Jabiru 2200 Installation Manual
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Jabiru 2200 Installation Manual

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INSTALLATION MANUAL
th
FOR 4
GENERATION
JABIRU 2200 and 3300 AIRCRAFT ENGINES
DOCUMENT No. JEM0008-1
This Manual is a guide to correctly install the Jabiru 2200 engine into an airframe.
If you have any questions or doubts about the contents, please contact Jabiru Aircraft P/L.
Applicable to Jabiru Generation 4 2200 from S/No. 22A3936 and 3300 engines from
S/No. 33A2974

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Summary of Contents for Jabiru 2200

  • Page 1 JABIRU 2200 and 3300 AIRCRAFT ENGINES DOCUMENT No. JEM0008-1 This Manual is a guide to correctly install the Jabiru 2200 engine into an airframe. If you have any questions or doubts about the contents, please contact Jabiru Aircraft P/L. Applicable to Jabiru Generation 4 2200 from S/No. 22A3936 and 3300 engines from...

  • Page 2: Table Of Contents

    Pusher Installations ......................52 12.7 Amphibian or Seaplane Installations .................. 52 12.8 Slow Speed Installations ....................53 Appendix B – Jabiru Aircraft Installation ..............54 13.1 Known Airframe / Engine Details ..................54 13.2 Normal Operation Data ....................... 54 Engine Installation Checklist ..................55...

  • Page 3: Table Of Figures

    Figure 53. Oil Cooler Duct Design ............................48 Figure 54. Oil Cooler Installation ............................. 48 Figure 55: Lip to aid cooling as installed on a Jabiru....................... 49 Figure 56. Effect of Angle of Attack on Cowl Outlets ....................... 49 Figure 57.

  • Page 4: List Of Effective

    Jabiru Aircraft Pty Ltd Installation Manual Gen 4 2200 and 3300 engines 1.2 List of Effective Pages • This manual is revised as a complete document. All pages must display the same revision number. See the table below for the revision history...

  • Page 5: Engine Information

    Pty Ltd Installation Manual Gen 4 2200 and 3300 engines 1 Engine Information All specification data relevant to the Gen 4 2200 and 3300 engine is found in the following manuals: • JEM0005: Maintenance Manual – contains the following General Specifications...
  • Page 6 Access for maintenance must also be considered. • All Jabiru aircraft models have specially designed engine mounts available. Firewall forward kits have also been developed for a number of other light sport aircraft. Contact Jabiru aircraft or an authorised dealer for more information •...

  • Page 7: Controls

    Jabiru Aircraft Pty Ltd Installation Manual Gen 4 2200 and 3300 engines 2 Controls This section comprises of the mechanical controls and electrical switches. 2.1 Throttle and Choke • The throttle cable attaches to the cable mount arm fitted to the carburettor.
  • Page 8 Jabiru Aircraft Pty Ltd Installation Manual Gen 4 2200 and 3300 engines Choke Cable connected to carburettor arm Figure 3: Choke cable fitted • Choke cable doesn’t have any adjustment. • Install choke cable and trim to length before fitting end ferrule to choke cable.

  • Page 9: Ignition And Starter Systems

    Figure 6: Choke cable end assembled. 2.2 Ignition and Starter Systems • The only electrical controls for the Jabiru Engine are the ignition switching and the start button or starter key. • The ignition switches earth the corresponding corresponding coil to ground, to turn the coil off.

  • Page 10: Engine Crankcase Breather, Catch Bottle And Dipstick

    Gen 4 2200 and 3300 engines 3 Engine Crankcase Breather, Catch Bottle and Dipstick • The Jabiru 2200 and 3300 Gen4 engines have a crankcase breather connection built into the dipstick housing. This is to be connected as shown in Figure 7 below. •...

  • Page 11: Electrical Equipment

    4.1 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 the engine.

  • Page 12: Ignition

    Figure 8 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.

  • Page 13: Starter Motor

    Jabiru Aircraft Pty Ltd Installation Manual Gen 4 2200 and 3300 engines • The ignition is turned OFF by grounding the coils via the ignition switches. This is the reverse of most electrical systems: when the ignition switch is in the open (not connected) position the coil is LIVE and will fire.

  • Page 14: 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 15 Jabiru Aircraft Pty Ltd Installation Manual Gen 4 2200 and 3300 engines Figure 13: Example of engine wiring connections. Dated : Aug 2021 Page: 15 of 55 ISSUE...

  • Page 16: Instrumentation

    Electronic engine monitors can use the pulses from the alternator to measure engine RPM. Inductive pickup use. • The inductive pickup works with the VDO tachometer as stocked by Jabiru.. Detailed instructions on its installation are supplied by the instrument manufacturer. •...
  • Page 17 Figure 15. Inductive pickup to VDO Tachometer Connections Hall Effect Sender Installation • The inductive pickup works with the VDO tachometer as stocked by Jabiru and also with some electronic engine monitors. • The Sender senses the magnetic fields of the ignition magnets as they pass.
  • Page 18 Jabiru Aircraft Pty Ltd Installation Manual Gen 4 2200 and 3300 engines Figure 17: Hall effect sender mounting location on 3300 engine. Connect to Blue Wire of hall effect sender to terminal 8 Connect both Black wire of hall effect sender and aircraft earth to terminal 3.
  • Page 19 Oil Temperature Sender • The Oil Temperature Gauge uses an electric probe mounted in the base of the sump. Jabiru supplied oil temperature senders are recommended which will work with the Jabiru supplied analogue oil temperature gauges and many EMS systems. Jabiru also supply Dynon oil pressure senders for Dynon EMS.
  • Page 20 Jabiru Aircraft Pty Ltd Installation Manual Gen 4 2200 and 3300 engines Oil Temperature sender with wire connected Engine sump drain plug Figure 20. Oil Temperature Sender Dated : Aug 2021 Page: 20 of 55 ISSUE...
  • Page 21 The parts supplied by Jabiru are recommended. • If a single CHT gauge, Loom and Thermocouple sensor are purchased from Jabiru, these must be installed as per the instrument manufacturer’s directions. If the cable is too long it must be looped as many times as necessary and strapped behind the instrument panel.
  • Page 22 Jabiru Aircraft Pty Ltd Installation Manual Gen 4 2200 and 3300 engines • If a system that monitors all CHTs is used, it is recommended that the thermocouple is extended using thermocouple extension wire. • Ensure that wire is not chaffing on the fibreglass air duct or cooing fins.

  • 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 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 Gen 4 2200 and 3300 engines • To counteract RF noise, Jabiru Aircraft run shielded wiring on all radio and intercom wiring. In our experience, the “Earth Return” method of shielding (where the shield for the wire is also used to form the earth connection) does not work as well as the “Faraday Cage”...

  • Page 25: Fuel Supply System

    5.4 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.
  • Page 26 • 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 27 Because idle adjustments cannot accurately be made on the dynamometer (the testing equipment for every engine run before dispatch), some adjustment of the 7mm idle set screw may be required. A hot idle of around 900RPM (2200) or 800RPM (3300) is desirable. •...
  • Page 28 The shape of the taper of the needle controls the mixture at a given throttle setting. The needle used in Jabiru engines has 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 29: 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. 5.6 Fuel Lines •...

  • Page 30: Air Intake System

    Turbulence, swirl and sharp edges all affect the mixture metering system of the carburettor. • If a balance tube to the airbox is used (2200 only) the roughness of the induction between the balance port location and the carburettor can cause the mixture to be non-standard. A 3300 style cobra head with integrated balance port is recommended if 2200 mixture issues are encountered.
  • Page 31 Cobra head helps with mixture stability. Induction duct “Cobra Head” removes a sharp corner in SCAT tube prevents bunched SCAT hose. Figure 36. Typical “Cobra Head” Installation on a Jabiru Aircraft Dated : Aug 2021 Page: 31 of 55 ISSUE...

  • Page 32: Air Filter

    Jabiru is recommended. 6.4 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 33: Exhaust System

    Back pressure at Takeoff Performance – 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.

  • Page 34: Propeller And Spinner

    6 holes at both 101.6mm (4”) PCD and 111.12mm (4 3/8”) PCD (total of 12 holes). • The Jabiru Engine does not have a hydraulic pressure supply or a governor mounting pad required for a hydraulic constant speed or variable propeller. •...

  • Page 35: Engine Installation Procedure

    Air box to carburettor – shown in Figure 42. • Fit throttle cable to carburettor. 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 –...
  • Page 36 Jabiru Aircraft Pty Ltd Installation Manual Gen 4 2200 and 3300 engines Male rubber – Female rubber Washer engine engine mount engine mount mount spacer – Washer engine mount Cooling Duct Spring Propeller Rivet guide bush Lock wire – to...
  • Page 37 Jabiru Aircraft Pty Ltd Installation Manual Gen 4 2200 and 3300 engines Figure 40. Engine Mount Detail Dated : Aug 2021 Page: 37 of 55 ISSUE...

  • Page 38: Before First Start

    Jabiru Aircraft Pty Ltd Installation Manual Gen 4 2200 and 3300 engines Fuel line from firewall fitting to mechanical fuel pump Fuel line from mechanical fuel pump carburettor Figure 41. Fuel Connections General SCAT hose from hot air SCAT hose...

  • Page 39: Auxiliary Units

    Jabiru Aircraft Pty Ltd Installation Manual Gen 4 2200 and 3300 engines 11 Auxiliary Units 11.1 Vacuum Pump Drive Pad • The engine has a vacuum pump drive pad at the rear of the engine. This can be used to drive auxiliary devices such as a vacuum pump or secondary alternator.

  • Page 40: 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 41 Jabiru Aircraft Pty Ltd Installation Manual Gen 4 2200 and 3300 engines High pressure air entering Air from ram air ducts Balanced Flow cowl through ram air ducts and oil cooler mixing Cowl outlet sucks air out High temperature air of the cowls.

  • Page 42: Flow Visualisation

    Jabiru Aircraft Pty Ltd Installation Manual Gen 4 2200 and 3300 engines 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 43: Air Inlet And Ram Air Ducts

    Figure 46 - Position ram-air duct on engine • With the ram-air duct in place mark the position of all rocker cover capscrew hole (four marks for a 2200, 6 marks for a 3300) Remove the duct so as to avoid damage to the engine when drilling and sanding.
  • Page 44 Jabiru Aircraft Pty Ltd Installation Manual Gen 4 2200 and 3300 engines For the other holes, sand a circular relief in the duct using round tube wrapped in coarse emery cloth or garnet paper. The reliefs should be 12-14mm typically)
  • Page 45 Jabiru Aircraft Pty Ltd Installation Manual Gen 4 2200 and 3300 engines • Install the small tension spring on the tag at the front of the engine. Pull the spring up to the duct and mark the position where the duct is closest to install corresponding tag.
  • Page 46 Jabiru Aircraft Pty Ltd Installation Manual Gen 4 2200 and 3300 engines • With the ducts installed on the engine the front air dams are sized, trimmed and bonded into the ram-air cooling ducts. Place each dam in the front of the ducts so the upper lip is in contact with the cylinder and the...

  • Page 47: Oil Cooling

    • Figure 54 shows an 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 from engine vibrations –...

  • Page 48: 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 55 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. •...
  • Page 49 (Long Outlet). • Figure 57 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 50 Jabiru Aircraft Pty Ltd Installation Manual Gen 4 2200 and 3300 engines Fuselage cut away to give deeper & larger cowl outlet Figure 57. Cowl Outlet Geometry Figure 58. Outlet Restriction Caused By Flange On Lower Firewall Dated : Aug 2021...
  • Page 51 Jabiru Aircraft Pty Ltd Installation Manual Gen 4 2200 and 3300 engines Cooling System Testing and Evaluation • For new installations (new designs rather than new aircraft of a known type) the pressure drop across both Ram air ducts must be checked.

  • 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: Wherever possible the cowl outlets should be vertical openings with lips that come close to the propeller –...

  • Page 53: Slow Speed 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 B - Jabiru Aircraft Installation

    • 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. • Poor installations will result in poor performance, so installations must be designed referencing the information given in the main body of this manual.

  • Page 55: Engine Installation Checklist

    Jabiru Aircraft Pty Ltd Installation Manual Gen 4 2200 and 3300 engines 14 Engine Installation Checklist ENGINE MOUNT AIR INDUCTION SYSTEM “Cobra Head” fitted Positions engine for correct aircraft CG Positions engine for correct thrust line Duct to carburettor as direct as possible...

This manual is also suitable for:

3300

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