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Jabiru Aircraft
Pty Ltd
Instruction & Maintenance Manual
Jabiru 2200 Aircraft Engine
Hydraulic Valve Lifter Models
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REVISION
0
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9
Dated : June 2010
Issued By: DPS
Page: 4 of 116
L:\files\Manuals_For_Products\Engine_Manuals\Transition\JEM2204-9_I&M_unsigned.docx
9.7
S
UBASSEMBLY
D
–
C
OMPONENT
A
SSEMBLY
P
ROCEDURE
...................................................................... 87
9.8
S
UBASSEMBLY
D
–
C
OMPONENT
R
EGISTER AND
P
ARTS
I
NSPECTION
R
ECORD
........................................ 88
9.9
S
UBASSEMBLY
E
–
C
OMPONENT
A
SSEMBLY
P
ROCEDURE
...................................................................... 89
9.10
S
UBASSEMBLY
E
–
C
OMPONENT
R
EGISTER AND
P
ARTS
I
NSPECTION
R
ECORD
.................................... 90
9.11
S
UBASSEMBLY
F
–
C
OMPONENT
A
SSEMBLY
P
ROCEDURE
................................................................... 91
9.12
S
UBASSEMBLY
F
–
C
OMPONENT
R
EGISTER AND
P
ARTS
I
NSPECTION
R
ECORD
..................................... 92
9.13
S
UBASSEMBLY
G
–
C
OMPONENT
A
SSEMBLY
P
ROCEDURE
.................................................................. 93
9.14
S
UBASSEMBLY
H
–
C
OMPONENT
A
SSEMBLY
P
ROCEDURE
.................................................................. 94
10
JABIRU 2200 ENGINE RUN-IN & TESTING ......................................................................... 95
10.1
R
UN
-I
N
S
CHEDULE
............................................................................................................................ 95
10.2
J
ABIRU
2200A
A
ERO
E
NGINE
G
ROUND
T
EST
F
ORM
........................................................................... 96
10.3
R
UN
-I
N
C
HECKS
............................................................................................................................... 97
10.4
J
ABIRU
2200
–
E
NGINE
P
OST
R
UN
P
ROCEDURE
................................................................................ 97
11
TABLE OF LUBRICANTS ...................................................................................................... 98
12
TORQUE SPECIFICATION FOR BOLTS & NUTS ................................................................ 99
12.1
PRESCRIBED
SEALANTS
AND
PRIMERS ................................................................................. 100
12.2
NEW
TOLERANCES .................................................................................................................... 101
12.3
MAXIMUM
ALLOWABLE
CLEARANCES
(W
EAR
L
IMITS
) ............................................................. 102
12.4
ELECTRICAL
SYSTEMS
SPECIFICATIONS ............................................................................... 103
13
OPERATING NOTES
– QUICK REFERENCE GUIDE ......................................................... 104
13.1
N
EW
E
NGINE
N
OTES
....................................................................................................................... 104
13.2
N
ORMAL
O
PERATION
N
OTES
........................................................................................................... 105
13.2.1
Regular Checks ....................................................................................................................................... 105
13.2.2
Oil ............................................................................................................................................................ 106
13.2.3
Engine Cooling ........................................................................................................................................ 106
13.2.4
Consumables .......................................................................................................................................... 107
13.2.5
Starting .................................................................................................................................................... 107
13.2.6
Trouble Shooting ..................................................................................................................................... 107
14
TROUBLE SHOOTING ........................................................................................................ 108
14.1
T
ROUBLESHOOTING
T
ABLES
............................................................................................................ 108
14.1.1
Engine Won't Start .................................................................................................................................. 108
14.1.2
Engine Idles Unsteadily After Warm-Up Period: Smoky Exhaust ........................................................... 108
14.1.3
Engine Runs Erratically or Misfires Occasionally .................................................................................... 108
14.1.4
Engine Runs Too Hot - Oil Temperature Above 110oC (230
o
F) ............................................................. 109
14.1.5
Unsatisfactory Power Output .................................................................................................................. 109
14.1.6
Low Oil Pressure ..................................................................................................................................... 109
14.1.7
Engine Keeps Running with Ignition Off .................................................................................................. 109
14.1.8
Excessive Oil Consumption .................................................................................................................... 109
14.1.9
Knocking Under Load .............................................................................................................................. 110
14.1.10
Engine Hard to Start at Low Temperature ............................................................................................... 110
14.1.11
Hydraulic Valve Lifters ............................................................................................................................ 110
14.2
T
ROUBLESHOOTING
Q
UICK
G
UIDE
................................................................................................... 111
14.2.1
Low Oil Pressure ..................................................................................................................................... 111
14.2.2
Flicking Of Oil Pressure Gauge ............................................................................................................... 111
14.2.3
CHT ......................................................................................................................................................... 111
14.2.4
RPM ........................................................................................................................................................ 111
14.2.5
Magneto Checks ..................................................................................................................................... 111
14.2.6
Rough Cylinder Running ......................................................................................................................... 111
14.2.7
Carby Breather ........................................................................................................................................ 111
14.2.8
Limitations ............................................................................................................................................... 111
15
AIRWORTHINESS LIMITATIONS SECTION ....................................................................... 112
16
NEW ENGINE
– JABIRU’S LIMITED, EXPRESS WARRANTY ........................................... 113
17
JABIRU’S LIMITED, EXPRESS WARRANTY: CLAIM FORM ............................................. 116