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Aircraft Service Manual Jabiru J170-SP

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Aircraft Service Manual Jabiru J170-SP Jabiru J170-SP Special Light-Sport Aircraft Aircraft Service Manual Publication No. JSA SM170SP-A1 Copyright© 2010 Jabiru USA Sport Aircraft, LLC 2842 Highway 231 N Shelbyville, Tennessee 37160 USA JSA SM170SP Record of Revisions Revision Date Pages/Section Description Signature Jabiru USA Sport Original 1-July-2010 ALL Initial Release Aircraft, LLC A1 1-April-2011 1-3, 5-9, 11-12, Periodic Update; Jabiru USA Sport Appendix See Revision Aircraft, LLC Summary THIS PAGE INTENTIONALLY BLANK JSA SM170SP Revision Summary Section Pages Affected Revision Description Date ToC All A1 Updated Table of Contents 1-April-2012 1-9 1-9 A1 Corrected air filter part number 1-April-2012 1-15 1-12 A1 Revised approved fuels—ethanol prohibited 1-April-2012 2-1 2-1 A1 Added towbar information 1-April-2012 2-7 2-8 A1 Added parking/tiedown information 1-April-2012 2-10.9 2-12 A1 Reversed steps 6 and 7 1-April-2012 2-11.1 2-13 A1 Added window buffing information 1-April-2012 2-11.3 2-14 A1 Clarified paragraph 1-April-2012 2-12 2-15 A1 Clarified inspection procedures and defined “Line” 1-April-2012 and “Heavy” maintenance 3-8.2 3-13 A1 Added horizontal stabilizer replacement 1-April-2012 3-9.2 3-13 A1 Added vertical stabilizer replacement 1-April-2012 5-7.1 5-8 A1 Added brake O-ring fluid compatibility caution 1-April-2012 5-7 5-8 to 5-10 A1 Removed owner authorization for main wheels 1-April-2012 5-11 5-21 to 5-22 A1 Removed owner authorization for nose wheel 1-April-2012 5-11.5 5-22 A1 Removed reference to brake assembly 1-April-2012 6-4 6-7 to 6-9 A1 Added flap position sensor information 1-April-2012 7-19 7-30 A1 Removed owner authorization for head torque; 1-April-2012 Changed head torque value to 20 ft-lbs 8-8 8-9 A1 Added fuel system schematic diagram 1-April-2012 9-1 9-1 A1 Removed owner authorization for spinner removal; 1-April-2012 Added spinner replacement information; Added note on over-tightening spinner screws 9-7 9-6 A1 Removed owner authorization for wood prop 1-April-2012 torque 11-3.3 11-2 A1 Added instructions for recharging dead battery 1-April-2012 11-10.5 11-11 to 11-12 A1 Added instructions for GRT map features update 1-April-2012 11-10.8 11-15 A1 Added note on WxWorx radio static 1-April-2012 11-11 11-16 A1 Added note on WxWorx radio static 1-April-2012 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 Section Pages Affected Revision Description Date JSA SM170SP 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 SM170SP-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 1-April-2012 Foreword A0 1-April-2010 Section 1 A1 1-April-2012 Section 2 A1 1-April-2012 Section 3 A1 1-April-2012 Section 4 A0 1-April-2010 Section 5 A1 1-April-2012 Section 6 A1 1-April-2012 Section 7 A1 1-April-2012 Section 8 A1 1-April-2012 Section 9 A1 1-April-2012 Section 10 A0 1-April-2010 Section 11 A1 1-April-2012 Section 12 A1 1-April-2012 THIS PAGE INTENTIONALLY BLANK Jabiru J170-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………………………………………………...…….……………… 1-3 1-5 Weight & Balance Information………………………………………...………………. 1-3 1-6 Tire Inflation Pressures……………………………………………………………………. 1-3 1-7 Equipment List………………………………………………………………………………... 1-4 1-8 Sources to Purchase Parts……………………………………………………………….. 1-8 1-9 Disposable Replacement Parts………………………………………………………….. 1-8 1-10 Approved Oils and Capacities………………………………………………………….. 1-9 1-11 Recommended Fastener Torque Values…………………………………………... 1-9 1-12 General Safety Information…………………………………………………………….. 1-9 1-13 Reporting Safety of Flight or Service Difficulties……………………………….. 1-9 1-14 Extreme Climactic Conditions…………………………………………………………. 1-10 1-15 Approved Fuels…………………………………………………………………………….. 1-11 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 SM170SP-A1 Page 1 Jabiru J170-SP Aircraft Service Manual 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 2-12 Standard Practices for Inspection, Repair and Alteration...................... 2-15 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 Page 2 JSA SM170SP-A1 Jabiru J170-SP Aircraft Service Manual Section Title Page 5-9 Nose Wheel Fairing…………………………………………………………………………. 5-19 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…………………………………………………………………….. 6-3 6-4 Wing Flap Control System………………………………………………………………... 6-6 6-5 Elevator Control System…………………………………………………………………... 6-11 6-6 Elevator Trim Control System…………………………………………………………... 6-15 6-7 Rudder Control System……………………………………………………………………. 6-19 Section 7: Engine Systems 7-1 Engine……………………………………………………………………………………………. 7-1 7-2 Basic Engine Compartment Inspection………………………………………………. 7-3 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……………………………………………………………………….. 7-17 7-10 Carburetor……………………………………………………………………………………. 7-18 7-11 Induction Air System……………………………………………………………………... 7-19 7-12 Flexible Hoses……………………………………………………………………………….. 7-21 7-13 Throttle Control…………………………………………………………………………….. 7-22 7-14 Choke…………………………………………………………………………………………... 7-23 7-15 Carburetor Heat……………………………………………………………………………. 7-24 JSA SM170SP-A1 Page 3 Jabiru J170-SP Aircraft Service Manual Section Title Page 7-16 Ignition System…………………………………………………………………………….. 7-26 7-17 Spark Plugs…………………………………………………………………………………... 7-26 7-18 Exhaust System…………………………………………………………………………….. 7-27 7-19 Head Bolt Tension Check (Head Torque) Procedure………………………….. 7-29 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 Propeller...........................………………………………………………………………. 9-2 9-3 Balancing………………..……………………………………………………………………... 9-4 9-4 Propeller Tracking Procedure……………………………………………………………. 9-4 9-6 Approved Installations……………………………………………………………………... 9-4 9-7 Identification Stampings………………………………………………………………….. 9-4 9-8 Propeller Bolt Tension Check……………………………………………………………. 9-7 Section 10: Utility Systems 10-1 Cabin Heat……………………………………………………………………………………. 10-1 10-2 Cabin Ventilation…………………………………………………………………………... 10-2 10-3 Stall Warning System…………………………………………………………………….. 10-2 Page 4 JSA SM170SP-A1 Jabiru J170-SP Aircraft Service Manual Section Title Page Section 11: Electrical System and Instruments 11-1 General Description……………………………………………………………………….. 11-1 11-2
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