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Engine Maintenance Manual
Jabiru Aircraft
Pty Ltd
JEM0002-5
Jabiru 2200 & 3300 Aircraft Engines
This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled.
ISSUE
1
2
3
4
5
Dated : 2nd June 2015
Issued By: AS
Page: 4 of 103
L:\files\Manuals_For_Products\Engine_Manuals\Engine Maintenance Manual 22 & 33\JEM0002-5.docx
9.14
T
ACHOMETER AND
S
ENDER
.............................................................................................................. 65
9.15
H
EAD
B
OLT
T
ENSION
C
HECK
............................................................................................................ 66
9.16
I
NSPECT
V
ALVE
S
PRINGS
&
R
OCKERS
.............................................................................................. 67
9.17
V
ALVE
C
LEARANCE
A
DJUSTMENT
(S
OLID
L
IFTER
E
NGINES
O
NLY
) ...................................................... 68
9.18
C
OMPRESSION
C
HECK
..................................................................................................................... 69
9.18.1
Compression Gauge: ................................................................................................................................ 69
9.18.2
Pressure Differential Test: ......................................................................................................................... 69
9.18.3
Identifying Compression Leaks ................................................................................................................. 70
9.19
F
UEL
F
LOW
R
ATE
T
EST
.................................................................................................................... 70
9.20
H
YDRAULIC
V
ALVE
L
IFTER
M
AINTENANCE
......................................................................................... 71
9.20.1
Hydraulic Lifter Removal ........................................................................................................................... 72
9.20.2
Valve Rockers ........................................................................................................................................... 72
9.21
I
GNITION
C
OIL
&
A
LTERNATOR
E
LECTRICAL
I
NSPECTIONS
.................................................................. 73
9.22
F
LYWHEEL
S
CREW
B
ASIC
I
NSPECTION
.............................................................................................. 74
9.23
F
LYWHEEL
S
CREW
D
ETAILED
I
NSPECTION
......................................................................................... 74
9.24
U
SE OF
S
AFETY
W
IRE
...................................................................................................................... 74
9.25
E
NGINE
O
VERHAUL AND
TBO ........................................................................................................... 77
9.25.1
Full Overhaul ............................................................................................................................................. 77
9.25.2
Top End Overhaul ..................................................................................................................................... 77
9.26
E
NGINE
R
EMOVAL
P
ROCEDURE
........................................................................................................ 78
9.27
E
NGINE
I
NSTALLATION
...................................................................................................................... 79
9.28
P
ROP
S
TRIKE
I
NSPECTION
................................................................................................................ 80
9.29
P
ROPELLER
F
LANGE
I
NSTALLATION
/
R
EMOVAL
................................................................................. 81
10
TROUBLE SHOOTING .......................................................................................................... 82
10.1
E
NGINE
W
ON
'
T
S
TART
..................................................................................................................... 82
10.2
E
NGINE
I
DLES
U
NSTEADILY
A
FTER
W
ARM
-U
P
P
ERIOD
:
S
MOKY
E
XHAUST
........................................... 82
10.3
E
NGINE
R
UNS
E
RRATICALLY OR
M
ISFIRES
O
CCASIONALLY
................................................................ 82
10.4
F
ULL
P
OWER
S
TATIC
RPM
B
ELOW
S
PECIFICATIONS
......................................................................... 82
10.5
E
NGINE
R
UNS
T
OO
H
OT
-
O
IL
T
EMPERATURE
A
BOVE
110
O
C
(230
O
F) ................................................ 83
10.6
CHT
R
EADING
E
RROR
..................................................................................................................... 83
10.7
U
NSATISFACTORY
P
OWER
O
UTPUT
.................................................................................................. 83
10.8
L
OW
O
IL
P
RESSURE
......................................................................................................................... 84
10.9
O
IL
P
RESSURE
V
ARYING
.................................................................................................................. 84
10.10
E
NGINE
K
EEPS
R
UNNING WITH
I
GNITION
O
FF
.................................................................................... 84
10.11
E
XCESSIVE
O
IL
C
ONSUMPTION
......................................................................................................... 84
10.12
O
IL
C
OLLECTOR
B
OTTLE ON
F
IREWALL
F
ILLS
Q
UICKLY
...................................................................... 84
10.13
E
XCESSIVE
V
IBRATION
..................................................................................................................... 85
10.14
K
NOCKING
U
NDER
L
OAD
.................................................................................................................. 85
10.15
E
NGINE
H
ARD TO
S
TART AT
L
OW
T
EMPERATURE
–
C
OLD
S
TART
C
HECKLIST
...................................... 86
10.16
I
RREGULAR
/
L
OW
C
OMPRESSIONS
................................................................................................... 87
10.17
H
YDRAULIC
V
ALVE
L
IFTERS
.............................................................................................................. 88
11
ENGINE MAINTENANCE WORKSHEETS ............................................................................ 89
11.1
25-H
OUR
I
NSPECTION
W
ORKSHEET
.................................................................................................. 89
11.1.1
Engine & Engine Compartment (refer to section 8.8) ................................................................................ 89
11.2
50
HOUR
,
100
HOUR AND
A
NNUAL
I
NSPECTION
W
ORKSHEET
............................................................. 90
11.2.1
Engine & Engine Compartment (refer to section 8.8) ................................................................................ 90
12
NEW ENGINE
– JABIRU’S LIMITED, EXPRESS WARRANTY ............................................. 94
13
JABIRU’S LIMITED, EXPRESS WARRANTY: CLAIM FORM ............................................. 100
14
REVISIONS .......................................................................................................................... 101
15
FEEDBACK AND REPORTING ........................................................................................... 102
15.1.1
Continued Operational Safety Reporting ................................................................................................. 103
15.1.2
Owner Change of Address Notice ........................................................................................................... 103