INSTRUCTION AND MAINTENANCE MANUAL FOR JABIRU 2200 ...

Jabiru Aircraft Pty LtdInstruction & Maintenance ManualJabiru 2200 Aircraft EngineHydraulic Valve Lifter Models7.5.1 Jabiru 2200 Component Inspection and Assembly Procedure7.5.1.1 Sub-Assembly A - Crankshaft, Prop Mount and Con-RodsA1A2A3A4A5A6A71. Remove welsh plugs from crankshaft2. Clean conrods and crankshaftNote - Make sure all old loctite is removed from threads3. Strip paint off prop flange and crankshaft.4. Magnetic particle inspect crankshaft , prop flange, cam and conrodsMeasure crankshaft and record in Build SheetInspect Oil Holes for Cleanliness and insert new front welsh plugs (2 off) and rearwelsh plug.Inspect prop flange. Paint prop flange and end of crankshaft to prevent rusting1) Magnetic Particle Inspect conrods for cracks.2) Fit bearings with a light smear of bearing blue on back of shells.3) Torque Caps to 18 lbs (with new bolts)4) Measure Big End Bearings. Record in Build Sheet.5) Measure Piston Pin Bore. Record in Build Sheet. Check CRUSH.6) Remove caps and check bearing back contact (Must be at least 90%)7) Remove all blue and thoroughly clean surfaces. Refit bearing shells.8) Clearance as close to 0.05mm is recommended.Temporarily mount prop flange to crankshaft and mount to stand vertically.(Flange is removed later to fit front oil seal)1) Spray conrod bolts and conrod bolt threads with Loctite 7471 primer andallow to dry.2) Mount conrods to crankshaft. Use plenty of oil on journals. Closest to propflange is number 1. Use Loctite 620 on rods and bolts torque up to 24.0 NM(18 ft/lbs)3) Wipe off excess locktite at bases of cap screws on the end capThis 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: 43 of 116L:\files\Manuals_For_Products\Engine_Manuals\Transition\JEM2204-9_I&M_unsigned.docx