INSTRUCTION AND MAINTENANCE MANUAL FOR JABIRU 2200 ...
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INSTRUCTION AND MAINTENANCE MANUAL FOR JABIRU 2200 ...

INSTRUCTION AND MAINTENANCE MANUAL FOR JABIRU 2200 ... INSTRUCTION AND MAINTENANCE MANUAL FOR JABIRU 2200 ...

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Jabiru Aircraft Pty LtdInstruction & Maintenance ManualJabiru 2200 Aircraft EngineHydraulic Valve Lifter Models3) O Rings in4) Piston/Cylinder Assembly complete5) Thrust washers in position6) Dowels in7) Lifters are placed after joining3. You will need1) An extra person2) 4 7/16 Ring Open End spanners3) 2 9/16 Ring Open End spanners4) 2 3/8 Plain grade 5 nuts5) 2 3/8 Belleville Washers6) 18 through stud nuts (MS21042L6)7) 6 through studs8) Torque wench9) 7/16 x 3/8 drive 2" extension10) Long Nose PliersNote: An extra person makes it easier to bolt up and also can cross check work.H3H4H5H6H71. Stage Inspection2. Oil all bearings, crank and camshaft3. Fit halves over crankshaft assembly and squeeze up by hand1. Using spacers and plain nuts on rear studs and belleville washers andMS21042L6 nuts on the front studs pull the crankcase together (but don't do uptight)2. Remove rear nutsPut all through studs in1. Fit piston/cylinder assemblies to No. 1 & 2 conrods2. Fit circlips cross check circlips for correct fit. Push cylinders home.3. Put cylinder base nuts (MS21042L6) on. Do up both sides at the same timeusing 2 7/16 ring spanners. If one nut goes on more than 3 turns put the 3/8plain nut on top of it and use a 9/16 ring spanner to hold the nut, locking up thestud. Torque up by hand lightly.4. Turn engine 1/2 turn so No. 3 & 4 conrod are out. repeat procedure on No. 3 &4.1. Torque to 15 ft lbs then 30 ft lbs.Note: Keep an eye on the amount of thread through each nut. Both sides shouldhave approx 2 turns hanging out.2. Put anti sabotage paint on nuts (to show if nuts move).STAGE INSPECTIONH8Camshaft Timing1. Fit crankshaft gear as drawing and put one bolt in crankshaft to hold gearThis 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: 68 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 ModelsFigure 35. Drawing 9432064 – Timing Gear AlignmentNote: Timing marks on cam gear are on 2 teeth. Crankgear marked on one tooth.2. Mount a dial indicator on cylinder with the plunger on the center of the piston.3. Zero the indicator at T.D.C.4. Fix a wire pointer of the oil seal bolt hole and roughly set to T.D.C.5. Turn 1/4 turn backwards then forward until the piston is 2mm from T.D.C. Notedegrees.6. Turn past T.D.C. to 2mm down from T.D.C. Note degrees.Add two together then divide by 2 and set pointer at this (with piston down 2mm)Note: The crank is mounted to turn the engine in direction of rotation. Turncrankcase anti clockwise when viewed from rear.7. Repeat again to check.Note: It is important to find T.D.C. accurately as it is the datum for setting the camtiming and ignition timing.8. Set dial indicator up to measure lift on No. 1 exhaust. Set to 0 on max lift.9. Turn 1/4 turn backwards then turn until 0.5mm (0.020") from peak. notedegrees, continue turning until 0.5mm (0.020") after peak.Note: Always turn in direction of rotation to eliminate back lash in gears.10. Calculate total degrees and divide by 2 to find peak. Peak should be 70 o -72 oafter B.D.C.11. The cam shaft gear has 22 teeth and 6 bolt holes, so if it needs adjusting.Move the gear around and re check. Record final measurement in build sheet.This 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: 69 of 116L:\files\Manuals_For_Products\Engine_Manuals\Transition\JEM2204-9_I&M_unsigned.docx

Jabiru Aircraft Pty LtdInstruction & Maintenance ManualJabiru <strong>2200</strong> Aircraft EngineHydraulic Valve Lifter ModelsFigure 35. Drawing 9432064 – Timing Gear AlignmentNote: Timing marks on cam gear are on 2 teeth. Crankgear marked on one tooth.2. Mount a dial indicator on cylinder with the plunger on the center of the piston.3. Zero the indicator at T.D.C.4. Fix a wire pointer of the oil seal bolt hole and roughly set to T.D.C.5. Turn 1/4 turn backwards then forward until the piston is 2mm from T.D.C. Notedegrees.6. Turn past T.D.C. to 2mm down from T.D.C. Note degrees.Add two together then divide by 2 and set pointer at this (with piston down 2mm)Note: The crank is mounted to turn the engine in direction of rotation. Turncrankcase anti clockwise when viewed from rear.7. Repeat again to check.Note: It is important to find T.D.C. accurately as it is the datum for setting the camtiming and ignition timing.8. Set dial indicator up to measure lift on No. 1 exhaust. Set to 0 on max lift.9. Turn 1/4 turn backwards then turn until 0.5mm (0.020") from peak. notedegrees, continue turning until 0.5mm (0.020") after peak.Note: Always turn in direction of rotation to eliminate back lash in gears.10. Calculate total degrees and divide by 2 to find peak. Peak should be 70 o -72 oafter B.D.C.11. The cam shaft gear has 22 teeth and 6 bolt holes, so if it needs adjusting.Move the gear around and re check. Record final measurement in build sheet.This 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: 69 of 116L:\files\Manuals_For_Products\Engine_Manuals\Transition\JEM2204-9_I&M_unsigned.docx

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