Jabiru 3300 Installation Manual
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Jabiru 3300 Installation Manual

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INSTALLATION MANUAL
FOR
JABIRU 3300 AIRCRAFT ENGINE
DOCUMENT No. JEM3302-7
This Manual is a guide to correctly install the Jabiru 3300 engine into an airframe.
If you have any questions or doubts about the contents, please contact Jabiru Aircraft P/L.
Applicable to Jabiru 3300cc Engines, S/No. 33A961 Onwards (Hydraulic Lifter Type)
(Including 33A927, 33A928, 33A947, 33A948, 33A949, 33A950)

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Summary of Contents for Jabiru 3300

  • Page 1 JABIRU 3300 AIRCRAFT ENGINE DOCUMENT No. JEM3302-7 This Manual is a guide to correctly install the Jabiru 3300 engine into an airframe. If you have any questions or doubts about the contents, please contact Jabiru Aircraft P/L. Applicable to Jabiru 3300cc Engines, S/No. 33A961 Onwards (Hydraulic Lifter Type)

  • Page 2: Table Of Contents

    Amphibian or Seaplane Installations .................. 53 12.9 Slow Speed Installations ..................... 53 Appendix A – Wiring Diagrams ................. 54 Appendix B – Jabiru Aircraft Installation ..............55 14.1 Known Airframe / Engine Details ..................55 14.2 Normal Operation Data ....................... 55 Engine Installation Checklist ..................

  • Page 3: Table Of Figures

    Figure 54. Oil Cooler Duct Design ............................49 Figure 55. Oil Cooler Installation ............................. 49 Figure 56: Lip to aid cooling as installed on a Jabiru......................50 Figure 57. Affect of Angle of Attack on Cowl Outlets ......................50 Figure 58.

  • Page 4: List Of Effective

    Jabiru Aircraft Pty Ltd Installation Manual Jabiru 3300 Aircraft Engine List of Effective Pages The dates of issue for original & revised pages are: Page Revision Date Page Revision Date Page Revision Date 14-8-09 1-9-15 14-8-09 14-8-09 14-8-09 14-8-09 14-8-09...

  • Page 5: Model

    Description Model This Manual applies to all Jabiru 3300 Engine Models, but particularly those from S/No 961 on. Details for operating and servicing are supplied in the Engine Instruction & Maintenance Manual. Only those details relevant for installation are duplicated below – for all other information please refer to the Instruction &...
  • Page 6 26 L/hr @ Continuous Rating Takeoff/Max Continuous Rating Oil Consumption 0.1 L/hr (max) Note that fuel and oil consumption figures are based on a typical installation in a Jabiru Aircraft. Values will differ for other installations. 1.5.3 Fuel Fuel Consumption: ........... 35 L/hr @ Takeoff Rating Fuel Consumption: ...........
  • Page 7 700°C (1292°F) EGT Min (Above 50% Power):…………………… ... 600°C (1112°F) Note: An EGT gauge is included as standard equipment on the Jabiru factory built aircraft, for other installations it is required equipment. 1.5.8 Ground Running Limitations Ground Idle Speed ........... 900 RPM (set while engine is hot) Ground Oil Pressure –...

  • Page 8: Dimensions

    Jabiru Aircraft Pty Ltd Installation Manual Jabiru 3300 Aircraft Engine Dimensions Figure 1. Drawing W000509-2 Engine Dimensions Dated : 1 Dec 2016 Page: 8 of 56 REVISION...

  • Page 9: Figure 2. Cylinder Firing Order

    Jabiru Aircraft Pty Ltd Installation Manual Jabiru 3300 Aircraft Engine 1.6.1 Denomination Of Cylinders Figure 2. Cylinder Firing Order Cylinder Firing Order: 1 – 4 – 5 – 2 – 3 – 6 Figure 3. Distributor Cylinder Map Dated : 1...

  • Page 10: Engine Mount

    The mount must position the engine at the correct height and angle so that the engine’s thrust line suits the aircraft. In most installations, Jabiru Engines need to have their thrust axis offset to the right (tractor installations) by between 1° and 2°.

  • Page 11: Figures 5 & 6. Typical Upper Engine Mount, Air Intake Installation

    Jabiru Aircraft Pty Ltd Installation Manual Jabiru 3300 Aircraft Engine Custom air intake tube (“Cobra Head”) Figures 5 & 6. Typical Upper Engine Mount, Air Intake Installation Dated : 1 Dec 2016 Page: 11 of 56 REVISION...

  • Page 12: Controls

     All Jabiru engines are run-in on a Dynamometer before delivery. It is impossible to accurately set the idle RPM when the engine is on the dynamometer, so the Idle Stop Screw (shown in Figure 7) must be adjusted as a part of the engine installation process.

  • Page 13: Engine Crankcase Breather, Catch Bottle & Dipstick

    Jabiru 3300 Aircraft Engine Engine Crankcase Breather, Catch Bottle & Dipstick  The Jabiru 3300 engine has a crankcase breather connection built into the dipstick housing. This is to be connected as shown in Figure 8 below.  The catch bottle is designed to catch most oil vapour from the crankcase breather air. It must be monitored in service and periodically emptied of waste oil.

  • Page 14: Electrical Equipment

    Alternator  The alternator fitted to the Jabiru 3300 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 the engine.

  • Page 15: Regulator

    Jabiru 3300 Aircraft Engine 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.). ...

  • Page 16: Ignition

     The ignition unit is a dual breakerless transistorised ignition with the magnets mounted on the flywheel and the coils mounted on the alternator mount plate. Figure 9 shows the coils of a Jabiru 6-cylinder engine.  The current from the coils flows to the distributor from where it is distributed to the spark plugs.

  • Page 17: Battery

    For optimum starting the battery used must have a high Cranking Amp Capacity (also known as Pulse Amp Capacity). The standard battery used by Jabiru Aircraft has a Pulse Amp rating of 625 Amps. Batteries with higher Pulse Amp ratings may be used and will improve engine starting in colder climates.

  • Page 18: Instruments

    Jabiru Aircraft Pty Ltd Installation Manual Jabiru 3300 Aircraft Engine Instruments 4.8.1 Electronic Tachometer  General wiring information for the Tachometer is given in the Wiring Diagram, Figure 26. Detailed instructions on it’s installation are supplied by the instrument manufacturer.

  • Page 19: Figure 17. Oil Temperature Sender

    4.8.2 Oil Temperature Gauge  The Oil Temperature Gauge uses an electric probe mounted in the base of the sump. Jabiru Part No. PI10752N is recommended.  The gauge has 3 pins, one marked “+” – which is connected to power, one “S” – which is connected to the sensor and one un-marked –...

  • Page 20: Figure 19. Oil Pressure Sender

    4.8.3 Oil Pressure Gauge  An electric oil pressure sender is fitted to the engine for an Oil Pressure Gauge. Jabiru Part No. PI10762N is the recommended gauge.  The gauge has 3 pins, one marked “+” – which is connected to power, one “S” – which is connected to the sensor and one un-marked –...

  • Page 21: Figure 22. Cht Sender (Thermocouple) Installation

    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. ...

  • Page 22: Figure 23. Cht Terminal Installation

    When installing Engine monitoring systems always follow the manufactures instructions.  There is alternative means of getting a tacho signal, such as from the alternator or coils. See EMS manufacture or Jabiru aircraft for details. Dated : 1 Dec 2016...

  • Page 23: Radio Frequency (Rf) Noise Reduction

    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 27) is provided connecting the carburettor to the rest of the engine, so the throttle and choke cables are connected to earth through this wire.

  • Page 24: Figure 25. Rg400 Co-Axial Antenna Cable

    Jabiru Aircraft Pty Ltd Installation Manual Jabiru 3300 Aircraft Engine Outer shield layer Inner shield layer Black outer insulation Figure 25. RG400 Co-Axial Antenna Cable Dated : 1 Dec 2016 Page: 24 of 56 REVISION...

  • Page 25: Figure 26. Wiring Diagram

    Jabiru Aircraft Pty Ltd Installation Manual Jabiru 3300 Aircraft Engine Figure 26. Wiring Diagram Dated : 1 Dec 2016 Page: 25 of 56 REVISION...

  • Page 26: Figure 27. Wiring Diagram Key

    Jabiru Aircraft Pty Ltd Installation Manual Jabiru 3300 Aircraft Engine Figure 27. Wiring Diagram Key Dated : 1 Dec 2016 Page: 26 of 56 REVISION...

  • Page 27: Fuel Supply System

    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.

  • Page 28: Figure 29. Carburettor Installation

     A method for performing a fuel flow test is available from Jabiru if required. In 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.

  • Page 29: Figure 30. Carburettor Intake & Balance Tube Detail

    Jabiru Aircraft Pty Ltd Installation Manual Jabiru 3300 Aircraft Engine Air filter Balance tube 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.

  • Page 30: Figure 32. Needle Jet (Jabiru Needle)

    The 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.

  • Page 31: Fuel Lines

    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.  Jabiru Aircraft or our local representative can provide assistance during this phase. Fuel Lines ...

  • Page 32: Air Intake System

    Intake Hose & Air Filter Box  Jabiru Aircraft recommend that engine intake air be drawn from outside the cowl wherever possible.  Due to the way the carburettor works (as described above) it is sensitive to the air flowing into it.

  • Page 33: Figure 34. Air Filter Box Plumbing – Incorrect

    Glass “Cobra Head” removes a sharp corner in SCAT tube Glass duct prevents bunched SCAT hose from blocking sensor holes on carburettor inlet Figure 36. Typical “Cobra Head” Installation on a Jabiru Aircraft Dated : 1 Dec 2016 Page: 33 of 56 REVISION...

  • Page 34: Air Filter

    RAF 17 (Repco) Ram Air Bleed  The hot air mixer box / filter boxes manufactured by Jabiru Aircraft have a Ram Air Bleed flap incorporated.  This flap prevents excess ram air pressure in the induction system. ...

  • Page 35: Exhaust System

     Jabiru Aircraft now has a composite scimitar propeller which is the standard installation for new LSA and kit aircraft. A vibration survey was conducted on this propeller design and the characteristics are known when installed with a Jabiru engine within the range of typical pitch setting angles specified.

  • Page 36: Figure 39. Jabiru Propeller & Spinner Installation

    Jabiru Aircraft Pty Ltd Installation Manual Jabiru 3300 Aircraft Engine Figure 39. Jabiru Propeller & Spinner Installation Dated : 1 Dec 2016 Page: 36 of 56 REVISION...

  • Page 37: Engine Installation Procedure

    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.

  • Page 38: Figure 40. Engine Accessory Pack Contents

    Jabiru Aircraft Pty Ltd Installation Manual Jabiru 3300 Aircraft Engine  The Tachometer sensor used is a 6.35 x 22 mm analogue magnetic pick-up and is fitted to a bracket on the alternator housing. Refer to Figure 15. The sensor picks up on 2 tags fitted behind the flywheel.

  • Page 39: Figure 42. Engine Mount Detail

    Jabiru Aircraft Pty Ltd Installation Manual Jabiru 3300 Aircraft Engine Figure 42. Engine Mount Detail Dated : 1 Dec 2016 Page: 39 of 56 REVISION...

  • Page 40: Figure 43. Fuel Connections General

    Jabiru Aircraft Pty Ltd Installation Manual Jabiru 3300 Aircraft Engine Fuel line from firewall fitting to mechanical fuel pump Fuel line from mechanical fuel pump carburettor Figure 43. Fuel Connections General SCAT hose from hot air SCAT hose from muff on exhaust to air box NACA inlet to air box Figure 44.

  • Page 41: Figure 46. Control Connections To Carburettor

    Jabiru Aircraft Pty Ltd Installation Manual Jabiru 3300 Aircraft Engine Kit Throttle Cable Carburettor end Throttle lever end Jabiru Aircraft Throttle cable connected Figure 46. Control Connections to Carburettor Dated : 1 Dec 2016 Page: 41 of 56 REVISION...

  • Page 42: Before First Start

    Jabiru Aircraft Pty Ltd Installation Manual Jabiru 3300 Aircraft Engine 10 Before First Start  Expel inhibiting oil from cylinders and pressure up (wind engine on starter until a the oil pressure gauge shows a reading) before first start. ...

  • Page 43: Cooling Systems

    – i.e. head #4 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.

  • Page 44: Figure 47. Cowl Airflow (Best Viewed In Colour)

    Jabiru Aircraft Pty Ltd Installation Manual Jabiru 3300 Aircraft Engine High pressure air entering Air from ram air ducts Balanced Flow cowl through ram air ducts and oil cooler mixing High temperature air Cowl outlet sucks air out of under cylinder heads the cowls.

  • Page 45: Flow Visualisation

    Jabiru Aircraft Pty Ltd Installation Manual Jabiru 3300 Aircraft Engine 12.2 Flow Visualisation  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.

  • Page 46: Air Inlet & Ram Air Ducts

    Jabiru Aircraft Pty Ltd Installation Manual Jabiru 3300 Aircraft Engine 12.3 Air Inlet & Ram Air Ducts  The engine should be installed using RAM AIR ducts provided with the engine. The ducts themselves are to be assembled as detailed in Section 12.3.1.

  • Page 47: Figure 51. Coil Cooling Detail

    Jabiru Aircraft Pty Ltd Installation Manual Jabiru 3300 Aircraft Engine Pipes blowing cool air over the ignition coils Figure 51. Coil Cooling Detail 12.3.1 Ram Air Duct Assembly & Installation  As supplied, the seam at the front of the ram air duct is not joined. This joint must be bonded using 5- minute epoxy &...

  • Page 48: Oil Cooling

     Figure 55 shows an oil cooler installation of a Jabiru 3300. 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 from engine vibrations –...

  • Page 49: Air Outlet

    As noted above, as a rule of thumb the cowl outlet area should be at least 3 times the combined area of all the cowl inlets.  Figure 56 shows a small lip added to the rear of the cowls of a Jabiru Aircraft. This lip gives a large improvement to pressure differentials and engine cooling. Dated : 1...

  • Page 50: Figure 56: Lip To Aid Cooling As Installed On A Jabiru

    (Long Outlet).  Figure 58 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).

  • Page 51: Cooling System Testing & Evaluation

    Jabiru Aircraft Pty Ltd Installation Manual Jabiru 3300 Aircraft Engine Fuselage cut away to give deeper & larger cowl outlet Figure 58. Cowl Outlet Geometry Figure 59. Outlet Restriction Caused By Flange On Lower Firewall 12.6 Cooling System Testing & Evaluation ...

  • Page 52: Pusher Installations

    For pusher installations the details given above hold, though some changes are necessary for the different configuration.  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:...

  • Page 53: Amphibian Or Seaplane Installations

     Installations where the cruise speed is below around 70 – 80 knots are considered slow speed installations.  Jabiru ram air ducts are available for slow speed installations. These are larger than the ducts used for faster aircraft. ...

  • Page 54: Appendix A - Wiring Diagrams

    Jabiru Aircraft Pty Ltd Installation Manual Jabiru 3300 Aircraft Engine 13 Appendix A – Wiring Diagrams Figure 63. Wiring Details Dated : 1 Dec 2016 Page: 54 of 56 REVISION...

  • Page 55: Appendix B - Jabiru Aircraft Installation

    Jabiru 3300 Aircraft Engine 14 Appendix B – Jabiru Aircraft Installation  The following information describes the installation and performance of a Jabiru SP Aircraft fitted with the 3300 engine.  The information given can be used to estimate the performance of different designs, though obviously there will be differences depending on how similar the aircraft is to the Jabiru described below.

  • Page 56: Engine Installation Checklist

    (i.e. resistive or voltage type). Cowl outlets located & shaped correctly Cowl inlets “sealed” Sender units used chosen to suit typical parameter ranges of a Jabiru Engine Crankcase and coil cooling correct Aircraft grade wiring used. Pressure differentials correct CHT cold junction positioned correctly.

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