Home

div/Instruction and Maintenance 2200

1. 1 Master Switch 3 Main Bus Bar 5 Battery 7 Regulator T O A be Ly Dle Lo i AA y re B 2 Voltage Reference Line 4 Fusible Link 6 Permanent Magent Alternator 8 Charge Lamp The charging system supplies electrical devices and also charges the battery while the engine runs It consists of a Permanent Magnet Alternator PMA and a Regulator 1 This permanent magnet alternator PMA is a 10 pole rotating magnet type generator It is a simple construction consisting of a stator and rotor The rotor is made up of ten permanent magnets alternator body and magnet retainer mounted on the flywheel The stator has ten poles with coils and is mounted on the rear plate the stator goes inside the rotor Page No 52 Issue No 4 Date 240103 Issued By PJA Am er _ 1 4 FEMALE SS ca tt Wik a i A TY J ss 9 fo 58 A A o T WN eH iin N M Hi HH X A i aoe ANA INSULATED TERN MINAL CORE ASS WY TOR IRK EM 2 yV p Page No 53 MAGNET 15 om Ff 10 ALTERNATOR BODY l MAGNET RET TAIN
2. I hereby certify that the subassembly has been completed using the approved procedures and data and is fit for installation Signed Date For Jabiru Aircraft Pty Ltd Certificate of Approval 3501 Notes Page No 77 Issue No 2 Date 130598 Issued By PJA Component Register and Parts Inspection Record Subassembly B Crankcase and Camshaft Assy Batch Serial No Date Description Part No Batch Item Details Crankcase LS 4308052 Crankcase RS 4309052 1 2 3 4 5 6 Camshaft 4279042 Studs Long Barrel 4291044 Cam Tunnel Studs Short Barrel 4292044 Cam Studs Front 4293044 1 2 3 4 3 Outer Gear 4333054 Inner Gear 4066123 Cam Followers Crankshaft Gear 4643084 LHS Main Bearings 5M1869 RHS I hereby certify that the above listed parts conform with the dimensions have been engraved and installed as recorded Signed Date For Jabiru Aircraft Pty Ltd Certificate of Approval 3501 Page No 78 Issue No 2 Date 130598 Issued By PJA Jabiru 2200 Component Assembly Procedure Subassembly C Pistons Cylinders and Cylinder Heads No Details Sign Date Cl Clean and deburr all parts C2 Record all measurements C3 Install pushrod tube O Rings C4 Check valve seats fit spring retainers install valves C5 Fit intake pipes to heads
3. y 0 04 Lazo agro INLET VALVE SEAT DETAILS EXHAUST VALVE SEAT DETAILS This will give maximum number of overhauls on heads The above diagram gives general valve seat cut geometry Changes have occurred to production engines S N 01 208 used above geometry S N 209 743 used wider contact seat area Engines 745 used seat width cut from approved dwg 4797004 1 and 4790004 E Above valve diameters change S N 189 on 6 Use ground and serviceable valves to check seat contact Page No 42 Issue No 4 Date 240103 Issued By PJA Note If machine has a vacuum tester vacuum test valves 7 Heads of valves must be above the level of the combustion chamber If they are below the valve seats and valves must be replaced 8 Measure valve stem for wear Record in build sheet if within limits or replace valves 9 Grind valve seats If margin is too small replace valves INLET VALVE 0 6 MIN EXHAUST VALVE 1 0 MIN z 0 024 040 TE Ta ee Drawing 9444064 1 DETAILS C3 1 Clean heads and valves ready for assembly 2 Measure valve springs Replace if they are shorter than service limits 40 0mm 41 8mm 1 580 1 688 Page No 43 Issue No 4 Date 240103 Issued By PJA 3 4 Page No 44 N A DA Zirh Ar cn aaa A or NAN U U ZU OU 40 G 010 O OU YO HTTTTITTTI nvIT
4. 5 Run in Follow run in program 6 Cool down at least 12 hours 7 Retorque heads 8 Adjust valves 9 Rerun 10 Check leak down Note There is a run in program and run in checklist to fill out 7 5 Engine Installation Operation Tools Page No 71 Issue No 4 Date 240103 Issued By PJA 1 Fit engine to engine mount 2 Torque engine mount bolts up 3 Fit muffler if not already fitted and fit carburettor heat muff and hose 4 Connect left and right ignition coils leads 5 Connect Tacho sender 6 Connect exhaust gas temp if fitted 7 Connect cylinder head sender 8 Connect hourmeter 9 Connect oil temp gauge sender 10 Connect oil pressure gauge sender 11 Connect starter 12 Connect Battery 13 Connect fuel line 14 Connect Oil Breather 15 Connect Choke Cable 16 Connect Throttle Cable 17 Connect Air Inlet 18 Fit Propeller and spinner 19 Fit Cooling Ducts 20 Prime Fuel system with electric pump and inspect Page No 72 Issue No 4 Date 240103 7 16 Tube Socket 7 16 Ring Open End Spanner 3 16 Ball End Allen Key 18mm Spark Plug socket Screw Driver 7 16 Ring Open End Spanner 10mm Ring Open End Spanner Screw Driver Screw Driver Long Nose Pliers Long Nose Pliers Screw Driver 7 16 Ring Open End Spanner Phillips Screw Driver 3 16 Allen Key Issued By PJA for leaks 21 Check for oil Fill if needed 2 3L oil 2 43 US quarts 22 Wind over to ge
5. Prior to takeoff follow the Starting amp Warm Up procedure observe the engine behaviour amp throttle response Check temperatures amp pressures Conduct a short ground test at full power a few seconds consult aircraft Flight Manual NOTE Any prolonged running at full power can cause engine damage while on the ground 5 2 Periodic Checks After the initial 25 hours check in accordance with para 5 3 Page No 20 Issue No 4 Date 240103 Issued By PJA After 50 hours of operation check in accordance with para 5 4 amp thereafter after each 50 hours of operation After 100 hours of operation check in accordance with para 5 5 and thereafter after each 100 hours of operation At TBO overhaul in accordance with para 5 6 5 3 Check After Initial 25 Hours Details of specific operations are shown in Chapter 6 Maintenance Remove engine cowlings check engine mounts Thoroughly check engine for missing or loose bolts nuts pins etc amp for abrasions Check induction and exhaust flange for loose bolts Check safety wires cooling air ducts amp baffles ignition wiring amp hose connections Oil Change 2 0 litres Use normal aviation running oil Change oil filter First 25 hours only Inspect old filter Retorque cylinder head bolts 24 ft lbs in diagonal pattern Check tappet clearance and adjust as necessary refer Para 6 8 0 010 cold inlet and exhaust Check exhaust sys
6. e atmospheric fallout or flood hail salt wind etc f failure to carry out proper maintenance service g use of incorrect types and or grades of fuel oil or lubricants h alteration or modification of the engine by any party not authorised in writing by JABIRU i the fitting of parts or accessories not marketed by JABIRU j any work carried out on the engine by someone other than an Authorised JABIRU Service Centre or someone else authorised by JABIRU in writing k the use of any engine oil or fuel additive s or oil stabiliser s BY J ABIRU or as otherwise decided by J ABIRU MAKING GOOD THE DEFECT BY REPAIR OR AT THE OPTION OF J ABIRU BY REPLACEMENT Excluded from this Warranty are service items such as engine tuning adjustments replacement of air and oil filters spark plugs etc which are required as part of normal engine maintenance This Warranty is given to the person who is entitled to possession of the engine whether as owner lessee or otherwise and is given in addition to all right conferred by law on that person Warranty repairs do not extend the original warranty Due to the substantial number of problems that can arise due to installation errors JABIRU shall not be liable for any labour and or service charges for removal reinstallation and adjustment which are the responsibility of the buyer and are not covered by this Warranty Consequential damages and freight costs are also not covered by this Warranty
7. 13 14 14 14 15 16 16 16 17 19 21 21 21 21 21 Issued By PJA 6 5 Spark Plugs 22 6 6 Exhaust System 22 6 7 Bolts amp Nuts 22 6 8 Tappet Adjustment 23 6 9 Tachometer and Sender 23 6 10 Additional Checks 23 7 0 Service amp Repair 24 7 1 Engine Overhaul and TBO 24 7 2 Engine Removal Procedure 25 T3 Disassembly 26 7 4 2200 Engine Overhaul 29 1 Subassembly A Crankshaft Prop Mount and Con rods 30 2 Subassembly B Crankcase and Camshaft 33 3 Subassembly C Pistons Cylinders and Cylinder Heads 35 4 Subassembly D Sump and Oil Pump 42 5 Subassembly E Flywheel and Ignition Coils amp Alternator amp Alternator Operation 44 6 Subassembly F Gear Case 49 7 Subassembly G Fuel Pump amp Carburettor amp Carburettor Operation 50 8 Subassembly H Final assembly of subassemblies 56 9 Runin 65 7 5 Engine Installation and First 25 hours 66 7 6 Prop Strike Inspection 67 71 1 Build Sheets and Run in programme 68 8 0 Table of Lubricants 87 9 0 Torque Specifications 88 9 1 Prescribed Sealants and Primers 89 9 2 New Tolerances 90 9 3 Maximum Allowable Clearances Wear Limits 91 9 4 Electrical System Specifications 92 10 0 Trouble Shooting 93 10 1 Engine Won t Start 93 10 2 Engine Idles Unsteadily After Warm Up Period Smoky Exhaust Emission 93 10 3 Engine Runs Erratically or Misfires Occasionally 93 10 4 Engine Runs Too Hot Oil Temperature above 110 C 230 F 94 10 5 Unsatisfactory Power Output 94 10 6 Low O
8. Date 130598 Issued By PJA 9 4 ELECTRICAL SYSTEMS SPECIFICATIONS All Dimensions are in Millimetres Ignition Primary Resistance 8 8R to 1 0R Secondary Resistance 5 9kR to 7 1kR Coil Gap 0 27 Plug Gap 0 55 Ignition Harness Resistance 6 7kR per 300mm of length Alternator Coil Resistance 0 5 to 1 1R Coil Earth Resistance Infinite A C Output 30 VAC at 3000 RPM D C Output 14 2 VDA at 3000 RPM Tacho Coil Resistance 160 to 170R Gap 0 4 Page No 98 Issue No 2 Date 130598 Issued By PJA 10 0 TROUBLE SHOOTING 10 1 Engine Won t Start _ Possible Cause Ignition OFF Switch ON Spark plug gap too large Adjust gap to 0 6 0 7mm or renew plugs Closed fuel tap or clogged filter Open tap renew filter check fuel system for leaks 4 No fuel in tank Refuel Wrongly connected high tension leads Connect as shown on leads Starting Speed too low faulty or discharged Recharge or replace battery battery 11 Plug face wet by fuel due to excessive actuation Dry spark plugs trace possible faults in fuel system PP lithic credo feat orate towatent n eE 14 Water in carb Drain amp clean carb fuel line amp filter Water drain fuel tank 16 Engine damage Inspect oil strainer filter amp oil filter for metallic particles If present an engine overhaul may be necessary C powo e 10 3 Engine Runs Erratically or Misfires Occasionally _ Possible Cause 1 Spark plug failure Check plugs clean inside amp o
9. For Jabiru Aircraft Pty Ltd Certificate of Approval 3501 Notes Page No 75 Issue No 4 Date 240103 Issued By PJA Component Register and Parts Inspection Record Subassembly A Crankshaft Propeller Mount Flange and Conrods Batch Serial No Date Description Part No Batch Item Details Mains Big End 1 2 3 4 1 2 3 4 Crankshaft 4644082 Propeller Mount Flange 4525064 Conrod 1 4651183 2 4651183 3 4651183 4 4651183 Conrod SHCS 5 16 x 1 UNF Bearings ACL 4B8290 Thereby certify that the above listed parts conform with the dimensions have been engraved and installed as recorded Signed Date For Jabiru Aircraft Pty Ltd Certificate of Approval 3501 Page No 76 Issue No 2 Date 130598 Issued By PJA Jabiru 2200 Component Assembly Procedure Subassembly B Crankcase and Camshaft Assembly No Details Sign Date Bl Inspect case deburr clean check oil holes B2 Fit inner stud O rings B3 Fit all studs B4 Fit outer oil suction and conrod welch plugs B5 Fit oil relief valve oil pressure sender and pressure switch B6 Fit bearing shells 12 B7 Assemble and torque to 30 ft lbs B8 Measure main tunnel and camshaft bearings B9 Measure Cam Follower Bores B10 Fit Lifters Bll Check Camshaft End Float B12 Check Crankshaft End Float
10. G3 Record jet size G4 Record needle position G5 Reassemble carburettor Page No 61 Issue No 4 Date 240103 Issued By PJA Jabiru 2200 Component Inspection and Assembly 7 4 8 Sub Assembly H Final Assembly Crankcase Joining H1 a Photocopy Degree Wheel increase by 226 to bring to full size then glue to stiff cardboard and cut out Drawing 9427063 Page No 62 Issue No 4 Date 240103 Issued By PJA b Stand crankshaft Sub assembly A up vertically mounted on the prop flange as per drawing J SS Se Gg e a A ps WHEEL DEGREE Drawing 9429063 2 CRANKSHAFT amp CONROD ASSEMBLY Drawing 9429063 Page No 63 Issue No 4 Date 240103 Issued By PJA H2 H3 H4 H5 H6 Page No 64 c a b c a b c a b Apply Loctite 515 to left side of the crankcase Fit cam shaft to left side Inspect 1 Bearing shell in position 2 Loctite on all areas 3 O Rings in 4 Piston Cylinder Assembly complete 5
11. JABIRU makes no representation that this engine is suitable for installation in any particular aircraft and the responsibility for determining such suitability rests without the Buyer Under no condition shall JABIRU or a JABIRU Authorised Service Centre be liable for any contingent costs through the engine or aircraft being out of service for whatever reason Page No 102 Issue No 1 Date 220100 Issued By PJA SPECIAL NOTICE TO OWNERS AVAILABILITY OF SERVICE AND PARTS AFTER WARRANTY JABIRU Aircraft Pty Ltd maintains a substantial stock of spare parts and operates a Service Exchange Programme in respect to some components Every endeavour is made to ensure that JABIRU carries adequate stocks of service parts and that Authorised Service Agents are equipped to provide satisfactory service but JABIRU does not make any promise that after the expiration of the warranty such parts or service will be available or available at any specific location or at any particular time UNAUTHORISED STATEMENTS IN RELATION TO JABIRU PRODUCTS No JABIRU Authorised Service Centre or other person is authorised or permitted to give or make any statement assertion or undertaking in relation to the quality performance characteristics descriptions or fitness for any purpose of any JABIRU product or in connection with the supply of any JABIRU product which is at variance with any written statement assertion or undertaking on any of these subjects given or made by JABI
12. Stage Inspection Pre joining Crankcase H3 Locate crankcase half over crankshaft and camshaft H4 Tension front 2 and rear 2 studs H5 Fit oil pump assembly and front seal housing H6 Place all through bolts in crankcase H7 Fit piston and cylinder assemblies and check circlips Stage 4 Stage Inspection Piston Circlips H8 Tension the cylinder base studs to 25 ft lbs then 30 ft lbs H9 Fit sump H10 Fit heads to cylinder torque 12 ft lbs 24 ft lbs H11 Fit push rod and valve gear Set gap to 0 10 0 25mm H12 Check camshaft timing DEGREES H13 Fit fuel pump H14 Fit engine mount plate and gearbox housing H15 Fit flywheel alternator mount plate and ignition coils and lead H16 Fit carby assembly H17 Fit exhaust system Sign Date I hereby certify that the subassembly has been completed using the approved procedures and data and is fit for installation Signed Date For Jabiru Aircraft Pty Ltd Certificate of Approval 3501 Notes Page No 88 Issue No 2 Date 130598 Issued By PJA Jabiru 2200A Engine Test Schedule and Report Engine s n Date Temp Wind QNH Humidity Run in Use Test Rig 1 Test Propeller J1 Run into the Wind Use Schedule Provided Oil Aeroshell 100 Test Results Time Start Oil Press Oil Temp EGT CHT CHT CHT CHT min Time kPa C C 1 2 3 4 C C C C 0 30 4
13. 80 100 120 Outside Air Temp 170C to 250C 150C to 35 C Above 350C Normal Operations Oil W80 W100 W120 Outside Air Temp 170C to 250C 150C to 35 C Above 350C OIL SUPPLY TO CRANKCASE FROM OIL FILTER RELIEF VALVE LOIL SUPPY TO CRANK MAINS OIL TO COOLER FROM OIL PUMP OIL PRESSURE SENDER OIL RETURN FROM COOLER OIL FROM COOLER OIL RETURN TO CRANKCASE a OIL PUMP PICKUP TO R VALVE poo LOIL FILTER EN Ai wal Taa OIL RETURN FROM OIL COOLER ADAPTOR N RELIEF VALVE HOUSI U N OIL PICKUP FOR PUMP OIL CIRCUIT W O OIL COOLER Page No 93 Issue No 2 Date 130598 Issued By PJA 9 0 TORQUE SPECIFICATION FOR BOLTS amp NUTS Part Spark Plugs Cylinder Head Bolts Crankcase Main Studs Flywheel Gear Bolts Crankshaft Prop Flange Cap Screws Lockwire Oil Pump Cap Screws Tappet Cover Cap Screws Starter Motor Bolts Carburettor Flange Bolts Engine Mount Plate Bolts Gearbox Cover Bolts Alternator
14. Air Intake Filter Clean filter by removing from the intake housing amp blowing compressed air against the direction of the intake flow For operation in heavy dusty conditions clean air filter at shorter intervals than recommended for normal conditions A clogged filter will reduce engine performance as well as promote premature engine wear 6 3 Carburettor Adjustment Open idle mixture screw approximately 1 1 4 turns fine adjust for a smooth idle The determination of the main jet is carried out on a dyno at 107 ft above Mean Sea Level IMPORTANT Check amp oil carburettor joints amp linkage 6 4 Compression Check Measure compression using a compression tracer Readings are taken with fully open throttle valve at engine oil temperature between 30 amp 70 degrees C 90 to 160 degrees F Page No 27 Issue No 4 Date 240103 Issued By PJA If readings are below 6 bar 90 psi a check of the pistons cylinders valves amp cylinder heads must be undertaken Alternatives Pressure loss or leakage tester eg SUN or BOSCH tester max allowable pressure loss is 25 Checking by commonly used pressure difference method place orifice of 1 mm ID and 3mm length between the two pressure gauges This will give the same result as with the above instrument Max pressure drop is 25 6 5 Spark Plugs Do not use steel or brass brushes for cleaning amp never sandblast plugs Clean with plastic brush in a solvent Check
15. Drawing 9436064 8 3 Measure and record in Build Sheet 4 Bead blast C cylinder outer to remove all old paint and rust n 5 Etch prime and paint with high temperature black paint 6 Run 5 16 UNF Tap through head threads to remove all beads and to insure that head bolts torque up fully 7 Clean in kero then in hot soapy water to remove all honing oil etc Page No 46 Issue No 4 Date 240103 Issued By PJA Pistons C7 C8 Page No 47 1 2 3 1 3 4 Note Once cleaned oil up cylinders straight away Store in a cool dry place in a sealed container Clean oil out of pistons Dip Pistons in cold dip solvent i e Redik DKT degreaser decarboniser paint stripper as per manufacturers instructions to remove all carbon Note The head of the piston can be bead blasted but never bead blast the ring grooves piston skirt and piston pin bores Use an old ring to clean carbon out of ring grooves but care must be taken not to scratch grooves Any scratching will cause Gas Leakage past the rings A piece of 2mm 0 080 perspex can also be used as it is kinder to the pistons Clean thoroughly Visually inspect pistons for cracks or damage Measure pistons and record in build sheet t j MEASURE DIA AT THIS HEIGHT AND POSITION TO PIN pa A Drawing 9434064 i Clean inhibitor off new rings il Measure end gap of rings in the cy
16. GEAR AS SH AS CLOSE AS HOLES ALL Date 240103 GEAR Issued By PJA 2200 Component Inspection and Assembly Procedure 7 4 2 Sub Assembly B Crankcase and Camshaft Bl 1 Clean crankcase remove old Loctite and clean oil gallerys 2 Visually inspect crankcase B2 Fit inner stud O Rings with a small smear of rubber grease B3 Inspect all studs for tightness threads and stretching B4 1 Check oil suction pipe for security 2 Check conrod welsh plugs They don t need to be removed for overhaul If removing a conrod in the field the plug has to be removed first to gain access to conrod bolts Steel conrods are removed from cylinder direction B5 Fit oil relief valve assembly oil pressure sender and front plug hourmeter switch LS CRANK CASE OIL PUMP RELIEF VALVE CAVITY Drawing 9435064 1 OIL RELIEF VALVE ASSEMBLY Drawing 9435064 B6 1 Lightly blue bearing shells and one crankcase half 2 Fit bearing shells Page No 39 Issue No 4 Date 240103 Issued By PJA B7 B8 B9 B10 Bll B12 F F4 Va LAN i gt i Sey i V
17. Jabiru for their own particular application An integral alternator using rare earth magnets provides alternating current for battery charging and electrical accessory drive The alternator is attached to the flywheel and is driven directly by the crankshaft The ignition system is a transistorised electronic system two fixed coils mounted adjacent to the flywheel are energised by rare earth magnets attached to the flywheel The passing of the coils by the magnets creates the high voltage current which is then transported by high tension leads to the centre post of two automotive type distributors which are simply rotors and caps before distribution to automotive spark plugs two in the top of each cylinder head The ignition system is fixed timing and therefore removes the need for timing adjustment It is suppressed to prevent radio interference The ignition system is fully redundant self generating and does not depend on battery power The crankshaft is designed with a double bearing at the propeller flange end and a main bearing between each big end it therefore does not have flying webs 48mm main bearings are also of the automotive slipper type Thrust bearings are located for and aft of the front double bearing allowing either tractor or pusher installation Pistons are sourced in Australia and are re machined to include a piston pin circlip groove They are fitted with 3 rings the top rings being cast iron to complement the chrome m
18. Key Screwdriver 7 32 Allen Key 5 32 Allen Key 7 32 Allen Key 7 16 Socket 5 16 Ring O End Spanner 3 16 Allen Key 3 16 Allen Key 3 16 Allen Key 7 32 amp 3 16 Allen Key Screwdriver Issued By PJA 20 21 22 23 24 25 26 Remove Sump 3 16 Allen Key Remove Exhaust and Induction Pipes 3 16 Allen Key Remove Tappet Covers Remove Rocker Blocks and Push Rods From S N 225 rocker blocks were not used Remove Cylinder Head Remove Push Rod Tubes Remove Cylinder Removal of Piston 27 28 29 30 Remove 1 Wrist Pin Circlip Remove Wrist Pin keep pin matched with its piston Remove Piston Rings keep rings matched with its piston Repeat Operations 27 30 on other pistons if required Crankcase Disassembly 31 32 33 34 35 36 Page No 33 Issue No 4 Date 240103 Remove main Stud Nuts on Front 2 studs Double check that every bolt is removed and sump gear case engine mount plate oil pump and Front Oil Seal Carrier is removed Tap Crankcase slightly and open Crankcase by removing half Crankcase Remove both Crankcase Halves of Crankshaft and Remove Cam Shaft Remove Valve Lifters 8 Note Keep valve lifters matched to each Crankcase half Remove Thrust Washers front and rear 2 without tang on right half case 3 16 Allen Key 1 2 Spanner 1 2 Socket 5 32 Allen Key 1 4 Allen Key 7 32 Allen Key 1 2 Socket 7 16 Crowsfoot Long
19. Nose Pliers 7 16 Socket Plastic Mallet Issued By PJA 37 38 39 2 with tang on left half case Note visually check for marks or scratches keep matched to their seats Remove Main Bearing Inserts 12 Note visually check for marks or scratches keep matched to seats Remove Crankcase dowels Remove O Rings and Discard Note do not attempt to remove studs as they are loctited in with 620 loctite Remove Oil Gallery Plugs and Oil Pressure Sender Remove Oil Relief Valve Cylinder Head Disassembly 40 41 Remove Valve Springs and Valves Valve Spring Compressor Remove Push Rod Circlips and O Rings Internal Circlip Pliers Gearbox Cover Disassembly 42 43 Remove Distributor Shafts Remove Oil Seals Crankshaft amp Camshaft Disassembly 44 45 46 7 4 Remove Bolts from Conrod allen key 10mm Socket Note Rods will need to be heated 3 8 Ratchet Big End Bolts are Discarded on Removal Hot Air Gun Rags Remove Rod Bearing Inserts Note visually inspect for marks and scratches keep matched to their seats Remove Camshaft Gears Discard Camshaft Bolts Remove welsh plug in rear of camshaft 2200 ENGINE OVERHAUL Inspection and Assembly of Sub Assemblies Page No 34 Issue No 4 Date 240103 Issued By PJA 1 Sub Assembly A Crankshaft Prop Mount and Con Rods 2 Sub Assembly B Crankcase and Camshaft 3 Sub Assembly C Pistons Cylinders and Cylinder Heads
20. amp Coil Mount Bolts Sump Cap Screws Conrod Bolts Propeller Bolts Camshaft Gear Bolts Lockwire Page No 94 Issue No 2 Nom Dia mm 12mm 5 16 3 8 1 4 5 16 3 8 5 16 1 4 5 16 1 4 1 4 5 16 1 4 1 4 1 4 8mm 5 16 1 4 1 4 Date 130598 Torque nm ft lbs 11 8 34 40 20 24 40 20 7 20 11 14 16 14 14 14 14 24 24 30 5 18 30 15 5 5 8 10 12 10 10 10 10 18 9 5 7 16 12 Issued By PJA 9 1 PRESCRIBED SEALANTS AND PRIMERS Item Sealant Spark Plugs NGK D9EA i O Tighten to finger tight to seat then with plug socket turn an additional 1 2 turn xk 9 2 Page No 95 8 ft lbs for a new plug All gasket areas use Loctite Gasket Eliminator 515 NEW TOLERANCES Issue No 2 Date 130598 Issued By PJA All Dimensions are in Millimetres Crankshaft Mains Journals Big Ends Journals Thrust Face Crankcase Main Bearings Cam Bearings Cam Thrust Face Lifter Bores Crank Thrust Con Rods Big Ends Little Ends Length Between Bore Radius Cam Shaft Journals Valve Lift Fuel Pump Lift Thrust Faces Lifter Stems Dia Sidering Clearance Pin Dia Ring End Gap Pistons Cylinder Bore Dia 47 938 to 47 918 44 988 to 45 000 56 95 to 57 05 47 975 to 48 005 20 00 to 20 020 14 95 to 15 10 9 000 to 9 050 56 65 to 56 85 45 028 to 45 070 23 005 to 23 015 74 485 to 74 498 19
21. an Australian Civil Aviation Safety Authority CASA approved Quality Assurance System to exacting standards Jabiru recommend a TBO of 1000 hours for both of their engines A Guaranteed Fixed Price Overhaul Plan is offered with both engines Contact your regional distributor or Jabiru Aircraft for details Top End overhauls are also available on later model engines Jabiru engine Warranty is 200 hours or 12 months whichever comes first from date of sale or from date of independently verified first flight Conditions Apply Page No 7 Issue No 4 Date 240103 Issued By PJA 1 1 Denomination of Cylinders l i SESER E l A 4 Cao iF va TT He a O E P an m e ALT i D qe E g E a a ay CAOC Page No 8 Issue No 4 Date 240103 Issued By PJA 2 0 TECHNICAL DATA 2 1 Dimensions and Weights Bore Stroke Displacement Compression Ratio Direction of Rotation on Prop Shaft Engine Curb Weight 2 2 Normal Equipment Ignition Unit Ignition Timing Firing Order Spark Plugs Electrode Gap Generator DC Output Carburettor Air Intake Filter Fuel
22. and allow to dry 2 Mount conrods to crankshaft Use plenty of oil on journals Closest to prop flange is number 1 Pins to prop drive Use Loctite 620 on rods and bolts torque up to 24 0 NM 18 ft lbs Note Alloy rods are not reused but replaced with steel type Page No 36 Issue No 4 Date 240103 Issued By PJA DEGREE WHEEL Jrawing 9429063 2 CRANKSHAFT amp CONROD ASSEMBLY Drawing 9429063 A8 1 Clean and visually inspect camshaft 2 Measure journal diameter 3 Measure lobe lift CAM LIFT A B LIFT MEASUREMENT Drawing 9433064 1 CAN Drawing 9433064 4 Inspect fuel pump lobe for wear 5 Spray camshaft rear gears and bolts with Loctite 7471 Primer 6 Fit gears and new bolts Use Loctite 620 torque to 8 ft Ibs amp Lock Wire 7 Fit end welsh plug Page No 37 Issue No 4 Date 240103 Issued By PJA INNER TIMING GEAR SHAFT m SPACER OUTER TIMING GEAR HEX BOLT WELSH PLUG IN END OF CAM SHAFT ev Si A9 Page No 38 Issue No 4 TELI purupuru WIRE ALL LOCK PIN TO ALIGN D Drawing 9448064 Stage Inspection by 2nd person of Sub Assembly a AVA INNER ALIGN OUTER
23. carburettor overflows The float chamber 44 incorporates an overflow pipe to allow fuel to drain off if the specified level in the float chamber is exceeded substantially due to a leaking needle valve MAIN REGULATING SYSTEM WITH PRESSURE REGULATOR The amount of mixture drawn in by the engine and thus its performance is determined by the cross sectional area in the choke tube which is opened by the throttle valve 23 The throttle valve is secured to the valve shaft 24 by two screws 25 The end projecting from the carburettor housing carries the throttle levers 27 28 which are secured by the nut 3 and washer 29 to which the Bowden cable operating the throttle shaft is attached The sealing ring 26 provides the seal between valve shaft and housing The retaining arm 31 attached to the carburettor housing by means of screws 32 and washers 33 engages the notch in the valve shaft and thus prevents it from moving in axial direction The return spring 35 whose action opposes the Bowden cable is attached between a bent over tab at the lower end of the retaining arm and the throttle lever 28 If the throttle valve 23 is opened while the engine is running the increased air flow in the choke tube results in a vacuum building up at the outlet of the needle jet 3 which draws fuel from the float chamber through the jet system At low speeds and in particular in the case of four stroke engines this vacuum is not sufficient for an
24. is possible to connect a pressure gauge in the simplest case a U tube pressure gauge to a nipple below the throttle valve shaft bearing point which is normally closed off by screw 39 To select the idling speed the idling screw 34 is in this case adjusted until the same vacuum is indicated for all carburettors By slightly opening the throttle valve via a turning handle or the accelerator it is also possible to adjust Bowden cables or linkages evenly by making this vacuum comparison STARTING CARBURETTOR BING constant depression carburettor is provided with a rotary valve starting carburettor as an aid for staring a cold engine using a Bowden cable A disc 47 resting against the carburettor housing is turned via a shaft in the starting carburettor housing 48 so that the starting carburettor chamber into which air enters from the air filter side of the carburettor is connected to the engine side of the carburettor via a duct The airport in the disc 47 is shaped in such a way that depending on the disc position more or less air is drawn in At the same time the disc opens the fuel system of the starting carburettor via bores matched to the disc position The fuel flows from the float chamber through the starting jet into the Page No 59 Issue No 4 Date 240103 Issued By PJA vented starting chamber also contained in the float chamber 44 and from there through a riser where it is pre mixed with air via transverse bores into the s
25. method of calibration They can vary to manufacturers claims 24 ft Ib on head bolts 010 on valve clearance cold Early heads require a 1 2 inch ring spanner and 3 16 allen key Later engines use a 9 16 socket and 3 16 allen key or blade screwdriver Easiest method of setting valves requires you to pull the prop until exhaust valve on No 1 cylinder is fully depressed Note the O clock position Rotate prop 360 and adjust valve This puts the cam and lifter at 180 to the peak lift Repeat for each valve Heads and valves should be done at least twice at 5 hrs and 10 hrs on a new engine Remember to go over exhaust cap screws They are fitted with shakeproof washers to prevent loosening Page No 16 Issue No 4 Date 240103 Issued By PJA AIR DUCTS Periodic research and development does cause at time changes to occur Ones supplied need to be fitted See instructions manual FILTERS Inspections down the track are a must for fuel and air filters Conditions will dictate when changed The air box has a rubber flap to give partial inspection of filter SPARK PLUGS NGK D9EA are recommended Plug gap of around 022 to 024 Remember plugs are installed at around 8 ft Ib or given 1 2 turn after contact with head 18mm Plug spanner used COMPRESSION TESTING Condition of compression can be done by a compression gauge Wide open throttle engine warm Turn over on starter Below 90 PSI would indicate removal of head and
26. minimum 2 7 Operating Speeds and Limits Max Speed Continuous Speed Idle Speed Oil Pressure Normal Operations Min Max Idle Min Starting amp Warmup Max Oil Temperature Min Max Continuous Temperature Max Cylinder Head Temperature Climb Continuous Cylinder Head Temperature Cruise Page No 10 Issue No 4 3300 RPM 3300 RPM 900 RPM 220 kPa 31 psi 525 kPa 76 psi 80 kPa 11 psi 525 kPa 76 psi 15 C S99F 118 C 244 f 80 100 OC 176 2120F 175 OC 3480F 150 C 302 F Read Cylinder Head Temperature under the spark plug nearest to the exhaust on the hottest cylinder Date 240103 Issued By PJA 3 0 PERFORMANCE GRAPHS Engine Performance Curves Jabiru 2200A Engine 160 150 140 130 A S 120 E a 110 g 100 90 80 70 1500 1700 1900 2100 2300 2500 2700 2900 3100 3300 Speed RPM 4 0 OPERATING INSTRUCTIONS Page No 11 Issue No 4 Date 240103 Issued By PJA To ensure that the engine operates reliably carefully observe all of the operating amp maintenance instructions 4 1 Pre Start Checks Daily Checks See Paragraph 5 1 Move throttle position to FULL amp check for ease of movement over the entire range 4 2 Starting Procedure Fuel Tap OPEN Choke ON in cold conditions Fuel Pump ON for 10 seconds then off Throttle CLOSED to Stop Master ON Ignition BOTH ON Starter PRES
27. rockers matched i e left stays left and right stays right 7 Put a small amount of Loctite 290 wickin on bushes to lock them on 8 Ream bushes with an adjustable ream to dia 12 03mm 12 05mm 0 474 0 475 9 Measure rocker shafts for wear and inspect for scratching scuffing etc Record in Build Sheet 10 Inspect rocker blocks Note If the clamp capscrew comes loose it will let the shaft rock Any blocks like this must be replaced 11 Assemble rocker block 12 Actions 5 8 refer to earlier bushed rockers up to engine 118 Engines Page No 45 from 189 onwards use either 12mm or 15mm wide GLASIER type bush These were pushed in to fit friction fit no compound used to lock Issue No 4 Date 240103 Issued By PJA BUSH ASSEMBLY O RINGS FIRST INSERT SHAFT ROCKER ASSEMBLY Drawing 9449064 13 Put capscrew through clamp hole and check rocker end float Must be 0 1 to 0 4mm 0 004 to 0 010 Face off outside bushes to adjust 14 Clean up oil well and reassemble Cylinders C6 1 Clean and visually inspect 2 Mount cylinders in honing machine by base and hone with Sunnen mm 33 J85 Stone BARREL HONE PATTERN 5 4 ot ZN am
28. shafts and record on build sheet Measure distributor shaft posts and record in build sheet Fit shafts into gearcase and using a straight edge and feeler gauge measure end float Record in build sheet Visually inspect gears for wear Fit seals to gear case Lube shafts and fit to gear case Fit rotors Visually inspect engine mount plate for 1 Damaged Threads 2 Wear from distributor shafts Seal up and store for final assembly Page No 55 Issue No 4 Date 240103 Issued By PJA Jabiru 2200 Component Inspection and Assembly 7 4 7 Sub Assembly G Fuel Pump and Carburettor and Carburettor Operation Fuel Pump The fuel pump on the 2200 engine is replaced as a complete unit at overhaul It can be inspected for faults by removing the top half Things to look for are 1 Stuck or leaking valves 2 Torn diaphragm 3 Weak springs 4 Broken actuating lever Carburettor Operation The BING constant depression carburettor type 64 3 or 94 40 comprises a cross draught butterfly valve carburettor with variable choke tube double float system arranged centrally below the carburettor venturi and a rotary valve type starting carburettor It features a throttle slide which is suspended from a roller diaphragm and projects into the venturi It changes the smallest cross section choke tube of the venturi as a function of the vacuum at this point The throttle valve diameter is 36mm MOUNTING The carburettor is secured to the en
29. 4 Sub Assembly D Sump and Oil Pump 5 Sub Assembly E Flywheel Ignition Coils and Alternator 6 Sub Assembly F Gear Case 7 Fuel Pump and Carburettor 8 Final Assembly of Sub assemblies 9 Run In Page No 35 Issue No 4 Date 240103 Issued By PJA Jabiru 2200 Component Inspection and Assembly Procedure 7 4 1 Sub Assembly A Crankshaft Prop Mount and ConRods Al 1 Remove welsh plugs from crankshaft 2 Clean conrods and crankshaft Note Make sure all old loctite is removed from threads 3 Strip paint off prop flange and crankshaft 4 Magnet particle inspect crankshaft prop flange cam and conrods A2 Measure crankshaft and record in Build Sheet A3 Inspect Oil Holes for Cleanliness and insert new front welsh plugs 2 off and rear welsh plug A4 Inspect prop flange Paint prop flange and end of crankshaft to prevent rusting AS 1 Magnet particle Inspect conrods for cracks 2 Fit bearings with a light smear of bearing blue on back of shells 3 Torque Caps to 18 Ibs with new bolts 4 Measure Big End Bearings Record in Build Sheet 5 Measure Piston Pin Bore Record in Build Sheet 6 Remove caps and check bearing back contact Must be at least 90 7 Remove all blue and thoroughly clean surfaces Refit bearing shells A6 Temporarily mount prop flange to crankshaft and mount to stand vertically Flange is removed later to fit front oil seal A7 1 Spray conrod bolts and conrod bolt threads with Loctite 7471 primer
30. 5 60 90 105 120 Maximum RPM Fuel Grade Fuel Consumption Avgas 100LL L I hereby certify that this engine has been tested in accordance with the approved procedures and the Jabiru Aircraft Pty Ltd Engines Division Policy and Procedures Manual and is fit for use Signed Date Page No 89 Issue No 2 Date 130598 Issued By PJA JABIRU 2200 ENGINE RUN IN SCHEDULE SPEED RPM ENGINE ATA A E A Al ry gt TAP Se oe CO Cc O CD 7 N N E I wr TIM min Drawing 9486093 1 RUN IN SCHEDULE Page No 90 Issue No 2 Date 130598 Issued By PJA Jabiru 2200A Aero Engine Ground Test Form Date Start Time Operator Finish Time Block Total Seq Time Duration Condition RPM Rec RPM CHT 1 CHT 2 CHT 3 CHT 4 EGT Oil Temp Oil Press Current 1 5 Start and Idle 1200 2 3 Take Off Power 2500 Full 3 5 Cooling Run 1200 4 5 Take Off Power Full 5 5 Cooling Run 1500 2000 6 5 Take Off Power Full 7 5 Cooling Run 2000 8 15 15 Power 2800 9 5 Cooling Run 2000 10 60 Max Cont Power Full 2000 Full 15 mins 2500 2800 Full 30 mins 2500 Full 45 mins Full 2500 60 mins 11 5 Cooling Run 1200 Record of Replenish
31. 5183 Ring Gear 4066423 Coil 1 PI10522N 2 PI10522N I hereby certify that the above listed parts conform with the dimensions have been engraved and installed as recorded Signed Date For Jabiru Aircraft Pty Ltd Certificate of Approval 3501 Page No 84 Issue No 2 Date 130598 Issued By PJA Jabiru 2200 Component Assembly Procedure Subassembly F Gear Case No Details Sign Sign Date Fl Deburr clean and inspect all of the gears F2 Measure the shaft post internal diameters and the distributor shaft diameters F3 Using loctite 515 fit the shaft posts to the gear housing F4 Fit the distributor shaft seals and rear crankshaft seal F5 Fit shafts to gears with 24 hour araldite F6 Fit the distributor shafts and gears to the gear housing F7 Check end clearance of distributor shaft to case flange Stage 2 F8 Stage Inspection of Assembly _ _ J I hereby certify that the subassembly has been completed using the approved procedures and data and is fit for installation Signed Date For Jabiru Aircraft Pty Ltd Certificate of Approval 3501 Notes Page No 85 Issue No 2 Date 130598 Issued By PJA Component Register and Parts Inspection Record Subassembly F Gear Case Batch Serial No Date Description Part No Batch Item Details ne Distributor Mount Spacer 1 4632074 2 4632074 Dist
32. 96 to 19 97 6 900 to 7 100 2 45 to 2 55 15 18 to 15 25 8 965 to 8 990 97 50 to 97 53 0 01 to 0 02 22 990 to 23 000 0 400 to 1 000 Height 64 00 65 50 97 59 to 97 61 Length over flanges A 106 450 to 106 500 B 106 950 107 00 Valve Stem Dia Inlet Stem Dia Exhaust Guide I D Inlet Guide I D Exhaust Spring Free length Shaft dia Shaft Post I D Shaft End Float Distributor 6 970 to 6 990 6 970 to 6 990 7 040 to 7 050 7 040 to 7 050 39 5 to 42 14 940 to 14 970 15 00 to 15 03 Imm Note Early engine components can exhibit slight variations to these new tolerances but still be serviceable Page No 96 Issue No 2 Date 130598 Issued By PJA 9 3 MAXIMUM ALLOWABLE CLEARANCES Wear Limits All Dimensions are in Millimetres Mains Big Ends Little Ends Camshaft Journals Crank End Float Cam End Float Lifter Crankcase Piston Cylinder Ring Side Clearance Pin Piston Ring End Gap Inlet Valve Guide Exhaust Valve Guide Min Spring Length Distributor Shaft Post Distributor Shaft End Float Cylinder Dia at Half stroke Rocker Shaft Rocker Arm Oil Pump Gears Bearing Clearances main Big Ends 0 10 0 08 0 03 0 08 0 80 0 50 0 12 0 15 0 05 0 04 1 20 0 10 0 12 39 50 0 10 1 20 97 65 0 18 0 15 0 04 0 09 typical 0 04 0 06 typical Note Variation can occur overall tolerances may be acceptable with advice from Jabiru Aircraft Pty Ltd Page No 97 Issue No 2
33. C6 Complete rocker shafts and rocker assemblies C7 Fit cylinder base O rings C8 Fit front circlip C9 Check ring end gaps fit rings to pistons C10 Install piston assembly to cylinder just clear of the oil ring I hereby certify that the subassembly has been completed using the approved procedures and data and is fit for installation Signed Date For Jabiru Aircraft Pty Ltd Certificate of Approval 3501 Notes Page No 79 Issue No 2 Date 130598 Issued By PJA Component Register and Parts Inspection Record Subassembly C Pistons Cylinders and Cylinder Heads Batch Serial No Date Description Part No Batch Item Details Guides Inlet Outlet Head 1 4577062 2 457806N 3 4577062 457806N 4554062 4554062 4554062 4554062 Piston 1 4685083 2 4685083 3 4685083 4 4685083 Rockers LH 4647084 RH 464808N Gudgeon Pin 4299054 I hereby certify that the above listed parts conform with the dimensions have been engraved and installed as recorded Signed Date For Jabiru Aircraft Pty Ltd Certificate of Approval 3501 Page No 80 Issue No 2 Date 130598 Issued By PJA Jabiru 2200 Component Assembly Procedure Subassembly D Sump No Details Sign Date DI Deburr and wash sump inspect for defects D2 Fit oil temperat
34. CAP S REW Page No 50 EL 064 mAai GA Zl awing wv Yale J it LDL NS Issue No 4 1 MAGN C i ET PA FAC _ LOCKWIRE TO FORM LOOP ET PULL TEST Drawing 9438064 Date 240103 ALT E WITH SPRIN ERNATIOR Issued By PJA RALLEL TO FLYWHE O CRA DVALE Ignition Coil Inspection E4 1 Using a multimeter measure the primary resistance from the earth terminal to the iron core It should be 0 8 R to 1 0 R K ff IGNITION COIL N J RESISTANCE PROBES Drawing 9439064 1 IGNITION PRIMARY RESISTANCE Drawing 9439064 2 Measure the secondary resistance from the high tension lead to the iron core it should be between 5 9 KR to 7 1 KR RESISTANC PROB y IGNITION COIL Drawing 9439064 1 IGNITION SECONDARY RESISTANCE Drawing 9439064 Alternator Inspection Page No 51 Issue No 4 Date 240103 Issued By PJA E5 1 Use multimeter to test resistance of windings Resistance should be 0 5 to 1 1 R 2 Use multi meter to test resistance to ground Resistance should be infinite Permanent Magnet Alternator PMA Operation
35. Dip heads in a cold dip solvent i e Redik dkt Degreaser Decarboniser Paint stripper as per manufactures instructions to remove all carbon deposits 3 Note The heads can be bead blasted but care must be taken 4 Wire buff valves 5 Clean all other parts Cylinder Head Inspection and Repair C2 1 2 3 4 5 Page No 41 Inspect cylinder head for flatness If sealing surface show signs of leakage it may need refacing When refacing remove only the minimum to clean up Measure valve guide wear If wear is excessive remove guides Measure valve guide bore in the head The new guide must have at least 0 05mm 0 002 interference on the outside diameter Note The standard guide has no dimples in top P N 4518064 In P N 4519064 Ex 0 05mm 0 002 has one dimple 0 05mm 0 004 has two dimples 0 05mm 0 006 has three dimples Press guides back in Note Oil hole must go up Special Note Guides Guides are installed at 7 05mm bore diameter Guides from 7 08mm can cause oil usage in the engine max valve stem to guide clearance is 0 12mm SPECIAL TOOL FOR VALVE GUIDE FITTING _ VALVE GUIDE Issued By PJA Wa 5 Mount head up and cut seats as per drawing Note When cutting seats cut enough to clean up but try to remove as little as possible ae 549 a 1 34 pore 60 399 a E 5 i 1 26 Loo ue 280 ee 1 10 0 02
36. ER 1 ITEM PART No DESCRIPTION QTY Drawing 453 Issue No 4 ALT ERNATOR ASSEMBLY Date 240103 Issued By PJA 2 Regulator REGULATOR WIRING GN 1 GN 2 STARTER MASTER STROBE FU P The regulator performs rectification and voltage regulation The regulator converts A C into D C which flows through the power consuming circuits and the battery and also charges the battery If however the battery voltage exceeds a certain level the D C is cut off from the charging circuit to prevent over charging For best results it is recommended that positive and negative of the regulator go directly to the battery Page No 54 Issue No 4 Date 240103 Issued By PJA 7 4 6 Fl F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 Jabiru 2200 Component Inspection and Assembly Sub Assembly F Gear Case Remove distributor shaft seals and rotor seal and discard Inspect Distributor shaft posts for signs of leaking Note If there is no signs of leaking don t disassemble But if it is leaking disassemble and clean off old master gasket Inspect surfaces and reassemble Clean gear case distributor shaft and engine mount plate Measure distributor
37. Filtration Fuel Pump Starting System 97 5 mm 74mm 2209 cc 8 3 1 s n 1004 onwards have 8 1 Clockwise Pilot s view tractor applications 60 kg complete with Engine Oil Exhaust and Starter Motor Jabiru dual ignition breakerless transistorised Battery Independent 25 degrees BTDC 1 3 2 4 NGK D9EA 0 55 0 6mm 0 022 0 024 Jabiru permanently excited single phase AC generator with rectifier regulator 10 amps continuous BING constant depression Type 64 32 or type 94 40 1 x folder paper cartridge 0 1 mm 100 Micron maximum particle size Camshaft driven diaphragm type Electric 12 V 1 0 kW 2 3 Performance Data Take Off Maximum Continuous RPM 60 kW 80 hp 3300 RPM 2 4 Fuel Consumption Fuel Consumption Takeoff Max Continuous Rating 21 litres hr 2 5 Fuel and Lubricant Fuel AVGAS 100 LL amp AVGAS 100 130 Leaded and Unleaded Automotive Gasoline above 95 Octane Ron Page No 9 Issue No 4 Date 240103 Issued By PJA Run in Period Oil 80 Outside Air Temp 170C to 250C 1 to 7790F Normal Operations Oil W80 Outside Air Temp 170C to 250C 10 to 77 f 2 6 Cooling System 100 120 150C to 35 C Above 35 C 590 to 950F Above 95 F W100 W120 150C to 35 C Above 35 C 59 to 95 F Above 95 F Free air cooled Ensure that baffles are correctly fitted amp located The required pressure drop across the cylinders at 1 3 Vs in take off configuration is 4 3 cm 1 7 water gauge
38. 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 amp 2200J Models Page No 1 Issue No 4 Date 240103 Issued By PJA Paragraph 1 0 1 1 2 0 2 1 Dee 23 2 4 2 5 2 6 ZT 3 0 4 0 4 1 4 2 4 3 4 4 4 5 4 6 4 7 5 0 5 1 5 2 5 3 5 4 5 5 5 6 5 7 5 8 6 0 6 1 6 2 6 3 6 4 Page No 2 Table of Contents Description Table of Contents List of Amendments Description Denomination of Cylinders Technical Data Dimensions amp Weights Normal Equipment Performance Data Fuel Consumption Fuel amp Lubricant Cooling System Operating Speeds amp Limits Performance Graphs Operating Instructions Pre Start Checks Starting Procedure Warm Up Period Ground Test Take Off Engine Stop Engine Stop amp Start During Flight Addition Early Operation of Engine Checks on Engine amp Installation Daily Checks Periodic Checks Check After Initial 25 Hours 50 Hours Check 100 Hours Check TBO Engine Preservation Operation in Winter Maintenance Lubrication System Air Intake Filter Carburettor Adjustment Compression Check Issue No 4 Page me rR OO OO Aa O oo 12 12 12 12 12 13
39. ONWOMGNWOGORVOOQTOTECTOCUCNOCUOQOCU taddatta lanha ui weldade 012345 7 MEASUREMENT 443064 1 VALVE SPRING Drawing 9443064 Inspect valve spring seats valve spring retainers and valve collets Replace any that show signs of wear Lube valves well Install valves valve spring seats springs retainers and collets ER SPRING Drawing 944 064 ASSEI MBLY Drawing 94470641 2 Issue No 4 Date 240103 BASE SPRING SPRING COLLETS gt RETAINER Issued By PJA C4 Install Push Rod Tube O Rings with a small amount of rubber grease Rocker Assembly C5 1 Disassemble and clean off all carbon 2 Inspect rocker tip for wear Replace any with excessive wear 3 Measure bushes and record on build sheet 4 If over service limits replace gt SOCKET ROCKER ASSY SPECIAL PUNC OR SOCKET 4 L Drawing 9449064 1 ROCKER BUSH REMOVAL Drawing 9449064 5 Clean off old Loctite from rocker bore 6 Press in Bushes Note The width of the bushes is critical for the correct amount of end float so they must be pushed right home By putting the outer wider flange bushes to the left makes a left bush and vice versa Always keep
40. RU in its published sales literature and the company does not accept any such unauthorised action WARRANTY ON JABIRU REPLACEMENT PARTS JABIRU warrants in respect of JABIRU parts and accessories required as replacement parts that it will make good by repair or at its option by replacement 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 warranty does not cover those parts listed as exclusions in the New Engine Warranty and is subject to the same general exclusions Page No 103 Issue No 1 Date 220100 Issued By PJA J ABIRU WARRANTY CLAIM FORM FROM DATE ENGINE PARTS o AIRFRAME PARTS o ENGINE NUMBER AIRFRAME KIT NUMBER PART NUMBER TOTAL HOURS OWNER PREVIOUS OWNER PART DESCRIPTION CLAIM FAULTY GOODS RETURNED YES o COURIER Co REF NO NO o ALL GOODS THAT ARE BOXED AND HAVE TO PASS THROUGH CUSTOMS HAVE TO BE CLEANED AND FREE FROM CONTAMINATION WITH A STATEMENT ATTACHED SPECIFING HOW THEY WERE CLEANED AND THAT THEY ARE FREE OF DIRT AND GRASS SEEDS IF THEY ARE NOT CLEANED TO CUSTOMS SATISFACTION AN EXTRA CLEANING CHARGE WILL APPLY IF WARRANTY CLAIM IS NOT COMPLETELY AND CORRECTLY COMPLETED WARRANTY MAY BE REFUSED OFFICE USE ONLY APPROVED NOT APPROVED REASON PRINTED NAME SIGNED Page No 104 Issue No 1 Date 220100 Issued By PJA
41. Remove Tacho Lead 16 Remove Left and Right Ignition Coil Leads 17 Remove Muffler Assy 18 Undo Engine Mount Bolts 19 Remove Engine from Engine Mount Frame Page No 31 Issue No 4 Date 240103 Tools Phillips Screwdriver 7 16 Socket 7 16 Spanner Screwdriver Screwdriver 2 Plugs Long Nose Pliers Long Nose Pliers Screwdriver Screwdriver 1 4 Plugs 7 16 R OE 10mm R OE Screwdriver 3 16 Ball End Allen Key 7 16 Tube Socket 7 16 Spanner Issued By PJA 7 3 No 10 11 12 13 14 15 16 17 18 19 Page No 32 ENGINE DISASSEMBLY Operation Mount Engine on an engine stand in vertical position Remove Spark Plugs Remove Oil Pressure Sensor Remove Oil Filter Oil Pressure Valve may be removed by removing snap ring 1 Extract Valve Seat 1 Valve 1 Spring 1 Remove Oil Pump Assembly Housing Rotor Stator amp Backing Plate Remove 4 capscrews in front oil seal carrier and break seal on crankcase Remove Fuel Line and Carburettor Remove Fuel Pump Gasket and Push Rod Remove Distributor Cap Clamps Caps and Rotors Remove Starter Motor Remove Alternator Mount Remove Ignition Coils from Alternator Mount Remove Flywheel Remove Gearbox Cover Remove Engine Mount Plate Remove Crankshaft Timing Gear Remove Lower Induction Pipes Issue No 4 Date 240103 Tools Spark Plug Socket 17mm Spanner Snap Ring Pliers 7 32 Allen Key 3 16 Allen
42. S Attention Activate Starter for a max 20 seconds followed by a cooling period of 1 minute When engine runs adjust throttle to achieve smooth running at approximately 1200 RPM Deactivate Choke Check Oil Pressure has risen within 5 seconds if not shut down It is stongly advised to close choke while cranking on first attempt To much choke will cause over fueling in the venturi and loss of start 4 3 Warming Up Period Ground Test Start the warming up period with the engine running at 1200 RPM Continue at 2000 RPM depending on ambient temperature until oil temperature reaches 15 C 59 F Check the two ignition circuits at 2000 RPM Note RPM with only one ignition should not drop by more than 100 RPM DO NOT apply full power until CHT reaches 100 C 2120F DO NOT allow cylinder heads to rise above 150 during ground running 4 4 Take Off Climb with the engine at maximum continuous power Observe Oil amp Cylinder Head Temperatures amp Oil Pressure Limits must not be exceeded Max continuous RPM at Full Throttle is 3300 RPM 4 5 Engine Stop Page No 12 Issue No 4 Date 240103 Issued By PJA In normal conditions cooling down the engine during descent amp taxiing will permit the engine to be stopped by switching OFF the ignitions 4 6 Engine Stop and Start During Flight Reduce power to 2000 RPM to cool engine for 30 seconds then to idle Switch ignitions OFF Starting procedure is the same as ground
43. TN 7 z 9 7 x A E zZ 7 T So ft if 5 6f pearine TPE SLY SLA 1 PLAIN a 2 GROOVE amp HOLE 1 GROOVE amp HOLE l s GROOVE amp HOLE r p a IJ T a Drawing 9441064 1 BEARING POSITION amp TYPE Drawing 9441064 1 Make spacers as per drawing DRILL 10 DIA Drawing 9442064 1 SPACER FOR MEASURING CRANKCASE Drawing 9442064 2 Join crankcase halves 3 Put through studs in case Note the cylinders by themselves can be used as spacers It is just a bit harder to measure the main tunnels 4 Fit old nuts and torque to 40 NM 30 ft lbs in two stages Measure main tunnel and cam tunnel and record in build sheet 1 Disassemble 2 Remove shells and check back contact must be at least 90 3 Check mating surface on crankcase 4 Remove all blue and thoroughly clean surfaces Refit bearing shells Measure cam lifters and bores and record on build sheet Check Lifter face for excessive scuffing Oil and refit Use a small amount of Molybdenum disulphide grease on lifter faces Check cam shaft end float in both halves Record in build sheet Check crankshaft end float in both halves and record in build sheet Page No 40 Issue No 4 Date 240103 Issued By PJA Jabiru 2200 Component Inspection and Assembly Procedure 7 4 3 Sub Assembly C Pistons Cylinders and Cylinder Heads Cylinder Head Clean Up Cl 1 Clean oil off heads 2
44. Thrust washers in position 6 Dowels in 7 Lifter are in with moly grease on faces You will need 1 An extra person 2 4 7 16 Ring Open End spanners 3 2 9 16 Ring Open End spanners 4 2 3 8 Plain grade 5 nuts 5 2 3 8 Belleville Washers 6 18 through stud nuts MS21042L6 7 6 through studs 8 Torque wench 9 7 16 x 3 8 drive 2 extension snap on no fres 14 10 Long Nose Pliers Note An extra person makes it easier to bolt up and also can cross check work Stage Inspection Oil all bearing crank and camshaft Fit halves over crankshaft assembly and squeeze up by hand Using spacers and plain nuts on rear studs and belleville washers and MS21042L6 nuts on the front studs pull the crankcase together but don t do up tight Remove rear nuts Put all through studs in a b c Fit piston cylinder assemblies to No 1 amp 2 conrods Fit circlips cross check circlips for correct fit Push cylinders home Put cylinder base nuts MS21042L6 on Using 2 7 16 ring spanners do up each side together If one nut goes on more than 3 turns put the 3 8 plain nut on top of it and use a 9 16 ring spanner to hold the nut locking up the stud Issue No 4 Date 240103 Issued By PJA Torque up by hand lightly d Turn engine 1 2 turn so No 3 amp 4 conrod are out repeat procedure on No 3 amp 4 H7 a Torque to 15 ft lbs then 30 ft Ibs Note Keep an eye on the amount of thread through each nut Both sides should have appr
45. UNDER NO CIRCUMSTANCES USE AUTOMOTIVE OIL IN THIS ENGINE Use only oils which are designed for Air Cooled Aero Engines gt Some brands of automotive oils have been shown to cause very rapid cylinder wear This will not be covered under warranty gt Operate engine only on AVGAS 100LL or highest octane available MOGAS above 95 octane containing lead Failure to do so could result in engine damage and void warranty USE OF OIL FUEL ADDITIVES VOID WARRANTY Vv Page No 74 Issue No 4 Date 240103 Issued By PJA Jabiru 2200 Component Assembly Procedure Subassembly A Crankshaft Propeller Mount Flange and Conrods No Details Sign Sign Al Inspect for Burrs Oil Holes Chamfers Clean Crankshaft Conrods and Propeller Mount Plate A2 Inspect Oil Holes and Insert Welch Plugs A3 Measure Crankshaft refer to Goods Inwards Inspection Sheet A4 Inspect and Measure Propeller Mount Flange A5 Inspect and Measure Conrods refer to Goods Inwards Inspection Sheet A6 Mount Propeller Mount Flange to crankshaft Torque to 30ft lbs Lockwire A7 Fit the Conrods to the Crankshaft Use Loctite 620 on the bolts and torque to 18ft lbs Stage A8 1 Stage Inspection of Assembly Conrods Crankshaft Date I hereby certify that the subassembly has been completed using the approved procedures and data and is fit for installation Signed Date
46. adequate fuel supply it must therefore be increased artificially by using a pressure regulator For this purpose the BING constant depression carburettor type 64 is provided with a plunger 13 operating in conjunction with a diaphragm 16 which reduces the cross sectional area or the needle Page No 57 Issue No 4 Date 240103 Issued By PJA jet outlet by virtue of its own weight or in some applications with the additional pressure from a spring 22 and thus increases air velocity and vacuum at this point The plunger 13 is located centrally in the cover 20 which is secured to the carburettor housing by screws 21 The diaphragm 16 is connected to the plunger 13 by a retaining ring 17 and four screws 18 and washers 19 each The vacuum in the choke tube acts on the top of the diaphragm and the plunger via a bore U in the plunger 13 and attempts to lift the plunger against its own weight and spring 22 The considerably lower vacuum between air filter and carburettor is applied to the underside of the diaphragm via duct V as a reference pressure If the throttle valve 23 is opened when the plunger 13 is closed then a vacuum will build up in the small cross section at the bottom of the plunger 13 which is sufficient to provide a supply of fuel The weight of the plunger 13 and the force of the spring 22 are matched in such a way that this vacuum will be maintained with increasing speed until the plunger has fully
47. al If the engine is not fitted to an airframe ignore those items referring to the airframe 5 7 1 Flyable Storage Flyable storage is defined as a maximum of 30 days non operational storage Ensure that the engine has been stopped by turning off the fuel valve thereby not leaving any fuel in the carburettor bowl Every 7th day the propeller should be rotated through 5 revolutions without running the engine Leave the propeller in the horizontal position to ensure even distribution of liquids in the wood If left in the vertical position liquids will drain to the lower tip resulting in an unbalanced propeller CAUTION Ensure that the Master and Ignition Switches are OFF 5 7 2 Returning Engine to Service After flyable storage returning the engine to service is accomplished by performing a thorough pre flight inspection Ensure all protective covers are removed 5 7 3 Temporary or Indefinite Storage Temporary storage is defined as aircraft in non operational status for a maximum of 90 days Treat as for flyable storage see Paragraph 5 7 1 plus For temporary storage fill fuel tank with correct grade of fuel to prevent moisture accumulation For indefinite storage drain fuel tank ensure carburettor bowl is empty by running engine with fuel valve off until it stops or by draining bowl Then 1 Disconnect spark plug leads and remove spark plugs from each cylinder 2 Using a spray atomiser spray the oil through the spar
48. aling surfaces d Use loctite 515 on crankshaft seal carrier to crankface and loctite on cap screws Put a little grease on seal Install seal e Prime crankshaft and new prop flange bolts with loctite primer Using loctite 262 fit flange and torque to 40 nm 30 ft lbs f Wire flange Page No 70 Issue No 4 Date 240103 Issued By PJA 7 4 9 Engine Run In The Jabiru engine is run in on a DYNOMOMETER and cooled with fan driven air In the absence of a DYNO controlled run engines can be run in in the airframe Very large air ducts must be constructed to get adequate airflow for cooling in the static situation The flying air ducts must not be used for this purpose Extreme care must be taken with the cylinder head temps if run in is done in the airframe Engine run in procedure allows progressive build up of the B M E P break mean effective pressure in the cylinders while carefully limiting the heat build up In essence short amounts of hard work increasing in intensity while limiting the heat build up is the format This can be seen in detail after the engine build sheets All engines are run in before delivery including overhauled engines as well When delivered they are ready for flight Run Procedure to be used only if engine has not been run in 1 Mount Engine on test rig See engine installation 2 Fill with non detergent oil 3 Remove spark plugs and wind over until oil pressure is reached 4 Fit plugs and cooling ducts
49. coming slack The fuel passes through the idling jet 5 whose bore will determine the amount of fuel Behind the jet bore the fuel mixes with air which is supplied via cross ducts in the jet throat from the idling air channel the amount of air admitted being determined by the size of the idling air jet at the inlet of this duct This initial mixture then flows through the idling outlet bore LA the cross sectional area of which can be adjusted by the mixture control screw 7 it then reaches the choke tube via bypass or transition passages BP where it is mixed further with pure air Idling should always be with the engine at operating temperature First the mixture control screw 7 is turned fully clockwise and then backed off by the number of turns specified for the particular engine Turning in clockwise direction results in a leaner mixture and turning in anti clockwise direction in a richer mixture The idling setting quoted serves as a guide only The optimum will generally differ slightly First select the desired idling speed by using the idling stop screw 34 When subsequently adjusting the mixture control screw starting from the basic setting a speed drop will be noticed in both directions The optimum setting will generally be found half way between the two settings at which this speed drop was noticed To facilitate the idling setting on engines having several carburettors where it is important that they are evenly adjusted it
50. cumulation of water Add up to 2 isopropyl to fuel Note Addition of alcohol raises vapour pressure and may aggravate vapour lock in warm weather this practice should be used only when needed and not in warm weather Prevent condensation of humidity ie avoid temperature differences between the aircraft amp fuel Page No 25 Issue No 4 Date 240103 Issued By PJA IMPORTANT Fuels containing alcohol always carry a small amount of water in solution In situations where there are changes in temperature or where there is an increase in alcohol content water or a mixture of water amp alcohol may settle amp could cause problems Re 2 Carburettor icing due to humidity may occur in the carburettor venturi amp leads to performance loss due to changes in the mixture The only effective remedy is to preheat the intake air by use of the Carburettor Heat Control WARNING When using auto fuels ensure all components of the fuel delivery system are cooled to prevent fuel vaporization Page No 26 Issue No 4 Date 240103 Issued By PJA 6 0 MAINTENANCE 6 1 Lubrication System Oil Change Oil Filter Change Visual Check for Leaks Drain the oil while engine is still warm Change the oil filter at 100 hour inspection Fill with oil Capacity is 2 3 litres 2 43 US Quarts Check oil level The MAX mark must not be exceeded Use only registered brand oils meeting the specification detailed in Para 2 5 6 2
51. e a long reliable life All moving parts need freeing up especially piston rings to cylinder walls This is best accomplished when the greatest B M E P Break Mean Effective Pressure occurs That is at 75 power and above Careful monitoring by the pilot is needed during this initial period to ensure long life of the engine and its components Do not use any type of automotive oil These oils have not been blended for the purpose of air cooled aero engine operation and will be detrimental to its operation Page No 15 Issue No 4 Date 240103 Issued By PJA 12 Use AVGAS 100 LL or the highest Octane Mogas above 95 containing lead Engines not shimmed on the cylinder base should only be run on AVGAS 13 When you change oil from the run in type to the normal oil at or around 25 hrs replace oil filter You may want to cut the filter open for inspection It is usual in J abiru engines to find a small amount of aluminium but definitely no metal If bearing metal is present contact the J abiru Service Department 14 With ignition and master OFF and throttle closed turn the prop by hand and observe engine for odd noises or heavy movements Check for regular compressions if irregular firstly check tappet adjustment Operation with incorrectly adjusted tappets with result in damage to valves valve seats guides and overhead gear HEAD TORQUING VALVE SETTING Your tension wrench should be accurate It should have had some
52. ed By PJA 3 CHT Possible not reading can be cause by a break in the sender wires or incorrect polarity High readings can result with poorly centred sender under the spark plug Normal cruise CHT should not exceed 150 C and climb must not exceed 175 C Air ducts supplied at present give results below these figures 4 RPM Tacho s may need adjustment when a new engine is fitted Inducted magnet sender units require coil gap to flywheel gear teeth of 014 or 35mm Tacho s using this sender require a pot adjustment access through outside of case Tacho s using the magneto as sender requires a sequence of operation for correction This information can be faxed if required Later engines use 2 tags under the ring gear in conjunction with the induction sender 5 MAGNETO CHECKS Possible causes of abnormal drop could be loose leads faulty leads rotor buttons coil gaps spark plugs 6 ROUGH CYLINDER RUNNING Check plugs valve clearance and the induction system for looseness 7 CARBY BREATHER Later model carbies have a brass fitting for venting This is easily connected via a clear plastic hose to a fitting screwed into the carby heat box On earlier carbies we supplied a kit for this purpose as no internal carby fitting was installed 8 LIMITATIONS Warranty notes follow J abiru recommend TBO of 1000 hrs A guaranteed fixed price overhaul exists through the J abiru factory Warranty is 200 hours or 12 mont
53. electrode gap amp if necessary adjust to 0 55 0 6mm 0 022 0 024 by carefully bending the electrode Recommended Plugs NGK D9EA IMPORTANT Only tighten spark plugs on cold engine amp only to the torque values shown in para 9 0 using appropriate anti seize compound Note When plugs are removed from a warm engine the following are indicators Light Coloured to Brown Plug amp calibration is correct Velvet Black Mixture too rich Check choke Insufficient air intake Check for clogged air filter Oily Glossy Coating Misfiring Too much oil in combustion chamber Worn cylinder amp piston rings Whitish with Melt Droplets Mixture too lean Leaking valves 6 6 Exhaust System Visual check for damage leaks amp general condition 6 7 Bolts and Nuts Check for tightness re torque if necessary see para 9 0 Page No 28 Issue No 4 Date 240103 Issued By PJA 6 8 Tappet Adjustment Tappets must be adjusted to Inlet 0 254mm 010 Exhaust 0 254mm 010 Adjust the tappets when the engine is cold Head torqued to 24 ft lb when cold Carry out this adjustment after five hours of operation and again after ten hours of operation At the 25 hour inspection this is done again CAUTION Continued operation with incorrectly adjusted tappets will result in damage to valves valve seats valve guides amp overhead gear 6 9 Tachometer and Sender Many apparent engine problems can be caused through inaccura
54. f up to around 500 kpa doesn t necessarily indicate a malfunction Low battery charge Fit fully charged battery Note Running this engine on low octane fuel will cause piston damage and in extreme case failure of the top ring gland or holed piston due to detonation Page No 101 Issue No 2 Date 130598 Issued By PJA 11 0 JABIRU AIRCRAFT PTY LTD NEW ENGINE WARRANTY Jabiru Aircraft Pty Ltd hereinafter JABIRU warrants that it will make good without charge any defect which appears in this engine Provided 1 the defect has been notified in writing to JABIRU a before the engine has operated a total of 200 hours or b within twelve 12 months of the date of delivery of the engine to the first retail purchaser or from the date of independent Authority authenticated first flight whichever comes first and 2 the engine has been delivered to a JABIRU Approved Service Centre or such other service facility as advised by JABIRU and 3 the engine has been installed in an aircraft type in accordance with a JABIRU approved installation system and 4 JABIRU has determined that the defect complained of is one of workmanship and is not caused by a misuse or abuse of the engine such as by operation outside the approved Flight Manual or Maintenance and Operation Manual etc or by neglect b improper installation including overheating c operation of the engine after it is known to be defective d accident or deliberate act
55. gine using a 43mm diameter push on connection which takes a flexible connecting piece with clamps On the intake side the carburettor is provided with a socket having a diameter of 50mm and a length of 12mm for connecting an air filter or intake silencer FUEL INTAKE CONTROL The float 40 of the carburettor consists of two plastic float elements joined by a metal hinge The float is arranged centrally below the carburettor choke tube so that the carburettor can be tilted very far in all directions without impairing operation The object of the float is to maintain the fuel level in the float chamber 44 constant When the fuel has reached a specified level in the float chamber then the float 40 mounted on pin 41 is lifted until the float needle 42 is pressed against the seat of the float needle valve thus preventing any further supply of fuel When the engine draws in fuel from the carburettor the level in the float chamber 44 drops and so does the float The float needle then opens the valve again and allows fuel to flow in from the tank The float needle valve regulates the fuel supply in conjunction with the float but it does not act as a stop valve when the engine is at a standstill Minute foreign bodies may be deposited between valve Page No 56 Issue No 4 Date 240103 Issued By PJA seat and needle tip thus preventing complete closure of the valve When stopping the engine therefore the fuel cock on the tank should always be c
56. hs which ever comes first CAREFULLY READ MANUALS Page No 19 Issue No 4 Date 240103 Issued By PJA 5 0 CHECKS ON ENGINE amp INSTALLATION 5 1 Daily Checks Ensure free movement of throttle amp choke cables Check Oil Level replenish if necessary Oil level should be between the MAX amp MIN marks but must never be below the MIN mark Before long periods of operation ensure that the level is at least at the mid position Difference in the oil quantity between MAX amp MIN mark is 0 5 litres 0 528 US Quarts See section 4 7 for first 25 hours of operation Check security of spark plugs leads amp electrical connections Check lubrication amp fuel system for leaks Check exhaust system for security amp leaks With Ignition amp Master OFF and throttle closed turn propeller by hand amp observe engine for odd noises or heavy movements Check for regular compression If irregular firstly check tappet adjustment see para 6 8 IMPORTANT Prior to pulling through the propeller by hand both ignition circuits amp the Master must be switched OFF the brakes applied throttle closed amp the cockpit attended by a trained person WARNING A hot engine may fire with the ignition s switched OFF CAUTION Continued operation with incorrectly adjusted tappets will result in damage to valves valve seats valve guides amp overhead gear Head torque and valve adjustment at 5 10 hrs from initial start up
57. il Pressure 94 10 7 Engine Keeps Running with Ignition OFF 94 10 8 Excessive Oil Consumption 95 10 9 Knocking Under Load 95 10 10 Engine Hard to Start at Low Temperature 95 Page No 3 Issue No 4 Date 240103 Issued By PJA 11 0 Engine Warranty Form 102 Engine Warranty Form 103 List of Amendments Page Amendment Date Issue Page No 4 Issue No 4 Date 240103 Issued By PJA 1 0 DESCRIPTION OF DESIGN 4 Stroke 4 Cylinder Horizontally Opposed One Central Camshaft Pushrods OHV Ram Air Cooled Wet Sump Lubrication Direct Propeller Drive Dual Transistorised Magneto Ignition Integrated AC Generator Electric Starter Mechanical Fuel Pump Pressure Compensating Carburettor Bing Type 64 32 or type 94 40 AS D RR eR a S It is said that aircraft are designed around available engines Jabiru believe that the Jabiru range of very light engines will now offer new opportunities for light aircraft designers to develop a new generation of light aircraft Jabiru engines are designed to be manufactured in small batch quantities using the very latest Computer Numerically Controlled CNC machine tools The vast majority of the components are manufactured in Southern Queensland in a network of high technology small companies The crankcase halves cylinder crankshaft starter motor housings gearbox cover the gearbox powers the distributor rotors and coil mounts together with many smaller components are machined using the la
58. k plug hole with the piston down then rotate until both valve are open and respray to coat the induction and exhaust system When all cylinders are treated leave prop horizontal and retreat each cylinder Page No 23 Issue No 4 Date 240103 Issued By PJA NOTE Use Shell Aero fluid 2UN MIL C 6529C Type 1 Corrosion Preventive Concentrate or similar engine preservative CAUTION Ensure that the Master and Ignition Switches are OFF 3 Install spark plugs and connect leads 4 Seal exhaust pipes Attach a red streamer to each seal DO NOT seal fuel tank breather 5 Attach a warning placard to the propeller stating that vents and breathers have been sealed and prop should not be turned The engine must not be started with the seals in place 5 7 4 Inspection During Storage 1 Generally inspect airframe and clean as necessary 2 Inspect the interior of at least one cylinder through the spark plug hole for corrosion at least once a month 3 If at the end of the 90 day period the aircraft is to be continued in non operational storage repeat Steps 1 5 above most will only need to be checked 5 7 5 Returning Engine to Service After temporary storage the procedures for returning the aircraft to service are as follows 1 Check battery and install 2 Check carburettor air filter and service if necessary 3 Remove warning placard from propeller 4 Remove materials used to cover openings 5 Remove clean and gap spa
59. ke sure the sump is level with the rear crank case face b Fit 3 amp 4 induction pipe to heads then 1 amp 2 c Fit lower pipes and hoses Gear Case and Rear H11 a Insure Gear case is fitted up Backing plate is ready All bolts are ready Loctite 515 Loctite 242 Loctite 262 b Turn engine around until it is 25 B T D C No 1 compression c Put loctite 515 on crankcase Fit engine mount plate Make sure 2 inside cap screws are in Use loctite 242 on all cap screws Page No 67 Issue No 4 Date 240103 Issued By PJA d Put loctite on gear case and point rotors to No Position Nata Tt io rannammandad that ratara ara attachad unith omall amaunt af cilactin ar amp minuta Page No 68 Issue No 4 EAR P Date 240103 CAP SCRE UA SURE OF CRANK INTO R T J gt Ad GAP SCRE T OF CRANKCASE UNDER TIMING BOLTS Issued By PJA IN O R zA LOC STEN a XQ EARS A AT MEN ED Drawing 9431064 2 REAR PLATE GEAR HOUSING Drawing 9431064 Note When gear case goes on 1 Make sure No 1 is 25 before T D C compression Both valves should be seated 2 The rotors point to the No 1 position on the rotor caps Fit cap screws with loctite 242 and torque H12 a Fit flywheel with the magnets horizon
60. linder and record in build sheet iii Fit rings with dots up Note End of oil ring expanded must be butted together iv Fit pistons in cylinders Oil Ring should only just enter so piston pin can be fitted later Note Arrows on inside of pistons point in direction of rotation Oil Rings and pistons and bore well Also notch on the piston crown faces the Propeller Flange v Fit front piston pin circlip vi Fit cylinder base O Ring vit Seal up in plastic bags ready for final assembly Issue No 4 Date 240103 Issued By PJA Jabiru 2200 Component Inspection and Assembly Procedure 7 4 4 Sub Assembly D Sump and Oil Pump Sump D1 1 Clean sump and remove all gasket eliminator 2 Inspect oil pick up D2 Remove induction O Rings D3 Inspect carburettor coupling replace if it is damaged or showing signs of deterioration Note It is very important that the carburettor and coupling are free of oil If there is any oil present at all it is possible for the carburettor to slip out of the coupling or if the clamp is not positioned to the rubber edge facing the carby D4 Fit new induction O Rings to Induction Pipes Oil Pump D5 1 Inspect oil pump inner and outer for damage to rotor surfaces 2 Measure rotor clearance OUTER CLEARANCE INNER CLEARANCE Drawing 9440064 1 OIL PUMP CLEARANCES Drawing 9440064 Housing to Outer Rotor clearance 0 07mm to 0 14mm 0 003 to 0 006 Inner Rotor to Outer Rot
61. losed In addition the fuel should be filtered before it reaches the carburettor The filter should be selected so that foreign bodies greater than 0 1mm are filtered out and the fuel supply is not impeded to too great an extent The float needle 42 contains a spring loaded plunger which contacts the float hinge This absorbs vibrations on the float 40 In addition the float needle 42 is connected to the float hinge by the retaining spring 43 to prevent it from moving between float and valve seat and thus reducing the fuel supply Spring and retaining guide make a considerable contribution towards keeping the fuel level in the float chamber constant When fitting a new float the fuel level must be adjusted When doing this care must be taken to ensure that the fuel needle spring is not compressed by the float weight It is therefore advisable to put the carburettor in a horizontal position until the float just contacts the float needle In this position the point on the float hinge is set in such a way that the float top edges are parallel to the top edge of the float chamber The float chamber 44 is secured to the carburettor housing by a spring yoke 45 A seal 46 is provided between float chamber and carburettor housing The space above the fuel level is connected to atmosphere by two ducts When these ducts are blocked an air cushion forms above the fuel The fuel will not lift the float sufficiently to close the needle valve and the
62. ments Record of Maintenance or Adjustment Start Fuel Quantity Fuel Added Finish Fuel Quantity Fuel Used During Block Oil Added Page No 91 Issue No 2 Date 130598 Issued By PJA Run In Checks 1 Preliminary Paperwork Complete Sufficient Fuel Correct Oil Level All Connections Correct and Secure 2 Start Run Start Time End Time 3 Ignition Checks repeat a couple of times for each side Left Side 1000 2000 rpm Right Side 1000 2000 rpm 4 Oil Leaks Check Visually 5 Instruments Working and Correct Range 6 Idle Check idle screw 3 4 to 1 turn out 7 General Running Smoothness Noises Manifold Sealing 8 Oil Pressure and Temp 9 Check FERRIT Ignition light to Tacho Test Rig Top End RPM 10 Check alternator Charging Voltage Jabiru 2200A Engine Post Run Procedure SIGN DATE 1 Heads retorqued 32 Nm 24 ft lb Valves Adjusted 2 Check induction exhaust bolts 3 Any changes to be made 4 Rerun check for oil leaks and or any modifications made oil pressure leaks etc 5 Check charging rate of alternator Volts 6 Leak Down 80 80 80 80 Cyl 1 2 3 4 7 Cheqk all paper eal 8 Drain fuel oil Prepare for Shipment Page No 92 Issue No 2 Date 130598 Issued By PJA 8 0 TABLE OF LUBRICANTS Use only oils of registered brands meeting the specification detailed at para 2 5 Acceptable engine lubricating oils Run in Period Oil
63. olybdenum cylinder bores Valves are 7mm stem dia which are purpose manufactured for the Jabiru engine The valve gear includes pushrods from the camshaft from the camshaft followers to valve rockers which are CNC machined from steel plate induction hardened and polished on contact surfaces and mounted on a shaft through a teflon bronze steel bush Valve guides are manufactured from aluminium bronze as is found in larger aero engines and high performance racing engines Replaceable valve seats are of nickel steel and are shrunk into the aluminium cylinder heads The valve gear is lubricated from the oil gallery An internal gear pump direct mounted on the camshaft and incorporating a small automotive spin on filter provides engine lubrication An oil cooler adapter is provided Most installations require an oil cooler to meet oil temperature limits The standard engines are supplied with two RAMAIR cooling ducts which have been developed by Jabiru to facilitate the cooling of the engine and direct air from the propeller to the critical areas of the engine particularly the cylinder heads and barrels The fitment of these RAMAIR cooling ducts is a great bonus for the home builder or engine installer as they obviate the need to design and manufacture baffles and the establishment of a plennum chamber which is the traditional method of cooling air cooled aircraft engines The fact that these baffles and plennum chamber are not required also ensure
64. opened the carburettor cross section From this point onwards the carburettor acts as a throttle valve carburettor with fixed choke tube The vacuum increases with increasing speed The space in the cover 20 above the plunger guide is vented through bore D Its diameter is designed in such a way that it acts as a restrictor for air flowing in and out and therefore acts as a vibration damper for the plunger On its way from the float chamber to the choke tube the fuel passes through the main jet 1 the jet carrier 10 and the needle jet 3 as it leaves the needle jet it is pre mixed with air which is brought in from the air filter via an air duct Z and the atomiser 2 in an annular flow around the needle jet This air flow assists the atomising process to form minute fuel droplets and thus favourably affects the fuel distribution in the intake manifold and combustion in the engine The conical section of the jet needle 4 which is secured to the plunger 13 with the retaining spring 14 and the serrated washer 15 engages into the needle jet 3 Depending on the dimension of the flat cone at the end of the jet needle the annular gap between jet needle and needle jet is enlarged or decreased and thus the fuel supply is throttled to a lesser or greater extent The jet needle 4 can be located in the plunger 13 in four different positions which similarly to the jet needle cone affect the amount of fuel drawn in For example needle p
65. or 0 07mm to 0 14mm 0 003 to 0 006 3 Fit Inner Rotor into Outer Rotor Using straight edge check end clearance End Clearance 0 03mm to 0 006mm 0 0015 to 0 003 Page No 48 Issue No 4 Date 240103 Issued By PJA STRAIGHT EDGE OIL PUMP CLEARANCE GEAR SET OIL PUMP HOUSING Drawing 9428064 1 OIL PUMP END CLEARANCE Drawing 9428064 Page No 49 Issue No 4 Date 240103 Issued By PJA 7 4 5 Jabiru 2200 Component Inspection and Assembly Procedure Flywheel Inspection El E2 E3 Inspect ring gear for damaged teeth Use a spring scale and a prop cap screw as per drawing to test ignition magnet strength Pull off should be 1 5 to 2 5 kg 3 3 to 5 5 Ibs FLYWHEEL Iy ASSEMBLY S POLF A NWY POLE PL T PROP FLANGE CAP S CREW Sub Assembly E Flywheel amp Ignition Coils amp Alternator amp Alternator Operation fo i L ye RS N yyy yp Jj Si A _Lockwir 9437064 1 q 7 PULL S WITH SPRII E TO FORM LOOP QUARE TO FLYWHEEL SCALE MAGN EE PULLTESI Drawing 9437064 Use spring scale and prop cap screw as in E2 to test alternator magnets Pull off should be 1 5 to 2 5 kg 3 3 to 5 5 Ibs ERNATOR ASSEMBLY ALTERNATOR MAGNET PROP FLANGE
66. osition 3 means that the jet needle has been suspended from the retaining spring 14 with the third notch from the top To achieve the height adjustment the jet needle is turned through 90 and pushed up or down the retaining spring engaging the next notch in the jet needle If the needle is suspended higher up this will result in a richer mixture and vice versa In short the main regulating system is set using main jets and needle jets of various diameters and also jet needles plungers and pistons of various types Between main jet 1 and nozzle stock 10 a washer 12 is provided which together with the float chamber forms an annular gap In particularly severe operating conditions this ensures that the fuel is not spun away from the main jet Page No 58 Issue No 4 Date 240103 Issued By PJA A rubber ring 11 seals the nozzle stock 10 off from the carburettor housing to avoid any fuel being drawn in via the thread and thus bypassing the main jet IDLING SYSTEM During idling and low load running the throttle valve 23 is closed to such an extent that the air flow underneath the plunger 13 no longer forms a sufficient vacuum The fuel is then supplied via an auxiliary system the idling system which consists of the idling jet 5 the idling air jet LLD no spare part and the mixture control screw 7 which is sealed off against the carburettor housing by the rubber ring 9 and secured by spring 8 to prevent it from be
67. ox 2 turns hanging out b Put anti sabotarge Paint on nuts STAGE INSPECTION Camshaft Timing H8 a Fit crankshaft gear as drawing and put one bolt in crankshaft to hold gear ALIGN MARKS A ON GEARS oh ae can TN e o o P Drawing 9432064 1 TIMING GEAR ALIGNMENT Drawing 9432064 b Mount a dial indicator on cylinder with the plunger on the center of the piston Page No 65 Issue No 4 Date 240103 Issued By PJA c d e 2 h i 9 Head Fitting H9 a b c Page No 66 Zero the indicator at T D C Fix a wire pointer of the oil seal bolt hole and roughly set to T D C Turn 1 4 turn backwards then forward until the piston is 2mm from T D C Note degrees Turn past T D C to 2mm down from T D C Note degrees Add two together then divide by 2 and set pointer at this with piston down 2mm Note The crank is mounted to turn the engine in direction of rotation turn crankcase anti clockwise viewed from rear Repeat again to check Note It is important to find T D C accurately as it is the datum for setting the cam timing and ignition timing Set dial indicator up to measure lift on No 1 exhaust Set to 0 on max lift Turn 1 4 turn backwards then turn until 0 5mm 0 020 from peak note degrees continue turning until 0 5mm 0 020 after peak Note Always turn in direction of rotation to eliminate back lash in gears Calculate
68. possibly cylinder PRESSURE DIFFERENTIAL TEST Leak down This is a much better test for condition of rings bore head sealing and valve Engine in warm to hot condition This is the normal test used in aviation requiring specific equipment for the job Pressure input of 80 PSI a second gauge reads the differential when supplying 80 PSI This is done with piston on TDC on the firing stroke Prop needs to be restrained The differential cut off is 80 60 Problems can be better identified eg gt BLOW BY CRANKCASE VENT RINGS BORE SEAL gt LEAKING FROM CARBY INTAKE VALVE SEAL gt LEAKING FROM EXHAUST EXHAUST VALVE SEAL gt HEAD LEAK HEAD GASKET OR HEAD TO CYLINDER SEAL Correction work can then be carried out COIL GAP Best done with a piece of plastic or thin card of a thickness 010 Cut into a strip approximately 15mm wide Place between magnets on flywheel and coil Check both sides that is each coil to each magnet 4 checks Page No 17 Issue No 4 Date 240103 Issued By PJA STARTING A warm idle of around 950 RPM will automatically create the right starting environment Idle set screw may have to be adjusted Carby has been factory set Normal start requires throttle closed that is the idle criteria has just cracked the butterfly in the throat body and also apply choke The engine is difficult to start if throttle is cracked open somewhat As the engine is cranked the choke should be pushed off Engine sho
69. ributor Drive Shaft 1 4332154 2 4332154 Gear Housing 4631073 Distributor Gear 1 4333054 2 4333054 I hereby certify that the above listed parts conform with the dimensions have been engraved and installed as recorded Signed Date For Jabiru Aircraft Pty Ltd Certificate of Approval 3501 Page No 86 Issue No 2 Date 130598 Issued By PJA Jabiru 2200 Component Assembly Procedure Subassembly G Fuel Pump and Carburettor No Details Sign Date Gl Fuel Pump Disassembly G2 Drill hole in spacer and insert breather G3 Final assembly checked for correct flow G4 Drill and tap upper half for 900 elbow and fit G5 Clean and reassemble G6 Carburettor needle position G7 Fit fuel line G8 Remove bowl and check jet size G9 Reassembly bowl G10 Fuel pump and carby engraved I hereby certify that the subassembly has been completed using the approved procedures and data and is fit for installation Signed Date For Jabiru Aircraft Pty Ltd Certificate of Approval 3501 Notes Page No 87 Issue No 2 Date 130598 Issued By PJA Jabiru 3300 Component Assembly Procedure Subassembly H Final Assembly No Details Sign HI Apply Loctite 515 to crankcase halves lubricate where necessary H2 Locate camshaft and crankshaft in crankcase half Stage 3
70. rk plugs 6 While spark plugs are removed rotate propeller several revolutions to clear excess preservative oil from cylinders CAUTION Ensure that the Master and Ignition Switches are OFF 8 Install spark plugs torque to 11 Nm 8 ft Ibs Page No 24 Issue No 4 Date 240103 Issued By PJA 9 Check fuel filter replace if necessary 10 If returning to service after indefinite storage fill fuel tank with correct grade of fuel 11 Check fuel tank and fuel lines for moisture and sediment Drain enough fuel to eliminate any moisture and sediment 12 Check fuel tank breather is clear 13 Perform a thorough pre flight inspection 14 Start and warm engine 5 8 Operation in Winter It is recommended to carry out an engine service prior to the start of the cold season For selection of oil consult the table of lubricants at Paragraph 2 5 Follow the following advice for operation at extremely low temperatures 5 8 1 Carburettor Icing It is important to distinguish between two kinds of icing 1 Icing due to water in fuel and 2 Icing due to high air humidity Re 1 Water in fuel will accumulate at the lower parts of the fuel system amp can lead to freezing of fuel lines filters or jets Remedies are Drain using fuel tank water drain Ensure fuelling without traces of water If in doubt use a chamois as a filter Install a generously sized water separator Ensure that fuel lines do not permit the ac
71. s a cleaner engine installation which in turn facilitates maintenance and inspection of the engine and engine component So the hard work of engine installation has largely been done for you by the Jabiru design team RAMAIR ducts are available for tractor or pusher configurations Special ducts are available for certain installations Page No 6 Issue No 4 Date 240103 Issued By PJA The engine is fitted with a 1 5 kw starter motor which is also manufactured by Jabiru and provides very effective starting The engine has very low vibration levels however it is also supported by four large rubber shock mounts attached to the engine mounts at the rear of the engine An optional bed mount is available The fuel induction system comprises a BING pressure compensating carburettor Following carburation the fuel air mixture is transported through a swept plenum chamber bolted to the sump casting in which the mixture is warmed prior to entering short induction tubes attached to the cylinder heads An effective stainless steel exhaust and muffler system is fitted as standard equipment ensuring very quiet operations which in the Jabiru aircraft have been measured at 62dB at 1000 full power flyover for 2200 engine For those owners wanting to fit vacuum instruments to their aircraft the Jabiru engine design includes a vacuum pump drive direct mounted through a coupling on the rear of the crankshaft The Jabiru engine is manufactured within
72. starting without choke for a warm engine amp with choke for a cold engine Note Engine cools quickly with propeller stopped in flight Choke will therefore normally be needed to restart Page No 13 Issue No 4 Date 240103 Issued By PJA 4 7 Addition Early Operation of Engine J ABIRU ENGINE NOTES NEW ENGINE NOTES This engine has been ground run to a specific run in program and is ready for flight It has been INHIBITED however if you intend to store for any length of time please refer to 5 7 Section 3 of INSTRUCTION AND MAINTENANCE MANUAL Removing spark plugs and turning over will help periodically Before initial start oil engine 2 3 litres with cooler remove one plug per head activate starter to remove excess inhibitor Once oil pressure is obtained replace plugs and continue start up sequence The following are tips to ensure a long life 1 OIL Use a non compounded AVIATION oil gt Aero Shell 100 gt Mobil Red Band gt BP Aviation Oil 100 Use for 20 25 hours Drain and replace with a compounded oil Aero Shell W100 Aero Shell 15W50 for cooler climates Mobil Aero 100 SAE 50 BP Aero Oil D100 BP Multigrade Aero Oil D SAE 20 W 50 Aero Shell W 100 Plus The normal running oils are detergent and ashless dispersant types See MAINTENANCE SECTION 5 3 VV VV Y 2 Add 2 Litres without oil cooler 2 3 litres with an oil cooler 3 Avoid prolonged ground running at elevated RPM Engine can be over hea
73. stomers if we know what our engine is in and what has been done to it Fax Number Within Australia 07 4155 2669 Outside Australia 61 74155 2669 Page No 73 Issue No 4 Date 240103 Issued By PJA Jabiru Aircraft Pty Ltd WARNING This engine has been run in and is ready for flight DO NOT GROUND RUN THIS ENGINE This engine has been inhibited and the oil system drained Before first start of new engine remove spark plug from each head Add the required run in oil to sump 2 3 litres engine must have oil cooler fitted Press starter to obtain oil pressure and to throw out excess inhibiting oil in cylinders Replace plugs NOTE ALL plastic bungs must be removed At each 5 hours for first 15 hours check tappet clearances 0 010 cold and cylinder head bolt torque 24 ft lbs 32nm Note New style heads have a 1 8 NPT plug to be unscrewed to uncover head bolt No 5 After torquing reset plug with Loctite 243 gt For the first 25 hours of operation add 2 litres of Shell 100 oil After 25 hours drain oil retorque cylinder head bolts to 24 ft Ibs and check valve clearances inlet and exhaust 0 010 cold Use 2 litres of W100 oil for normal operation or W80 oil for cold weather operation Shell also manufacture a multigrade oil Aeroshell 15W50 which is particularly suited for operations in cold climates
74. t oil pressure 23 Start and inspect for leaks 24 Test Fly Note First flight is a test flight so fly conservatively 25 Remove Cowls and inspect for anything loose rubbing or leaking 26 After 5 10 and possibly 15 hours retorque heads adjust valves and inspect engine installation Heads torqued to 24 22 ft lb and valve clearance 0 010 27 After 25 hours retorque heads adjust valves and inspect engine installation Change oil and filter Cut filter open and inspect Check engine leak down 28 Ifoil consumption is stable fill with W100 W80 in cold conditions and W120 in very hot conditions If it is still using oil remain on W100 oil 7 6 Prop Strike Inspection After ground contact of a wooden propeller check the crankshaft flange for run out at the front seal surface If run out is evident the engine will have to be stripped and crankshaft checked for cracks If an engine stoppage due to force is not recorded in the logbook and not advised to Jabiru the liability for all subsequent and consequential damage will remain with the owner This applies to both prior to and after engine overhaul 7 7 Build Sheets and Run In Programme Included with the build sheets are Pre Run Check List Run In Programme Post Run Checklist Photocopy all documents and use photocopies to fill in When complete fax to Jabiru Aircraft so all documents can be kept up to date This helps us provide a better service to our cu
75. tal they then should line up with the coils Note The small hole in the flywheel will line up with the hole in the crankcase It may not line up with the hole in the gear if it has been moved for cam timing Put loctite 262 on new flywheel cap screws and torque to 20 nm 15 ft lbs b Fit coil mount posts and alternator mount c Fit coils and set gap to 0 25mm 0 010 Page No 69 Issue No 4 Date 240103 Issued By PJA Note A strip of 0 25mm 0 010 card is best because it is not a magnet H13 Fit Carburettor assembly Note Itis very important to make sure hose clamp is at the outside end of coupling the coupling and carby are free of oil and the carburettor goes fully into coupling clamp is of 10mm wide stainless type H14 Fit Fuel Pump Assembly Note Use loctite 242 on cap screws Use molybdenum disulphide grease on push rod Oil Pump H15 a Put loctite 515 on back face of oil pump backing plate and fit b Fit woodruff key c Fit inner gear to camshaft d Fit outer gear to housing and fill with oil e Fit O Ring f Fit Oil pump on Use loctite 242 on cap screws Note When torqued up rotate engine carefully to ensure oil pump is not binding If oil pump binds it can sheer the end of camshaft H16 Fit exhaust system Use a little anti seize on cap screws and shake proof washers Front Seal amp Flange H17 a Remove from vertical stand and mount on engine mount stand b Remove prop flange c Clean off oil from se
76. tarting carburettor There it forms a particularly rich mixture with the air drawn in and this mixture bypasses the main carburettor to flow into the intake manifold of the engine direct During starting the throttle valve has to be closed to make sufficient vacuum available for the starting carburettor When the engine is at a standstill and also during normal operation the fuel level in the float chamber compartment incorporating the riser will be the same as in the rest of the float chamber When starting with opened up starting carburettor the fuel will initially be drawn in from this compartment which forms a very rich mixture The fuel supplied subsequently will only be the amount allowed through by the starting jet This ensures that once the engine has started it is not supplied with an excessively rich mixture and stalled The starting carburettor is therefore matched to any given engine by modifying the starting jet and matching the space behind it The starting carburettor is secured to the carburettor housing by four screws 51 and protected against ingress of dirt and water by the seal 50 between the two The starting shaft is also sealed against the starting carburettor housing by a rubber ring 49 Nadelstellung Carburettor Overhaul Note As a guide to overhaul read carburettor operation Gl Disassemble carburettor Page No 60 Issue No 4 Date 240103 Issued By PJA G2 Using over haul kit replace all components
77. te tachometers Where engine performance is observed to be outside limits the tachometer should be checked against a calibrated instrument Tachometer sender gap is 0 4mm 0 016 6 10 Additional Checks Check engine for ease of starting Conduct idle test run Page No 29 Issue No 4 Date 240103 Issued By PJA 7 0 SERVICE amp REPAIR 7 1 Engine Overhaul and TBO These are carried out only by the manufacturer Jabiru Aircraft Pty Ltd or by a specifically approved Jabiru Engine Service Centre contact Jabiru for details The engine must be sent in a complete state with logbook to Jabiru or the Approved Service Centre after reaching the TBO limit Changes to the TBO due to operational experience will be advised by Jabiru through Service Bulletins Page No 30 Issue No 4 Date 240103 Issued By PJA 7 2 ENGINE REMOVAL PROCEDURE No Operation 1 Remove Spinner and Propeller 2 Remove Carby Heat hose from Hot Box Muffler 3 Remove Air Inlet Hose from Carburettor and blank off Carburettor and Air Cleaner 4 Disconnect Throttle Cable 5 Disconnect Choke Lever 6 Remove Oil Breather Line 7 Remove Fuel Line from Fuel Pump and plug Fuel Line and Fuel Pump 8 Remove starter Motor Cable from Solenoid 9 Disconnect Earth at Battery 10 Remove Oil Pressure Gauge Lead 11 Remove Oil Temperature Gauge Lead 12 Remove Hourmeter Lead 13 Remove Cylinder Head Temperature Gauge Lead 14 Remove Exhaust Gas temperature Gauge Lead 15
78. ted remember air ducts are designed for in flight cooling NOTE remove ALL plastic bungs on engine EXHAUST 4 CARBY 2 OIL VENT 1 FUEL PUMP 1 4 DO TAKE OFF AT FULL POWER For the first few take offs climb at a higher airspeed Reduce power at cross wind leg and shallow climb lower nose Page No 14 Issue No 4 Date 240103 Issued By PJA 10 11 VARY your RPM when flying Avoid high nose altitude continual climbs The higher the climb out speed the better for engine cooling No low speed high nose altitude climb outs Ring bed in is accomplished better at 75 power and above Avoid heat build up Monitor CHT and oil temps Vary RPM Initial temps will be elevated due to friction of a new engine CIRCUIT WORK is possibly a good sequence for initial run in work Abbreviate circuits initially step climb climb shallow No glide approaches Gradually reduce power Avoid sudden heating up and sudden cooling down RETORQUE heads as suggested on warning sheet 24 ft Ib and 010 valve clearance all done cold Subsequent torquing of around 22 to 24 seems to help in settling down head bolts and heads Don t BABY YOUR ENGINE but monitor carefully CHT and oil temp initially especially during the first few hours of operation Remember engines need to be flown They are designed for this purpose Do not use full power before CHT reaches 100 C The purpose of breaking in an engine correctly is to ensur
79. tem Check fuel system for leaks amp abrasion Check wiring for damage amp for tightness Engine test run Observe starting warm up amp acceleration behaviour to maximum RPM 10 seconds max Check temperatures amp pressures Engine stop Page No 21 Issue No 4 Date 240103 Issued By PJA 5 4 50 Hours Check Details of specific operations are shown in Chapter 6 Maintenance Conduct the items shown under 25 Hour Check at para 5 3 5 5 100 Hours Check Details of specific operations are shown in Chapter 6 Maintenance Conduct the items shown under 25 Hour Check at para 5 3 Renew spark plugs if necessary 5 6 TBO Details of specific operations are shown in Chapter 6 Maintenance Engine Overhaul in accordance with Service Bulletins Conduct the items shown under 25 Hour Check at para 5 3 Check clearance on throttle valve shaft If radial clearance exceeds 0 5mm 0 020 repair carburettor The overhaul work must be carried out to Jabiru specifications at an approved aeronautical service facility or by an approved Jabiru Service Centre If necessary changes to the TBO Limit due to operational experience will be announced by Jabiru in a Service Bulletin Page No 22 Issue No 4 Date 240103 Issued By PJA 5 7 Engine Preservation The following procedures assume that the engine is installed in a Jabiru LSA airframe For other aircraft types refer to the manufacturer s service manu
80. test CNC machine tools The sump oil pan is the only casting The cylinders are machined from solid bar 4140 chrome molybdenum alloy steel with the pistons running directly in the steel bores The crankshaft is also machined from solid bar 4140 chrome molybdenum alloy steel the journals of which are precision ground prior to being Magnaflux inspected The camshaft is manufactured from 4140 chrome molybdenum alloy steel journals and cams nitrided The propeller is direct crankshaft driven and does not use a reduction gearbox This facilitates its light weight design and keeps maintenance costs to a minimum The crankshaft features a removable propeller flange which enables the easy replacement of the front crankshaft seal and provides for a propeller shaft extension to be fitted should this be required for particular applications Cylinder heads are machined from solid aluminium billet which is purchased directly from one of Australia s largest aluminium companies as is all alloy used in the engine thereby providing a substantive quality trail to material source Conrods are machined from 4130 alloy steel the 45mm big end bearings are of the automotive slipper type Various components of the engines are sourced from many Suppliers These items include camshaft followers and the bendix gear in the starter motor The ignition coils are also Page No 5 Issue No 4 Date 240103 Issued By PJA sourced from outside Suppliers and are modified by
81. total degrees and divide by 2 to find peak Peak should be 700 729 after B D C The cam shaft gear has 22 teeth and 6 bolt holes so if it needs adjusting Move the gear around and re check Record final measurement in build sheet Insure All O Rings are place and greased Have all head bolts Head Gaskets Push rod tubes Push Rods Rocker Blocks Loctite 515 Loctite 626 Fit heads by hand Push the push rod tube through the head and all the way home Fit circlips Issue No 4 Date 240103 Issued By PJA Note Make sure outside of tubes are smooth or it will damage the O Rings d Oil Push rods and fit Note Make sure ball end of push rod is in the socket of the lifter It also helps if the lifter is on the base circle of the lobe e Put loctite 515 on the base of the rocker block and fit long bolt torque lightly by hand heads with separate rocker block Put loctite 262 on rocker block cap screw and torque to 16 ft lbs Note Engine serial no 225 on do not have rocker blocks 14 unc cap screw is torqued to amp ft lb f Torque heads to 16 nm then 32 nm 12 ft Ibs then 24 ft lbs g Adjust all valves to 0 25 mm 0 010 Note Valves must be adjusted with the lifter 180 to the peak lift to ensure it is on the base circle Sump and Induction H10 a Fit sump using loctite 515 on faces and loctite 242 on threads Note Because the engine mount plate goes on the sump and crankcase it is important to ma
82. uld fire The choke is only used for a cold start Prolonged cranking with choke will only flood the intake system making starting difficult Should this occur leave or clear the system on full throttle momentarily mags off Cranking speed if too slow poor battery or starter fault will prevent magneto operation J ump starting with care will point towards poor battery condition or faulty alternator charging Further testing would then be required in these areas to identify the problem POSSIBLE PROBLEMS See Trouble Shooting Section of 10 0 of Maintenance Manual It is unusual for a problem to occur however a few of common type are listed 1 LOW OIL PRESSURE A sudden drop of pressure usually is caused by a small piece of foreign matter being lodged under the relief valve Simply remove oil filter and cooler adaptor if fitted Remove matter by depressing plunger or removing relief mechanism Replace and check operation by ground run If low pressure persists the problem will need further investigation We strongly recommend the fitting of an approved oil cooler to J abiru engines 2 FLICKING OF OIL PRESSURE GAUGE It is not uncommon for the J abiru engine to display flicking of the needle pointer for brief periods but still within normal operating regions If it continues check continuity of sender lead and or possible sender change We are assuming oil level is OK Page No 18 Issue No 4 Date 240103 Issu
83. ure sender I hereby certify that the subassembly has been completed using the approved procedures and data and is fit for installation Signed Date For Jabiru Aircraft Pty Ltd Certificate of Approval 3501 Notes Page No 81 Issue No 2 Date 130598 Issued By PJA Component Register and Parts Inspection Record Subassembly D Sump Batch Serial No Date Description Part No Batch Item Details Sump 4630072 I hereby certify that the above listed parts conform with the dimensions have been engraved and installed as recorded Signed Date Page No 82 Issue No 2 Date 130598 Issued By PJA Jabiru 2200 Component Assembly Procedure Subassembly E Flywheel and Ignition Coils No Details Sign Date El Deburr and Clean E2 Fit magnets using silastic E3 Using loctite 620 fit the ring gear E4 Fit the alternator rotor E5 Fit the plugs to the ignition coils I hereby certify that the subassembly has been completed using the approved procedures and data and is fit for installation Signed Date For Jabiru Aircraft Pty Ltd Certificate of Approval 3501 Notes Page No 83 Issue No 2 Date 130598 Issued By PJA Component Register and Parts Inspection Record Subassembly E Flywheel Assy Batch Serial No Date Description Part No Batch Item Details Flywheel 464
84. utside adjust electrode gap If necessary renew plugs Faulty HT leads Dry damp leads renew damaged leads Faulty ignition unit Clogged fuel filter Renew fuel filter Page No 99 Issue No 2 Date 130598 Issued By PJA 10 4 Engine Runs Too Hot Oil Temperature Above 110 C 230 F Possible Cause Remedy o complete engine overhaul necessary engine overhaul necessary Faulty oil temperature gauge Exchange gauge 10 5 Unsatisfactory Power Output _ Possible Cause 1 Ignition failure Check ignition circuits check wiring and pick ups replace ignition units 6 Leak in air intake Check and tighten all connections check carby sockets Carby diaphragm damage renew diaphragm ee 10 7 Engine Keeps Running with Ignition Off Possible Cause Idle speed too high Adjust to proper idle speed 900 RPM Faulty ignition switch Check switch amp cables Repair replace as necessary Overheated engine Conduct cooling run at 900 RPM 10 8 Excessive Oil Consumption Worn broken or wrongly fitted piston rings Repair engine overhaul necessary Page No 100 Issue No 2 Date 130598 Issued By PJA Poor oil quality Oil change use specified oil Worn valve guides Repair of cylinder head necessary Oil leaks Seal leaks BS E a l Remove cylinder heads amp in combustion chamber remove deposits Determine oil consumption Possible Cause Remedy 1 Starting speed too low At very low temperatures a pressure reading o

div/Instruction and Maintenance 2200

Contents

Download Pdf Manuals

Related Search

Related Contents