INSTALLATION MANUAL FOR JABIRU 2200 AIRCRAFT ENGINE
Contents
1. re Gea MM ENGINE MOUNT PLATE WASHER ENGINE MOUNT ENGINE MOUNT W ASSY 12 _ Ga 26 REF REF a 26 REF sx l K J 54 L 60 REF REF j Jf SCH SEE DETAIL PIN ENG MOUNT F 4 lis DRILL 066 359 L 13701 HO Ve me og TO A p i K CHAMFER i gt o CS1030 STEEL TO PSJED 07 1 X 45 ALUMINIUM GRADE 2011 16 MOUNT BUSH FIREWALL SECTION BB WASHER ENGINE MOUNT 9467073 1 Figure 8 Engine Mount Assembly EDO oase paean Jabiru Aircraft pty ta aech W i Installation Manual Jabiru 2200 Aircraft Engine 3 Controls This section comprises of the mechanical controls and electrical switches 3 1 Throttle and Choke e The throttle and choke cables both attach to the cable mount arm fitted to the carburettor e Note Since a pressure compensating carburettor is used there is no mixture control e The cables for the choke and throttle can be adjusted using the adjuster screws and nuts shown in Figure 9 A 7mm spanner is required e The cables used must have an adequate radius wherever they turn a corner Bending the cables too sharply will increase the cable friction making it difficult to use2. Figure 26 CHI Gauge COnMe e TEE 22 Figure 27 RG400 Co Axial Antenna Cable nnennsnennnennnnenneertetrtrtrtrnsrrrnrrresrtrntrtrntrtttrtttrtterEEar EEan ErEanEEna rrr nn rEn aneren eeen 23 CURA Au E E a ER EE bre 24 leit 29 Wining Diagram dE 25 Figure 30 Mechanical Fuel P UMD NEES 26 Figure 31 Carburettor Installation oooocccconnccnnoonnnnonocnnononnnonnncnnonnnonnnnnrnnnnnnrnnnnnrnnnnnnnnn non nrnnnnnnnnnnnnrnnnnnnrnrrnnnrnrnnnrnnnenanoss 27 Figure 32 Carburettor Intake amp Balance Tube Detail 28 Figure ele ee E e 28 Figure 34 Needle Jet Jabiru Needle AAA 29 Figure 35 Air Intake Connechons antr etrr antr SAEAE AAEE AEEE SAEED anr EnenrEr strena nrene trenne 31 Figure 36 Air Filter Box Plumbing INCOrrect uk 32 Figure 97 Ar Filter Box Plumbing ele tt 32 Figure 38 Typical Cobra Head Installation on a Jabiru Aircraft o oooncccconncnccnnnnononnnnonnnnnonnnnnnonononnnnnrnnnnnnrnnnnnnnnnnnarnnonnnnnnss 32 Figure 39 Cobra Head for Installations with Minimum Carburettor Clearance snsnnuesnnnnsnnnnrnrrnrrrnnrrrnsrrnnsrrrrsrrrnsrrrnsrrren 33 Figure 40 Ram Air Be EE 33 Figure 41 Jabiru Propeller amp Spinner Installaton 36 Figure 42 Engine Accessory Pack Contents AA 38 Figure 43 Upper amp Lower Engine Mount Detail 38 Figure 44 Engine Mount DEE EE 39 Figure 45 Fuel Connections General is 40 oO Hos DEA EE 40 Figure 47 Balance TUDE RI 40 Figure 48 Control Connections to Ca
3. 14 Regulator Plug Wiring Details 5 3 Ignition e The ignition unit has dual breakerless transistorised ignition with the magnets mounted on the flywheel and the coils mounted on the alternator mount plate Figure 12 shows the coils of a Jabiru 6 cylinder engine For the 2200 engine the system is the same however the position of the coils and the magnets on the flywheel are slightly different e The current from the coils flows to the distributor from where it is distributed to the spark plugs remo oi efes Teran paean Jabiru Aircraft pty Lta Gr Installation Manual Jabiru 2200 Aircraft Engine e The ignition is turned OFF by grounding the coils via the ignition switches This is the reverse of most electrical systems when the ignition switch is in the open not connected position the coil is LIVE and will fire Wiring details are shown in Figure 28 e The ignition is timed to 25 BTDC Ignition timing is fixed it is set by the position of the flywheel magnets relative to the crankshaft e The temperature limit for the ignition coils is approximately 70 C This should be checked by the installer It is recommended that pipes of 12mm dia be fitted to the top rear of each air duct directing air onto the coils for cooling purposes e Coil gaps are set at 0 25mm to 0 30mm 0 010 to 0 012 e When installing new ignition coils the output leads go in the directon of prop rotation RHS coil output lead is up LHS coi
4. 3198 LON OG SIMLIAMIN NI SNOISN3AIO OLT Ald HOLA Y 30 LNISNOD LNO Jo LUN L y LHIIYA JOS SI HL WW NA d val iY E i O 3 m 00 O O N Oo gt gt O Oo D m 28 Wiring Figure elsje Page 24 of 57 opt REVISION A k SNG NIYA OL TOSLNOI JJYLT0A MOTTA LHOM ONINSTA JOYLIOA MOT OL N3349 740 7 133H5 031411439 09 Lf DNIBYONNE d VAN Z 0OOVY HIZY TH 14044lY YITMNIH Je EN ME onono Wd HOALAW ma wawa ef am 3LYa ssi A Geer NIHLEV3 HOLLIYNGHV CS S0 6 rt 1 3195 ONIHIM dH ANY OIANY WOU 9 O 9 W oppe 2 Wa AVMV SJHIM SOVLIOA HOIH 3LNOY 5 EAN YILdYOY DIVIN LO TEO TESTS EIN LINA HLOG HO SLINN Nid HO dil ONIM Y3HLI3 p N ONISIM DN Td OC TE IGOUL6 Ni HAL fade y S V O O AYiLYA OL 033 HOLVWNHILTY WO ama awd IF YOLYNYALTY NOYJ om E O LLI Sn O KL lt o N N 5 O o gt ama 31d gt AHILLYE OL 197719 SY 00 oan Ap INNON 3180 S ONIM 1331 ZE UIOA HEH ______ D N ONIHIM JJOHLS irae Gee v A 3 NOILdO SAD Ce a9nvo D E NOILAO YJONOASNVEL ZE sun yusadWaL AV3H HIANITAD oU 2 HOLYNIGHOOO NHNL DIHL0373 L HIONIS 3HNIVHIAWIL TIO SL E NIHIA 39NVO NOILdO Z deep TE a I z HIJONIS IYNSSIHd 110 EL ke JYMLVMYUIdNIL OVSH YIONITAD L OIOVH JHA 97 S9NYD IUNSSAHd TIO 21 2 HOLIMS 3HNSS3Hd 13N3 27 YSL 38M3 LL D m a je NOVHOOVEIG D pio VS U3
5. 80 C 100 C 176 F 212 F Oil Pressure Normal Cperatons Min 220 kPa 32 psi ee ee Max 525 kPa 76 psi remos Jo lelles Preme J Passos Jabiru Aircraft py GN Installation Manual Jabiru 2200 Aircraft Engine Oil Pressure Idle ENEE Min 80 kPa 12 psi Oil Pressure Starting amp Warm Up Max 525 kPa 76 psi MENS UN PO near 0 1 L hr max USE Gears Aero Oil W Multigrade 15W 50 or equivalent complying with NE ET a MIL L 22851C or E EN NE Lycoming Spec 301F or EEE EEE Teledyne Continental Spec MHF 24B 1 3 4 Additives Note No Oil or fuel additives should be used Use of oil or fuel additives will void warranty 1 3 5 Cylinder Head Temperature CHT Maximum Peak Cylinder Head Temperature Led 200 C 392 F Maximum Continuous Temperature 00nn0ann000na 180 C 356 F Note Time with CHT at between 180 C and 200 C is not to exceed 5 Minutes 1 3 6 Exhaust Gas Temperature EGT EGT Mid Range Cruise ccccesseeeeeeeeeeeeeens Min 680 720 C 1256 1328 F EGT Above 70 Power coccccooocccnnccococcconccononccnnnnnns Min 640 680 C 1184 1256 F Note An EGT gauge is not included as standard equipment on the Jabiru 2200 engine though a system can be Supplied as an option 1 3 7 Ground Running Limitations Ground Idle Speed oooocccocccccoccccconcncnoncncnnncncnnncnnnns 900 RPM set while engine is hot Ground Oil Pressure Idle S
6. Revision Date OO OO JO Om P Gobhi Issue Notes d OO Om OO OO oon on ooo o1 Om On Y O1 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 Page Revision Date LD OO Om OO OO OO OO OO OF OFF C1 C1 O1 Ol 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 an ooo OO OO OO On OO OF O Ol Page Revision Date 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 Add pressure differential information wos Jo elel Perez I vanskene Jabiru Aircraft py gt Za Installation Manual Jabiru 2200 Aircraft Engine 1 Description 1 1 Model This Manual applies to all Jabiru 2200 Engine Models but particularly those from S No 2068 on Details for operating and servicing are supplied in the Engine Instruction amp Maintenance Manual Only those details relevant for installation are duplicated below for all other information please refer to the Instruction 8 Maintenance Manual 1 2 Manuals Instruction and Maintenance Manual Installation Manual Parts Catalogue 1 3 Specifications All information given in this manual assumes static sea level ra
7. by the sensor wires and cutting the wire upsets the instrument s calibration e Ensure that wire is not chaffing on the fibreglass air duct or cooing fins e No power connection is required the instrument reads directly off the voltage created by the thermocouple wire e Temperature of the cold junction for best results should be around 50 C Ensure cold junction is mounted as far from the thermo couple probe as possible o Cold Junction Plug terminal under spark plug CHT Thermocouple Cold Junction Spark Plug Terminal H Eg HE I Figure 24 CHT Sender Thermocouple Installation reo Jo 2 5 assure atte pase 21 ot Jabiru Aircraft pty Lta _ aech W i Installation Manual Jabiru 2200 Aircraft Engine CHT TERMINAL NIA TERMINAL NOT CENTRED UNDER PLUG SPARK PLUG Ba CENTRED UNDER PLUG 7 Figure 25 CHT Terminal Installation 350 y 600 Cylinder Head Temp Figure 26 CHT Gauge Connections 5 8 6 Exhaust Gas Temperature Gauge e An optional Exhaust Gas Temperature Gauge can be fitted The probe should be positioned 100mm from the port flange on the exhaust pipe of a convenient cylinder Jabiru Part No PIO325N is the recommended gauge 5 9 Radio Frequency RF Noise Reduction e RF noise is a common problem with aircraft Symptoms include y Radio squelch setting needs to be high ll Excess noise in the background during transmissions jii Squeals or other
8. the control accurately This is a particular problem for the throttle cable as it will make setting the idle accurately very difficult e Al Jabiru engines are run in on a Dynamometer before delivery It is impossible to accurately set the idle RPM when the engine is on the dynamometer so the Idle Stop Screw shown in Figure 9 must be adjusted as a part of the engine installation process ur Idle stop screw Throttle Cable connected to throttle arm Cable mount bracket Choke Cable connected to throttle arm Adjustors to fine tune choke Y and throttle operation pa 7 Figure 9 Choke and Throttle Connections to Carburettor 3 2 Ignition amp Starter Systems e The only electrical controls for the Jabiru Engine are the ignition switching and the start button e The ignition switches and starter system wiring are connected as shown by the circuit diagram Figure 29 e Section 5 gives details of the electrical systems for the engine remos oi ejes ferina paean Jabiru Aircraft pty ta Gr Installation Manual Jabiru 2200 Aircraft Engine 4 Engine Crankcase Breather Catch Bottle amp Dipstick e The Jabiru 2200 engine has a crankcase breather connection built into the dipstick housing This is to be connected as shown in Figure 10 below e The catch bottle is designed to catch most oil vapour from the crankcase breather air It must be monitored in service and periodically emptied of waste oil e Figure 5
9. which is connected to the sensor and one un marked which is connected to earth e The temperature sender is a brass fitting installed in the engine sump beside the drain plug e The oil temperature relies on a good earth connection between the sensor the engine and the airframe earth terminal If there is excess resistance at any of these points gauge reading errors will occur Oil Temperature sender with wire connected Engine sump drain plug Figure 20 Oil Temperature Connections remo oi ejes Teran rea Jabiru Aircraft pty Lta rn o Installation Manual Jabiru 2200 Aircraft Engine 5 8 3 Oil Pressure Gauge e An electric oil pressure sender is fitted to the engine for an Oil Pressure Gauge Jabiru Part No PI10762N is the recommended gauge e The gauge has 3 pins one marked which is connected to power one S which is connected to the sensor and one un marked which is connected to earth fk ei Oil filter Oil Temperature sender with wire connected Figure 22 Oil Pressure Connections 5 8 4 Voltage Gauge Optional e A voltage gauge can be connected to the aircraft systems e The gauge has 2 pins one marked which is connected to power and one un marked which is connected to earth Figure 23 Voltage Gauge Connections remos Ell presiunea T Page 20 of s7 Jabiru Aircraft pty Lta Gr Installation Manual Jabiru 2200 Aircraft Engi
10. 8 shows more clearly the outlet from the catch bottle the catch bottle outlet is secured in the cowl outlet The position of this outlet and the catch bottle itself must be assessed and oriented so that the crankcase of the engine is exposed to pressure close to ambient If the breather is open to a high or low pressure partial vacuum area the pressure inside the crankcases will also change with unpredictable effects on engine oil consumption and oil flow within the engine This is because several areas of the engine are lubricated via low pressure or spray oil feeds and drained by gravity pressure differences cause airflow changes and modified airflow can significantly affect the oil feeds in these areas e Over the course of it s development the 2200 engine has used several different sumps and dipstick lengths Figure 11 gives an explanation of these lengths and what oil levels should be maintained e When installed in a tail dragger aircraft re calibration of the dipstick will be required by the owner so that it can be read accurately with the aircraft sitting on it s wheels Hose from engine Hose from engine to catch bottle Catch bottle attached to firewall Figure 10 Crankcase Breather Installation msn oi ejes oase pase oa Jabiru Aircraft pty Lta Installation Manual Jabiru 2200 Aircraft Engine Parts List There are a total of 3 sumps which have been used ITEM PART NUMBER DESCRIPTION on Jab
11. INSTALLATION MANUAL FOR JABIRU 2200 AIRCRAFT ENGINE DOCUMENT No JEM2202 5 This Manual is a guide to correctly install the Jabiru 2200 engine into an airframe If you have any questions or doubts about the contents please contact Jabiru Aircraft P L Applicable to Jabiru 2200cc Enginers S No 2068 Onwards Hydraulic Lifter Type Jabiru Aircraft py gt Za Installation Manual Jabiru 2200 Aircraft Engine A a A 3 te ic nn eee eee 4 1 PN D 1 1 MOOG A 5 PETE EEE sa sectsaneenstecseaseas D UE Ve e 0 9 JE PP EE EE 5 14 DIMENSION Seine T 2 EE MO 9 XA ERE 11 31 TORNER pibe tii 11 32 hs SATS 11 4 Engine Crankcase Breather Catch Bottle amp Dipstick 2 0 0 0 cccccc ccc secseeeeeeeeeeeeeeeeeees 12 gt BETENT 14 EE O EE EEE 14 e IIe 14 A a ee nn a 15 o A saneecseacndeess 16 J9 AT TN 16 a 17 DST PT 17 DE TN 18 5 9 Radio Frequency RF Noise Reduction cooccccoccccconcncccncncconcnonnncnonnnnnonncnnnnnnnnnnnrnnnnnrnnnnnnnos 22 O Fe SUDDIV SV STO E 26 6 1 FAT A A E UE ERA 26 De FANN 26 6 3 Mechanical Fuel PUMP EEN 26 oA A EE EE ewan ainsi wade debs E EEO E 26 nn E ENE A eee eee eee 26 OG FANEN ee eee ee ee nee 30 TAES 31 7 1 Te GP l rs 0 EE 31 7 2 Intake Hose amp Air Filter BOX ccccccccsccccececeeeeceeeeceecceecsaceceueesaueeeaeeseasessueesueesaeessaeeseneess 31 EEE EE 33 FE o AAPP Pa 33 SS e ES REE EOI a 34 io lol EE 35 10 Engine Installation Hrocecdure 37 11 PICTON S FI SU
12. Jabiru Engine an earth wire Shown in Figure 29 is provided connecting the carburettor to the rest of the engine so the throttle and choke cables are connected to earth through this wire e It is normal amp unavoidable that the engine s ignition system produces some RF noise This can be minimised by L Ensuring all spark plug gaps are set properly ll Ensure ignition coil gaps are set properly iii Ensure all high tension leads Spark plug leads are firmly fitted at both ends to the spark plug and to the distributor In addition the lead from each ignition coil to the distributor must be firmly fitted to the distributor IV Ensure Distributor caps and rotors are in good condition e To counteract RF noise Jabiru Aircraft run shielded wiring on all radio and intercom wiring In our experience the Earth Return method of shielding where the shield for the wire is also used to form the earth connection does not work as well as the Faraday Cage where the shield is a shield only it is not a part of the circuit method of shielding e Earth Loops where a wire is connected to earth at both ends can introduce RF noise into the system All shields should be connected to the aircraft s earth system at one end only e The cable used for the Antenna should be high quality such as RG400 Shown in Figure 27 This cable has a double layer of shielding and better RF insulation than other cable types Note that the c
13. NV3Y8 LINOHIO Ol a e S NOV 00VEld 0 31 DNINHYM Sp dau eech SE 97 VOL HAMVAHE LINDYID 6 D NOVSOOVEI El 9 S DE AE pet le e N3389 LHDIT ER Kick GZ a TEO A a ES O NOV LOVE Id HOLSIS38 NOILONGSH ADVLIOA bad J0YZ90Y HOLIMS di Z ES 5 NLOWPAMAd NOILdO HOSNIS 73437 ANVL HIOVIH Lp HOLON dY Ce N9LEOI d E oO NOILdO HIANIS 39NY9 13N3 Or HOLVINDAY HOLYNHALIV oC HOLIAS 319901 440 NO S Q NOILdO LINN AV3H 39NY9 13N4 BE dANd 134 Le N90 01d NOLLNG HILYLS tr e NZO0V Id TIVAS HOSSI3HddNS HH BE HALAW LIOA Oe AIONITOS HALHVIG N900VbId SDYV1 HOSSIHddNS JH ZE HONG OILANDVW HALAWOHOVL 61 HILHVIS 2 E NOILdO S143 VO L G NONAG Op HILS HOH HILINOHOVL 81 TETI YEI al NSO0Vbld HILI 3SION SE HOSNAS INIOd NOILDANNOOD JJOHLS t SYN LVYHSdWSL OVSH HIANITAD 41 AIM INYHODVIG LINDYID nousyroyud 3195 LON Od SIMLIANIN NI SNOISNINIG eh EE EE Een N A REVISION
14. Ol GE 42 12 Au Xlary E EE EE AERA AEREE A ERA EAEE 43 12 1 Een RT e EE 43 t ONS Nr 44 13 1 General Principles Lavere este 44 13 2 EON es Le GE 46 13 3 Air niers Ram Air hr 47 13 4 ER ELE e e EE 48 13 5 A a 49 13 6 Cooling System Testing Evaluaton 52 13 7 o el Le AMA In snastatssw neue EEEE 53 13 8 Amphibian or Seaplane Installations ccooonccccncconnoconncconccnonccnnnocanonnancnnanonnnnnnanoos 53 13 9 Slow Speed Installatons 54 14 Appendix A Wiring Diagrams occoccoccccnconconconioninnoccncnnnononnonnnnnonnnnnnnnnnonennennennennss 55 15 Appendix B Jabiru Aircraft Installation o coocoonconconionioniornonnconooncononconononos 56 15 1 Known Airframe Engine Detalls cccccccccccecccseececeeececeeeeeceeceeeeecesseecesseeeesseeeseneeesaeees 56 15 2 Normal Operation Da one 56 16 Engine Installation Checker 57 ess To I I omme J Pae zors Jabiru Aircraft py gt Za Installation Manual Jabiru 2200 Aircraft Engine 1 1 Table of Figures Figure 1 Drawing 9404041 1 Engine Dumensions strt t ttrtantrren trenn rnrn rnrn rrean T Figure 2 Drawing W000505 Engine Dimensions S No 2553 On rrnrnnnrnnnnnenvnnnrenvnnnrnnnnnnennnnerennnsnennnnsrnnnnsernnnsneennnnsrenrnsennnnn T Figure 3 Cylmder Firing Ude EE 8 RIUS rm Distibutor Cylinder Map estos eri EE EE NN 8 Figure 5 Engine e n e a eer de Lu 9 Figures 6 amp 7 Typical Upper Engine Mount Air Intake Installa
15. feedback noises heard during transmission IV Intermittent static or noise breaking through the squelch e RF noise is a complex problem and is influenced by many different factors The following points do not contain everything there is to know about RF noise but they are given as recommendations of general good practice to minimise it s effect e Ensure all connections particularly engine earths are clean and un corroded e lf the aircraft has a metallic firewall it can be used as a shield to block the majority of RF noise To be most effective any wire that passes through the firewall should be fitted with a Ferrite Bead also known as a Suppressor or RF Suppressor Bundles of wires can have a single large Suppressor fitted rather than a reo oi ejes Teran J Page 2z or sr Jabiru Aircraft py gt Za Installation Manual Jabiru 2200 Aircraft Engine Suppressor for each wire The wiring diagram in Figure 28 shows suppressors in schematic form These suppressors are readily available at local electronics stores e A Noise Filter can be fitted to the radio s power supply Again these filters are readily available from local electronics stores The manufacturer s instructions must be followed for installation e Cables passing through the firewall such as throttle cables choke carburettor heat and cabin heat cables can transmit RF noise back into the cabin This can be minimised by earthing the cables at ONE end On the
16. has the effect of raising average oil levels 268 TO TOP MARK 302 5 TO TOP MARK RECOMMENDED OIL LEVEL 268 TO TOP MARK 310 5 TO TOP MARK 3300 The dipstick used for the 3300 engine has never changed length Older engines used a straight version newer engines a bent type The dipstick shown second from far left is used The oil levels recommended are given for general guidance only Due to differences in installations operating regimes subtle internal differences in the engine etc every engine has slightly different oil consumption patterns Owners must familiarise themselves with the oil usage rates etc of their particular engine and tailor their target oil level to suit 3300 ENGINE RECOMMENDED OIL LEVEL BETWEEN UPR amp LWR MARKS DIPSTICK SETTINGS FAMILY TREE COMPARISON 8A035A0D 1 8 4 08 Figure 11 Dipstick Family Tree reo Ill aseene pase of Jabiru Aircraft pty Lta Sr Installation Manual Jabiru 2200 Aircraft Engine 5 Electrical Equipment 5 1 Alternator e The alternator fitted to the Jabiru 2200 engine is a single phase permanently excited with a regulator e The rotor is mounted on the flywheel and the stator is mounted on the alternator mount plate at the back of the engine The alternator mount plate is also the mount for the ignition coils and the vacuum pump e Note The electrical system is Negative Earth Specifications Power Max 120W Continuous Up
17. he engine has four engine mounting points located at the rear of the engine shown in Figure 1 or Figure 2 from which the engine is to be mounted An optional bed mount may be fitted ENGINE MOUNT POINTS Figure 5 Engine Mount Point Locations e Each engine mounting point is rubber mounted to damp the engine vibrations The correct installation of these rubbers is shown below in Figure 5 e f required corrections of the engine angle or propeller position can be made by fitting spacers under the rubber cushions The maximum spacer thickness on any one mount is 3mm remos Jl Laien Page oor Jabiru Aircraft pty Lta Shaun W i Installation Manual Jabiru 2200 Aircraft Engine Custom air intake tube Cobra Head Figures 6 amp 7 Typical Upper Engine Mount Air Intake Installation PIN ENGINE MOUNT BREAK A rs 88 SHARP CORNERS 60 eg 1 5 A AQ NS 6 35 ER i F I 18 14 R 17 20 38 Y yA 8 Bes MACHINE a UNLESS SHOWN OTHERWISE A CS1020 CS1030 STEEL TO PSIJED O 15 E Va SECTION AA
18. igure 1 Drawing 9404041 1 Engine Dimensions NE A ie eres p NOT SCALE AVTECH PAL ab cs PEGS ES ACH 010 TREATS Iess Ol ZA ENE Seel iy mee i HINA ER A ENGINE ASSY JABIRU 2200 BUNDABERG 4470 5 pen Figure 2 Drawing W000505 Engine Dimensions S No 2553 On CADDA TE Jabiru Aircraft pty Lta rn W i Installation Manual Jabiru 2200 Aircraft Engine 1 4 1 Denomination Of Cylinders ig Sp 1 O ui Il r g U T J gt Gs T J J J J J Drawing 9483093 1 Figure 3 Cylinder Firing Order Cylinder Firing Order 1 3 2 4 NOTE 1 ALL DISTRIBUTORS SHOWN LOOKING FROM THE PROP DRIVE END OF THE ENGINE 2 EXHAUST amp INTAKE REFER TO THE POSITION OF THE SPARK PLUGS IN THE CYLINDER ON THE EXHAUST OR INTAKE SIDE OF THE HEAD EXHAUST INTAKE EXHAUST INTAKE 4 1 6 CYLINDER ENGINE 2 CYLINDER ENGINE i FIRING ORDER 1 4 5 2 3 6 FIRING ORDER 1 2 INTAKE EXHAUST L 4 LAS OR IP Ke NG 3 8 CYLINDER ENGINE FIRING ORDER 1 5 8 3 2 6 7 4 DATE JABIRU ENGINE DISTRIBUTOR CYLINDER 4A266A0D 2 MAP ALL ENGINES SHEET1 OF 1 AA Figure 4 Distributor Cylinder Map remos To 1 I I omme Page oot Jabiru Aircraft p
19. iru 2200 and 3300 Engines built since the 1 4A400B0D 3 OIL DIPSTICK 2 2L SUITS SUMP P No 4A298A0D 1 year 2000 They are shown opposite and for this 533064 5 DIPSTICK ASSY 2 2L document will be called 2200 Finned 2 4 H pn nm H 3 4A400B0D 2 OIL DIPSTICK 2 2L SUITS SUMP P No 4A298A0D real al ieo 4 4533064 DIPSTICK ASSY 2 2L Kua Finned sump which has the intake manifold cast 2 into the sump For this type of sump the details given for the 2200 Finned sump also apply oil level dipstick length etc 2200 FINNED The dipstick length used for this engine is shown The straight dipstick on the far left was used on earlier 2200 and 3300 engines 2200 engines with this sump run best when the FINS 3300 SUMP 2200 FINNED SUMP 2200 UN FINNED SUMP oil level is maintained at approximately the A lower mark of the dipstick 2200 UN FINNED Two dipstick lengihs have been used for this sump Newer engines use a shorter dipstick which gives a larger volume of oil in the sump 283 en The older longer dipstick is set to read 2200 ENGINE 2200 ENGINE RECOMMENDED 302 5 accurately when the engine was cold Due to several RECOMMENDED NC LES eee incidents of owners running their engines virtually OIL LEVEL OIL LEVEL out of oil the dipstick length has been shortened to read accurately when the engine is hot and oil is spread throughout the engine and oil system This also
20. l output lead goes down See Figure 12 HS es a Ram air cooling duct gr Za pr M ME Coil cooling tube Ignition coil gt S i Figure 15 Ignition Coil Cooling Tube 5 4 Starter Motor e The starter is mounted on the top of the engine and drives the ring gear on the flywheel e The motor is activated by engaging the starter button the master switch has to be ON which trips the solenoid hence current flows from the battery to the motor e The cable from Battery to starter should be minimum 16mm copper e Wiring details are shown in Figure 28 5 5 Starter Solenoid e The starter Solenoid is mounted on the firewall as shown in Figure 13 e The Solenoid body forms a part of the electrical circuit and MUST be earthed to function correctly EDO EE Jabiru Aircraft py GN Installation Manual Jabiru 2200 Aircraft Engine SOLENOID BODY START BUTTON E TO MAIN POWER BUS EARTH CONNECTION BETWEEN SOLENOID A IAG VIA REWALL SHE POS Figure 16 Starter Wiring Details 5 6 Battery e The battery should be of a light weight 12V 20 Ah type able to accept a charging voltage up to 14 V 0 8V and a 30 AMP Input e For optimum starting the battery used must have a high Cranking Amp Capacity also known as Pulse Amp Capacity The standard battery used by Jabiru Aircraft has a Pulse Amp rating of 625 Amps Batteries with higher Pulse Amp ratings may be used and will improve e
21. ne 5 8 5 Cylinder Head Temperature Gauge e The Cylinder Head Temperature Gauge uses a thermocouple which is installed to the exhaust spark plug of the hottest cylinder of the engine e The head temperatures of air cooled engines are typically quite variable differences of 50 C 90 F between the hottest and coolest head are not uncommon Refer to Section 13 for additional information on cooling e For a new installation an audit must be done to establish which is the hottest cylinder The CHT thermocouple probe is then fitted under the exhaust spark plug on that cylinder Cylinder number 4 often runs hottest in normal tractor installations however for new installations this MUST be checked and confirmed Jabiru Part No PI10732N is the recommended gauge e Care must be taken when installing the spark plug terminal the terminal must be aligned with the spark plug If the terminal is not aligned the spark plug seal will be poor and hot combustion gasses can leak out These very hot gases will cause the thermocouple to mis read and show high CHT s Figure 25 shows properly and improperly fitted CHT terminals e Loom and Thermocouple sensor are supplied with the instrument These must be installed as per the instrument manufacturer s directions If cable is too long it must be looped as many times as necessary and strapped behind the instrument panel DO NOT CUT TO LENGTH The Thermocouple sensor works by reading small voltages generated
22. ngine starting in colder climates 5 7 Wiring Practices e Using aircraft grade wiring is strongly recommended Compared to other grades of wire aircraft grade can carry higher currents for the same physical size and weight The insulation used on aircraft grade wire is also frame resistant and is designed for better resistance to damage caused by chaffing or rubbing e Care should be taken to identify each wire via labels or similar This makes troubleshooting electrical issues much easier e Wherever possible wires should be identified as carrying Power or Earth This can be done by using different colour connectors or applying rings of coloured heat shrink during assembly Again this step simplifies troubleshooting or later modification e Wires should be laid out in bundles and supported along their length to prevent failures due to fatigue remo oi ejes fosse Paseo s7 Jabiru Aircraft pty Lta Sr Installation Manual Jabiru 2200 Aircraft Engine 5 8 Instruments 5 8 1 Electronic Tachometer e General wiring information for the Tachometer is given in the Wiring Diagram Figure 28 Detailed instructions on it s installation are supplied by the instrument manufacturer e The tachometer picks up on 2 metal tabs attached to the inside of the flywheel e The Pickup used is a Magnetic Induction sender type It is a passive device requiring no external power e They Pickup outputs a voltage in response to variatio
23. ns in their self induced magnetic field caused by proximity to moving ferrous metal parts such as the tags fitted to the rear of the flywheel e The Tachometer sender must be adjusted to have approximately a 0 4mm gap between the tip of the sender and the tag Note that due to normal bearing clearances the crankshaft moves slightly when the engine is running so if this gap is set too small the sender will hit the tag The sender is fragile and most times damage like this means that the sender must be replaced If the gap is different for each of the two tags then one tag can be carefully bent to be the same as the other e Ensure gauge is reading correctly While large errors will be obvious smaller errors are harder to pick and it is recommended to check the gauge reading with another instrument Such as a hand held optical prop tach Tachometer Sender Connect to Red Wire of tachometer pick up Connect to Black wire of tachometer pick up Connect to Earth Bus Connect to positive such as the Instrument Wiring Bus Figure 18 Tachometer Connections seo oi ejes aseene Pane te or s7 Jabiru Aircraft pty ta aech W i Installation Manual Jabiru 2200 Aircraft Engine 5 8 2 Oil Temperature Gauge e The Oil Temperature Gauge uses an electric probe mounted in the base of the sump Jabiru Part No PI10752N is recommended e The gauge has 3 pins one marked which is connected to power one S
24. oaxial cable included in most antenna kits tends to have a single layer of insulation BNC connectors are recommended for most applications and wherever possible crimped connectors which require a special crimper to assemble should be used Crimped connectors are much less prone to RF leakage or assembly issues than other types such as screw together BNC connectors e Wires and antenna cables must be routed carefully Bending or coiling Co axial cable such as is used for antennas sharply will significantly degrade the cable s RF shielding and must be avoided wherever possible Coiling antenna cables or any wire carrying current Sensor wires carry very low current so are generally exempt from this requirement into loops can induce RF noise in other systems GPS antennas in particular are powered both the antenna and any excess antenna cable must be positioned carefully as far away from the radios antennas and intercom as possible e While not a part of the engine installation strobes can produce significant RF noise Most brands of strobes require that the box containing the strobe head unit electronics is earthed and this is essential to minimise noise The cables used for the strobe lights themselves must be shielded and the shield must be earthed properly at ONE end only The Box containing the strobe electronics can also be installed on the engine side of the firewall to further reduce RF noise The strobe units manufacturer normally pr
25. ovides good instructions for minimising their effect on radio noises Outer shield layer Inner shield layer mm gt gt gt Figure 27 RG400 Co Axial Antenna Cable Black outer insulation reo TT oase pase of sr 2 l gt D E ken O lt 5 O n Jabiru 2200 Aircraft Eng Installation Manual a OI 740 13585 GaldlLYID 09 L 5438YONNE N 1334 OVINA LH NI 03117130 SLNINNYLSNI 9 00W 9Z2W p 1u0dulyY YITVANIH 009 1906 ONIMYYHO YId ON OMG 9348 S HSYNLOYANNYA OL ONIHIAA NOLLYTTYLSNI HSONOdSNYHL S ESAS emm LEUNLDVANNYA AS CET SLOSNAS Y ONIHIM E Spurs a Wa AT LAOS Yau TYNOULOIS Y OS WWEL 319 HILYVIG 0370114100 N 3349 VEL y3MOdy 038 3000410100 3 HIM HOSNIS SHOSS IHddNS 2 Y 139N HLA 031 114 39 G110H8 A et SE 6 91 91 662 22 N GE 1 TRAIL HONOHHL SHIA 3000 SHIM e SILON TIVALITINO Oe 1839 HOS ET j HVYS sng z B D SOINOIAY ave SNE NIV SOINOIAW LNAIWNYLNI 311513 ININLYVANOD Hia Il 303 NI oa AMALIA Z LON 33S gt IN S N ld AJO DIONTIOS 111543 YILYVIG Z e e 1909 NOLLINO VW MIA M7130 335 fe YOLVTINDIU UIJONIS OHIVL GI IVL Y30N3I5 OHOVL LINA INO WOO NOLINSI 5 114M3414 HONOYHL SNAU JAM HOY DOWIZOYL ON d INLLLIY 300443414 ISNA STAGOWN WIA S9 ILON LT P MS SEI 199 EIN y VW LNIALHY NOD INIONI dyg SNE HLYVI IF 4 nousyosd
26. rburettor oocccconccncccccnccnoconononcnnnoncnnnnnnnnnonnrnnnnnnnnnnnnnnnnnnnrnnnnnnnnrrnnrnnnnnnrnnrnnrnrrnnrnnnnnnnnns 41 Figure 49 Cowl Airflow Best Viewed in Colourt 45 Figure 50 Cowl Airflow Black amp White Version 45 Figure 51 FlIOWVISUAIS ON anar iia 46 Figure 52 Front On View Into Ram Air Duc 47 e MAME Mes a EN EE PP eee ee ee eee ee 48 Fe NEDE EE 48 Figure 55 Oil Cooler Installaton ee eeee ese eee eae eee AAA eEeE Ga SeeS AGA EeE AG aS eeesA GG Sessa aa eeesaaeeetsaaeeeeaaaeeesaaeeeeseeeeas 49 Figure 56 Lip to aid cooling as installed on a Job uk 50 Figure 57 Affect of Angle of Attack On Cowl Outlets ccocooccccccoccccoccnconoconononcnnonononnnnnnnnnoncnnnnnnrnnnnnnrnnnnnnrnnnnnnrnnnnnrinnnannnns 50 Figure 56 Cowl Outlet GEOMET EE 50 Figure 59 Outlet Restriction Caused By Flange On Lower Eirewalt 51 Figure 60 Cooling pressure measurement nneenesennserrorrrrrrrrrrrrrrrrrrirtntrrtnttrantrrtntE entre trEnanEE an EEEDenrEnatrEna nren snrrnnnrernt renne 52 Figure 61 Ram Air duct pressure tapping issisrisicsisiiirscitiiiisriniiricsrriisierin a coin 53 Figure 62 Augmentor Exhaust System nsnsicraniina iia craneal tina RIBA AA A A aa 54 Figure 63 Wiring DEE SEE EEE EN 55 remos To I I omme vesen Jabiru Aircraft pty Lta gt Za WN Installation Manual Jabiru 2200 Aircraft Engine 1 2 List of Effective Pages The dates of issue for original 8 revised pages are Page
27. tartup Min 80 kPa 11 psi ET TE Max 525 kPa 76 psi Ground Oil Temperature Max 100 C 212 F Ground Maximum Cylinder Head Temperature 180 C 356 F Note If ground temperature limits are reached shut the engine down or cool it by pointing the aircraft into wind 1 Measured with sensor ring fitted under exhaust spark plug eme Jo 2 9 5 omme Page oot Jabiru Aircraft pty Lta _ aech W i Installation Manual Jabiru 2200 Aircraft Engine 1 4 Dimensions BIRON CO EH SN ___ oi a ES A C N 010 910 077 JABIRU AIRCRAFT P L HH P O BOX 5186 ine ca ge a lt BUNDABERG 4670 bk i QUEENSLAND AUSTRALIA SE ST ds l E O PH 07 4155 1778 FAX 07 4155 2669 l d E E RES Und 2200 JABIRU ENGINE Qu AA OPTIONAL FRONT Ce A ck BED MOUNT a pa L L L J 323 12 72 DIMENSIONS IN ARE INCHES 8 560 B 582 Si 22 12 22 91 ge 100 250 15 75 8 OPTIONAL FRONT MV ED MOUNT 380 KE 14 96 14 28 F
28. tings under the following conditions e International Standard Atmospheric conditions at sea level e Aircraft service equipment drives unloaded Vacuum Pump not fitted e Full rich fuel air mixture e Standard Jabiru air filter and hot air mixer box assembly e Standard exhaust muffler e Jabiru Propeller e Jabiru Airframe 1 3 1 Ratings RPM Maximum Hedlme 3300 RPM RPM Maximum Continuous ccceseeeeeeeeees 3300 RPM RPM Recommended Cruise 2 50 RPM 3100 RPM Power Rating 85 hp 3300 RPM 1 3 2 Fuel Fuel Consumption rrrnnannnnanennnnennnnnnnennanennnnennnnn 21 L hr Takeoff Max Continuous Rating Fuel Consumption rrrrrnrnnnnrvrrnnnnvnnnnnnennnnnnrnnnnnnnen 13 15 L hr 75 nominal power setting Fuel Pressure to Carburettor Maximum 20 kPa 3 psi Fuel Pressure to Carburettor Minimum 5 kPa 0 75 psi Recommended Fuel Grade cccoccccccnccccncccccccnnnnnonos Avgas 100LL amp Avgas 100 130 Note Leaded and Unleaded Automotive Gasoline above 95 Octane RON may be used however due to the lack of a strong quality control system for automotive fuels Jabiru Aircraft recommend using AVGAS wherever possible 1 3 3 Oil OS AD AGI EEE 2 3 Litres Oil Minimum Temperature for Take Off 50 C 122 F Oil Maximum Peak Oil Temperature 118 C 244 F Oil Maximum Continuous Oil Temperature
29. tion ooocccooonnnccocnnnnnonnnonononnnnanonononnnnnnnncnnnnnnnnononennos 10 Figure 8 Engine Mount Assembly Au 10 Figure 9 Choke and Throttle Connections to Carburettor rrrrrrrnnrrrrnnrrrrrnnrrrrnnerrnrnnnrrrnnerernnnerennnnnrnnnnsrnnnnnsrennnsnennnnsnennnnssen 11 Figure 10 Crankcase Breather Installaton A 12 Figure TT DIPSUCK la CAE 13 Figure 12 Ignition amp Alternator Detail 14 Figure 13 Electrics Installation BE UE 15 Figure 14 Regulator Plug VVINING DEGNS EE 15 Figure 15 Ignition Coil Cooling Tube 16 Figure 16 Starter Wiring Details A 17 Figure 17 Tachometer Sender Installation cccccccccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseeeeesaeeeeseeeeeseaeeeesaaeeesseeeeessaeeeesaeeeeeseeeeeas 18 Figure 18 Tachometer Connections nn nnn nn RR RR RR n RR enn nn nnnnnrnnnnnnnrnnrarenananess 18 Figure 19 Oil Temperature Gender 19 Figure 20 Oil Temperature Connections cnn anne n RR nn RR Rnrnnnnnnnnrnrnnnnnrnnrarenanenes 19 e Rer A e e a 20 Fig re 22 011 Press re Connections EE 20 Figure 23 Voltage Gauge Conpnechons nn R RR RR RR RR nn RR nnnrnnrnnnrnrrnnrnrrnannns 20 Figure 24 CHT Sender Thermocouple Installation ccccccccccseececseeeeeeeeeeeeeeeeeeseeeeeseeeeeeeeeeeeeseeeesaeeeeeseeeesseeeeesaeeeeesaeeeeeas 21 Figure 25 CHT Terminal Installation ccccccsceccccseceeceeeeeseeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseeeeeseeeeeeseaeeeeseaeeesaeeeesseaeeesseeeesageeesseeseseas 22
30. to Engine S No 2661 Power Max 200W Continuous Engine S No 2662 onwards E Wire to ignition switch Ignition coil 1 of 2 Alternator rotor mounted on flywheel Alternator stator mounted on alternator mount plate fixed to rear of engine Ignition magnets mounted on flywheel KI Figure 12 Ignition 4 Alternator Detail 9 2 Regulator e The regulator has been selected to match the voltage and current of the integral alternator Only Jabiru Part No PI10652N should be used The regulator output voltage is 14 volts 0 8 volt e Recommended wiring of regulator is positive and negative of the regulator directly to the battery A 20A fuse or circuit breaker may be used between the regulator amp battery e The regulator is equipped to illuminate a Low Voltage Warning Light Refer to Figure 14 for plug pin details remos o ees Toons page ia 5 Jabiru Aircraft pty Lta aech W i Installation Manual Jabiru 2200 Aircraft Engine Firewall Starter Solenoid Power Earth cables to starter motor y Regulator Plug NA Y Regulator Grey finned block gt SN d b AR Figure 13 Electrics Installation to Firewall Em BLACK 2 TO BATTERY PALE BLUE SN FROM ALTERNATOR 1 PALE BLUE d FROM ALTERNATOR 2 RED TO BATTERY 3 TO LOW VOLTAGE WARNING LIGHT ES TELLOW VOLTAGE CONTROL IO MAIN BUS REGULATOR PLUG WIRING Figure
31. y GN Installation Manual Jabiru 2200 Aircraft Engine 2 Engine Mount The design of the engine mount must balance many requirements e The mount must be strong enough to carry the loads applied by the weight and power of the engine e The mount must be stiff enough that the engine does not sag or move too much when power is applied e The mount must position the engine at the correct height and angle so that the engine s thrust line suits the aircraft In most installations Jabiru Engines need to have their thrust axis offset to the right tractor installations by between 1 and 2 e The mount must position the engine at the right place The weight of the engine is a very significant part of the overall aircraft weight and it s position must be calculated to place the centre of gravity of the aircraft CG in the right spot e The mount must be designed to allow enough room for the air intake to the Carburettor as well as accessories like vacuum pumps Access for maintenance must also be considered e The final design of the engine mount is a compromise and sometimes special parts will be required to make it work Figure 7 shows the installation of a Jabiru 8 cylinder engine into a Van s RV 6 To give a good CG location the engine had to be mounted as close to the firewall as possible This meant that custom air intake tubes had to be developed to get the intake air to the carburettor with a minimum disturbance and turbulence T
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