INSTRUCTION AND MAINTENANCE MANUAL FOR JABIRU 2200 ...

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Jabiru Aircraft Pty LtdInstruction & Maintenance ManualJabiru 2200 Aircraft EngineHydraulic Valve Lifter Models9.7 SUBASSEMBLY D – COMPONENT ASSEMBLY PROCEDURE ...................................................................... 879.8 SUBASSEMBLY D – COMPONENT REGISTER AND PARTS INSPECTION RECORD ........................................ 889.9 SUBASSEMBLY E – COMPONENT ASSEMBLY PROCEDURE ...................................................................... 899.10 SUBASSEMBLY E – COMPONENT REGISTER AND PARTS INSPECTION RECORD .................................... 909.11 SUBASSEMBLY F – COMPONENT ASSEMBLY PROCEDURE ................................................................... 919.12 SUBASSEMBLY F – COMPONENT REGISTER AND PARTS INSPECTION RECORD ..................................... 929.13 SUBASSEMBLY G – COMPONENT ASSEMBLY PROCEDURE .................................................................. 939.14 SUBASSEMBLY H – COMPONENT ASSEMBLY PROCEDURE .................................................................. 9410 JABIRU 2200 ENGINE RUN-IN & TESTING ......................................................................... 9510.1 RUN-IN SCHEDULE ............................................................................................................................ 9510.2 JABIRU 2200A AERO ENGINE GROUND TEST FORM ........................................................................... 9610.3 RUN-IN CHECKS ............................................................................................................................... 9710.4 JABIRU 2200 – ENGINE POST RUN PROCEDURE ................................................................................ 9711 TABLE OF LUBRICANTS ...................................................................................................... 9812 TORQUE SPECIFICATION FOR BOLTS & NUTS ................................................................ 9912.1 PRESCRIBED SEALANTS AND PRIMERS ................................................................................. 10012.2 NEW TOLERANCES .................................................................................................................... 10112.3 MAXIMUM ALLOWABLE CLEARANCES (WEAR LIMITS) ............................................................. 10212.4 ELECTRICAL SYSTEMS SPECIFICATIONS ............................................................................... 10313 OPERATING NOTES – QUICK REFERENCE GUIDE ......................................................... 10413.1 NEW ENGINE NOTES ....................................................................................................................... 10413.2 NORMAL OPERATION NOTES ........................................................................................................... 10513.2.1 Regular Checks ....................................................................................................................................... 10513.2.2 Oil ............................................................................................................................................................ 10613.2.3 Engine Cooling ........................................................................................................................................ 10613.2.4 Consumables .......................................................................................................................................... 10713.2.5 Starting .................................................................................................................................................... 10713.2.6 Trouble Shooting ..................................................................................................................................... 10714 TROUBLE SHOOTING ........................................................................................................ 10814.1 TROUBLESHOOTING TABLES ............................................................................................................ 10814.1.1 Engine Won't Start .................................................................................................................................. 10814.1.2 Engine Idles Unsteadily After Warm-Up Period: Smoky Exhaust ........................................................... 10814.1.3 Engine Runs Erratically or Misfires Occasionally .................................................................................... 10814.1.4 Engine Runs Too Hot - Oil Temperature Above 110 o C (230 o F) ............................................................. 10914.1.5 Unsatisfactory Power Output .................................................................................................................. 10914.1.6 Low Oil Pressure ..................................................................................................................................... 10914.1.7 Engine Keeps Running with Ignition Off .................................................................................................. 10914.1.8 Excessive Oil Consumption .................................................................................................................... 10914.1.9 Knocking Under Load .............................................................................................................................. 11014.1.10 Engine Hard to Start at Low Temperature ............................................................................................... 11014.1.11 Hydraulic Valve Lifters ............................................................................................................................ 11014.2 TROUBLESHOOTING QUICK GUIDE ................................................................................................... 11114.2.1 Low Oil Pressure ..................................................................................................................................... 11114.2.2 Flicking Of Oil Pressure Gauge ............................................................................................................... 11114.2.3 CHT ......................................................................................................................................................... 11114.2.4 RPM ........................................................................................................................................................ 11114.2.5 Magneto Checks ..................................................................................................................................... 11114.2.6 Rough Cylinder Running ......................................................................................................................... 11114.2.7 Carby Breather ........................................................................................................................................ 11114.2.8 Limitations ............................................................................................................................................... 11115 AIRWORTHINESS LIMITATIONS SECTION ....................................................................... 11216 NEW ENGINE – JABIRU’S LIMITED, EXPRESS WARRANTY ........................................... 11317 JABIRU’S LIMITED, EXPRESS WARRANTY: CLAIM FORM ............................................. 116This 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: 4 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 Models1.1 Table of FiguresFigure 1. Drawing 9404041/1 Engine Dimensions ............................................................ 15Figure 2. Cylinder Denomination & Firing Order ................................................................ 16Figure 3. Distributor Cylinder Map ..................................................................................... 16Figure 4. Power Curve ....................................................................................................... 17Figure 5. Power Curve, 2200C, 2200B Engines ................................................................ 17Figure 6. High-Tension Lead Connections ........................................................................ 30Figure 7. Cam Identification Markings ............................................................................... 33Figure 8. Drawing 9429063 – Crank & Rod Assembly ...................................................... 44Figure 9. Drawing 9433064 – Cam Lift Measurement ....................................................... 44Figure 10. Drawing 9448064 – Cam Gear Assy ................................................................ 45Figure 11. Drawing 9435064 – Oil Pressure Relief Valve Assy ......................................... 46Figure 12. Drawing 9441064 – Crankcase Bearings ......................................................... 46Figure 13. Drawing 9442064 – Crankcase Spacer ............................................................ 47Figure 14. Drawing 944064 – Valve Guide Replacement .................................................. 49Figure 15. Valve Seats ...................................................................................................... 49Figure 16. Drawing 9444064 – Valve Details ..................................................................... 50Figure 17. Drawing 9443064 – Valve Spring Measurement .............................................. 51Figure 18. Drawing 9447064 – Valve Assy ........................................................................ 51Figure 19. Drawing 9449064 – Rocker Bush Removal ...................................................... 52Figure 20. Drawing 9A011A0D – Rocker Shaft Install ....................................................... 52Figure 21. Drawing 9436064 – Barrel Hone ...................................................................... 53Figure 22. Drawing 9434064 – Piston Diameter ................................................................ 54Figure 23. Drawing 9440064 – Oil Pump Clearances ....................................................... 55Figure 24. Drawing 9428064 – Oil Pump End Clearance .................................................. 55Figure 25. Drawing 9437064 – Magnet Pull Test Flywheel ................................................ 56Figure 26. Drawing 9438064 – Magnet Pull Test Alternator .............................................. 56Figure 27. Drawing 9439064 – Ignition Primary Resistance .............................................. 57Figure 28. – Ignition Secondary Resistance ...................................................................... 57Figure 29 – Alternator Circuit Diagram .............................................................................. 58Figure 30. – Alternator Core Assy...................................................................................... 59Figure 31. Regulator Wiring ............................................................................................... 59Figure 32 – Carburetor Details .......................................................................................... 65Figure 33. Drawing 9427063 – Degree Wheel .................................................................. 66Figure 34. Drawing 9429063 – Crank & Rod Assy ............................................................ 67Figure 35. Drawing 9432064 – Timing Gear Alignment ..................................................... 69Figure 36. Drawing 9430064 – Rear Plate Through Bolts ................................................. 71Figure 37. Drawing 9431064 – Gearbox & Distributor Rotors ............................................ 72Figure 38 Dial Indicator Position for Crankshaft & Prop Flange Run Out .......................... 76Figure 39 – Head Bolt Locations ....................................................................................... 79Figure 40. Drawing 9486091 – Run-In Schedule ............................................................... 95Figure 41. Oil System Schematic ...................................................................................... 98This 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: 5 of 116L:\files\Manuals_For_Products\Engine_Manuals\Transition\JEM2204-9_I&M_unsigned.docx
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