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Aircraft Service Manual J230-SP and J250-SP

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Aircraft Service Manual J230-SP and J250-SP J230-SP and J250-SP Special Light-Sport Aircraft Aircraft Service Manual Publication No. JSA SM230SP-A1 Copyright© 2011 Jabiru USA Sport Aircraft, LLC 2842 Highway 231 N Shelbyville, Tennessee 37160 USA JSA SM230SP Record of Revisions Revision Date Section Description Signature Initial Release Jabiru USA Sport Original 1-April-2010 ALL Aircraft, LLC 1-3, 5-9, 11- Periodic Update; See A1 16-May-2011 12, Appendix Revision Summary THIS PAGE INTENTIONALLY BLANK JSA SM230SP Revision Summary Section Pages Affected Revision Description Date ToC All A1 Updated Table of Contents 16-May-2011 1-7 1-6 A1 Added GRT/Garmin Combo Panel 16-May-2011 1-9 1-9 A1 Corrected air filter part number 16-May-2011 1-15 1-12 A1 Revised approved fuels—ethanol prohibited 16-May-2011 2-1 2-1 A1 Added towbar information 16-May-2011 2-7 2-8 A1 Added parking/tiedown information 16-May-2011 2-10.9 2-12 A1 Reversed steps 6 and 7 16-May-2011 2-11.1 2-13 A1 Added window buffing information 16-May-2011 2-11.3 2-14 A1 Clarified paragraph 16-May-2011 3-8.2 3-13 A1 Added horizontal stabilizer replacement 16-May-2011 3-9.2 3-13 A1 Added vertical stabilizer replacement 16-May-2011 5-7.1 5-8 A1 Added brake O-ring fluid compatibility caution 16-May-2011 5-7 5-8 to 5-10 A1 Removed owner authorization for main wheels 16-May-2011 5-11 5-21 to 5-22 A1 Removed owner authorization for nose wheel 16-May-2011 5-11.5 5-22 A1 Removed reference to brake assembly 16-May-2011 6-4 6-7 to 6-9 A1 Added flap position sensor information 16-May-2011 7-19 7-30 A1 Removed owner authorization for head torque; 16-May-2011 Changed head torque value to 20 ft-lbs 8-1 8-1 A1 Updated fuel system description 16-May-2011 8-3 8-2 A1 Updated fuel vent line description 16-May-2011 8-7 8-6 A1 Added G3X information to fuel gauge description 16-May-2011 8-8 8-9 to 8-10 A1 Added fuel system schematic diagrams 16-May-2011 9-1 9-1 A1 Removed owner authorization for spinner removal; 16-May-2011 Added spinner replacement information; Added note on over-tightening spinner screws 9-8.2 9-9 A1 Removed owner authorization for wood prop 16-May-2011 torque 9-8.3 9-10 A1 Removed owner authorization for carbon prop 16-May-2011 clamp bolt torque 11-3.3 11-2 A1 Added instructions for recharging dead battery 16-May-2011 11-10.5 11-11 to 11-12 A1 Added instructions for GRT map features update 16-May-2011 11-10.6 11-13 A1 Added text to include Garmin magnetometer 16-May-2011 11-10.8 11-15 A1 Added note on WxWorx radio static 16-May-2011 11-11 11-16 A1 Added note on WxWorx radio static 16-May-2011 Section Pages Affected Revision Description Date 11-14 11-21 A1 Added PM3000 to intercom description 16-May-2011 11-15.1 11-21 A1 Added autopilot pitch cable note 16-May-2011 12-1 12-1 A1 Added note about structural repair authorization 16-May-2011 12-3 12-2 A1 Revised structural fiberglass repair section 16-May-2011 12-4 12-4 to 12-6 A1 Added paint codes for base white 16-May-2011 7-16 7-25 A2 Added reference to rotor service bulletin, JSA-009 28-Feb-2013 JSA SM230SP-A1 List of Effective Sections The table below shows the effective sections and dates for the most current revision of this manual. Appendices are issued and controlled separately by the Appendix Log. The revision number is found in the footer of each page after the document number. For example, Revision A1 would look like JSA SM230SP-A1. A list of affected pages is found in the Revision Summary in the front of this manual. Section Revision Date Table of Contents A1 16-May-2011 Foreword A0 1-April-2010 Section 1 A1 16-May-2011 Section 2 A1 16-May-2011 Section 3 A1 16-May-2011 Section 4 A0 1-April-2010 Section 5 A1 16-May-2011 Section 6 A1 16-May-2011 Section 7 A2 28-Feb-2013 Section 8 A1 16-May-2011 Section 9 A1 16-May-2011 Section 10 A0 1-April-2010 Section 11 A1 16-May-2011 Section 12 A1 16-May-2011 THIS PAGE INTENTIONALLY BLANK Jabiru J230-SP/J250-SP Aircraft Service Manual Table of Contents Section Title Page Foreword……………………………………………………………………………………………………...……………. i Section 1: General Description 1-1 Aircraft Description………………………………….………………………………………. 1-1 1-2 Aircraft Specifications…………………………………….………………………………... 1-1 1-3 Three-View Drawings…………………………………………...…………………………. 1-2 1-4 Engine Specifications………………………………………………...…….……………… 1-4 1-5 Weight & Balance Information………………………………………...………………. 1-4 1-6 Tire Inflation Pressures……………………………………………………………………. 1-4 1-7 Equipment List………………………………………………………………………………... 1-5 1-8 Sources to Purchase Parts……………………………………………………………….. 1-9 1-9 Disposable Replacement Parts………………………………………………………….. 1-9 1-10 Approved Oils and Capacities………………………………………………………….. 1-10 1-11 Recommended Fastener Torque Values…………………………………………... 1-10 1-12 General Safety Information…………………………………………………………….. 1-11 1-13 Reporting Safety of Flight or Service Difficulties……………………………….. 1-11 1-14 Extreme Climactic Conditions…………………………………………………………. 1-11 1-15 Approved Fuels…………………………………………………………………………….. 1-12 Section 2: General Care and Inspection 2-1 Ground Handling…………………………………………………………………………….. 2-1 2-2 Jacking the Aircraft………………………………………………………………………….. 2-3 2-3 Jacking Nose Gear…………………………………………………………………………... 2-4 2-4 Hoisting………………………………………………………………………………………….. 2-4 2-5 Leveling…………………………………………………………………………………………. 2-5 2-6 Weighing the Aircraft………………………………………………………………………. 2-5 2-7 Parking and Tiedown……………………………………………………………………….. 2-8 JSA SM230SP-A1 Page 1 Jabiru J230-SP/J250-SP Section Title Page 2-8 Storage………………………………………………………………………………………….. 2-8 2-9 Inspection Intervals…………………………………………………………………………. 2-11 2-10 General Inspection Guidelines…………………………………………………………. 2-11 2-11 Cleaning……………………………………………………………………………………….. 2-13 Section 3: Fuselage Structure 3-1 Description……………………………………………………………………………………... 3-1 3-2 Windows………………………………………………………………………………………... 3-1 3-3 Doors…………………………………………………………………………………………….. 3-5 3-4 Seats……………………………………………………………………………………………... 3-11 3-5 Upholstery………………………………………………………………………………………. 3-12 3-6 Baggage Area…………………………………………………………………………………. 3-12 3-7 Seat Belts………………………………………………………………………………………. 3-12 3-8 Horizontal Stabilizer………………………………………………………………………... 3-12 3-9 Vertical Stabilizer…………………………………………………………………………….. 3-13 Section 4: Wing Structure 4-1 Wings…………………………………………………………………………………………….. 4-1 4-2 Wing Struts…………………………………………………………………………………….. 4-4 Section 5: Landing Gear and Brakes 5-1 General Description…………………………………………………………………………. 5-1 5-2 Landing Gear Troubleshooting Chart…………………………………………………. 5-1 5-3 Main Wheel Fairings………………………………………………………………………... 5-2 5-4 Main Gear Top Fairing/Lower Strut Fairing…………………………………………. 5-4 5-5 Main Gear Leg Assembly………………………………………………………………….. 5-4 5-6 Main Wheel Stub Axle………………………………………………………………………. 5-6 5-7 Main Wheels and Brakes………………………………………………………………….. 5-8 5-8 Master Cylinder/Parking Brake Assembly……………………………………………. 5-14 5-9 Nose Wheel Fairing…………………………………………………………………………. 5-19 Page 2 JSA SM230SP-A1 Jabiru J230-SP/J250-SP Aircraft Service Manual Section Title Page 5-10 Nose Gear Leg………………………………………………………………………………. 5-19 5-11 Nose Wheel…………………………………………………………………………………… 5-21 Section 6: Flight Controls 6-1 Control Column……………………………………………………………………………….. 6-1 6-2 Control Cables………………………………………………………………………………… 6-1 6-3 Aileron Control System…………………………………………………………………….. 6-4 6-4 Wing Flap Control System………………………………………………………………... 6-7 6-5 Elevator Control System…………………………………………………………………... 6-12 6-6 Elevator Trim Control System…………………………………………………………... 6-16 6-7 Rudder Control System……………………………………………………………………. 6-20 Section 7: Engine Systems 7-1 Engine……………………………………………………………………………………………. 7-1 7-2 Basic Engine Compartment Inspection………………………………………………. 7-2 7-3 Engine Cowls………………………………………………………………………………….. 7-5 7-4 Cooling Air Baffles…………………………………………………………………………... 7-6 7-5 Engine Mount…………………………………………………………………………………. 7-10 7-6 Shock Mounts…………………………………………………………………………………. 7-10 7-7 Oil System………………………………………………………………………………………. 7-12 7-8 Oil Cooling System………………………………………………………………………….. 7-14 7-9 Oil Recovery System……………………………………………………………………….. 7-16 7-10 Carburetor……………………………………………………………………………………. 7-17 7-11 Induction Air System……………………………………………………………………... 7-20 7-12 Flexible Hoses……………………………………………………………………………….. 7-20 7-13 Throttle Control…………………………………………………………………………….. 7-22 7-14 Choke…………………………………………………………………………………………... 7-23 7-15 Carburetor Heat……………………………………………………………………………. 7-24 JSA SM230SP-A1 Page 3 Jabiru J230-SP/J250-SP Aircraft Service Manual Section Title Page 7-16 Ignition System…………………………………………………………………………….. 7-25 7-17 Spark Plugs…………………………………………………………………………………... 7-25 7-18 Exhaust System…………………………………………………………………………….. 7-26 7-19 Head Bolt Tension Check (Head Torque) Procedure………………………….. 7-30 Section 8: Fuel System 8-1 General Description…………………………………………………………………………. 8-1 8-2 Fuel Tanks……………………………………………………………………………………... 8-1 8-3 Fuel and Vent Lines…………………………………………………………………………. 8-2 8-4 Fuel Pumps…………………………………………………………………………………….. 8-3 8-5 Fuel Filters……………………………………………………………………………………... 8-4 8-6 Fuel Sump Drains……………………………………………………………………………. 8-5 8-7 Fuel Gauges……………………………………………………………………………………. 8-6 8-8 Fuel Draining Procedure…………………………………………………………………... 8-8 Section 9: Propeller & Spinner 9-1 Spinner Assembly……………………………………………………………………………. 9-1 9-2 Fixed-Pitch Wood Propeller………………………………………………………………. 9-2 9-3 Ground-Adjustable Carbon Propeller………………………………………………….. 9-4 9-4 Balancing………………..……………………………………………………………………... 9-6 9-5 Propeller Tracking Procedure……………………………………………………………. 9-6 9-6 Approved Installations……………………………………………………………………... 9-6 9-7 Identification
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