Engine Overhaul Manual
Jabiru Aircraft
Pty Ltd
Jabiru 2200 & 3300 Aircraft Engines
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Dated : 28/10/2014
Issued By: AS
Page: 21 of 201
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completed and the engine re-assembled. However, often the customer will decide to incorporate a
mini-overhaul or top-end into the bulk strip.
The point of the bulk strip is to check several critical items inside the engine to ensure that it is suitable
to be returned to service. Depending on what has happened to the engine some parts will mandatorily
be replaced.
In addition to the potential damage to the engine which required the bulk strip in the first place it is
Jabiru policy that the engine must be made up-to-date and airworthy before being re-assembled. This
means that items which are listed as a “Mandatory Update” within this manual must be carried out
during a bulk strip as they would be during an overhaul. For example a crankshaft which has no
flywheel dowels must be updated to accept them or replaced by a new assembly during a bulk strip.
3.4.1.1
Bulk Strip Checklist
Personnel carrying out a bulk strip must be qualified to the same degree as those carrying out a full
overhaul.
The tools, equipment, sealants and compounds used in the bulk strip are the same as those used for a
full overhaul
– the person carrying out this work must have all available.
Measure crankshaft and propeller flange run-out before disassembling the engine to help gauge the
potential severity of the damage to the engine. Use the procedure detailed in Section 4.4.1.
Engine strip and cleaning are the same as detailed in Section 4.
Check for mandatory updates as detailed in Section 4 and replace / rework parts as necessary.
Re-measure crankshaft and propeller flange run-out on the bench for best accuracy.
MPI test the propeller flange, crankshaft and connecting rods.
Replace all screws used in the propeller flange, flywheel and connecting rod attachments.
Replace O rings and gaskets as required.
Replace piston circlips with new parts
Assembly of the engine is as detailed in Section 7.
Fill out engine build sheets.
Carry out engine test runs
Carry out post-run inspections.
Complete a report for the customer, detailing what was found in the engine and which parts were
replaced.
3.4.2 Propeller strike procedures
Propeller strike is categorized as being one of 2 types: low power strike and high power strike.
A low power strike is defined as a propeller strike encountered while the engine is operating at a low
power setting (eg. while taxiing) with a standard Jabiru softwood propeller. Damage to the propeller
must extend no more than 100mm inwards from the blade tips. If any of these parameters are not met
the event is considered to be a high power strike.
High power strikes also include any other type of abrupt engine stoppage at any other engine operating
condition.
The flywheel retaining cap screws (6) and propeller flange retaining screws (6) need to be replaced
after any prop strike.
3.4.2.1
Low Power Prop Strike Checklist
The flywheel retaining cap screws (6) and propeller flange retaining screws (6) need to be replaced
after any prop strike.
If a low power strike has been encountered then crankshaft runout must be checked as detailed in
Section 4.4.1 and if necessary the propeller flange and/or the crankshaft may need to be replaced.
When replacing the flywheel and propeller flange cap screws remember that they are held in place with
Loctite 620, which is very strong. They will be very difficult to undo and great care must be taken not to
break any of them. Lock the crankshaft from turning and then apply heat to the area around the cap
screws, and then try to crack each cap screw loose using an Allen key and a 3/8” breaker bar. This step
may involve heating the end of the crankshaft several times until you can safely undo each cap screw.
Details on removing these screws are included in Section 4.5.4. The procedure to be used for replacing
the screws in the propeller flange is the same.