Name: Jabiru j120
Brand: Jabiru
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Aircraft Service Manual

Jabiru Aircraft Pty Ltd

JTM001-1

J120, J160, J170, J200/J400, J230/J430, J250/J450 Variants

REVISION

Dated: Nov 2011

Issued By: SW

Page: 107 of 233

Figure 72 – Brake Master Cylinder & Lever Assy (Type 1)

Figure 73 – Brake Master Cylinder & Lever Assy (Type 2)

1 Table of Contents2
- Table of Figures6
  - List of Tables10
2 Section 2 - Service Manual11
- Foreword / Applicability11
- List of Effective Pages / Issue Status14
- Introduction14
- Reading this Manual14
- Degree of Difficulty14
- Calibrations15
- Use-By Dates & Storage15
- General Description15
- Owner Maintenance16
- Aircraft Specifications16
- Centre of Gravity Limitations16
- Torque Values (in Fibreglass)16
- Standard Practices17
- Aircraft Structure17
- Engines18
- Aircraft Specifications19
- Figure 1 – J120-C General Arrangement20
- Figure 2 – J160 General Arrangement21
- Figure 3 – J170-C & Variants General Arrangement22
- Figure 4 – J170-D General Arrangement23
- Figure 5 – J200 / J400 General Arrangement24
- Figure 6 – J230 / J430 General Arrangement25
- Figure 7 – J250 / J450 General Arrangement26
3 Ground Handling & Storage27
- Towing27
- Jacking27
- Hoisting28
- Levelling28
- Parking28
- Tie down28
- Storage29
4 Inspection & Servicing31
- Basic Inspection Procedure31
- Mandatory Inspections & Lifed Items31
- Inspection Chart32
- Servicing36
- General Inspection Guidelines36
- Engine Pre-Inspection Run-Up37
- Propeller 100-Hourly37
- Engine Compartment 100-Hourly37
- Fuel System 100-Hourly39
- Landing Gear 100-Hourly39
- Airframe 100-Hourly40
- Control Systems 100-Hourly41
- Lubrication41
- Special Inspections - Propeller42
- Special Inspections - Weighing42
- Figure 9 – Weighing Diagram43
- Special Inspections - Control Cables44
- Special Inspections - Control Surfaces45
- Figure 11 – Rudder Gap Cross Section46
- Figure 12 – Aileron Clearance47
- Figure 15 – Scratches on Rudder48
- Special Inspections - Main Wheel Alignment49
- Figure 18 – Alignment Measurements50
- Figure 19 – Camber / Toe-In Adjustment51
- Special Inspections - Fuel Gauge Decal Setup52
- Figure 21 - Fuel Gauge Calibration Decal Parts53
- Special Inspections - Fuel Sender Calibration54
- Figure 24 – Fuel Line Clamps55
- Figure 25 – EMS Calibration Screen #156
5 Cleaning57
- Windshield and Windows57
- Interior Surfaces57
- Exterior Surfaces57
- Aluminium Surfaces57
- Engine and Engine Compartment58
- Propeller58
- Wheels58
6 Fuselage59
- Windshield and Windows59
- J160-Type Cabin Doors61
- J160-Type Cabin Door Latches61
- Figure 27 – J160-Type Door Hinge Assy62
- Figure 29 – J120-Type Door Assembly63
- Figure 31 – J160-Type Rear Door Assy64
- J200 Type Cabin Doors65
- J200-Type Cabin Door Latches66
- Figure 35 – J200-Type Front Door Assembly67
- Seats68
- Upholstery69
- Soundproofing69
- Safety Provisions69
7 Wings & Empennage70
- General70
- J120 Wings70
- J160 Wings71
- Figure 38 – J160 Wing Assembly Sheet 1 (Ser X)73
- Figure 40 – J160 Wing Assembly Sheet 1 (Ser XIV)74
- J170 Wings75
- Figure 43 – J170 Friese Aileron Installation76
- J200 Wings77
- J230 Wings78
- Figure 47 – J230 Wing Assembly Sheet 2 (Ser 13)79
- J250 / J450 Wings80
- Wing Struts81
- Landing Light(S)82
- Landing Light Adjustment (Night-Vfr Models)82
- Figure 52 – Night-VFR Lighting Aim Diagram83
- Dynon Pitot84
- Wing Inspection Window85
- Fin86
- Horizontal Stabiliser86
8 Landing Gear & Brakes87
- General Description87
- Main Undercarriage Removal (Jacking)87
- Main Wheel Fairing (Spats)88
- Main Gear Top Fairing (Speed Fairing)89
- Main Wheels89
- Figure 58 – Main Wheel to Leg Assy91
- Main Wheel Stub Axle92
- Wheel Balancing93
- Main Gear Leg93
- Trouble Shooting - Main Undercarriage94
- Figure 61 – Main Undercarriage (Type 1)95
- Nose Wheel Speed Fairing (Spat)96
- Nose Wheel96
- Figure 63 – Nose Wheel Hub Assembly97
- Nose Wheel Steering / Centring System98
- Nose Undercarriage Leg99
- Trouble Shooting - Nose Leg101
- Nose Wheel Balancing102
- Figure 68 – Nose Leg Assy103
- Nose Leg Housing104
- Brake Master Cylinder105
- Figure 72 – Brake Master Cylinder & Lever Assy (Type 1)107
- Hydraulic Brake Lines108
- Wheel Brakes108
- Parking Brake109
- Brake Lining Installation109
- Brake System Bleeding109
- Brake Pad Adjustment110
- Brake Disc Wear Limit110
- Trouble Shooting - Brakes111
- Figure 75 – Single Calliper Detail (Non Quick Change)112
9 Aileron Control System113
- Figure 78 – Aileron System Schematic – Type 2114
10 Wing Flap Control System123
- Figure 93 – J200 Family Manual Flap System Sheet 1124
11 Elevator Control System137
- Figure 110 – Elevator Control System – Type 1, Sheet 2138
12 Rudder Control System148
- Rudder Pedal System148
- Figure 121 – Rudder Pedal - Non-Adjustable149
- Figure 122 – Adjustable Rudder Pedal Assy – Type 1150
- Rudder Centring System151
- Figure 125 – Steering/Rudder Centring Assy – Type 2152
- Figure 127 – Steering/Rudder Assy – Type 3 (Sheet 2)153
- Rudder154
- Rudder Control Cable155
- Rudder Balance156
- Rigging156
13 Engine & Engine Installation157
- Engine Cowls157
- Figure 131 – Typical Upper Cowl Assy158
- Engine159
- Flexible Hoses159
- Figure 133 – Fuel Hose Assy – Engine Bay160
- Cooling Air Baffles161
- Engine Mount162
- Engine Fuel System163
- Engine Throttle Control163
- Figure 135 – Throttle Assy (Seat Mounted)164
- Figure 136 – Throttle Assy (Panel Mounted)165
- Choke Cable166
- Air Intake System & Carburetor Heat167
- 13.10 Exhaust System168
- Figure 141 – 2200 Exhaust System169
- Figure 142 – 3300 Exhaust System Type 1170
- 13.11 Cabin Heater System171
- Figure 144 – Cabin Heat Mixer Assembly172
- 13.12 Extreme Climatic Conditions173
- Figure 147 – 2200 Engine Installation174
- Figure 149 – J200 Family Engine Installation Type 1175
14 Fuel System176
- Description176
- Figure 151 – In-Cabin Fuel System177
- Figure 153 – Fuel System Schematic – Type 2178
- Figure 155 – Fuel System Schematic – Type 4179
- Fuel Lines180
- Figure 157 – Sample Fuel Line Details181
- Fuel Tanks182
- Figure 160 – Header Tank Installation – Type 1183
- Fuel Vents184
- Fuel Shut-Off Valve185
- Fuel Gauges186
- Table 14 – Trouble Shooting – Fuel Gauge187
- Figure 165 – Fuel Gauge – Electric Sender Installation188
- Fuel Filters189
- Fuel Pumps189
15 Instruments & Instrument Systems191
- General191
- Instrument Panel191
- Figure 168 – Instrument Panel Layout Type 1192
- Instrument Panel Mount193
- Instruments194
- Pitot & Static Systems195
- Figure 174 – Static Probe System Assembly196
- Figure 175 – Pitot / Static Water Trap197
- Table 15 – Trouble Shooting – Pitot-Static System199
- Table 16 – Trouble Shooting – Airspeed Indicator200
- Table 18 – Trouble Shooting – Vertical Speed Indicator201
- Alternate Static Source202
- Analogue Tachometer203
- Figure 179 – Hall Effect Sensor Wiring (for Tach with Jabiru Logo on Face)204
- Analogue Engine Gauges205
- Digital Displays206
- 15.10 Magnetic Compass207
- Gyro Instrument Package (Option)207
16 Section 14 - Electrical Systems208
- Electrical Power Supply System208
- Figure 181 – Wiring Diagram Sheet 1209
- Figure 182 – Wiring Diagram Sheet 2210
- Minor Electrical Equipment211
- Battery System212
- Electrical Load Analysis (Ela)213
- Radio Installation213
- Figure 186 – Second VHF Antenna Installation (J120 / J160 Families)214
- Transponder215
18 Painting & Finishing216
- Exterior216
19 Placards218
- Model-Specific Decals218
- Placards General220
20 Fairings225
- Description225
22 Appendix IV - Propeller Service Manual226
- Certified Propeller Models226
- Approved Installations226
- Identification Stampings226
- Description227
- Installation227
- Figure 189 – Propeller Installation228
- To Remove Existing Propeller229
- To Assemble and Replace Propeller Assembly229
- Servicing and Repairs229
- Propeller Balancing Procedure230
23 Appendix - Airworthiness Limitations231
- General232
- Interior Flame Retardant Maintenance Limitations232
- Composite Inspection & Maintenance232
- REVISION 1 Dated: Nov 2011 Issued By: SW Page: 2 of233
- REVISION 1 Dated: Nov 2011 Issued By: SW Page: 4 of233
- Control Surface Balancing233

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Jabiru j120 Specifications

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Brand	Jabiru
Model	j120
Category	Aircrafts
Language	English

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