLASS INSTRUMENT PANEL MOULDED SUPPORT ASSY 1 23 3 005100 1 THROTTLE STO
47. Figure 44 Exhaust System Revision Dated Feb 2006 Issued By RAS Page 117 of 171 LMiles Technical manuals 230 J430M230 J430 Work filesJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft un Aircraft Service Manual Jabiru J230 C 11 9 EXTREME CLIMATIC CONDITIONS 11 9 1 DUST Dust induced into the carburettor air intake system is probably the greatest single cause of early engine wear When operating under high dust conditions the carburettor air filters should be serviced regularly as outlined in Paragraph 11 7 4 Servicing intervals for aircraft operating in extreme conditions are at the operator s discretion 11 9 2 SEACOAST AND HUMID AREA In salt water areas special care should be taken to keep the engine and accessories clean to prevent oxidisation In humid areas fuel should be checked frequently and drained of condensed moisture Revision Dated Feb 2006 Issued By RAS Page 118 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru J230 C Jabiru Aircraft Aircraft Service Manual Oddly HITNIH ELB 992 010 Nav c 2 o c 5 o LL A lt
48. SOS Occ 9 1 01 5300 39NIH 2903 SNOW Old lt 5 096 OL S 13 8 0 5 OL NIS3H AXOd3 003621 ISN E ANONWLLNV 965 NIVLNOO OL TYoNw OL 31130Hd 5 3NIJ3O OL HWw dovegov AINON ISN INIS 88 NOILO3S 9 AXOd3 HUM HOWL ASSY 9 HO1VO 6 1902 5 5 Qnis 9 9 0092 t 0L LSA 4042189 9 NOILV2O1 9 901NvO ONVid WNININN TY S zsz0zsW 2 L MOD Nivrrovl I sNOISN3HIO e TEE IK E SETTE ALD 031905 38 LON 15 ONY LHSIMAdOO SI SIHL gt o 2 e 5 D i N e lt e 2 o 2 e e N LL a LMiles Technical 51 230 24301 230 430 Work filesJ230 C Tech Rev 1 doc REVISION Print Date 14 01 2009 4 41 00 PM ft Pity Pta ircra A Aircraft Service Manual iru
49. 30 45 606 lt 0 1 L 1108 8 N3lsvW oz M3HSVM 9iv 096NV 1108 9 6L 6062092 9 149 H3ISVW Td INNON 60009 8L Svea LAAN 7605206 5 T1A9 W 5 4 760990 21 2 11 5891 6 v N3Ovds 602706 SNOT SONY 602 lt 06 YSHSVM NOTAN 7601702 SL INN Z lNOddns aovezove L lJOHS SONY 601202 Nid Ec 1 S99vZSW EL ALD NOlLdldoS3 0 Lad ALO 2530 dvd E _ 31 25 LON 00 SIHLINITIN NI SNOISN3NIQ mp mH 9 260 OO Figure 20 Brake Master Cylinder Assy Page 74 of 171 Issued By RAS co e e N Q LL a Print Date 14 01 2009 4 41 00 PM LMiles Technical manuals J230 J430230 J430 Work filesJ230 C Tech Rev 1 doc Jabiru Aircraft me 524 un Aircraft Service Manual Jabiru J230 C 7 SECTION 7 AILERON CONTROL SYSTEM 7 1 AILERON CONTROL SYSTEM Refer to Figure 21 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 e
50. 37 424 37 4 2 5 SCI ICIS EE 37 4 2 6 GL 38 4 2 7 MEC EE 38 4 2 8 9 1 A 38 43 CABIN DOORS 38 4 3 1 Removal and Installation e ea ase es a a 38 432 AUSTEN sue o uera iate estos esten 41 4 3 3 Door Sedis do 41 4 3 4 oe 43 4 47 SEATS vex Cork ve ea ES a Yoox E 43 4 4 1 TAG DAN P A 43 45 UPHOLSTERY diee 43 4 5 1 UPHOLSTERY CLEANING FLAME RETARDANT 43 4 6 SOUNDPROOEING ter Wa sexo Dess bes 43 Ad SAFETY PROVISIONS dese n ar ior d 43 4 7 1 SOCAL m 43 5 SECTION 5 WINGS AND EMPENNA Q E ccccccsssssssscsccsssssscccscccssssssscsccccesssssssccccccessssssscscccsecescssssccsscessceees 44 5 1 WINGS 44 5 1 1
51. 5121 ORING 85121 VITON 1 8 950 FLAT WASHER 6 SCREW 1 9 017 FUEL GAUGE SENDER MECHANISM ASSY SIDEK 1 1 X ES A 7 gt 2 x NS 2 AN 2 EV MAY BE BENTFOR 60 2 gt 777 2 FINAL ADJUSTMENT N Je ZK 3 rs gt MO CN x APPLY FLOCKFLLETRA jjl 5 LAYERS 12 NK AROUND FITTING P AROUND FITTING FUEL TANK ENDPANEL SECTION A A Reverse the preceding steps for installation SEALWITHLOCTITES77 ON FINAL INSTALLATION ayo FUEL TANK BOSS NEEDS TO BE BONDED IN SO SCREW HOLES ARE HORIZONTAL AS SHOWN USE SPOT OF SILICON TO BED IN GAUGE Remove the 4 screws holding the sender mount to the tank boss amp remove the Wiring details for the system are given in Figure 59 and Figure 60 BOND IN ARM WITH 5 MINUTE ARALDITE INSTALLATION ENSURE FLOAT ARM CLEARS FUEL TANK BREATHER LOCK SCREWS WITH LOCTITE 243 ON FINAL INSTALLATION BENT IF CONNECTORS FOUL FUSELAGE ie VARS Gi x NOTE FUEL GAUGE MUST CALIBRATED TO READ EMPTY WHEN TANK HAS ONLY UNUSEABLE FUEL DIMENSIONS PROJECTION SH a Es m GENERAL TOLERANCES ONE DEC 0 25 TWO DEG WHOLE NO S 165 os 20 05 ANGLES 05 forsan JW MATERIAL
52. 8 Instrument panel shock mounts decals amp labels 9 Fresh air ventilation system P 10 Cabin heat 11 Cabin upholstery trim 12 Switches fuses B 13 Pitot amp static system Revision Dated Feb 2006 Issued By RAS Page 35 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft me un Aircraft Service Manual Jabiru J230 C Annual Inspection Each 200 Hours Each 100 Hours 14 Radio intercom amp headsets 15 Antenna amp cable 16 Door catches 17 Stall warning 18 Battery battery cradle amp cables 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 1 Cables amp clamps 2 Rod ends P 3 Trim control amp cable 4 Travel stops 5 Decals amp labels 6 Flap control amp linkages 7 Elevator control amp linkages 8 Rudder pedals amp linkages 9 Exterior surfaces of control surfaces 10 Control horns hinges amp hinge lock tabs 11 Aileron controls amp linkages 12 Rigging check flight 13 Throttle controls Revision Dated Feb 2006 Issued By RAS Page 36 of 171 LMilesTechnic
53. Leak in instrument case indicator and check reading Replace instrument Check shock mounts Partially plugged static line Excessive vibration Replace defective shock Hand vibrates TURIS Substitute known good Defective diaphragm indicator and check for vibration Replace instrument 13 3 10 PITOT TUBE ALIGNMENT Refer to Figure 56 For correct airspeed indication pitot tube must be properly aligned Open end of tube must be perpendicular to longitudinal axis of the aircraft Refer to Figure 56 for alignment details Revision Dated Feb 2006 Issued By RAS Page 139 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM ft Pity Pta ircra A Aircraft Service Manual iru Jab Jabiru J230 C 30 I33HS L QOVSSOVS 3ovi3snd 3015110 OL 3801 29 0640 ASSY 5u3avaNng lMOdMIV M3 DINIH 46 982 010 1 21115 SV AVIS LV SAMT 0119199530 ON IHVd ASSY lOlld 911915 7608701 ASSY LOLId 607 06 6 2 1 216 14 ASSY 4 HILM 00 70 0 4 3913503 JASNI OL 310H 3801 9 135 3 OLNI NYHL INL eg Jd4 A138 03345 SAIL 912 HLM SONILL 9 SLNAWNYLSNI OL
54. NIOOYZ0d amp 2 dOd 9 75 BL 8 St 81 HIL 2 l 1 04 ASSY 21 2 E102202 9 631536 ASSY 1 0 401 YOQA 201 202 6 00 7 002 51 MOQNIM LNOHJ 0 4 v 91 LNOWS E HOIBSLNI 1 0961 I AN3ASOHOJNISH 39NIH 202602 ALD 2830 Lud 9 WALI 157 S18 Vd Figure 5 Front Door Assembly 89 of 171 Page RAS Issued By co e e N LL Renson Pa Print Date 14 01 2009 4 41 00 PM LMiles Technical manuals J230 J430230 J430 Work filesJ230 C Tech Rev 1 doc ft Pty Pia ircra A Aircraft Service Manual iru Jab Jabiru J230 C 40 Lars sv WIAA 10 O0v 00Z ASSY YOO uso NISIH AXO 009521980 ASN sui Vd HOSLAY Eg oF sunn NIMS HOOG OL NO 207 SI HOIHSLNI t 106202 8 l HOLYD ONINIOF 340438 325 HOVLLY SSDNIH H000 3H3HA 30 SHSAY1ESINIMS JO SH3AV1Z SI NIMS 1 tM9OOL6 Yad SV JI8W3SSV E 9 0013 HLM NI SIIYY ANOA di 544 ONITINOW MOIS3LNI OL NO Q39014 IN3A3OHOANI3H ONY SSOVAYNS N334138 29014 9 5 ONITINOW 3
55. NN ENYA 1NN YOHONY 404 e NOLLO3P Odd 31405 LON 00 S3HL3NFTIW SNOISN3HIQ 011 Ald JO LN3SNOO LNOHLIM 131900 3 ON 15 LHSIMAdOO SI SNIMWVHO SIHL 801690 1250 2 5 5 5 D E co co lt tc m a 2 o 2 N gt 2 REVISION Print Date 14 01 2009 4 41 00 PM LMiles Technical manuals J230 J430J230 J430 Work filesJ230 C Tech Rev 1 doc Jabiru Aircraft un Aircraft Service Manual Jabiru J230 C IMPORTANT The Spinner is an important and integral part of the propeller Assembly It is essential to ensure adequate engine cooling The aircraft must not be flown with the Spinner removed 21 5 TO REMOVE EXISTING PROPELLER Remove Machine Screws and Tinnerman Washers from Spinner Remove Spinner Unbolt Propeller Bolts 6 off Remove Bolts Spinner Flange Aluminium Propeller Flange Belleville Washers and Propeller TO ASSEMBLE AND REPLACE PROPELLER ASSEMBLY Ensure that Propeller drive bushes 6 off are in place in the Crankshaft Propeller Flange Fit the rear spinner backing plate to the flange Fit propeller to flange Ensure that the drive pins are snug fit in the propeller Loose pins can cause propeller fretting and
56. 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 WARNING Use only automotive brake fluid DO NOT use aircraft hydraulic fluid or damage will result 6 8 6 BRAKE PAD ADJUSTMENT Brake Pads may be adjusted by removing the Main Wheel Spats and tightening the brake pad attaching bolts and nuts until the wheel just rotates freely Revision Dated Feb 2006 Issued By RAS Page 71 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft Mn un Aircraft Service Manual Jabiru J230 C 6 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 6 8 6 2 Bleed air from brake system as described in Paragraph 6 8 6 revision 0 Dated Feb 2006 Issued By RAS Page 72 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM ft Pty Pia ircra A Aircraft Service Manual iru Jab Jabiru J230 C 049v
57. OL H JHM 91 1 SSIMESHLO NMOHS SS3 NI1 38 amods 6 91 91 65 22 W 2346 OMY 91 ONTHIM 1 No TEE SHIA 3000 SHIM SILON Iv 1838 SOINOIAY uva sna Yva SNE NIV SOINOIAW LNAWNY_LNI LNAWLYYdINOD NISNI 3 1 sna 1 1 1 E 4 9 Tans ties 9 5 Ol SOflld YAS 0 3105 YALYWLS 3463 YOLOW M3luvis 72 109 NOLLINOI OWL 30 35 LINN 3NO NOLLINSI DwA 344 SNO JHM HOS GOVIZOVE ON d 9NILLIJ JoOuHd3ul ISN 5713004 50 310N 42 H 3NISN3 GN 7 1 J38N 7 8 2 130208 6 02 271725 LON TE S38L3ATTIN 011 Ald 40 LN3SNO2 l OOHLIM 031409 38 LON 1504 ONY LHSIMAdOO SI SIHL SNOISN3MWICI uva sna Figure 59 Wiring Diagram Sheet 1 Page 148 of 171 Issued By RAS co e e N Q LL o LMiles Technical 51 230 24301 230 430 Work filesJ230 C Tech Rev 1 doc REVISION Print Date 14 01 2009 4 41 00 PM ft Pity Pta ircra A Aircraft Service Manual iru Jab Jabiru J230 C
58. et eee 69 6 8 4 Wheel Brake 5 69 6 8 5 Brake System Bleeding 1 sesenta 71 6 9 6 wo Brake Pad Adjustment teet titer te e re puse e nter ee tuber tea 71 687 Brake tees bes tends te a exce bee vette eee tea bue 72 7 SECTION 7 AILERON CONTROL SYSTEM eeeeeeee eese esses stas 75 7 1 AIEERONOONTROESYSEEM ase tesa eene ak e aaa 75 7 2 CONTROL COLUMN iere bete etr Reste te re ibt ttr eee E on EF 77 7 2 1 Control Column 77 7 2 2 Control column inspection amp repair esses deseen rnnt 77 72 3 Control Column Installation 77 7 3 5 79 7 3 1 Control Cable 12 100000000000000000000 79 73 2 Control Cable Inspection amp Repair esses ss 79 7 33 Control Cable Installation esses 79 ro HEP Re cce RE mm mem mS 79 7 4 1 Removal amp installati 22 2 79 742 Inspection amp
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62. 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft un Aircraft Service Manual Jabiru J230 C 13 3 1 PITOT STATIC SYSTEM MAINTENANCE Proper maintenance of pitot and static system is essential for proper operation of the altimeter airspeed indicator and vertical speed indicator if fitted Leaks moisture and obstructions in the pitot system will result in false airspeed indications while static system malfunctions will affect readings of all three instruments Cleanliness and security are the principal rules for system maintenance The pitot tube and static ports MUST be kept clean and unobstructed 13 3 1 1 PITOT STATIC WATER TRAPS Figure 55 shows the general layout of the pitot static system The water trap for the static system is located inside the ventral fin the faring under the tail which covers the trim mechanism The water trap for the pitot system is located inside the fairing at the lower end of the wing strut Both traps should be inspected and if necessary drained during scheduled maintenance In addition if the aircraft is parked flown or otherwise exposed to rain or moisture the water traps should be checked and if necessary drained 13 3 2 STATIC PRESSURE SYSTEM INSPECTION amp LEAKAGE TEST The following procedure outlines inspection and testing of the static pressure system assuming that the altimeter has been tested and inspected in accordance with the current Regu
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64. 39 Remove the Cam Locks from the front amp rear of the cowling 2 Remove Hinge Pin Grasping the cowl around the front nose pull carefully upwards 4 Remove the cowl 5 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 can not be damaged by persons walking around the aircraft or by wind 6 Reverse the preceding steps for installation WARNING Ensure the cam locks are properly engaged before starting engine 11 1 1 2 LOWER COWL Refer to Figure 40 1 Remove the top cowl Refer above 2 Disconnect the engine air inlet SCAT hose and cabin heat inlet hose if fitted 3 Remove lower cowl screws at rear of cowl 4 Reverse the preceding steps for installation revision 0 Dated Feb 2006 Issued By RAS Page 106 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM ft Pity Pta ircra A Aircraft Service Manual iru Jab Jabiru J230 C Lo mm __ 7551 0 8 92 O dV 1v 3402 NT H3AVI H1079 NIA 08 Ob dV 43AO 5 55779 JO 3903 4000 55300 3NION3 M04 31990 4334 73903 ONY LNO LAD W3NNIdS SLONG 35N LNI Old SYYT
65. 8 119130 OL H343H OlQvs 7 39NIH Nid OL 30 8 39NIH 401 8 MJA TIVL30 OL 93334 j3H 3NIuno OLI Ald LN3SNOO LNOHLIM 231902 38 LON 5 ONY LHIIYAJOI SI SNIMwHO SIHL 3105 LON 04 NI SNOISN3MIG I wouoaeoua AXOd3 009 91 9 80073 NOLLOO SNISN T3NNYHO OL ANCA 40 3915 M3HLI3 SdldlS 2 001 SdlHlS v ONISN 39vT3Snd OL QNOS 39VH8 dOL Nid Figure 38 Rudder Installation Page 105 of 171 Issued By RAS co e e N LL o a LMiles Technical manuals J230 J430230 J430 Work filesJ230 C Tech Rev 1 doc REVISION Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft me un Aircraft Service Manual Jabiru J230 C 11 Section 11 Engine amp Engine Installation 11 14 ENGINE COWLS The engine cowls comprise both an Upper and Lower composite structure The Upper Cowl is fitted with five locating Cam Locks two at the front amp three at the rear of the cowlings Hinges run along the join line on either side holding the top amp bottom together The Lower Cowl is attached to the Fuselage with 8 machine screws mounting into anchor nuts 11 1 1 ENGINE COWLS REMOVAL amp INSTALLATION 11 1 1 1 UPPER COWL to Figure
66. By RAS Page 13 01171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft un Aircraft Service Manual Jabiru J230 C 2 2 GENERAL DESCRIPTION The JABIRU J230 C is a 2 seat high wing monoplane composite aircraft of monocoque construction It is 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 2 3 OWNER MAINTENANCE 2 3 1 J230 C The J230 C has been specifically designed as a simple aircraft which can be maintained by owners to a large degree Jabiru Aircraft allows normal maintenance up to 100 hourly servicing to be carried out by the owner This includes Oil amp oil filter changes Fuel filter changes Brake pad changes Tyre changes Spark plug changes Normal engine maintenance between 100 hourly maintenance ie 33 and 66 hour maintenance Refer to Engine Maintenance Manual for details Every 100 hours or Annually whichever happens first a 100 hour inspection must be inspected by an Authorised Person such as a LAME Refer to the RAAus Operations Manual for RAAus aircraft Australia Jabiru Aircraft recommend that any aircraft being used for flight training or any other form of hire and reward operatio
67. INNER ATTACHMENT REAR AND FASTENER USING SELF TAPPER 4 2 2 2A05080D J160 DYNON PITOTSTRUT 1 3 ATTITUDE INDICATOR HEAD DYNON EFIS 1 SCALE 1 16 2 05 SCREW P HEAD SELF TAPPING amp CG X 1 2 4 1 3 2 5 PH9952N SPEED NUT 6 GAUGE 4 ISS DATE EP TITLE DWG NO LIMITS 1 0 oraw AVTECH J160 DYNON PITOT 2A051A0D 1 HINKLER 2 MATERIAL 5 DETAILED APPR BUNDABERG STRUT FAIRING ASSY SHEET 1 Figure 10 Dynon Pitot Probe Installation 5 4 LANDING LIGHT OPTION 5 4 1 DESCRIPTION A landing light may be fitted to the wing strut as an option refer to Figure 11 5 4 2 LANDING LIGHT REMOVAL amp INSTALLATION 1 Remove the screw holding the lens retainer to the light mount amp remove the retainer amp lens from the housing 2 Un screw the clamp screw at the rear of the light assembly 3 Remove the housing from the strut 4 Assembly is the reverse of the above Note the application of silicone sealant to prevent vibration as detailed in Figure 11 below Revision Dated Feb 2006 Issued By RAS Page 50 of 171 LMiles Technical manuals 230 J430M230 J430 Work filesJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft Aircraft Service Manual Jabiru J230 C Parts List ITEM PART NUMBER DES
68. J230 Models Horizontal Tail amp Elevator 94 Figure 31 J170 Models Horizontal Tail amp Elevator 95 Figure 32 Elevator Travel Limits 96 Figure 33 Elevator Trim Handle 5 98 Figure 34 Trim Controls At 99 Figure 35 Rudder Ernte eterne entire ened 101 Figure 36 Rudder System 104 Figure 37 Rudder Installatiom 2 Lecce cce 105 Figure 38 Upper Cowl e ette ree eos ena 107 Figure 39 Lower Cowl Assy 1 eese nnne nennen ener nnns 108 Figure 40 LSA Variant Throttle Panel 113 Figure 41 Instrument Panel amp Throttle 114 Figure 42 Carburetor Heat BOX sissies pede nnne nnne nenne nnne nnne 115 43 Exhaust e eek ce ren 117 Figure 44 Engine Installation sess 119 Figure 45 Fuel System Schematic LSA 5 121 Figure 46 Vented Fuel Cap ASSy etre ree tete ii etienne rn 125 Figure 47 Single Line Tap iie ire 127 Figure 48 Fuel Gauge Electric Sender Installation 128 F
69. N LL 9 2 rc Print Date 14 01 2009 4 41 00 PM LMiles Technical manuals J230 J430230 J430 Work filesJ230 C Tech Rev 1 doc Jabiru Aircraft 2 Aircraft Service Manual Jabiru J230 C 72 WARNING LIGHTS STARTER O0 a Yd UM CHARGE i mercon ASI x o 7 he COM SELECTOR PN xz 3 EFIS 0100 ADC EFIS D100 GPS FUEL PRESSURE o ETC MASTER GREEN M T a o ge Cw o O 77 9 o VEEN 41 9 9 NC J ye T zs m N ENS S UO GO amp P gt 200 a NE IGNITION 13 gt r 72 pP Q a pA gt lt IGNITION 42 7 7 aig ELAS MASTER starter 7 x N X b M 0 25A N FUEL PUMP MAP LIGHT L FUEL PUMPN 10A Se STROBE INSTRUMENT AVIONICS INTERIOR LIGHT _ STROBE INSTRUMENT LIGHTS DANDING LIGHT L MASTER C avionics INTERIOR 5 10A FLAPS Figure 54 Instrument Panel Layout Glass Instrument Panel 13 2 3 INSTRUMENT REMOVAL Most instruments are secured to the panel with screws inserted through the panel face To re
70. RAS Page 44 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft un Aircraft Service Manual Jabiru J230 C 13 Unbolt and remove front wing attachment bolt 14 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 15 Carefully remove wing by moving it out to clear the aileron cable from the fuselage 16 Place wing on cushioned structure to avoid damage to wing strut attachment 17 Unbolt lower wing strut bolt and remove wing strut 18 Repeat Steps 5 16 to remove other wing 5 1 2 REPAIR The wing is a composite monocoque structure All repairs must be referred to JABIRU AIRCRAFT Pty Ltd or our approved local agent 5 1 3 INSTALLATION 1 Fit the lower strut 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 saw horse and routing aileron cable through hole in fuselage wing root 2 Install front and rear wing attaching bolts nuts 4 Put top wing strut attaching bolt in your pocket 5 Lift wing tip and install wing strut to wing strut attachment with bolt from pocket Install nut WARNING Do Not Tighten nut or
71. REFER TO PART DRAWINGS BUNDABERG 4670 SIGHT GLASS ASSY SP WET WING 1 OF Figure 51 Fuel Gauge Sight Glass Revision 0 EN Dated Feb 2006 Issued By RAS Page 129 of 171 L Miles Technical_manuals J230_J430 J230 J430_Work_files J230 C_Tech_Rev_1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft Aircraft Service Manual Jabiru J230 C 12 6 HEADER TANK LOW LEVEL WARNING OPTION The J230 C may be fitted with a low level warning light in the header tank as an option See Figure 52 12 6 1 DESCRIPTION The sensor is a solid state LED which illuminates a red warning light on the instrument panel if the fuel level in the header tank falls below approximately 3 litres 12 6 2 FUEL VALVE REMOVAL amp INSTALLATION 4 Remove the header tank as detailed in Section 12 2 2 1 5 Remove the sender from the header tank 6 Assembly is the reverse of the above Note the torque limitations amp thread sealant notes for the sender indicated in Figure 52 THES PRO E GOREY DIMENSIONS IN MILIMETRES 00 NOT SCALE PROJECTION PARTS LIST ITEM PART NUMBER DESCRIPTION am 1 14066A0D HEADER TANK ASSY 1 1 2 _ 44220000 8055 FUEL LEVEL SENSOR 1 amg Bur 50 5 FUEL LEVEL SENSOR 1 i Sene w
72. REMOVAL aaa 44 91 2 BOD Em 45 5 1 3 iiM 45 52 WINGSTRU TS iitin 49 5 2 1 Removal and Installation ee eet 49 5 2 2 REPAIR ED EV UE 49 bg PITOT PROBE 5 a 49 5 3 1 v 49 5 3 2 Removal 8 49 5 4 LANDING LIGHT 0 50 5 4 1 PI n ER n rc 50 5 4 2 LANDING LIGHT Removal amp 1 5 50 5 9 B c Ecc eu 51 5 5 1 Removal Installation Inspection and 02 000000006000000000000099 9 2 51 5 6 2 d e tu e on ra E e 51 5 6 1 Removal and Installatioti 51 6 SECTION 6 LANDING GEAR AND BRAKES cccccssssssssssscscccssssssscssccccsssssesscccccessssssscscccsscsscssssecsccessceess 52 6 1 LANDING GEAR er er em a EO 52 6 2 TROUBLE SHOOTING MAIN
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74. and on the engine nose 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 revision 0 _ Dated Feb 2006 Issued By Page 26 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft me un Aircraft Service Manual Jabiru J230 C 3 4 4 ALUMINIUM SURFACES The aluminium surfaces require a minimum of care but should not be neglected Wash and clean as detailed in Section 3 4 above 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 3 4 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 CAUTION DO NOT hose engine Electrical components may be damaged by mo
75. as this usually requires special equipment and data and should be handled by instrument specialists Malfunctioning instruments should be either returned to JABIRU AIRCRAFT Pty Ltd or sent to an approved instrument overhaul and repair station for servicing Our concern here is with preventive maintenance on the various instrument systems and correction of system faults which will result in instrument malfunctions The descriptive material maintenance and trouble shooting information in this Section is intended to help the owner or mechanic determine malfunctions and correct them up to the defective instrument itself at which point an instrument technician should be called in Some instruments such as Oil Temperature and Pressure Gauges are simple and relatively inexpensive and repairs will usually cost more than a new instrument Flight instruments on the other hand are usually well worth repairing The words replace instrument in the text therefore should be taken only in the sense of physical replacement in the aircraft Whether replacement is to be with a new instrument an exchange one or an original instrument is to be repaired must be decided on the basis of the individual circumstances 13 2 INSTRUMENT PANEL The instrument panel assembly consists of a stationary panel The instruments are screw mounted to the panel Two different sized instrument panels are offered with the J230 C both using the same construction and assembly proce
76. doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft Mm 524 Jabiru J230 C Airworthiness Limitations Table 19 Control Surface Balancing Limits Control Hinge Moment Limits Weight Limits Manual Section 56300g mm 2200g Rudder 4000g mm 1009 10 4 RUDDER BALANCE Aileron 94000g mm 1150g 7 4 3 AILERON 4000g mm 100g BALANCING Elevator 323300g mm 5000g 9 3 2 ELEVATOR 4000g mm 100g BALANCING 22 4 1 1 CABLES Cables must be inspected as detailed in 3 6 3 2 CONTROL CABLE INSPECTIONS Table 20 Mandatory Inspection Times Description Part No Interval Hours Rudder Cable 1714 1000 Elevator Cable 1814 1000 Aileron Cable 2 01614 1000 22 4 2 MANDATORY REPLACEMENT The following components MUST be replaced at the intervals described hereunder Table 21 Mandatory Replacement Times Description Part No Interval Hours Rudder Cable 1714 10 000 Elevator Cable 01814 10 000 Aileron Cable 2 1614 10 000 REVISION o Dated 2006 Issued By RAS 171 of 171 L files Technical_manuals J230_J430 J230 J430_Work_files J230 C_Tech_Rev_1 doc Print Date 14 01 2009 4 41 00 PM
77. engine damage Fit Propeller Bolts 6 off Fit front spinner backing plate to front of propeller The fit Aluminium Propeller Flange Belleville Washers 48 off 8 per Bolt assembled in pairs as shown Progressively tighten bolts ensuring equal distribution of load and in a normal criss cross torque sequence Using Torque Wrench tighten Bolts to 6ft lbs 72 inch lbs Check tracking of Propeller by locating a fixed object on a flat floor so that it just clears the Propeller tips when rotating the Propeller by hand Check that each blade clears the object by the same amount If the Propeller is outside the approved tolerance refer to JABIRU Aircraft Pty Ltd or a JABIRU Approved Service Centre Maximum Tracking Error Tolerance is 2mm Locate Spinner on Spinner Flange and fix with Machine Screws through tinnerman Washers Check Spinner for balance by locating a fixed object on a flat floor to just clear the lower edge of the front dome of the Spinner Rotate the propeller by hand and check that the Spinner runs true Correct any imbalance by loosening and retightening Machine Screws REVISION ol Dated May 2006 Issued By RAS Page 167 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft un Aircraft Service Manual Jabiru J230 C 21 7 SERVICING AND REPAIRS Any service or repair must t
78. in Table 2 3 Tighten clamp bolts nuts 2 OFF See Torque Value in Table 2 4 Connect flexible brake line 5 Top up brake master cylinder with fresh brake fluid and bleed brakes see Paragraph 6 8 5 6 Lower aircraft 6 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 or our local approved agent Revision Dated Feb 2006 Issued By RAS Page 53 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft Mn un Aircraft Service Manual Jabiru J230 C 6 3 4 MAIN WHEEL FAIRING REMOVAL AND INSTALLATION 1 Remove the machine screws around the join of the inner and outer sections of the fairing 2 Remove the bolt on the outside of the fairing 3 Remove the machine screws 2 OFF on the inboard side of the leg 4 Reverse the preceding steps for installation 6 3 5 MAIN GEAR TOP FAIRING REMOVAL AND INSTALLATION The fairing at the top of the main undercarriage leg is removed by rem
79. is not approved by the factory or were not maintained to the manufacturer s requirements As Experimental LSAs cannot be used for hire and reward operations it is very important that owners maintain their aircraft in an appropriate manner for their operational requirements It is the owner s responsibility to become fully aware of the particular maintenance requirements and limitations applicable to the appropriate registration The details given above are intended to give owners a broad appreciation of the rules for LSA further details can be gained by contacting CASA the RAA or Jabiru Aircraft The information in this manual is based upon data available at the time of publication and is supplemented and kept current by Service Bulletins amp Service Letters published by JABIRU AIRCRAFT Pty Ltd These are distributed directly to owners of J230 C aircraft in addition to being posted on the JABIRU website 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 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 Service
80. lever at the lever end To operate outer covers of the cable must be clamped firmly at both ends 9 6 4 REMOVAL AND INSTALLATION The Trim Control Cable is a Primary Control and may not be repaired or removed without reference to JABIRU AIRCRAFT Pty Ltd or our approved local agent 9 6 5 INSPECTION AND REPAIR Inspect Trim system generally for security and any signs of wear Pay particular attention to the bearing blocks friction plates bearing springs cable and attachments REVISION gl Dated Feb 2006 Issued By RAS Page 97 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM ft Pty Pia ircra A Aircraft Service Manual iru Jab Jabiru J230 C ey E 20 1338S MIO 9 SLIVWHY SNISN YAHISSOL SWALI ONOG Add HOJLAY 30 LH3SHOO JHL OIlS 38 LON LSNIN LH9IA dOS SI ONIN SIHL 2 YY t 00 002 A18IA3SSV 1OSLNOO 9297 SR EE sd anui 26 982 OLO Vd HO3 LAV 3SWeBHIOO3JO3dS SS31Hf SLANT SSHLSATTA Nil gh JWS LON 00 ONIMVHMSO SIHL JO L SLASHS NI NMOHS SV AIAWISSY TOXLNOD WHL ATWO JHL NSAID SSILILNYND SYSBWNN 1 niravn NON
81. metal fatigue may result Washer must be free to rotate 6 Connect all fuel lines to wing Connect wires to fuel gauge sender WARNING Ensure no fuel or breather lines are kinked 7 Put about 1015 of fuel in each tank 4 check for any leaks 8 Attach flap to wing ensuring all bushes are in place 9 Install bolt nut in flap control rod 10 Install bolt nut in aileron control cable on main control stick horn Revision Dated Feb 2006 Issued By RAS Page 45 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft un Aircraft Service Manual Jabiru J230 C 11 12 13 14 15 Install clamp block and pin in aileron control cable clamp at rear of seat On RH wing reconnect Pitot tube Replace wing strut fairings top and bottom Replace wing root fairings 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 about 1 litre per minute flow rate NOTE After carrying out the fuel flow test check that both wing tanks are feeding fuel by blocking fuel from both wing tanks pumping about a litre out of the header tank then allowing fuel to
82. or deflate nose wheel remember to re inflate to operating pressure before use 4 Using a square or a plumb bob mark the wheel centres on to the floor or scale surface Both sides of the nose wheel axle must be marked to eliminate any error if it isn t exactly straight Also again using a plumb bob or a level mark the datum wing leading edge onto the floor Use points outboard of the main wheels on the wing leading edge for the datum 5 Take the wheel weights When the wheel weights are being taken there must be nil wind blowing on the aircraft Due to the light nature of the J230 even a small breeze can cause significant weight transfer and so C of G errors 6 Using a string line or similar mark the datum across under the aircraft on the floor Measure the horizontal for aft distance for each wheel both sides of nose wheel to the datum All distances aft of the datum are consider positive and all distances forward of the datum are negative See Figure 2 Weighing Diagram Revision Dated Feb 2006 Issued By RAS Page 23 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft Aircraft Service Manual Jabiru J230 C 7 Repeat steps 5 and 6 again to avoid errors 8 Due to the light weight of this aircraft measurements must have an accuracy of at least 0 5kg and 1mm 9 Average of the measur
83. possible repair REVISION o Dated May 2006 Issued By RAS Page 169 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft _ Jabiru J230 C Airworthiness Limitations 22 APPENDIX V AIRWORTHINESS LIMITATIONS 22 1 GENERAL This section is approved and sets forth each mandatory replacement time structural inspection interval and related structural inspection procedures established for the J230 C aircraft 22 2 INTERIOR FLAME RETARDANT MAINTENANCE LIMITATIONS Most materials used in the interior upholstery of the J230 C have been treated with a flame retardant to meet the flammability requirements of LSA This treatment must be renewed after an article has been washed 5 times Section 4 5 1 UPHOLSTERY CLEANING FLAME RETARDANT gives details 22 3 COMPOSITE INSPECTION amp MAINTENANCE As the J230 C s primary structure is all Fibreglass Epoxy composite a degree of specialist training is required to properly carry out inspections amp maintenance of the structure This may take the form of an Airworthiness Authority approved Composites Licence or a Jabiru Approved Certification Jabiru Aircraft offers training amp certification for people wishing to gain Jabiru approval to inspect 6 maintain J230 C structures Note that this does not include repairs Repairs of structural parts must be referred to J
84. rear rod end aligns with the hole in the control horn Fit bolt nut and washers Scribe a line from the centre of the Rudder trailing edge onto the Fuselage Displace the Right Rudder Pedal to the Rudder Pedal Stop Measure the Rudder displacement at the Rudder trailing edge with reference to the previously scribed line It should be 98mm 2mm Repeat Step 6 for Left Pedal and adjust Rudder Pedal Stops as required WARNING The Rudder Pedal Stops should engage NOT the Control Surface Stops on the tail DO NOT move the Cable Anchor Points or adjust control surface stops These are factory set revision 0 Dated Feb 2006 Issued By RAS Page 103 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru J230 C ft Pity Pta ircra A Aircraft Service Manual iru Jab LiL 37995 88 NOILO3S CE NI SNOISNaWIG do ae To LMiles Technical manuals 230 J430M230 J430 Work filesJ230 C Tech Rev 1 doc 130 119395 IAW 0916 Fl m main b 5 ON id 1 00 90 6
85. sandpaper or similar and bonding new rubber strips in place with 5 Minute Araldite 11 4 ENGINE MOUNT The engine mount is a welded assembly Its purpose is to support the engine and attach the engine to the airframe The engine is attached to the mount with rubber cushions which absorb engine vibrations Spaces are used to correctly align the engine Ensure that they are correctly marked on removal and correctly replaced on reassembly IMPORTANT The engine mounts should not be repaired If damaged replace with a new part 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 11 5 ENGINE FUEL SYSTEM 11 5 1 FUEL SYSTEM GENERAL The engine is equipped with a carburettor mounted below the engine and a fuel pump at the Starboard rear of the engine Refer to engine Maintenance amp instruction manual for carburettor jet removal idle adjustment and carburettor bowl cleaning procedures WARNING Fuel lines within the engine compartment are fitted with fireproof sleeves These sleeves must not be removed revision 0 _ Dated Feb 2006 Issued By RAS Page 111 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft me un Aircraft Service Manual Jabiru J230 C 11 5 2 LSA AIRCRAFT FUEL SYSTEM 1 A schematic drawin
86. skin and embodying a composite control horn at the centre An elevator trim system is attached Refer Paragraph 9 6 9 3 1 REMOVAL AND INSTALLATION 1 Unbolt cable from control horn 2 Unbolt trim linkage from control horn 3 Loosen screws in hinge pin retainers and lift hinge pin retainers from hinge pins It is not necessary to remove these parts 4 Remove hinge pins 5 Remove Elevator 6 Reverse the preceding steps for installation 9 3 2 ELEVATOR BALANCING The J230 Elevator is balanced during construction A standard weight of 750 grams of lead is placed in each control horn to balance the elevator In service there should be no reason to rebalance the elevator Balance may be checked with the control fitted to the aircraft amp the control amp trim removed Measure the force at the trailing edge required to keep the elevator level Weight amp hinge moment values are given below REVISION Dated Feb 2006 Issued By RAS Page 90 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft un Aircraft Service Manual Jabiru J230 C Weight 5000g 100g Hinge Moment 323300g mm 4000g mm 9 3 3 INSPECTION AND REPAIR Inspect elevator for any signs of delamination or cracking Pay particular attention to the Control Horn and hinges and their surrounding areas Repairs must be referred
87. the side to be jacked or both spats if 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 revision 0 Dated Feb 2006 Issued By RAS Page 18 of 171 L files Technical_manuals J230_J430 J230 J430_Work_files J230 C_Tech_Rev_1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft un Aircraft Service Manual Jabiru J230 C 3 Place a solid block preferably wood under the bottom of the composite glass leg which 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 Chock the opposite wheel 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 th
88. to outsides of main wheel spats Baggage Zone Decal P No 5A063A0D Baggage area on right side below horizontal rib Position line 500mm aft of Whalebone REVISION Dated Feb 2006 Issued By RAS Page 157 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft 2 sro Aircraft Service Manual Jabiru J230 C 16 2 COCKPIT PLACARDS GENERAL Table 15 General Cockpit Decals Decal Detail Preview LSA Warning decal P No 5A060A0D THIS AIRCRAFT WAS MANUFACTURED IN ACCORDANCE WITH LIGHT SPORT AIRCRA AIRWORTHINESS STANDARDS AND DOES NOT CONFORM STANDARD AIRWORTHINESS REQUIREMENTS To be fitted above the windscreen to the right of the Warning Placard Owners Manual FLIGHT OWNERS MANUAL P No 5036194 Fitted to Inside of RH Door above the Door Pocket Door Open LHS NE Fitted to the Outsides of LH Door Above the Door Catch Lever Door Open RHS P No 5028094 Fitted to the outside of RH Door Above the Door Catch Level Door String Placard P No5026094 PULL TO OPEN Fitted on Inside of both Doors Above Door Handle No Smoking P No 5A035A0D Placed in a prominent position on the instrument panel Fuel Contents P No 5A022A0D WF Fitted to sight glasses of wing fuel tanks Fuel Content
89. worn Replace with new parts revision 0 Dated Feb 2006 Issued By RAS Page 68 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft me 522 un Aircraft Service Manual Jabiru J230 C 6 8 2 BRAKE MASTER CYLINDER The brake master cylinder located on the front of 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 6 8 2 1 BRAKE MASTER CYLINDER REMOVAL amp INSTALLATION 1 Remove the flexible hose from one wheel brake assembly and drain the hydraulic fluid from the brake system 2 Unbolt amp remove brake handle 3 Disconnect flexible hose at master cylinder 4 Unbolt master cylinder retaining bolts 2 5 Plug or cap hydraulic fittings and hoses to prevent the entry of foreign material 6 Reverse the preceding steps to install brake master cylinder then fill and bleed brake system in accordance with Paragraph 6 8 5 6 8 2 2 BRAKE MASTER CYLINDER REPAIR Figure 20 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 6 8 3 HYDRAULIC BRAKE LINES These lines are f
90. 0 RUDDER CONTROL SYSTEM eee eeee 100 10 1 RUDDER PEDAL 2 etit ei ee hes 100 10 1 1 Removal 100 10 1 2 Inspection and 100 10 2 RUDDER e EE 102 10 2 1 Removal amp Installation 102 10 2 2 Inspection amp ieee 102 10 3 CONTROL CABLE amp ATTACHMENTS 102 10 3 1 Removal amp Installation 102 10 4 RUDDER BALANCE iier tnter rrt c ne e ere rr 102 10 5 RIGGING isaac M 103 11 SECTION 11 ENGINE amp ENGINE INSTALLATIONN eere eere eerte tenens einst tn seas tnos 106 11 1 ENGINE COWES HH 106 11 1 1 Engine Cowls Removal amp Installation sessi eene 106 11 1 2 Cleaning Inspection 109 TALS AERE E 109 11 2 ENGINE erit tie p ebd e et 109 11 2 1 Engine Data f JL asus aaa 109 11 22 Engine Trouble Shooting essi siis sedens enne nnns tnnt nnns 109 11 2 8 Engine 109 11 2 4 Engine Accessories Removal 109 152 5 A
91. 00 Hours Each 100 Hours PROPELLER 1 Spinner 2 Spinner Flange 1 3 Spinner screws 4 Propeller li 5 Propeller bolts nuts Tension 6 Spinner Prop Tracking ENGINE COMPARTMENT Check for oil fuel exhaust amp induction leaks then clean entire engine amp compartment before inspection NOTE REFER TO ENGINE MAINTENANCE MANUAL FOR ENGINE SPECIFIC INSPECTIONS 1 Carburetor air filter i 2 Engine baffles and air ducts 3 Cil Hoses lines fire sleeve amp fittings 4 Fuel Hoses lines fire sleeve amp fittings 5 SCAT Hose Condition 6 Electrical wiring 7 Engine controls and linkages d 8 Engine mounts mount structure REVISION ol Dated Feb 2006 Issued By RAS Page 33 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft 2 sro Aircraft Service Manual Jabiru J230 C 10 11 12 13 14 15 16 10 Annual Inspection Each 200 Hours Each 100 Hours Starter solenoid and electrical connections Coils and electrical connections Carburettor heat system Firewall Exhaust System Including Muffler Fuel pressure warning light switch Cabin heat system Engine cowlings and clips Fuel System Fuel filters drain valves carburetor bowl Electronic fuel boost pump and fittings Fuel lines and connectors Fuel line routing betw
92. 06 Issued By RAS Page 151 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM ft Pity Pta ircra A Aircraft Service Manual iru Jab Jabiru J230 C 094 JO 19395 OH38vaNnag 3 amp Goleoc NOLVZIMVIOd IM3A WOO JHA sib m ES ge HIJI me uwa 031410345 SSTINN 0 SS 28901 8 31892 XVOD 31892 Xvoo 0 285 98 0 HOV3 G10909 AOTIV Gla yva We X ZL N3HM 499 SL 58 37725 LON OQ NI SNOISN3MIG U 2 dy bo Figure 61 VHF Antenna Installation N T A lt E a 2 40 e N LL o o 2 rc Print Date 14 01 2009 4 41 00 PM LMiles Technical manuals 230 J430M230 J430 Work filesJ230 C Tech Rev 1 doc Jabiru Aircraft me un Aircraft Service Manual Jabiru J230 C 15 SECTION 15 PAINTING amp FINISHING 151 EXTERIOR 15 1 1 PAINTING The following painting procedure as used at the Jabiru factory had proven successful in ensuring good presentation of the aircraft 2 part paint should be used for best result
93. 1 19 ANA4 14A BOLT 1 20 520365 428 1 4 NYLOC NUT 1 21 PBOO78N BEARING DEEP GROOVE EE2 2RS 2 T ELEVATOR CABLE 22 3103284 BEARING RETAINER TRIM CONTROL 1 REF 23 3103184 BEARING PIVOT MOUNT BLOCK 1 24 PH0199N 1 8 AL POP RIVET CPNo 73 54 6 6 2 25 3043294 SPACER ROD END 1 26 00194 3 16 FEMALE ROD END 3 28 3 16 BOLT 1 29 AN3 13A 3 16 BOLT 1 3061094 PIVOT BLOCK 1 31 3043194 SLEEVE PIVOT BLOCK 1 32 3131014 SPRING RETAINING ROD 1 3129014 SPRING CAP RETAINER TRIM CONTROL 2 34 AN960 616 3 8 FLAT WASHER 2 35 524665 132 COTTER PIN 2 36 PBOO09N 3 16 MALE ROD END 1 37 3063094 EXT TRIM HORN 1 38 AN3 07A 3 16 BOLT 1 39 00694 TRIM SPRING 2 40 AN316 3 3 16 NUT 5 42 01484 TRIM CABLE ASSEMBLY 3 45 PC0099N CABLE CLAMP SHIM 3 46 PCO089N CABLE CLAMP 3 50 59 METALTHREAD M4x25 BOLT 1 51 469 5 32 FLAT BRASS WASHER 1 52 PHO209N M4 NYLOC NUT 1 53 AN3 06A 3 16 BOLT 2 921 10 Yey ISCALE PAOIECTION p AVTECH PIL REWRITE VAR DATE LIMITS UNLESS SPECIFIED OTHERWISE 1 DRAWN DS See E TITLE DWG No MATERIAL APPR BUNDABERG 4670 RIM CONTROL ASSEMBLY J200 J400 3250023 1 SHEET 2 OF 3 4 3 2 1 2 0 zr Pid Jabiru Aircraft
94. 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft un Aircraft Service Manual Jabiru J230 C Note Prepare all parts separately and paint separately 2 Completely sand all outside surface area with 150 grit to give paint adhesion The factory uses a Random Orbital Sander and 150mm Stickit discs Note Ensure that glass is not cut into in the sanding process 3 Grind excess resin from joints being careful not to grind into fiberglass layers Take care not to grind into the horn of any control surfaces 4 A clean wire brush is used to search out any crab holes or pinholes Give the entire aircraft a good scrub all over especially around corners etc 5 Wear a breathing respirator with painting cartridges right from initial sanding through to painting Hint Body Filler sets quickly in high temperatures particularly when larger mixes are necessary Use cold packs under the Body Filler board to extend setting time 6 Follow instructions carefully and experiment with setting times 7 On large radius e g sides of fuselage an extra large homemade spatula 9 thin tin plate is very handy when applying Bogy Filler 8 When filling up to window edges grind chamfer onto edge of window to give depth for bog adhesion WARNING THE GEL COAT IS MICRO THIN SO SANDING IS ALWAYS A CAREFUL PROCEDURE IF GEL COAT IS INADVERTENTLY PENETRATED DO NOT CONTINUE SANDING INTO STRUCTURAL GLASS 9 With
95. 14 6 VOLTAGE REGULATOR The voltage regulator is a sealed unit Service is limited to inspection of terminals for security and replacement of the unit 14 7 STROBE SYSTEM OPTION A white strobe light may be installed in the rear lower fuselage or in the cabin roof The power source for the strobe light is located behind the fuel tank WARNING The strobe system is a high voltage device Do Not remove or touch tube assembly while in operation Wait at least 5 minutes after turning off power before commencing any activity near the strobe light 14 8 AUXILIARY POWER SOCKET The jabiru is fitted with an auxiliary power socket that accepts a 12V cigarette lighter plug The circuit breaker for this plug is rated a 10 Amps However it should be noted that the maximum continuous alternator output is also 10 Amps 14 9 ELECTRICAL LOAD ANALYSIS ELA An ELA has been carried out as part of the aircraft s certification basis Any changes to the electrical system which affect the ELA require a new ELA to be raised For Special category LSAs this must be approved by Jabiru Aircraft 14 10 RADIO WIRING DIAGRAM OPTION The optional aircraft radio system diagram is provided with the radio manuals 14 101 VHF ANTENNA INSTALLATION The VHF antenna used consists of two aluminium bars permanently bonded in place inside the spar channel of the vertical fin Figure 61 shows the position details of the two bars REVISION ol gl Dated Feb 20
96. 30 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft un Aircraft Service Manual Jabiru J230 C 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 1 Remove the through bolts holding the caliper halves together and withdraw the inboard pad amp backing plate 2 Use a drill and punch to remove the rivets holding the pad onto the backing plate 3 Replace lining in accordance with steps given above 4 Install axle and wheel assembly see Paragraph 6 4 6 5 Install outboard brake pad and refix with through bolts and springs 6 8 5 BRAKE SYSTEM BLEEDING Fill the brake master cylinder with automotive brake fluid 2 Loosen the bleed nipple s at the brake cylinder s 3 Pull the handbrake back to the rear stop amp hold in same position until nipple has been re torque Release the hand brake amp repeat step 3 until all air is expelled from lines
97. 4 Ald HOSLAY JO LN3SNOO LNOHLIM 04405 38 LON 15 ONY 409 SI SIHL Figure 46 Fuel System Schematic LSA Variants jrevsion 121 of 171 Page RAS Issued By co e e N LL Print Date 14 01 2009 4 41 00 PM LMiles Technical manuals J230 J430230 J430 Work filesJ230 C Tech Rev 1 doc Jabiru Aircraft Mm un Aircraft Service Manual Jabiru J230 C 12 1 3 FUEL SYSTEM TROUBLE SHOOTING Table 8 Trouble Shooting Fuel System Trouble Probable Cause Remedy Fuel shut off valve not turned ON Fuel tank empty Turn valve ON Service with proper grade and amount of fuel Fuel line disconnected or Connect or repair fuel lines broken No fuel to carburettor Fuel tank outlet strainer Remove and clean strainer plugged and flush out fuel tank Defective fuel shut off valve Replace shut off valve Plugged fuel filter Replace filter Fuel line plugged Clean out or replace fuel line Partial fuel flow from preceding causes Use the preceding remedies Fuel Starvation after starting Plugged fuel vent See Paragraph 11 3 Drain fuel tank sump fuel Water in fuel lines and filter 12 2 FUEL TANK 12 2 1 DESCRIPTION The composite fuel tanks are located in the left amp right hand wings A sump drain plug is provided in each wing root on the un
98. 4 Lnd LO TVLNOZIHOH 102 TOYLNOD 1238 SIOSNOD 3H1N32 1817 8084 gt a lt c E o o o Lud c o 3 iL m KR KR A lt E a 2 40 co e e N LL a z o o 2 rc Print Date 14 01 2009 4 41 00 PM LMiles Technical manuals J230 J430230 J430 Work filesJ230 C Tech Rev 1 doc Jabiru Aircraft me 522 un Aircraft Service Manual Jabiru J230 C 7 3 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 7 3 1 CONTROL CABLE REMOVAL 1 Unbolt the connections rod end bearings at either ends of the cable 2 Unbolt the clamps at either end of the cable 3 Where required remove any ties etc used to restrain the cables in the aircraft 4 Tie a string or light wire to one end of the cable 5 Draw the cable out of the aircraft leaving the string wire in place to allow installation of a replacement part 7 3 2 CONTROL CABLE INSPECTION amp REPAIR Repair of control cables is limited to the installation of new parts 7 3 3 CONTROL CABLE INSTALLATION Installation procedure is the opposite of removal procedure outlined above 7 4 AILERON
99. 6 27 1 16 5 06 87 1 16 5 06 147 1 16 5 06 28 1 16 5 06 88 1 16 5 06 148 1 16 5 06 29 1 16 5 06 89 1 16 5 06 149 1 16 5 06 30 1 16 5 06 90 1 16 5 06 150 1 16 5 06 31 1 16 5 06 91 1 16 5 06 151 1 16 5 06 32 1 16 5 06 92 1 16 5 06 152 1 16 5 06 33 1 16 5 06 93 1 16 5 06 153 1 16 5 06 34 1 16 5 06 94 1 16 5 06 154 1 16 5 06 35 1 16 5 06 95 1 16 5 06 155 1 16 5 06 36 1 16 5 06 96 1 16 5 06 156 1 16 5 06 37 1 16 5 06 97 1 16 5 06 157 1 16 5 06 38 1 16 5 06 98 1 16 5 06 158 1 16 5 06 39 1 16 5 06 99 1 16 5 06 159 1 16 5 06 40 1 16 5 06 100 1 16 5 06 160 1 16 5 06 41 1 16 5 06 101 1 16 5 06 161 1 16 5 06 42 1 16 5 06 102 1 16 5 06 162 1 16 5 06 43 1 16 5 06 103 1 16 5 06 163 1 16 5 06 44 1 16 5 06 104 1 16 5 06 164 1 16 5 06 45 1 16 5 06 105 1 16 5 06 165 1 16 5 06 46 1 16 5 06 106 1 16 5 06 166 1 16 5 06 47 1 16 5 06 107 1 16 5 06 167 1 16 5 06 48 1 16 5 06 108 1 16 5 06 168 1 16 5 06 49 1 16 5 06 109 1 16 5 06 169 1 16 5 06 50 1 16 5 06 110 1 16 5 06 170 1 16 5 06 51 1 16 5 06 111 1 16 5 06 171 1 16 5 06 52 1 16 5 06 112 1 16 5 06 172 1 16 5 06 53 1 16 5 06 113 1 16 5 06 173 1 16 5 06 54 1 16 5 06 114 1 16 5 06 174 1 16 5 06 55 1 16 5 06 115 1 16 5 06 175 1 16 5 06 56 1 16 5 06 116 1 16 5 06 176 1 16 5 06 57 1 16 5 06 117 1 16 5 06 177 1 16 5 06 58 1 16 5 06 118 1 16 5 06 178 1 16 5 06 59 1 16 5 06 119 1 16 5 06 179 1 16 5 06 60 1 16 5 06 120 1 16 5 06 Revision Notes Dated Feb 2006 Issued
100. 98lL 1 Vd HOSLAV 00 0021 S1 ASSY 45 000 038149530 Sv 909611 609611 ONISN AUSOddO SI SH 2 QO3red OL AYOd3 009601 val ASN SNITINOW OL NO Q349014 3Y LN3W39S8OJNI3H 39NIH ONY 39NIH SOIH31NI 5 3480438 1 0 13 530109 HO1VO NI MIO WY MalA NOLL23S S3ovJHnS ONILVM N334138 49073 SNISN ONITINOW YOMALNI 4000 OL SI NIMS 8000 NMS 01 NO OMIO YH SI HOIBSLNI HOOQ S71 ASSY 1 0 2102202 OMM HO Had Y ASSY HOV LLV S39NIH 0 30 SH3AVTE SI NINS JO SHIA 1 SI NIMS 1 NIMS X000 LNO34 SLON 126 53 Lld OL 5 5 1015 109 062 55419 SH3JAVI TYNOILIOOY NMOHS NI NIMS YOOd YANNI 398043NI3H T 31 25 LON 00 5 5 011 Ald JO LN3SNOO LNOHLM 03002 38 JON ISAW ONY SI SIHL ONNE 194205 007 0 z 00tf 2 39NIH 01 Was
101. ANNI 31372 318vo H3AOO HOLVOIGNI NOILISOd dv14 00259096 3578 YOLVOIONINOILISOd ____ 1817 sped 9 9 c 9 o a c LL N 3 5 N T co oO lt oc en 2 2 e e N LL O o a LMiles Technical manuals J230 J430230 J430 Work filesJ230 C Tech Rev 1 doc REVISION Print Date 14 01 2009 4 41 00 PM Jabiru J230 C ft Pity Pta ircra A Aircraft Service Manual iru Jab 7 30 5 049 aaviaa sv VQovesove IOHLNOO NOI LISOd 46 982 010 OV wa S A S ON 530 WHANAD alva ssi Ald HO31AV 40 LNSSNOO daldoo Vid HO31AV S3313NITTIIN NI suum T oM LON 1STIH LHOINAdOS SI SIHL SNOISN3HIG LE NOUS Seld 3718v2 NO LSNFOY OL SH3HSVM ISN SNNY NI 318v2 Figure 28 Flap Position Indicator Drive Cable Assembly 6810 Zl WMWOZX POE S S MIYOS NpOOVEHd 22 1108 9118 9I ENV OL
102. AV JO LN38NO2O 031900 Vd HO31AV S3HL3NITTTIIN NI eve 39 LON 15 LH9IAdOO SI VHS SNOISN3MIG e z sa ja gi 5052 C LY COR 9 962 5 5 H3lSViAl SS3Hd 3nd 39HvH2 o D 5 5 cH J Q Gio ah 4 SLE gz orz 10313 WODH3LENI woo em a Gor S3ovid 2 AX Od3 009601 HLIASSv 193H8l 0 Jv SH3AV 9 34819 ZLZOV H3AVT SEV IS NOSMHVO HO L33HS S3 OH LNVOVA HOS lt 38V 2 STIOH TW HLIM 5 ST3NVd L ALON YALYVLS T3A371 H3OV3H kN 9020 6 ON d NOISH3A TV NE 8020vGS CN d NOISHSA NOSHVO TLE cE 0 5 6 CN d NOISH3A TY NISOZOVS CN d NOISH3A NOSHVO Sci Al ore GLL 9681 SEC 59 2 v6c Figure 53 Instrument Panel Layout Std Panel X A lt T a 2 o 40 e
103. Aircraft Service Manual Service Schedule Inspection Schedule Engine Instruction amp Maintenance Manual Propeller Instruction Manual Airworthiness Limitations Mandatory Replacement Times Structural Inspection Intervals Structural Inspection Procedures REVISION Dated May 2006 Issued By RAS Page 1 of 171 LMilesVTechnical manuals 230 J430230 J430 Work 1 5 230 Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft un Aircraft Service Manual Jabiru J230 C FOREWORD This manual contains JABIRU recommended procedures and instructions for ground handling servicing and maintaining the following Jabiru aircraft models J230 C LSA Factory Built Jabiru 3300 powered 2 Seat J230 C LSA Kit Built Jabiru 3300 powered 2 Seat The J230 C is an LSA acceptable aircraft In Australia the J230 C may be registered by CASA with a VH prefix as a Light Sport Aircraft LSA or by Recreational Aviation Australia RAAus with a 24 prefix In both categories the J230 C has a 600kg MTOW There are two divisions within the LSA category LSA Special and LSA Experimental Special LSAs are generally those which have been built by the factory then maintained in accordance with the manufacturers requirements any modifications must also be approved by the factory Experimental LSAs are those built from kits or those aircraft which have a modification which
104. CRIPTION QTY 1 5A049A1D 1 LANDING LIGHT FIBREGLASS MOULDING 2 1 GUOTHAMERVEBIREETION 2 5A049A2D 1 LANDING LIGHT FIBREGLASS MOULDING 2 1 LAC 5105294 3 RETAINING RING LANDING LIGHT LENSE 1 4 5 50W x 12V LIGHT 15 DEGREE LANDING LIGHT 1 FIT RETAINING RING TO HOUSING 5 M4 x 12 LONG SCREW 1 USING 2 SCREWS LOCATED AS SHOWN 6 M4 FLAT BRASS WASHER 2 7 PHO209N M4 NYLOC NUT 1 8 0138 SCREW SELF TAPPING 6GG X 1 4 2 5 NOTES 1 USE LY3600 EPOXY RESIN MOULDS DEFINE SHAPE DIMENSIONS GIVEN FOR REFERENCE Se BASIC LAYUP 3 LAYERS AF303 GLASS APPLY PEEL PLY ON ALL BONDING SURFACES Pa INSTALL LIGHT 1 BELOW THE LOWEST END OF THE UPPER WING STRUT FAIRING ON LHS WING 6 DRILL 3 6 HOLE IN STRUT TO ALLOW WIRES TO RUN INSIDE JOIN PARTS WITH FLOCK WHERE THERE IS A JOGGLE LAY 2LAYERS AT312 2 TAPE IN JOINT WHERE THERE IS NO JOGGLE STRUT DE BURR HOLE amp APPLY DURALAC BEFORE ASSEMBLING lt I EI 4 91 X HOUSING TO STRUT USING SILICONE SEALANT TO PREVENT VIBRATION APPLY SILICONE SEALANT BETWEEN PARTS ON ASSEMBLY DIMENSIONS THIS DRAWING 15 COPYRIGHT AND MUST NOT BE SCALE 1 17 1 06 PROJECTION Qc IN MILLIMETRES DO NOT SCALE AVTECH PIL COPIED WITHOUT THE CONSENT OF AVTECH PTY LT
105. D VAR ISS DATE GENERAL TOLERANCES WHOLENO S 05 DS 010 786 973 TITLE DWG No HINKLER AIRPORT LANDING LIGHT ASSEMBLY 5A049A0D 1 MATERIAL AS DETAILED APPR BUNDABERG 4870 1 oe 1 Figure 11 Landing Light Assembly 5 5 FIN The Fin is a moulded composite structure supported by ribs and a rear spar Hinges attach the rear spar to the rudder 5 5 1 REMOVAL INSTALLATION INSPECTION AND REPAIR The fin is an integral part of the fuselage structure and cannot be removed All repairs must be referred to JABIRU AIRCRAFT Pty Ltd or our approved local agent 5 6 HORIZONTAL STABILISER The horizontal stabiliser is a moulded monocoque structure of rigid cellular polystyrene bonded to a fibreglass skin and rear spar 5 6 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 or our approved local representative Revision Dated Feb 2006 Issued By RAS Page 51 of 171 LMiles Technical manuals 230 J430M230 J430 Work filesJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft me un Aircraft Service Manual Jabiru J230 C 6 SECTION 6 LANDING GEAR and BRAKES 6 1 LANDING GEAR Main gear comprises two separate composite beams which are bolted to the fuselage at the top a
106. DITIONS 118 11 91 1517 EY E 118 11 92 Seacoast and Humid 118 12 SECTION 12 FUEL SYSTEM bisccsscssessesessessesscostessescsscessccsssescscascssscesseaseafeccedeussee soosseostecsseacsecssasesecssasexessnaes 120 12 1 DESCRIPTIONS An 120 12 1 1 LSA Aircraft Fuel 120 1212 ire rtm tren ier an ie rm Res 120 12 1 3 Fuel System Trouble Shooting sss desees nnne 122 12 2 FUEL TANK CN 122 122027 T ati aceasta 122 12 2 2 Fuel Tank Removal amp Installation 122 12 3 gb dz pP 123 EE DOS Em 123 12 3 2 CHECKING m een oes 123 12 4 FUEL SHUWTSOFE VALVE b cie enne ere ee 126 12 4 1 Nerd iie 126 12 4 2 Fuel Valve Removal amp Installation 126 12 5 FUEL GAWGES T 127 12 5 1 Description SIGHT GLASSES 127 12 5 2 Fuel SIGHT GAUGE Removal 8 Installation esses einen 127 12 53 ELECTRIC FUEL GAUGE 5 128 12 54 ELECTRIC Fuel GAUGE SENDER Removal 4 Installation sss sss sss 128 12 6 HEADER TANK LOW LEVE
107. IHO 5931 9510 TVNOLLO3SIO NOLLO3SICO NOILLV LOS T33HAA NOLLV TIVI SNI H3dlTVO O3llddV 38V 6 NSHAA Q3SS3HdIlNOO 38 OL Q3 1N3IHO 38 LSNW 5931 9510 SW3ISAS HS ITV Vna H LIM S3l 1d aV NOILV IN3IHO IWYS H3dl IVO JAYA STONIS HLIAA OSIA 3 LON c o S o o 2 a x o a T 3 D N T N c oO lt cc en 2 2 c e LL O ij a z 9 o 2 tc Print Date 14 01 2009 4 41 00 PM LMiles Technical manuals 230 J430M230 J430 Work filesJ230 C Tech Rev 1 doc Jabiru Aircraft me un Aircraft Service Manual Jabiru J230 C 65 NOSE GEAR The nose gear comprises a steerable nose wheel mounted on a welded steel assembly with an aluminium wheel yoke and a rubber spring system The steel tube is constrained within two Ertalite bushes mounted in an aluminium housing which is attached to the front of the firewall Nose wheel steering is achieved by connecting the rudder pedal assembly to the nose wheel steering link by push rods The nosewheel is centred by springs A nose wheel speed fairing wheel spat is standard equipment Disassembly inspection repair and reassembly of the nose wheel assembly are described in separate paragraphs The wheel is in two halves which are j
108. INS OL GON 00 900 6 Ir IAN ANN N EZOHd OL NZL108d H3JHSVAA SLS D96NY 8 NOUWTIWLSNI 1108 Z NOLLSOd V z RE dO N35vds 5 000 9 dv TWNGIAIONI 2 1108 MELENV 17109 91 VOL ENV v LON 2 601 5950094 u3HSVM 0i 090NV SAM 5 0 008 HSNd 9 601 506 ZL 3 VW N60008d ALO NOL HOSS Leivd Wall o 1517 sued iu tc Print Date 14 01 2009 4 41 00 PM LMiles Technical manuals J230 J430230 J430 Work filesJ230 C Tech Rev 1 doc Jabiru J230 C ft Pity Pta ircra A Aircraft Service Manual iru Jab t 1 1 v 1 2 1 2 0497 43 T4NIH 16982 OLO Wa Vd HO31AV avos og S38ISNITIVI NI SNOISN3MIG oorr oozr ASSY LJVHS SAM dv14 O17 Ald 40 1H3SHO29 031400 38 LON 1SNF LI IOTHAdOO SI SII LL o gt o o lt a 2 o o K a N 2 o LL O oO n lt tc a 2 20 e N LL a z o o 2 rc 13Al4 dOd 91 6 DOTAN SLIE _ 2201 592025 YIHSYM LV S
109. IRS 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 4 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 REVISION ol Dated Feb 2006 Issued By RAS Page 37 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft un Aircraft Service Manual Jabiru J230 C 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 4 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 th
110. IX II JABIRU ENGINE PARTS BOOK Please insert your copy of the INSTRUCTION AND MAINTENANCE MANUAL that comes with your engine into this section THIS PAGE IS INTENTIALLY LEFT BLANK revision 0 Dated Feb 2006 Issued By RAS Page 162 of 171 LMilesVTechnical manuals 230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft un Aircraft Service Manual Jabiru J230 C 20 APPENDIX ENGINE INSTALLATION MANUAL Please insert your copy of the INSTALLATION MANUAL that comes with your engine into this section THIS PAGE IS INTENTIALLY LEFT BLANK revision 0 Dated Feb 2006 Issued By RAS Page 163 of 171 LMilesVTechnical manuals 230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft Aircraft Service Manual Jabiru J160 J170 Variants 21 APPENDIX IV PROPELLER SERVICE MANUAL 21 1 APPROVED INSTALLATIONS The following combinations are approved Table 18 Approved Propeller Installations Airframe Engine Propeller Dia x Pitch Remarks Limits 1524 x 1346 Jabiru J230 C Jabiru 3300 C000262 60 x 53 Not above 3300 RPM 21 2 IDENTIFICATION STAMPINGS Each propeller is marked with the particulars indicated below 1 The Propeller Drawing No 2 The diameter and pitches in metres proceeded by the lette
111. Jab Jabiru J230 C EE esamas 5 Sv 100975401 T GEE oov 00zf 1402 U3MO Wd wa Xs DOSE E 551 AMIXOIML ANOINLLNV SL OL SLN CInOW OL 311308d 40 2 92 awas 3NI430 OL 009590 1 GINOW ISN L ALON MBIA TILIA NIM 53003 133 5 55779 3943 198405 100 102 H3NNIJS M3AO SHAYI 431005 10 HAO Ol ELEY JANIH 343HM YAW 3943 ONNOYY Old TW HOR ovrt OF X SUYI HILO 3HIN3O 06 H1079 GHY 982 096 t l3AIH 4S9 2 YSNIVLSY 9OTWVO 212 9 IWAN 3409 JAYI 9 H3HSVA SS3 INIVLS WSO vrzZLoselev 9 HLO0 N3AYI id AW TADO 9 MIHIS SS3 INIVLS ASI LS0 69FeSN uw v 0 ISAM dOd ISO E498 WdVl L ONvId WNININNTY 4 sszoesW 2 L MOD H3MO1 NIVSFOVLI T 31725 LON 00 NI SNOISN3HIC 38 JON USAW ONY
112. L WARNING OPTION 130 MO een E 130 12 6 2 Fuel Valve Removal amp Installation 130 12 7 FUELFILTER S rette ae e desea etae eere cae 130 TAA Fuel titen 130 12 7 2 Fuel Filter Removal amp Installation sss 131 12 8 EUEL PUMPS 131 1281 m 131 12 8 2 Secondary PUMP salads esasan danane ges aaa 131 13 SECTION 13 INSTRUMENTS amp INSTRUMENT 5 8 5 4140 4 0 000 132 13 1 GENERAL n 132 13 2 INSTRUMENT PANE Lessee cass sg eere eco 132 13 2 1 Instrument Panel Removal amp Installation sees 132 13 22 INSTRUMENT SJ 1 m mme eerie 133 13 2 3 Instrument enim pe nane e n raten pne aa nnne 134 13 2 4 Installation LJ Messer ma aaa 134 13 3 PITOT amp STATIC SYSTEMS itc rper cette etit exo earn 134 13 3 1 Pitot Static System Maintenance sss deseen nnne nnne nnne nnn 135 13 3 2 Static Pressure System Inspection amp Leakage 135 13 3 3 Pitot System Inspection amp Leakage Test einen nnne 136 13 3 4 Blowing Qut Lines itte tar d Do ed
113. LE 1108 9 LAN JOTAN YSHSVM OSENY 1708 dvd 91419373 1 8801 1041 02 39NV 13 138330 d3 31 NOILdI42S3G 1511 Sued 1 2 T T 5 T 9 Print Date 14 01 2009 4 41 00 PM LMiles Technical manuals J230 J430230 J430 Work filesJ230 C Tech Rev 1 doc ft Pity Pta ircra A Aircraft Service Manual iru Jab Jabiru J230 C 0297 9H38vaNna 6 982 NOV wa Ald HO3LA JO IN3SNOO LNOHLIM 031909 Vd HO3L1AV 38 LON 5 ONY 4 9 SI SIHL 3798 LON OG sv 7319 IT NOLLO 3 OHd SNOISN3IWIG E NIA WW 0 MON SSvug WWG H3HSVAM 30438 NOLLVH3dO HLOOWS H3HSVM 139 318W3SSY 38V8 NO WOW 553038 LNIVd 39v1S QNO23S 91813 IHL MeV IHL NOM OL NOLLISOd 318Vv2 15 NOLLISOd NI ONY 03 18 388 V JINO f 5 JAS 18315 ONY 31850 OL NO MOY H30710S OL XI OL 3 3735 JSN LAA dOd 91 6 9 9 SY 2 YIHSYM 91 ZIL X 999 5NIddv L 3138 AVAH d MIYOS N6ELOHd MOV HOLVOIQNI NOILISOd dv 13 Y
114. Letters are also posted on the JABIRU web site and provided to JABIRU dealers 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 For both kit built and factory built aircraft owners remain able to conduct maintenance on aircraft for which they are the registered owner If the aircraft is being used for training Revision Dated Feb 2006 Issued By RAS Page 2 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft me 524 un Aircraft Service Manual Jabiru J230 C etc maintenance is required to be done by approved persons L2 or LAME depending on the registration 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 Revision Dated Feb 2006 Issued By RAS Page 3 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft Shaun un Aircraft Service Manual Jabiru J230 C 1 Table of Contents 1 TABLE OF CONTENTS Cm 4 1 1 TABLE OF FIGURES 25 2
115. ND SLIND Vd HO31AV 3 yos SZSLINITIW 3 nouoaroua SNOISN3HIQ NMOHS SNIOVdS 0217 091 geb 0917 NOISN3SWIO 39N3H343MH 028 ATINO NOISNAWIC 32N3H33H 297 INO S130 0W ATIAWA 02 LP 091 NO O38In O3 2018 39NIH 3HLIN32 Z NAADHS SV 9 OLLE 097 007r 0027 O13 dS SN LIM SMOTIOS Sv STSCOW NIJAL S3IHVA SNIOVdS JHLIN32 L SSLON 9 DOTAN 91 ctOLS9COCSW SL e UdHSVM 1913 SL 9 9 1108 Sh VSZENV EL 1104 9 1108 2018 TWwdsd Sadans 1 40490096 1 1 31v ld div 1o 2 00 1 0 96 Ol E saaans dio S v60S 106 8 v LAN t t N6EZOHd 8 MIYOS v Saved JOL ON L SdOLS LINANI ASSY 33800 871 z Q0v9rOvVE 9 SINS 301 ON L 840158 LIINENI ASSV M Wadsd Sy c Q0vSvOvE 5 LAN DOTAN t h 821 59 0254 v 8 H3HSVM 1919 t h 9Lt 096Nv E t dOd 81 LSA dOd 8 1 e t 51 4015 ONI Z veOr LOE ALO Wall 3811 NOISN3IAIC 39N3HJ3H 986 Figure 36 Rudder Pedal Assy
116. NG CENTRING ASSEMBLY The Nosewheel Centring Assembly consists of springs which are stretched when the nose leg is moved to the left or the right Repair is limited to replacement of parts 6 7 2 NOSE WHEEL STEERING ASSEMBLY Refer to Figure 17 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 parts 6 8 BRAKE SYSTEM The hydraulic brake system consists of one master cylinder located on the front of the main longitudinal beam flexible hoses connecting the master cylinder to each wheel brake cylinder and the single disc and a floating cylinder type brake assembly located at each main landing gear wheel 6 8 1 TROUBLE SHOOTING BRAKES Table 7 Trouble Shooting Brakes Trouble Probable Cause Remedy Brake handle binding Check and adjust Worn or broken master Repair or install new master cylinder piston return spring cylinder Dragging brakes Drain brake line clear with compressed air If cleaning lines fails the master cylinder may be faulty and should be repaired or replaced If master cylinder or wheel Leak in system cylinders are leaking repair or install new parts Restriction in hydraulic lines or in master cylinder Air in system Bleed system Lack of fluid in master cylinder Fill and bleed system Master cylinder defective Repair or install new parts Brake pads
117. NSDOCUON PEE ER 110 11 3 COOLING AIR BAFFLES is e e ren Ro cet 111 11 3 1 Cleaning and 5 amass dasamsa nase maaan e 111 11 3 2 Cooling Air Baffle Removal 8 Installation sessi sessi nnne 111 14 33 TOD AUG vaste E e A E E 111 11 4 ENGINE MOUNT 111 11 5 ENGINE FUEL SYSTEM enter rante tor Sak 111 11 5 1 Fuel System 000000000000 0 dones nenas 111 11 5 2 LSA Aircraft Fuel System 112 11 6 SPARK PLUGS mH M n 112 11 7 ENGINE CONTROLS T n 112 voi 112 11 22 Throttle Syste s ee ntt a ea eni eo 112 Oc Y 114 11 7 4 Air Intake System amp Carburetor Heat sss sisse einen nnne nnns 114 Revision Dated Feb 2006 Issued By RAS Page 7 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft un Aircraft Service Manual Jabiru J230 C 11 8 TEM iratsi eiae S 116 11 8 1 Exhaust System Removal Installation sessi 116 11 8 2 Exhaust Inspection se see eed PA 116 11 9 EXTREME CLIMATIC CON
118. OIMH31NI 4009 OL SI NIMS TT 3wos LON oa SH3AV1 TWNOILIGQY 5 NI NIMS 000 YANNI 393043NI34H 44 5 5 3480438 HO1VO 113 ONY 530109 21 2 NI MIO 07 5 NI SNOISN3WIQ HLM NIMYHU 5 SJIANYH YOOd 404 SNIMS NI 1015 1029 HF 082 OSL 00 2 M3H2S 134208 MIO0v Od l 2 00 9 was MIO0v Od 4 dOd 9 vS EZ l St 81 un 6 80035 PEOSEO 1 8 l 40005 uly 602601 2 81 ASSY 21 2 10620 9 l 931599 ASSY 21 2 401 HOOG YZOLEO2 5 HELYIS t MOONIM 09479 1 00 600 57 NIMS HOOO 1NOH 0281 S1 HOIB3LNI H000 0 611 1 39NIH 202602 29530 1 191 Rear Door Assembly Figure 6 N T CU lt oc en 2 2 e e N LL O ij a wee Jo Print Date 14 01 2009 4 41 00 PM LMiles Technical manuals J230 J430230 J430 Work filesJ230 C Tech Rev 1 doc Jabiru Aircraft
119. P INNER 3 24 0778 GRUB SCREW 3 16 UNF x 1 4 3 DIMENSIONS THIS DRAWING IS COPYRIGHT AND MUST NOT BE 1 2646 PROJECTION IN MILLIMETRES 00 NOT SCALE AvTECH P L COPIED WITHOUT THE CONSENT OF PTY LTD NS 155 DATE GENERAL IOLERANCES WHOLE NO S U5 Ds A C N 010 786 973 TITLE DWG RE BETALE HINKLER AIRPORT INSTRUMENT PANEL ASSY GLASS 1 MATERIAL APPR BUNDABERG 4670 SHEET 1 Qr 1 Figure 42 Instrument Panel amp Throttle Assembly 11 7 3 CHOKE The Choke Control is located in the main instrument panel amp is connected to the carburettor by a control cable 11 7 4 AIR INTAKE SYSTEM amp CARBURETOR HEAT The engine air intake system comprises a cold air inlet in the lower cowl a hot air muff attached to the exhaust system a mixer assembly mounted on the firewall and connected to a carburettor The mixer box incorporates the air filter control flaps etc Carburettor Heat is activated by pulling the Carburettor Heat Control on the panel OUT This opens the hot air valve in the mixer assembly and permits hot air to flow from the muff into the carburettor The air filter should be inspected every 100 hours or more regularly if the engine is operated in dusty conditions Refer Paragraph 11 9 Dirty filters can be cleaned once by blowing out with compressed air w
120. PM Jabiru Aircraft un Aircraft Service Manual Jabiru J230 C Section Ground Handling Servicing Lubrication amp Inspection 3 1 GROUND HANDLING 3 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 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 Tail Plane take care that you do not jam your fingers under the rudder the rudder hinge remember that it is Connected to the Nose Wheel 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 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 3 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 3 1 2 1 JACKING MAIN GEAR 1 Remove main gear spat on
121. Pity Pta ircra A Aircraft Service Manual iru Jab Jabiru J230 C O17 Ald HO3I AY 40 IN3SNOO I NOH 39 LON LSA ONY LI IOIHAdOO SI ONAYA SILL ALO Dvd Wall 1811 SHEd SIHLJO L SL33HS NI O3 TIVL3O SV A THA3SSV TIOHLNOO 3137909 NSAID S3ILLLNV IO ALON gt 9 5 o 5 N 5 5 LL N 5 lt e 2 o 2 e e N LL a a z 9 rtc Print Date 14 01 2009 4 41 00 PM LMiles Technical manuals J230 J430230 J430 Work filesJ230 C Tech Rev 1 doc Jabiru J230 C ft Pity Pta ircra A Aircraft Service Manual iru Jab d 39 7138 lt 206 2 lt OM 6 Ald HO3I AY 40 IN3SNOO AHI 91409 LON ISAN ONY LI ISIdAdOO SI SII LL S1709 HOWLLY ANY 318v 2 HOIVA313 e LT Exi gt 9 5 c o 2 5 5 5 N T co CU lt oc en 2 2 e e N LL O ij a z 9 o 2 tc
122. Right hand fuel tanks near the wing root A third drain is located under the fuselage behind the sound curtain at the rear of the cabin Drain fuel from each drain after each refueling to ensure moisture and contaminants are not present 3 3 5 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 100 hours of engine operating time and more frequently if warranted by the operating conditions Clean only with compressed air 3 3 6 BATTERY The Battery is a sealed type and so is not a serviceable item If electrolyte corrosion occurs Use bicarbonate of soda baking soda and clean water to neutralise electrolyte of corrosion Follow with a thorough flushing with clean water Remove battery and clean residue from aircraft Clean cable and terminal connections with a wire brush then coat with petroleum jelly before connecting cables 3 3 7 TYRES Maintain tyre pressure at the air pressure specified in Aircraft Specifications above When checking tyre pressure examine tyres for wear cuts bruises and slippage Re
123. S Ailerons comprise a moulded and bonded monocoque structure embodying a composite control horn at the outboard end 7 4 1 AILERON REMOVAL amp INSTALLATION 1 Unbolt cable from aileron control arm 2 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 3 Remove hinge pins 4 Remove aileron 5 Reverse the preceding steps for installation 7 4 2 AILERON INSPECTION amp 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 or our approved local agent revision 0 Dated Feb 2006 Issued By Page 79 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft un Aircraft Service Manual Jabiru J230 C 7 4 3 AILERON BALANCING The aileron does not have balancing weights fitted The control does however have limits for weight and hinge moment Weight 1150g 100g Hinge Moment 94000g mm 4000g mm The aileron balance is checked at the factory during assembly and unless they are repaired or refinished the balance should not change To balance the ailerons they must be removed from the aircraft Balancing is done around the hinges with the hinge pi
124. S if equipped Baggage P No 5111154 BAGGAGE LOAD BEHIND SEATS ONL 10 AFT OF THIS a f ECTON 6 MRCRAFT FLIGHT E OADING TO DETERMINE AIRCRAFT TRIM Fit to inside of fuselage on right side just below horizontal rib Locate vertical line in line with base of bulkhead Baggage P No 5A037A0D BAGGAG V SKG MAXIMUM BEHIND E 1 FE TOTAL BAGGAGE CAPACI Fit to inside of fuselage on right side just below middle rear window Revision Dated Feb 2006 Issued By RAS Page 156 of 171 LAMfilesNTechnical manualsJ230 J4301J230 J430 Work filesJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft 2 Aircraft Service Manual Jabiru J230 C Decal Detail Preview Loading Limitations ENS LOADING LIMITATIONS mum Gr eight of aireradt i 1 exceed 2 All baggage mi stowed eitl the pa on the floor the front seats D ad the seat bac 5 Plots must use Load amp Trim Sheet given in Section 6 ers Manual lo check trim Fitted on inside of fuselage of RHS of cabin below Rear Window Engine Details P No 5A008A0D 1 OFF Attach to upper cowl beside oil door or to oil door itself Nose Wheel Inflation P No 5A062A0D Attach to left side of nose wheel spat Main Wheel Inflation P No 5A061A0D Attach
125. SION o Dated May 2006 Issued By RAS Page 165 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM ft Pty Pia ircra Jabiru A ircraft Serv J230 iru Jab v 30 H3HS 106002 0 18 008 ASSY N3NNIdS ONY ON 9u38vYQNng 140449 YSTANIH 26 982 010 d HOSLAY aava SY NOlLdlH2S30 Lid AM MP NA YANNIdS SUNN ol 31905 Nd ice Manual A 20905 ASSY YSHSVM 31 NOLINTINISNI LAN jHOHONY 8 719130 WASTE 11139 OL Wall 39NY14 dOdd ANOYOL 12348002 404 SIHL 38 5 SNOILO3MIQ 3llSOddO NI 3973 SH3HSVM 517109 N3TI3dOHd 404 30 3 035 j9NY 15 dONd LJVHSMNYHO 8 335 NOLIVTIVISNI z YANNIdS 39NYTJ 43HSVM Y VrTLOT VrZ LVLO GELEV 21 AN3HOS VIVO 29 93 7 83438 1108 1982 69 705 1 V9v vNV 9 LAN M201AN ALNO MH SH3HSVM 3TIIA3TT38 SCvy S9 0c SN NSIOVv Hd 9 Gee 5 5 7806897 19 9 dONd 31774 9NDIOvB 33NNIdS INY 3S3 80 89 7002087 e 10N HOHONY VV 11035
126. SV ALVIS HOS NMOHS LON 3LON 16 005 D OOTAN 9 ZEOL SOLOZSW OL t 1913 SLE 01 096 6 1104 91 v90 tNv 8 LON JOTAN tih 9ct S9 0cSVI 2 t YIHSYA 1V 13 t h 9Hr096NV 9 T 1108 vLPNV 9 2610 7620009 t E 620084 L 9 T33HAA YSLNO 18v2 8201149 6 l 9 AIM HINNI 1579 2200109 ALO Wall 1811 sued lt o 5 iL T N T o oO lt oc en 2 2 e e N LL O ij a z 9 o 2 tc Print Date 14 01 2009 4 41 00 PM LMiles Technical manuals J230 J430230 J430 Work filesJ230 C Tech Rev 1 doc ft Pity Pta ircra A Aircraft Service Manual iru Jab Jabiru J230 C 049v S Uagavauns WIN TVIS3 L VIA 220 NOLLV TIV LSNI OSIA SMV TWNOILOSUIC 6 987 000 NOV 90 5 310HM SSONVYSTIOL TVH3N39 ssi Ald HO3 AV 40 1IN3SNOO LNOHLIM 031409 Vd SSYLSWITHA NI 1 VS LON 1HOIHAdOO SI SIHL NOS LRL UR SNOISN3WIO SE Q3l lddV 3HV S3MVH8 N3HAA Q3SS38dWOO 38V 8593105 LN3
127. T SPECIFICATIONS Model J230 C 600kg Aircraft Maximum Weight 1320 Fuel Capacity 135 litres AVGAS 100 130 MOGAS with Octane Rating 95 RON AKI 90 or above may be used if AVGAS is not available Propeller Type Fuel Type Fuels Containing Alcohols Ethanol etc will damage the fuel tank sealant and MUST NOT BE USED IN JABIRU AIRCRAFT Oil Capacity 3 5 litres Oil Type Refer Engine Manuals Engine Model Refer To Appendix For Engine Data Jabiru 2 bladed Wooden Propeller Diameter 60 dia 1524mm Propeller Pitch Jabiru 53 pitch 1346mm Wheel Sizes Standard 500 x 6 rim Tyres Standard 6 wide 6 Ply Tyre Pressures Standard Mains 228 kpa 45 psi Tyre Pressures Standard Nose 193 kpa 30 psi Wheel Alignment At Gross Weight Camber Toe In 0 0 Battery Location In Engine Compartment REVISION Dated Feb 2006 Issued By RAS Page 15 01171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft Aircraft Service Manual Jabiru J230 C 2660 105 6550 257 8 342 13 C3 2400 94 4 Figure 1 J230 C General Arrangement Revision Dated Feb 2006 Issued By RAS Page 16 of 171 LM
128. UGE OPTION The Exhaust Gas Temperature Gauge is a Thermo couple instrument and is not connected to the aircraft electrical system See Wiring Diagram Figure 59 Should the instrument fail to operate 1 Check for loose terminal connections and damage to wiring 2 Replace thermo couple Replace Gauge 13 9 HOURMETER The Hourmeter is an electronic instrument An optional Airspeed Switch may be fitted Should the instrument fail to operate 1 Check 10 instrument fuse and replace if necessary 2 Check 15amp main circuit breaker and re set if necessary 3 Remove Instrument Panel see Paragraph 13 2 3 and check cable terminals for security 4 Replace Gauge 13 10 MAGNETIC COMPASS The Magnetic Compass is liquid filled with expansion provisions to compensate for temperature changes It is equipped with compensating magnets adjustable from the front of the case No maintenance is required on the compass except an occasional check on a compass rose for adjustment and compensation revision 0 _ Dated Feb 2006 Issued By RAS Page 145 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft me 522 un Aircraft Service Manual Jabiru J230 C 13 11 EFIS WHERE EQUIPPED A detailed description of the instrument it s installation and operation can be found in the appropriate Dynon User amp Inst
129. URNS FURTHER IT 7 PG4A023N 5010 O RING 1 YES YES YES MUST BE RE ASSEMBLED PROPERLY 8 PG4A024N BS013V O RING 2 YES YES YES 9 4A120B0D SINGLE LINE FUEL TAP BODY 1 YES YES YES 10 4920223 HOSETAIL SIGHT GLASS 2 YES YES YES 11 4A120COD FUEL SHEATH SPIGOT 2 NO YES YES 12 4A120D0D SINGLE LINE FUEL TAP LARGE LEVER 1 NO YES NO SECURE WITH LOCTITE 243 PAINT HANDLES RED BEFORE INSTALLATION lt i N JW 4 041005 i d i DS 21 9 05 ps 2 405 due DIMENSIONS THIS DRAWING IS COPYRIGHT AND MUST NOT BE SCALE 4 17 03 04 PROJECTION IN MILLIMETRES DO NOT SCALE AVTECH P L COPIED WITHOUT THE CONSENT OF AVTECH PTY LTD 1 1 ISS DATE LIMITS UNLESS SPECIFIED OTHERWISE 9 5 prawn DM A C N 010 786973 TITLE DWG No AS DETAILED HINKLER AIRPORT SINGLE LINE FUEL TAP ASSY 4A120A0D 4 MATERIAL IN PART DRAWINGS APPR BUNDABERG 4670 M Figure 48 Single Line Fuel Tap 12 5 FUEL GAUGES Two different fuel gauge systems are used in the J230 family The first uses sight gauges located in the wing roots while the second uses senders in the tanks to drive electronic LCD gauges fitted in the instrument panel NOTE Both gauges are intended to require no servicing the information below is provided for ref
130. V L SH3AV T NIMS TVI LHVd 5 HO HLOTO NV LOM WWOS ONIS 9 N33M138 Was 296 314 r 280 GAP BETWEEN VG HOWS 30 3OV ld NI 9 NIS3H AXOd3 LOHS QV31 40 sw6ogz XIN AXOd3 3204 NOLLOO ONISN OL 1191 QNOS 2350 2205 25 Horizontal Tail amp Elevator Assy 2 o z e N 9 5 o N T oO lt cc en 2 2 e LL O a z 9 o 2 tc Print Date 14 01 2009 4 41 00 PM LMiles Technical manuals 230 J430M230 J430 Work filesJ230 C Tech Rev 1 doc ft Pity Pta ircra A Aircraft Service Manual iru Jab Jabiru J230 C a eres de TE 00 0027 ouaavanna aucun um A TBWA3SSV 3NV Id TYL WLNOZIHOH ate Sd wavuc 174 SSWWNSHIOGSIgIOSdS SSSTINT VAHOB Tyo ov oa
131. Vd HO3LAV LOZLOtL SIM 38 LON 1 LI IOTHAdOO SI SII LL SNOISN3INIC 4 sa NLOBZO0Z ASSY S H NLL8ZOZ ON d YOOO SY ONISN JAIS LH9IH 3 T8 3SSV Z N t etc NA OHS SV 5 1331 oH 8 la 5 1 2 81 00y 21 2202 6 521435 49014000 ON rds 00 B z Nid 1105 c i seaezsW z H3HSVA 1713 9 6 9 9 096NV 9 a t WNOSH31INnOO 9LE SrO t69rcsW 2 samasr Ho1vo 9 TIWNSLNI 1 161202 Noo 9122202 ALO 1 1511 Swed 2 F T T 8 gt a E 0 lt z o 9 G l o a 5 5 LL N T N oO lt oc en 2 2 e e N LL O o ij a REVISION Print Date 14 01 2009 4 41 00 PM LMiles Technical manuals J230 J430230 J430 Work filesJ230 C Tech Rev 1 doc Jabiru Aircraft un Aircraft Service Manual Jabiru J230 C 4 3 4 LOCKS An optional cylinder and key lock is available When fitted the keyed barrel lock is located in the fuselage at the re
132. abiru Aircraft 22 3 1 EXTERNAL PAINT FINISHING LIMITATIONS The J230 C is manufactured of a Fibreglass Epoxy composite which can be weakened by extreme heat Because of this the outer finish is subject to the following limitations Overall paint colour must be white e Registration markings under the wings must be produced in an outline text style with line width in the range 18 22mm Markings may be any colour which meets visibility requirements including black e Registration markings on vertical surfaces may be produced in a bold text style and may be any colour which meets visibility requirements including black Lines used in the registration markings may not be more than 22mm wide e Other markings on vertical surfaces including pinstripes model identification markings etc may be applied but are limited to lighter colours over small areas Markings of any kind on the upper faces the aircraft such as the top surfaces of wings fuselage and horizontal stabiliser are not permitted 22 4 CONTROL SURFACE BALANCING The J230 C primary control surfaces are balanced during construction In service there should be no reason to rebalance the controls Balance checks of the controls are only required after repair or refinishing or at the 5000 hourly major airframe inspection REVISION Dated May 2006 Issued By RAS Page 170 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1
133. ack cloth to pick up the final dust particles 15 Wash down the floor of the spray area to settle dust and proceed to spray as per your selected technique 16 You are now ready to spray final coat GOOD LUCK WARNING The Jabiru aircraft is only approved to be painted in basic White colour so as to minimise the effects of heat and ultra violet light to the aircraft structure In addition colour including stripes etc must not be applied to horizontal upper surfaces Revision Dated Feb 2006 Issued By RAS Page 155 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft Aircraft Service Manual Jabiru J230 C 16 SECTION 16 PLACARDS 161 230 DECALS Table 14 J230 C Decals Decal Detail Preview Warning Placard P No 5A051A0D Fitted above windscreen in front of wing carry through beam across to the left side Compass Card For N 30 60 E 120 150 P No 5123024 Steer For 5 210 240 W 300 330 Steer Fit in compass card holder attached to compass EFIS Warning c P No 5A042A0D NON CALIBRATED SECONDARY INSTRUMENT 1 OFF Fit to upper frame of DYNON EFIS if equipped EMS Warning m m 4 m P No 5A042BOD VOL AGE US L DI 5 UN ED ALL IMES 1 OFF Fit to upper frame of DYNON EM
134. aft Service Manual Jabiru J230 C x z 1 E A A A Figure 33 Elevator Travel Limits Revision Dated Feb 2006 Issued By RAS Page 96 of 171 LAMfilesNTechnical manualsJ230 J4301J230 J430 Work filesJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft un Aircraft Service Manual Jabiru J230 C 9 6 ELEVATOR TRIM CONTROL SYSTEM See Figure 35 The elevator trim control system comprises a Trim Cable connected to a lubron block so that the cable is able to move the block fore and aft approximately 35mm An aluminium rod is free to slide through this lubron block and is centred by 2 compression springs The output end of the rod is connected to the Elevator Horn 9 6 1 OPERATIONAL CHECK Movement of the Trim Lever FORE AFT should result movement of the Main Control FORE and AFT and movement of the Elevator UP and DOWN See Figure 34 WARNING It is important to carry out this operational check whenever the trim cable has been disconnected to ensure it has been correctly installed 9 6 2 TRIM HANDLE ASSEMBLY See Figure 34 9 6 3 CONTROL CABLE AND ATTACHMENTS The control cable is of the enclosed push pull type with the cable bolted directly to the Trim Horn Extension at the rear end and to the trim control
135. ake account of the risk of subsequent Propeller failure Therefore repairs are limited to the filling of small nicks in the Propeller Maximum size of nicks approved for repair is Those Leading Edge 4mm deep x 20mm long 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 the changes to balance of the Propeller and therefore the Propeller should be removed in accordance with the procedure described above It must be checked for balance see Paragraph 8 prior to refitting see Paragraph 6 checked for tracking after reassembly see Paragraph 6 4 and the Spinner checked for balance after reassembly see Paragraph 6 7 Only nicks within the size tolerances described above may be repaired All propellers with cracks or splits or any delamination of the composite sheath in the case of sheathed Propellers must be either Rejected as unserviceable or returned to JABIRU Aircraft Pty Ltd or our local approved agent for assessment and possible repair In composite leading edges nicks of a size described above may be repaired by filling with epoxy resin and Fibreflock using the procedure outlined below Propeller Repair Kit is available from JABIRU as Part 49 1 Remove Propeller as per Paragraph 5 2 Sand nick with abrasive paper to remove any fractured particles 3 Mix resin carefully and thoroughly equal parts resin and hardener
136. al manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft un Aircraft Service Manual Jabiru J230 C 4 Section 4 Fuselage 4 4 FUSELAGE The Fuselage is a composite monocoque self supporting structure and includes both the Horizontal Stabiliser and Vertical Fin All repairs must be referred to Jabiru Aircraft Pty Ltd or approved local representative 4 2 WINDSHIELD AND WINDOWS 4 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 In the event of a bird strike the windshield is 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 those longer than 25 mm should NOT repaired the windshield must be replaced 4 2 2 CLEANING Refer to Section 3 4 4 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 CAUTION 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 4 2 4 REPA
137. allation manuals In brief the EFIS is an electric instrument which generates a digital display of Airspeed true or indicated Vertical Speed Heading G acceleration System voltage Angle of attack Outside air temperature Roll angle Pitch artificial horizon Balance ball e Clock The EFIS incorporates an internal battery to allow the instrument to run for a minimum of 1 5 hours 13 12 EMS WHERE EQUIPPED A detailed description of the instrument it s installation and operation can be found in the appropriate Dynon User amp Installation manuals In brief the EMS is an electric instrument which in the J230 C generates a digital display of RPM Cylinder head temperatures up to 6 Exhaust gas temperatures up to 6 Oil temperature Oil pressure Fuel flow Fuel pressure System voltage Amps Carburettor temperature Manifold air pressure Revision Dated Feb 2006 Issued By RAS 146 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft un Aircraft Service Manual Jabiru J230 C 14 SECTION 14 ELECTRICAL SYSTEMS 14 4 ELECTRICAL POWER SUPPLY SYSTEM Electrical energy for the aircraft is supplied by a 12 volt direct current single wire negative ground electrical system 12 volt battery supplies power for starting and furnishes a reserve source of power
138. and thicken with Fibreflock to form a paste 4 Apply paste to sanded nick and allow to cure moisture environment for 24 hours 5 Lightly and carefully sand excess cured resin to a smooth surface matching exactly the previous aerofoil 6 Refurbish with clear Epoxy paint JABIRU Part No PPOO69N 7 Rebalance Propeller see Paragraph 8 8 Reassemble and replace Propeller and Spinner see Paragraph 6 9 Check Propeller tracking and Spinner balance see Paragraph 6 10 Damaged urethane leading edges should be referred to Jabiru Aircraft Pty Ltd for repair REVISION o Dated May 2006 Issued By RAS Page 168 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft AN Aircraft Service Manual Jabiru J230 C 21 8 PROPELLER BALANCING PROCEDURE Propeller balance should be checked by locating a 16mm tube to firmly fit the centre mounting hole of the Propeller and balancing on knife edges Tolerances e Imbalance shall not exceed the following limit whatever the position of the Propeller in the plane of rotation 750 mm gms approximately 1 gm at the tip The balance may only be corrected by the application of epoxy paint Any other method of securing balance is PROHIBITED Propellers outside these limits should be rejected as unserviceable or returned to JABIRU for assessment and
139. ar of the Port Starboard amp Rear doors Spare keys are available to JABIRU registered owners by quoting the aircraft Serial Number 4 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 The seat backs are also essential to restrain baggage in crash conditions WARNING DO NOT MODIFY SEATS 4 4 1 REPAIR As seats are integral to the aircraft structure any repair must be referred to JABIRU AIRCRAFT Pty Ltd or our local approved representative 4 5 UPHOLSTERY Seat upholstery is provided through slip on covers These are easily removed for cleaning and inspection of the seat structures Note that the seat covers are treated with a flame retardant which must be re applied after every 5 washes Optional Hood and Cabin lining is available together with Door Pockets 4 5 1 UPHOLSTERY CLEANING FLAME RETARDANT The upholstery used in the J230 C has been treated with a flame retardant to meet the flammability requirements of LSA This treatment will withstand 5 washes or dry cleans before requiring re application The washing of cabin upholstery must be noted in the aircraft s maintenance log book and the flame retardant re applied by an authorized person after 5
140. ber from the aluminium spacers between the rubber blocks Inspect aluminium wheel yoke for damage or bending 4 Inspect bolts nuts for torque see torque values Table 2 5 Repairs to the welded nose leg assembly beam must be referred to JABIRU AIRCRAFT Pty Ltd or our approved local agent 6 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 6 6 NOSE WHEEL 6 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 yoke 4 Reverse the preceding steps to install nose wheel Tighten axle bolt 6 6 2 NOSE WHEEL DISASSEMBLY Completely deflate tyre and break tyre beads loose at wheel rim Refer to Figure 18 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 1 Remove through bolts and separate wheel halves 2 Remove wheel hub 3 Remove tyre and tube from wheel halves 4 Remove bearings revision 0 _ Dated Feb 2006 Issued By RAS Page 64 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tec
141. ble Shooting Airspeed Indicator Trouble Probable Cause Remedy Test line and connections for Pitot pressure connection not Essa e ilies properly connected to pa Hand fails to response ressure line from pitot tube damaged line tighten P P connections mE Check line for obstructions Pitot or static lines clogged Blow out lines Test lines and connections for Leak in pitot or static lines pa or Incorrect indication or 055 connections hand oscillates Substitute known good Defective mechanism or indicator and check readin leaking diaphragm 9 Replace instrument Check panel shock mounts Excessive vibration Replace defective shock mounts vib rolek Check clamps and line connections for security Excessive tubing vibration Tighten clamps and connections replace tubing with flexible hose 13 3 8 TROUBLE SHOOTING ALTIMETER Table 12 Trouble Shooting Altimeter Trouble Probable Cause Remedy ee Check line for obstructions Static line plugged Blow out lines Instrument fails to operate Substitute known good Defective mechanism altimeter and check reading Replace instrument Hands not carefully set Reset hands with knob Substitute known good Leaking diaphragm altimeter and check reading Replace instrument Compare reading with known Pointers out calibration good altimeter Replace in
142. cs should be replaced with a new part Sand smooth small nicks and scratches 4 Carefully inspect bearings for damage and discolouration NOTE revision 0 _ Dated Feb 2006 Issued By Page 56 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft un Aircraft Service Manual Jabiru J230 C Bearings are pre packed DO NOT clean with solvents as it will remove the packing 5 Replace bearings 6 Apply automotive wheel rim lubricant to the bead areas of the rim halves Note that If this step is missed disassembly of the wheels in future will be very much harder 7 Position tyre and tube between wheel halves with tube inflation valve through hole in outside wheel half 8 Mate wheel halves While holding halves together 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 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 9 Insert through bolts through brake disc and position disc on the inner wheel hub flange Note that if directional brake discs are fitted the discs must be oriented in for the correct direction of rotation Refer to Figure 16 be
143. d not change the rudder is found to be unbalanced outside the specified limits cause for this condition should be ascertained before proceeding To balance the rudder it must be removed from the aircraft Balancing is done around the rudder hinges with the hinge pin line horizontal and on the high side of the rudder The balance weight takes the form of a epoxy resin and lead shot mixture set inside the leading edge of the rudder horn The balance should be changed by either removing lead or adding to this mass with a similar mixture The hinge moment can be measured using masses on the trailing edge or by measuring the force needed to maintain the rudder for aft centreline horizontal Weight and moment values are given below Weight 2200g 100g Hinge Moment 56300g mm 4000g mm Revision Dated Feb 2006 Issued By RAS Page 102 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft me un Aircraft Service Manual Jabiru J230 C 10 5 RIGGING 1 To establish the neutral position raise the nose wheel off the ground by leaning down on the horizontal stabiliser Allow the nose wheel and therefore the rudder pedals to centralise Align the rudder 5mm to the right at the top of the rudder when referenced to the lower lip of the fin Adjust the rod ends on the cable so that the hole in the
144. der side wing skin third sump drain plug is provided in the header tank located behind the rear bulkhead These three points must be checked as part of the daily inspection and after each refueling to drain and trapped water or sediment 12 2 2 FUEL TANK REMOVAL amp INSTALLATION As the wing fuel tanks are part of the wing integrity these fuel tanks can not be removed The header tank may be removed if necessary to check outlet strainers etc 12 2 2 1 HEADER TANK REMOVAL Ta Drain fuel from wing tanks 2 Remove the drain plug and drain the fuel from the header tank 3 Remove the header tank access panel from the rear bulkhead revision 0 Dated Feb 2006 Issued By RAS Page 122 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft un Aircraft Service Manual Jabiru J230 C 4 Remove tank restraints 5 Loosen hose clamps remove hoses amp remove tank 6 Installation is the reverse of removal 12 3 FUEL VENTS 12 3 1 DESCRIPTION Refer to Figure 47 Positive ventilation is provided vented fuel caps The caps incorporate a check valve to prevent excess fuel leakage when the aircraft is parked on an angle or flown out of balance All three tanks are interconnected to ensure uniform breather pressure and even feeding from all tanks 12 3 2 CHECKING Vent lines can become blocked re
145. dures 13 2 1 INSTRUMENT PANEL REMOVAL amp INSTALLATION The panel is secured to the Firewall and for normal maintenance is not considered removable Access to instruments etc is gained by removing the panel fascia containing the instruments from the fascia 1 Unscrew amp remove the fascia retaining screws from around the perimeter if the panel 2 If the panel is to be completely removed unscrew throttle knobs Otherwise the panel maybe be supported up 75mm 3 from the panel on the throttle shafts Remove the front fascia It is normally best to lie the fascia on a cushion or similar while working to reduce the risk of damaging the instruments or fascia 4 Take care not to strain connections on wires or tubes 5 Assembly is the reverse of the above procedure Revision Dated Feb 2006 Issued By RAS Page 132 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM ft Pity Pta iru Aircra Jab Aircraft Service Manual Jabiru J230 C INSTRUMENTS Refer to Figure 53 amp Figure 54 13 2 2 v 30 1955 049v OH3avaNna SALON 338 Hia rv 20 33red oL ax1iv13a Sv dogoeovs 5 09 VIOSV3 TANVd LNSANYLSNI 1 26 984 010 sa lt SIONYNTIOI 1 alvd ssi Ald HO31
146. e main longitudinal beam 12 4 2 FUEL VALVE REMOVAL amp INSTALLATION 1 Turn OFF both taps between wing tanks and header tank Cover both tank cap vents On LSA models the fuel system must be drained as there is no taps between wings and header tank 2 Remove fuel shut off valve cover 3 Remove shut off valve handle 4 Remove cover plate 5 Disconnect and cap fuel lines at shut off valve 6 Remove shut off valve 7 Reverse the preceding steps for installation WARNING Fuel valves between wing tanks and header tanks must be in the ON position during flight Ensure wing tank cap vent covers are removed revision 0 Dated Feb 2006 Issued By RAS Page 126 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft Aircraft Service Manual Jabiru J230 C ITEM PART NUMBER DESCRIPTION QTY 4A120A0D 4A120E0N 4A120FON 1 4905214 SPOOL FUEL TAP J SERIES 1 YES YES YES NOTES 2 PH4A020N ROLL PIN DIA 2 x 12 LONG 2 YES YES YES 1 ORIENTATION OF LEVER IN ASSY WHEN 3 4905314 FUEL TAP LEVER J SERIES 1 YES NO YES Norden e E d CU 4 PH4A019N CIRCLIP EXT DIA 14 1 YES YES YES ARROW ON TAP BODY TAP WILL ONLY 5 535206 246 SCREW 1 YES YES YES THRUN THRU 90 DEG WHEN ASSEMBLED 6 PH4A021N PLAIN GAL WASHER ID 5 OD 12 5 1 YES YES YES PROPERLY IF TAP T
147. e aircraft from rocking Ensure that no fittings are strained 3 1 2 2 JACKING NOSE GEAR 1 Push down on tail Plane NOT THE ELEVATOR until nose gear is off the ground 2 Place trestle or drum under rear fuselage together with absorbent material such as foam block sandbags or a pillow CAUTION Ensure trestle does not foul Ventral Fin 3 Weigh down tail plane with sandbags or similar heavy absorbent not hard hard items like bricks are likely to damage the aircraft material CAUTION Do not lift using control surfaces Damage to the control surface or control system may result 3 1 3 HOISTING This procedure should not be necessary for most service or maintenance procedures Should hoisting be necessary 1 Drain Fuel from both wings amp Remove wings See details below 2 Fit shackles to wing support brackets 4 off Fit cables rope to shackles and to a centre lift shackle Revision Dated Feb 2006 Issued By RAS Page 19 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft un Aircraft Service Manual Jabiru J230 C 4 Hoist only from this point ensuring that cables ropes do not mark the top of the fuselage at corners above wing support brackets 3 1 4 LEVELLING Method 1 For longitudinal levelling use a spirit level on either side of the lower door sills Fo
148. ect 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 If the 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 For directional brake discs refer to Figure 16 for installation details 6 8 4 3 WHEEL BRAKE INSTALLATION 1 Place brake cylinder assembly in position on backing plate 2 Install bolts springs outboard pad and nuts washers 3 Reconnect flexible hose 4 Fill master cylinder reservoir with brake fluid 5 Bleed brakes Refer to Paragraph 6 8 5 6 8 4 4 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 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 Revision Dated Feb 2006 Issued By RAS Page 70 of 171 LMilesTechnical manuals J230 J430230 J4
149. ection of the exhaust system must be undertaken anytime exhaust fumes are noticed in the cabin 1 Remove engine cowlings 2 Inspect complete system starting at the connection to the head securing bolts and moving outwards Especially check areas adjacent to welds Look for exhaust gas deposits in surrounding areas indicating that exhaust gas is escaping through a hole or crack For a more thorough inspection the following procedure is recommended 1 Remove manifolds and or muffler 2 Use rubber expansion plugs to seal openings 2 Using manometer or gauge apply approximately 1 1 2 psi 8 inches of mercury air pressure while the manifold and or muffler are submerged in water All leaks will appear as bubbles and can be readily detected 4 It is recommended that any exhaust system component found to be defective is replaced with a new part before the next flight revision 0 _ Dated Feb 2006 Issued By RAS Page 116 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft Aircraft Service Manual Jabiru J230 C 4A293A0D 1 EXHAUST ASSY 3300 TRACTOR DESCRIPTION EXTRACTOR EXHAUST PIPE SET MUFFLER W ASSY 3 3L W O OUTLET SPRING EXHAUST RETAINER SPRING EXHAUST RETAINER 8 CYL PART No 4A175A0D 01094 PE4A003A0D 4A199A0D ITEM 1 2 3 4
150. ed teret ste rr Rete eiit e 29 Table 4 Inspection CRAs a ee e ae ee a 33 Table 5 Trouble Shooting Main 52 Table 6 Trouble Shooting Nose 0 enne 63 Table 7 Trouble Shooting Brakes rr troppe ee ree nire reete bere 68 Table 8 Trouble Shooting Fuel System 2 4 4 100000 assesses 122 Table 9 Trouble Shooting Fuel GaUQe assassin 128 Table 10 Trouble Shooting Pitot Static System 137 Table 11 Trouble Shooting Airspeed Indicator 138 Table 12 Trouble Shooting Altimeter 138 Table 13 Trouble Shooting Vertical Speed Indicator Option 139 Table 14 J230 G Decals cte ie ots a 156 Table 15 General Cockpit 158 Table 16 Cockpit Control Decals 158 Table 17 External Decals TT Redeem 159 Table 18 Approved Propeller Installations 164 Table 19 Control Surface Balancing 171 Table 20 Mandatory Inspection 5 171 Table 21 Mandatory Replacement 5 171 Revision
151. een wing amp header tanks no U s or inverted U s Fire sleeves Fuel line sheath inside cabin Fuel tank caps amp placards Fuel tank vent ball valve check Fuel Tanks Fuel shut off valve amp placards Landing Gear Main gear wheels amp fairings Nose gear wheel steering links tension links amp fairings jrevsion 0 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Dated Feb 2006 Issued By RAS Page 34 of 171 Jabiru Aircraft me un Aircraft Service Manual Jabiru J230 C Annual Inspection Each 200 Hours Each 100 Hours 3 Wheel bearings 1 4 Nose gear strut j Nose gear housing amp bushes 6 Main gear struts clamps bolts amp nuts 7 Tyres amp tubes li 8 Brake fluid hoses linings discs brake assemblies amp master cylinder 9 Rod ends condition freedom of movement f 10 Brake operational check a Airframe 1 Aircraft exterior 2 Aircraft structure 3 Windows windshield doors amp seals 4 Seatbelts amp shoulder harnesses 5 Seat structure i 6 Instruments amp markings 7 Instrument plumbing amp wiring
152. ements taken for each quantity and the average of the two nose wheel distances are now used to calculate the aircrafts C G NOSE WHEEL e DATUM LEFT RIGHT MAIN MAIN NOSEWHEEL BATUM MAIN im dim ENL V NL M A B C D 1 Figure 2 Weighing Diagram 3 3 SERVICING Servicing requirements are shown in the service table below Table 4 Inspection Chart The following paragraphs supplement this table by adding details not included Note that Inspection Requirements are detailed at Paragraph 3 5 3 3 1 ENGINE SERVICING SCHEDULE 3 3 1 1 PRE FLIGHT e Refer to Flight Manual 3 3 1 2 OTHER SERVICING e Refer to Engine Instruction amp Maintenance Manual Revision Dated Feb 2006 Issued By RAS Page 24 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft un Aircraft Service Manual Jabiru J230 C 3 3 2 OTHER SERVICING Replace flexible oil amp fuel line in engine compartment every 2 years or when visible deterioration cracking hardening occurs 3 3 3 FUEL The fuel tanks should be filled immediately after flight to lessen condensation of moisture The tank capacity is listed in the Aircraft Specifications Above 3 3 4 FUEL DRAIN A fuel drain is located in the Left amp
153. er drain holes for flying in rain and must be removed before leak testing the pitot system 5 3 2 PITOT REMOVAL amp INSTALLATION 1 Un screw the pitot mount from the wing strut fairing 2 Disconnect the pitot amp angle of attack hoses Ensure both ends are marked to avoid confusion re assembly 3 Assembly is the reverse of the above revision 0 Dated Feb 2006 Issued By RAS Page 49 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft 2 ano Aircraft Service Manual Jabiru J230 C THIS DRAWING 15 COPYRIGHT MUST NOT BE COPIED C WITHOUT CONSENT OF AVTECH PTY LTD DIMENSIONS IN MILIMETRES DO NOT SCALE PROJECTION E TUBES ROUTED DOWN WING STRUT 8 POP RIVET PITOT TO STRUT PLASTIC TUBE UST HANE MINIMUM OF 1 OVERLAP m ON ALUMINUM TUBE PITOT AND AOA TUBES TAKE CARE NOT TO b DRILL PITOT TUBES B BOND LINE CUT TUBE END ON ANGLE INSERT IN 1 4 1D Nh MIN INSERTION 50 MAX GAP BETWEEN BOND ENDS 50MM THIS EDGE BONDED TO WING UNDERSURFACE 3 USING FLOCK PARTS LIST ITEM NUMBER DESCRIPTION 1 2 050 00 J160 WING STRUT FAIRING WITH DYNON PITOT 1 USE SPEED NUT 5 ON
154. erence 12 5 1 DESCRIPTION SIGHT GLASSES The gauge consists of an aluminium body with a clear window which allows fuel level to be read directly Decals fixed to the window show fuel level Refer to Figure 51 for details of the gauge assembly 12 5 2 FUEL SIGHT GAUGE REMOVAL amp INSTALLATION 1 Remove the wing as detailed in Section 5 1 1 above 2 Remove the gauge from the aircraft 3 Reverse the preceding steps for installation Revision Dated Feb 2006 Issued By RAS Page 127 of 171 LMiles Technical manuals 230 J430M230 J430 Work filesJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft 2 ano Aircraft Service Manual Jabiru J230 C 12 5 3 Table 9 Trouble Shooting Fuel Gauge ELECTRIC FUEL GAUGE TROUBLESHOOTING Trouble Probable Cause Remedy Gauge on panel reads Bad connection between sender amp gauge Fix connection full tanks low Sender has lost calibration Remove sender amp re calibrate 12 5 4 ELECTRIC FUEL GAUGE SENDER REMOVAL amp INSTALLATION 1 Remove the wing as detailed in Section 5 1 1 above 2 sender ITEM PART No DESCRIPTION QTY 1 4A278COD FUEL TANK BOSS GAUGE MOUNTING 1 2 4 278800 FUEL GAUGE MOUNT ADAPTOR 1 3 016 FUEL GAUGE FACE SIDEK 1 4 535206 228 SCREW 6 32 X 3 8 1 5 535206 243 SCREW 8 32 X 3 8 4
155. ey INSTALLATION SEAL LL SENSOR WIRES THREAD WITH LOCTITE 577 ff LAY 3 LAYERS AT313 TAPE OVER FITTING ORIENT TAPE AS SHOWN P y aisi nie y be UN CAUTION ut TAKE EXTREME CARE NOT V N 5 TO OVERTIGHTEN SENSOR S 5 N N TIGHTENING TORQUE gt EN 1 5Nm 13 26in Ib MAX NS e y SECTION A A NOTE WHEN HEADER IS INSTALLED _ ENCLOSURE ENSURE CLEARANCE BETWEEN SCALE 1 16 2 06 SENSOR AND ENCLOSURE SIDE 135 ISS DATE P L z DWG NO LIMITS RAE FUEL SCHEMATIC SUPPLEMENT 4A214COD 1 MATERIAL 5 DETAILED been asn Mme LEVEL SENSOR INSTALLATION SHEET 1 1 Figure 52 Header Tank Low Level Sensor Installation 12 7 FUEL FILTERS 12 7 1 FUEL FILTER The fuel filter is of the in line type and is located inside the header tank enclosure behind the rear cabin bulkhead Revision Dated Feb 2006 Issued By RAS Page 130 of 171 LAMfilesNTechnical manualsJ230 J4301J230 J430 Work filesJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft un Aircraft Service Manual Jabiru J230 C 12 7 2 FUEL FILTER REMOVAL amp INSTALLATION 1 Drain fuel system wing tanks and header tanks 2 Place a cloth beneath the filter to collec
156. f 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM ft Pity Pta ircra A Aircraft Service Manual iru Jab Jabiru J230 C 9338vaNng 601106 ASSY 4015 1OMINOO 043v 2265 984 010 Q31NvOIQNI SY E 31 25 LON 00 S3HL3ATTIA SNOISN3AIQ Ald dO LIN3SNOO LNOHLIM 031909 38 JON 15 DA ONY ON 1 4 HO3LAV SEP Pt 310 551 Bel 060110 168060 6 LAN M3MlMIS NONMTIIV vc0c606 S 4 JOMINOO NOM3IIV 0715 762 105 Y 6 MSE t l 20 LAN L NOYFTIV 31Vld v6LL1108 4 MS8 LAN ON 1 WALI SlHAdOO SI SIHL Figure 23 Aileron Stops T N T oO lt oc en 2 2 e e N LL O ij a z 9 o 2 tc Print Date 14 01 2009 4 41 00 PM LMiles Technical manuals J230 J430230 J430 Work filesJ230 C Tech Rev 1 doc Jabiru Aircraft un Aircraft Service Manual Jabiru J230 C 8 SECTION 8 WING FLAP CONTROL SYSTEM 81 WING FLAP CONTROL SYSTEM Refer to Figures 24 to 26 The wing flap con
157. flow from the left wing 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 Revision Dated Feb 2006 Issued By RAS Page 46 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM 097 Su3HvONnas dav L Q stguAVAD 110H 9NO1 0097 S 1ASSV ONIM YAS ewes Tuu 26 98Z OLO NOv WO Vd HOSLAV 40 INASNOD I NOH IHAA 9109 ft Pty Pia ircra A Aircraft Service Manual iru Jab Jabiru J230 C LON ONY SI SILL SNOISN 3WOS LON oq 2H13NI TI NL d ONVH 3180990 SH NOBSLOVZ SY S7 00761072 Figure 8 4230 Wing Assembly Sheet 1 Page 47 of 171 Issued By RAS co e e N LL a 3ONIH 30 08 02 4 INN 8 amp zeol sseozsw O v 4 14 u35vdS REM NNNM 31614 11 35NIH
158. g fin damage 2 Inspect baffles baffle seals amp brackets for cracks deterioration or damage 3 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 NOTE Avoid excessive flexing amp sharp bends when examining hoses for stiffness 4 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 irrespective of age 5 For major engine repairs refer to JABIRU AIRCRAFT Pty Ltd or an Approved Jabiru Service Centre 11 2 5 1 FLEXIBLE HOSES Leak Test After each 100 hours of operation flexible hoses should be checked for leaks Examine the exterior of hoses for evidence of leakage or wetness Replace any doubtful hoses Replacement Hoses should not twisted on installation Provide as large a bend radius as possible Hoses should have a minimum of 12mm clearance from other hoses or surrounding objects or be tie clamped to them 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 cracki
159. g of the system is shown as Figure 46 2 The fuel filter and auxiliary electronic fuel pump are mounted inside the header tank enclosure 3 The low fuel pressure switch is located in the fuel line between the mechanical engine fuel pump and the carbuettor 4 All fuel lines inside the cabin are housed within plastic sheath This sheathing must be maintained in good condition 5 The main fuel valve is located on the Main Beam in the cabin 11 6 SPARK PLUGS Refer to Engine Instruction amp Maintenance Manual 11 7 ENGINE CONTROLS 11 7 1 RIGGING When adjusting any engine control it is important 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 11 7 2 THROTTLE SYSTEM The throttle system used is shown in Figure 41 Note that the same system is used irrespective of the instrument panel option fitted Figure 42 shows the system fitted inside the Glass instrument panel Revision Dated Feb 2006 Issued By RAS Page 112 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM ft Pty Pia ircra A Aircraft Service Manual iru Jab Jabiru J230 C py 5 049v 9u3avauna SONIMVHO 01 43434 E Wl 00 500 6 0917 31LLOHHL LNNOW H9IH
160. gnition Switches are OFF Revision Dated Feb 2006 Issued By RAS Page 22 of 171 LMilesTechnical manuals J230 J430230 J430 Work 1 230 Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft un Aircraft Service Manual Jabiru J230 C 8 Install spark plugs torque to 20 Nm 180 inch lbs 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 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 breather is clear 14 Perform a thorough pre flight inspection 15 Start and warm engine 3 2 WEIGHING 3 2 1 SCALE LOCATIONS For weighing three scales are used Position one under each main wheel and one under the nose wheel 3 2 2 PROCEDURE 1 Position the aircraft on the scales on a level surface preferably one that positions can be marked on to in the configuration to be weighed 2 Chock the main wheels and make sure the brake is released If the chocks are of significant weight their weight will need to be subtracted from the relevant scale reading Level the aircraft using technique 3 1 4 Levelling If the nose needs to be raised place packers under the nose wheel If the nose needs to be lowered pack under main wheels
161. h Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft Shaun un Aircraft Service Manual Jabiru J230 C NOTE The bearings are press fit in the wheel hub and should not be removed unless a new part is to be installed 6 6 3 NOSE WHEEL INSPECTION AND REPAIR 1 Clean metal parts in solvent and dry thoroughly 2 Inspect wheel halves for cracks Cracked wheel halves should be discarded new parts used Sand out nicks gouges and corroded areas Clean thoroughly 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 6 6 4 NOSE WHEEL REASSEMBLY 1 Replace bearings in wheel hub 2 Apply automotive wheel rim lubricant to the tyre bead faces on the inside of the wheel rims Note that if this step is skipped disassembly of the wheel in future will be made much more difficult 3 Position tyre 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 2 WARNING 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 fa
162. hen the filter becomes dirty again it must be replaced Refer to Figure 43 Dated Feb 2006 Issued By RAS revision L Mfiles Technical_manuals J230_J430 J230 J430_Work_files J230 C_Tech_Rev_1 doc Print Date 14 01 2009 4 41 00 PM Page 114 of 171 Jabiru Aircraft _ N Aircraft Service Manual Jabiru J230 C x 5 5 58 5 a sU ul gt 5 5 nz x gt Y 3 m or Ec X c ci ee E 42 olg z a te 215 a 1 RA Po eja 12191 i E O T Ist mL F cm i 59 gt N ni 4 6 nj ZE S PARS E ta in o x AIS x lt E HH E i l
163. ickness of material An unfluted drill should be used 4 2 7 REMOVAL As the windscreen and windows are bonded into the fuselage it is not possible to remove them without destroying them Once windows have been broken out any screws used in the original installation should be removed 4 2 8 INSTALLATION 1 Ensure all old epoxy resin has been removed from the fuselage sealing strips around the window frames 2 Check new windscreen for fit File or grind away any excess material to ensure a close fit Do not attempt to cut with any type of saw 3 Wet the window frame joggle with raw epoxy resin Apply 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 43 CABIN DOORS 4 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 Refer to Figure 5 and Figure 6 below Revision Dated Feb 2006 Issued By RAS Page 38 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM ft Pty Pia ircra A Aircraft Service Manual iru Jab Jabiru J230 C 30 L33HS 6 60
164. igure 49 Fuel Gauge Electric Sender Assembly nnns 129 Figure 50 Fuel Gauge Sight 129 Figure 51 Header Tank Low Level Sensor Installation 130 Figure 52 Instrument Panel Layout Std 133 Figure 53 Instrument Panel Layout Glass Instrument Panel sisse 134 Figure 54 Pitot Statice System Water Trap 140 Figure 55 Pitot Assembly Std ete ec 141 Figure 56 Static Probe System 55 142 Figure 57 Static System 143 Revision Dated Feb 2006 Issued By RAS Page 11 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft Mn un Aircraft Service Manual Jabiru J230 C Figure 58 Wiring Diagram Sheet 1 0 2 22 011 0 0000 einen kanai Ka aSK eaaa 148 Figure 59 Wiring Diagram Sheet 2 149 Figure 60 VHF Antenna 5 152 Figure 61 Propeller Installation 166 1 2 LIST OF TABLES Table 1 J230 Specifications 15 Table 2 Recommended Bolt Torque 17 Control Free Play o
165. il Pressure Gauge is an electronic instrument Should the instrument fail to operate 1 2 5 6 Check 10amp instrument fuse and replace if necessary Check 15amp main circuit breaker and re set if necessary Remove Instrument Panel see Paragraph 13 2 3 and check cable terminals for security Check wiring at Sender for security Replace Sender Replace Gauge 13 6 OIL TEMPERATURE GAUGE The Oil Temperature Gauge is an electronic instrument Should the instrument fail to operate 1 2 Check 10amp instrument fuse and replace if necessary Check 15amp main circuit breaker and re set if necessary Remove Instrument Panel see Paragraph 13 2 3 and check cable terminals for security RESON Dated Feb 2006 Issued By RAS Page 144 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft un Aircraft Service Manual Jabiru J230 C 4 Check wiring at Sender for security 5 Replace Sender 6 Replace Gauge 13 7 CYLINDER HEAD TEMPERATURE GAUGE The Cylinder Head Temperature Gauge is a Thermo couple instrument and is not connected to the aircraft electrical system See Wiring Diagram Figure 59 Should the instrument fail to operate 1 Check for loose terminal connections and damage to wiring 2 Replace thermo couple Replace Gauge 13 8 EXHAUST GAS TEMPERATURE GA
166. iles Technical manuals 230 J430M230 J430 Work filesJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft un Aircraft Service Manual Jabiru J230 C 2 8 RECOMMENDED TORQUE VALUES FIBREGLASS Table 2 Recommended Bolt Torque Values Bolt Size Torque Inch Ib 20 25 2ftlb AN4 50 70 4 5 ft lb AN5 100 140 8 12 ft Ib ANA Propellor 72 6 ft Ib e These values relate only to steel nuts on oil free cadmium plated threads e Engine Bolt Torque Values see Engine Instruction amp Maintenance Manual 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 GENERAL RULE DO NOT REUSE SELF LOCKING NUTS 2 9 AIRCRAFT STRUCTURE In the J230 due to it s monocoque construction the majority of the structure is primary The components of the aircraft which are secondary structure can be identified by the fact that they are designed as fairings and are generally removable Examples of secondary structure are the engine cowls speed fairings ventral fin and wheel spats revision 0 Dated Feb 2006 Issued By Page 17 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00
167. ilure 5 Inflate tyre to seat the tyre beads adjust to correct tyre pressure Refer Aircraft Specifications above 6 6 5 WHEEL BALANCING Refer to Paragraph 6 4 8 for wheel balancing information REVISION gl Dated Feb 2006 Issued By RAS Page 65 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM ft Pity Pta iru Aircra Jab Jabiru J230 C 1 5 1003 918 SAMOA v QOv200v9 ASSY T33HM 9 931 ISON 0 97 H3 TINIH ddV 1HVd OL 88434 5 d3SIMH3HLO 0231512345 59131 SLIAIT e 6 981010 NOV o M ons 099 e sa wo eoeo v Wa LAN DOTAN 9 cE 0L S9 07SW 26 SS3NMOIHL 2 1 1913 101 096 LE 2 1709 9 VZC NV 08 NOISNAdSNS LNOYS HVT1OO 7001619 62 MALVS GANIHOVW INIT SNIH331S 7100029 8c 9313SON Q3NIHOVW aeozoov9 zz 1003 918 NOISN3dsns HSNa N60 v09 92 8
168. in the event of electrical power system failure An engine driven Alternator is the normal source of power during flight and maintains a battery charge controlled by a voltage regulator The following paragraphs provide brief descriptions of the elements of the electrical system They should be read in conjunction with the Wiring Diagram in Figures 59 and 60 14 2 WIRING DIAGRAM The Wiring Diagram is shown in Figures 59 and 60 revision 0 Dated Feb 2006 Issued By RAS Page 147 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM ft Pity Pta ircra A Aircraft Service Manual iru Jab Jabiru J230 C JO 133 5 09 Lf Hddv Qna LIYA JHI O3TI7L30 SLNIWNHLSNI 9 00818076 Yad IAN IOVIO WNL Td suan O3dS 5 OL NOLLYTI LSNI HSONOdSNYHL 6 Q0V1907 Had 0848 S H3HRLOVJDNVWI OL NOILYTIYLSNI Higv3 14 ANAANNYLSNI HO Lud S Ad aariddns SHOSN3S 9 YaMOd 5 30couno1023uM YOSNIS HOSS3Hdans 4 14406 NMNOLLO3S X OS WWE 31872 d3lHVIS i SYIM
169. ises 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 Revision Dated Feb 2006 Issued By RAS Page 31 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft eM Aircraft Service Manual Jabiru J230 C 3 7 MAJOR INSPECTION REPLACEMENT 3 7 1 MANDATORY INSPECTION 3 7 1 1 AIRFRAME The J230 C does not have an overall airframe life limitation 3 7 1 2 UNDERCARRIAGE Main undercarriage bolts and nose leg pivot bolts shown in Figure 4 are to be changed every 500 hours TIS 7 Bolts amp nuts in total to be replaced Figure 4 Undercarriage Revision Dated Feb 2006 Issued By RAS Page 32 of 171 LAMfilesNTechnical manualsJ230 J4301J230 J430 Work filesJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft Mn un Aircraft Service Manual Jabiru J230 C 3 7 2 INSPECTION CHART IMPORTANT READ ALL INSPECTION RQUIREMENTS PRIOR TO USING THESE CHARTS Table 4 Inspection Chart Annual Inspection Each 2
170. ist chamois DO NOT rub the plastic with a dry cloth as this builds up an electrostatic charge which attracts dirt Oil and grease may be removed by using a soft cloth moistened with mineral turpentine CAUTION 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 3 4 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 3 4 3 EXTERIOR SURFACES The exterior surfaces under normal conditions require a minimum of polishing and buffing CAUTION 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
171. isture 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 brush and cloth 3 4 6 PROPELLER Wash with soap and water rinse with clean water and dry with cloth or chamois CAUTION Do not use a wax based substance as this would make it almost impossible to refurbish the prop if needed at a later stage 3 4 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 6 Discard cracked wheel halves flanges or hubs and install new parts 3 5 LUBRICATION There are no lubrication requirements for the JABIRU other than those detailed in Appendix 1 3 5 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 REVISION ol Dated Feb 2006 Issued By RAS Page 27 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft Shaun un Aircraft Service Manual Jabiru J230 C 3 06 INSPECTION 3 6 1 INSPECTION INTERVALS A tolerance of plus or min
172. lations 1 Ensure the static system is free from entrapped moisture and restrictions Refer to 2 Ensure no alternations of airframe surface have been made which would effect the relationship between air pressure in the static pressure system and truce ambient static air pressure for any flight configuration 3 Attach a source of suction to static pressure source opening Figure 58 shows one method of obtaining suction 4 Slowly apply suction until the altimeter indicates a 1000 foot increase in altitude CAUTION When applying or releasing suction do not exceed the range of either vertical speed indicator or airspeed indicator 5 Cut off suction source to maintain a closed system for one minute Leakage shall not exceed 100 feet altitude loss as indicated on the altimeter 6 If leakage rate is within tolerance slowly release suction source NOTE If leakage rate exceeds maximum allowable first tighten all connections then repeat leakage test If leakage rate still exceeds maximum allowable use the following procedure 1 Disconnect static pressure lines from airspeed indicator vertical speed indicator Revision Dated Feb 2006 Issued By RAS Page 135 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft un Aircraft Service Manual Jabiru J230 C 2 Use suitable fitti
173. lesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft Aircraft Service Manual Jabiru J230 C 1048094 DESCRIPTION PITOT TUBE BENT Static Probe End WIRE TIE TUBE TOP OF TAIL FIN PART No 104819N 1048204 0139 0029 ASSY WIRE TIE TO ATTACH TUBE ES eJ z te EJ gt COTTON FLOCK amp EPOXY TUBE TO TAIL FIN ENSURE TUBE 15 ALIGNED WITH TOP OF FIN AND FUSELAGE Figure 57 Static Probe System Assembly Revision Dated Feb 2006 Issued By RAS Page 142 of 171 L Miles Technical_manuals J230_J430 J230 J430_Work_files J230 C_Tech_Rev_1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft _ N Aircraft Service Manual Jabiru J230 C STATIC SI EQUIPMENT PRESSURE BLEED VALVE _ SURGICA V THICK CHECK VALVE VALVES measuring Squeeze air bulb to expel as much air as 2 Hold suction hose firmly against 5 lease air bulb to obtain maintain suction APPLY PRESSURE CAUTION DO NOT APPLY PRESSURE VERTICAL SPEED INDICATOR CONN SYSTEM nose firmly against
174. lexible hoses connected through a tee piece Repair is limited to replacement 6 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 19 for caliper details Figure 14 for installation of the caliper to the leg 6 8 4 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 19 for disassembly of either wheel brake assembly 6 8 4 2 WHEEL BRAKE INSPECTION AND REPAIR 1 Clean all parts except brake linings in dry cleaning solvent and dry thoroughly Revision Dated Feb 2006 Issued By RAS Page 69 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft un Aircraft Service Manual Jabiru J230 C 2 New piston sealing O Rings should be installed each time the brakes are disassembled If re use 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 3 Check brake linings for deterioration or excessive wear 4 Insp
175. low 10 Inflate tyre to seat tyre beads then adjust to correct tyre pressure Refer Aircraft Specifications above 6 4 4 MAIN WHEEL INSTALLATION Ji 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 6 8 5 8 Install speed fairing if used as outlined in Paragraph 6 3 4 6 4 5 MAIN WHEEL STUB AXLE REMOVAL 1 Remove speed fairing if installed in accordance with Paragraph 6 3 4 2 Remove wheel in accordance with Paragraph 6 4 1 Revision Dated Feb 2006 Issued By RAS Page 57 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft un Aircraft Service Manual Jabiru J230 C 3 Disconnect flexible brake hose and drain brake fluid 4 Remove 4 bolts nuts washers securing axle to leg 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 alignmen
176. lternator diodes radio protection diodes and radio transistors 3 Disconnect the cable from the positive battery terminal 4 Lift the battery out of the battery box 5 To replace the battery reverse this procedure 14 4 4 CLEANING THE BATTERY For maximum efficiency the battery and connections should be kept clean at all times 1 Remove the battery and connections in accordance with the preceding paragraph 2 Wipe the battery cable ends battery terminals and the entire surface of the battery with a clean cloth moistened with a solution of bicarbonate of soda baking soda and water revision 0 Dated Feb 2006 Issued By Page 150 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft Mm 524 un Aircraft Service Manual Jabiru J230 C 3 Rinse with clear water wipe off excess water and allow battery to dry 4 Brighten up cable ends and battery terminals with emery cloth or a wire brush 5 Install the battery in accordance with the preceding paragraphs 6 Coat the battery terminals with petroleum jelly or an ignition spray product to reduce corrosion 14 4 5 BATTERY BOX The battery box is located on the firewall in the engine compartment 14 5 STARTER SOLENOID The starter solenoid is a sealed unit Service is limited to inspection of terminals for security and replacement of the unit
177. move an instrument disconnect wiring or pluming to the instrument remove mounting screws and take instrument out from behind or in some cases from the front of the panel In all cases when an instrument is removed disconnected lines or wires should be protected Cap open lines and cover pressure connections on instrument to prevent thread damage and entrance of foreign matter Wire terminals should be insulated or tied up so that accidental ground or short circuiting will not occur 13 2 4 INSTALLATION Generally the installation procedure is the reverse of the removal procedure Ensure mounting screws and nuts are tightened firmly but do not over tighten particularly on instruments having plastic cases The same rule applies to connecting plumbing and wiring 13 3 PITOT amp STATIC SYSTEMS Refer to Figures 55 56 and 57 Also Figure 10 where the aircraft is equipped with an AOA probe The pitot system conveys ram air pressure to the airspeed indicator The static system vents vertical speed indicator if fitted altimeter and airspeed indicator to atmospheric pressure through plastic tubing connected to a static port The pitot and static systems each have a water trap fitted as shown in Figure 55 which must be checked during scheduled maintenance or after flying through rain Revision Dated Feb 2006 Issued By RAS Page 134 of 171 LAMfilesNTechnical manualsJ230 J4301J230 J430 Work filesJ230 C Tech Rev
178. move 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 3 3 8 HYDRAULIC BRAKES Check brake master cylinder and refill with automotive brake fluid DOT 3 or DOT 4 Bleed the brake system of any trapped air whenever there is a spongy response on the brake lever Refer to Section 6 8 for filling and bleeding of the brake system Revision Dated Feb 2006 Issued By RAS Page 25 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft un Aircraft Service Manual Jabiru J230 C CAUTION The JABIRU uses automotive brake fluid DOT 3 or DOT 4 DO NOT use Aircraft hydraulic fluid mineral based or damage to the brake system will result 3 4 CLEANING Keeping the aircraft clean is important Besides maintaining the appearance of the aircraft cleaning makes inspection and maintenance easier 3 4 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 mo
179. n Aircraft Service Manual Jabiru J230 C 8 222 X Inspection and ter ette eir ate eee 83 825 des 83 8 2 4 RIGGING as per template entes nnne 83 9 SECTION 9 ELEVATOR CONTROL 5 8 90 9 1 ELEVATOR CONTROL SYSTEM tec eee rem pacc re pei e 90 9 2 CONTROL COLUMN 90 9 2 1 Removal 90 9 3 ELEVATOR Es EE 90 9 3 1 Removal 90 9 3 2 ELEVATOR BALANCING 90 9 3 3 Inspection and Repair assesses assoc asas aaa 91 9 4 CONTROL CABLE AND 91 9 4 1 Removal and Installation bc na aane 91 9 5 S 91 9 6 ELEVATOR TRIM CONTROL SYSTEM 97 9 6 1 Operational Check uo p ans va 97 9 6 2 Tim Handle Assembly ritieni peer n 97 9 6 5 Control Cable and Attachments sss sites 97 9 64 Removal and Installation N sada alee eae 97 9 65 Inspection and Nest eiecit nes 97 10 SECTION 1
180. n 1 Clean aircraft thoroughly 2 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 cool dry place Service the battery periodically and charge as required NOTE 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 Using an oil 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 Aero fluid 2UN MIL C 6529C Type 1 or similar engine corrosion inhibitor Rotate the propeller 10 12 times leaving it in the horizontal position CAUTION RESON Dated Feb 2006 Issued By RAS Page 21 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft un Aircraft Service Manual Jabiru J230 C Ensure that the Master and Ignition Switches are OFF 7 Install spark plugs and connect leads 8 Seal exhaust pipes Attach a red streamer to each DO NOT seal fuel tank breathers 9 Place protective covers over Pitot tube static so
181. n be maintained by an authorised maintenance person or organisation 2 4 AIRCRAFT SPECIFICATIONS Leading particulars of this aircraft with dimensions based on gross weight are given in Figure 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 2 5 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 or an person authorized to revise an aircraft s weight and balance information such as the holder of a CASA Weight Control Authority Revision Dated Feb 2006 Issued By RAS Page 14 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft 2 sro Aircraft Service Manual Jabiru J230 C 2 6 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 2 7 Table 1 J230 Specifications AIRCRAF
182. n line horizontal and on the high side of the ailerons The hinge moments can be measured by measuring the upwards force needed to maintain the flat side of the aileron horizontal Note that as this load is small a finely graduated spring balance or similar measuring instrument will be required 7 5 CONTROL RIGGING 1 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 2 Check UP travel on both ailerons using the Aileron Rigging Template see Appendix 3 3 Use the Aileron Control Stop adjustment see Figure 23 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 4 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 NOT CROSS CABLES Revision Dated Feb 2006 Issued By RAS Page 80 o
183. nd centre and to the wheel stub at the bottom The nose gear is a welded steel trailing arm assembly with rubber spring system The nose wheel is steerable with the rudder pedals Nose Wheel and Main Wheel Speed Fairings wheel spats are optional equipment 6 2 TROUBLE SHOOTING MAIN UNDERCARRIAGE Table 5 Trouble Shooting Main Undercarriage Trouble Probable Cause Remedy Incorrect tyre inflation Inflate to pressure shown at above Aircraft leans to one Landing gear attaching parts Tighten loose parts Replace side not tight defective parts Bent axle stubs Install new part s Inflate to pressure shown in Incorrecttyre inflation above Main wheels out of alignment Align as specified above Tyres wear excessively Bent axle stubs Install new part s Dragging Brakes Refer to Para 6 8 6 3 MAIN GEAR Figures 12 15 an 14 illustrate the main landing gear The illustrations should be used in conjunction with the following procedures during removal and installation of component parts 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 The wheels comprise tw
184. ng 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 Revision Dated Feb 2006 Issued By RAS Page 110 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft me un Aircraft Service Manual Jabiru J230 C 11 3 COOLING AIR BAFFLES The baffles installed around the engine direct the cooling air flow to the oil cooler and to other engine components to provide optimum engine cooling The baffles air inlets and outlets and air scoops are accurately positioned to maintain engine cooling efficiency and their removal will cause improper air circulation and engine overheating 11 3 1 CLEANING AND INSPECTION Engine baffles should be cleaned with a suitable solvent Mineral Turpentine to remove dirt and oil Inspect baffles for cracks splits or damage Replace defective parts 11 3 2 COOLING AIR BAFFLE REMOVAL amp INSTALLATION Baffles are removed by unbolting from the engine and removing tension springs and their attaching wires Reverse the preceding steps for installation 11 3 3 REPAIR Repair of baffles is limited to the replacement of rubber seals Rubber seals may be replaced by removing the existing rubber parts rubbing back the bonding face of the fiberglass baffles to bare glass using 80 grit
185. ngs to connect lines together so that the altimeter is the only instrument still connected into the static pressure system Repeat leakage test to check whether static pressure system or the bypassed instruments are the cause of the leakage If instruments are at fault they must be repaired by an appropriately authorised repair station or replaced If static pressure system is at fault use the following procedure to locate the leakage 4 Attach a source of positive pressure to the static source opening Figure 58 shows one method of obtaining positive pressure CAUTION Do not apply positive pressure with airspeed indicator or vertical speed indicator connected to the static pressure system 5 Slowly apply positive pressure until altimeter indicates a 500 foot decrease in altitude and maintain this altimeter indication while checking for leaks Coat line connectors and static course flange with solution of mild soap and water watching for bubbles to locate leaks 6 Tighten leaking connections Repair or replace parts found to be defective 7 Reconnect airspeed and vertical speed indicators into static pressure systems and repeat leakage test steps 3 through 6 13 3 3 PITOT SYSTEM INSPECTION amp LEAKAGE TEST To check pitot system for leaks place a piece of rubber or plastic tubing over pitot tube close opposite end of tubing and slowly roll up tube until airspeed indicator registers in the cruise range Secure tube and afte
186. o 136 13 3 5 Removal amp Installation of 137 13 3 6 Trouble Shooting Pitot Static System sse 137 13 3 7 Trouble Shooting Airspeed Indicator esses esee 138 13 3 8 Trouble Shooting 138 13 3 9 Trouble Shooting Vertical Speed Indicator Option sess 139 13 3 10 Pilot Alignment edere ced nie a e per ed cese Lee ege 139 13 4 TACHOMETER m O 143 13 5 OIE PRESSURE tte e hentai Jena 144 13 6 OIL TEMPERATURE GAUGE sss 144 13 7 CYLINDER HEAD TEMPERATURE 145 13 8 EXHAUST GAS TEMPERATURE GAUGE OPTION 145 Revision Dated Feb 2006 Issued By RAS Page 8 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft Mn un Aircraft Service Manual Jabiru J230 C 13 9 HOURME TER m 145 1310 MAGNETIC COMPASS 145 13 11 EFIS WHERE EQUIPPED ASAS 146 13 12 EQUIPPEB eterne torre e es 146 14 SECTION 14 ELECTRICAL SYSTEMS
187. o the wing strut and pull it out from the strut far enough to disconnect the pitot line The static mast is fixed and cannot be removed To gain access to disconnect the static tube from the static mast remove the VHF antenna cover at the top of the fin Pitot and static tubing is removed in the usual manner Installation of tubing will be simplified if a guide wire is drawn in as the tubing is removed When replacing tubing and fittings tighten connections firmly but avoid overtightening and distortion of fittings or tubing 13 3 6 TROUBLE SHOOTING STATIC SYSTEM Table 10 Trouble Shooting Pitot Static System Trouble Probable Cause Remedy Low or sluggish Test pitot tube and line for airspeed indication Pitot tube obstructed leak or leaks or obstructions Blow normal airspeed and obstruction in pitot line out tube and line repair or vertical speed replace damaged line Incorrect or sluggish oa Test ine for leaks and response all 3 Leaks or obstruction in static obstructions Repair or instruments line replace line blow out obstructed line Revision Dated Feb 2006 Issued By RAS Page 137 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft un Aircraft Service Manual Jabiru J230 C 13 3 7 TROUBLE SHOOTING AIRSPEED INDICATOR Table 11 Trou
188. o wheel halves which are assembled as shown in Figure 15 During assembly of the main wheels the through bolts nuts should be tightened to the value specified in Table 2 The assembly of the wheels to the undercarriage leg is shown in Figure 14 REVISION ol gl Dated Feb 2006 Issued By RAS Page 52 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft Mn un Aircraft Service Manual Jabiru J230 C 6 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 1 Jack the aircraft in accordance with the details given in Section 3 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 6 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 bolts nuts 2 OFF Do not tighten at this stage 2 Locate top end bolt install and tighten nut See Torque Value
189. oined by through bolts to the wheel hub as shown in Figure 18 During assembly of the nose wheel the through bolts must be tightened evenly and torqued to the value specified in Table 2 6 5 1 TROUBLE SHOOTING NOSE LEG Table 6 Trouble Shooting Nose Leg Trouble Probable Cause Remedy Nose strut bolts loose Tighten bolts Loose or worn steering link Tightenrepiace Nose wheel shimmy Nose wheel out of balance Refer Paragraph 6 6 5 Wheel bearings loose Replace 6 5 2 NOSE GEAR REMOVAL AND INSTALLATION See Figures 17 and 18 1 Weight or tie down tail of aircraft to raise nose wheel off floor 2 Disconnect nose wheel steering pushrods and steering yoke 3 Unbolt steering yoke 4 Remove upper collar steering yoke dependant on aircraft S No from the top of the leg 5 Pull the nose wheel strut assembly down from the bushes in the fuselage 6 To install the nose gear reverse the preceding steps REVISION ol Dated Feb 2006 Issued By RAS Page 63 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft me un Aircraft Service Manual Jabiru J230 C 6 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 rub
190. oving the securing screws To install reverse this procedure REVISION gl Dated Feb 2006 Issued By RAS Page 54 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM ft Pity Pta ircra A Aircraft Service Manual iru Jab Jabiru J230 C 205029 091 OOF ASSY J N 931 NOISN3dShS ai GASN 38 AVN S1108 YS9NO071 LNN 103 67 IVNIINON NSAIDS SHLSN371 L108 Z LON 39V7SSNs 30 310SNOO t 1108 8 6 V9C 9NV e 9 LAN DOTAN 8 6 29 59 025 1 LL 8 9 H3HSVAA 8 6 919 096NV OL 4 l1O8 8 VVC 9NV 6 2 18 ANVHLAYN JOVIMHeIvOHSON 202029 8 2 DORNOZA 35 vlslvOH30Nn v60E009 4 2 9 H3HSVM v60E 09 9 t I9VIHUVAHIONN HSNA 7607809 t 1039 NMI v609 09 31914 ONIMOVE 2 1 604 09 t 4 00 002 987 NIYA tc vOc9 ASSY 5 4 duva ALO Wall 1511 sped 2 2 E 9 0 5 c 2 E T 5 iL T N T LO LO iJ lt cc en 2 2 e LL O
191. parts Refer to Figure 26 for guidance 8 1 6 FLAP CROSS SHAFT INSTALLATION Installation procedure is the reverse of assembly REVISION ol Dated Feb 2006 Issued By RAS Page 82 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft un Aircraft Service Manual Jabiru J230 C 8 1 7 FLAP POSITION INDICATOR REMOVAL Refer to Figures 27 and 28 for guidance 1 Undo screws holding indicator to A pillar 2 Drill rivets and disassemble indicator 3 Loosen bolt on flap drive motor shaft amp remove cable 8 1 8 FLAP POSITION INDICATOR INSPECTION amp REPAIR Repair of the position indicator is limited to replacing worn or damaged parts 8 1 9 FLAP POSITION INDICATOR INSTALLATION Installation procedure is the reverse of the removal procedure outlined above 8 1 10 FLAP CONTROL ROD To remove unbolt at both ends and remove Reverse for installation 8 2 FLAP The flaps comprise a moulded and bonded monocoque structure embodying a composite control arm at the inboard end 8 2 1 REMOVAL AND INSTALLATION 1 Unbolt rod end from flap control arm 2 Remove each flap hinge bolt and spacer 3 Remove Flap 4 Reverse the preceding steps for installation Replace all three nyloc nuts and torque in accordance with Table 2 8 2 2 INSPECTION AND REPAIR Inspect flaps for any signs of delamination or c
192. r 3 0 mm Aileron 3 25 mm 3 6 3 3 AIRFRAME STRUCTURE A visual inspection should be conducted each 100 hours Check for cracking of the paintwork whiting of unpainted areas movement of wing attachments and threaded bushes movement of undercarriage attachments loosening of firewall engine attachments Wing struts should be inspected for loose bolts excessive clearance in wing strut attachments or corrosion Cable clamps should be inspected for evidence of movement and security 3 6 3 4 MOVEABLE PARTS 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 3 6 3 5 FLUID LINES AND HOSES leaks cracks kinks chafing proper radius security corrosion deterioration obstruction and foreign matter Ensure that all lines have a steady gradient from the wing tank to the header tank no humps or dips U s or inverted U s in the line Figure 3 refers Revision Dated Feb 2006 Issued By RAS Page 29 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft me un Aircraft Service Manual Jabiru J230 C 7 VAT kA ON 7 FNEL dH R INVI QV
193. r a few minutes recheck airspeed indicator Any leakage will have reduced the pressure in the system resulting in a lower airspeed indication Slowly unroll tubing before removing it so pressure may be released gradually Otherwise instrument may be damaged If the test reveals a leak in the system check all connections for tightness 13 3 4 BLOWING OUT LINES Condensation may collect at points in the pitot system and produce a partial obstruction To clear line disconnect airspeed indicator Using low pressure air blow from indicator end of line toward pitot tube CAUTION Never blow through pitot or static lines towards the instruments Like pitot lines static lines may be kept clear and connections tight When necessary disconnect static line at first instrument to which it is connected then blow line clear with low pressure air Check all static pressure lines for tightness If hose or hose connections are used check for general condition and clamps for security Replace hose which has cracked hardened or shows signs of deterioration Revision Dated Feb 2006 Issued By RAS Page 136 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft me _ Aircraft Service Manual Jabiru J230 C 13 3 5 REMOVAL amp INSTALLATION OF COMPONENTS To remove pitot mast remove the two rivets fastening it t
194. r lateral leveling use an accurate level placed against the flap drive cross tube inside the cabin in the roof above the seats Longitudinal Method 2 Use the join line of the cowl top amp bottom halves 3 1 5 PARKING Parking precautions depend principally on local conditions As a general precaution chock 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 below if a hangar is not available 3 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 while 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 3 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 thereby not leaving any fuel in the carburettor bowl Every 7 day the propeller should be rotated through 5 revolutions without running the engine Leave the propeller in the hori
195. racking Pay particular attention to the Control Horn and hinges and their surrounding areas Repairs must be referred to JABIRU AIRCRAFT Pty Ltd or our approved local agent 8 2 3 FLAP BALANCING The flaps on the J230 are not balanced 8 2 4 FLAP RIGGING AS PER TEMPLATE 1 With the flap selector lever 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 flap so that the trailing edge of the flap sits on the straight edge and there is 4mm clearance between straight edge and trailing edge of the wing revision 0 Dated Feb 2006 Issued By RAS Page 83 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft un Aircraft Service Manual Jabiru J230 C 2 Adjust with the rod ends Ensure that the lock nut is tight on the control ends and that the thread is visible through the hole in the rod 3 Check for FULL DOWN travel using the Flap Rigging Template see Appendix 3 Please note There is only a requirement to check the down deflection because it has the highest value in travel Revision Dated Feb 2006 Issued By RAS Page 84 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft pty
196. rk filesJ230 C Tech Rev 1 doc Jabiru Aircraft Shaun un Aircraft Service Manual Jabiru J230 C 7 2 CONTROL COLUMN Refer to Figure 22 7 2 1 CONTROL COLUMN REMOVAL 1 If required unbolt amp remove the control stick from the pivot plate 2 Unbolt and remove the aileron cable ends from the aileron drive arms at the lower end of the control column 3 Unbolt amp remove the aileron drive yoke from the lower end of the control column 4 Unbolt and remove the pivot plate from the upper end of the control column 5 draw the column out of the centre console 7 2 2 CONTROL COLUMN INSPECTION amp REPAIR Repair is limited to replacing worn parts Refer to Figure 22 for guidance 7 2 3 CONTROL COLUMN INSTALLATION Installation is the reverse of the procedure given above revision 0 Dated Feb 2006 Issued By Page 77 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM ft Pty Pia ircra A Aircraft Service Manual iru Jab Jabiru J230 C 8 2600006 did9 dO 37TVIN3H H3HSVM Lv 14 tl 1109 SLE 1108 96 5 LAN DOTAN 91 YAHSVM 15713 ILE 1108 LOAId WYLNSS J39VdS WOILS SNOT LOAld 3 T1ONVH JAYO 1 ONIM 330
197. rs D and P respectively 3 The type of engine for which the propeller has been designed 4 Manufacturing Serial No DWG D 1524 P 1346 JABIRU 3300 J J 6 0001 LC NO Jabiru Jabiru 4 Stroke Serial No Leading Edge Composite Prop Engine Protection Sheath 21 3 DESCRIPTION The Propellers are constructed from 4 laminations of approved species timber and are manufactured in accordance with the relevant approved Drawing They are single piece 2 blade propellers with an inlaid leading edge urethane The propeller finish is a composite sheath and clear epoxy paint JABIRU Part No PPOO39N WARNING ENSURE IGNITION SYSTEM IS OFF BEFORE COMMENCING ANY WORK ON PROPELLER REVISION o Dated May 2006 Issued By RAS Page 164 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft un Aircraft Service Manual Jabiru J230 C DO NOT RUN ENGINE WITH PROPELLER DISCONNECTED OR ENGINE DAMAGE WILL RESULT 21 4 INSTALLATION Refer to Figure 62 The Propeller is bolted to the Propeller Drive Flange with 6 x aircraft grade bolts attaching to Nyloc Nuts There are 8 Belleville Washers between the Aluminium Propeller Flange and each nut These Belleville washers must be fitted in pairs as shown in the attached drawing Bolts should be torqued to 6 nm 72 inch lbs in a standard torque sequence REVI
198. s 5A050A0D Fitted beside fuel gauges in instrument panel 16 3 COCKPIT CONTROL DECALS Table 16 Cockpit Control Decals Decal Detail Preview REVISION Dated Feb 2006 Issued By RAS Page 158 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft 2 Aircraft Service Manual Jabiru J230 C Decal Detail Preview Trim Position P No5024094 NOSE DOWN NEUTRAL TRIM NOSE UP BRAKE ON gt Fitted on the Top of the Main Beam Beside the trim control Fuel Tap Position P No 5026194 P No 502319N ON FUEL Fitted on the Main Beam in front of the Fuel SELECTOR Valve Choke Cable P No5051094 CHOKE PULL ON Fitted at the base of the choke cable Carby Heat CARB HEAT C PULL ON Fitted at the base of the CARBY Heat Cable 16 4 EXTERNAL FUSELAGE Table 17 External Fuselage Decals Decal Detail Preview P No 5043094 Attach to LHS of Vertical Fin in line with Static Tube Electrical Earthing EARTH ON NOSE LEG Attach above the Earthing Pole adjacent to the Fuel Filler Fuel Grade FUEL P No 5091344 Em AVGAS 100LL 67 LITRE CAPACITY E EARTH ON POST Attach to top skin of wing adjacent to Fuel Filler Cap REVISION
199. s Due to the variation between different paints we recommend carefully following the pack recommendations relating to surface preparation and safety Use a bare minimum of undercoat preferably white or cream and topcoat to keep weight down If you have had no previous painting experience a short course may be available from TAFE NOTE It is very easy to dramatically increase the weight of the aircraft with a heavy paint job Care must be taken to use the absolute minimum amounts of filler undercoat and topcoat Certain brands of filler are significantly lighter that others checking densities and using lighter materials can save around 5kg on a typical Jabiru airframe 15 1 2 MATERIALS RECOMMENDED 15 1 2 1 PAINTS FILLERS Top Coat 5 Lts MUST BE WHITE Base Coat 4 Lts Ensure compatibility with top coat e Polyester Filler 4 kg Spot Putty 1 Ib tube Claw Glaze recommended 15 1 2 2 SANDPAPER Note aluminum oxide type most effective e stall over sand 150 grit 20 3M Brand e Bog Sand 120 grit 20 3M Brand e Spot Putty Sand 180 grit 20 3M Brand e Final Sand 320 grit 20 3M Brand 15 1 3 PAINTING EQUIPMENT REQUIRED Random Orbital Sander approximately A 70 00 Gas Mask Compressor Spray Gun 15 1 4 PAINTING PROCEDURE jm Wash all parts to remove release agent revision 0 _ Dated Feb 2006 Issued By RAS Page 153 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev
200. se inspections are to be carried out as described below Measure the movement of the trailing edge of each control allowed by cable free play e Disconnect both ends of the cable Move the cable by hand through it s full range of movement to check freedom of movement Using a spring balance with graduations of no more than 300g measure the friction required to move the cable Repeat this step to give a minimum of 5 friction measurements in each direction of travel Reconnect one end of the cable and measure slack in the cable Revision Dated Feb 2006 Issued By RAS Page 28 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft un Aircraft Service Manual Jabiru J230 C The cable must be replaced if the following is found e Excess friction maximum allowable force to move cable 1 9kg Excess slack in cable maximum allowable cable slack 3 5mm Hard or tight patches of the cable travel Gritty or rough operation e Significant visible damage or degradation such as corrosion scoring etc Remedial Action Remedial action replacement or re routing of cable to reduce measured values is required if the control free play exceeds the values given in Table 3 Control Free Play Limits Table 3 Control Free Play Limits Control Free Play Elevator 4 0 mm Rudde
201. static pressue tube opening 2 air bulb tc 5 to static system xessure slowly Drawing 9017093 1 STATIC TEST EQUIPMENT Figure 58 Static System Test 13 4 TACHOMETER The tachometer is electronic and driven from a magnetic pick up Should the tachometer fail to operate 1 Check 10amp instrument circuit breaker and re set if necessary 2 Check 15amp main circuit breaker and re set if necessary Revision Dated Feb 2006 Issued By Page 143 of 171 LAMfilesNTechnical manualsJ230 J4301J230 J430 Work filesJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft un Aircraft Service Manual Jabiru J230 C Remove Instrument Panel see Paragraph 13 2 3 and check cable terminals for security Check wiring see Wiring Diagram Figure 59 Check correct installation of magnetic sensor on engine Refer to engine Instruction amp Maintenance Manual Should the instrument give incorrect readings 1 2 Check 10amp instrument fuse and replace if necessary Check 15amp main circuit breaker and re set if necessary Check correct installation of magnetic sensor on engine Refer to engine Instruction amp Maintenance Manual Refer to an Authorised Service Centre to have Alternator and Regulator checked Refer instrument to VDO Service Centre or JABIRU AIRCRAFT Pty Ltd for inspection and possible repair 13 5 OIL PRESSURE GAUGE The O
202. strument Check lines for obstruction or Hand oscillates Static pressure irregular leaks Blow out lines tighten connections Revision Dated Feb 2006 Issued By RAS Page 138 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft un Aircraft Service Manual Jabiru J230 C Trouble Probable Cause Remedy Check other instruments and Leak in airspeed or vertical system plumbing for leaks speed indicator installations Blow out lines tighten connections 13 3 9 TROUBLE SHOOTING VERTICAL SPEED INDICATOR OPTION Table 13 Trouble Shooting Vertical Speed Indicator Option Trouble Probable Cause Remedy Check line for obstructions Blow out lines Instrument fails to Check line for damage operate connections for security Repair or replace damaged line tighten connections Check line for obstructions Blow out lines Substitute known good Incorrect indication Ruptured diaphragm indicator and check reading Replace instrument Static line plugged Static line broken Partially plugged static line Pointer off zero Reset pointer to zero Check line for obstructions Blow out lines Test lines and connections for Leak in static line eas replace Pointer oscillates damaged lines tighten connections Substitute known good
203. sulting in fuel starvation of the engine Also the vent line if plugged can result in pressure from expanding fuel pressurising the tank The following procedure may be used to check the tank and tube 1 Have an assistant hold a rubber glove or balloon over the vent tube on one cap 2 Blow into the cap vent on the other wing If the balloon glove inflates the breather lines between the tanks are open and the tanks are cross feeding 3 Correct any blockage To check the breather line for the header tank 1 Turn off taps or clamp lines between the wing tanks and the header tank 2 Disconnect the fuel line from the mechanical fuel pump on the engine 3 Allow fuel to flow from the line for approximately a minute WITHOUT turning the electric boost pump on If the fuel flows freely the breather connection between the header tank and the main tanks is clear 4 Correct any blockage amp reassemble WARNING Fuel valves between wing tanks and header tanks must be in the ON position during flight To check the operation of the fuel vent check valve 1 Remove the cap and shake it The ball inside should move freely producing a rattling sound Revision Dated Feb 2006 Issued By RAS Page 123 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft me un Aircraft Service Manual Jabiru J230 C
204. t disturbed 5 Remove inboard brake plate 6 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 6 4 4 6 4 7 MAIN WHEEL ALIGNMENT Refer to Figure 13 6 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 Revision Dated Feb 2006 Issued By RAS Page 58 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM ft Pty Pia ircra A Aircraft Service Manual iru Jab Jabiru J230 C 30 I33HS 08 06 ssl IN3ANSIIV 133HM 1 9 1 31 25 2 931 5 345016 NIV LL 31 25 LON 00 SNO lHOdMlv 994 010 d31vi30 Sv 30934 5 LN3A3O T3A31 HLOOWS 9 051 TYM S L X 6 NIA 5431108 MOIHL 61 NIA ONO 000 0355340 Nom 3Ovdsns 5 5 5 TWwINOZIMOH
205. t a E o lt e N m 5 2 o N T CU lt oc en 2 2 e e N LL O ij a REVISION Print Date 14 01 2009 4 41 00 PM LMiles Technical manuals J230 J430230 J430 Work filesJ230 C Tech Rev 1 doc Jabiru Aircraft me un Aircraft Service Manual Jabiru J230 C 5 2 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 bolted 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 5 2 1 REMOVAL AND INSTALLATION See Wing Removal Paragraph 5 1 1 and Wing Installation Paragraph 5 1 3 5 2 2 REPAIR Wing struts are structural components and therefore all repairs must be referred to JABIRU AIRCRAFT Pty Ltd or our approved local agent A dented cracked or deformed wing strut should be replaced prior to next flight 5 3 PROBE 5 3 1 DESCRIPTION Where equipped the EFIS can use a special Pitot probe which also incorporates an angle of attack sensor The probe is mounted on a special mount rather than off the wing strut as normal for the J230 C Details of the probe s installation are given in Figure 10 below Note that this probe incorporates wat
206. t any fuel which may be split during removal of the filter 3 Disconnect the fuel lines at both ends of the filter 4 Remove filter 5 Reverse the preceding steps for installation Ensure waste cloth is removed WARNING Ensure wing tank cap vent covers are removed The fuel filter must only be installed in one direction An arrow on the side of the filler marks the fuel flow direction Ensure this arrow is pointed towards the Firewall and Engine 12 8 FUEL PUMPS 12 8 1 PRIMARY PUMP The Primary Fuel Pump is located on the Starboard rear of the Engine Refer to engine Maintenance amp Instruction Manual for details 12 8 2 SECONDARY PUMP A secondary electronic pump is mounted inside the header tank enclosure behind the rear cabin bulkhead This pump is a back up to the Primary Pump is recommended that the Secondary Pump be engaged at least during take off and landing revision 0 Dated Feb 2006 Issued By RAS Page 131 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft un Aircraft Service Manual Jabiru J230 C 13 SECTION 13 INSTRUMENTS amp INSTRUMENT SYSTEMS 13 1 GENERAL This Section describes the typical instrument installation and its operating system Emphasis is placed on trouble shooting and corrective measures only It does NOT deal with specific instrument repairs
207. the surface satisfactorily prepared white primer is required only on the discolored areas i e Body Filled areas Pin holes become evident after the primer is applied so use spot putty to fill Be careful and meticulous to find all pin holes because primer and top coat will not fill holes 10 Your final product can only be as good as your preparation Remember paint does NOT cover a multitude of sins 11 The factory uses a low pressure pot gun for spraying at pressures from 60 100 psi 12 is mandatory that exterior color is WHITE only broken if desired by pin strips on the vertical surfaces i e Sides of fuselage but not horizontal surfaces i e top of wings or fuselage as the heat build up under the tape in hot sun is considerable 13 After filling all pinholes spray another coat of primer on the discolored areas An all over primer coat is not required over the gel coat as gel coat is a sufficient undercoat Revision Dated Feb 2006 Issued By RAS Page 154 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft un Aircraft Service Manual Jabiru J230 C 14 The final rub is with 320 grit all over and if satisfied with the surface preparation remember paint will simply change color not hide lumps bumps scratches and holes blow off the dust and give an all over wipe with a t
208. to JABIRU AIRCRAFT Pty Ltd or our approved local agent 9 4 CONTROL CABLE AND ATTACHMENTS 9 4 1 REMOVAL AND INSTALLATION The Control Cable is a Primary Control and may not be repaired or removed without reference to JABIRU AIRCRAFT Pty Ltd or our approved local agent 9 5 RIGGING 1 Refer to Figure 33 2 Using the factory anchor points make sure each end of the cable is secure 3 Set the full up travel first using the factory templates Making sure the control column is hard back Adjust the female ball ends in or out if adjustment is needed 4 To establish the neutral position align balance horn with horizontal stabiliser 5 Adjust cable rod ends to achieve UP and DOWN travel using the Elevator Rigging Template see Appendix 3 6 DO NOT move the Cable Anchors These are factory set 7 Ensure lock nut is tight on rod ends and that cable is visible through hole in spherical bearing revision 0 Dated Feb 2006 Issued By RAS Page 91 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Z JO t LJJHS 6206726 007 002 ozar oiaavauna ASSY W31SAS TOHLINOO HOLVA3T3 LHOdulV H3 NIH 3uu 26 982 OLO N O V Y HddV 15 OL 5 318v2 50 imwa nmm 091419995 5537 5 WIT LOAN OLS ft
209. trol system comprises a switch amp position indicator mounted on the instrument panel and a electronic linear actuator driven common shaft assembly with pushrods connecting to the flap control surface horns WARNING All spherical rod end bearings must be fitted with a large washer on the outside of the through bolt to prevent the bearing case and cable releasing in the event of a bearing failure 8 1 1 OPERATIONAL CHECK Operate flaps through their full range of travel observing for uneven or jumpy motion or binding in the system Ensure flaps are moving together through their full range of travel 8 1 2 FLAP SWITCH ASSEMBLY The flap position controlling switch uses a manual toggle switch with position indicator to control the flap deflection 8 1 3 FLAP CROSS SHAFT ASSEMBLY See Figure 26 8 1 4 FLAP CROSS SHAFT REMOVAL T Remove one wing to allow removal of shaft Refer to Section 5 1 1 for details on wing removal procedure 2 Disconnect the flap drive motor from the cross shaft input arm 3 Remove external flap drive arm from the end of the shaft nearest the remaining wing 4 Remove the bolts holding the input arm to the flap cross shaft If fitted it will be necessary to remove any upholstery and paint from the shaft to allow it to be drawn out through the bearings on the sides of the fuselage 5 Draw the tube out of the fuselage 8 1 5 FLAP CROSS SHAFT INSPECTION amp REPAIR Repair is limited to replacing worn
210. ttachment lug or fork Both wing attachments are contained in a reinforced Wing End Plug and bond to the wing skins The Wing End Plug distributes load from the attachments to the main spar Both attachments are through stainless steel threaded bushes bonded into the attachment blocks 5 1 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 2 Drain Fuel out of Quick Drain Note This will take some time 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 it 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 amp breather tubes between the wing amp fuselage 10 Disconnect fuel gauge sender electrical wires 11 With one person supporting wing tip unbolt top wing strut bolt and lower wing strut to the ground 12 Lower wing tip to towards the ground making sure you do not crush the under side of the wing on the fuselage wing root Rest the wing tip on a saw horse or other suitable stand Revision Dated Feb 2006 Issued By
211. uivalent layup across the damage and normal fibreglass repair techniques repaired refer SECTION 15 PAINTING amp FINISHING for repainting and filling techniques Self tapper holes that become stripped may be repaired using be using the next size up self tapper from 6 gauge to 8 gauge however it is not recommended to go any larger The hole maybe filled using 5 minute araldite and redrilled again to the original smaller size again If the hole has been exposed to oil or similar it will need to be cleaned with a solvent such as acetone revision 0 Dated Feb 2006 Issued By Page 160 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft un Aircraft Service Manual Jabiru J230 C 18 APPENDIX I JABIRU 3300 ENGINE Appendix 1 of this Manual is the Instruction and Maintenance Manual for the Jabiru 3300 engine Please insert your copy of the INSTRUCTION AND MAINTENANCE MANUAL that comes with your engine into this section if you are printing this out THIS PAGE 15 INTENTIALLY LEFT BLANK revision 0 Dated Feb 2006 Issued By RAS Page 161 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft 2 un Aircraft Service Manual Jabiru J230 C 19 APPEND
212. umbered 6 Refer to Engine Instruction amp Maintenance Manual for detailed engine data For repair amp overhaul of the engine refer to the applicable publication issued by Jabiru Aircraft Pty Ltd 11 2 1 ENGINE DATA Refer Engine Instruction amp Maintenance Manual 11 2 2 ENGINE TROUBLE SHOOTING Refer Engine Instruction amp Maintenance Manual 11 2 3 ENGINE CLEANING Refer Section 3 3 11 2 4 ENGINE ACCESSORIES REMOVAL Removal of engine accessories for inspection involves stripping the engine of parts accessories 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 If suitable covers are not available tape should be used to cover the opening Revision Dated Feb 2006 Issued By RAS Page 109 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft un Aircraft Service Manual Jabiru J230 C 11 2 5 INSPECTION For specific items to be inspected and for periodic inspection details refer to Engine Instruction amp Maintenance Manual 1 Visually inspect the engine for loose bolts nuts cracks leaks amp coolin
213. urce vents air vents and openings in engine cowl to prevent the entry of foreign material or beings especially wasps 10 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 11 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 3 1 10 INSPECTION DURING STORAGE 1 Generally inspect airframe and clean as necessary 2 Inspect the interior of at least one cylinder through the spark plug hole for corrosion at least once a month 3 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 3 1 11 RETURNING AIRCRAFT TO SERVICE After temporary storage the procedures for returning the aircraft to service are as follows 1 Remove aircraft from blocks and check tyres for proper inflation 2 Check battery and install 3 Check carburettor air filter and service if necessary 4 Remove warning placard from propeller 5 Remove materials used to cover openings 6 Remove clean and gap spark plugs 7 While spark plugs are removed rotate propeller using the starter motor for several revolutions to clear excess preservative oil from cylinders CAUTION Ensure that the Master and I
214. us 3 hours is allowable on all of the service intervals given within this manual i e a 100 hourly inspection may be carried out at any time between 97 and 103 hours of operation 3 6 2 INSPECTION CHARTS The chart at Paragraph 3 7 2 shows the recommended intervals at which items are to be inspected As shown in the chart there are items to be inspected each 100 hours and each 200 hours There are also special inspection items which require inspection of servicing at intervals other than the above The engine Instruction Manual also details engine inspection schedules and should be consulted in addition to this chart e When conducting an inspection at 100 hours all items marked under EACH 100 HOURS would be inspected serviced or otherwise completed as necessary to ensure continuous airworthiness At each 200 hours the 100 hours items would be completed in addition to the items marked under EACH 200 HOURS as necessary to insure continuous airworthiness Acomplete aircraft inspection includes all 100 and 200 hour items together with those shown in the Engine Instruction Manual 3 6 3 INSPECTION GUIDELINES 3 6 3 1 ENGINE Refer to Engine Instruction amp Maintenance Manual 3 6 3 2 CONTROL CABLE INSPECTIONS Inspections are required to be carried out on the primary control cables aileron elevator and rudder at intervals detailed in the Airworthiness Limitations Section of this Manual Appendix V or Section 22 The
215. vent of a bearing failure See Figure 21 revision 0 Dated Feb 2006 Issued By Page 75 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft Jabiru J230 C Aircraft Service Manual TOYINOD NOURI 2989 tronu ane eun 173 wwe 6 L ON dvd ASSY 960000 ANO 338 4 1108 vOL NY 4 9 LON 4901 8L Nv NOUITIY 318v2 191099 5 21 OL OS6NY 9 4 W3HSvA 9 0968 4 i 3TwW34 ONI Y8LODBd 8 4 37872 3903 605 6 7 N6SZOHd OL vOL ENV 11 2 WIHS dhyo 318v5 N88002d ZL Z dWvIO HOHONY 3789 57 ONIN I 334 L SY ONIN St 434 v 1108 9 31725 LON 00 NI SNOISN3HIO o 2 G E M gt o 4 2 N 5 iL co oO n lt tc a 2 2 co e e N LL 0 o o 2 rc Print Date 14 01 2009 4 41 00 PM LMiles Technical manuals J230 J430230 J430 Wo
216. washes 4 6 SOUNDPROOFING A curtain of soundproofing material is used at the rear of the cockpit baggage area This curtain is attached to the forward rib of the fuselage using 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 47 SAFETY PROVISIONS 4 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 or stitching is broken Attaching parts should be replaced with equivalent parts if excessively worn or defective Revision Dated Feb 2006 Issued By RAS Page 43 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft me un Aircraft Service Manual Jabiru J230 C 5 SECTION 5 Wings And Empennage 51 WINGS Refer to Figures 8 and 9 Each composite wing is a semi cantilever monocoque type with a main spar The wing is a moulded structure with a series of ribs that are bonded through the moulding process to the fibreglass skin fuel tanks and to the spar The forward wing attachment is an extension of the forward sub spar The rear attachment is an extension of the rear sub spar also know as the wing a
217. xiliary electronic fuel pump are mounted inside the header tank enclosure 4 The fuel cap vents incorporate a check valve to prevent excess fuel spilling out of the vent when the aircraft is parked on an angle or flown out of balance B All fuel lines inside the cabin are housed within plastic sheath 6 The main fuel valve is located on the Main Beam in the cabin 12 1 2 PRECAUTIONS There are certain general precautions and rules concerning the fuel system which must be observed when performing the operations and procedures in this Section 1 During all fuelling defuelling tank purging and tank disassembly ground the aircraft to avoid static electricity sparks 2 Residual fuel draining from hose constitutes a fire hazard Use caution to prevent the accumulation of fuel when hoses are disconnected Cap open hoses and cover connections to prevent the entrance of foreign matter Revision Dated Feb 2006 Issued By RAS Page 120 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM ft Pty Pia ircra A Aircraft Service Manual iru Jab Jabiru J230 C MIN ww uu LINZ MV 1 1 1 565 1005 ON d H314 N6900Zd oN d 5 1 8 1 TIYAYA OL 3170 551 ZSOZE ONILIJ 39Nv14 609047 IWS NBCOZd N d
218. zontal 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 Revision Dated Feb 2006 Issued By RAS Page 20 of 171 LMilesTechnical manuals J230 J430230 J430 Work filesNJ230 C Tech Rev 1 doc Print Date 14 01 2009 4 41 00 PM Jabiru Aircraft un Aircraft Service Manual Jabiru J230 C 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 3 1 8 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 3 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 Paragraph 3 1 7 plus temporary storage fill fuel tank with correct grade of gasoline to prevent moisture accumulation indefinite storage drain fuel tank ensure carburettor bowl is empty by running engine with fuel valve off until it stops or by draining bowl The

Aircraft Service Manual - Jabiru Aircraft & Engines Australia

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Aircraft Service Manual - Jabiru Aircraft &amp; Engines Australia

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Aircraft Service Manual - Jabiru Aircraft & Engines Australia