Jabiru 3300 - Trouble Shooting

Engine Maintenance Manual
Jabiru Aircraft Pty Ltd
JEM0002-5
Jabiru 2200 & 3300 Aircraft Engines
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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 TACHOMETER AND SENDER .............................................................................................................. 65
9.15 HEAD BOLT TENSION CHECK ............................................................................................................ 66
9.16 INSPECT VALVE SPRINGS & ROCKERS .............................................................................................. 67
9.17 VALVE CLEARANCE ADJUSTMENT (SOLID LIFTER ENGINES ONLY) ...................................................... 68
9.18 COMPRESSION CHECK ..................................................................................................................... 69
9.18.1 Compression Gauge: ................................................................................................................................ 69
9.18.2 Pressure Differential Test: ......................................................................................................................... 69
9.18.3 Identifying Compression Leaks ................................................................................................................. 70
9.19 FUEL FLOW RATE TEST .................................................................................................................... 70
9.20 HYDRAULIC VALVE LIFTER MAINTENANCE ......................................................................................... 71
9.20.1 Hydraulic Lifter Removal ........................................................................................................................... 72
9.20.2 Valve Rockers ........................................................................................................................................... 72
9.21 IGNITION COIL & ALTERNATOR ELECTRICAL INSPECTIONS .................................................................. 73
9.22 FLYWHEEL SCREW BASIC INSPECTION .............................................................................................. 74
9.23 FLYWHEEL SCREW DETAILED INSPECTION......................................................................................... 74
9.24 USE OF SAFETY WIRE ...................................................................................................................... 74
9.25 ENGINE OVERHAUL AND TBO ........................................................................................................... 77
9.25.1 Full Overhaul ............................................................................................................................................. 77
9.25.2 Top End Overhaul ..................................................................................................................................... 77
9.26 ENGINE REMOVAL PROCEDURE ........................................................................................................ 78
9.27 ENGINE INSTALLATION ...................................................................................................................... 79
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 ENGINE RUNS ERRATICALLY OR MISFIRES OCCASIONALLY ................................................................ 82
10.4 FULL POWER STATIC RPM BELOW SPECIFICATIONS ......................................................................... 82
10.5 ENGINE RUNS TOO HOT - OIL TEMPERATURE ABOVE 110
O
C (230
O
F) ................................................ 83
10.6 CHT READING ERROR ..................................................................................................................... 83
10.7 UNSATISFACTORY POWER OUTPUT .................................................................................................. 83
10.8 LOW OIL PRESSURE ......................................................................................................................... 84
10.9 OIL PRESSURE VARYING .................................................................................................................. 84
10.10 ENGINE KEEPS RUNNING WITH IGNITION OFF .................................................................................... 84
10.11 EXCESSIVE OIL CONSUMPTION ......................................................................................................... 84
10.12 OIL COLLECTOR BOTTLE ON FIREWALL FILLS QUICKLY ...................................................................... 84
10.13 EXCESSIVE VIBRATION ..................................................................................................................... 85
10.14 KNOCKING UNDER LOAD .................................................................................................................. 85
10.15 ENGINE HARD TO START AT LOW TEMPERATURE – COLD START CHECKLIST ...................................... 86
10.16 IRREGULAR / LOW COMPRESSIONS ................................................................................................... 87
10.17 HYDRAULIC VALVE LIFTERS .............................................................................................................. 88
11 ENGINE MAINTENANCE WORKSHEETS ............................................................................ 89
11.1 25-HOUR INSPECTION WORKSHEET .................................................................................................. 89
11.1.1 Engine & Engine Compartment (refer to section 8.8) ................................................................................ 89
11.2 50 HOUR, 100 HOUR AND ANNUAL INSPECTION WORKSHEET ............................................................. 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