Engine Overhaul Manual
Jabiru Aircraft
Pty Ltd
Jabiru 2200 & 3300 Aircraft Engines
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Dated : 28/10/2014
Issued By: AS
Page: 22 of 201
L:\files\Manuals_For_Products\Engine_Manuals\Overhaul_Manual\JEM0001-7_Overhaul_Manual_DRAFT_(29_10_14).docx
Do NOT apply heat directly to the cap screws because this could weaken the screw material, but rather
apply the heat to the area around the cap screws. This is particularly important because you will need to
apply considerable turning force to undo each cap screw.
Clean out all threads and then prime the threads and the new cap screws with Loctite 7471 cure
accelerator and allow to dry. Apply a few drops of Loctite 620 Retainer to each thread and each cap
screw and tighten in sequence to the recommended torque value from the table of limits. Section 7.8
details the assembly of the flywheel and propeller flange to the engine
– these procedures are also to
be used here.
3.4.2.2
High Power Strike Repair Checklist
Jabiru policy for a high power strike is to Bulk Strip in accordance with Section 3.4.1.1: Disassemble,
clean and inspect the engine updated. Re-assemble the engine, complete build sheets, test run, carry
out a post-run inspection and complete a report for the customer.
In particular, carefully check that the engine mount plate has not been bent, check the propeller flange
for condition and straightness and inspect the flywheel connection for damage. Replace the crankshaft
and MPI inspect the connecting rods. Check and carry out any mandatory updates.
3.4.3 Abrupt Engine Stoppage
An abrupt engine stoppage may be caused by a number of different failures within the engine but
essentially any hard, harsh stoppage of the engine is considered to fall into this category. A piston
failure is a typical example.
Abrupt engine stoppages are treated the same as high power propeller strike.
3.5 Sequence of Events
1.
Engine Build Sheet / Checklists
– fill out the necessary documents to record the details of the
engine. Prepare the necessary sheets to record the configuration / condition of the engine as it
is disassembled, cleaned and inspected.
2.
Disassemble
– disassemble the engine to the extent necessary for the proposed work – i.e. the
top end only for a top end overhaul or completely for a full overhaul.
3.
Clean, Inspect, Measure And Assess
– clean the engine components, measure wear items
and assess the engine’s parts for re-use. Inspect parts as required (i.e. visual or Magnetic NDT
processes). Refer to the mandatory replacement list given in Section 5 and if applicable,
remove and quarantine any superseded components. Refer also to all the supplementary data
applicable to the engine
– such as Service Bulletins and Service Letters. This step is critical for
the overhauler to assess the overall condition of the engine.
4.
Assemble
– Re-assemble the engine.
5.
Test Run
– A proof run and then running-in is necessary before the overhaul is considered
complete. Running-in may be carried out in the air or, preferably, on a specialised ground-run
stand using special oversized cooling ducts and oil cooler.
6.
Record
– The records of the overhaul must be completed, including lists of parts replaced and
the records of the run-in (temperatures, pressures etc).
