2200 Installation Manual
Contents
1. Installation Manual Jabiru 2200 Aero Engine 6 0 CONTROLS This section comprises of the mechanical controls and electrical switches 6 1 Throttle and Choke Provisions for the connection of the throttle and choke are made on the carburettor Note Since a pressure compensating carburettor is used there is no mixture control 6 2 Master Switch Ignition Switches and Starter Button The switches are connected as shown by the circuit diagram on Page 10 7 0 INSTRUMENTS 7 1 Electronic Tachometer The tachometer uses a pick up mounted on the alternator mounting bracket which counts the teeth of the flywheel ring gear Jabiru Part No PI10772N is the recommended tachometer Note On later engines tacho picks up on 2 metal tabs attached to the inside of the flywheel Pickup is of induction sender type Tachometer Wiring 3 Tachometer Negative 3 to Earth 4 Tachometer Positive 4 to Instrument 8 Tachometer to Red Wire tachometer pick up 7 Tachometer to Black Wire tachometer pick up 7 2 Oil Temperature Gauge The Oil Temperature Gauge uses an electric probe mounted in the base of the sump Jabiru Part No PI10752N is recommended Oil Temperature Wiring Black Oil Temperature Gauge Negative to Earth Red Oil Temperature Gauge Positive to Instrument White Oil Temperature Gauge Sensor S to Oil Temperature Sensor Lower Left Eng Sump 7 3 Oil Pressure Gauge An electric2. Main jet 2 10 mm or Bing metered jet marked 230 64 32 Fuel Pump Mechanical Jabiru P N PG10332N Ignition System Jabiru dual magneto high voltage transistorised contactless P N PI10522N Spark Plugs NGK D9EA Alternator Integrated Jabiru permanent magnet single phase alternator P N 4532064 4535064 with regulator rectifier P N PI10652N Starter Jabiru 12V 1 0 kW engagement via reduction gear and freewheel Bosch tpye p n 4776093 b The following optional equipment may be driven by or fitted to the engine subject to the type number being included in the approved Jabiru Aircraft Pty Ltd engine specification REVISION 0111 ES Dated 13 Nov 2000 Page 18 C Jabiru Master Doc ENGINE MANUALS 2200 Engine Manuals Installation Manual 2200 Issue 3 doc Print Date 12 November 2001 12 04 PM Page 19 Installation Manual Jabiru 2200 Aero Engine Vacuum Pump 8 MANUALS Instruction and Maintenance Manual Installation Manual Parts Catalogue REVISION 0111 2 3 Dated 13 Nov 0 C Jabiru Master Doc ENGINE MANUALS 2200 Engine Manuals Installation Manual 2200 Issue 3 doc Print Date 12 November 2001 12 04 PM
3. 9 1 Fuel Tank 9 2 Fuel Filtration 9 3 Mechanical Fuel Pump 9 4 Carburettor 9 5 Fuel Lines 10 0 AIR INTAKE SYSTEM 10 1 Air Filter 11 0 EXHAUST SYSTEM REVISION 0111 2 3 Dated 13 Nov 2000 C Jabiru Master Doc ENGINE MANUALS 2200 Engine Manuals Installation Manual 2200 Issue 3 doc Print Date 12 November 2001 12 04 PM 15 15 15 15 16 Installation Manual Jabiru 2200 Aero Engine 12 0 COOLING SYSTEMS 13 0 PROPELLER SELECTION 14 0 AUXILIARY UNITS Appendix A Appendix B LIST OF EFFECTIVE PAGES The dates of issue for original amp revised pages are Page Issue Date 1 3 13 11 00 2 3 13 11 00 3 3 13 11 00 4 3 13 11 00 5 3 13 11 00 6 3 13 11 00 7 3 13 11 00 8 3 13 11 00 9 3 13 11 00 10 3 13 11 00 11 3 13 11 00 12 3 13 11 00 13 3 13 11 00 14 3 13 11 00 15 3 13 11 00 16 3 13 11 00 17 3 13 11 00 18 1 13 11 00 19 3 13 11 00 20 3 13 11 00 Issue Notes Issue 3 Raised to Include Revised CHT specification for New Heads Effects Appendix B data Only REVISION 0111 2 3 Dated 13 Nov 2000 Page 3 C Jabiru Master Doc ENGINE MANUALS 2200 Engine Manuals Installation Manual 2200 Issue 3 doc Print Date 12 November 2001 12 04 PM Installation Manual Jabiru 2200 Aero Engine 1 0 DESCRIPTION 4 Stroke 4 Cylinder Horizontally Opposed 1 Central Camshaft Push Rods Over Head Valves OHV Ram Air Cooled Wet Sump Lubrication Direct Propell
4. carburettor electric starter generator mechanical fuel pump Vacuum pump 2209 cm2 97 5 mm 74 mm 8 3 1 60 includes exhaust starter flywheel alternator Models Jabiru 2200A 1 MANUFACTURER 2 ENGINE PARTICULARS 2 1 Description 2 2 Displacement 2 3 Bore 2 4 Stroke 2 5 Compression Ratio 2 7 Net Dry Weight 2 8 Propeller Rotation Direction Clockwise viewed from rear 3 ENGINE PERFORMANCE Static sea level ratings under the following conditions a International Standard Atmospheric conditions at sea level b Aircraft service equipment drives unloaded Vacuum Pump not fitted c Full rich fuel air mixture d Maximum cylinder head temperature e Standard Jabiru air filter and cold air f Standard exhaust muffler Dated 18 Nov 2000 Page 16 REVISION 0111 2 3 C Jabiru Master Doc ENGINE MANUALS 2200 Engine Manuals Installation Manual 2200 Issue 3 doc Print Date 12 November 2001 12 04 PM Installation Manual Jabiru 2200 Aero Engine 3 1 Engine Ratings 80 HP 3300 RPM 21 L hr Takeoff Max Continuous Rating 0 1 L hr max 3 1 1 Takeoff Max Continuous 3 1 2 Fuel Consumption 3 1 3 Oil Consumption 4 OPERATING LIMITATIONS 4 1 RPM Continuous 3300 RPM Full Throttle 4 2 Engine Cooling Cylinder Head Temperature measured under exhaust spark plug Applicable to Engines with lt Cylinder Heads P No Engines with All other Types Condition 478000N and 477
5. the engine is to be mounted An optional bed mount may be fitted Figure 1 0 Engine Mount Point Locations _g ENGINE MOUNT POINTS N REVISION 0 12 3 Dated 13 Nov 2000 Page 6 C Wabiru Master Doc ENGINE MANUALS 2200 Engine Manuals Installation Manual 2200 Issue 3 doc Print Date 12 November 2001 12 04 PM Installation Manual Jabiru 2200 Aero Engine The correct installation is shown below in figure 2 0 PIN BREAK ALL SHARP CORNERS 60 15 53 ENGINE MOUNT O PSJED 07 SECTION j BER ENGINE MOUNT PLATE Va ENGINE MOUNT W ASSY 26 REF 1 de N Wa Vi se ur SEE DETAIL PIN ENG MOUNT 030 STEEL TO PSJED 07 GRADE 2031 T6 7 MOUNT BUSH FIREWALL ALUMINIUM ON BB WASHER ENGINE MOUNT 9467073 1 Figure 2 0 Engine Mount Assembly Corrections of the engine alignment may be made using spacers under the rubber cushions The maximum spacer thickness on any one mount is 3mm REVISION 011121 3 Dated 13 Nov 2000 Page 7 C Wabiru Master Doc ENGINE MANUALS 2200 Engine Manuals Installation Manual 2200 Issue 3 doc Print Date 12 November 2001 12 04 PM
6. 9002 of Heads Fitted Fitted Maximum Peak Temperature 200 C 175 C Continuous Operation 180 C 150 C 4 3 Fuel 4 3 1 Specifications Avgas 100LL amp Avgas 100 130 Leaded and Unleaded Automotive Gasoline above 95 Octane Ron 4 3 2 Pressure to Carburettor above ambient a Maximum b Minimum 20 kPa 5 kPa WARNING When using auto fuels ensure all components of the fuel delivery system are cooled to prevent fuel vaporization 4 4 Oil 4 4 1 Specifications Aero Oil W Multigrade 15W 50 or equivalent Lubricant complying with MIL L 22851C or Lycoming Spec 301F or i Cylinder heads P No 4779002 and 478000N have more cooling fin area and a different construction REVISION 0111 21 3 Dated 13 Nov 2000 C Jabiru Master Doc ENGINE MANUALS 2200 Engine Manuals Installation Manual 2200 Issue 3 doc Print Date 12 November 2001 12 04 PM Page 17 Installation Manual Jabiru 2200 Aero Engine Teledyne Continental Spec MHF 24B 4 4 2 Inlet Temperature Minimum for Operation 150C Maximum 1180C Continuous 80 C 100 C 4 4 3 Pressure Normal Operations Min 220 kPa Max 525 kPa Idle Min 80 kPa Starting amp Warm Up Max 525 kPa 5 TYPES OF PROPELLER Fixed pitch wooden propellers Maximum propeller diameter 1727mm 68 6 EQUIPMENT a The following equipment is included in the engine approval Carburettor 1 x Bing constant Pressure carburettor type 94 40 Main jet is Bing 255
7. ED MOUNT DIMENSIONS ARE INCHES OPTIONAL FRONT BED MOUNT Drawing 9404041 1 Engine Dimensions Dated 18 Nov 2000 Page 5 1 2 3 REVISION C Wabiru Master Doc ENGINE MANUALS 2200 Engine Manuals Installation Manual 2200 Issue 3 doc 0 Print Date 12 November 2001 12 04 PM Installation Manual Jabiru 2200 Aero Engine 4 0 DENOMINATION OF CYLINDERS vid The I np anh ul Cylinder Firing Order 1 3 2 4 5 0 ENGINE MOUNT The design of the engine mount must not only take into account the structural loadings but must make allowances for accessibility of components and the removal of equipment located at the rear of the engine The engine has four engine mounting points located at the rear of the engine refer to figure 1 0 from which
8. Installation Manual Jabiru 2200 Aero Engine INSTALLATION MANUAL FOR JABIRU 2200 AIRCRAFT ENGINE pou A C zm ff qe lt YV 4 5 Dos if A vc S 7 N HA 21 Al l 7 7 TA This Manual has been prepared as a guide to correctly install the Jabiru 2200 engine into an airframe Should you have any questions or doubts about the contents of this manual please contact Jabiru Aircraft Pty Ltd REVISION 0 12 3 Dated 13 Nov 2000 Page 1 C Jabiru Master Doc ENGINE MANUALS 2200 Engine Manuals Installation Manual 2200 Issue 3 doc Print Date 12 November 2001 12 04 PM o 0 00 00 00 a AR e ojo e F ROG A A A do Page 2 Installation Manual Jabiru 2200 Aero Engine Table of Contents 1 0 DESCRIPTION 2 0 SPECIFICATIONS 3 0 DIMENSIONS 4 0 DENOMINATION OF CYLINDERS 5 0 ENGINE MOUNT 6 0 CONTROLS 6 1 Throttle and Choke 6 2 Master Switch Ignition Switches and Starter Button 7 0 INSTRUMENTS 7 1 Electronic Tachometer 7 2 Oil Temperature Gauge 7 3 Oil Pressure Gauge 7 4 Cylinder Head Temperature Gauge 7 5 Exhaust Gas Temperature Gauge 8 0 ELECTRICAL EQUIPMENT 8 1 Alternator 8 2 Regulator 8 3 Ignition 8 4 Starter Motor 8 5 Battery 8 6 Additional Wiring Information 9 0 FUEL SUPPLY SYSTEM
9. Issue 3 doc Print Date 12 November 2001 12 04 PM Installation Manual Jabiru 2200 Aero Engine 9 3 Mechanical Fuel Pump The mechanical fuel pump is mounted on the engine crankcase and is camshaft driven It is designed to supply fuel at the pressure described in the following paragraph 9 4 Carburettor A Bing constant depression type 94 40 is used This carburettor has a minimum delivery pressure of 5 kPa 0 75 Psi and a maximum pressure of 20 kPa 3 psi To confirm that the fuel system is capable of delivering this pressure a fuel flow test must be performed A method for performing a fuel flow test is available from Jabiru if required A drip deflector to deflect overflowing fuel from the exhaust system is supplied as standard equipment on the engine Engines to S N 698 used 64 32 9 5 Fuel Lines Fuel lines are nominally 6mm bore All hoses forward of the firewall require fire resistant sheathing and those between moving sections such as between engine and firewall should be flexible Hoses must be changed every two years 10 0 AIR INTAKE SYSTEM 10 1 Air Filter The air filter must be of a type so as to not cause positive RAM induction pressure The filter must be capable of supplying 250 kg hr 550 pph of air The filter may have to be changed at regular intervals if the engine is to be used ina dusty environment 11 0 EXHAUST SYSTEM An exhaust system is provided with the engine Both Pusher and Tractor systems are ava
10. Nov 2000 Page 12 C Jabiru Master Doc ENGINE MANUALS 2200 Engine Manuals Installation Manual 2200 Issue 3 doc Print Date 12 November 2001 12 04 PM Installation Manual Jabiru 2200 Aero Engine Regulator Pale Blue No Coding Pale Blue Wire Regulator plug to one Alternator Wire Pale Blue No Coding Pale Blue Wire Regulator plug to the other Alt Wire Black Black Wire Regulator Plug to Earth Red 10g Positive to Red Wire Reg Plug Yellow 16g Positive to Yellow Wire Reg Plug Green Terminal is not connected Regulator Plug Pale Blue Black Pale Blue Green Yellow Red Battery Cables Black Starter Motor Mount Engine Rear to Battery Negative Red Battery Positive to Starter Solenoid Red Starter Solenoid Switched to Starter Motor Part of 9 0 FUEL SUPPLY SYSTEM 9 1 Fuel Tank The fuel tank must be fitted with an outlet strainer of between 8 and 16 mesh per inch with a minimum total mesh area of 5 9 2 FuelFiltration A Fuel filter capable of preventing the passage of particles larger than 0 1mm 100um must be installed between the fuel tank outlet and the fuel pump The filter must be present in the system for the fuel flow test The size of the filter should give consideration to allow adequate flow with a used filter A Ryco Z15 or similar filter has been used successfully REVISION 0 1 2 3 Dated 13 Nov 2000 Page 13 C Wabiru Master Doc ENGINE MANUALS 2200 Engine Manuals Installation Manual 2200
11. R SELECTION The hub of the propeller must be drilled with holes to match the flange The propeller must be carefully selected to match the airframe and the engine Propellers up to 1727mm 68 in diameter and between 762mm 30 and 1219mm 48 in pitch may be used The propeller flange is drilled with 6 holes at both 4 PCD and 100mm PCD Moment of inertia up to 0 25 kgm2 Applications outside this range should be referred to Jabiru 14 0 AUXILIARY UNITS Vacuum Pump For the installation of an artificial horizon and or a direction gyro a vacuum pump is necessary A Tempest 212CW or equivalent vacuum pump can be fitted to the alternator mounting plate and directly coupled to the crankshaft The drive pad is dry The pad and spline are SAE Standard Appendix A REVISION 0 112 3 Dated 13 Nov 2000 Page 15 TA H 0 M ETE WI N p ation Manual 2200 Issue 3 doc SEN STARTER LOOM WIRING MAIN BUS INST BUS 21 43 2 1 STARTER OOOQOOO OOOC SOLENOID o 4 WHITF Installation Manual Jabiru 2200 Aero Engine Appendix B SPECIFICATION SHEET Jabiru Aircraft Pty Ltd P O Box 5186 Bundaberg West Queensland 4670 Four cylinder horizontally opposed four stroke engine direct propeller drive air cooled wet sump pressure lubricated dual magneto high voltage transistorised contactless ignition 1 x constant pressure
12. S 2200 Engine Manuals Installation Manual 2200 Issue 3 doc Print Date 12 November 2001 12 04 PM Installation Manual Jabiru 2200 Aero Engine 8 4 Starter Motor The starter is mounted on the top of the engine and drives the ring gear on the flywheel 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 The cable from Battery to starter should be minimum 16mm copper Starter Wiring Starter Button Switch lower to Main Bus Starter Button Switch upper to Start Solenoid through Grommet 8 5 Battery 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 10 AMP Input 8 6 Additional Wiring Information Engine Hourmeter Wiring Red Hourmeter Positive to Positive Black Oil Pressure Switch to Engine Sump Bolt Black Hourmeter to Oil Pressure Switch Fwd Eng Left Earth Wiring Black Battery Earth Negative to Firewall Earth Engine Bay Black Battery Earth Negative to Earth Bus Master Wiring Red Starter Solenoid to Main Fuse Red Main Fuse to Master Switch Lower Red Master Switch Upper to Main Bus Red Main Bus to Red on Regulator Fuel Pump Wiring Red Main Bus to Fuel Pump Fuse Red Fuel Pump Fuse to Fuel Pump Switch Lower Red Fuel Pump Switch Upper to fuel Pump Red Wire Black Fuel Pump Black Wire to Earth Bus REVISION 01112 3 Dated 13
13. e at each 50 hourly inspection one end of each scat hose Inspect for holes leaks and condition of helical wound in a wire former Replace if any signs of corrosion is evident REVISION 0111 2 3 Dated 13 Nov 2000 Page 9 C Jabiru Master Doc ENGINE MANUALS 2200 Engine Manuals Installation Manual 2200 Issue 3 doc Print Date 12 November 2001 12 04 PM Installation Manual Jabiru 2200 Aero Engine SENDER TACH COMPARTMENT BATTERY ENGINE ENCODER ADF 1 i RADIO F SE 5A FU 10 FUSE Ne ad 3 ELECTRICAL REVISION 0 112 3 Dated 13 Nov 2000 Page 10 C Wabiru Master Doc ENGINE MANUALS 2200 Engine Manuals Installation Manual 2200 Issue 3 doc Print Date 12 November 2001 12 04 PM Installation Manual Jabiru 2200 Aero Engine 8 0 ELECTRICAL EQUIPMENT 6 1 Alternator The alternator fitted to the Jabiru 2200 engine is a single phase permanently excited with a regulator The ro
14. er Drive Dual Transistorised Magneto Ignition Integrated AC Generator Electric Starter Mechanical Fuel Pump Naturally Aspirated 1 Pressure Compensating Carburettor 6 Bearing Crankshaft 2 0 SPECIFICATIONS Displacement 2200 cc Bore 97 5 mm Stroke 74 mm Compression Ratio 8 3 1 Note Eng S N 832 on have lowered compression again Direction of Rotation as standard of Prop Shaft Clockwise Pilot s view Tractor Applications Ramp Weight 60 kg 132 Ibs Complete including Exhaust Carburettor Starter Motor Alternator amp Ignition System Ignition Timing 25 BTDC Firing Order 1 3 2 4 DC Output 10 Amps Fuel Consumption 75 Power 15 I hr 4 US gal hr Fuel AVGAS 100 130 Oil Aero Oil W Multigrade 15W 50 or equivalent Lubricant complying with MIL L 22851C or Lycoming Spec 301F or Teledyne Continental Spec MHF 24B Oil Capacity 2 3 1 2 2 quarts Spark Plugs NGK D9EA Automotive REVISION 0111 2 3 Dated 13 Nov 2000 Page 4 C Jabiru Master Doc ENGINE MANUALS 2200 Engine Manuals Installation Manual 2200 Issue 3 doc Print Date 12 November 2001 12 04 PM Installation Manual Jabiru 2200 Aero Engine 3 0 DIMENSIONS Ga n T UJ T G2 T 2200 J OPTIONAL FRONT B
15. ilable Muffler Volume Capacity 3 litres Back pressure at Takeoff Performance Max 0 2 bar 2 9 psi readings taken 70mm from muffler flange connections Exhaust Gas Temperature EGT Nominal 650 750 1202 F 1382 F measured 100mm from the exhaust manifold flange REVISION 0111 21 3 Dated 13 Nov 2000 Page 14 C Jabiru Master Doc ENGINE MANUALS 2200 Engine Manuals Installation Manual 2200 Issue 3 doc Print Date 12 November 2001 12 04 PM Installation Manual Jabiru 2200 Aero Engine 12 0 COOLING SYSTEMS The engine should be installed using RAMAIR ducts provided with the engine Cylinder and cylinder head cooling is achieved by ducting air over the cylinders The Static Air Pressure inside the cooling ducts must not be lower than 4 3cm 1 7 water gauge at 1 3 times the stall speed An oil cooler should be installed and sized to achieve oil temperatures within the engine limits Hoses should be nominally 8mm 5 16 bore Hoses must be changed every two years The limits in the Specification Sheet contained in Appendix B must be strictly adhered to Warranty will not be paid on engine damage attributed to overheating of cylinders or oil The cooling ducts provided are only a starting point in establishing effective engine cooling The ducts may require to be increased in size and additional baffles provided to achieve the specified maximum cylinder head temperature of 175 C 13 0 PROPELLE
16. oil pressure sender is fitted to the engine for an Oil Pressure Gauge Jabiru Part No PI10762N is the recommended gauge Oil Pressure Wiring Black Oil Pressure Gauge Negative to Earth Red Oil Pressure Gauge Positive to Instrument REVISION 0111 2 3 Dated 13 Nov 2000 Page 8 C Jabiru Master Doc ENGINE MANUALS 2200 Engine Manuals Installation Manual 2200 Issue 3 doc Print Date 12 November 2001 12 04 PM Installation Manual Jabiru 2200 Aero Engine White Oil Pressure Gauge Sensor S to Oil Pressure Sensor Fwd Top Eng 7 4 Cylinder Head Temperature Gauge The Cylinder Head Temperature Gauge uses a thermocouple An audit must be done to establish the hottest cylinder and the thermocouple probe should be fitted under the exhaust spark plug on that cylinder Jabiru Part No 211073210 is the recommended gauge Cylinder Head Temperature Wiring Loom and sensor is supplied with the instrument These must be installed as per 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 Ensure that wire is not chaffing on the fibreglass air duct or cooing fins No power connection is required 7 5 Exhaust Gas Temperature Gauge 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 SCAT HOSE Remov
17. tor is mounted on the flywheel with the stator 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 Specifications Power Max 120W Continuous Note The electrical system is Negative Earth 8 2 Regulator 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 8 3 Ignition The ignition unit has dual breakerless transistorised ignition with the magnets mounted on the flywheel and the coils mounted on the alternator mount plate The current from the coils flows to the distributor from where it is distributed to the spark plugs See also Regulator Wiring at Page 12 The ignition is turned off by grounding the coils via the ignition switches The ignition is timed to 25 BTDC The temperature limit for the ignition coils is 100 C This should be checked by the installer Transistorised Ignition 1 Wiring No 1 Switch Upper to Left Transistorised Ignition No 1 Switch Lower to Earth Switch Open for Ignition ON closed for Ignition OFF Transistorised Ignition 2 Wiring No 2 Switch Upper to Right Transistorised Ignition No 2 Switch Lower to Earth Switch Open for Ignition ON closed for Ignition OFF REVISION 01112 3 Dated 13 Nov 2000 Page 11 C Jabiru Master Doc ENGINE MANUAL
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