Jabiru 2200, Maintenance Manual

Page 1: ...is document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled Every effort is made to ensure that the information provided is accurate a...

Page 2: ...00C 12 3 1 4 2200A 12 3 2 3300 ENGINE MODELS 13 3 2 1 3300L 13 3 2 2 3300A 13 3 3 DESIGN DETAILS 14 3 4 GENERAL SPECIFICATIONS EQUIPMENT 15 3 5 FULL POWER STATIC RPM 16 3 6 PERFORMANCE 16 3 6 1 Engine...

Page 3: ...eturning Engine to Service After Temporary Indefinite Storage 43 7 2 6 New Engine Storage 44 7 3 CLEANING ENGINE AND ENGINE COMPARTMENT 44 8 MAINTENANCE 45 8 1 SERVICE INTERVAL TOLERANCE 45 8 2 BASIC...

Page 4: ...9 9 28 PROP STRIKE INSPECTION 80 9 29 PROPELLER FLANGE INSTALLATION REMOVAL 81 10 TROUBLE SHOOTING 82 10 1 ENGINE WON T START 82 10 2 ENGINE IDLES UNSTEADILY AFTER WARM UP PERIOD SMOKY EXHAUST 82 10 3...

Page 5: ...Figure 18 Valve Leakage Vacuum Tester 36 Figure 19 Valve Spring Compressor Collet Remover 37 Figure 20 Leak Down Tester 37 Figure 21 Hand Press Inserts 37 Figure 22 Optical Tachometer 37 Figure 23 Sup...

Page 6: ...cted engine stoppage engine damage or harm to other parts of the aircraft to which it may be fitted and may lead to injury or death Jabiru Aircraft Pty Ltd does not support any modifications to the en...

Page 7: ...components are machined from solid The sump oil pan is cast aluminium The cylinders are machined from bar 4140 chrome molybdenum alloy steel with the pistons running directly in the steel bores The c...

Page 8: ...and direct air from the propeller to the critical areas of the engine particularly the cylinder heads and barrels The fitment of these ducts is a great bonus for the home builder or engine installer...

Page 9: ...where you can enter keywords For example searching for the word life will allow you to quickly find all reference to lifed maintenance items 2 6 Degree Of Difficulty In this manual we have used a spa...

Page 10: ...lled out quickly and easily 2 9 Manufacturer Jabiru Aircraft Pty Ltd P O Box 5792 Bundaberg West Queensland 4670 2 10 Engine Manuals JEM0002 Engine Maintenance Manual JEM0001 Overhaul Manual JEM2202 2...

Page 11: ...the manufacturer with current contact information where the manufacturer may send the owner operator supplemental notification bulletins The owner operator of a LSA shall be responsible for notifying...

Page 12: ...ft The CASA Type Certificate Number for the J160 C Aircraft is VA 515 2200B engines with a serial number of 22B001 and above are Manufacturer Certified to the ASTM F2339 design standard 3 1 3 2200C Th...

Page 13: ...gine has a maximum continuous RPM rating of 2850RPM The engine may be operated at engine speeds between 2850RPM 3300RPM for up to 10 minutes All other engine specifications and limitations are identic...

Page 14: ...Manuals Engine Maintenance Manual 22 33 JEM0002 5 docx 3 3 Design Details 4 Stroke 4 2200 or 6 3300 Cylinder Horizontally Opposed 1 Central Camshaft Push Rods Over Head Valves OHV Solid Valve Lifters...

Page 15: ...435 3300 23 BTDC S No S No 2436 on Firing Order 2200 1 3 2 4 3300 1 4 5 2 3 6 Fuel Consumption 2200 13 15 l hr 3 5 4 0 US gal hr 75 Power 3300 23 25 l hr 6 1 6 6 US gal hr Fuel AVGAS 100 130 or 100LL...

Page 16: ...ives unloaded Vacuum Pump not fitted Full rich fuel air mixture Maximum cylinder head temperature Standard Jabiru air filter and cold air Standard exhaust muffler 3 6 1 Engine Ratings Table 2 Engine R...

Page 17: ...llations or configurations refer to the Jabiru Engine Installation Manual for additional details 3 8 Lubricant The following chart is intended to assist in choosing the correct grade of oil and must b...

Page 18: ...rcial Designations Equivalence of SAE and commonly used Commercial Grade designations SAE 20 30 40 50 60 Commercial 55 35 80 100 120 Figure 1 Oil System Schematic 3 9 Cooling System Type Free air cool...

Page 19: ...si solid lifter engines Max 525 kPa 76 psi solid lifter engines Max 350 kPa 51psi hydraulic lifter engines Max 350 kPa 51 psi hydraulic lifter engines Idle Min 80 kPa 11 psi Min 80 kPa 11 psi Starting...

Page 20: ...opeller Bolts For wooden propellers manufactured by Jabiru Aircraft only 1 4 8 9 5 6 7 3 12 Propeller Selection Specifications WARNING Correct propeller selection tuning and maintenance are vital for...

Page 21: ...02 5 docx 3 13 Electrical System Specifications Table 11 Ignition System Honda Coil PI0524N Jabiru Coil CPI4A023A0D Jabiru Coil NEGCOIL6ASSY Primary Resistance 1 9 to 2 1 1 6 to 2 5 1 6 to 2 5 Seconda...

Page 22: ...u server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 2nd June 2015 Issued By AS Page 22 of 103 L files Manuals_For_Products Engine_Manuals Engine Maintenance Ma...

Page 23: ...u server Once this no longer applies the document becomes uncontrolled ISSUE 1 2 3 4 5 Dated 2nd June 2015 Issued By AS Page 23 of 103 L files Manuals_For_Products Engine_Manuals Engine Maintenance Ma...

Page 24: ...103 L files Manuals_For_Products Engine_Manuals Engine Maintenance Manual 22 33 JEM0002 5 docx 3 18 Distributor Cylinder Map Figure 6 Distributor Cylinder Map 3 19 2200 Power Curve Multiply Kilowatts...

Page 25: ...e_Manuals Engine Maintenance Manual 22 33 JEM0002 5 docx Figure 8 Power Curve Typical 2200C 2200B Engine 3 20 3300 Power Curve Figure 9 Power Torque Curves Typical 3300 Engine 4 CYLINDER POWER CURVE 2...

Page 26: ...ess Limitations 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 26...

Page 27: ...use v Also see Section 5 10 for special operating procedures for the first 25 hours of operation or after an overhaul Check lubrication fuel system for leaks i Visually inspect for signs of leakage on...

Page 28: ...y full power until CHT reaches 100 C 212 F DO NOT apply full power until Oil Temperature reaches 40 C 104 F DO NOT allow cylinder heads to rise above 180 C 356 F during ground running 5 4 Ground Runni...

Page 29: ...n lead to freezing of fuel lines filters or jets Remedies are a Drain using fuel tank water drain b Ensure fuelling without traces of water If in doubt use a chamois as a filter c Install a generously...

Page 30: ...nd power settings Failure to operate at realistic power settings could be detrimental to engine condition long term performance Always take off using full power especially when the engine is new Avoid...

Page 31: ...un supervised 6 5 Tool Gauge Control Tool and gauge control is an important part of aviation maintenance systems Tools and gauges must be accurate enough for the intended use i e a 12 steel ruler is n...

Page 32: ...ion containment recycling Dial indicator and magnetic stand vee blocks Hand press Heat gun or small butane propane torch with a soft pencil flame Micrometer and internal measuring tools must read up t...

Page 33: ...ctite 7471 Cure Accelerator Loctite 7471 is used where increased cure speed of Loctite anaerobic products is required 7471 is particularly recommended when prevailing temperature is low 15 C Used as a...

Page 34: ...an operating range of 29 C to 482 C Used on spark plugs and cylinder head screws Loctite Nickel Anti Seize is copper free Recommended for stainless steel and other metal fittings For preventing corro...

Page 35: ...a minute is not recommended particularly if cure accelerator spray Loctite 7471 is used Only use as much as required specified Excess compound can make it nearly impossible to disassemble the parts l...

Page 36: ...an simplify maintenance and are shown in the photos below Note that only those tools applicable to normal maintenance are shown below refer to the Jabiru Engine Overhaul Manual for additional tools re...

Page 37: ...om the valve and then the valve to be removed from the head Also used for installation Figure 20 Leak Down Tester Figure 21 Hand Press Inserts A hand press is used to install rocker bushes distributor...

Page 38: ...th pins that pit into the propeller flange holes Allows the crank to be held easily while tightening or loosening propeller flange or flywheel screws Figure 25 Carburettor Needle Seat Remover and Inst...

Page 39: ...anuals Engine Maintenance Manual 22 33 JEM0002 5 docx Figure 26 Crowsfoot Adaptor Figure 27 Universal Joint tool FU14B Figure 28 Safety Wire Wire Pliers Wire used to secure items nuts bolts etc to pre...

Page 40: ...gure 26 is also necessary it allows high torque settings to be used on small nuts without damaging them The crankcase through bolt nuts used on Jabiru engines are a good example of an application suit...

Page 41: ...ccurate bolt torque reading is going to be obtained Firstly the nut must be tightened smoothly Any jerks or bumps can cause the torque reading to be obtained prematurely The torque must be obtained wh...

Page 42: ...ined in the manual will affect claims upon Jabiru s Limited Express Warranty 7 2 1 Flyable Storage Flyable storage is defined as a maximum of 30 days non operational storage Ensure that the engine has...

Page 43: ...it if there is no escape path 9 Attach a warning placard to the instrument panel stating that vents and breathers have been sealed and that the engine must not be started with the seals in place 10 Ev...

Page 44: ...tory or ii Repeat the Temporary Storage procedures given in Section 7 2 3 at a suitable interval 90 days nominally depending on ambient temperature humidity etc and periodically inspect the engine in...

Page 45: ...detailed in the Engine Overhaul Manual Mandatory inspections are detailed in Table 13 8 4 1 Flexible Hoses All flexible hoses in the engine compartment should be replaced at engine overhaul or every 2...

Page 46: ...ry from inadvertent engine start Table 13 Engine Inspection Chart Annual Inspection Each 200 Hours Each 100 Hours Each 50 Hours Each 25 Hours PROPELLER 1 Spinner 2 Spinner Mount Plates 3 Spinner Screw...

Page 47: ...r air filter mandatory replacement 10 Engine baffles and air ducts 11 Cylinders 12 Crankcase front crankcase seal 13 Fuel hoses lines and fittings 14 Intake and exhaust systems 15 Ignition harness dis...

Page 48: ...el filter s 2 Drain valves carburettor bowl 3 Electronic fuel boost pump and fittings 4 Fuel lines taps and connectors 5 Fire sleeves 6 Fuel Flow Rate 8 6 Pre Maintenance Inspections As all possible c...

Page 49: ...nce to check for abnormalities If oil pressure is outside limits it may be corrected by adjusting the oil pressure relief valve per Section 9 6 2 Engine Cowlings Fasteners Remove check for damage or w...

Page 50: ...3 4 It is recommended to set the gaps at the minimum limit during winter for easier starting 16 Spark plugs Replace at the intervals specified in Table 13 Adjust the gap of the new plugs to within th...

Page 51: ...wear Ensure that where the hose connects to the carburettor there is minimum bunching a rough surface here from bunched hose can adversely affect the function of the carburettor 38 Engine Post Inspect...

Page 52: ...ty wires ignition wiring hose connections 19 Re torque cylinder head bolts to the setting noted in Table 10 in a diagonal pattern see Section 9 15 20 Check valve clearances Solid lifter engines only 2...

Page 53: ...eed additional attention WARNING Using a non approved propeller may lead to unforeseen operational airworthiness safety financial or legal problems Jabiru Aircraft accept no responsibility for such is...

Page 54: ...ual Inspection Each 500 Hours Each 100 Hours Each 50 Hours 1 Spinner spinner flange hardware Check condition 2 Propeller general condition visual hand check 3 Propeller blade pitch tracking 4 Propelle...

Page 55: ...failure Positioned with consideration to other personnel i e where noise impacts are minimised During the run up observe the following making note of any discrepancies or abnormalities Engine temperat...

Page 56: ...inner Rotate the propeller by hand and check that the Spinner runs true Spinner tracking can be adjusted by loosening the mounting screws moving the tip in the required direction and re tightening If...

Page 57: ...e the oil seal of the old filter comes away from the engine with the filter Inspect the sump plug seal replace if worn or damaged Re fit the sump plug Tighten to the tension given in Table 10 lock wir...

Page 58: ...if required Additional flat washers if required Type of Maintenance Line Maintenance Level of Certification L2 or LAME A P or LSA Repairman Maintenance Return to Service L2 or LAME A P or LSA Repairm...

Page 59: ...Required Tools Screwdrivers Air compressor with airgun Parts and Material N A Type of Maintenance Line Maintenance Level of Certification L1 L2 or LAME Owner A P or LSA Repairman Maintenance Return to...

Page 60: ...ION When working at the rear of the engine care must be taken to ensure no metallic materials are captured by the ignition or alternator magnets 9 9 High Tension Lead Inspection Maintenance Required T...

Page 61: ...turn to Service L1 L2 or LAME Owner A P or LSA Repairman Maintenance Do not use steel or brass brushes for cleaning never sandblast plugs Clean with plastic brush in a solvent Check electrode gap if n...

Page 62: ...dard idle mixture screw position is 1 1 4 turns out Fine adjustment may be necessary to give a smooth idle Remove the spring clip and detach the bowl from the carburettor Measure the distance from the...

Page 63: ...poxy with cotton flock Type of Maintenance Heavy Maintenance Level of Certification L2 or LAME A P or LSA Repairman Maintenance Return to Service L2 or LAME A P or LSA Repairman Maintenance Remove the...

Page 64: ...required Type of Maintenance Line Maintenance Level of Certification L1 L2 or LAME Owner A P or LSA Repairman Maintenance Return to Service L1 L2 or LAME Owner A P or LSA Repairman Maintenance Replace...

Page 65: ...y apparent engine problems can be caused through inaccurate tachometers Where engine performance is observed to be outside limits the tachometer should be checked against a calibrated instrument befor...

Page 66: ...the spark plugs and the ducts may be swung away to allow access Remove the rocker covers and the 1 8 NPT plug which gives access to the lower head bolt see at the location indicated as bolt 5 in Figur...

Page 67: ...fit the ram air cooling ducts CAUTION Do not over tighten Over tightening will eventually loosen fit between plug head to the point where the plug will not be secure Figure 39 Head Bolt Locations 9 16...

Page 68: ...t a cylinder head bolt tension check Section 9 15 before adjusting valve clearances Valve clearance must be adjusted to Inlet 0 254mm 010 Exhaust 0 254mm 010 Adjust the tappets when the engine is cold...

Page 69: ...or LSA Repairman Maintenance Always carry out a cylinder head bolt tension check Section 9 15 and where applicable valve clearance checks Section 9 16 before testing compression 9 18 1 Compression Gau...

Page 70: ...ting section below please contact Jabiru Aircraft or our local authorized representative After testing note the results in the maintenance worksheet and re assemble the engine 9 18 3 Identifying Compr...

Page 71: ...ugh running This must be carried out with the cowls removed Note that due to the need to have a person at the controls of the aircraft this is a two person job CAUTION Whenever the engine is running t...

Page 72: ...the engine b Ensure the piston of the cylinder being worked on is at the bottom of its stroke c Use a valve compression tool Figure 16 to open both valves slightly This takes the spring load off the r...

Page 73: ...21 Ignition Coil Alternator Electrical Inspections Required Tools Multimeter Parts and Material N A Type of Maintenance Line Maintenance Level of Certification L2 or LAME A P or LSA Repairman Maintena...

Page 74: ...LAME A P or LSA Repairman Maintenance Remove the alternator stator to allow access to the flywheel Where equipped the vacuum pump must also be removed Set a torque wrench to one of the following sett...

Page 75: ...uct or tube must not cross over or obstruct a flow passage when an alternate routing can be used h Check the units to be safety wired to make sure that they have been correctly torqued and that the wi...

Page 76: ...ns 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 76 of 103 L files Manuals_For_Products Engine_Manuals Engine...

Page 77: ...lts woodruff key oil pump crankcase through bolts and crankcase studs Cylinder heads and dizzy shafts are usually replaced at a full overhaul depending on condition As a part of the overhaul process t...

Page 78: ...by Heat hose from hot air muff on muffler Flat bladed Screwdriver 3 Remove Air Inlet Hose from Carburettor and blank off Carburettor and Air Cleaner Flat bladed Screwdriver 2 Plugs 4 Disconnect Thrott...

Page 79: ...s 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 Connect oil temp gauge sender 10 Connect oi...

Page 80: ...he Engine Overhaul Manual Replacement flywheel cap screws Type of Maintenance Heavy Maintenance Level of Certification L2 or LAME A P or LSA Repairman Maintenance Return to Service L2 or LAME A P or L...

Page 81: ...ion to run an engine after a prop strike and after carrying out the above run out checks rests with the owner If you have any doubt about the action to take then consult the Jabiru factory or your Aut...

Page 82: ...gs trace possible faults in fuel system or over flow of carb 12 Float valve dirty or jammed Clean or renew float valve 13 Jets in carb clogged Clean jets 14 Water in carb Drain clean carb fuel line fi...

Page 83: ...eratures Verify original reading using a second thermometer such as a hand held infrared thermometer 3 Cold junction temperature The standard gauges used in Jabiru Aircraft assume that the cold juncti...

Page 84: ...ssary 2 Sender gauge or connection fault Check continuity of sender wire Check sender body is earthed to engine Check gauge replace with known good gauge if possible Adjust oil pressure relief valve 1...

Page 85: ...just spinner balance see Section 0 or manufacturer s instructions 5 Unsuitable propeller Replace propeller Quality 2 bladed fixed pitch wooden types recommended 6 Incorrect Tuning Check adjust carbure...

Page 86: ...battery charge Fit fully charged battery The life of a Battery varies but is generally less than 4 years 10 Operation Minimise the time spent at low RPM with high powered devices running At low RPM t...

Page 87: ...engine Figure 48 Choke Schematic 10 16 Irregular Low Compressions Symptoms Possible Cause Remedy 1 Compression on 1 or more cylinders low Debris on valve seat Blow debris off seat Section 9 18 2 refe...

Page 88: ...lace lifter s Soft lifter s due to low oil pressure See Low Oil Pressure section above Soft lifter s due to air in lifter Run engine Up to 15 minutes running may be required to completely expel air fr...

Page 89: ...MANUAL JEM0002 BEFORE USING THESE CHARTS WORKSHEETS AIRCRAFT MAKE MODEL REGO S N ENGINE MAKE MODEL S N TT AIRFRAME TT ENGINE CARRIED OUT BY print name signature date 11 1 1 Engine Engine Compartment...

Page 90: ...n parts replaced etc IMPORTANT READ ALL INSPECTION AND MAINTAINANCE REQUIREMENTS IN THIS MANUAL JEM0002 BEFORE USING THESE CHARTS WORKSHEETS AIRCRAFT MAKE MODEL REGO S N ENGINE MAKE MODEL S N TT AIRFR...

Page 91: ...s noted in section 9 16 13 Hydraulic lifter rocker inspection Check as noted in section 9 20 14 Compression leak down check Conduct in accordance with section 9 18 1 80 2 80 3 80 4 80 5 80 6 80 15 Oil...

Page 92: ...oves smoothly function correctly 26 SCAT hose condition Check for damage and wear ensure that where the hose connects to the carburettor there is minimum bunching 27 Cabin heat system Inspect for dama...

Page 93: ...ailed in section 9 23 Replace at 500 hours regardless of condition 36 Crankcase front crankcase seal Check for leaks 37 Ignition harness distributor caps rotors Insect for damage wear adjust as needed...

Page 94: ...ovided for in Section IV Exclusions below which appears in the engine provided that 1 Notice of the defect has been provided in writing to JABIRU a Before the engine has operated a total of 200 hours...

Page 95: ...U Flight Manual or Maintenance and Operation Manual service documents airworthiness directives bulletins instructions and recommendations or by neglect 4 Improper installation including overheating 5...

Page 96: ...TATIONS IDENTIFIED IN THIS WARRANTY THEREFORE THE ABOVE STATED DISCLAIMERS AND OR LIMITATIONS MAY BE INAPPLICABLE THIS WARRANTY GIVES THE OWNER SPECIFIC LEGAL RIGHTS AND THE OWNER MAY ALSO HAVE OTHER...

Page 97: ...eplacement any defect occurring in any such JABIRU parts and accessories within twelve 12 months from the date of acquisition Normal wear and tear is excluded This Limited Express Warranty does not co...

Page 98: ...r liquids Further for any engine to be delivered to a JABIRU Dealer Distributor located outside Australia it is the owner s sole responsibility to comply with any and all cleaning requirements imposed...

Page 99: ...icular time XIII Changes and modification of this Warranty JABIRU reserves the right to modify this warranty at any time in writing However any such modification will not change the terms of the warra...

Page 100: ...__ ENGINE PARTS AIRFRAME PARTS ENGINE NUMBER AIRFRAME KIT NUMBER __________ PART NUMBER TOTAL HOURS __________________ OWNER PREVIOUS OWNER _______________ PART DESCRIPTION CLAIM FAULTY GOODS RETURNED...

Page 101: ...ral Information Section Add Revisions Section 14 AS 05 05 14 4 Add requirement for 100 hourly flywheel screw replacement for non approved propellers Add requirement for inhibitor application inside th...

Page 102: ...iles Manuals_For_Products Engine_Manuals Engine Maintenance Manual 22 33 JEM0002 5 docx 15 Feedback and Reporting Any issues or corrections required of Jabiru publications are requested to be passed o...

Page 103: ...ficulty upon discovery The following proforma may be used Date Aircraft Model Aircraft Registration Aircraft S No Propeller Model Propeller S No Engine Model Engine S No Details of item Name of Report...