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INSTALLATION MANUAL FOR JABIRU 2200 AIRCRAFT ENGINE

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1. JABIRU AIRCRAFT P L HH P O BOX 5186 Dm BUNDABERG 4670 QUEENSLAND AUSTRALIA 4 2 5 PH 07 4155 1778 FAX 07 4155 2669 9 84 LA Ha 2200 JABIRU ENGINE MIN OPTIONAL FRONT Pad BED MOUNT Dm P J 1 J DIMENSIONS IN ARE INCHES 582 rm 22 91 250 9 84 ON 152 N g 6 0 3 74 9 74 4 CENT T 10 24 205 Lo 88 8 07 ON 1 EA S Whe OPTIONAL FRONT 1 BED MOUNT 5 po 14 96 14 29 Figure 1 Drawing 94040411 Engine Dimensions aT DPTIONALFRONT 77 BED MOUNT L DPTIONALFRONT BED MOUNT DIMENSIONS THIS DRAWING IS COPYRIGHT AND MUST NOT z PROJECTION IN MILLIMETRES COPIED WITHOUT THE CONSENT OF AYTECH PTY LTO GENERAL TOLERANCES WHOLE NO S 25
2. BREAK A 88 SHARP CORNERS 60 15 53 6 354 R3 d 18 14 17 20 38 it MACHINE Z UNLESS SHOWN OTHERWISE CS1020 CS1030 STEEL TO PSJED 07 NEL SECTION Semen REAR ENGINE MOUNT PLATE WASHER ENGINE MOUNT ENGINE MOUNT W ASSY _ 12 _ 26 pe 26 REF 34 fA 60 REF REF i yi SEE DETAIL PIN ENG MOUNT d 2 DRILL 6 35 6 i um ossi ds xil e 13 7018 56 p B CS1030 STEEL TO 5 07 X 45 ALUMINIUM GRADE 2011 16 MOUNT BUSH FIREWALL SECTION WASHER ENGINE MOUNT 9467073 1 Figure 8 Engine Mount Assembly seo Panaon ve vs Jabiru Aircraft Installation Manual Jabiru 2200 Aircraft Engine 3 Controls This section comprises of the mechanical controls and electrical switches 3 1 Throttle and Choke e he 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 adjuster screws and nuts shown in Figure 9 A 7mm spanner is required he cables
3. 1 11 1 11 DLE ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF OFF ON d GO E FUEL MAIN RADIO FUEL MAIN RADIO PUMP FUSE INST PUMP FUSE INST IGN 1 2 STARTER MASTER STROBE FUEL FUS FUSE IGN 1 IGN 2 STARTER MASTER STROBE FUEL F SE EIS PUMP EGULATO Em MASTER WIRING Wi lt lt MAIN BUS INST BUS 7654321 4321 OOOO OO G SOLENOID eo lol STARTER BATTERY EARTH BUS E EARTH BUS MAIN BUS INST BUS 00000000000 110987654321 7644321 4321 00090000000 OOOO 11 __ d i 1 LI LE ff fy ON ON OFF ON OFF OFF d ON ON OFF ON OFF J FUEL MAIN RADIO SUMP FUSE INST wan FUSE GN 1 10 2 STARTER MASTER STROBE FUEL Quer FUSE Figure 65 Wiring Details seo 5 5 7 soo Jabiru Aircraft Installation Manual Jabiru 2200 Aircraft Engine is Appendix B Jabiru Aircraft Installation The following information describes the installation and performance of a Jabiru SP Aircraft fitted with the 2200 engine he information given can be used to estimate the performance of different
4. vn 0 Jabiru Aircraft Installation Manual Jabiru 2200 Aircraft Engine 2 Engine Mount The design of the engine mount must balance many requirements he mount must be strong enough to carry the loads applied by the weight and power of the engine he mount must be stiff enough that the engine does not sag or move too much when power is applied he 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 2 he 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 in the right spot he 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 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 ha
5. 7 qni WN 1 3ivid INNON 3NION3 334 1 bo 11 12 ih 4 au n M un M M 1 1 1 1 1 ul 11 i1 4 3 1 it M M M it 1 1 ut 31714 SNISNS 5738 NOLL23 03d 31705 ION NI HOSLAY 40 IN3SNOO 1 0314092 JA LON LSOW ONY SIHL Mount Deta igure 44 Engine F 2 3 4 58 39 of 58 Page 2 e e REVISION Jabiru Aircraft Mo Installation Manual Jabiru 2200 Aircraft Engine S ES Fuel line from firewall fitting to mechanical fuel pump Fuel line mechanical fuel pump to carburettor Figure 45 Fuel Connections General SCAT hose SCAT hose from hot air inlet to air muff on exhaust to air box Figure 46 SCAT Hose Detail Balance tube connecting filtered side of air mixer box to nipple on carburettor seo ss Jabiru Aircraft pty Li 2 Installation Manual Jabiru 2200 Aircraft Engine Kit Throttle Cable Carburettor end Throttle lever end Jabiru Aircraft Throttle cable connected Figure 48 Control Connections to Carburettor seo ol
6. lt lt NOLLdO H3QN3S 1314 Or HOLYNHALTV gg HOLIMS 31650 HO NO 5 Q o NOILdO LINN 1an3 68 dWNd 14 4 Le N90 0ld NOLLIS H31VIS c NZ00Vtld TIVI AS HOSSSHdd NS HALAW LIOA 02 CIONS10 3oOHv1HOSS3HddnS JH 8 HOSN3S OILJNOVII 6 Z t NOILdO 143 NONAG 92 HSLSAWOHOVL 8 E HILTI 3SION SE HOSN3S INIOd NOLLO3NNOO 38OHLS 11 AJA 46 31 25 LON 00 NI SNOISN3HIG pies REVISION Jabiru Aircraft Installation Manual Jabiru 2200 Aircraft Engine 6 Fuel Supply System 6 1 Fuel Tank e 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 cm Ensure the fuel tank is properly vented 6 2 Fuel Filtration Fuel filler capable of preventing the passage of particles larger than 0 1 100um must be installed between the fuel tank outlet and the fuel pump e 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 Z15 disposable paper element automotive f
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8. Installation Manual Jabiru 2200 Aircraft Engine 5 8 2 Temperature Gauge Oil Temperature Gauge uses an electric probe mounted in the base of the sump Jabiru Part No 10752 is recommended The gauge has 3 pins one marked which is connected to power S which is connected to the sensor and one un marked which is connected to earth hetemperature sender is a brass fitting installed in the engine sump beside the drain plug he 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 seo ss Jabiru Aircraft n Installation Manual Jabiru 2200 Aircraft Engine 5 8 3 Pressure Gauge e electric oil pressure sender is fitted to the engine for an Oil Pressure Gauge Jabiru 10762 is the recommended gauge e The gauge has 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 Oil filter Oil pressure sender with wire connected kPa x TON 7 Figure 22 Oil Pressure Connections
9. 15 Figure 15 Ignition Coll Cooling TUDE 16 Figure 16 Stamer 17 Figure 17 Tachometer Sender 5 18 Figure 18 Tachometer 18 Figure 19 Oil Temperature Sender 19 Figure 20 Oil Temperature 19 Figure 21 RR m 20 Figure 22 Oil Pressure 20 Figure 23 Voltage Gauge 5 20 Figure 24 CHT Sender Thermocouple Installation nnne nnn nnn nnns nnn 21 Figure 25 CHT Terminal 22 Figure 26 CHT Gauge Connections lt lt pna a supe nc a eoa os E riean eee 22 Figure 27 RG400 Co Axial Antenna Cable 00000 0000010000 E nnns enean nnn riis assa a annis 23 Winnog ID 24 Figure 29 Wiring Diagram Key 25 Fig re Fuel PUMP 26 31 Carburettor TEE
10. seins Jabiru Aircraft Installation Manual Tht Balance tube EN Air filter nipple Correct location for balance tube connection on Clean side of air filter in an area where the air is Sense ports relatively slow moving Fuel inlet nipple E Sense port eos Poor location for balance tube inm E Figure 32 Carburettor Intake amp Balance Tube Detail 6 5 1 Carburettor Operation Diaphragm spring Diaphragm Needle carrier Air density sense port Needle Idle circuit inlet aperture Atomiser density sense port Needle Jet Jet Carrier Idle Jet Figure 33 Carburettor Schematic sesion Jabiru Aircraft Installation Manual Jabiru 2200 Aircraft Engine The Bing altitude compensating carburettor uses bowl float level and two main air circuits the idle and the needle main to control the mixture Both circuits use jets to meter the rate at which fuel is allowed to flow The jets are small brass parts with precisely controlled openings both the size of the opening and the shape surrounding the opening affect fuel flow rate which can be changed to adjust engine mixture he main and idle jets have simple fixed apertures while the effective size of the needle jet aperture varies depending on the diameter of the needle
11. VLE VNV 9 99968 Zl 4 S S dOMd HSns8 34109 INNOW Ol LI cl YANNIdS 0917 TC 3 8 850 21 HOHONY 901690129 Jabiru Propeller amp Spinner Installation VV 11035 Figure 41 Page 36 of 58 st A c 2 e 2 34 567 REVISION Jabiru Aircraft Installation Manual Jabiru 2200 Aircraft Engine 10 Engine Installation Procedure e Attach male engine mount rubbers to all engine mount pins on the engine mount Place AN4 31A bolt through each mount Note that an engine mount spacer washer is fitted between the male rubber amp the lower engine mount pins Refer to Figure 44 below With the Back of the Aircraft Supported the wheels chocked lift the engine onto the engine mount e Insert the upper engine mount rubbers into the engine backing plate first by tilting the front of the engine up Once both upper rubbers are through the engine backing plate fit the female rubber engine mount spacer washer engine mount washer washer amp Heat Proof nut e place the nuts on the mount bolts the rubbers must be compressed Do this by using a deep reach Socket inside the engine mount pins amp clamping the rubber mount assembly using a G clamp with the swivel ta
12. ino 56 e o 5 5 7 Jabiru Aircraft Installation Manual Jabiru 2200 Aircraft Engine 1 2 List of Effective Pages The dates of issue for original amp revised pages are Page Revision Date Page Revision Date Revision Date 11 8 09 11 8 09 11 8 09 11 8 09 11 8 09 11 8 09 11 8 09 11 8 09 11 8 09 11 8 09 11 8 09 11 8 09 11 8 09 11 8 09 11 8 09 11 8 09 11 8 09 11 8 09 9 9 OD 9 9 9 9 9 0 9 OH 9 0 9 9 9 9 9 9 OH 9 9 0 Issue Notes Change drawing page 39 9s Jabiru Aircraft 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 amp Maintenance Manual 1 2 Manuals Instruction and Maintenance Manual Installation Manual
13. Min 640 680 C 1184 1256 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 5 900 RPM set while engine is hot Ground Oil Pressure Idle Startup Min 80 kPa 11 psi Max 525 kPa 76 psi Ground Oil Max 100 212 F Ground Maximum Cylinder Head Temperature 180 C 356 Note ground temperature limits are reached shut the engine down or cool it by pointing the aircraft into wind Measured with sensor ring fitted under exhaust spark plug enson gt gt Jabiru Aircraft Installation Manual Jabiru 2200 Aircraft Engine 1 4 Dimensions 4 55 es lel A C N 010 910 077 gt
14. 56 15 Appendix B Jabiru Aircraft Installation 57 15 1 Known Airframe Engine 57 15 2 mE 16 Engine Installation 58 sesion ZHE Jabiru Aircraft Installation Manual Jabiru 2200 Aircraft Engine 1 1 Table of Figures Figure 1 Drawing 9404041 1 Engine 7 Figure 2 Drawing W000505 Engine Dimensions S No 2553 On 7 Figure 3 Cylinder Qrde m 8 Figure 4 Distributor Cylinder RE E 8 Figure 5 Engine Mount Point Locations 9 Figures 6 amp 7 Typical Upper Engine Mount Air Intake Installation 10 Figure 8 Engine Mount ASSemDl y Tu m 10 Figure 9 Choke and Throttle Connections to 99 11 Figure 10 Crankcase Breather 12 Foure Family TIOE E 13 Figure ignition amp Alternator Detall E 14 Figure 13 Electrics Installation to nns nnn nnn nnns 15 Figure 14 Regulator Plug Wiring
15. E D dud TI 1 TIvAA3HI 3 S3HIAA 3000 SHIM SALON Tv Old vH 1838 HV8 sng 2 B D SOINOIAY 518 SOINOIAW LNINNYLNI Page 24 of 58 5 LLI gt 4 e N N 5 Q 1 MR sna H 335 lt a 59 5 d CN 58 AA AA AA 3 QIoN3105 4 A CN 43145415 Z 2 d eias NOLLINOI g YAJA 0 338 YSONSS OHOVL 6L 35 LINA 1109 NOLLINSI LI Jabiru Aircraft Installation Manual 1 HOnouWHl SNO GOVLZOVE 351 5813001 1 59 ILON n MS 3 H dyg SNe E 31voS LON OQ SNOISN3HIQ z REVISION bs SNG NIYA OL 39 MOTT3A 9NINHYM 39v 10A OL 3349 229 2 13365 9314332 09 Lf ERST Ll V sum ava 551 SJN Te so e vl V ywos ONIHIA ANY 9
16. seins Jabiru Aircraft Installation Manual Parts List There are a total of 3 sumps which have been used ITEM PART NUMBER DESCRIPTION on Jabiru 2200 and 3300 Engines built since the 1 4A400B0D 3 OIL DIPSTICK 2 2L SUITS SUMP P No 4A298A0D year 2000 They are shown opposite and for this 4533064 5 DIPSTICK ASSY 2 2L W document will be called 2200 Finned 2 n n 3 4A400B0D 2 OILDIPSTICK 2 2L SUITS SUMP P No 4A298AOD cda 4 engines used a slightly different version of the 2200 Finned sump which has the intake manifold cast into the sump For this type of sump the details given for the 2200 Finned sump also apply oil level dipstick length etc 4533064 3 DIPSTICK ASSY 2 21 p 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 ihe 2200 UN FINNED SUMP oil level is maintained at approximately the lower mark of the dipstick 2200 UN FINNED Two dipstick lengths have been used for this sump Newer engines use a shorter dipstick which gives a larger volume of oil in the sump 283 288 The older longer dipstick is set to read 2200 ENGINE 2200 ENGINE 302 5 accurately when the engine was cold Due to several RECOMMENDED OIL LEVEL incidents of owners running their engines v
17. Carburettor Cobra Head Duct Figure 39 Cobra Head for Installations with Minimum Carburettor Clearance 7 3 Air Filter e The induction system must not cause positive RAM induction pressure as this will have an unpredictable affect the fuel air mixture supplied to the engine The filter must be capable of supplying 250 kg hr 550 pph of air filter have to be changed at regular intervals if the engine is to be used in a dusty environment e flow should be as direct as possible no tight bends and air taken from outside the cowl Current air filter is RAF 17 Repco 7 4 Ram Air Bleed he hot air mixer box filter boxes manufactured by Jabiru Aircraft have a Ram Air Bleed flap incorporated e This flap prevents excess ram air pressure in the induction system e the engine ever backfires the also acts as a relief valve to let the excess pressure escape without damaging the induction system Rubber flap covers holes amp prevents excess bust etc entering airbox Vent holes to release pressure on un filtered side of airbox Figure 40 Ram Air Bleed se Jabiru Aircraft Installation Manual Jabiru 2200 Aircraft Engine 8 Exhaust System Anexhaust system is provided with the engine Both Pusher and Tractor systems are available e Muffler Volume Capacity litres Back pressure at Takeoff Performanc
18. Eel EI EET 26 26 0e MT E 26 6 3 Mechanical Fuel 26 Fuel Flow Meters ULM _____ ___ 26 26 00 30 iub m 31 Make 31 7 2 Ntake Hose amp Air Filar BOX _ Vd Us CUR a VIA 31 Ho TAN WINE e 33 33 Exhaust E RR 34 F eel desee 35 10 Engine Installation usus sen tex Dae rx ouo bue 37 11 LET RETE 42 POA UN CPI 43 12 1 43 12 ee eI 44 13 1 44 13 2 46 13 3 Air Inlet amp Ram Air Ducts 47 13 4 Ee E 49 13 5 Dgon m 50 13 6 Cooling System Testing amp 53 13 7 54 13 8 Amphibian Seaplane Installations 54 13 9 Slow Speeg InstallatoliS 55 14 Appendix Wiring Diagrams
19. meses Jabiru Aircraft Installation Manual Jabiru 2200 Aircraft Engine 11 Before First Start e Expel inhibiting oil from cylinders and pressure up wind engine on starter until a the oil pressure gauge shows a reading before first start Ensure correct run in type oil is used for the first 25 30 hours to ensure proper ring bedding in Once past the initial 25 30 hours ensure the oil used meets the specifications given above e coolers are mandatory unless operating in very cold ambient temperatures Refer to Oil Cooling section above for allowable oil operating temperature ranges Do not overfill the engine this may result in high oil temperatures Check for contact of engine cooler or ducts on cowl Any contact will cause excessive vibration 8 if the oil cooler is rubbing it will eventually fail amp leak seo sesion Jabiru Aircraft sm I Installation Manual Jabiru 2200 Aircraft Engine 12 Auxiliary Units 12 1 Vacuum Pump e 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 e For later engines S No 2732 and onwards the vacuum pump drive spline is an option extra not included with t
20. WSS PALE BLUE SV N FROM ALTERNATOR 1 y PALE BLUE LF y FROM ALTERNATOR 2 NN y ii M Ls 7 4 GREEN TO LOW VOLTAGE WARNING LIGHT YELLOW VOLTAGE CONTROL MAIN BUS REGULATOR PLUG WIRING Figure 14 Regulator Plug Wiring Details 5 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 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 current from the coils flows to the distributor from where it is distributed to the spark plugs seo 7 Jabiru Aircraft pty Li Installation Manual Jabiru 2200 Aircraft Engine he ignition is turned OFF by grounding the coils 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 ignition is timed to 25 BTDC Ignition timing is fixed it is set by the position of the flywheel magnets relative to the crankshaft temperature limit for the ignition coils is approximately 70 C This should be checked by the installer is recommended that pipes
21. e installations where there is very little room between the carburettor the firewall a special duct has been developed to minimise pressure drop and turbulence shown in Figure 39 he intake hose should align as closely as possible with the carburettor body having the intake duct come at the carburettor from one side encourages swirl and can give uneven mixture Rough entry into hose high Smooth entry into hose turbulence and pressure difference y turbulence or pressure difference Balance tube Balance tube Hose bunched covering sense ports adding turbulence amp swirl ff Cobra Head duct fitted to carburettor Air filter box Figure 35 Air Intake Connections seo 5 5 7 Jabiru Aircraft 44 oN _ Installation Manual Jabiru 2200 Aircraft Engine Figure 36 Air Filter Box Plumbing Incorrect Correct plumbing sharp lips amp abrupt corners rounded amp smoothed off Gradual bends only SCAT hose Glass Cobra Head removes a sharp corner in SCAT tube Glass duct prevents bunched SCAT hose from blocking sensor holes on carburettor inlet Figure 38 Typical Cobra Head Installation on a Jabiru Aircraft sesion Jabiru Aircraft Installation Manual Jabiru 2200 Aircraft Engine Firewall
22. Figure 34 below shows three different throttle settings in the needle jet and the corresponding difference in aperture On the left is a low power setting where the needle jet is nearly completely blocked by the needle The middle throttle setting corresponds approximately to a high cruise power setting The gap between the needle and the sides of the jet is much larger The final setting corresponds approximately to wide open throttle The needle jet is now effectively not there and the amount of fuel flowing is controlled by the main jet located upstream of the needle jet in this circuit he shape of the taper of the needle controls the mixture at a given throttle setting The needle used in Jabiru engines been optimized for use with a propeller which puts a very non linear load on the engine to double the RPM of a propeller a lot more than double the power has to be applied e To achieve a good mixture with the type of load applied by a propeller the Jabiru needle uses two stage taper and a straight tip The more gradual taper at the upper end of the needle gives a leaner mixture in low power cruise settings and at lower RPM where the propeller is using relatively little power The sharper taper at the lower end ramps up rapidly to a much richer mixture at higher power settings The straight tip of the needle is used when the throttle is wide open and the engine s mixture is being controlled by the main jet This rich mixture at full power p
23. MAIN BUS INST BUS C552 21 E UE STARTER 0000 SOLENOID MAIN BUS BUS O looooooo oooc 2 FARTH BUS L et eee _ OODOOOODQOO mem n 1110987654321 1110987 9 d 23 Z 1
24. from engine vibrations coolers installed with a soft mount like this are much less likely to fail in service seo s Jabiru Aircraft Installation Manual Jabiru 2200 Aircraft Engine Controlled gap leaking air over the sump and lower parts of the engine Airflow in Oil Cooler iu 1129015 BOTTOM COWL 3300 2301004 04 comm ADAPTOR we mo 2308 ou 5 OIL COOLER ADAPTOR REFER TO DETAIL VIEW B m REFER TO DETAIL GENERAL VIEW NOTE 2200 ENGINE INSTALLATION SHOWN OIL COOLER OF 3300 THE WITH LONGER COWLS TO SUIT ENGINE SCREWS INTO L S CRANKCASE PLACE amp TRIM INTAKE DUCT OF COWL TO FIT FRONT OF SUMP amp OIL COOLER AN3 BOLT 1 4 BUNDY TUBE SPACER 12mm 10 OIL COOLER DETAIL VIEW B OIL COOLER ADAFTOR INSTALLATION PENNY WASHER HOLD FIRE SLEEVE TO OIL LINE USING SAFETY WIRE MAX 0 75 BETWEN END DF SLEEVE AND END OF OIL HOSE RUBBER MOUNT NE 1 1 5 03 DETAIL VIEW OL COOLER INSTALLATION VAR Jona Tos od DETAIL VIEW C OIL COOLER E MOUNTING DETALE OIL COOLER INSTALLATION 2 21 SAM SA 3 Figure 57 Oil Cooler Installation AIR FLOWING THRU COOLER REF 13 5 Air Outlet 5 sections above describe getting air out of the cowling is often the factor limiting how much air can be pushed through the engine and how well
25. he 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 60 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 high 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 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 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 its wheels Hose from engine gt q Hose from engine to catch bottle Catch bottle attached to firewall Hose to outlet Figure 10 Crankcase Breather Installation
26. Backfire flap fitted to air box Drain holes drilled in air box Carburettor sense pipe connected correctly 8 evaluated EXHAUST SYSTEM clearance no rubbing on aircraft Heat muffs for carb and cabin heat included Outlet positioned correctly Noise levels satisfactory COOLING Cowl inlet outlet ratio correct Cowl inlets located amp shaped correctly Cowl outlets located amp shaped correctly Cowl inlets sealed Crankcase and coil cooling correct Pressure differentials correct Engine temperatures correct seo 7 s or
27. air flow rate Air leaking past oil cooler through oil cooler reduces air flow rate through cylinder heads Figure 50 Cowl Airflow Black amp White Version seo 7 ss Jabiru Aircraft Installation Manual Jabiru 2200 Aircraft Engine 13 2 Flow Visualisation e In designing the cooling system the designer must have a basic understanding of how air flows and behaves inside the cowl The pictures below are intended to explain it in simple terms e Figure 51 shows two schoolrooms drawn as if seen from above Each room represents an engine and oil cooler inside a cowling There are two doors in the inlet side of the room and one on the outlet side ii Several desks are placed the room representing the engine cylinders and the oil cooler lil Students walk through from left to right representing the air flow through the cowls IV On each desk is a pile of homework papers representing heat generated by the engine e Air always takes the path of least resistance It tries to escape quickly to the playground without taking the homework he desks and doorways form restrictions If the desks are too close not enough students can pass through If the desks are too far apart some students will not pick up their homework If the inlet doorways are too large then there will be a traffic jam trying to get out of the outlet door e Gaps leave room for students to pass wi
28. and loading lil Whether the engine is cowled or open by affecting the temperature of the induction pipes and carburettor IV The airframe type V The intake system Because of these factors we recommend that whenever a new engine installation is being developed that the engine be fitted with EGT probes and the tuning checked e Jabiru Aircraft or our local representative can provide assistance during this phase 6 6 Fuel Lines e Fuel lines are nominally 6mm bore e All hoses forward of the firewall require fire resistant sheathing visible as an orange covering on the fuel lines in Figure 30 above Note that wherever possible the sheathing should be extended past the hose clamp The ends of the sheath must be held in place using safety wire to prevent the sheathing moving and exposing the fuel line e Fuel lines between moving sections such as between engine and firewall should be flexible SAE standard automotive rubber hoses are adequate provided they are protected with fire resistance sheathing In many countries including Australia standard airworthiness requirements state that all flexible hoses must be changed every two years though if there are visible signs of degradation such as cracking or hardening the hose should be changed immediately seo Page 00 or Jabiru Aircraft Installation Manual Jabiru 2200 Aircraft Engine 7 Air Intake System 7 1 Inta
29. designs though obviously there will be differences depending on how similar the aircraft is to the Jabiru described below e Poor installations will result in poor performance so installations must be designed referencing the information given in the main body of this manual 15 1 Known Airframe Engine Details Jabiru SP 2 Seater e Propeller 60 x 42 1525mm x 1067mm e 60 x 44 1525mm x 1118mm 15 2 Normal Operation Data The following are typical values for the engine when installed in a Jabiru SP E E 900 950 RPM Take Off POW 2800 RPM 60 x 44 Propeller T HC 2900 RPM 60 x 42 Propeller SOLE eee omia uide uade 3200 RPM 60 x 44 Propeller E 3300 RPM 60 x 42 Propeller Cruise At 7596 2 50 2850 RPM Oil PreSSUl B 400 58 Oil Temperature 80 C 175 Oil Temperature 95 203 6 c p WE 121 C 250 SEES a Ep 177 C 350 F CIMO 650 C 1202 Cue EGT cm 690 C 1274F Mechanical Fuel Pump Pressure 3 lbs 20 kPa seo sesion Jabiru Aircraft Mox Installation Manual Jabiru 2200
30. divided up by fitting louvers or vanes Augmentor type exhausts Figure 64 can also be used to suck air out of the cowlings e In pusher installations the inlets into the cowl are harder to get right than in a tractor installation Intake ducts should be as straight as possible with no sharp corners or other restrictions to the flow The position of the cowl air inlets is critical inlets on the upper surface of the aircraft are generally in low pressure zones while those on the underside are normally in high pressure zones Depending where the inlet is located the area ratio between inlet and outlets may need to be modified 13 8 Amphibian or Seaplane Installations e Water taxiing requires relatively high power settings for long periods and this is often the most critical condition for cooling systems in these aircraft e Increased duct size scooping more air through the engine be necessary e For amphibian or seaplane aircraft using a pusher engine installation the methods outlined above can use the propeller to suck air out of the cowls but ultimately the effect is limited and can conflict with cooling requirements in other modes of flight For these installations some form of active venting for the cowls such as flaps fans or an augmentor type exhaust system See Figure 64 may be required seo Page oo Jabiru Aircraft Installation Manual Jabiru 2200 Air
31. he Bing carburettor has a Balance tube also known as a sense tube which connects the carburettor to the air box The tube runs from a nipple on the carburettor to the airspace in the air box on the clean side of the air filter This tube is part of a system or ports which tells the carburettor how hard the engine is working and controls how the carburettor varies the fuel air mixture delivered to the engine Tuning issues and poor running will result if this tube is blocked or connected to the wrong spot Figure 32 shows the tube installation Note that the balance tube must not be connected to the air box in a location where the air is moving fast rapid flows produces pressure changes and boundary layer effects which mean the balance tube gives the carburettor bad information which can cause poor mixture control and running issues e drip deflector to deflect overflowing fuel from the exhaust system is supplied as standard equipment on the engine Because idle adjustments cannot accurately be made on the dynamometer where every engine is run before delivery some adjustment of the 7mm idle set screw may be required hot idle of around 900RPM is desirable e Fitting an earth strap from carby to crankcase is recommended to eliminate possible radio interference Balance tube Idle screw Vent tube from mechanical fuel pump Fuel bowl clip Fuel bowl Drip deflector Figure 31 Carburettor Installation
32. hours depending on the propeller manufacturer s recommendations e Belleville washers may be used as shown in Figure 41 to allow for expansion and contraction of Jabiru wooden propellers e 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 two sets of holes which can be used for propeller mounting 6 holes at both 101 6mm 47 PCD and 111 12mm 4 3 8 PCD total of 12 holes he Jabiru Engine does not have a hydraulic pressure supply a governor mounting pad required for hydraulic constant speed or variable propeller e Propellers with excess pitch can cause high temperatures and engine damage Nominally all propellers must be able to obtain 2800rpm static and 3150rpm to 3300rpm wide open throttle straight and level However in some particularly low drag airframes it may be necessary to use a propeller which does not achieve 2800 static rpm In these cases propellers should be chosen based on their RPM at wide open throttle straight and level flight e Do not cruise or climb in the range 2100rpm 2400rpm Maximum moment of inertia 0 25 Applications outside this range should be referred to Jabiru WARNING Engine MUST NEVER BE RUN WITHOUT THE PROPELLER Damage Will occur in this state Pitch measurements are taken from the angle of the r
33. it is cooled The shape of the outlet of the cowls controls how effectively air is sucked out of the cowling and is arguably the single most important aspect of cowling design e As noted above as a rule of thumb the cowl outlet area should be at least times the combined area of all the cowl inlets e Figure 58 shows a small lip added to the rear of the cowls of Jabiru Aircraft This lip gives a large improvement to pressure differentials and engine cooling seo 7 ss Jabiru Aircraft pty Li _ Or Installation Manual Jabiru 2200 Aircraft Engine e Figure 59 shows an aircraft at varied angles of attack to the surrounding air The cowl inlets and outlets must both be designed to work effectively at all angles which the aircraft will normally experience e Figure 60 shows two different cowl outlets one is basically an opening in the flat bottom of the cowl while for the other the opening is oriented at 90 to the airflow direction Vertical orientations Deep Outlet give better pressure differentials and are less affected by aircraft angle of attack than horizontal Long Outlet e Figure 60 also shows the lower firewall section of a Jabiru Aircraft The lower part of the fuselage has two large ramps moulded in which increase the depth and area of the cowl outlet and also provides mounting points for the rudder pedals This type of feature is not mandatory for good engine cooling but it
34. 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 When installing new ignition coils the output leads go in the directon of prop rotation RHS coil output lead is up LHS coil output lead goes down See Figure 12 air cooling duct Coil cooling tube Ignition coil Figure 15 Ignition Coil Cooling Tube 5 4 Starter Motor 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 cable from Battery to starter should be minimum 16 copper e Wiring details are shown in Figure 28 5 5 Starter Solenoid e The starter Solenoid is mounted the firewall as shown in Figure 13 he Solenoid body forms a part of the electrical circuit and MUST be earthed to function correctly seo s Jabiru Aircraft Installation Manual Jabiru 2200 Aircraft Engine SOLENOID BODY BUTTON E ER BUS EARTH CONNECTION BETWEI FAM VL N SOLENOID WALL SHEEI POS Figure 16 Starter Wiring Details 5 6 Battery The battery should be of light weight 12V 20 Ah type able to accept a c
35. of 5 minute Epoxy and flock and use it to fix the air dam into place Leave to cure then sand away any rough edges Hemove the masking tape and roughen the underside of the duct and the back of the air dam Mix a small batch of epoxy resin structural resin not 5 minute epoxy and brush 2 layers of AF303 glass fibre cloth to the underside of each duct covering the join line and wrapping up around the back edge of the air dam Leave overnight to cure The completed baffle is shown in Figure 52 seo Page Jabiru Aircraft Installation Manual Jabiru 2200 Aircraft Engine Figure 55 Air Dam Installation 13 4 Oil Cooling The dipstick cap must be screwed fully in before removal for reading oil level e oil cooler adapter is supplied with the engine 8 fits under the oil filter The cooler can be plumbed either way to the adaptor flow direction is not important Oil coolers are available from Jabiru Aircraft e Unless consistently operating in low temperatures oil coolers are mandatory Note if you fly in cold weather and don t have an oil cooler you can t fly if it warms up You can always block the oil air off in cold conditions e In continuous operation oil temperatures between 80 and 90 176 194 F are desirable 70 158 F is the minimum allowable temperature for continuous running and 100 C 212 F is the maximum allo
36. s speed is 1 3 times the stall speed 1 3 x Vs The cooling ducts provided are a starting point in establishing effective engine cooling The ducts require to be increased in size and additional baffles provided for best cooling Tubes of approximately 12mm diameter are required to provide cooling air to the ignition coils Figure 53 e For an air cooled engine it is entirely normal for there to be significant differences the temperature of each cylinder head Often the head which is hottest in the climb will not be the hottest during cruise amp descent This is only a problem if the hotter heads exceed the engine s set limits e Gull Wing baffles can be used to fine tune the restriction to airflow caused by the engine and this in turn affects the volume of air flowing through the engine and into the cowls Fitting the baffles will give a higher restriction as it forces air to flow through the small gaps between fins Leaving the out provides larger gaps and a higher volume of relatively cool air blows through these gaps into the Hot zone immediately under the cylinder heads Wherever possible it is recommended to leave the baffles out However compared to an installation with the Gull Wings fitted a significantly larger volume of air must be sucked out of the cowl outlet This often requires a larger cowl outlet or a larger lip on the existing outlet Pressure differentials must be maintained Chec
37. the oil filter and this can be seen in Figure 21 The sensor used is VDO 360 001 he exhaust gas probe used Jabiru engines is a VDO 310 306 Pyrometer which is supplied as complete kit The probe is mounted in a fitting which is welded to an exhaust pipe Note that this fitting is not standard The installation of the fitting is best done at the time of order though if required the exhaust pipe may be returned to Jabiru and the fitting added Note that in this case it will normally take around 2 weeks before the pipe is returned to you The fitting is welded to the pipe 100mm down from the exhaust manifold mounting plate seins Jabiru Aircraft Installation Manual Jabiru 2200 Aircraft Engine he sensor used is 6 35 x 22 mm analogue magnetic pick up and is fitted to a bracket on the alternator housing Refer to Figure 17 The sensor picks up on 2 tags fitted behind the flywheel Female rubber Washer engine engine mount mount spacer Male rubber engine mount xe Propeller 2 guide bush Lock wire o attach ram air cooling ducts G nh 9 i x E24 WC Exhaust 0 Ga ME 2 EIS E Figure 42 Engine Accessory Pack Contents G Clamp with Deep long Engine mount Female engine engine swivel removed reach socket washer mount rubber m
38. 1 Figure 49 Cowl Airflow Best Viewed in 45 Figure 50 Cowl Airflow Black amp White Version 45 FOW Aie 46 Figure 52 Front On View Into Ram Air Duct rona spawn a oen a 47 Figure qo eee are M 48 Figure 54 Ram Air Duct Front 48 Figure 99 Price 49 RR UU m er 50 Figure 57 Oil Cooler INStAllati Ose 50 Figure 58 Lip to aid cooling as installed on a Jabiru 51 Figure 59 Affect of Angle of Attack on Cowl 6 51 Figure 60 0 2 2 52 Figure 61 Outlet Restriction Caused By Flange On Lower Firewall 52 Figure 62 Cooling pressure 53 Figure 63 Ram Air duct pressure 0 54 Figure 64 Augmentor Cuna tio da uasa ots Coda uasa t 55
39. 5 8 4 Voltage Gauge Optional Avoltage gauge can be connected to the aircraft systems 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 seu Jabiru Aircraft pty Li Installation Manual Jabiru 2200 Aircraft Engine 5 8 5 Cylinder Head Temperature Gauge e he Cylinder Head Temperature Gauge uses a thermocouple which is installed to the exhaust spark plug of the hottest cylinder of the engine head temperatures of air cooled engines are typically quite variable differences of 50 90 between the hottest and coolest head are not uncommon Refer to Section 13 for additional information on cooling e For a new installation 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 hig
40. Aircraft Engine 16 Engine Installation Checklist EI LI LI LI L LI LI LI LI LI LI LI LI LI LI LI LI ENGINE MOUNT Positions engine for correct aircraft CG Positions engine for correct thrust line Sufficient strength Sufficient stiffness Provides access for maintenance Provides clearance the engine and mount are not rubbing on other parts of the aircraft ENGINE CONTROLS Control cables bend radii sufficient Control cables not rubbing on other parts Control cables set up to work in the correct direction ELECTRICAL SYSTEMS Correct sized circuit beakers used Connections for power amp earth correct size Correct type of sender units used for instruments i e resistive or voltage type Sender units used chosen to suit typical parameter ranges of a Jabiru Engine Aircraft grade wiring used CHT cold junction positioned correctly EGT probe located correctly Starter solenoid earthed Regulator earthed Battery mounted close to the engine Anti RF noise measures taken FUEL SUPPLY SYSTEM Electric backup pump installed Electric pump supply pressure within limits Fuel line bend radii sufficient All fittings fwd of firewall fireproof System designed to prevent vapour lock 0000 AIR INDUCTION SYSTEM Cobra Head fitted Duct to carburettor as direct as possible No sharp edges or sharp corners in system Carburettor heat system working correctly
41. INSTALLATION MANUAL FOR JABIRU 2200 AIRCRAFT ENGINE DOCUMENT No JEM2202 7 fae This Manual is a guide to correctly install the Jabiru 2200 engine into an airframe lf you have any questions or doubts about the contents please contact Jabiru Aircraft P L Applicable to Jabiru 2200cc Engines S No 2068 Onwards Hydraulic Lifter Type Jabiru Aircraft Installation Manual Jabiru 2200 Aircraft Engine Pe ee ee eee ee 3 Listo Eifecive m gt 4 MEME mm 5 MO ee 5 I 9 P 5 UE 2 ENJNEMOUN 9 2 i em 11 Throttle and _______ 11 3 2 Ignition Starter Syslems ee renean ran nnn onn ran 11 4 Engine Crankcase Breather Catch Bottle amp Dipstick 12 5 Electrical 14 AEA OM eres sees 14 MEE PRO QUAL OM PERROS 14 solo ru 15 S udo T M 16 9 0 16 17 5 7 Wiring Practices RTT 17 Do e E 18 5 9 Radio Frequency RF Noise Reduction 22
42. Off 50 C 122 F Oil Maximum Peak Oil Temperature 118 C 244 Oil Maximum Continuous Oil Temperature 80 C 100 C 176 212 F Oil Pressure Normal Operations Min 220 kPa 32 psi eee 525 kPa 76 psi enson anena Jabiru Aircraft Mn Installation Manual Jabiru 2200 Aircraft Engine Oil Pressure Idle Min 80 kPa 12 psi Oil Pressure Starting amp Warm Up Max 525 kPa 76 psi Oil Consumption 0 1 L hr max Oil Standard Aero Oil W Multigrade 15W 50 or equivalent complying with EE PEN E MIL L 22851C Lycoming Spec 301F or 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 200 C 392 Maximum Continuous Temperature 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 Mid Range 5 Min 680 720 1256 1328F Above 70 Power
43. Parts Catalogue 1 3 Specifications All information given in this manual assumes static sea level ratings under the following conditions 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 3300 RPM RPM Maximum Continuous 3300 RPM RPM Recommended 2750 RPM 3100 RPM Power Rating 85 hp 3300 RPM 1 3 2 Fuel Fuel 8 21 L hr Takeoff Max Continuous Rating Fuel 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 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 Cil T E 2 3 Litres Oil Minimum Temperature for Take
44. STATIC PRESSURE TO PRESSURE DIFFERENCE BRAZE OR SOLDER END CLOSED BOTH mm DETAIL STATIC PRESSURE TUBE _ ARALDITE STATIC TUBE SCALE 1 230407 amp PVC TUBE TO FIREWALL On ci ISS DATE AVTECH L TITLE DWG NO A C N 010 786 973 HINKLER AIRPORT BUNDABERG QAN D 4 9AO016A0D JABIRU ENGINE COOLING PRESSURE DIFFERENTIALS MATERIAL Figure 62 Cooling pressure measurement seo Page s Jabiru Aircraft pty Li _ 224 _ Figure 63 Ram Air duct pressure tapping 13 7 Pusher Installations e For pusher installations the details given above hold though some changes are necessary for the different configuration e Versions of Jabiru ram air ducts are available for high speed and low speed pusher installations The propeller can be used to suck air out of the cowls using the following as a guide l Wherever possible the outlets should be vertical openings with lips that come close to the propeller as close a possible without the blades hitting the cowls ii The propeller blade must have significant pitch and chord in the section which passes over the outlets iii The cowl openings should each be reasonably small As each blade passes the opening it will create a suction in the cowl behind it but if the cowl opening is large this effect will be dissipated Alternatively larger openings can be
45. ailed instructions on it s installation are supplied by the instrument manufacturer The tachometer picks up on 2 metal tabs attached to the inside of the flywheel The Pickup used is a Magnetic Induction sender type It is a passive device requiring no external power They Pickup outputs a voltage in response to variations 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 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 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 s Jabiru Aircraft
46. ature Gauge 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 0325 is the recommended gauge 5 9 Radio Frequency RF Noise Reduction HF noise is a common problem with aircraft Symptoms include l Radio squelch setting needs to be high Excess noise in the background during transmissions lii Squeals or other feedback noises heard during transmission IV Intermittent static or noise breaking through the squelch HF 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 Ensure all connections particularly engine earths are clean and un corroded e the aircraft has a metallic firewall it can be used as a shield to block the majority of RF noise 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 have a single large Suppressor fitted rather than oT 7 seins Jabiru Aircraft Installation Manual Jabiru 2200 Aircraft Engine for each wire The wiring diagram in Figure 28 shows suppressors in schematic form The
47. craft Engine Air is sucked out of the cowl and entrained with the exhaust inside the augmentor tube c gt AMBIENT AIR gt EXHAUST UA Figure 64 Augmentor Exhaust System 130 Slow Speed Installations e Installations where the cruise speed is below around 70 80 knots are considered slow speed installations e Jabiru ram air ducts are available for slow speed installations These are larger than the ducts used for faster aircraft Increased duct size scooping more air through the engine be necessary for slow speed installations e Increased outlet size and more aggressive outlet lips may be required e In some of these installations where the airframe has lot of drag it is preferable to do away with cowls altogether and run an open installation Aircraft such as the Thruster Vision Drifter X Air and some RANS models are examples of this In these cases large ram air ducts are used and the rest of the engine is exposed to the propeller wash for cooling seo 5 5 ss Jabiru Aircraft Installation Manual Jabiru 2200 Aircraft Engine 14 Appendix A Wiring Diagrams M S ON M
48. d outlet sizes required will vary depending on the aircraft s speed drag and the positions of the inlets and outlets the areas given should be used as a guide and starting point only Ageneralised picture of the airflow air temperature is shown in Figure 49 Most of the time air leaking through gaps instead of flowing though a cylinder head oil cooler or similar is waste air it does not transfer heat and does not cool the engine Sometimes air leaking through controlled gaps such as the holes in the front of the ram air ducts Figure 52 or the gaps between cylinders can have beneficial effects However it is recommended that gaps around the engine and oil cooler be closed as a starting point he propeller amp rush of air from the aircraft s speed make it easier to get air into the cowl than to get it out Too much air flowing through the oil cooler can restrict airflow through the cylinder heads amp vice versa e The pressure difference between the low pressure outlet area of the cowls and the high pressure inlet areas controls the amount of air flowing through the engine The pressure differential testing described in Section 13 5 gives target pressures e During developmental work it is strongly recommended that each cylinder head has it s own temperature sensor Modifications to cowls etc can have unpredictable effects and normally a change will affect each cylinder head differently i e head 4
49. d to be developed to get the intake air to the carburettor with a minimum disturbance and turbulence The 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 E um E BB Figure 5 Engine Mount Point Locations Each engine mounting point is rubber mounted to damp the engine vibrations The correct installation of these rubbers is shown below in Figure 5 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 e o 5 5 7 Jabiru Aircraft pty Li M o 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
50. does help An alternative is to make the bottom corner of the firewall as smooth and rounded as possible to help airflow and minimise the outlet restriction Some aircraft types have a flange running around the firewall Particularly on metal types this flange is a useful way of mounting the cowls However if the flange runs across the edge of the firewall where the cowl outlet is located then it causes a significant flow restriction Figure 61 shows a drawing of the lower section of a firewall with a flange of this type Wherever possible flanges across the cowl outlet should be avoided Alternatively a fairing can be built inside the cowl to smooth airflow over the lip amp reduce flow restriction 4148 TAN at Line shows direction of ambient airflow Figure 59 Affect of Angle of Attack on Cowl Outlets seo Page sr Jabiru Aircraft Installation Manual Jabiru 2200 Aircraft Engine Figure 60 Cowl Outlet Geometry Firewall Flange on fuselage Detail View Location Figure 61 Outlet Restriction Caused By Flange On Lower Firewall seo sesion Jabiru Aircraft Installation Manual Jabiru 2200 Aircraft Engine 13 6 Cooling System Testing amp Evaluation For new installations new designs rather than new aircraft of a known type the pressure drop across both air ducts must be checked The follo
51. e Max 0 2 bar 2 9 psi Readings taken 70mm from muffler flange connections Only complete mufflers supplied with Jabiru Aircraft are welded all others require tail pipes to be TIG welded to the muffler body NOTE Drilled ends of pipes go inside muffler cavity The tail pipes go completely through the muffler body and are welded on both top and bottom e When fitting the muffler one or more of the exhaust pipes can be loosened at the connection to the cylinder head to allow easy fit of the muffler They then must be tightened e Exhaust Gas Temperature limits are given in Section 1 3 6 7 Jabiru Aircraft Installation Manual Jabiru 2200 Aircraft Engine Propeller amp Spinner The hub of the propeller must be drilled with holes to match the flange e Fixed pitch wooden propellers are preferred To safely use a propeller made of metal or composite a crankshaft vibration resonance survey has to be conducted to ensure that there are no damaging vibrations Note that this refers to each new propeller design using composite or metal blades once proven the propellers do not need to be tested for each individual installation However due to their inherent vibration damping qualities wooden propellers can be used without this testing Wooden propellers require periodic inspections to maintain proper attachment bolt tension Typically every 50 or 100
52. e resistant 6 5 Carburettor 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 psi To confirm that the fuel system is capable of delivering this pressure a fuel flow test must be performed ssim Jabiru Aircraft Installation Manual Jabiru 2200 Aircraft Engine WARNING When using auto fuels the fuel delivery system must be designed to prevent fuel vaporization To check pressure insert a piece between the mechanical pump amp carburettor Test boost pump with engine off then mechanical fuel pump with engine on then combine with electrical boost pump as well before first flight method for performing a fuel flow test is available from Jabiru if required brief the fuel line is disconnected from the carburettor fuel is pumped into a calibrated container and the rate at which the fuel is pumped or drained for gravity fed systems without a pump is calculated Most regulations require that the fuel system including pumps supplying the engine be capable of delivering 1 25 to 1 5 times the maximum flow rate required for the engine For a Jabiru 2200 engine this equates to approximately 27 to 32 Litres per hour see Section 1 3 2 The electric boost pump used on Jabiru Aircraft generally manages a flow rate of approximately 60 litres per hour
53. e 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 aircrafts earth system at one end only 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 coaxial 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 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 installati
54. ear face of the prop blade Other propeller manufacturers may specify pitch measured from the blade mean chord line or other reference Make sure you are comparing equivalent pitch units when specifying a propeller 05 ors 5 gt ru 9 lt 2 9 Installation Manual Em 902010 2 19070901 e 1234409 304 SIHL 38 15 3llSOddO NI 3091 SH3HSV A ALON Lu ASSY B3NNldS JILL 6 1 21425 ASSY 31lA31138 1139 OL WALI 39315 YANNIdS SIIGH 93 9 9349307 SLNN YOHONY Z G e 9 pP l 51708 H3TIl3dOHd 804 30 3 035 31955 LON GO 938v Nf 4 HITNIH 6 98 010 1 S3HL3ATTIA SNOISN3MIQ 937115139 Sw mu NOLLVTIVISNI LON jJOHONV TINH 13 dOsd LJVHSONYO 335 LAN SOHONY 03 011 Ald 1435405 LNOHLIM 0389900 38 LON ISNA ONY LHOlAdOO SI SNIA WHO SIHL 18 9 WALI 00868 QoQgeSlvv H3NNIdS 0917 H3NNIdS 0917 YIHSWM VFZ ZLO GELEV 9 33334 1108 IAN 43201AN ALNO AAH
55. h CHT s Figure 25 shows properly and improperly fitted CHT terminals 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 by the sensor wires and cutting the wire upsets the instrument s calibration 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 Temperature of the cold junction for best results should be around 50 Ensure cold junction is mounted as far from the thermo couple probe as possible Cold Junction Plug terminal under spark plug CHT Thermocouple Cold Junction Spark Plug Terminal Figure 24 CHT Sender Thermocouple Installation seo sesion Jabiru Aircraft Installation Manual Jabiru 2200 Aircraft Engine CHT TERMINAL TERMINAL ua d CENTRED UNDER DB uon m e SPARK PLUG TERMINAL CORREC IL Y CENTRED UNDER Figure 25 CHT Terminal Installation 350 600 Cylinder Head Temp 4 Figure 26 Gauge Connections 5 8 6 Exhaust Gas Temper
56. harging voltage up to 14 V 0 8V and a 30 AMP Input 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 engine 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 Wherever possible wires should be identified as carrying Power or Earth This be done by using different colour connectors or applying rings of coloured heat shrink during assembly Again this step simplifies troubleshooting or later modification Wires should be laid out in bundles and supported along their length to prevent failures due to fatigue seins AE Jabiru Aircraft Installation Manual Jabiru 2200 Aircraft Engine 5 8 Instruments 5 8 1 Electronic Tachometer General wiring information for the Tachometer is given in the Wiring Diagram Figure 28 Det
57. he engine The alternator mount plate is also the mount for the ignition coils and the vacuum pump Note The electrical system is Negative Earth Specifications Power 120W Continuous Up to Engine S No 2661 Power 200W Continuous Engine S No 2662 onwards 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 4 Figure 12 Ignition amp Alternator Detail 5 2 Regulator e The regulator has been selected to match the voltage and current of the integral alternator Only Jabiru No 10652 should be used The regulator output voltage is 14 volts 0 8 volt Hecommended 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 The regulator is equipped to illuminate Low Voltage Warning Light Refer to Figure 14 for plug pin details seo T Pape sss Jabiru Aircraft Installation Manual Jabiru 2200 Aircraft Engine Firewall Starter Solenoid Power Earth cables to starter motor Regulator Plug Regulator Grey finned block Figure 13 Electrics Installation to Firewall BLACK BATTERY Y M N
58. he standard engine it must be ordered separately seo Jabiru Aircraft Installation Manual Jabiru 2200 Aircraft Engine 13 Cooling Systems 13 4 General Principles Anideal cooling system Controls engine temperatures through speeds ranging from taxiing on the ground through to ii Controls the engine temperatures through a wide range of angles of attack Is simple to build install and maintain IV Produces minimum drag V Requires no pilot attention vi Is not affected by rain dirt or insects sticking to it vii And weighs next to nothing e For sake of the following discussion is considered an opening roughly large enough to slide two fingers into around 13mm by 32mm 0 5 by 1 e The total area of the air intakes combined cylinder head and oil cooling openings should generally no more than one third the total area of the cowl outlet the outlet area must be a minimum of about 3 times as large as the total area of the inlets This assumes that the outlet area is oriented effectively see Figure 60 e Each cylinder head Inlet of a Jabiru Aircraft has an area of approximately 10 500mm 16 25 Oil cooler inlets have an area of approximately 12 500mm 19 4 This gives a required total outlet area of approximately 100 500mm 155 These sizes are based a Jabiru Aircraft Inlet an
59. igher Check you have sufficient margin for all conditions you plan to fly in engine gets too hot during testing don t push it Something needs to be changed For low speed cooling a lip on the front edge cowl outlet can add up to 20mm of pressure drop 65kts lip 25mm deep at 60 to the shown in Figure 58 e Refer to Figure 24 CHT terminals must be placed correctly or inaccurate too high readings can result po DIMENSIONS IN MILIMETRES DO NOT SCALE PROJECTION ES mu MOUNTED FLUSH WITH INSIDE OF BOTH RAM AIR DUCT Y SPARK PLUG RAM AIR DUCTS BETWEEN SPARK PLUGS 77 p N p a 6 mm CLEAR PVC TUBE N 6 mm STEEL TUBE BENT 90 LOCATION OF TUBE RAM DEGREES AND ARALDITED AIR DUCT ON BOTH SIDES RAM AIR DUCT WITH TAIL m DUC FACING AFT TO CONNECT TO PCV TUBE o 4 d 7 1 lt FIT STATIC TUBE AS DETAILED IN FRONT OF OIL COOLER pu 7 CONNECT TO CLEAR TUBE MANOMETER RN o 10 m s Y 717 THRU 91 0 5 HOLES FIT STATIC PRESSURE TUBE S Hi INDEXED AT 90 AS DETAILED THRU FIREWALL EN Ei Ly XM AND CONNECT TO MANOMETER V Ni tope 1 66 STEEL TUBE 0 8 WALL Vd Ple m UL PETI RU REN N
60. ilter has been used successfully Note that this filter or any other filter with a plastic body must not be used on the engine side of the firewall regulations and common sense both require that all fittings in the fuel system on the engine side of the firewall must be fire resistant 6 3 Mechanical Fuel Pump he mechanical fuel pump is mounted on the engine crankcase and is camshaft driven lt is designed to supply fuel at the pressure described in the following paragraph e airworthiness categories require that a backup fuel pump be fitted in case the primary pump fails Jabiru Aircraft recommend fitting an electrical boost pump If fitted this pump must also fulfil the fuel input criteria for the carburettor given below Some airworthiness categories also require an additional drip tray be fitted to the fuel pump This optional tray is shown in Figure 30 Fuel line from pump to carburettor Fuel Pump Fuel line from firewall fitting to fuel pump Fuel pump drip tray Optional Figure 30 Mechanical Fuel Pump 6 4 Fuel Flow Meters Where a Fuel Flow Meter is to be installed to the aircraft Jabiru Aircraft recommend that the flow transducer is not installed on the engine side of the firewall Most transducers are made of either plastic or light aluminium and are not fire resistant Regulations and common sense both require that every part of the fuel system on the engine side of the firewall must be fir
61. irtually OIL LEVEL OIL LEVEL out of oil the dipstick length has been shortened 268 to read accurately when the engine is hot and oil is spread throughout the engine and oil system TO TOP MARK 268 340 5 TO TOP MARK p g g RECOMMENDED This also has the effect of raising average oil levels OIL LEVEL TO TOP MARK 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 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 3300 ENGINE consumption pattems Owners must familiarise RECOMMENDED OIL LEVEL 1 themselves with the cil usage rates etc of their BETWEEN UPR 8 LWR MARKS particular engine and tailor their target oil level to suit DIPSTICK SETTINGS FAMILY TREE COMPARISON 8A035A0D 1 8 4 08 Figure 11 Dipstick Family Tree seo s Jabiru Aircraft n Installation Manual Jabiru 2200 Aircraft Engine o Electrical Equipment 5 1 Alternator The alternator fitted to the Jabiru 2200 engine is a single phase permanently excited with a regulator The rotor is mounted on the flywheel and the stator is mounted on the alternator mount plate at the back of t
62. k for contact of engine cooler or ducts on cowl Any contact will cause excessive vibration amp if the oil cooler is rubbing it will eventually fail amp leak Front baffle in duct to prevent air slipping Hear baffle to direct air under cylinder amp head into rear cylinder head Hole in ram air duct to blow cool air over the crankcase Gull Wing baffles fitted between cylinders PAREN E us Figure 52 Front On View Into Ram Air Duct seu Jabiru Aircraft M Installation Manual Jabiru 2200 Aircraft Engine Pipes blowing cool air over the ignition coils 4 Figure 53 Coil Cooling Detail 13 3 1 Ram Air Duct Assembly amp Installation supplied the seam at the front of the ram air duct is not joined This joint must be bonded using 5 minute epoxy amp flock Use a length of masking tape on the join line at the bottom of each duct inlet to hold the join firm and prevent Epoxy flock from leaking through Seam bonded with 1 4 o minute epoxy A Figure 54 Ram Air Duct Front Seam e Before installation the front air dams need to be cut to size Take the length of glass fibre sheet with the curved edge hold it against the rear of the duct inlet with the curve towards the top rear of the duct and mark around the bottom of the duct then cut to shape Figure 55 refers e Tape the air dam into place Mix a small batch
63. ke Air Heating The Jabiru 2200 engine can experience carburettor icing in some conditions Jabiru Aircraft strongly recommend that a system for heating engine intake air be included in the induction system design 7 2 Intake Hose amp Air Filter Box e Jabiru Aircraft recommend that engine intake air be drawn from outside the cowl wherever possible e Due to the way the carburettor works as described above it is sensitive to the air flowing into it Turbulence swirl and sharp edges all affect the mixture metering system of the carburettor he hose type recommended for induction systems is SCAT aircraft type WARNING SKEET type which has an inner liner must NOT be used Over time the inner lining can detach and collapse blocking the hose SKEET hose should be used for positive pressure applications only Tight corners in the hose as shown in Figure 35 can introduce both swirl and turbulence to the air flowing into the carburettor e Connecting the hose directly to the carburettor can cause the hose to bunch up and cover the sense ports A Cobra Head duct or similar is recommended to prevent this Sharp corners inside the air filter box cause turbulence and a pressure drop The pressure drop means that the carburettor balance tube pressure reading is inaccurate while the turbulence affects the readings at the carburettor sense ports Both items can cause power loss and rough running particularly at high power settings
64. ken off the ball See Figure 43 Start nuts on both upper mount bolts Once bolts of the upper rubbers are started continue lowering the front of the engine amp align the lower engine mount pins with the engine backing plate e Use the weight of the engine to compress the lower rubbers fit the nuts to the bolts he lower engine mount rubbers are assembled in the same way except the male engine mount rubber is fitted to the engine mount pins first Refer to Figure 44 below e Tighten nuts until firm Engine mount washer will touch the engine mount pin as the rubbers compress e Connect the fuel line to fuel pump Refer to Figure 43 Ensure the fireproof sleeve is in place Ensure the fuel line from fuel pump to the carburettor is connected 4 protected by fireproof sleeve Ensure that the fuel overflow line is in place and secured to vent overboard This is the small clear hose shown leading from the fuel pump in Figure 43 e Fit the oil over flow bottle to the firewall by drilling and Riveting oil bottle holder in place using 73AS 6 6 rivets Refer to Figure 10 Connect the oil breather line from the engine breather Ensure that the oil overflow line is in place and vents overboard e Fit Scat hoses from duct to Air Inlet Housing Assembly from hot air to carburettor heat inlet on the hot air mixer box and from the hot air mixer box to carburettor shown in Figure 46 e Fit throttle cable to carb
65. may cool down while head 3 heats up Testing of an installation in a Jabiru Aircraft showed that the heat radiating from the engine exhaust system normally has a minimal effect Wrapping the exhaust in insulation etc does not produce a measurable temperature reduction during taxi or in the air WARNING 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 sos Jabiru Aircraft Installation Manual High pressure air entering Balanced Flow Air from ram air ducts cowl through ram air ducts 3 and oil cooler mixing Cowl outlet sucks air out of the cowls Low pressure warm air flows out High temperature air under cylinder heads Air entering cowl through oil cooler Un Balanced Flow Un Balanced Flov Air leaking past cylinder heads reduces air flow rate through oil cooler Air leaking past oil cooler S reduces air flow rate through cylinder heads Figure 49 Cowl Airflow Best Viewed in Colour High pressure air entering Balanced Flow Air from ram air ducts cowl through ram air ducts and oil cooler mixing Cowl outlet sucks air out of the cowls Low pressure warm air flows out High temperature air under cylinder heads Un Balanced Flow Air leaking past cylinder heads reduces
66. nts in the corridor causing restriction amp jostling at the exit Figure 51 Flow Visualisation seo Jabiru Aircraft Installation Manual Jabiru 2200 Aircraft Engine 13 3 Inlet amp Ram Air Ducts engine should be installed using RAM AIR ducts provided with the engine The ducts themselves must be assembled as detailed in Section 13 3 1 he ram air ducts are screwed to the engine using the normal rocker cover screws Note that if the duct is not fastened to the engine then air pressure at high speed can lift the ducts off the engine This will upset the pressure balance inside the cowl and impede cooling More importantly with some types of ducts the duct lifting will dislodge the spark plug high tension leads causing the engine to run roughly or stop e For best cooling on the ground during climb and low speed flight the propeller used must have significant pitch and blade area on the section immediately in front of the air inlets At low speeds the airflow does not have much energy and the acceleration and pressure provided by the propeller greatly assists in getting air into the ram air ducts e Each duct must have a 25mm hole at the inside top front to bleed air over the crankcase The pressure differential between the inside the cooling ducts and the outlet must not be lower than 60mm 2 47 water gauge at when the aircraft
67. omm 27 Figure 32 Carburettor Intake amp Balance Tube Detail 28 Figure 33 Carburettor 28 Figure 34 Needle Jet Jabiru Needle 29 Figure 35 Air Intake amp 31 Figure 36 Air Filter Box Plumbing Incorrect 32 Figure 37 Air Filter Box Plumbing 32 Figure 38 Typical Cobra Head Installation on a Jabiru Aircraft 32 Figure 39 Cobra Head for Installations with Minimum Carburettor 33 BEE ENT T t Em 33 Figure 41 Jabiru Propeller amp Spinner 1 1 nennen nennen 36 Figure 42 Engine Accessory Pack 38 Figure 43 Upper 4 Lower Engine Mount 38 Figure 44 Engine T 39 Figure 45 Fuel Connections General 40 Figure 46 SCAT Hose 40 Figure 47 Balance Tube Detail e E E 40 Figure 48 Control Connections to Carburettor 4
68. on 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 provides good instructions for minimising their effect on radio noises Outer shield layer Inner shield layer Figure 27 RG400 Co Axial Antenna Cable Black outer insulation seins 2 240 V L33HS 0315119379 09 Lf 5u3avaung vafan JASHS 1 SLNSWNYLSNI 9 QqOovr9zvr 33 DINIH 008 190 Sound 2885 SHSYNLOYANNYW OL NOLLYTIYLSNI H30NOdSNY HL 8 00719076 Had 1 0 SN Y 9349 OL NOLLYTIYLSNI v 31725 V n Wd Odd NS SHOSN3S ALOS v3uv NOLLO3S X OS 31879 5 qaTOoLll1n4dlno N3342 H3MOd HOSN35 33088 3 99 5 SLL 38 ___ ___ E 6 91 21 66 22
69. ount rubber J I Figure 43 Upper amp Lower Engine Mount Detail seo 7 peius ss Jabiru Aircraft O C LLI lt o e N N 5 Installation Manual AS Aor Os38v0Nng8 CIPE E ALS VOlLdiJos3 NOLLYTIVISNI LNNOW Jugo 31734 LNNOW NI SNOILVTIVLSNI 3NIS9N3 0022 ANY 0022 nuiavr 318 21144 JW LINNON 5 NOILV In19I3NOO LNNOW H3MOT1 INTUS RITE B3HSvM 2 2 ETN N EN N NE PARED 9 X gt 4 m b t gt Y X 1 qi 8 WN 3100801 JvdS INA B3HSVM A 1 A 1 V 1 V t A 11 11 A 11 1433 V MM 1 aU 1 M M L4 A M ti X MM GM M M it d 1 LT m MM 1 M MM TI ALLL M A MM M VA 11 VA MA VA OM ALD A Uh MM 1 NI SNOLLVTIVISNI ANIONS 0022 ANY 0022 nsiavr 318 21144 7 M WA M M 4 e LA m MM GN M M Y M T 7
70. rotects the engine from detonation The transition from lean cruise mixtures to richer full power mixture will occur at around 2800 3000 rpm on 4 and 6 engines when fitted with an appropriate propeller For most efficient operation the transition must be above cruise rpm The transition can clearly be seen by changes in the EGT Jabiru 3300 needle shown with 3 shallow grooves machined above taper olow linear taper for lt cruise power amp below Jabiru Needl abiru Neede Needle Jet cross 2 section view oteeper linear taper for transition between lean cruise mixture and rich WA high power mixture Parallel end for full power View looking through needle jet N _ Needle Jet Needle Figure 34 Needle Jet Jabiru Needle Because of the way the carburettor uses the sense ports and balance tube to regulate the mixture it is sensitive to the way the intake air moves and to the conditions of the intake system Section 7 below contains information on setting up the induction system sesion Jabiru Aircraft Installation Manual Jabiru 2200 Aircraft Engine 6 5 2 Carburettor Tuning he mixture supplied to the engine by the carburettor is affected by a large number of variables including l Ambient temperature li Propeller size coarse or fine
71. se suppressors are readily available at local electronics stores e 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 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 t is normal unavoidable that the engine s ignition system produces some RF noise This can be minimised by Ensuring all spark plug gaps are set properly ii Ensure ignition coil gaps are set properly lii 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 o counteract 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 th
72. thout picking up homework e Given a group of desks as shown students can follow many paths through them from front to rear from top to bottom or any combination e Slowing down the students as they pass through the desks means they will pick up their homework but if they are slowed down anywhere else it only reduces the amount of students that can get through the room e If the exit becomes jammed with people installing bigger inlet doors will not increase the number of students passing through the room Exits should be as clear and free of obstructions as possible to let people out e Students will often have a preferred desk to take their homework from meaning that some cylinder heads will have more heat removed than others temperatures will wary between different heads Partition Cylinder head desks Oil cooler desks Desk t C a otudents carrying 8 8 8 homework Sy 9 6 8 95658 8 8 8 55 2 8 8 8 8 amp Partitions are used to force the students to walk No partitions are used so students walk around through the desks the desks instead of through them Each student picks up the homework Most students don t come close enough to a desk Outlet door is 90 to the flow of students in the to pick up the homework corridor there is no restriction 4 jostling at the exit Outlet door is parallel to the flow of stude
73. urettor Note that Jabiru Aircraft kits come with a throttle cable cut to length and with the correct end fitting attached Engines used in firewall forward kits will be supplied with a length of throttle cable with no end the builder must cut the cable to length and fit the carburettor end fitting 5 16 washers are used on the cable end fitting one washer either side of cable end fitting to align cable Use R clip to assemble Figure 48 refers e Fit choke cable to carburettor Use an R clip to assemble Note that the fuel line from the fuel pump to the carburettor passes between the choke and throttle cables The choke is shown in Figure 9 Connect the fuel balance tube from the nipple on the carburettor to a fitting on the filtered air side of the air mixer box Fit cylinder head temperature CHT sensor The CHT sensor used in Jabiru aircraft is J type thermocouple The VDO 310 980 Cylinder Head Temperature Gauge Kit is compatible with this sensor and is installed as standard equipment in Jabiru Aircraft Note that to ensure an accurate temperature reading it is important to have the cold junction for the CHT the plug between the stiff thermocouple wires and the normal plastic insulated gauge wires located away from the heat of the engine Refer to Figure 24 he Oil Temperature Sensor used is a VDO 320 028 which is located in the bottom of the sump as shown Figure 19 e The oil pressure sensor is located at the base of
74. 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 use the control accurately This is a particular problem for the throttle cable as it will make setting the idle accurately very difficult e All Jabiru engines are run in on Dynamometer before delivery It is impossible to accurately set the idle RPM when the engine is the dynamometer so the Idle Stop Screw shown in Figure 9 must be adjusted as a part of the engine installation process Idle stop screw Throttle Cable connected to throttle arm Cable mount bracket Choke Cable connected to throttle arm Adjustors to fine tune choke 2 and throttle operation Figure 9 Choke and Throttle Connections to Carburettor 3 2 Ignition amp Starter Systems heonly electrical controls for the Jabiru Engine are the ignition switching and the start button 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 Paseo Jabiru Aircraft Installation Manual Jabiru 2200 Aircraft Engine Engine Crankcase Breather Catch Bottle amp Dipstick 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
75. wable temperature for continuous running e Over filling with oil is not desirable It can cause elevated temperatures amp excessive oil use 4 loss Hoses should be nominally 10mm 3 8 bore Hoses must be changed every 2 years or if visible degradation cracking hardening is visible at inspection pressure drop of at least 60mm 2 4 water pressure between the air flowing into the cooler and the air flowing out of the cowls should provide sufficient oil cooling if using a standard Jabiru oil cooler Section 13 1 noted that air leaking through gaps the cooling system ducts is generally waste air not contributing to cooling though it noted that there were exceptions to this rule Oil cooling is the feature of engine installations that is most often improved by leaks like this A controlled amount of free air blowing over the sump crankcase and underside of the engine can significantly improve oil temperatures Figure 56 shows a duct of this type fitted to a Jabiru 6 cylinder engine However for this to work the cowl installation must be able to cope with the extra volume of air flowing into the cowl space the outlet area or outlet lip size may need to be increased to suck out the extra volume 57 shows oil cooler installation of a Jabiru 2200 Note Detail C in the lower corner of the drawing which shows the cooler being fitted using rubber mounts This is very important as it insulates the cooler
76. wing is a guide to evaluating an engine installation to see if it meets minimum cooling requirements he easiest way to measure the air pressure drop across the engine and oil cooler is using U tube manometer using water lt is basically a piece of clear tube bent into a U and half filled with water if the water is hard to see add a bit of food colouring For ram air duct pressure connect one side of to a static port inside the ram air duct and the other to a static probe inside the cowl near the outlet For the pressure drop across the oil cooler plumb a static probe against the front of the cooler and a static probe inside the cowl near the outlet The further the probe is in front of the cooler the less the static pressure that will be measured so place the probe no more than 5mm in front of the cooler and parallel to it e Using multiple U tubes several measurements can be taken in one flight e Details of a typical static probe are shown in Figure 62 e Note that probes must be fitted in the same place each time to ensure you get consistent measurements Some hints e Usually the most critical situation for cooling is climb however this is not always true so check all situations he change air temperature is approximately the same as the change in engine temp For example if you did all your testing in 15 and you want to flying in up to 35 weather in 35 all your engine temps will be approximately 20 C h
77. yz JW DEC 0 25 DEC 0 06 ANGLES 20 5 Figure 2 Drawing W000505 Engine Dimensions S No 2553 On sew ZME Jabiru Aircraft Mn Installation Manual Jabiru 2200 Aircraft Engine 1 4 1 Denomination Of Cylinders 1 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 m 1 9 WOLF BLANK 6 CYLINDER ENGINE 2 CYLINDER ENGINE FIRING ORDER 1 4 5 2 3 6 FIRING ORDER 1 2 EXHAUST in ia P EXHAUST 8 CYLINDER ENGINE FIRING ORDER 1 5 8 3 2 6 7 4 310306 AVTECH P L THIS DRAWING IS COPYRIGHT AND MUST NOT BE ams 29 9 05 COPIED WITHOUT THE CONSENT OF AVTECH PTY LTD 155 010 786 973 155 DATE HINKLER AIRPORT JABIRU ENGINE DISTRIBUTOR CYLINDER 4A2866A0D 2 BUNDABERG 4670 MAP ALL ENGINES CL Figure 4 Distributor Cylinder Map

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