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Aircraft Technical Manual

Jabiru Aircraft Pty Ltd

JTM001-5

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

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ISSUE

Dated: 29th October 2014

Issued By: AS

Page: 244 of 298

WARNING

When removing fascia it is common for some wires connecting to switches on the bottom of

the panel to be dislodged. Ensure all wires are securely re-connected before fitting fascia.

Take care not to strain, bend or damage any wires or lines.

While working within the instrument panel ensure that the starter motor system or main

battery is disconnected so that the motor cannot be started accidentally via a short or similar.

Figure 182 – Instrument Panel Layout Type 1 (all J-Series)

Figure 183 – Instrument Panel Layout Type 2 (all J-Series)

Main Page

Default Chapter2
- Table of Contents2
  - Table of Figures6
  - List of Tables11
Section 2 - General Information12
- Foreword / Applicability12
- List of Effective Pages / Issue Status15
- Introduction15
- Reading this Manual15
- Degree of Difficulty16
- Use-By Dates & Storage16
- General Description16
- Owner Maintenance17
- Aircraft Specifications17
- Centre of Gravity Limitations17
- Standard Practices17
- Aircraft Structure18
- Engines18
- Equipment List19
- Source of Purchase Parts20
- List of Disposable Replacement Parts20
- Aircraft Specifications21
- Figure 1 – J120-C General Arrangement22
- Figure 2 – J160 General Arrangement23
- Figure 3 – J170-C & Variants General Arrangement24
- Figure 4 – J170-D General Arrangement25
- Figure 5 – J200 / J400 General Arrangement26
- Figure 6 – J230 / J430 General Arrangement27
- Figure 7 – J250 / J450 General Arrangement28
- Torque Values (in Fibreglass)29
Maintainer Requirements30
- Facilities30
- Training30
- Rating30
- Experience30
- Tool & Gauge Control30
- Tools30
- Equipment31
- General31
- Special Tools & Compounds32
- Figure 9 – Optical Tachometer33
- Figure 13 – Torque Wrench & Crowsfoot Adaptor Setting 234
Cleaning, Ground Handling & Storage36
- Cleaning36
- Ground Handling37
- Storage39
Inspection & Servicing42
- Service Interval Tolerance42
- Basic Inspection Procedure42
- Mandatory Inspections & Lifed Items42
- Figure 15 – Undercarriage43
- Inspection Chart44
- Servicing48
- General Inspection Guidelines48
- Engine Pre-Inspection Run-Up49
- Propeller 100-Hourly49
- Engine Compartment 100-Hourly49
- Fuel System 100-Hourly51
- Landing Gear 100-Hourly52
- Airframe 100-Hourly53
- Control Systems 100-Hourly54
- Lubrication54
- Special Inspections - Propeller54
- Special Inspections - Weighing55
- Figure 16 – Weighing Diagram56
- Special Inspections - Control Cables57
- Special Inspections - Control Surfaces58
- Figure 17 – Normal and Jammed Control Illustration59
- Figure 18 – Rudder Gap Cross Section60
- Figure 20 – Test Load Application61
- Figure 22 – Scratches on Rudder62
- Special Inspections - Main Wheel Alignment63
- Figure 24 – Alignment Straight Edge in Position64
- Figure 26 – Camber / Toe-In Adjustment65
- Special Inspections - Fuel Gauge Decal Setup66
- Figure 27 – Max Empty (Left) and Acceptable Empty (Right) Indications67
- Special Inspections - Fuel Sender Calibration68
- Figure 31 – Fuel Line Clamps69
- Figure 32 – EMS Calibration Screen #170
- Special Inspections - Wing & Strut Bush Service71
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- Figure 34 – Wing Lug Versions73
- Figure 35 – Bond Details74
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Structures76
Fuselage77
- Windshield and Windows77
- Shockwatch Indicator78
- Figure 36 – Shockwatch Indicator79
- J160-Type Cabin Doors80
- J160-Type Cabin Door Latches80
- Figure 37 – J160-Type Door Hinge Assy81
- Figure 39 – J120-Type Door Assembly82
- Figure 41 – J160-Type Rear Door Assy83
- J200 Type Cabin Doors84
- J200-Type Cabin Door Latches85
- Figure 45 – J200-Type Front Door Assembly86
- Seats87
- Upholstery88
- Soundproofing88
- Safety Provisions88
Wings & Empennage89
- General89
- J120 Wings89
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- J160 Wings91
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- Figure 48 – J160 Wing Assembly Sheet 1 (Ser X)93
- Figure 50 – J160 Wing Assembly Sheet 1 (Ser XIV)94
- J170 Wings95
- Figure 53 – J170 Friese Aileron Installation96
- Figure 54 – J170-UL Wing Assy Sheet 1 (Ser IX)97
- J200 Wings98
- J230 Wings98
- Figure 56 – J230 Wing Assembly Sheet 1 (Ser 13)99
- J250 / J450 Wings100
- Figure 58 – J230 Wing Assembly Sheet 3 (Ser 13)100
- Figure 59 – J250 Family Wing Assy (SP-I Type)101
- Wing Struts102
- Landing Light(S)103
- Landing Light Adjustment (Night-Vfr Models)103
- Figure 61 – Light Installed (Left) & Slotted Hole in Housing104
- Figure 63 – Night-VFR Landing / Taxi Light Assy105
- Dynon Pitot106
- Wing Inspection Window107
- Fin108
- Horizontal Stabiliser108
Landing Gear & Brakes109
- General Description109
- Main Undercarriage Removal (Jacking)109
- Main Wheel Fairing (Spats)110
- Main Gear Top Fairing (Speed Fairing)111
- Main Wheels112
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- Figure 68 – Main Wheel to Leg Assy114
- Main Wheel Stub Axle115
- Wheel Balancing116
- Main Gear Leg116
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- Trouble Shooting - Main Undercarriage118
- Nose Wheel Speed Fairing (Spat)119
- Nose Wheel120
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- Nose Wheel Steering / Centring System122
- Figure 74 – Nose Leg Soft Link Assy (J160 Family)123
- Nose Undercarriage Leg124
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- Trouble Shooting - Nose Leg127
- Nose Wheel Balancing127
- Figure 77 – 4" Wheel Nose Leg Assy128
- Nose Leg Housing129
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- Figure 81 – Machined Nose Leg Housing131
- Brake Master Cylinder132
- Figure 82 – Brake Master Cylinder & Lever Assy (Type 1)133
- Hydraulic Brake Lines134
- Wheel Brakes134
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- Parking Brake136
- Brake Pad Lining Installation (Solid Rivet Retained Pads Only)136
- Brake System Bleeding137
- Brake Pad Adjustment137
- Brake Disc Wear Limit138
- Trouble Shooting - Brakes138
- Figure 84 – Dual Calliper Brake Assy (Quick Change Pads)139
- Figure 86 – Single Calliper (Legacy Brake System)140
Aileron Control System141
- Figure 88 – Aileron System Schematic – Type 2142
Wing Flap Control System154
- Figure 103 – J200 Family Manual Flap System Sheet 1155
Elevator Control System171
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- Control Column173
- Elevator173
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- Elevator Control Cables176
- Rigging176
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- Elevator Trim - Control Lever Assy178
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- Elevator Trim - Aft Assembly180
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- Trim Control Cables182
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Rudder Control System184
- Rudder Pedal System184
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- Rudder Centring System187
- Rudder191
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- Rudder Control Cable193
- Rudder Balance193
- Rigging194
Engine & Engine Installation195
- Engine Cowls195
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- Engine198
- Flexible Hoses199
- Cooling Air Baffles200
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- Engine Mount202
- Engine Fuel System203
- Engine Throttle Control204
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- Choke Cable207
- Air Intake System & Carburettor Heat208
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- Exhaust System210
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- Cabin Heater System213
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- Extreme Climatic Conditions215
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Fuel System219
- Description219
- Fuel Lines223
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- Fuel Tanks225
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- Fuel Vents228
- Fuel Shut-Off Valve229
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- Fuel Gauges231
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- Fuel Filters234
- Fuel Pumps234
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Propeller Service Manual236
- Certified Propeller Models236
- Approved Installations236
- Identification Stampings237
- Description238
- Installation238
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- To Remove Existing Propeller241
- To Assemble and Replace Propeller Assembly241
- Servicing and Repairs241
- Propeller Balancing Procedure242
Utility Systems242
Instruments & Instrument Systems243
- General243
- Instrument Panel243
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- Instrument Panel Mount246
- Instruments247
- Pitot & Static Systems247
- Alternate Static Source256
- Analogue Tachometer257
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- Analogue Engine Gauges260
- Digital Displays261
- Magnetic Compass262
- Gyro Instrument Package (Option)262
Electrical Systems263
- Electrical Power Supply System263
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- Minor Electrical Equipment266
- Battery System267
- Electrical Load Analysis (Ela)268
- Radio Installation268
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- Transponder270
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Structural Repair272
Painting & Finishing273
- Exterior273
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Placards275
- Model-Specific Decals275
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- Placards General277
Fairings282
- Description282
18 Revisions283
19 Feedback and Reporting284
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Appendix A - Worksheets286
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- This Document Is Controlled While It Remains on the Jabiru Server. Once this no Longer Applies the Document Becomes Uncontrolled290
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Appendix B - Airworthiness Limitations296
- General297
- Interior Flame Retardant Maintenance Limitations297
- Composite Inspection & Maintenance297
- Engine Airworthiness Limitations297
- Control Surface Balancing297
- ISSUE Dated: 29Th October 2014 Issued By: as Page: 2 of298
- ISSUE Dated: 29Th October 2014 Issued By: as Page: 4 of298
- Mandatory Inspections and Replacements298

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