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Jabiru 2200, Instruction And Maintenance Manual

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Jabiru 2200 Instruction And Maintenance Manual Download Page 70

Jabiru Aircraft 

Pty Ltd

 

 

Instruction & Maintenance Manual 

Jabiru 2200 Aircraft Engine 

Hydraulic Valve Lifter Models 

 

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:  70 of 116 

L:\files\Manuals_For_Products\Engine_Manuals\Transition\JEM2204-9_I&M_unsigned.docx 

 

Head Fitting 

H9 

1.  Insure 

 

*  All O Rings are place and greased 

 

 

 

*  Have all head bolts 

 

 

 

*  Push rod tubes 

 

 

 

*  Push Rods 

 

 

 

* Loctite 515 

 

 

 

* Loctite 243 

2.  Fit heads by hand. 
3.  Oil hydraulic lifters liberally & place into sockets in case. 
4.  Fit O-rings to case & push rod adaptors and install adaptors to case. 
5.  Push the push rod tube through the head and all the way home.  Fit circlips. 

Note:  Make sure outside of tubes are smooth or it will damage the O-Rings 

 
6.  Oil Push rods and fit. 

Note:  Make sure ball end of push rod is in the socket of the lifter.  It also helps if 
the  lifter  is  on  the  base  circle  of  the  lobe.  Lifters  should  be  filled  with  oil  before 
fitting.

 

 
7.  Put  loctite  243  on  rocker  shaft  cap  screw  and  torque  to  8  ft  lbs  after  fitting 

rockers. 

8.  Torque head bolts to 16 nm then 32 nm (12 ft lbs then 24 ft lbs). 
 

 

Sump and Induction 

H10  1.  Fit sump using loctite 515 on faces and loctite 243 on threads. 

Note:  Because  the  engine  mount  plate  goes  on  the  sump  and  crankcase  it  is 
important to make sure the sump is level with the rear crank case face. There are 
two additional cap screws between the backing plate and the sump, covered by the 
gear case.  These screws have been removed from later engines. 

 
2.  Fit 3 & 4 induction pipe to heads then 1 & 2 
3.  Fit lower pipes and hoses 

 

Gear Case 

H11  1.  Insure 

 

*  Gear case is fitted up 

 

 

 

*  Backing plate is ready 

 

 

 

*  All bolts are ready 

 

 

 

*  Loctite 515 

 

 

 

*  Loctite 242 

 

 

 

*  Loctite 620 

2.  Turn engine around until it is 25

°

 B.T.D.C. No. 1 compression 

3.  Put loctite 515 on crankcase.  Fit engine mount plate.  Make sure 4 inside cap 

screws are in.  Use loctite 242 on all cap screws. 

4.  Put loctite on gear case & point rotors to No. 1 Position. 

Note: It is recommended that rotors are attached with small amount of silastic or 5 
minute  araldite/flox  mix.    This  will  prevent  them  from  loosening.    This  still  allows 
rotors to be removed when necessary. 
 

Summary of Contents for 2200

Page 1: ...pplicable Service Bulletins and have them implemented as soon as possible Failure to do this may render the aircraft un airworthy and void Jabiru s Limited Express Warranty This document is controlled...

Page 2: ...T 13 3 5 1 Run in Period 13 3 5 2 Normal Operations 13 3 6 COOLING SYSTEM 13 3 7 OPERATING SPEEDS AND LIMITS 14 3 7 1 Ground Operating Limits 14 3 7 2 In Flight Operating Limits 14 3 8 PROPELLER SELEC...

Page 3: ...1 Full Overhaul 37 7 2 2 Top End Overhaul 38 7 3 ENGINE REMOVAL PROCEDURE 38 7 4 ENGINE DISASSEMBLY 39 7 5 2200 ENGINE OVERHAUL 42 7 5 1 Jabiru 2200 Component Inspection and Assembly Procedure 43 7 5...

Page 4: ...ANTS AND PRIMERS 100 12 2 NEW TOLERANCES 101 12 3 MAXIMUM ALLOWABLE CLEARANCES WEAR LIMITS 102 12 4 ELECTRICAL SYSTEMS SPECIFICATIONS 103 13 OPERATING NOTES QUICK REFERENCE GUIDE 104 13 1 NEW ENGINE N...

Page 5: ...ement 49 Figure 15 Valve Seats 49 Figure 16 Drawing 9444064 Valve Details 50 Figure 17 Drawing 9443064 Valve Spring Measurement 51 Figure 18 Drawing 9447064 Valve Assy 51 Figure 19 Drawing 9449064 Roc...

Page 6: ...6 8 10 95 9 6 8 10 16 9 6 8 10 56 9 6 8 10 96 9 6 8 10 17 9 6 8 10 57 9 6 8 10 97 9 6 8 10 18 9 6 8 10 58 9 6 8 10 98 9 6 8 10 19 9 6 8 10 59 9 6 8 10 99 9 6 8 10 20 9 6 8 10 60 9 6 8 10 100 9 6 8 10...

Page 7: ...ntenance manual Any variation of any kind including alteration to any component at all whether replacement relocation modification or otherwise which is not strictly in accordance with this manual may...

Page 8: ...um The crankshaft features a removable propeller flange which enables the easy replacement of the front crankshaft seal and provides for a propeller shaft extension to be fitted should this be require...

Page 9: ...manufacture baffles and the establishment of a plenum chamber which is the traditional method of cooling air cooled aircraft engines The fact that these baffles and plenum chamber are not required als...

Page 10: ...4 Stroke 4 Cylinder Horizontally Opposed 1 Central Camshaft Push Rods Over Head Valves OHV Hydraulic Valve Lifters with Automatic Adjustment Ram Air Cooled Wet Sump Lubrication Direct Propeller Drive...

Page 11: ...ied to the CS 22 Subpart H Design Standard by the Civil Aviation Safety Authority of Australia The CASA Type Certificate Number for the 2200C Engine is VE 501 Specifications of the engine are availabl...

Page 12: ...lugs NGK D9EA Automotive Electrode Gap 0 55 0 6mm 0 022 0 024 Generator Jabiru permanently excited single phase AC generator with rectifier regulator Carburettor BING constant depression Type 94 40 Ai...

Page 13: ...g the correct grade of oil and must be considered as a guide only Multiviscosity grades can also be used as indicated Average Ambient Temperature Mineral Grades Ashless Dispersant Grades Above 35 C 95...

Page 14: ...Oil Continuous Temperature 80 100 C 176 212 F Max CHT Climb 200 C 392 F Max Continuous CHT Cruise 180o C 356o F Notes Time with CHT at between 180 C and 200 C is not to exceed 5 Minutes Read Cylinder...

Page 15: ...VISION 0 1 2 3 4 5 6 7 8 9 Dated June 2010 Issued By DPS Page 15 of 116 L files Manuals_For_Products Engine_Manuals Transition JEM2204 9_I M_unsigned docx All propellers must be maintained in accordan...

Page 16: ...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 16 of 116 L files Manuals_For_Products Engine_Manuals Transition JEM2204 9_I M...

Page 17: ...Transition JEM2204 9_I M_unsigned docx 3 12 Power Curve POWER CURVE 20 0 25 0 30 0 35 0 40 0 45 0 50 0 55 0 60 0 65 0 70 0 1500 1700 1900 2100 2300 2500 2700 2900 3100 3300 RPM kW 50 100 150 200 250...

Page 18: ...hin 5 seconds if not shut down It is strongly advised to close choke while cranking on first attempt Too much choke will cause over fueling in the venturi flooding the engine and loss of start 4 2 1 C...

Page 19: ...ontinuous power Observe Oil Cylinder Head Temperatures Oil Pressure Limits must not be exceeded Max continuous RPM at Full Throttle is 3300 RPM 4 5 Engine Stop In normal conditions cooling down the en...

Page 20: ...age on the ground where the aircraft was parked overnight ii Inspect the oil cooler for leaks through the cowl opening iii Visually inspect the underside of the aircraft for fresh oil or fuel residue...

Page 21: ...tervals After the initial 10 hours check in accordance with para 5 3 After the initial 25 hours check in accordance with para 5 4 After 50 hours of operation check in accordance with para 5 5 thereaft...

Page 22: ...s Thoroughly check engine for missing or loose bolts nuts pins etc Check fit of cooling air ducts baffles Check the engine including oil cooler for signs of abrasion against cowls and ducts Check indu...

Page 23: ...to Jabiru specifications at an approved aeronautical service facility or by an approved Jabiru Service Centre If necessary changes to the TBO Limit due to operational experience will be announced by J...

Page 24: ...Temporary storage is defined as aircraft in non operational status for a maximum of 90 days nominal depending on ambient temperature humidity etc Disconnect or remove battery Treat as for flyable sto...

Page 25: ...ngine with fuel valve off until it stops or by draining the bowl manually Long term storage Flood the cylinder sump with corrosion inhibitor Periodically remove one spark plug per head turn engine ove...

Page 26: ...ance with Section and 5 8 4 or iii Treat and maintain the engine for Indefinite Storage per Section 5 8 5 above When the engine is to be run the storage measures must be reversed as detailed in the ap...

Page 27: ...e fuels with Ethanol or similar additives to a Jabiru Aircraft fiberglass fuel tank The sealant in these tanks will be damaged if it comes into contact with alcohol leading to leaks f Prevent condensa...

Page 28: ...oil lines and lead to hoses slipping off the cooler 6 2 Air Intake Filter Clean filter by removing from the intake housing blowing compressed air against the direction of the intake flow For operation...

Page 29: ...s bore head sealing and valve This is the normal test used in aviation and requires specific equipment The test is carried out with the engine in warm to hot condition Input pressure is best set at 80...

Page 30: ...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 30 of 116 L files Manuals_For_Products En...

Page 31: ...nti seize compound Note When plugs are removed from a warm engine the inspection of the tip of the spark plug can be used to indicate the health of the engine Brown to Dark Brown Plug calibration is c...

Page 32: ...ne without a qualified person at the controls Troubleshooting information is given in Section 14 1 11 Air can be caught inside the lifters after maintenance Running the engine at a high idle approx 15...

Page 33: ...the lifters Whenever lifters are removed the working face of the cam and the lifter should be inspected for damage If damage is found contact Jabiru Aircraft P L or our local representative for furth...

Page 34: ...checks to monitor their engine particularly propeller installation and flywheel attachment Airworthiness and issues when claiming upon Jabiru s Limited Express Warranty may also result 6 11 2 Engine...

Page 35: ...r Flange 3 Spinner screws 4 Propeller 5 Propeller bolts nuts Tension 6 Spinner Prop Tracking ENGINE ENGINE COMPARTMENT Check for oil fuel exhaust induction leaks then clean entire engine compartment b...

Page 36: ...on harness distributor caps rotors Spark plugs Compression check or leak down check Electrical wiring Fuel pump Engine controls and linkages Engine mounts mount structure Starter solenoid and electric...

Page 37: ...ng an overhaul or Top End particular attention must be paid to Section 12 Torque Specifications Prescribed sealants Tolerances and Maximum Allowable Clearances MPI testing is carried out on the cranks...

Page 38: ...leads oil seals induction and exhaust capscrews carby heads and barrels Engine assembled and test run Run In Program 7 3 Engine Removal Procedure No Operation Tools Required 1 Remove Spinner and Prope...

Page 39: ...SSEMBLY No Operation Tools Required 1 Mount Engine on an engine stand in vertical position As required for stand 2 Remove Spark Plugs Spark Plug Socket 3 Remove Oil Pressure Sensor 17mm Spanner 4 Remo...

Page 40: ...Remove Sump Note there are screws holding the sump to the engine backing plate which are only visible with the gearbox removed 3 16 Allen Key 21 Remove Exhaust and Induction Pipes 3 16 Allen Key 22 Re...

Page 41: ...Note Hydraulic Valve Lifters are to be replaced at 1000 hrs TIS 36 Remove Thrust Washers front and rear 2 without tang on right half case 2 with tang on left half case Note visually check for marks o...

Page 42: ...d Camshaft Bolts Remove welsh plug in rear of camshaft 7 5 2200 ENGINE OVERHAUL Inspection and Assembly of Sub Assemblies a Sub Assembly A Crankshaft Prop Mount and Con Rods b Sub Assembly B Crankcase...

Page 43: ...nliness and insert new front welsh plugs 2 off and rear welsh plug A4 Inspect prop flange Paint prop flange and end of crankshaft to prevent rusting A5 1 Magnetic Particle Inspect conrods for cracks 2...

Page 44: ...ted June 2010 Issued By DPS Page 44 of 116 L files Manuals_For_Products Engine_Manuals Transition JEM2204 9_I M_unsigned docx Figure 8 Drawing 9429063 Crank Rod Assembly A8 1 Clean and visually inspec...

Page 45: ...rson of Sub Assembly 7 5 1 2 Sub Assembly B Crankcase and Camshaft B1 1 Clean crankcase remove old Loctite and clean oil galleries 2 Visually inspect crankcase B2 Fit inner stud O Rings with a small s...

Page 46: ...uals_For_Products Engine_Manuals Transition JEM2204 9_I M_unsigned docx Figure 11 Drawing 9435064 Oil Pressure Relief Valve Assy Figure 12 Drawing 9441064 Crankcase Bearings NOTE MAIN BEARINGS supplie...

Page 47: ...be inspected and re used as described below Note when ordering replacement lifters ensure that the engine S No and overhaul history is known and quoted to the supplier so that the supplier knows which...

Page 48: ...s C1 1 Clean oil off heads 2 Dip heads in a cold dip solvent i e Redik dkt Degreaser Decarboniser Paint stripper as per manufactures instructions to remove all carbon deposits 3 Note The heads can be...

Page 49: ...d docx Figure 14 Drawing 944064 Valve Guide Replacement Note When cutting seats cut enough to clean up but try to remove as little as possible This will give maximum number of overhauls on heads The d...

Page 50: ...June 2010 Issued By DPS Page 50 of 116 L files Manuals_For_Products Engine_Manuals Transition JEM2204 9_I M_unsigned docx height to valve face is 0 8mm 9 Measure valve stem for wear Record in build s...

Page 51: ...files Manuals_For_Products Engine_Manuals Transition JEM2204 9_I M_unsigned docx Figure 17 Drawing 9443064 Valve Spring Measurement 3 Inspect valve spring seats valve spring retainers and valve collet...

Page 52: ...docx C5 1 Disassemble and clean off all carbon 2 Inspect rocker tip for wear Replace any with excessive wear 3 Measure bushes and record on build sheet 4 If over service limits replace Figure 19 Draw...

Page 53: ...move all honing oil etc Note Once cleaned oil up cylinders straight away Store in a cool dry place in a sealed container Figure 21 Drawing 9436064 Barrel Hone Pistons C7 1 Clean oil out of pistons 2 D...

Page 54: ...iston pin can be fitted later Note Arrows on inside of pistons point in direction of rotation Oil Rings and pistons and bore well Notch on the piston crown faces the Propeller Flange 9 Fit front pisto...

Page 55: ...ucts Engine_Manuals Transition JEM2204 9_I M_unsigned docx Figure 23 Drawing 9440064 Oil Pump Clearances Housing to Outer Rotor clearance 0 07mm to 0 14mm 0 003 to 0 006 Inner Rotor to Outer Rotor 0 0...

Page 56: ...als Transition JEM2204 9_I M_unsigned docx E2 Use a spring scale and a prop cap screw as per drawing to test ignition magnet strength Pull off should be 1 5 to 2 5 kg 3 3 to 5 5 lbs Figure 25 Drawing...

Page 57: ...y DPS Page 57 of 116 L files Manuals_For_Products Engine_Manuals Transition JEM2204 9_I M_unsigned docx Figure 27 Drawing 9439064 Ignition Primary Resistance 2 Measure the secondary resistance from th...

Page 58: ...and also charges the battery while the engine runs It consists of a Permanent Magnet Alternator PMA and a Regulator This permanent magnet alternator PMA is a 10 pole rotating magnet type generator It...

Page 59: ...led 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 59 of 116 L files Manuals_For_Pr...

Page 60: ...d discard F2 Inspect Distributor shaft posts for signs of leaking Note If there is no signs of leaking there is no need to disassemble If it is leaking disassemble and clean off old master gasket Insp...

Page 61: ...in the float chamber then the float 40 mounted on pin 41 is lifted until the float needle 42 is pressed against the seat of the float needle valve thus preventing any further supply of fuel When the e...

Page 62: ...een a bent over tab at the lower end of the retaining arm and the throttle lever 28 If the throttle valve 23 is opened while the engine is running the increased air flow in the choke tube results in a...

Page 63: ...nded from the retaining spring 14 with the third notch from the top To achieve the height adjustment the jet needle is turned through 90o and pushed up or down the retaining spring engaging the next n...

Page 64: ...starting carburettor as an aid for staring a cold engine using a Bowden cable A disc 47 resting against the carburettor housing is turned via a shaft in the starting carburettor housing 48 so that the...

Page 65: ...65 of 116 L files Manuals_For_Products Engine_Manuals Transition JEM2204 9_I M_unsigned docx Figure 32 Carburetor Details Carburettor Overhaul Note As a guide to overhaul read carburetor operation G1...

Page 66: ...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 66 of 116 L f...

Page 67: ...lled REVISION 0 1 2 3 4 5 6 7 8 9 Dated June 2010 Issued By DPS Page 67 of 116 L files Manuals_For_Products Engine_Manuals Transition JEM2204 9_I M_unsigned docx Figure 34 Drawing 9429063 Crank Rod As...

Page 68: ...tion 2 Oil all bearings crank and camshaft 3 Fit halves over crankshaft assembly and squeeze up by hand H4 1 Using spacers and plain nuts on rear studs and belleville washers and MS21042L6 nuts on the...

Page 69: ...the piston is 2mm from T D C Note degrees 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 mounte...

Page 70: ...d with oil before fitting 7 Put loctite 243 on rocker shaft cap screw and torque to 8 ft lbs after fitting rockers 8 Torque head bolts to 16 nm then 32 nm 12 ft lbs then 24 ft lbs Sump and Induction H...

Page 71: ...nt 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 71 of 116 L files M...

Page 72: ...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 It may not line up with the hole...

Page 73: ...Loctite 515 on crankshaft seal housing crank face joint Put a little grease on seal lip and install seal and seal housing assembly to crankcase Apply Loctite to cap screws and torque to 20Nm 15 ft lb...

Page 74: ...n In When built the Jabiru engine is run in on a DYNOMOMETER and cooled with fan driven air In the absence of a DYNO controlled run engines can be run in in the airframe Very large air ducts must be c...

Page 75: ...Key 4 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 socket 8 Connect hourmeter Screw Driver 9 C...

Page 76: ...o fly conservatively 25 Remove Cowls and inspect for anything loose rubbing or leaking 26 Check Head bolt tensions torqued to 20 ft lb 27 At25 hours inspect engine installation Change oil and filter C...

Page 77: ...met and depending on the severity of the prop strike it could be prudent that an engine strip be performed and the crankshaft MPI tested as internal damage may have occurred and can only be revealed...

Page 78: ...issing teeth and that the clutch slides freely on the shaft replace if necessary Check the ball bearings on the motor rotor for serviceability replace if necessary Check the bushes at each end of the...

Page 79: ...ne remove 1 spark plug from each head Add the required run in oil to sump 2 3 litres engine must have oil cooler fitted Press starter to obtain oil pressure and to throw out excess inhibiting oil in c...

Page 80: ...old weather operation Shell also manufacture a multigrade oil Aeroshell 15W50 which is particularly suited for operations in cold climates CAUTION UNDER NO CIRCUMSTANCES USE AUTOMOTIVE OIL IN THIS ENG...

Page 81: ...Clean Crankshaft Conrods and Propeller Mount Plate A2 Inspect Oil Holes and Insert Welch Plugs A3 Measure Crankshaft refer to Goods Inwards Inspection Sheet A4 Inspect and Measure Propeller Mount Flan...

Page 82: ...ly A Component Register Parts Inspection Record Crankshaft Propeller Mount Flange and Conrods Batch ____________ Serial No ____________ Date ____________ Details Big End 4 I hereby certify that the ab...

Page 83: ...ssembly No Details Sign Date B1 Inspect case deburr clean check oil holes B2 Fit inner stud O rings B3 Fit all studs B4 Fit outer oil suction and conrod welch plugs B5 Fit oil relief valve oil pressur...

Page 84: ...ts Inspection Record Crankcase and Camshaft Assy Batch ____________ Serial No ____________ Date ____________ Details 6 Cam Tunnel I hereby certify that the above listed parts conform with the dimensio...

Page 85: ...ders and Cylinder Heads No Details Sign Date C1 Clean and deburr all parts C2 Record all measurements C3 Install pushrod tube O Rings C4 Check valve seats fit spring retainers install valves C5 Fit in...

Page 86: ...ter and Parts Inspection Record Pistons Cylinders and Cylinder Heads Batch ____________ Serial No ____________ Date ____________ Description Part No Batch Item Details Guides Inlet Outlet Head 1 49010...

Page 87: ...ssued By DPS Page 87 of 116 L files Manuals_For_Products Engine_Manuals Transition JEM2204 9_I M_unsigned docx 9 7 Subassembly D Component Assembly Procedure Sump No Details Sign Date D1 Deburr and wa...

Page 88: ...PS Page 88 of 116 L files Manuals_For_Products Engine_Manuals Transition JEM2204 9_I M_unsigned docx 9 8 Subassembly D Component Register and Parts Inspection Record Sump Batch ____________ Serial No...

Page 89: ...ucts Engine_Manuals Transition JEM2204 9_I M_unsigned docx 9 9 Subassembly E Component Assembly Procedure Flywheel and Ignition Coils No Details Sign Date E1 Deburr and Clean E2 Fit magnets using sila...

Page 90: ...uals_For_Products Engine_Manuals Transition JEM2204 9_I M_unsigned docx 9 10 Subassembly E Component Register and Parts Inspection Record Flywheel Assy Batch ____________ Serial No ____________ Date _...

Page 91: ...F1 Deburr clean and inspect all of the gears F2 Measure the shaft post internal diameters and the distributor shaft diameters F3 Using loctite 515 fit the shaft posts to the gear housing F4 Fit the d...

Page 92: ...JEM2204 9_I M_unsigned docx 9 12 Subassembly F Component Register and Parts Inspection Record Gear Case Batch ____________ Serial No ____________ Date ____________ Description Part No Batch Item Deta...

Page 93: ...onent Assembly Procedure Fuel Pump and Carburettor No Details Sign Date G1 Fuel Pump Disassembly G2 Drill hole in spacer and insert breather G3 Final assembly checked for correct flow G4 Drill and tap...

Page 94: ...over crankshaft and camshaft H4 Tension front 2 and rear 2 studs H5 Fit oil pump assembly and front seal housing H6 Place all through bolts in crankcase H7 Fit piston and cylinder assemblies and chec...

Page 95: ...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 95 of 116 L files Manuals_For_Products Engin...

Page 96: ...engines now take approx 50 minutes with this format but with shorter time intervals CAUTION When ground running engine special LARGE air ducts an OVERSIZE oil cooler MUST BE USED Otherwise overheating...

Page 97: ...________ 3 Ignition Checks repeat a couple of times for each side Left Side 1000 2000 rpm Right Side 1000 2000 rpm 4 Oil Leaks Check Visually 5 Instruments Working and Correct Range 6 Idle Check idle...

Page 98: ...DPS Page 98 of 116 L files Manuals_For_Products Engine_Manuals Transition JEM2204 9_I M_unsigned docx 11 TABLE OF LUBRICANTS Use only oils of registered brands meeting the specification detailed at p...

Page 99: ...nm ft lbs Spark Plugs 12mm 11 8 Cylinder Head Bolts 5 16 34 24 Crankcase Main Studs 3 8 40 30 Flywheel Gear Bolts 5 16 34 24 Crankshaft Prop Flange Cap Screws Lockwire for std length flange only 3 8 4...

Page 100: ...nsigned docx 12 1 PRESCRIBED SEALANTS AND PRIMERS Item Sealant Main Bearing Studs Loctite 620 Conrod Bolts Loctite 620 Oil Pump Bolts Loctite 243 Sump Plate Bolts Loctite 243 Engine Mount Bolts Loctit...

Page 101: ...ores 21 49 to 21 47 Crank Thrust 56 65 to 56 85 Con Rods Big Ends 45 028 to 45 070 Little Ends 23 005 to 23 015 Length Between 74 485 to 74 498 Bore Radius Cam Shaft Journals 19 96 to 19 97 Valve Lift...

Page 102: ...Limits All Dimensions are in Millimetres Mains 0 10 Big Ends 0 08 Little Ends 0 03 Camshaft Journals 0 08 Crank End Float 0 80 Cam End Float 0 50 Lifter Crankcase 0 19 Piston Cylinder 0 15 Ring Side...

Page 103: ...ge 103 of 116 L files Manuals_For_Products Engine_Manuals Transition JEM2204 9_I M_unsigned docx 12 4 ELECTRICAL SYSTEMS SPECIFICATIONS All Dimensions are in Millimetres Ignition Primary Resistance 8...

Page 104: ...HAUST 4 CARBY 2 OIL VENT 1 FUEL PUMP 1 VARY your RPM when flying with a new engine Do not Baby a new engine The purpose of breaking in an engine correctly is to ensure a long reliable life All moving...

Page 105: ...wide open throttle ignitions OFF Turn over on starter A reading below 90 PSI may indicate removal of head and possibly cylinder Pressure Differential Test As an alternative to a compression test a pr...

Page 106: ...een blended specifically for the difficult operating conditions found in an air cooled aero engine operation and using automotive will be extremely detrimental to its operation When you change oil fro...

Page 107: ...round 900 RPM will automatically create the right starting environment As the engine is run in on a dynamometer the Idle set screw may have to be adjusted to give 900 RPM idle when warm Normal start r...

Page 108: ...Thoroughly dry internally 10 Spark plugs damp due to condensation Thoroughly dry both inside and outside of plugs 11 Plug face wet by fuel due to excessive actuation of choke or overflow of carb Dry s...

Page 109: ...units 2 Too much oil in crankcase Check oil level adjust if necessary 3 Insufficient fuel supply Check fuel supply system 4 Fuel not according to specifications Re fuel with specified fuel 5 Incorrec...

Page 110: ...damage 14 1 10 Engine Hard to Start at Low Temperature Possible Cause Remedy 1 Starting speed too low Preheat engine 2 High oil pressure At very low temperatures a pressure reading of up to around 500...

Page 111: ...display flicking of the needle pointer for brief periods but still within normal operating regions If it continues check continuity of sender lead and or possible sender change We are assuming oil le...

Page 112: ...e document becomes uncontrolled REVISION 0 1 2 3 4 5 6 7 8 9 Dated June 2010 Issued By DPS Page 112 of 116 L files Manuals_For_Products Engine_Manuals Transition JEM2204 9_I M_unsigned docx 15 Airwort...

Page 113: ...i Before the engine has operated a total of 200 hours or ii Within twelve 12 months of the date of delivery of the engine to the first retail purchaser Whichever comes first and 2 The engine has been...

Page 114: ...re not covered by this Limited Express Warranty Consequential damages and freight costs are also not covered by this Limited Express Warranty JABIRU makes no representation that this engine is suitabl...

Page 115: ...nsition JEM2204 9_I M_unsigned docx LIMITED EXPRESS WARRANTY ON JABIRU REPLACEMENT PARTS As a part of its Limited Express Warranty JABIRU warrants in respect of JABIRU parts and accessories required a...

Page 116: ..._________ ENGINE PARTS AIRFRAME PARTS ENGINE NUMBER AIRFRAME KIT NUMBER __________ PART NUMBER TOTAL HOURS __________________ OWNER PREVIOUS OWNER _______________ PART DESCRIPTION CLAIM FAULTY GOODS R...

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