DOCSLIB.ORG

Overhaul Manual Jabiru 2200 & 3300 Aircraft Engines

Total Page：16

File Type：pdf, Size：1020Kb

Download full-text PDF Read full-text
Overhaul Manual Jabiru 2200 & 3300 Aircraft Engines OVERHAUL MANUAL FOR JABIRU 2200 & 3300 AIRCRAFT ENGINES DOCUMENT No. JEM0001-12 Date: 5th December 2017 This Manual has been prepared as a guide to correctly overhaul Jabiru 2200 & 3300 aero engines. It is the owner's responsibility to regularly check the Jabiru web site at www.jabiru.net.au for applicable Service Bulletins and have them implemented as soon as possible. Manuals are also updated periodically with the latest revisions available from the web site. Failure to maintain the engine or aircraft with current service information may render the aircraft un-airworthy and void Jabiru’s Limited, Express Warranty. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. Should you have any questions or doubts about the contents of this manual, please contact Jabiru Aircraft Pty Ltd. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE 12 Dated : 5/12/2017 Issued By: AS Page: 1 of 202 Engine Overhaul Manual Jabiru Aircraft Pty Ltd JEM0001-12 Jabiru 2200 & 3300 Aircraft Engines 1.1 TABLE OF FIGURES .................................................................................................................................................................. 7 1.2 TABLE OF TABLES.................................................................................................................................................................. 11 2 GENERAL INFORMATION .................................................................................................................................................. 12 2.1 LIST OF EFFECTIVE PAGES / ISSUE STATUS ................................................................................................................................. 12 2.2 INTRODUCTION .................................................................................................................................................................... 13 2.3 APPLICABILITY ...................................................................................................................................................................... 14 2.4 CERTIFICATION BASIS ............................................................................................................................................................ 14 2.5 READING THIS MANUAL ........................................................................................................................................................ 14 2.6 DEGREE OF DIFFICULTY .......................................................................................................................................................... 14 2.7 MANUAL LAYOUT ................................................................................................................................................................. 15 2.8 ENGINE LIFE......................................................................................................................................................................... 15 2.9 COMPLETE OVERHAUL, TOP END OVERHAUL, WEAR TOLERANCES .................................................................................................... 15 2.10 MANDATORY UPDATES .......................................................................................................................................................... 15 2.11 MANDATORY REPLACEMENT OF PARTS ...................................................................................................................................... 15 2.12 RECORDING ......................................................................................................................................................................... 15 2.13 GENERAL DESCRIPTION .......................................................................................................................................................... 16 2.13.1 Engine identification ................................................................................................................................................................... 17 2.13.2 Build Configurations ................................................................................................................................................................... 17 2.13.3 Part Identification ....................................................................................................................................................................... 17 2.13.4 Cylinder Numbering Convention ................................................................................................................................................. 17 2.13.5 Cylinder heads ............................................................................................................................................................................ 17 2.13.6 Valves, valve guides and seats .................................................................................................................................................... 17 2.13.7 Cylinders ..................................................................................................................................................................................... 17 2.13.8 Pistons ........................................................................................................................................................................................ 18 2.13.9 Connecting rods .......................................................................................................................................................................... 18 2.13.10 Crankshaft .................................................................................................................................................................................. 18 2.13.11 Crankcase ................................................................................................................................................................................... 18 2.13.12 Camshaft .................................................................................................................................................................................... 18 2.13.13 Valve operating mechanism ....................................................................................................................................................... 18 2.13.14 Solid lifters .................................................................................................................................................................................. 18 2.13.15 Hydraulic lifters ........................................................................................................................................................................... 18 2.13.16 Roller Followers .......................................................................................................................................................................... 18 2.13.17 Lubricating system ...................................................................................................................................................................... 18 2.13.18 Cooling system ............................................................................................................................................................................ 18 2.13.19 Induction system ......................................................................................................................................................................... 19 2.13.20 Ignition system ........................................................................................................................................................................... 19 2.13.21 Electrical charging system .......................................................................................................................................................... 19 2.13.22 Starter motor .............................................................................................................................................................................. 19 2.13.23 Sump ........................................................................................................................................................................................... 19 2.14 ASSESSING AN ENGINE .......................................................................................................................................................... 19 3 GENERAL OVERHAUL PROCEDURES ................................................................................................................................. 20 3.1 MANUAL LAYOUT ................................................................................................................................................................. 20 3.2 DIRECTIONAL REFERENCES ..................................................................................................................................................... 20 3.3 TOP END OVERHAUL VS FULL OVERHAUL .................................................................................................................................. 20 3.4 SPECIAL CLASSES OF OVERHAUL .............................................................................................................................................
Load more

Recommended publications
  • Leonard Milholland's Legal Eagle
    Vol.3 No.12 I December 2014 The Spirit of Homebuilt Aviation I www.eaa.org A Piel Beryl A vintage homebuilt The Determinator Klaus Savier’s experimental test bed Meet the Legal EagleUltralight or homebuilt fun! TOWER FREQUENCY The Pelton family and their Cessna 195: Jack, Rose, Christine, Ryan, and Christy with grandsons Noah and little Owen. Help Give the Gift of Flight BY JACK J. PELTON ALL RESEARCH SHOWS that a majority of us who fl y have a family We have done our best to pass on our values and passions member who is also a pilot or is deeply involved in aviation in and traditions to our kids and grandkids, and experiencing per- some other capacity. It could be a parent, grandparent, aunt or sonal aviation is a big part of that. Actually going fl ying is an uncle, or even a more distant relative. But the link is solid. important part of that tradition, but so is telling aviation stories, Families have been very successful at passing down the excite- reliving the experiences we have had over the years, and even ment and challenge of personal aviation. passing on the tales from earlier generations. Shared experi- But what about people who are not born into an aviation ences, shared traditions, and shared interests are what bond family? How can we best show them the great joy and feeling families and any other group of humans together. of accomplishment we all draw from personal aviation? EAA To keep the EAA family and what it means to all of us going, can be a big part of that solution.
    [Show full text]
  • Aircraft Service Manual
    Propeller Technical Manual Jabiru Aircraft Pty Ltd JPM0001-1 4A482U0D And 4A484E0D Propellers Propeller Technical Manual FOR 4A482U0D and 4A484E0D Propellers DOCUMENT No. JPM0001-1 DATED: 1st Feb 2013 This Manual has been prepared as a guide to correctly operate & maintain Jabiru 4A482U0D and 4A484E0D propellers. It is the owner's responsibility to regularly check the Jabiru web site at www.jabiru.net.au for applicable Service Bulletins and have them implemented as soon as possible. Manuals are also updated periodically with the latest revisions available from the web site. Failure to maintain the propeller, engine or aircraft with current service information may render the aircraft un-airworthy and void Jabiru’s Limited, Express Warranty. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. Should you have any questions or doubts about the contents of this manual, please contact Jabiru Aircraft Pty Ltd. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. ISSUE 1 Dated : 1st Feb 2013 Issued By: DPS Page: 1 of 32 L:\files\Manuals_For_Products\Propeller_Manuals\JPM0001-1_Prop_Manual (1).doc Propeller Technical Manual Jabiru Aircraft Pty Ltd JPM0001-1 4A482U0D And 4A484E0D Propellers 1.1 TABLE OF FIGURES ............................................................................................................................................. 3 1.2 LIST OF TABLES .................................................................................................................................................
    [Show full text]
  • September - October 2013
    publication agreement number 40050880 September - October 2013 Recreational Aircraft Association Canada www.raa.ca The Voice of Canadian Amateur Aircraft Builders $6.95 From The President’s Desk Gary Wolf WINNIPEG CHAPTER FLIGHT INITIATIVE of the non-critical work necessary to Rick Riewe, Winnipeg is in healthy It is no secret that the average pilot age bring the plane up to snuff, and within shape. is increasing, largely because younger a short time there was a nice Cessna generations cannot free up the money 150 that RAA members may use for PROP STRIKE REGS it takes to fly a plane. There is plenty $20 per hour plus fuel. CAR 605.88 is a wide ranging regula- of interest but until the kids have been tion that covers abnormal occurrences, put through school and the mortgage and a prop strike is abnormal, no has been buried, it is difficult to justify It is no secret that matter how lightly it has hit some- spending for pilot training and aircraft the average pilot age thing. The wording is firm and clear: ownership. (1) No person shall conduct a take-off Last year Jill Oakes, our Manitoba is increasing, largely in an aircraft that has been subjected Regional Director, organized some because younger to any abnormal occurrence unless the seven hundred women to take their generations cannot free aircraft has been inspected for damage first aircraft flights. Next step was to in accordance with Appendix G of the get many of them through ground and up the money it takes Aircraft Equipment and Maintenance flight school to gain their licenses.
    [Show full text]
  • Safety Spot Dec 2018
    Safety Spot KNEE-JERK REACTIONS, TAILPIPES, JABIRU Safety Spot FLYWHEELS AND By Malcolm McBride SEAT HARNESSES The latest LAA Engineering topics and investigations eason’s Greetings and welcome to this yuletide edition of Safety Spot. I hope that you (and yours) remain in good form and that, whilst reflecting on 2018, the emotions generated remain essentially positive. We can’t, after all, Smoan about the weather this year can we? Months of warmth, just about enough rain to keep the farmers happy and not too much wind – though in my case, the wind always seemed to be blowing the wrong way. True, flying members of the LAA have had their fair share of misadventure but, even if the list might just be a tad longer this year, this more-likely reflects an increasing acceptance that reporting failures has to be a good idea so more of you are putting pen to paper. Even though putting one’s hand up to an error can be difficult, well done to those of you who have shared the details of their misadventure for the benefit of aviation community at large. Another difficult thing to do, from a continuing airworthiness management perspective, is working out just what should happen after a report of a failure is received here at Engineering HQ. It’s easy to build automaticity into a response loop, but simple cause-effect programmes might look good from an often target-driven management perspective, but they may have little overall effect on fleet safety. Care is needed in deciding what an appropriate response might be – a knee-jerk happens before a signal is received by the brain.
    [Show full text]
  • Fly-By-Wire for Homebuilt Aircraft?
    ® www.kitplanes.com $4.99 CANADA $5.99 $4.99US $5.99CAN Fly-by-Wire 07 for Homebuilt Aircraft? 0 09281 03883 2 JULY 2004 VOLUME 21, NUMBER 7 ADVERTISER INFORMATION ONLINE AT WWW.KITPLANES.COM/FREEINFO.ASP ® On the cover: Brian Raeder’s dream of building an Flight Reports award-winning Sky Raider became a reality last year 32 THE ITALIAN JOB when he was honored at Oshkosh AirVenture with the How two builders constructed Italy’s most pop- Grand Champion award. Read about his triumph—and ular kit in six months; by Geoffrey P. Jones. what led up to it—on Page 8. Photo by Jim Raeder. 73 ROTOR ROUNDUP From helicopters to gyroplanes, continued; by Ken Armstrong. Builder Spotlight 8 GRAND CHAMPION SKY RAIDER How to build a show plane; by John M. Larsen. 14 GEAR UP! An RV-4 with a difference; by Ishmael Fuentes. 39 A LITTLE PERSONALITY Builders get creative on aircraft interiors and exteriors; edited by Cory Emberson. 44 BUILD A SEAREY, PART 3 We prepare the SeaRey for inspection and first flight; by Don Maxwell. 60 COMPLETIONS Builders share their successes. Shop Talk 55 AERO 'LECTRICS We test the ILS radios; by Jim Weir. 67 ENGINE BEAT Want to be your own mechanic? by John M. Larsen. Designer’s Notebook 52 WIND TUNNEL We discuss critical mach number; by Barnaby Wainfan. Exploring 2 AROUND THE PATCH Light-sport aircraft? Not quite yet; by Brian E. Clark. 6 WHAT’S NEW 8 Garmin’s 296 arrives; edited by Brian E. Clark. 19 LADIES AND GENTLEMEN, PLEASE BE SEATED How Oregon Aero “un-engineered” a safe seat for the RV-10; by Dave Martin.
    [Show full text]
  • Overhaul Manual Jabiru 2200 & 3300 Aircraft Engines
    OVERHAUL MANUAL FOR JABIRU 2200 & 3300 AIRCRAFT ENGINES DOCUMENT No. JEM0001-4 Date: 17th April 2013 This Manual has been prepared as a guide to correctly overhaul Jabiru 2200 & 3300 aero engines. It is the owner's responsibility to regularly check the Jabiru web site at www.jabiru.net.au for applicable Service Bulletins and have them implemented as soon as possible. Manuals are also updated periodically with the latest revisions available from the web site. Failure to maintain the engine or aircraft with current service information may render the aircraft un-airworthy and void Jabiru’s Limited, Express Warranty. This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled. Should you have any questions or doubts about the contents of this manual, please contact Jabiru Aircraft Pty Ltd. 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 Dated : 17th April 2013 Issued By: DPS Page: 1 of 197 C:\Aero_Craft_Australia\Jabiru\Jabiru_Documents_Edited\Overhaul_Manual\Overhaul_Manual_Iss4\JEM0001-4_Overhaul_Manual.docx Engine Overhaul Manual Jabiru Aircraft Pty Ltd JEM0001-4 Jabiru 2200 & 3300 Aircraft Engines 1.1 TABLE OF FIGURES .................................................................................................................................................................. 7 1.2 TABLE OF TABLES.................................................................................................................................................................
    [Show full text]
  • Aircraft Service Manual Jabiru J230-D Variants
    Jabiru Aircraft Pty Ltd Aircraft Service Manual Jabiru J230-D Variants MAINTENANCE MANUAL FOR JABIRU AIRCRAFT MODEL J230-D Serial Number XXX SAMPLE DOCUMENT No. JTM001-0-230-D-858 th DATED: 8 May 2014 This Manual has been prepared in accordance with ASTM Standard F2483 as a guide to correctly and specifically maintain Jabiru Aircraft Model J230-D Serial # 858. Other Maintenance Manuals for other configurations of the Jabiru J230 aircraft are not to be used for maintenance instructions for this aircraft. It is the owner's responsibility to regularly check the Jabiru web site at www.jabiru.net.au for applicable Service Bulletins and have them implemented as soon as possible. Manuals are also updated periodically with the latest revisions available from the web site. Failure to maintain the engine or aircraft with current service information may render the aircraft un- airworthy and void Jabiru’s Limited, Express Warranty. This document is controlled and kept with the aircraft compliance files at Jabiru Aircraft Pty, Ltd and a copy is also kept at Jabiru USA Sport Aircraft, LLC. It remains controlled while in the aircraft compliance files. Once this no longer applies the document becomes uncontrolled. Should you have any questions or doubts about the contents of this manual, please contact Jabiru Aircraft Pty Ltd. DOCUMENT No. JTM001-0-230-D-868 08 May 2014 Page 1 of 223 Jabiru Aircraft Pty Ltd Aircraft Service Manual Jabiru J230-D Serial # 868 Owner/Operator Responsibilities To maintain compliance with ASTM Standard F2295 which establishes the parameters for continued operational safety and is an underlying requirement for a LSA Airworthiness Certificate, the owner or operator of this aircraft must follow six rules that are specified in Section 5.4 of F2295.
    [Show full text]
  • Installation Manual for Jabiru 2200 Aircraft Engine
    INSTALLATION MANUAL FOR JABIRU 2200 AIRCRAFT ENGINE This Manual has been prepared as a guide to correctly install the Jabiru 2200 engine into an airframe. Should you have any questions or doubts about the contents of this manual, please contact Jabiru Aircraft Pty Ltd. Applicable to Jabiru 2200cc Enginers, S/No. 2068 Onwards (Hydraulic Lifter Type) Jabiru Aircraft Pty Ptd Installation Manual Jabiru 2200 Aircraft Engine 1 TABLE OF CONTENTS 1 TABLE OF CONTENTS _________________________________________________ 2 2 Description ____________________________________________________________ 5 3 Specifications __________________________________________________________ 6 4 Operating Limitations ___________________________________________________ 7 5 Dimensions ____________________________________________________________ 9 6 Denomination Of Cylinders ______________________________________________ 10 7 Engine Mount_________________________________________________________ 11 8 Controls______________________________________________________________ 13 9 Instruments___________________________________________________________ 14 10 Electrical Equipment _________________________________________________ 17 11 Fuel Supply System___________________________________________________ 20 12 Air Intake System ____________________________________________________ 22 13 Exhaust System ______________________________________________________ 23 14 Cooling Systems _____________________________________________________ 24 15 Propeller Selection ___________________________________________________
    [Show full text]
  • Know Thy Engine
    Modern Classic • Continental O-200 or Jabiru 3300 BuildBuild YYourselfourself A Texas Sport CuCubb • Steam Gauges or A Full-House EFIS Suite • Traditional Cub Yellow...or Something Else! Old School or High Tech! March 2008 Know Thy Engine $5.99CANADA 03 Our Engine Monitor Roundup Can Help That ’Ole Paint A Composite Primer: Prep to Finish Coat Holey Panel, Batman! 0 74820 08883 8 Make The Cut Right The First Time March 2008 | Volume 25, Number 3 On the cover: Kevin Wing photographed the Texas Sport Cub at the American Legend Aircraft factory in Sulphur Springs, Texas. 2008 Engine Directory 16 A comprehensive listing of traditional and alternative engines plus PSRUs; compiled by Julia Downie. Flight Reports 8 TEXAS SPORT CUB Classic Cub perfection that you can now build yourself; 16 by Marc Cook. Builder Spotlight 32 SYNERGY AIR ENERGIZES BUILDERS Wally Anderson’s new course quickens RV quickbuilding; by Dave Martin. 37 ALL ABOUT AVIONICS You should know what’s happening in front of the fi rewall. Here’s how; by Stein Bruch. 45 BUILD YOUR SKILLS: COMPOSITES Part 11: Painting the beast. Understand the subtleties of methods and materials before trying them on the real thing; by Bob Fritz. 52 COMPLETIONS Builders share their successes. Shop Talk 54 THE HOME MACHINIST Need to cut a precise hole? No problem—it’s easier than you think; by Bob Fritz. 7 0 AERO ’LECTRICS Solarize the battery; by Jim Weir. Designer’s Notebook 61 WIND TUNNEL Further fl ight testing and analyzing the data; by Barnaby Wainfan. 8 Exploring 2 AROUND THE PATCH Let go the carburetor; by Marc Cook.
    [Show full text]
  • Instruction and Maintenance Manual for Jabiru 2200 Aircraft Engine
    INSTRUCTION AND MAINTENANCE MANUAL FOR JABIRU 2200 AIRCRAFT ENGINE This Manual has been prepared as a guide to correctly operate, maintain and service the Jabiru 2200 engine. Should you have any questions or doubts about the contents of this manual, please contact Jabiru Aircraft Pty Ltd. Applicable to Jabiru 2200A, 2200B & 2200J Models Page No: 1 Issue No: 4 Date: 240103 Issued By: PJA Table of Contents Paragraph Description Page Table of Contents 2 List of Amendments 4 1.0 Description 5 1.1 Denomination of Cylinders 8 2.0 Technical Data 9 2.1 Dimensions & Weights 9 2.2 Normal Equipment 9 2.3 Performance Data 9 2.4 Fuel Consumption 9 2.5 Fuel & Lubricant 9 2.6 Cooling System 10 2.7 Operating Speeds & Limits 10 3.0 Performance Graphs 11 4.0 Operating Instructions 12 4.1 Pre-Start Checks 12 4.2 Starting Procedure 12 4.3 Warm-Up Period, Ground Test 12 4.4 Take-Off 12 4.5 Engine Stop 13 4.6 Engine Stop & Start During Flight 13 4.7 Addition } Early Operation of Engine 5.0 Checks on Engine & Installation 14 5.1 Daily Checks 14 5.2 Periodic Checks 14 5.3 Check After Initial 25 Hours 15 5.4 50 Hours Check 16 5.5 100 Hours Check 16 5.6 TBO 16 5.7 Engine Preservation 17 5.8 Operation in Winter 19 6.0 Maintenance 21 6.1 Lubrication System 21 6.2 Air Intake Filter 21 6.3 Carburettor Adjustment 21 6.4 Compression Check 21 Page No: 2 Issue No: 4 Date: 240103 Issued By: PJA 6.5 Spark Plugs 22 6.6 Exhaust System 22 6.7 Bolts & Nuts 22 6.8 Tappet Adjustment 23 6.9 Tachometer and Sender 23 6.10 Additional Checks 23 7.0 Service & Repair 24 7.1 Engine Overhaul
    [Show full text]
  • JSL007-7 Alcohol Lead Compression Ratio Fuel Guidance
    Jabiru Service Letter: JABIRU AIRCRAFT PTY LTD P.O. Box 5186 Phone:+61 7 4155 1778 Alcohol, Lead, Compression Bundaberg West Fax:+61 7 4155 2669 Ratio: Fuel Guidance Queensland, Web: www.jabiru.net.au Australia. Email: [email protected] Release Date: Effective Date: Affected Models: S/No. Range: JSL007-7 st Page 1 of 23 1 November 7th November See Applicability See Applicability 2017 2017 SERVICE LETTER: JSL 007-7 Issue: 7 Date: 1st November 2017 Subject: Alcohol, Lead, Compression Ratio: Fuel Guidance Release Date: 1st November 2017 Effective Date: 7th November 2017 Issue Reason for Issue Revision Status 1 Original Issue CANCELLED 2 New Information Added CANCELLED 3 Title changed, “High Lead” Avgas notes added CANCELLED 4 New gasoline information added, UL9 1 approval added. CANCELLED 5 Revise layout CANCELLED 6 Mogas Storage Time Reduced CANCELLED Add notes to Mogas advisory regarding the adverse effects on fuel system and 7 CURRENT airframe 1 BACKGROUND ................................................................................................................................................... 2 2 CERTIFIED MODELS .......................................................................................................................................... 2 3 LIGHT SPORT AIRCRAFT CATEGORY MODELS ........................................................................................... 3 4 OTHER AIRCRAFT CATEGORIES ...................................................................................................................
    [Show full text]
  • Propeller Loss Involving Jabiru J430, VH-TJP North of French Island, Victoria, 8 March 2013
    InsertPropeller document loss involving title Jabiru J430, VH-TJP LocationNorth of French| Date Island, Victoria | 8 March 2013 ATSB Transport Safety Report Investigation [InsertAviation Mode] Occurrence Occurrence Investigation Investigation XX-YYYY-####AO-2013-046 Final – 19 August 2014 Released in accordance with section 25 of the Transport Safety Investigation Act 2003 Publishing information Published by: Australian Transport Safety Bureau Postal address: PO Box 967, Civic Square ACT 2608 Office: 62 Northbourne Avenue Canberra, Australian Capital Territory 2601 Telephone: 1800 020 616, from overseas +61 2 6257 4150 (24 hours) Accident and incident notification: 1800 011 034 (24 hours) Facsimile: 02 6247 3117, from overseas +61 2 6247 3117 Email: [email protected] Internet: www.atsb.gov.au © Commonwealth of Australia 2014 Ownership of intellectual property rights in this publication Unless otherwise noted, copyright (and any other intellectual property rights, if any) in this publication is owned by the Commonwealth of Australia. Creative Commons licence With the exception of the Coat of Arms, ATSB logo, and photos and graphics in which a third party holds copyright, this publication is licensed under a Creative Commons Attribution 3.0 Australia licence. Creative Commons Attribution 3.0 Australia Licence is a standard form license agreement that allows you to copy, distribute, transmit and adapt this publication provided that you attribute the work. The ATSB’s preference is that you attribute this publication (and any material sourced from it) using the following wording: Source: Australian Transport Safety Bureau Copyright in material obtained from other agencies, private individuals or organisations, belongs to those agencies, individuals or organisations.
    [Show full text]