Jabiru j430 - 6 STRUCTURES

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Aircraft Technical Manual

Jabiru Aircraft Pty Ltd

JTM001-5

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

Dated: 29th October 2014

Issued By: AS

Page: 76 of 298

Do Not apply any load to the bush until it has cured.

Do Not use rapid-set (i.e. 5-miniute) epoxy.

6 Structures (all J-Series)

A description of and instructions for the maintenance, repair and alteration of the aircraft primary

structures is provided in the following section for each specific structural group

 Fuselage – Section 6A

 Wings and Empennage – Section 6B

 Landing gear and Brakes – Section 6C

 Aileron Control System – Section 6D

 Wing Flap Control System – Section 6E

 Elevator Control System – Section 6F

 Rudder Control System – Section 6G

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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- This Document Is Controlled While It Remains on the Jabiru Server. Once this no Longer Applies the Document Becomes Uncontrolled218
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 Uncontrolled289
- This Document Is Controlled While It Remains on the Jabiru Server. Once this no Longer Applies the Document Becomes Uncontrolled290
- This Document Is Controlled While It Remains on the Jabiru Server. Once this no Longer Applies the Document Becomes Uncontrolled291
- This Document Is Controlled While It Remains on the Jabiru Server. Once this no Longer Applies the Document Becomes Uncontrolled292
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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

Jabiru j430 - 6 STRUCTURES

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