INSTRUCTION AND MAINTENANCE MANUAL FOR JABIRU 2200 ...

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Jabiru Aircraft Pty LtdInstruction & Maintenance ManualJabiru <strong>2200</strong> Aircraft EngineHydraulic Valve Lifter ModelsFigure 37. Drawing 9431064 – Gearbox & Distributor RotorsNote: When gear case goes on1) Make sure No. 1 is 25 ° before T.D.C. compression. Both valves should beseated.2) The rotors point to the No. 1 position on the rotor caps. Fit cap screws withloctite 242 and torque.H12 1. Fit flywheel with the magnets horizontal (they then should line up with the coils).Note: The small hole in the flywheel will line up with the hole in the crankcase. (Itmay not line up with the hole in the gear if it has been moved for cam timing.) Putloctite 620 on new flywheel cap screws and torque to 24 nm (18 ft lbs).2. Fit coil mount posts and alternator mount.3. Fit coils and set gap to 0.25mm (0.010")Note: A strip of 0.25mm (0.010") card is best because it is not magnetic. Coildirection lead follows prop rotation.H13 Fit Carburettor assemblyNote: It is very important to make sure hose clamp is at the outside end ofcoupling, the coupling and carby are free of oil and the carburettor goes fully intocoupling, clamp is of 10mm wide stainless type.H14 Fit Fuel Pump AssemblyNote: Use loctite 242 on cap screws. Use molybdenum disulphide grease on pushrodThis 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: 72 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 ModelsOil PumpH15 1. Put loctite 515 on back face of oil pump backing plate and fit.2. Fit woodruff key3. Fit inner gear to camshaft.4. Fit outer gear to housing and fill with oil.5. Fit O Ring6. Fit Oil pump on. Use loctite 242 on cap screws.Note: Before torquing up, rotate engine carefully to ensure oil pump is not binding.If oil pump binds it can sheer the end of camshaft.H16 Fit exhaust system. Use shake proof washers.Note: There are no gaskets. When fitting the muffler the front exhaust pipes mayneed to be loosened to seat at the correct angle and ensure a good fit in themuffler. Re-tighten once muffler has been fitted.H17Front Seal & Prop FlangeCAUTION: This is a critical operation in the process of assembling the engineand must be only carried out by a suitably qualified competent person, withsuitable calibrated tools.1. Remove from vertical stand and mount on engine mount stand2. Remove prop flange.3. Clean oil from sealing surfaces of front seal.4. Fit seal to seal housing.5. Apply Loctite 515 on crankshaft seal housing - crank face joint. Put a littlegrease on seal lip and install seal and seal housing assembly to crankcase.Apply Loctite to cap screws and torque to 20Nm (15 ft lbs)6. Before fitting the prop flange check that the screws protrude through the propflange by 11 - 12 mm for correct engagement in the crankshaft. The screwsused to fit the original flange may be re-used provided they are the correctlength and are not visibly damaged. If the screws are replaced then highstrengthcap screws must be used – “Unbrako 1960” type or equivalent.7. Visually inspect the front face of the crankshaft and the mating face of thepropeller flange are clean, free from burrs, rust and defects and fit together withminimal radial clearance.8. If the screws are to be re-used their threads must be cleaned with a wire brushand primed with Loctite 7471 activator and allowed to air dry.9. The crankshaft threads must be cleaned using a 3/8” UNF tap to removeleftover retaining compound in the threads. Care must be taken to not crossthreadthe tap as it will damage the thread in the crankshaft. Blow out the holesusing dry compressed air and prime with Loctite 7471 activator and air dry.10. Apply a small amount – approximately the size of a large match head – ofLoctite 620 retaining compound to the flange screws and threads in thecrankshaft.11. Fit the flange to the crankshaft & fit the screws by hand, then tension thescrews using a calibrated torque wrench immediately. Tension the screws in astandard diagonal tightening pattern. Torque all screws first to 27 Nm (20 lb.ft),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: 73 of 116L:\files\Manuals_For_Products\Engine_Manuals\Transition\JEM2204-9_I&M_unsigned.docx
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INSTRUCTION AND MAINTENANCE MANUAL FOR JABIRU 2200 ...

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