JTM001-14 - Jabiru Aircraft

3.6 TOOLS: ........................................................................................................................................................................... 31 3.7 EQUIPMENT: .................................................................................................................................................................. 32 3.8 GENERAL: ...................................................................................................................................................................... 32 3.9 SPECIAL TOOLS & COMPOUNDS ................................................................................................................................. 33 4 CLEANING, GROUND HANDLING & STORAGE (ALL J-SERIES) .................................. 37 4.1 CLEANING ...................................................................................................................................................................... 37 4.2 GROUND HANDLING ..................................................................................................................................................... 38 4.3 STORAGE ....................................................................................................................................................................... 40 5 INSPECTION & SERVICING ............................................................................................. 43 5.1 SERVICE INTERVAL TOLERANCE ................................................................................................................................ 43 5.2 BASIC INSPECTION PROCEDURE ................................................................................................................................ 43 5.3 MANDATORY INSPECTIONS & LIFED ITEMS ............................................................................................................... 43 5.4 INSPECTION CHART...................................................................................................................................................... 46 5.5 SERVICING ..................................................................................................................................................................... 50 5.6 GENERAL INSPECTION GUIDELINES ........................................................................................................................... 50 5.7 ENGINE PRE-INSPECTION RUN-UP: ............................................................................................................................ 51 5.8 PROPELLER 100-HOURLY ............................................................................................................................................ 51 5.9 ENGINE COMPARTMENT 100-HOURLY........................................................................................................................ 51 5.10 FUEL SYSTEM 100-HOURLY ......................................................................................................................................... 53 5.11 LANDING GEAR 100-HOURLY ....................................................................................................................................... 54 5.12 AIRFRAME 100-HOURLY ............................................................................................................................................... 55 5.13 CONTROL SYSTEMS 100-HOURLY............................................................................................................................... 56 5.14 LUBRICATION ................................................................................................................................................................ 57 5.15 SPECIAL INSPECTIONS – PROPELLER........................................................................................................................ 57 5.16 SPECIAL INSPECTIONS – WEIGHING (ALL J-SERIES) ................................................................................................ 58 5.17 SPECIAL INSPECTIONS – CONTROL CABLES (ALL J-SERIES) .................................................................................. 60 5.18 SPECIAL INSPECTIONS – CONTROL SURFACES CLEARANCES (ALL J-SERIES) .................................................... 61 Aircraft Technical Manual Jabiru Aircraft Pty Ltd JTM001-14 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants This document is controlled while it remains on the Jabiru server. 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ISSUE 11 12 13 14 Date: 17 February 2025 Issued By: DM Page: 3 of 300 5.19 SPECIAL INSPECTIONS – CONTROL SURFACES HINGES (ALL J-SERIES)............................................................... 65 5.20 SPECIAL INSPECTIONS – MAIN WHEEL ALIGNMENT (ALL J-SERIES)....................................................................... 68 5.21 SPECIAL INSPECTIONS – FUEL GAUGE DECAL SETUP (ALL J-SERIES, N/A J120) .................................................. 71 5.22 SPECIAL INSPECTIONS – FUEL SENDER CALIBRATION (ALL J-SERIES, N/A J120) ................................................. 73 5.23 SPECIAL INSPECTIONS – WING & STRUT BUSH SERVICE (ALL J-SERIES).............................................................. 76 6 STRUCTURES (ALL J-SERIES) ....................................................................................... 83 6A Fuselage ....................................................................................................... 84 6.1 FUSELAGE (ALL J-SERIES) ........................................................................................................................................... 84 6.2 WINDSHIELD AND WINDOWS (ALL J-SERIES)............................................................................................................. 84 6.3 SHOCKWATCH INDICATOR (ALL J-SERIES) ................................................................................................................ 85 6.4 J160-TYPE CABIN DOORS (ALL J-SERIES, N/A J200/J400) ......................................................................................... 87 6.5 J160-TYPE CABIN DOOR LATCHES (ALL J-SERIES, N/A J200/J400) .......................................................................... 87 6.6 J200 TYPE CABIN DOORS (J200/J400) ......................................................................................................................... 91 6.7 J200-TYPE CABIN DOOR LATCHES (J200/J400) .......................................................................................................... 92 6.8 SEATS (ALL J-SERIES) .................................................................................................................................................. 94 6.9 UPHOLSTERY (ALL J-SERIES) ...................................................................................................................................... 95 6.10 SOUNDPROOFING ......................................................................................................................................................... 95 6.11 SAFETY PROVISIONS (ALL J-SERIES) ......................................................................................................................... 95 6B Wings & Empennage .................................................................................... 96 6.12 GENERAL ....................................................................................................................................................................... 96 6.13 J120 WINGS (J120) ......................................................................................................................................................... 96 6.14 J160 WINGS (J160) ......................................................................................................................................................... 98 6.15 J170 WINGS (J170) ........................................................................................................................................................102 6.16 J200 WINGS (J200/J400) ...............................................................................................................................................105 6.17 J230 WINGS (J230/J430) ...............................................................................................................................................105 6.18 J250 WINGS (J250/J450) ...............................................................................................................................................107 6.19 WING STRUTS (ALL J-SERIES) ....................................................................................................................................109 6.20 LANDING LIGHT(S) (ALL J-SERIES) .............................................................................................................................110 6.21 LANDING LIGHT ADJUSTMENT (NIGHT-VFR MODELS) (ALL J-SERIES) ...................................................................110 6.22 DYNON PITOT (ALL J-SERIES) .....................................................................................................................................113 6.23 WING INSPECTION WINDOW (ALL J-SERIES) ............................................................................................................114 6.24 FIN (ALL J-SERIES) .......................................................................................................................................................115 6.25 HORIZONTAL STABILISER (ALL J-SERIES) .................................................................................................................115 6.24.1 REMOVAL AND INSTALLATION ....................................................................................................................................115 6C Landing Gear & Brakes ........................................................................... 116 6.26 GENERAL DESCRIPTION (ALL J-SERIES) ...................................................................................................................116 6.27 MAIN UNDERCARRIAGE REMOVAL (JACKING) (ALL J-SERIES)................................................................................116 6.28 MAIN WHEEL FAIRING (SPATS) (ALL J-SERIES) ........................................................................................................117 6.29 MAIN GEAR TOP FAIRING (SPEED FAIRING) (ALL J-SERIES) ...................................................................................118 6.30 MAIN WHEELS (ALL J-SERIES) ....................................................................................................................................119 6.31 MAIN WHEEL STUB AXLE (ALL J-SERIES) ..................................................................................................................122 6.32 WHEEL BALANCING (ALL J-SERIES) ...........................................................................................................................123 6.33 MAIN GEAR LEG (ALL J-SERIES) .................................................................................................................................123 6.34 TROUBLE SHOOTING – MAIN UNDERCARRIAGE (ALL J-SERIES) ............................................................................125 6.35 NOSE WHEEL SPEED FAIRING (SPAT) (ALL J-SERIES) .............................................................................................126 6.36 NOSE WHEEL (ALL J-SERIES) .....................................................................................................................................127 6.37 NOSE WHEEL STEERING / CENTRING SYSTEM (ALL J-SERIES) ..............................................................................129 6.38 NOSE UNDERCARRIAGE LEG (ALL J-SERIES) ...........................................................................................................131 6.39 TROUBLE SHOOTING – NOSE LEG (ALL J-SERIES)...................................................................................................134 6.40 NOSE WHEEL BALANCING ..........................................................................................................................................134 6.41 BRAKE MASTER CYLINDER (ALL J-SERIES)...............................................................................................................139 6.42 HYDRAULIC BRAKE LINES ...........................................................................................................................................141 6.43 WHEEL BRAKES (ALL J-SERIES) .................................................................................................................................141 6.44 PARKING BRAKE (ALL J-SERIES) ................................................................................................................................143 6.45 BRAKE PAD LINING INSTALLATION (SOLID RIVET RETAINED PADS ONLY) (ALL J-SERIES) .................................143 6.46 BRAKE SYSTEM BLEEDING (ALL J-SERIES)...............................................................................................................144 Aircraft Technical Manual Jabiru Aircraft Pty Ltd JTM001-14 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants This document is controlled while it remains on the Jabiru server. 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ISSUE 11 12 13 14 Date: 17 February 2025 Issued By: DM Page: 4 of 300 6.47 BRAKE PAD ADJUSTMENT (ALL J-SERIES) ................................................................................................................144 6.48 BRAKE DISC WEAR LIMIT (ALL J-SERIES) ..................................................................................................................145 6.49 TROUBLE SHOOTING - BRAKES .................................................................................................................................145 6D Aileron Control System ........................................................................... 148 6.50 AILERON CONTROL SYSTEM (ALL J-SERIES) ............................................................................................................148 6.51 CONTROL COLUMN (ALL J-SERIES) ...........................................................................................................................150 6.52 CONTROL CABLES (ALL J-SERIES) .............................................................................................................................153 6.53 AILERONS (ALL J-SERIES) ...........................................................................................................................................157 6.54 AILERON RIGGING (ALL J-SERIES) .............................................................................................................................158 6E Wing Flap Control System ....................................................................... 161 6.55 WING FLAP CONTROL SYSTEM (ALL J-SERIES) ........................................................................................................161 6.56 MANUAL FLAP LEVER ASSEMBLY (ALL J-SERIES) ....................................................................................................163 6.57 ELECTRIC FLAP DRIVE ASSEMBLY (ALL J-SERIES) ..................................................................................................164 6.58 FLAP CROSS SHAFT ASSEMBLY (ALL J-SERIES) ......................................................................................................170 6.59 FLAP POSITION INDICATOR (ALL J-SERIES) ..............................................................................................................173 6.60 EXTERNAL FLAP PUSH ROD (ALL J-SERIES) .............................................................................................................176 6.61 FLAP (ALL J-SERIES) ....................................................................................................................................................176 6.62 FLAP RIGGING (AS PER TEMPLATE) (J170/SP) ..........................................................................................................177 6F Elevator Control System ......................................................................... 178 6.63 ELEVATOR CONTROL SYSTEM (ALL J-SERIES) ........................................................................................................178 6.64 CONTROL COLUMN (ALL J-SERIES) ...........................................................................................................................180 6.65 ELEVATOR (ALL J-SERIES) ..........................................................................................................................................180 6.66 ELEVATOR CONTROL CABLES (ALL J-SERIES) .........................................................................................................183 6.67 RIGGING (ALL J-SERIES)..............................................................................................................................................183 6.68 ELEVATOR TRIM – AFT ASSEMBLY (ALL J-SERIES) ..................................................................................................187 6.69 TRIM CONTROL CABLES (ALL J-SERIES) ...................................................................................................................189 6G Rudder Control System ........................................................................... 191 6.70 RUDDER PEDAL SYSTEM (ALL J-SERIES) ..................................................................................................................191 6.71 RUDDER CENTRING SYSTEM (ALL J-SERIES) ...........................................................................................................194 6.72 RUDDER (ALL J-SERIES) ..............................................................................................................................................198 6.73 RUDDER CONTROL CABLE (ALL J-SERIES) ...............................................................................................................200 6.74 RUDDER BALANCE .......................................................................................................................................................200 6.75 RIGGING (ALL J-SERIES)..............................................................................................................................................201 7 ENGINE & ENGINE INSTALLATION .............................................................................. 202 7.1 ENGINE COWLS ............................................................................................................................................................202 7.2 ENGINE (ALL J-SERIES) ...............................................................................................................................................205 7.3 FLEXIBLE HOSES .........................................................................................................................................................206 7.4 COOLING AIR BAFFLES (ALL J-SERIES) .....................................................................................................................207 7.5 ENGINE MOUNT ............................................................................................................................................................209 7.6 ENGINE FUEL SYSTEM ................................................................................................................................................210 7.7 ENGINE THROTTLE CONTROL (ALL J-SERIES)..........................................................................................................210 7.8 CHOKE CABLE (ALL J-SERIES) ....................................................................................................................................214 7.9 AIR INTAKE SYSTEM & CARBURETTOR HEAT (ALL J-SERIES) ................................................................................215 7.10 EXHAUST SYSTEM (ALL J-SERIES) .............................................................................................................................217 7.11 CABIN HEATER SYSTEM (ALL J-SERIES) ...................................................................................................................220 7.12 EXTREME CLIMATIC CONDITIONS (ALL J-SERIES) ...................................................................................................222 8 FUEL SYSTEM ................................................................................................................ 226 8.1 DESCRIPTION (ALL J-SERIES) .....................................................................................................................................226 8.2 FUEL LINES (ALL J-SERIES).........................................................................................................................................230 8.3 FUEL TANKS (ALL J-SERIES) .......................................................................................................................................232 8.4 FUEL VENTS (ALL J-SERIES) .......................................................................................................................................235 8.5 FUEL SHUT-OFF VALVE (ALL J-SERIES) .....................................................................................................................237 8.6 FUEL GAUGES (ALL J-SERIES, N/A J120) ...................................................................................................................239 8.7 FUEL FILTERS (ALL J-SERIES) ....................................................................................................................................242 8.8 FUEL PUMPS (ALL J-SERIES) ......................................................................................................................................242 Aircraft Technical Manual Jabiru Aircraft Pty Ltd JTM001-14 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants This document is controlled while it remains on the Jabiru server. 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ISSUE 11 12 13 14 Date: 17 February 2025 Issued By: DM Page: 5 of 300 9 PROPELLER SERVICE MANUAL .................................................................................. 244 9.1 CERTIFIED PROPELLER MODELS (J160-C) ................................................................................................................244 9.2 APPROVED INSTALLATIONS (ALL J-SERIES) .............................................................................................................244 9.3 IDENTIFICATION STAMPINGS......................................................................................................................................245 9.4 DESCRIPTION ...............................................................................................................................................................246 9.5 INSTALLATION (ALL J-SERIES) ....................................................................................................................................246 9.6 TO REMOVE EXISTING PROPELLER (ALL J-SERIES) ................................................................................................249 9.7 TO ASSEMBLE AND REPLACE PROPELLER ASSEMBLY (ALL J-SERIES) ................................................................249 9.8 SERVICING AND REPAIRS (ALL J-SERIES).................................................................................................................250 9.9 PROPELLER BALANCING PROCEDURE (ALL J-SERIES) ...........................................................................................250 10 UTILITY SYSTEMS ......................................................................................................... 251 11 INSTRUMENTS & INSTRUMENT SYSTEMS.................................................................. 252 11.1 GENERAL (ALL J-SERIES) ............................................................................................................................................252 11.2 INSTRUMENT PANEL (ALL J-SERIES) .........................................................................................................................252 11.3 INSTRUMENT PANEL MOUNT (ALL J-SERIES) ...........................................................................................................255 11.4 INSTRUMENTS (ALL J-SERIES) ...................................................................................................................................256 11.5 PITOT & STATIC SYSTEMS (ALL J-SERIES) ................................................................................................................256 11.6 ALTERNATE STATIC SOURCE (ALL J-SERIES)...........................................................................................................265 11.7 ANALOGUE TACHOMETER (ALL J-SERIES)................................................................................................................266 11.8 ANALOGUE ENGINE GAUGES (ALL J-SERIES) ...........................................................................................................267 11.9 DIGITAL DISPLAYS (ALL J-SERIES) .............................................................................................................................268 11.10 MAGNETIC COMPASS (ALL J-SERIES)........................................................................................................................269 11.11 GYRO INSTRUMENT PACKAGE (OPTION) (ALL J-SERIES) ........................................................................................269 12 ELECTRICAL SYSTEMS ................................................................................................ 271 12.1 ELECTRICAL POWER SUPPLY SYSTEM (ALL J-SERIES)...........................................................................................271 12.2 MINOR ELECTRICAL EQUIPMENT (ALL J-SERIES).....................................................................................................273 12.3 BATTERY SYSTEM (ALL J-SERIES) .............................................................................................................................274 12.4 ELECTRICAL LOAD ANALYSIS (ELA) ...........................................................................................................................275 12.5 RADIO INSTALLATION ..................................................................................................................................................275 12.6 TRANSPONDER (ALL J-SERIES) ..................................................................................................................................277 14 STRUCTURAL REPAIR .................................................................................................. 279 15 PAINTING & FINISHING ................................................................................................. 280 15.1 EXTERIOR (ALL J-SERIES) ...........................................................................................................................................280 16 PLACARDS ..................................................................................................................... 282 16.1 MODEL-SPECIFIC DECALS (MODELS AS SPECIFIED) ...............................................................................................282 16.2 PLACARDS GENERAL (ALL J-SERIES) ........................................................................................................................284 17 FAIRINGS ........................................................................................................................ 289 17.1 DESCRIPTION (ALL J-SERIES) .....................................................................................................................................289 18 FEEDBACK AND REPORTING ...................................................................................... 290 20 APPENDIX A – WORKSHEETS ...................................................................................... 292 Aircraft Technical Manual Jabiru Aircraft Pty Ltd JTM001-14 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants This document is controlled while it remains on the Jabiru server. 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ISSUE 11 12 13 14 Date: 17 February 2025 Issued By: DM Page: 6 of 300 1.1 Table Of Figures Figure 1 – J120-C General Arrangement ...................................................................................................................23 Figure 2 – J160 General Arrangement .......................................................................................................................24 Figure 3 – J170-C & Variants General Arrangement..................................................................................................25 Figure 4 – J170-D General Arrangement ...................................................................................................................26 Figure 5 – J200 / J400 General Arrangement ............................................................................................................27 Figure 6 – J230 / J430 General Arrangement ............................................................................................................28 Figure 7 – J250 / J450 General Arrangement ............................................................................................................29 Figure 8 – Sealants, Compounds & Lubricants #3 .....................................................................................................33 Figure 9 – Optical Tachometer ...................................................................................................................................34 Figure 10 – “Crowsfoot” Adaptor ................................................................................................................................34 Figure 11 – Safety Wire / Wire Pliers .........................................................................................................................34 Figure 12 – Torque Wrench & Crowsfoot Adaptor Setting 1 ......................................................................................34 Figure 13 – Torque Wrench & Crowsfoot Adaptor Setting 2 ......................................................................................35 Figure 14 – Using A Crowsfoot Adaptor .....................................................................................................................35 Figure 15 – Undercarriage (all J-Series) ....................................................................................................................44 Figure 16 - Rudder control cable shaft end ................................................................................................................56 Figure 17 - Check for free-play in flap drive shaft assembly ......................................................................................57 Figure 18 – Weighing Diagram. ..................................................................................................................................59 Figure 19 – Normal and Jammed Control Illustration (all J-Series)............................................................................62 Figure 20 – Rudder Gap Cross Section (all J-Series) ................................................................................................63 Figure 21 – Aileron Clearance (all J-Series) ...............................................................................................................63 Figure 22 – Test Load Application (all J-Series).........................................................................................................64 Figure 23 – Elevator Gap Cross Section (all J-Series) ...............................................................................................64 Figure 24 – Scratches on Rudder (all J-Series) .........................................................................................................65 Figure 25 - Aileron hinge from above .........................................................................................................................66 Figure 26 - Hinge pin unlocked ...................................................................................................................................66 Figure 27 - Moving hinge pin ......................................................................................................................................67 Figure 28 – Wheel Alignment Set Up (all J-Series) ....................................................................................................68 Figure 29 – Alignment Straight Edge In Position (all J-Series) ..................................................................................69 Figure 30 – Alignment Measurements (all J-Series) ..................................................................................................69 Figure 31 – Camber / Toe-In Adjustment (all J-Series) ..............................................................................................70 Figure 32 – Max Empty (Left) and Acceptable Empty (Right) Indications (all J-Series, n/a J120) ............................72 Figure 33 - Fuel Gauge Calibration Decal Parts (all J-Series, n/a J120) ...................................................................72 Figure 34 – 20L Indication on Sender & Decal to Match (all J-Series, n/a J120) .......................................................72 Figure 35 – EMS Fuel Calibration Screens (all J-Series, n/a J120) ...........................................................................73 Figure 36 – Fuel Line Clamps (all J-Series, n/a J120) ...............................................................................................74 Figure 37 – EMS Calibration Screen #1 (all J-Series, n/a J120) ................................................................................75 Figure 38 – EMS Calibration Screens #2 and #3 (all J-Series, n/a J120) ..................................................................75 Figure 39 - Installation of stainless steel bushes into fuselage lugs...........................................................................79 Figure 40 - Stainless steel fuselage bush installation schematic ...............................................................................80 Figure 41 – Wing Lug Versions (all J-Series) .............................................................................................................81 Figure 42 – Bond Details (all J-Series) .......................................................................................................................82 Figure 43 - stainless steel bushes used in Jabiru aircraft wing lugs ..........................................................................83 Figure 44 – ShockWatch Indicator (all J-Series) ........................................................................................................86 Figure 45 – J160-Type Door Hinge Assy (all J-Series, n/a J200/J400) .....................................................................88 Figure 46 – J160-Type Door Assembly (all J-Series, n/a J200/J400) ........................................................................88 Figure 47 – J120-Type Door Assembly (J120) ...........................................................................................................89 Aircraft Technical Manual Jabiru Aircraft Pty Ltd JTM001-14 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants This document is controlled while it remains on the Jabiru server. 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ISSUE 11 12 13 14 Date: 17 February 2025 Issued By: DM Page: 7 of 300 Figure 48 – J200-Type Door Assembly, J160-Type (J200/J400) ...............................................................................89 Figure 49 – J160-Type Rear Door Assy (J200/400, J230/430, J250/450) .................................................................90 Figure 50 – J160-Type Door Latch Mechanism Assembly (all J-Series, n/a J200/J400)...........................................90 Figure 51 – Top Door Catch Assy (all J-Series, n/a J200/J400) ................................................................................91 Figure 52 – J200-Type Door Hinge Assy (J200/J400) ...............................................................................................92 Figure 53 – J200-Type Front Door Assembly (J200/J400) ........................................................................................93 Figure 54 – J200-Type Rear Door Assy (J200/J400) .................................................................................................93 Figure 55 – J200-Type Door Latch Mechanism Assembly (J200/J400) ....................................................................94 Figure 56 – J160 Wing Assembly Sheet 1, Ser X (J160) .........................................................................................100 Figure 57 – J160 Wing Assembly Sheet 2, Ser X (J160) .........................................................................................100 Figure 58 – J160 Wing Assembly Sheet 1, Ser XIV (J160) ......................................................................................101 Figure 59 – J160 Wing Assembly Sheet 2, Ser XIV (J160) ......................................................................................101 Figure 60 – J160 Wing Assembly Sheet 3, Ser XIV (J160) ......................................................................................102 Figure 61 – J170 Friese Aileron Installation (J170) ..................................................................................................103 Figure 62 – J170-UL Wing Assy Sheet 1 Ser IX (J170) ...........................................................................................104 Figure 63 – J170-UL Wing Assy Sheet 2 Ser IX (J170) ...........................................................................................104 Figure 64 – J230 Wing Assembly Sheet 1, Ser 13 (J230/J430) ...............................................................................106 Figure 65 – J230 Wing Assembly Sheet 2, Ser 13 (J230/J430) ...............................................................................106 Figure 66 – J230 Wing Assembly Sheet 3, Ser 13 (J230/J430) ...............................................................................107 Figure 67 – J250 Family Wing Assy, SP-I Type (J250/450) .....................................................................................108 Figure 68 – J250 Family Wing Assy, SP-III Type (J250/450) ...................................................................................108 Figure 69 – Light Installed (Left) & Slotted Hole In Housing (all J-Series) ...............................................................111 Figure 70 – Night-VFR Lighting Aim Diagram (all J-Series) .....................................................................................111 Figure 71 – Night-VFR Landing / Taxi Light Assy (all J-Series) ...............................................................................112 Figure 72 – Day-VFR Light Assembly (all J-Series) .................................................................................................112 Figure 73 – Dynon Pitot Installation (all J-Series) ....................................................................................................113 Figure 74 – Wing Inspection Panel (all J-Series) .....................................................................................................114 Figure 75 – Wheel Spat Installation (all J-Series) ....................................................................................................118 Figure 76 – Main Wheel to Leg Assy (all J-Series) ..................................................................................................121 Figure 77 – Main Wheel Assembly (all J-Series)......................................................................................................121 Figure 78 – Directional Brake Disc Installation (all J-Series) ...................................................................................122 Figure 79 – Main Undercarriage (Type 1) ................................................................................................................125 Figure 80 – Main Undercarriage Assembly (Type 2) ................................................................................................126 Figure 81 – Nose Wheel Hub Assembly ...................................................................................................................129 Figure 82 – Nose Leg Soft Link Assy, J160 Family (J120, J160, J170) ...................................................................130 Figure 83 – Nose Leg Soft Link Assy, J200 Family (J200/400, J230/430, J250/450) ..............................................130 Figure 84 – Nose Leg Housing & Assembly (all J-Series) .......................................................................................134 Figure 85 – 4” Wheel Nose Leg Assy (J120) ............................................................................................................135 Figure 86 – Nose Leg Assy ......................................................................................................................................135 Figure 87 – Nose Leg Assy – Long Trail (J160, J170) .............................................................................................136 Figure 88 – Fabricated Nose Wheel Yoke Assy Nose Leg Housing ........................................................................136 Figure 89 – Machined Nose Leg Housing (all J-Series) ...........................................................................................138 Figure 90 – Brake Master Cylinder & Lever Assy (Type 1) ......................................................................................140 Figure 91 – Brake Master Cylinder & Lever Assy (Type 2) ......................................................................................141 Figure 92 – Dual Calliper Brake Assy (Quick Change Pads) (J200/J400, J230/J430, J250,J450) .........................146 Figure 93 – Single Calliper Detail (Mk III brakes) (all J-Series, n/a J120) ................................................................146 Figure 94 – Single Calliper (Legacy Brake System) (J120, J160, J170) ..................................................................147 Figure 95 – Aileron Controls – Type 1 ......................................................................................................................148 Aircraft Technical Manual Jabiru Aircraft Pty Ltd JTM001-14 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants This document is controlled while it remains on the Jabiru server. 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ISSUE 11 12 13 14 Date: 17 February 2025 Issued By: DM Page: 8 of 300 Figure 96 – Aileron System Schematic – Type 2. ....................................................................................................149 Figure 97 – Aileron System Schematic – Type 3. ....................................................................................................149 Figure 98 – Control Column Assy – Type 1 ..............................................................................................................151 Figure 99 – Control Column Assy – Type 2 ..............................................................................................................152 Figure 100 – Control Column Assy – Type 3 ............................................................................................................152 Figure 101 – Clamp Comparison (Primary Cable Clamp Upper on Right Picture) (all J-Series) .............................154 Figure 102 – Clamp Comparison & Installation (Rudder Cable) (all J-Series) .........................................................155 Figure 103 – Clamp Installations (Elevator & Aileron) (all J-Series) ........................................................................155 Figure 104 – Trim Cable Clamp Installation (all J-Series) ........................................................................................155 Figure 105 – Cable & Clamp Comparison (all J-Series) ..........................................................................................156 Figure 106 – Correct and Incorrect Clamp Installation (all J-Series)........................................................................156 Figure 107 – Aileron Stops – Type 1 ........................................................................................................................159 Figure 108 – Aileron Stops – Type 2 ........................................................................................................................160 Figure 109 – Aileron Stops – Type 3 ........................................................................................................................160 Figure 110 – Manual Flap Control System (all J-Series, n/a J200/J400) .................................................................161 Figure 111 – J200 Family Manual Flap System Sheet 1 (J200/J400)......................................................................162 Figure 112 – J200 Family Manual Flap System Sheet 2 (J200/J400)......................................................................162 Figure 113 – Linear Actuator Disassembled (all J-Series) .......................................................................................165 Figure 114 – Commutator Ring Close-Up (all J-Series) ...........................................................................................165 Figure 115 – Flap Controls – Sheet 1 (Fibreglass Motor Mount) (all J-Series) ........................................................166 Figure 116 – Flap Controls – Sheet 1 (Aluminium Motor Mount) (all J-Series) ........................................................167 Figure 117 – Flap Controls – Sheet 2 (J120, J160, J170) ........................................................................................168 Figure 118 – Flap Controls – Sheet 3 (Fibreglass Motor Mount) (J120, J160, J170) ..............................................168 Figure 119 – Flap Controls – Sheet 3 (Aluminium Motor Mount) (J120, J160, J170) ..............................................169 Figure 120 – J200 Family Electric Flap System Sheet 1 (J200/J400, J230/J430, J250/J450) ................................169 Figure 121 – J200 Family Electric Flap System Sheet 2 (J200/J400, J230/J430, J250/J450) ................................170 Figure 122 – Flap Cross Tube Assy J160 Family (J160) .........................................................................................171 Figure 123 – Flap Cross Tube Assembly J200 Family, Electric (J200/J400, J230/J430, J250/J450) .....................172 Figure 124 - Flap Cross Tube Assembly (J170) .......................................................................................................172 Figure 125 - Flap Cross Tube Assembly (J120) .......................................................................................................173 Figure 126 – Flap Position Indicator – Type 1 ..........................................................................................................174 Figure 127 – Flap Position Indicator – Type 2 ..........................................................................................................175 Figure 128 – Flap Position Indicator Drive Cable Assembly (all J-Series) ...............................................................175 Figure 129 – Elevator Control System – Type 1, Sheet 1 (J200/J400, J230/J430, J250/J450) ..............................178 Figure 130 – Elevator Control System – Type 1, Sheet 2 (J200/J400, J230/J430, J250/J450) ..............................179 Figure 131 – Elevator Control Assy Type 2 (J120, J160, J170) ...............................................................................179 Figure 132 – J160 Models – Horizontal Tail & Elevator Assembly (J120, J160) .....................................................181 Figure 133 - Horizontal Tail & Elevator Assembly – Type 1 (all J-Series, n/a J120, n/a J160) ................................182 Figure 134 – Horizontal Tail & Elevator Assembly Type 2 (all J-Series, n/a J120, n/a J160) ..................................182 Figure 135 – Elevator Travel Limits (all J-Series).....................................................................................................184 Figure 136 – Trim Lever Assy – Type 1 (J200/J400) ...............................................................................................186 Figure 137 – Trim Lever Assy – Type 2 (J200/J400) ...............................................................................................186 Figure 138 – Elevator Trim Handle Assy – Type 3 (all J-Series, n/a J200/J400) .....................................................187 Figure 139 – Trim Controls – At Tail (all J-Series) ...................................................................................................189 Figure 140 – Typical Rudder System Schematic (all J-Series) ................................................................................191 Figure 141 – Rudder Pedal - Non-Adjustable (all J-Series) .....................................................................................193 Figure 142 – Adjustable Rudder Pedal Assy – Type 1 (all J-Series) .......................................................................194 Figure 143 – Adjustable Rudder Pedal Assy – Type 2 (all J-Series) .......................................................................194 Aircraft Technical Manual Jabiru Aircraft Pty Ltd JTM001-14 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants This document is controlled while it remains on the Jabiru server. 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ISSUE 11 12 13 14 Date: 17 February 2025 Issued By: DM Page: 9 of 300 Figure 144 – Steering/Rudder Centring Assy – Type 1 (all J-Series) ......................................................................195 Figure 145 – Steering/Rudder Centring Assy – Type 2 ............................................................................................196 Figure 146 – Steering/Rudder Centring Assy – Type 3 (Sheet 1) ............................................................................196 Figure 147 – Steering/Rudder Assy – Type 3 (Sheet 2) ..........................................................................................197 Figure 148 – Steering/Rudder Centring Assy – Type 3 (Includes Soft Link) ............................................................197 Figure 149 – Typical Rudder Installation (Alloy Hinges) (all J-Series) .....................................................................199 Figure 150 – Typical Rudder Installation (Steel Hinges) (all J-Series) .....................................................................199 Figure 151 – Typical Upper Cowl Assy (all J-Series) ...............................................................................................204 Figure 152 – Typical Lower Cowl Assy (all J-Series) ...............................................................................................204 Figure 153 – Fuel Hose Assy – Engine Bay (all J-Series) .......................................................................................207 Figure 154 – Air Duct Hard Point Reinforcement .....................................................................................................209 Figure 155 – Throttle Assy (Seat Mounted) (all J-Series) ........................................................................................212 Figure 156 – Throttle Assy (Panel Mounted) (all J-Series) ......................................................................................213 Figure 157 – Throttle Assy (Large Panel Mount) (all J160) ......................................................................................213 Figure 158 – Control Cable End Fitting Installation (all J-Series ..............................................................................215 Figure 159 – Typical Carburettor Heat Box (all J-Series) .........................................................................................216 Figure 160 – Hot Air Duct Assy (all J-Series) ...........................................................................................................217 Figure 161 – 2200 Exhaust System (J120, J160, J170) ..........................................................................................219 Figure 162 – 3300 Exhaust System Type 1 (J200/J400, J230/J430, J250/J450) ....................................................219 Figure 163 – 3300 Exhaust System Type 2 (J200/J400, J230/J430, J250/J450) ....................................................220 Figure 164 – Cabin Heat Mixer Assembly (all J-Series) ...........................................................................................221 Figure 165 – Cabin Heat Exchanger Assy (all J-Series) ..........................................................................................222 Figure 166 – 2200 Engine Installation (J120, J160) .................................................................................................223 Figure 167 – 2200 Engine Installation (J120, J160) .................................................................................................223 Figure 168 – 2200 Engine Installation, Long Engine Mount (J170) .........................................................................224 Figure 169 – J200 Family Engine Installation Type 1 (J200/J400, J230/J430, J250/J450) .....................................224 Figure 170 – J200 Family Engine Installation Type 2 (J200/J400, J230/J430, J250/J450) .....................................225 Figure 171 – In-Cabin Fuel System (J120) ...............................................................................................................227 Figure 172 – Fuel System Schematic – Type 1 (all J-Series, n/a J120) ..................................................................227 Figure 173 – Fuel System Schematic – Type 2 (all J-Series, n/a J120) ..................................................................228 Figure 174 – Fuel System Schematic – Type 3 (all J-Series, n/a J120) ..................................................................228 Figure 175 – Fuel System Schematic – Type 4 (all J-Series, n/a J120) ..................................................................229 Figure 176 – Schematic (all J-Series) ......................................................................................................................231 Figure 177 – Sample Fuel Line Details (all J-Series) ...............................................................................................231 Figure 178 – Fuel Lines Showing Typical “U” Requiring Correction (all J-Series) ...................................................232 Figure 179 – Corrected Fuel Lines (all J-Series) ......................................................................................................232 Figure 180 – Header Tank Installation – Type 1 (all J-Series, n/a J120) .................................................................234 Figure 181 – Header Tank Installation – Type 2 (Sheet 1) (all J-Series, n/a J120) .................................................234 Figure 182 – Header Tank Installation – Type 2 (Sheet 2) (all J-Series, n/a J120) .................................................235 Figure 183 – Vented Fuel Cap Assy (all J-Series) ...................................................................................................237 Figure 184 – Single Line Fuel Tap (all J-Series) ......................................................................................................238 Figure 185 – Fuel Gauge – Electric Sender Installation (all J-Series, n/a J120) ......................................................240 Figure 186 – Fuel Gauge – Electric Sender Assembly (all J-Series, n/a J120) .......................................................240 Figure 187 – Fuel Gauge – Sight Glass (all J-Series, n/a J120) ..............................................................................241 Figure 188 – Wooden Propeller Installation (all J-Series) ........................................................................................247 Figure 189 - Scimitar propeller installation (all J-Series) ..........................................................................................248 Figure 190 – Instrument Panel Layout Type 1 (all J-Series) ....................................................................................253 Figure 191 – Instrument Panel Layout Type 2 (all J-Series) ....................................................................................253 Aircraft Technical Manual Jabiru Aircraft Pty Ltd JTM001-14 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants This document is controlled while it remains on the Jabiru server. 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ISSUE 11 12 13 14 Date: 17 February 2025 Issued By: DM Page: 10 of 300 Figure 192 – Instrument Panel Layout Type 3 (all J-Series) ....................................................................................254 Figure 193 – Instrument Panel Layout Type 4 (all J-Series) ....................................................................................254 Figure 194 – Instrument Panel Mount Installation (all J-Series) ...............................................................................255 Figure 195 – Pitot Assembly (all J-Series) ...............................................................................................................257 Figure 196 – Static Probe System Assembly (all J-Series) ......................................................................................258 Figure 197 – Pitot / Static Water Trap (all J-Series) .................................................................................................259 Figure 198 – Pitot-Static System – Water Trap Locations (all J-Series) ..................................................................259 Figure 199 – Static System Test (all J-Series) .........................................................................................................265 Figure 200 – Alternate Static Source Assy (all J-Series) .........................................................................................266 Figure 201 – Hall Effect Sensor Inst. (For Tach with Jabiru Logo on Face) (all J-Series) .......................................267 Figure 202 – Wiring Diagram Sheet 1. (all J-Series) ................................................................................................273 Figure 203 – Wiring Diagram Sheet 2. (all J-Series) ................................................................................................273 Figure 204 – VHF Antenna Installation (all J-Series) ...............................................................................................276 Figure 205 – Second VHF Antenna Installation (J120, J160, J170) ........................................................................276 Figure 206 – Second VHF Antenna Installation (J200/J400, J230/J430, J250/J450) ..............................................277 Figure 207 – Transponder Antenna Installation (all J-Series) ..................................................................................278 Aircraft Technical Manual Jabiru Aircraft Pty Ltd JTM001-14 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE 11 12 13 14 Date: 17 February 2025 Issued By: DM Page: 11 of 300 1.2 List Of Tables Table 2-1 - Typical Equipment List .............................................................................................................................20 Table 2-2 – J120-C Specifications ..............................................................................................................................23 Table 2-3 – J160 Specifications..................................................................................................................................24 Table 2-4 – J170 Specifications..................................................................................................................................25 Table 2-5 – J200/J400 Specifications .........................................................................................................................27 Table 2-6 – J230/J430 Specifications .........................................................................................................................28 Table 2-7 – J250/J450 Specifications .........................................................................................................................29 Table 2-8 – Recommended Bolt Torque Values (all J-series) ....................................................................................30 Table 5-1 – Mandatory Inspection Times ...................................................................................................................44 Table 5-3 – Mandatory Replacement Times ..............................................................................................................45 Table 5-4 – Inspection Chart ......................................................................................................................................46 Table 5-5 – Control Free Play Limits ..........................................................................................................................60 Table 6-1: Trouble Shooting – Main Undercarriage .................................................................................................125 Table 6-2 – Trouble shooting – Nose Leg. ...............................................................................................................134 Table 6-3 – Trouble Shooting – Brakes ....................................................................................................................145 Table 6-4: Aileron deflections ...................................................................................................................................158 Table 6-5: Flap deflections. ......................................................................................................................................177 Table 6-6: Elevator deflections. ................................................................................................................................184 Table 8-1 – Trouble Shooting – Fuel System ...........................................................................................................229 Table 8-2 – Trouble Shooting – Fuel Gauge ............................................................................................................239 Table 9-1 – Approved Propeller Installations ............................................................................................................244 Table 9-2 – Approved Scimitar Propeller Installations (Factory built Models) ..........................................................245 Table 9-3 – Approved Scimitar Propeller Installations (Kit built Models) .................................................................245 Table 9-4 - Propeller installation torque settings ......................................................................................................249 Table 11-1 – Trouble Shooting – Pitot-Static System ..............................................................................................262 Table 11-2 – Trouble Shooting – Airspeed Indicator ................................................................................................263 Table 11-3 – Trouble Shooting – Altimeter ...............................................................................................................263 Table 11-4 – Trouble Shooting – Vertical Speed Indicator .......................................................................................264 Table 11-5 – Trouble Shooting – Tachometer ..........................................................................................................267 Table 11-6 – Trouble Shooting – Engine Gauges ....................................................................................................268 Table 11-7 – Trouble Shooting – Digital Instruments Gauges .................................................................................269 Table 16-1 – Model-Specific Decals .........................................................................................................................282 Table 16-2 – General Decals ....................................................................................................................................284 Aircraft Technical Manual Jabiru Aircraft Pty Ltd JTM001-14 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE 11 12 13 14 Date: 17 February 2025 Issued By: DM Page: 12 of 300 2 Section 2 – General Information 2.1 Foreword / Applicability • This manual contains JABIRU recommended procedures and instructions for ground handling, servicing and maintaining the following Jabiru aircraft models: J120 - Kit-built J120 aircraft. J120-C - Factory-Built Light Sport Aircraft J160 - Kit-built J160 aircraft J160-C - Factory-Built Primary Category Aircraft J160-D - Factory-Built Light Sport Aircraft J170 - Kit-built aircraft J170-C - Factory-Built Light Sport Aircraft J170-D - Factory-Built Light Sport Aircraft J200/J400 - Kit-built aircraft J230/J430 - Kit-built aircraft J230-C - Factory-Built Light Sport Aircraft J230-D - Factory-Built Light Sport Aircraft J250/J450 - Kit-built aircraft Model MTOW (kg) Category J120-C 500 LSA / Experimental LSA All other J120 variants 500 Experimental J160-C 540 Primary J160-D 540 LSA / Experimental LSA All other J160 variants 544 Experimental J170-C 600 LSA / Experimental LSA J170-D 600 LSA / Experimental LSA All other J170 variants 544 Experimental J200 544 – RA-Aus 700 – CASA Experimental J400 700 – CASA Experimental J230-C 600 LSA J230-D 600 LSA All other J230 variants 544 – RA-Aus 700 – CASA Experimental / Experimental LSA J430 variants 700 Experimental J250 variants 544 – RA-Aus 700 – CASA Experimental J450 variants 700 Experimental • Some specialised variants are not shown. In these cases maintain the aircraft as detailed for the nearest corresponding model shown herein unless customised data is available. • It is the owner’s responsibility to become fully aware of the particular maintenance requirements and limitations applicable to the appropriate registration. Aircraft Technical Manual Jabiru Aircraft Pty Ltd JTM001-14 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE 11 12 13 14 Date: 17 February 2025 Issued By: DM Page: 13 of 300 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. Factory-built models must be maintained by an Authorised Person (LAME for CASA-registered aircraft, refer to Operations Manual for owner-maintenance levels allowed for RA-Aus-registered aircraft). Factory-built Light Sport Aircraft have a Special Certificate of Airworthiness which remains in force provided: - Only modifications and repairs approved by the manufacturer are incorporated on the aircraft; - The aircraft complies with all safety directions issued by the manufacturer; - The aircraft has been maintained in accordance with the manufacturer’s requirements; and - The continuing airworthiness functions are performed by the manufacturer (or a person appointed by CASA). If the aircraft no longer complies with one or more of these conditions, the C of A becomes void. Continued operation with an invalid C of A is a criminal offence. It is permissible, however, for the registration holder of a non-compliant aircraft to apply for an Experimental Certificate. For Experimental Category aircraft, builders remain able to conduct maintenance on aircraft for which they are the registered builder. This area of regulations varies across different countries and operators must ensure that they are complying with all local requirements. 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. Aircraft Technical Manual Jabiru Aircraft Pty Ltd JTM001-14 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE 11 12 13 14 Date: 17 February 2025 Issued By: DM Page: 14 of 300 WARNING: Jabiru Aircraft Pty Ltd has devoted significant resources and testing to develop the different Jabiru aircraft models for recreational flying and flight training. Any other uses or applications not approved by Jabiru Aircraft P/L may be extremely hazardous, leading to property damage, or injury or death of persons on or in the vicinity of the vehicle. Jabiru Aircraft Pty Ltd does not support the use of this aircraft in any applications which do not meet the requirements of the appropriate Pilot Operating Handbook or Flight Manual. Any non-compliant operation may render the aircraft un-airworthy and will void any warranty issued by Jabiru. Jabiru Aircraft are designed to be maintained only in strict accordance with the appropriate Technical Manual. Any variation of any kind, including alteration to any component at all, whether replacement, relocation, modification or otherwise which is not strictly in accordance with these manuals may lead to dramatic changes in the performance of the aircraft and may cause unexpected engine stoppage, loss of control or have other detrimental effects on the aircraft which may lead to injury or death. Jabiru Aircraft Pty Ltd does not support any modifications to an aircraft, its parts, or components. Any such actions may render the aircraft un-airworthy and will void any warranty issued by Jabiru. Maintenance and modification cannot be supervised by the manufacturer. Maintenance requires extreme cleanliness, exact parts, precise workmanship and proper consumables. It is your responsibility to ensure absolute attention to detail no matter who may become involved in work on this engine. Your safety, your life and your passenger’s lives rely on precise and accurate following of instructions in this manual. In exchange for the technical manual provided by Jabiru Aircraft Pty. Ltd. (“Jabiru”) I hereby agree to waive, release, and hold Jabiru harmless from any injury, loss, damage, or mishap that I, my spouse, heirs, or next of kin may suffer as a result of my use of any Jabiru product, except to the extent due to gross negligence or willful misconduct by Jabiru. I understand that proper skills and training are essential to minimize the unavoidable risks of property damage, serious bodily injury and death that arise from the use of Jabiru products. Aircraft Technical Manual Jabiru Aircraft Pty Ltd JTM001-14 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE 11 12 13 14 Date: 17 February 2025 Issued By: DM Page: 15 of 300 2.2 List Of Effective Pages / Issue Status • This manual is revised as a whole. All pages retain the revision status of the overall document. Issue Notes: Issue List of Changes Issued By Date 1 Initial Issue SW 2 Add procedure for correcting free-play in wing & strut attachments. DS 3 - Add maintainer requirements. - Revise logbook worksheet format. - Add notes regarding Shock-watch indicator. AS 08/04/14 4 - Include both Australian Maintainer types (L1, L2, LAME etc) and American Maintainer types (Owner, A&P, LSA) - Add ‘Required Tools’, ‘Parts and Materials’ and ‘Return to Service’ for each individual task - Add Equipment List in General Information Section - Add Source of Purchase parts in General Information Section - Add List of disposable parts in General Information Section - Add ‘Structural Repair’ Section 14 - Add ‘Revisions’ (section now removed) AS 05/05/14 5 - Reclassification of required level of certification for several tasks - LSA Owner/operator responsibilities added AS 29/10/14 6 - Control deflections added in appropriate sections - 5000hr inspection details expanded. - Section 5.23 updated to include fuselage lug bush installation - Update propeller section (section 9) DM AS 1/3/2015 19/05/15 25/02/15 7 - Add 5 year life on carby rubber connector (section 5.3.4 and 5.3.7.1) - Add notes on inspecting cable shaft ends for straightness (section 5.13) AS AS 26/08/15 14/12/15 8 - Add details regarding checking the flap drive shaft assembly for free play (section 5.13) - Add reference to JEM0005-1 (section 20.1.2, 20.1.3, and 21.3) - Removed ‘Revisions’ section (now section 2.2) MB 28/03/17 9 - Change Figure 75 - Additional check section 20.1.5 Pitot & Static System MB SW 28/04/17 13/12/18 10 - Updated wiring diagrams Section 12. - Add hinge inspection for corrosion Section 5.13 - Add end cap reference for stabilizer on aircraft in China with detachable end caps DM DM SW 16/01/218/0 2/21 11/10/21 11 - 21.1 delete reference to section 6.9 - 4.3 Edit Mogas storage to 14 days in line with JSL007 - 5.3.1 Remove requirement to 5000 hrly aircraft to be returned to Jabiru for inspection. - Remove section on Jabiru Tacho - 12.3.1 Remove reference to Odyssey battery and provide battery spec. SW SW DM DM 25/10/21 20/01/22 23/5/22 31/5/22 12 -5.23.1.3 Change stainless bush installation to 24hr araldite. 20 Appendix A 20.1.1 & 5.8 – add Removal of wooden prop to visually inspect the hub if aged. DM SW 9/9/22 18/01/23 Aircraft Technical Manual Jabiru Aircraft Pty Ltd JTM001-14 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE 11 12 13 14 Date: 17 February 2025 Issued By: DM Page: 16 of 300 13 20.1.3 Fuel SOV and placard check, carburettor bowl insp & electric boost pump rate check removed from check and added to JEM002 & JEM005. Wing gravity fuel flow check removed. PC 7/08/2024 14 9.2 Added note permitting glass leading edge Sensenich propellers 5.3.7.1 Added mandatory inspections and replacements JK JK 13/02/2025 13/02/2025 2.3 Introduction • The information in this manual is based upon data available at the time of publication, and is supplemented and kept current by Service Bulletins & Service Letters published by JABIRU AIRCRAFT Pty Ltd. These are distributed directly to owners of factory-built aircraft in addition to being posted on the JABIRU website or provided to your local distributor. New owners of pre-owned aircraft should ensure that the transfer of their aircraft has been advised to JABIRU AIRCRAFT Pty Ltd or your Jabiru representative so that our owner databases can be updated. Existing owners should ensure that they update Jabiru with their new contact details when they move or details change. • This Technical Manual has been developed to cover a range of different Jabiru Aircraft models. Many components and systems are common between these models; for example the main undercarriage legs are common between the J160, J170, J200/J400, J230/J430 and J250/J450 models and consequentially the procedures in this Manual apply equally to each of these aircraft. Where there are differences between the models this manual supplies guidance for each variant. • Before working on an aircraft the technician must be fully conversant with the appropriate Aircraft Technical Manual, Engine Maintenance Manual, Propeller Manual and any relevant Service Bulletins, Service Letters or other manufacturer’s data. Current information is available from the Jabiru Aircraft (Australia) web site – www.jabiru.net.au . • Maintenance must only be carried out by an approved person. Depending on the country and the category of the aircraft this may be a Licensed Aircraft Maintenance Engineer, an RA-Aus Level 2 or equivalent. The responsibility for determining what qualifications are necessary to carry out an overhaul belongs to the person carrying out the work. 2.4 Reading This Manual • If you are reading this manual on a computer and want to be able to quickly zoom in and out: Hold down the Ctrl key while rotating the wheel button on your mouse. In most programs this will instantly zoom in or out. • To do the same thing on a modern laptop either plug in a wheel mouse as detailed above or use the built-in track-pad. Put two fingers on the pad close together then move then apart diagonally. To reverse, put two fingers on the pad at opposite diagonal points on the pad and bring them together diagonally. This works on most modern PC-laptops. • This document has been created with hyperlinks between referenced items. So, when reading the manual on a computer you can click on the page number of an item on the table of contents and the computer will skip to that page. If a paragraph says “refer to Section 6.31” – then you can click on the “6.31” and automatically skip to that page. Similarly, if Figures or Tables are referenced. On some computers it may be necessary to hold the “Ctrl” key while clicking on the link. • To open a search window press “Ctrl-f”. Depending on the program, this will normally open a small search window where you can enter keywords. For example, searching for the word “life” will allow you to quickly find all reference to lifed maintenance items. Aircraft Technical Manual Jabiru Aircraft Pty Ltd JTM001-14 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE 11 12 13 14 Date: 17 February 2025 Issued By: DM Page: 17 of 300 2.4.1 Model Applicability This Airframe technical / Maintenance manual has been produced to cover all J series models (as shown on the title page. This has been done to ensure that as new maintenance requirements are developed and established a single manual can be updated rather than numerous separate documents thus removing the risk of omission of a particular maintenance task from a particular manual. To enable the maintainer to confidently determine which maintenance tasks are applicable to a particular model, each task heading includes the model applicability in parentheses (). Figures and drawings will also include the model applicability in the Figure note. In the case where a task, photograph or drawing is applicable to all models the note will read ‘(all J-Series)‘. Some tasks and figures apply to all models except one (this is particularly the case for the wing fuel system which does not apply to the J120) in this case the label will be (all J-Series, n/a J120) which indicates it applies to all models except the J120. If a heading of figure is undefined then by default it applied to all models. 2.5 Degree Of Difficulty • This manual is intended for use by experienced technicians and while all processes will be explained as clearly as possible, some knowledge is assumed. This manual is not intended to be sufficient reference for a person with no other training to safely maintain an aircraft. • In this manual we have used a “spanner scale” to help technicians approach a job. Anyone considering undertaking a task in this manual must realistically assess themselves against this scale and not attempt any task for which they lack knowledge or the required tools. The Spanner Scale Translation Simple, basic, straightforward. A careful layman, with guidance, can achieve this. Straightforward, but with some technical bits. Basic knowledge, care and guidance needed. Straightforward, but requires special tools, training and/or judgement. Sound basic knowledge guidance and a careful approach are required. A technical job. Take your time, double-check everything. Only for the experienced maintainer. A difficult job. Requires special tools, solid skills, good judgement. Only for experts. 2.6 Use-By Dates & Storage • Some products called for by this manual – including thread locking compound, resins and glues – have a use-by date. Care must be taken to ensure all such compounds are within their shelf life before applying them to an aircraft. • Loctite products typically do not have their use-by date marked on the bottle. For these products it is necessary to note the batch number on the bottle and contact the distributor for shelf-life information. • Similarly, for many products the shelf-life assumes a certain type of storage – i.e. sealed, temperature controlled etc. Maintainers must ensure that such products are stored appropriately. 2.7 General Description • The JABIRU aircraft described in this manual are 2-seat, high-wing monoplane composite aircraft of monocoque construction. They are equipped with fixed tricycle landing gear of composite construction. The steerable nose gear is a welded metal, trailing link assembly with rubber springs. Aircraft Technical Manual Jabiru Aircraft Pty Ltd JTM001-14 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE 11 12 13 14 Date: 17 February 2025 Issued By: DM Page: 18 of 300 • The aircraft are equipped with a JABIRU, 4 cylinder, 4 stroke engine of around 80hp or a JABIRU 6- cylinder, 4-stroke engine of around 120hp. Both engines are optimised to drive a 2-bladed, wooden, fixed pitch propeller. 2.8 Owner Maintenance 2.8.1 Factory-Built Models • All Jabiru Aircraft, including factory-built models, have been specifically designed as 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 wherever this is allowed by the aircraft’s operating category. This servicing includes: - Oil & oil filter changes - Fuel filter changes - Brake pad changes - Tyre changes - Spark plug changes - Normal engine maintenance between 100-hourly maintenance. Refer to Engine Maintenance Manual for details. • Every 100 hours or Annually (whichever happens first) a 100-hour inspection must be carried out by an Authorised Person (such as a LAME. Refer to the RAAus Operations Manual for RAAus aircraft Australia). CAUTION It is the operator’s responsibility to ensure that the factory-built aircraft is correctly maintained for the intended use. 2.8.2 Kit-Built Models • Many models discussed in this manual can be registered under a variety of different categories worldwide, at a variety of different weights and operating requirements. The owner must consult their local airworthiness authority to determine what level of owner maintenance is allowed. As an example, in Australia aircraft registered in the “Experimental” category may be maintained exclusively by the owner/builder, or by authorised aircraft maintainers. CAUTION It is the operator’s responsibility to ensure that the kit-built aircraft is correctly maintained for the intended use. 2.9 Aircraft Specifications • Leading particulars of the aircraft discussed in this manual are given in Section 2.14. 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. 2.10 Centre Of Gravity Limitations • All JABIRU models are relatively light weight. 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 a person authorized to revise an aircraft’s weight and balance information (such as the holder of a CASA Weight Control Authority) 2.11 Standard Practices • Do not over tighten bolts • Ensure a minimum of 1 full thread is clear of nuts. • Do not exceed 3 threads clear on nuts (use extra washers). Aircraft Technical Manual Jabiru Aircraft Pty Ltd JTM001-14 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE 11 12 13 14 Date: 17 February 2025 Issued By: DM Page: 19 of 300 • Ensure nuts are not thread-bound (i.e. the thread on the nut has hit the end of the thread on the bolt. • 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. i.e. a ¼” washer must be fitted to 3/16” bolts or a 5/16” washer to ¼” bolts. • AC43 or similar approved data gives guidance on accepted means for carrying out typical aircraft maintenance tasks – such as safety-wiring etc. WARNING Thread bound nuts can carry far less load and are much more susceptible to failure. WARNING DO NOT REUSE SELF-LOCKING NUTS 2.12 Aircraft Structure • In all Jabiru Aircraft, due to the 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. 2.13 Engines • The engines used in Jabiru Aircraft are not discussed within this manual. For details of installation, maintenance and overhaul refer to the engine manuals appropriate to the engine model. • Up-to-date engine manuals are available from the Jabiru Aircraft website; www.jabiru.net.au. Aircraft Technical Manual Jabiru Aircraft Pty Ltd JTM001-14 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE 11 12 13 14 Date: 17 February 2025 Issued By: DM Page: 20 of 300 2.14 Equipment List All possible combinations of equipment included in individual aircraft cannot be stated for reasons of physical space. Table 2-1 provides a list of the typical equipment found in Jabiru J-series Aircraft. Table 2-1 - Typical Equipment List Aircraft J120/J120-C/J160/J160- D/J170/J170-C/J170-D J200/J400/J230/J230- C/J230-D/J430/J250/J450 J160-C Engine 2200B (for factory built) 2200A (for all other) 3300A 3300L (Jab USA 230-D) 2200C Propeller Jabiru Wooden Sensenich Jabiru Scimitar Jabiru Wooden Sensenich Jabiru Scimitar Jabiru Wooden Special Purpose Toolkit Compasses Magnetic Instruments Altimeter EFIS (Dynon D10A or D100 are typical) EMS (Dynon D10 is typical) EFIS/EMS (Dynon FlightDEK D180) GPS (Garmin GPSmap296 or Aera 500 are typical) Voltage meter Pressure Gauges Engine Oil Pressure (analogue, part of EMS display) Engine Oil Temperature (analogue, part of EMS display) Engine Manifold Pressure (part of EMS display) Thermometers Engine Cylinder Head Temperature (analogue, part of EMS display) Engine Exhaust Gas Temperature (part of EMS display) Outside Air Temp (part of EFIS display) Indicators Airspeed (analogue, part of EFIS display) Tachometer (analogue, part of EMS display) Engine hours (incorporated into Tacho or EMS) Stall Warning Trim indicator Turn Coordinator (Electric, part of EFIS display) Balance ball (analogue, part of EFIS display) Vertical Speed (analogue, part of EFIS display) Flap position Lights Anti Collision Strobe (fin and/or wingtip mounted) Landing lights Beacon Interior Radio VHF Tx/Rx (1x or 2x microair M760 is typical) XPNDR (microair T200SFL is typical) Intercom (PM1000 is typical) UHF Tx/Rx Headsets Fluid Quantity Oil Lubricant – 2.3 litres Oil Lubricant – 3.3 litres Oil Lubricant – 2.3 litres Other Cabin Heater Wheels Spats Cargo Restraint Three point personal harness Aircraft Technical Manual Jabiru Aircraft Pty Ltd JTM001-14 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE 11 12 13 14 Date: 17 February 2025 Issued By: DM Page: 21 of 300 2.15 Source of Purchase Parts All replacement parts can be sources from Jabiru Aircraft Pty Ltd (details listed below) or an approved local agent Jabiru Aircraft P/L PO Box 5186 Bundaberg West, QLD 4670 Phone: 07 4155 1778 Fax: 07 4155 2669 Email: info@jabiru.net.au 2.16 List of Disposable Replacement Parts (all J series) Part Manufacturer Part # Air Filter Joywell Motor Corp TPG10242N Fuel Filter Joywell Motor Corp ZFF0002 Oil Filter Joywell Motor Corp TPG10162N Spark Plug NGK D9EA Distributor Cap BOSCH GB926 Battery Lead acid 12V See 12.3.1 Tyres , Main Trelleborg TA03331 Tyres, Nose Trelleborg TA03331 Inner Tube, Main Top Tyres TA3500687 Inner Tube, Nose Top Tyres TA3500687 2.17 Owner/operator responsibilities (LSA aircraft) The following responsibilities are applicable to owner/operators of LSA’s. These Responsibilities are prescribed in the ASTM standard F2295: • Each owner/operator of a LSA shall read and comply with the maintenance and continued airworthiness information and instructions provided by the manufacturer. • Each owner/operator of a LSA shall be responsible for providing the manufacturer with current contact information where the manufacturer may send the owner/operator supplemental notification bulletins. • The owner/operator of a LSA shall be responsible for notifying the manufacturer of any safety of flight issue or significant service difficulty upon discovery. • The owner/operator of a LSA shall be responsible for complying with all manufacturer issued notices of corrective action and for complying with all applicable aviation authority regulations in regard to maintaining the airworthiness of the LSA. • An owner of a LSA shall ensure that any needed corrective action be completed as specified in a notice, or by the next scheduled annual inspection. • Should an owner/operator not comply with any mandatory service requirement, the LSA shall be considered not in compliance with applicable ASTM standards and may be subject to regulatory action by the presiding aviation authority. Section 19.1.1 provides forms which may be filled out and submitted for the purposes of fulfilling Owner/Operator COSM (Continued Operating Safety Management) requirements. Aircraft Technical Manual Jabiru Aircraft Pty Ltd JTM001-14 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE 11 12 13 14 Date: 17 February 2025 Issued By: DM Page: 22 of 300 2.18 Aircraft Specifications 2.18.1 Universal Specifications (all J-Series) Item Specification Fuel Type • AVGAS 100LL or 100/130. • MOGAS with Octane Rating 95 RON (AKI 90) or above • Fuels blends containing up to 10% Ethanol may be used only where the aircraft is equipped with appropriate fuel tank sealant and fittings. Refer to Service Letter JSL007, the Pilot Operating Handbook or Flight Manual for details. CAUTION CASA-certified models may not use fuel containing alcohol. Operators who choose to use MOGAS do so at their own risk. Operators who choose to use fuel containing alcohol do so at their own risk. REFER TO SERVICE LETTER JSL007 FOR DETAILS Battery Location • In Engine Compartment Propeller Type • Jabiru • 2-bladed Wooden • 2-bladed Scimitar (Composite) Propeller Diameter • 60” dia (1524mm) Target Wheel Alignment (at gross weight) • 0° Camber, 0° Toe-in. Engine Oil Type • Refer Engine Manuals Aircraft Technical Manual Jabiru Aircraft Pty Ltd JTM001-14 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE 11 12 13 14 Date: 17 February 2025 Issued By: DM Page: 23 of 300 2.18.2 J120-C Table 2-2 – J120-C Specifications Model J120-C Other J120 Variants Aircraft Maximum Weight 500kg (1102lb) 500kg (1102lb) Fuel Capacity 65 litres 65 litres Oil Capacity 2.3 litres 2.3 litres Engine Model Jabiru 2200B Jabiru 2200A Propeller Pitch Jabiru 42” pitch (1067mm) Sensenich 43” pitch (1092mm) or Sensenich 46” pitch (1168mm) Jabiru Scimitar 38” pitch (965mm) Jabiru 42” pitch (1117mm) Nose Wheel Size 260 x 4” rim 260 x 4” rim Main Wheel Size 400 x 4” rim 400 x 4” rim Tyres Standard 4” wide, 4 Ply 4” wide, 4 Ply Tyre Pressures Standard - Mains 228 kPa (33 psi) 179 kPa (26 psi) Tyre Pressures Standard - Nose 193 kPa (28 psi) 137 kPa (20 psi) Figure 1 – J120-C General Arrangement Aircraft Technical Manual Jabiru Aircraft Pty Ltd JTM001-14 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants This document is controlled while it remains on the Jabiru server. 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ISSUE 11 12 13 14 Date: 17 February 2025 Issued By: DM Page: 24 of 300 Table 2-3 – J160 Specifications Model J160-C J160-D Other J160 Variants Aircraft Maximum Weight 540kg (1190lb) 540kg (1190lb) 544kg (1190lb) Fuel Capacity 135 litres 135 litres 135 litres Oil Capacity 2.3 litres 2.3 litres 2.3 litres Engine Model Jabiru 2200C Jabiru 2200B Jabiru 2200B Jabiru 2200A Propeller Pitch Jabiru 42” pitch (1067mm) Jabiru 42” pitch (1067mm) Sensenich 43” pitch (1092mm) or Sensenich 46” pitch (1168mm) Jabiru Scimitar 38” pitch (965mm) Jabiru 44” pitch (1117mm) Wheel Sizes Standard 500 x 6” rim 500 x 6” rim 500 x 6” rim Tyres Standard 6” wide, 6 Ply 6” wide, 6 Ply 6” wide, 6 Ply Tyre Pressures Standard - Mains 228 kPa (33 psi) 228 kPa (33 psi) 228 kPa (33 psi) Tyre Pressures Standard - Nose 193 kPa (28 psi) 193 kPa (28 psi) 193 kPa (28 psi) Figure 2 – J160 General Arrangement Aircraft Technical Manual Jabiru Aircraft Pty Ltd JTM001-14 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants This document is controlled while it remains on the Jabiru server. 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ISSUE 11 12 13 14 Date: 17 February 2025 Issued By: DM Page: 25 of 300 Table 2-4 – J170 Specifications Model J170-C J170-D J170-UL (Europe Kit) Other J170 Variants Aircraft Maximum Weight 600kg (1320lb) 450kg (992lb) 544kg (1190lb) Fuel Capacity 135 litres 75 litres 135 litres Oil Capacity 2.3 litres 2.3 litres 2.3 litres Engine Model Jabiru 2200B Jabiru 2200 Jabiru 2200 Propeller Pitch Jabiru 42” pitch (1067mm) or Sensenich 43” pitch (1092mm) or Sensenich 46” pitch (1168mm) Jabiru Scimitar 38” pitch (965mm) Jabiru 42” pitch (1067mm) Jabiru 42” pitch (1067mm) Wheel Sizes Standard 500 x 6” rim 400 x 4” rim 500 x 6” rim Tyres Standard 6” wide, 6 Ply 4” wide, 4 ply 6” wide, 6 Ply Tyre Pressures Standard - Mains 310 kPa (45 psi) 179 kPa (26 psi) 179 kPa (26 psi) Tyre Pressures Standard - Nose 207 kPa (30 psi) 137 kPa (20 psi) 137 kPa (20 psi) Figure 3 – J170-C & Variants General Arrangement Aircraft Technical Manual Jabiru Aircraft Pty Ltd JTM001-14 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE 11 12 13 14 Date: 17 February 2025 Issued By: DM Page: 26 of 300 Figure 4 – J170-D General Arrangement Aircraft Technical Manual Jabiru Aircraft Pty Ltd JTM001-14 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE 11 12 13 14 Date: 17 February 2025 Issued By: DM Page: 27 of 300 Table 2-5 – J200/J400 Specifications Model J200 J400 Number of Seats 2 4 Aircraft Maximum Weight 700kg 544kg (category limitation) 700kg Fuel Capacity 135 litres 135 litres Oil Capacity 3.5 litres 3.5 litres Engine Model Jabiru 3300A Jabiru 3300A Propeller Pitch Jabiru 53” pitch (1346mm) Jabiru Scimitar 52” pitch (1321mm) Jabiru 53” pitch (1346mm) Jabiru Scimitar 52” pitch (1321mm) Wheel Sizes Standard 500 x 6” rim 500 x 6” rim Tyres Standard 6” wide, 6 Ply 6” wide, 6 Ply Tyre Pressures Standard - Mains 310 kPa (45 psi) 310 kPa (45 psi) Tyre Pressures Standard - Nose 207 kPa (30 psi) 207 kPa (30 psi) Figure 5 – J200 / J400 General Arrangement Aircraft Technical Manual Jabiru Aircraft Pty Ltd JTM001-14 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE 11 12 13 14 Date: 17 February 2025 Issued By: DM Page: 28 of 300 Table 2-6 – J230/J430 Specifications Model J230-C, J230-D Other J230 Variants J430 Number of Seats 2 2 4 Aircraft Maximum Weight 600kg 700kg 544kg (category limitation) 700kg Fuel Capacity 135 litres 135 litres 135 litres Oil Capacity 3.5 litres 3.5 litres 3.5 litres Engine Model Jabiru 3300A Jabiru 3300A Jabiru 3300A Propeller Pitch Jabiru 53” pitch (1346mm) or Jabiru 55” pitch (1397mm) or Sensenich 53” pitch (1346mm) or Sensenich 55” pitch (1397mm) or Sensenich 56” pitch (1422mm) Jabiru Scimitar 52” pitch (1321mm) Jabiru 53” pitch (1346mm) or Jabiru 55” pitch (1397mm) Jabiru 53” pitch (1346mm) or Jabiru 55” pitch (1397mm) Wheel Sizes Standard 500 x 6” rim 500 x 6” rim 500 x 6” rim Tyres Standard 6” wide, 6 Ply 6” wide, 6 Ply 6” wide, 6 Ply Tyre Pressures Standard - Mains 310 kPa (45 psi) 310 kPa (45 psi) 310 kPa (45 psi) Tyre Pressures Standard - Nose 207 kPa (30 psi) 207 kPa (30 psi) 207 kPa (30 psi) Figure 6 – J230 / J430 General Arrangement Aircraft Technical Manual Jabiru Aircraft Pty Ltd JTM001-14 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE 11 12 13 14 Date: 17 February 2025 Issued By: DM Page: 29 of 300 Table 2-7 – J250/J450 Specifications Model J250 J450 Number of Seats 2 4 Aircraft Maximum Weight 700kg 544kg (category limitation) 700kg Fuel Capacity 135 litres 135 litres Oil Capacity 3.5 litres 3.5 litres Engine Model Jabiru 3300A Jabiru 3300A Propeller Pitch Jabiru 53” pitch (1346mm) Jabiru Scimitar 52” pitch (1321mm) Jabiru 53” pitch (1346mm) Jabiru Scimitar 52” pitch (1321mm) Wheel Sizes Standard 500 x 6” rim 500 x 6” rim Tyres Standard 6” wide, 6 Ply 6” wide, 6 Ply Tyre Pressures Standard - Mains 310 kPa (45 psi) 310 kPa (45 psi) Tyre Pressures Standard - Nose 207 kPa (30 psi) 207 kPa (30 psi) Figure 7 – J250 / J450 General Arrangement Aircraft Technical Manual Jabiru Aircraft Pty Ltd JTM001-14 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE 11 12 13 14 Date: 17 February 2025 Issued By: DM Page: 30 of 300 2.19 Torque Values (In Fibreglass) • Unless noted otherwise, all bolt torque settings detailed within this manual are for clean, dry threads. • When checking fastener torque, use the following procedure: - Ensure the fastener to be checked is clean and dry before proceeding. - Where a reversible wrench is being used, set the torque to a value slightly below the target torque and LOOSEN the fastener slightly (approx 1/3 or a turn). The wrench should “click” – indicating that the fastener had maintained its set torque. If the fastener torque has reduced significantly it may be an indication of damage or degradation to the assembly and should be investigated. - The fastener is first loosened slightly to ensure that it is free to move on its threads. If this step is not carried out it is possible for the fastener to corrode in place. If that happens, the friction of the corrosion will seize the fastener, ensuring that it appears to “pass” torque checks but in fact has lost tension and is no longer holding the assembly correctly. - Tighten the fastener smoothly to the set torque. Any jerks or bumps when tightening can cause the reading to be obtained prematurely. - The torque must be obtained while the nut is turning. If you stop to reposition the torque wrench and then the required torque reading is obtained without the nut turning, the nut needs to be loosened a little and then tightened again so the torque reading is obtained while turning. Table 2-8 – Recommended Bolt Torque Values (all J-series) Bolt Size Torque (Inch.lb) (Core-mat or thin laminate) Torque (Inch.lb) (Thick, glass-only laminate) AN3 20 - 25 (1.7 – 2.1lb.ft) Up to 4 lb.ft AN4 50 - 70 (4.2 – 5.8lb.ft) Up to 8 lb.ft AN5 100 –140 (8.3 – 11.7lb.ft) Up to 18 lb.ft AN6 N/A Up to 24 lb.ft AN4 Propeller 72 (6lb.ft) N/A • These values relate only to steel nuts on oil-free cadmium plated threads. • For Engine Bolt Torque Values see Engine 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. Aircraft Technical Manual Jabiru Aircraft Pty Ltd JTM001-14 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE 11 12 13 14 Date: 17 February 2025 Issued By: DM Page: 31 of 300 3 Maintainer Requirements (all J-Series) • The following are recommended as the minimum requirements for someone carrying out maintenance & inspection on Jabiru Aircraft: 3.1 Facilities • An enclosed workspace with sealed floor, adequate lighting, compressed air & mains electricity. 3.2 Training • For engines: completion of an approved instruction course specific to Jabiru Engines. Approved courses include those offered by Jabiru Aircraft Australia or by local Jabiru Aircraft representatives. • Airframe: completion of an approved instruction course specific to Jabiru Aircraft. Approved courses include those offered by Jabiru Aircraft Australia or by local Jabiru Aircraft representatives. 3.3 Rating • Commercial maintainers must hold suitable ratings as required by their local Airworthiness Authority. 3.4 Experience • A minimum of 2 years experience working on aircraft under supervision is recommended for commercial maintainers before working un-supervised. 3.5 Tool & Gauge Control • Tool & gauge control is an important part of aviation maintenance systems. Tools & gauges must be accurate enough for the intended use (i.e. a 12” steel ruler is not the appropriate tool to use to measure the cylinder bore diameter) & be accurately calibrated by an approved laboratory. • Calibrations must be kept up to date. This means a check calibration every year or more frequently for regularly used, critical tooling. • Even quality equipment will wear over time so items like reams and go / no-go gauges must periodically be checked to ensure they remain within limits. 3.6 Tools: Access to the following tools will be required. All tools must be good quality items: • Imperial Allen keys • Circlip pliers • Pliers: long nose, regular square jaw, side cutters • Ring/open end spanners: 5/16”, 3/8”, 7/16”, 1/2”, 9/16”, 10mm, 17mm • Ratchet 3/8” drive, breaker bar, 2” extension bar, 3/8”, 7/16”, 1/2” sockets, 7/16” tube socket, 18mm spark plug socket • Screwdrivers: flat blade and Phillips head in various sizes • Feeler gauges: metric and imperial sizes • Punch set • Torque wrench: 3/8” drive, “name” brand (Snap-On, Warren & Brown etc), recently calibrated. The wrench must have a suitable scale for use on the fasteners typically found on Jabiru Aircraft – for example a wrench with a scale from 20 – 100 lb.ft is unsuitable. • Adjustable reams • Picks / probes • Good quality wire strippers. Terminal crimp pliers, terminals, heat shrink etc. • Safety wire pliers & 0.032” stainless steel safety wire. • Inspection mirror / Boroscope Aircraft Technical Manual Jabiru Aircraft Pty Ltd JTM001-14 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE 11 12 13 14 Date: 17 February 2025 Issued By: DM Page: 32 of 300 3.7 Equipment: Access to the following equipment will be required: • Bench vice with padded jaws • Calipers: must read up to 180mm • Degreasing/cleaning system with solvent/solution containment/recycling • Hand press • Heat gun or small butane/propane torch with a soft pencil flame • Multimeter or an ohmmeter • Imperial thread taps: UNF and UNC • Adjustable wing stands • Saw-horses • Fuel-proof container with accurate volume markings • Soldering iron • Cable ties • An accurate tyre pressure gauge • Accurate scales and spirit level if the aircraft is to be weighed. 3.8 General: • Brass drifts, punches, rags, soft mallet, hammers • Greases: molybdenum disulphide, general purpose • TorqueSeal brand security marking lacquer or similar, such as coloured nail varnish • 5-Minute epoxy resin, Jabiru epoxy resin, cotton fibre flock, Q-cells (micro-balloons), containers, scales, mixers etc. • Scratch-removing compounds such as Novus Plastic Polish for windows. Aircraft Technical Manual Jabiru Aircraft Pty Ltd JTM001-14 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE 11 12 13 14 Date: 17 February 2025 Issued By: DM Page: 33 of 300 3.9 Special Tools & Compounds Figure 8 – Sealants, Compounds & Lubricants #3 • Loctite 620 is designed for the bonding of cylindrical fitting parts. Typical applications include locating pins in radiator assemblies, sleeves into pump housings and bearings in auto transmissions. Particularly suitable for applications where temperature resistance up to 200°C is required. Used as a ultra-strong threadlock. Loctite 620 is specified in several places in the Jabiru Aircraft where a reliable bond is essential. When using it, follow the rules below: WARNING Failure to use Loctite 620 correctly can result in bond failure. - Check use-by dates. Loctite 620 (like most other compounds) has a use-by date. Generally this is not printed on the bottle but can be found by contacting the distributor and telling them the batch number. - Work fast. Loctite 620 can cure very quickly. All screws must be torqued to final settings as quickly as practical. Anything more than a minute is not recommended, particularly if cure accelerator spray (Loctite 7471) is used. - Only use as much as required/specified. Excess compound can make it nearly impossible to disassemble the parts later. - Surface preparation is critical. Threads must be cleaned and prepared properly. - To Remove. Can normally be achieved by heating the screw to over 150°C using a pencil-point gas burner. Minimise direct heat applied to the head of the screw as this can weaken the drive socket – direct heat towards the thread as must as possible. • Loctite 290 is designed for the locking and sealing of threaded fasteners. Because of its low viscosity and capillary action, the product wicks between engaged threads and eliminates the need to disassemble prior to application. The product cures when confined in the absence of air between close fitting metal surfaces and prevents loosening and leakage from shock and vibration. The product can also fill porosity in welds, castings and powdered metal parts. • Loctite 262 is designed for the permanent locking and sealing of threaded fasteners. Typical applications include the locking and sealing of large bolts and studs (up to M25 ). A medium strength threadlock. • Loctite 243 is designed for the locking and sealing of threaded fasteners which require normal disassembly with standard hand tools. Particularly suitable for applications on less active substrates such as stainless steel and plated surfaces, where disassembly with hand tools is required for servicing. A medium-strong threadlock. Typically used for cap screws into castings or Aluminium. Aircraft Technical Manual Jabiru Aircraft Pty Ltd JTM001-14 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE 11 12 13 14 Date: 17 February 2025 Issued By: DM Page: 34 of 300 Figure 9 – Optical Tachometer Figure 10 – “Crowsfoot” Adaptor Figure 11 – Safety Wire / Wire Pliers • Wire used to secure items (nuts, bolts etc) to prevent rotation in service. 3.9.1 Torque / Tension Wrench Figure 12 – Torque Wrench & Crowsfoot Adaptor Setting 1 An accurate optical tachometer. Reads directly from reflective strips fitted to the propeller and is used whenever an accurate check of RPM is required. Will usually read propeller RPM in sunlight without reflective strips. Used to confirm accuracy of RPM readings of standard instruments. Commercially available tool designed for high- torque applications on small nuts. Also allows the use of a torque wrench in inaccessible locations. Note usage instructions below. L1 L2 Aircraft Technical Manual Jabiru Aircraft Pty Ltd JTM001-14 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE 11 12 13 14 Date: 17 February 2025 Issued By: DM Page: 35 of 300 Figure 13 – Torque Wrench & Crowsfoot Adaptor Setting 2 • A good torque wrench is an essential tool for maintaining Jabiru Aircraft. It’s important to realise however that even the best wrench needs calibrating occasionally. This can be done using a dead weight on the end of a known arm or – preferably – sending the wrench away to be calibrated. Note that Civil Aviation Authorities generally require that the tool be calibrated in a way which is traceable to a NATA-standard laboratory. • A “Crowsfoot” extension as shown in Figure 10 is sometimes necessary – it allows high torque settings to be used on small nuts without damaging them and access to difficult locations. However, when using the extension as shown in Figure 12 the extra length will throw off the torque setting of the wrench. This must be corrected using the following formula: 𝐴𝑑𝑗𝑢𝑠𝑡𝑒𝑑 𝑇𝑜𝑟𝑞𝑢𝑒 𝑆𝑒𝑡𝑡𝑖𝑛𝑔 = 𝑅𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑇𝑜𝑟𝑞𝑢𝑒 𝑆𝑒𝑡𝑡𝑖𝑛𝑔 × ( 𝐿1 𝐿1+𝐿2). • L1 is the distance from the middle of the grip of the handle to the centre of the wrench drive lug • L2 is the distance in the direction of the handle from the centre of the wrench drive lug to the centre of the nut socket of the adaptor. • For example: a nut needs to be tensioned to 30lb.ft. The torque wrench is 12” long and the crowsfoot extension is 2” long. The extension is oriented as shown in Figure 12. This means that the torque wrench must be set to: 𝐴𝑑𝑗𝑢𝑠𝑡𝑒𝑑 𝑇𝑜𝑟𝑞𝑢𝑒 𝑆𝑒𝑡𝑡𝑖𝑛𝑔 = 30 × ( 12 12 + 2) 𝐴𝑑𝑗𝑢𝑠𝑡𝑒𝑑 𝑇𝑜𝑟𝑞𝑢𝑒 𝑆𝑒𝑡𝑡𝑖𝑛𝑔 = 30 × 0.857 = 25.7𝑙𝑏. 𝑓𝑡 • If the extension is oriented at 90° to the wrench as shown in Figure 13 then no correction is needed because L2 is zero. Figure 14 – Using A Crowsfoot Adaptor L1 L2 = 0 Corrected Torque Setting Required No Correction Required. Aircraft Technical Manual Jabiru Aircraft Pty Ltd JTM001-14 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE 11 12 13 14 Date: 17 February 2025 Issued By: DM Page: 36 of 300 3.9.2 Torque Application Procedure • Good torque application technique is essential if an accurate bolt torque reading is going to be obtained. • Firstly the nut must be tightened smoothly. Any jerks or bumps can cause the torque reading to be obtained prematurely. • The torque must be obtained while the nut is turning. If you stop to reposition the torque wrench and then the required torque reading is obtained without the nut turning, the nut needs to be loosened a little and then tightened again so the torque reading is obtained while turning. • Unless specified otherwise all torque settings given in this manual are “dry” – i.e. no special lubricant is applied to the threads or parts. Where directed otherwise it is vital that the directions are followed exactly. Aircraft Technical Manual Jabiru Aircraft Pty Ltd JTM001-14 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE 11 12 13 14 Date: 17 February 2025 Issued By: DM Page: 37 of 300 4 Cleaning, Ground Handling & Storage (all J-Series) 4.1 Cleaning • Keeping the aircraft clean is important. Besides maintaining the appearance of the aircraft, cleaning makes inspection and maintenance easier. 4.1.1 Windshield And Windows • These should be cleaned carefully with plenty of fresh water and a mild detergent, using the palm of the hand to feel and dislodge any caked dirt or mud. A sponge, soft cloth or chamois may be used but only as a means of carrying water to the plastic. Rinse thoroughly then dry with a clean, moist chamois. DO NOT rub the plastic with a dry cloth as this builds up 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, Benzene, 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. 4.1.2 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. • Note that 4.1.3 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 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. 4.1.4 Aluminium Surfaces • The aluminium surfaces require a minimum of care, but should not be neglected. Wash and clean as detailed in paragraph 3.3.3 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. Aircraft Technical Manual Jabiru Aircraft Pty Ltd JTM001-14 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE 11 12 13 14 Date: 17 February 2025 Issued By: DM Page: 38 of 300 4.1.5 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 moisture. Ensure electrical components are protected against moisture. Caustic cleaning solutions should not be used. • Recommended cleaning procedure is lightly spray with degreasing fluid – after sealing coils and starter motor. WIPE clean with brush and cloth. 4.1.6 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 need at a later stage. 4.1.7 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 6C Landing Gear & Brakes. Discard cracked wheel halves, flanges or hubs and install new parts. 4.2 Ground Handling 4.2.1 Towing • All Jabiru aircraft are relatively light and should always be moved by hand. • Moving the aircraft is accomplished by using the wing struts, prop hub or landing gear struts as push points. CAUTION Do not use control surfaces to move the aircraft – Damage to the control system may result • When pushing or moving the aircraft, take care that you do not jam your fingers under the rudder or in the rudder hinge – remember that it is connected to the Nose Wheel and will move whenever the nose wheel direction changes. • 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. WARNING 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! 4.2.2 Jacking • Before jacking, ensure that it is as light as possible by removing luggage and any unnecessary fuel. 4.2.2.1 Jacking Main Gear 1. Remove main gear spat on the side to be jacked or both spats if both wheels to be jacked. 2. Where equipped, the fuel filler cap vent of the wing which is not being jacked may be blocked using a vent cap. This is to prevent fuel leaking onto the wing while the aircraft is jacked. Aircraft Technical Manual Jabiru Aircraft Pty Ltd JTM001-14 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE 11 12 13 14 Date: 17 February 2025 Issued By: DM Page: 39 of 300 CAUTION Where a vent cap is used ensure that it is large and highly visible to ensure it is removed on completion of the work. 3. 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 – lift at a point in line with the wing strut and about 1m (3 feet) outboard of the strut attachment. Be careful lifting close to the wing tip as the wing structure in this area is quite light and can easily be damaged by misplaced jacking loads. 4. 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. 5. Repeat for other side if necessary. 4.2.2.2 Jacking Nose Gear 1. Push down on Tail Plane (NOT THE ELEVATOR) until nose wheel is off the ground. 2. Place trestle or drum under rear fuselage together with absorbent material such as foam block, sandbags or a pillow. Alternately, a pillow or similar may be placed on the ground so that the ventral fin rests on it when the tail is pressed down. CAUTION If using a trestle, ensure it does not foul Ventral Fin. 3. Protect the paint of the horizontal tail using rags, pillows etc and weigh down tail plane with sandbags or similar heavy absorbent material – do not use anything hard as items like bricks are likely to damage the aircraft) material. Place weights as close as possible to the aircraft centreline and, where possible, apply weight symmetrically to both sides of the aircraft. CAUTION Do not lift using control surfaces. Damage to the control surface or control system may result. 4. Place a padded trestle or similar under the front of the fuselage immediately aft of the cowl outlet to ensure that the nose cannot drop down if the aircraft balance is disturbed. 4.2.3 Hoisting • This procedure should not be necessary for most service or maintenance procedures. Should hoisting be necessary: 1. Drain Fuel from both wings (Wet Wing models only) & Remove wings. 2. Fit shackles to wing support brackets (4 off). 3. Fit cables/rope to shackles and to a centre lift shackle. 4. Hoist only from this point ensuring that cables/ropes do not mark the top of the fuselage at corners above wing support brackets. • Refer to sections below for details on procedures for fuel draining, wing removal etc. 4.2.4 Levelling Longitudinal Levelling: • For longitudinal levelling use a spirit level on the lower door sills, or • For longitudinal levelling use a spirit level on the trim decal on the centre console. Lateral Levelling: • Apply a spirit level to the flap drive cross shaft, or • Apply a spirit level across the aircraft, referencing the join line of the cowl top & bottom halves. 4.2.5 Parking • It is strongly recommended that aircraft are stored in hangars wherever possible to minimise degradation caused by the elements and pests. • Parking precautions depend principally on local conditions. As a general precaution, check the wheels and tie the control handle back firmly with a seat belt to lock the controls. Park into the wind and tie down the aircraft as outlined in below if a hangar is not available. Aircraft Technical Manual Jabiru Aircraft Pty Ltd JTM001-14 J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE 11 12 13 14 Date: 17 February 2025 Issued By: DM Page: 40 of 300 • Whenever the aircraft is not active or being maintained it is strongly recommended that the following points are covered to prevent contamination and pest ingress: - Pitot tube - Static vent - Engine air inlet - Exhaust outlet - Fuel tank vent(s) WARNING Ensure that fuel tank vent covers are not tight-fitting. A tight cap can prevent fuel vapours escaping, pressurising the tank and severely damaging the tank and wings (for wing tanks). CAUTION Equip all covers with tags or other high-visibility devices to minimise the chance of inadvertent operation with covers still fitted. 4.2.6 Tie Down • When tying the aircraft down in the open, head into the wind if possible. Secure control surfaces by tying the control handle back firmly with the seat belts. • Then: 1. Tie ropes to the top end of each wing strut or to the strut tie-down lug (if equipped). 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. 4.3 Storage 4.3.1 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 7th day the propeller should be rotated through 5 revolutions, without running the engine. Leave the propeller in the horizontal position to ensure even distribution of liquids in the wood. If left in the vertical position, liquids will drain to the lower tip resulting in an unbalanced propeller. CAUTION Ensure that the Master and Ignition Switches are OFF before turning motor! WARNING Do not store MOGAS or fuels containing alcohol for longer than 14 days in a Jabiru aircraft. Refer to Service Letter JSL007 for details. • Store under cover, away from direct sunlight. • In addition to the normal parking covers detailed in Section 4.2.5, openings in the engine cowl and other similar openings should have protective covers fitted to prevent entry of foreign materials and pests (especially wasps). 4.3.2 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. 4.3.3 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: - For temporary storage, fill fuel tank with AVGAS (to prevent moisture accumulation).