INSTRUCTION AND MAINTENANCE MANUAL FOR JABIRU 2200 ...

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Jabiru Aircraft Pty LtdInstruction & Maintenance ManualJabiru 2200 Aircraft EngineHydraulic Valve Lifter Models1 Table of Contents1 TABLE OF CONTENTS ........................................................................................................... 21.1 TABLE OF FIGURES ................................................................................................................................. 51.2 LIST OF EFFECTIVE PAGES ..................................................................................................................... 62 DESCRIPTION ......................................................................................................................... 72.1 MODEL ................................................................................................................................................... 72.2 GENERAL INFORMATION .......................................................................................................................... 72.3 GENERAL DESCRIPTION .......................................................................................................................... 82.4 DETAILS ............................................................................................................................................... 102.5 MANUFACTURER................................................................................................................................... 102.6 MANUALS ............................................................................................................................................. 103 SPECIFICATIONS ................................................................................................................. 113.1 ENGINE MODELS .................................................................................................................................. 113.1.1 2200J ........................................................................................................................................................ 113.1.2 2200B ........................................................................................................................................................ 113.1.3 2200C ........................................................................................................................................................ 113.1.4 2200A ........................................................................................................................................................ 113.2 GENERAL SPECIFICATIONS & EQUIPMENT .............................................................................................. 113.3 PERFORMANCE .................................................................................................................................... 123.3.1 Engine Ratings ......................................................................................................................................... 123.4 FUEL .................................................................................................................................................... 133.5 LUBRICANT ........................................................................................................................................... 133.5.1 Run in Period ............................................................................................................................................ 133.5.2 Normal Operations .................................................................................................................................... 133.6 COOLING SYSTEM ................................................................................................................................ 133.7 OPERATING SPEEDS AND LIMITS ........................................................................................................... 143.7.1 Ground Operating Limits ........................................................................................................................... 143.7.2 In-Flight Operating Limits .......................................................................................................................... 143.8 PROPELLER SELECTION & SPECIFICATIONS ........................................................................................... 143.9 DIMENSIONS......................................................................................................................................... 153.10 DENOMINATION OF CYLINDERS ......................................................................................................... 163.11 DISTRIBUTOR CYLINDER MAP ............................................................................................................ 163.12 POWER CURVE ................................................................................................................................. 174 OPERATING INSTRUCTIONS ............................................................................................... 184.1 PRE-START CHECKS ............................................................................................................................ 184.2 STARTING PROCEDURE ........................................................................................................................ 184.2.1 Cold Engine ............................................................................................................................................... 184.2.2 Warm Engine ............................................................................................................................................ 184.3 WARMING UP PERIOD, GROUND TEST .................................................................................................. 184.4 TAKE-OFF ............................................................................................................................................ 194.5 ENGINE STOP ....................................................................................................................................... 194.6 ENGINE STOP AND START DURING FLIGHT ............................................................................................ 195 CHECKS ON ENGINE & INSTALLATION ............................................................................. 205.1 DAILY CHECKS ..................................................................................................................................... 205.2 PERIODIC CHECKS ............................................................................................................................... 215.3 CHECK AFTER INITIAL 10 HOURS ........................................................................................................... 215.4 CHECK AFTER INITIAL 25 HOURS .......................................................................................................... 225.5 50 HOURS CHECK ................................................................................................................................ 225.6 100 HOURS CHECK .............................................................................................................................. 235.7 TBO .................................................................................................................................................... 235.8 ENGINE PRESERVATION ........................................................................................................................ 235.8.1 Flyable Storage ......................................................................................................................................... 235.8.2 Returning Engine to Service From Flyable Storage .................................................................................. 245.8.3 Temporary Storage ................................................................................................................................... 245.8.4 Inspection During Storage ......................................................................................................................... 255.8.5 Indefinite Storage ...................................................................................................................................... 255.8.6 Returning Engine to Service After Temporary Storage ............................................................................. 25This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled.REVISION 0 1 2 3 4 5 6 7 8 9 Dated : June 2010 Issued By: DPS Page: 2 of 116L:\files\Manuals_For_Products\Engine_Manuals\Transition\JEM2204-9_I&M_unsigned.docx
Jabiru Aircraft Pty LtdInstruction & Maintenance ManualJabiru 2200 Aircraft EngineHydraulic Valve Lifter Models5.8.7 New Engine Storage ................................................................................................................................. 265.8.8 Operation in Winter ................................................................................................................................... 265.8.9 Carburettor Icing ....................................................................................................................................... 265.8.9.1 Icing Due to Water in fuel ...................................................................................................................... 265.8.9.2 Icing Due to High Air Humidity. ............................................................................................................. 276 MAINTENANCE ..................................................................................................................... 286.1 LUBRICATION SYSTEM .......................................................................................................................... 286.2 AIR INTAKE FILTER ............................................................................................................................... 286.3 CARBURETOR ADJUSTMENT .................................................................................................................. 286.4 COMPRESSION CHECK .......................................................................................................................... 296.4.1 Compression Gauge: ................................................................................................................................ 296.4.2 Pressure Differential Test: ......................................................................................................................... 296.5 IGNITION SYSTEM ................................................................................................................................. 306.5.1 High-Tension Lead Connections ............................................................................................................... 306.5.2 Spark Plugs ............................................................................................................................................... 316.6 EXHAUST SYSTEM ................................................................................................................................ 316.7 BOLTS AND NUTS ................................................................................................................................. 316.8 TAPPET ADJUSTMENT / HYDRAULIC VALVE LIFTERS ............................................................................... 316.9 HEAD BOLTS ........................................................................................................................................ 336.10 TACHOMETER AND SENDER ............................................................................................................... 336.11 ADDITIONAL CHECKS – POST SERVICE .............................................................................................. 336.11.1 Propeller .................................................................................................................................................... 346.11.2 Engine ....................................................................................................................................................... 346.11.3 Fuel System .............................................................................................................................................. 346.12 ENGINE INSPECTION CHART .............................................................................................................. 357 SERVICE & REPAIR .............................................................................................................. 377.1 SERVICE INTERVAL TOLERANCE ............................................................................................................ 377.2 ENGINE OVERHAUL AND TBO ............................................................................................................... 377.2.1 Full Overhaul ............................................................................................................................................. 377.2.2 Top End Overhaul ..................................................................................................................................... 387.3 ENGINE REMOVAL PROCEDURE ............................................................................................................ 387.4 ENGINE DISASSEMBLY.................................................................................................................... 397.5 2200 ENGINE OVERHAUL ................................................................................................................ 427.5.1 Jabiru 2200 Component Inspection and Assembly Procedure ................................................................. 437.5.1.1 Sub-Assembly A - Crankshaft, Prop Mount and Con-Rods................................................................... 437.5.1.2 Sub-Assembly B – Crankcase and Camshaft ....................................................................................... 457.5.1.3 Crankcase Decking / Machining ............................................................................................................ 487.5.1.4 Sub-Assembly C - Pistons, Cylinders and Cylinder Heads ................................................................... 487.5.1.5 Sub-Assembly D - Sump and Oil Pump ................................................................................................ 547.5.1.6 Sub-Assembly E – Flywheel, Ignition Coils, Alternator & Alternator Operation ..................................... 557.5.1.7 Permanent Magnet Alternator (PMA) Operation ................................................................................... 587.5.1.8 Regulator ............................................................................................................................................... 597.5.1.9 Sub-Assembly F - Gear Case ............................................................................................................... 607.5.1.10 Sub-Assembly G - Fuel Pump, Carburetor and Carburetor Operation .............................................. 607.5.1.11 Sub-Assembly H - Final Assembly .................................................................................................... 657.5.1.12 Engine Run In ................................................................................................................................... 747.6 ENGINE INSTALLATION .......................................................................................................................... 757.7 PROP STRIKE INSPECTION .................................................................................................................... 767.8 STARTER MOTOR OVERHAUL ................................................................................................................ 777.8.1 Starter motor disassembly and inspection ................................................................................................ 777.8.2 Reassembly .............................................................................................................................................. 787.9 BUILD SHEETS AND RUN IN PROGRAMME .............................................................................................. 788 NOTES BEFORE STARTING ENGINE .................................................................................. 799 SERVICE DOCUMENTATION ............................................................................................... 819.1 SUBASSEMBLY A – COMPONENT ASSEMBLY PROCEDURE ...................................................................... 819.2 SUBASSEMBLY A – COMPONENT REGISTER & PARTS INSPECTION RECORD ............................................ 829.3 SUBASSEMBLY B – COMPONENT ASSEMBLY PROCEDURE ...................................................................... 839.4 SUBASSEMBLY B – COMPONENT REGISTER & PARTS INSPECTION RECORD ............................................ 849.5 SUBASSEMBLY C – COMPONENT ASSEMBLY PROCEDURE ...................................................................... 859.6 SUBASSEMBLY C – COMPONENT REGISTER AND PARTS INSPECTION RECORD ........................................ 86This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled.REVISION 0 1 2 3 4 5 6 7 8 9 Dated : June 2010 Issued By: DPS Page: 3 of 116L:\files\Manuals_For_Products\Engine_Manuals\Transition\JEM2204-9_I&M_unsigned.docx
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