INSTRUCTION AND MAINTENANCE MANUAL FOR JABIRU 2200 ...

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Jabiru Aircraft Pty LtdInstruction & Maintenance ManualJabiru <strong>2200</strong> Aircraft EngineHydraulic Valve Lifter Modelsthen all to 34 Nm (25 lb.ft), and finally all to 40 Nm (30 lb.ft). This operationmust be done in one session so the Loctite does not cure before the finaltorque is applied to the cap screws.CAUTIONOver-tightening propeller flange screws can damage the screws and/or thecrankshaft. Ensure torque wrench is properly calibrated & do not overtensionscrews12. Lock-wire screws in pairs if a standard prop flange is used. Note: Where propflange extensions are used the cap screws are not lock wired.13. Allow the retaining compound time to cure (refer to manufacturer specifications)before starting the engine.CAUTIONIf for any reason prop flange or prop has been damaged, rear flywheel capscrews are to be replaced.7.5.1.12 Engine Run InWhen built, the Jabiru engine is run in on a DYNOMOMETER and cooled with fan drivenair. In the absence of a DYNO controlled run, engines can be run-in in the airframe. Verylarge air ducts must be constructed to get adequate airflow for cooling in the staticsituation. The flying air ducts must not be used for this purpose. Extreme care must betaken with the cylinder head temps if run in is done in the airframe. Engine run inprocedure allows progressive build up of the B.M.E.P. (break mean effective pressure) inthe cylinders while carefully limiting the heat build up. In essence short amounts of hardwork increasing in intensity while limiting the heat build up is the format. This can be seenin detail after the engine build sheets. All engines are run in before delivery - includingoverhauled engines. When delivered they are ready for flight. See early run section4.7 for first 25 hours of operation.Run Procedure to be used only if engine has not been run-in.i) Mount Engine on test rig (See engine installation)ii)iii)iv)Fill with non detergent oil.Remove spark plugs and wind over until oil pressure is reached.Fit plugs and cooling ducts.v) Run in. Follow run in program.vi)vii)viii)ix)Cool down (at least 12 hours)Retorque headsRerunCheck leak downNote: There is a run in program and run in checklist to fill out.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: 74 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 Models7.6 Engine InstallationNo. Operation Tools Required1 Fit engine to engine mount -2 Torque engine mount bolts 7/16 Tube Socket7/16 Ring Open End Spanner3 Fit muffler (if not already fitted) and fitcarburettor heat muff and hose3/16 Ball End Allen Key4 Connect left and right ignition coils leads -5 Connect Tacho sender -6 Connect exhaust gas temp (if fitted) -7 Connect cylinder head sender 18mm Spark Plug socket8 Connect hourmeter Screw Driver9 Connect oil temp gauge sender10 Connect oil pressure gauge sender11 Connect starter 7/16 Ring Open End Spanner12 Connect Battery (Earth lead first) 10mm Ring Open End Spanner13 Connect fuel line Screw Driver14 Connect Oil Breather Screw Driver15 Connect Choke Cable Long Nose Pliers16 Connect Throttle Cable Long Nose Pliers17 Connect Air Inlet Screw Driver18 Fit Propeller and spinner 7/16 Ring Open End Spanner7/16 Torque WrenchPhillips Screw Driver19 Fit Cooling Ducts 3/16 Allen Key20 Prime Fuel system with electric pump andinspect for leaks-21 Check for oil. Fill if needed. 2.3L oil (2.43 US quarts)22 Wind over to get oil pressure -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: 75 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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