INSTRUCTION AND MAINTENANCE MANUAL FOR JABIRU 2200 ...

Jabiru Aircraft Pty LtdInstruction & Maintenance ManualJabiru 2200 Aircraft EngineHydraulic Valve Lifter Modelsgun onto the starter housing in the area where the bolts enter the housing. If the Loctiteis not heated to soften it, there is a possibility that the bolts will shear off and a newstarter housing will be required. Clean and wash all parts in solvent except the motor. Clean the motor by wiping with aclean rag to remove dust and metal particles. Clean the commutator with a soft brushand a fast drying solvent. Check commutator for wear, if you are not experienced in this field then seek a suitablequalified person to check the commutator for serviceability. Check brushes for wear, if you are not experienced in this field then seek a suitablequalified person to check the brushes for serviceability, replace if they are less than 10mm long. Check bendix gear for chipped or missing teeth, and that the clutch slides freely on theshaft, replace if necessary. Check the ball bearings on the motor rotor for serviceability, replace if necessary. Check the bushes at each end of the clutch and bendix gear for wear and replace asrequired, lubricate the bushes with grease.7.8.2 Reassembly Assemble motor and starter housing, and include the earth wire, (refer to JSL 005-1service bulletin for details if the earth wire connection was not connected to the longthrough bolt on the starter motor). Assemble bolts with a small amount of Loctite 242 onthe threads of the long AN3 bolts and tighten, check that the armature is able to rotatefreely after tightening bolts. Apply grease to the clutch gear and assemble into the starter housing, then fit theclutch housing. The assembly is now ready to be fitted to the engine rear plate with the 3 socket headscrews and Belleville washers, torque to 20 Nm (15 ft.lbs)7.9 Build Sheets and Run In ProgrammeIncluded with the build sheets are * Pre Run Check List* Run In Programme* Post Run ChecklistPhotocopy all documents and use photocopies to fill in. When complete, fax to JabiruAircraft so all documents can be kept up to date. This helps us provide a better service toour customers if we know what our engine is in and what has been done to it.Fax Number Within Australia 07 4155 2669Outside Australia + 61 7 4155 2669This 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: 78 of 116L:\files\Manuals_For_Products\Engine_Manuals\Transition\JEM2204-9_I&M_unsigned.docx