Jabiru 3300 Instruction And Maintenance Manual
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Jabiru 3300 Instruction And Maintenance Manual

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INSTRUCTION AND MAINTENANCE MANUAL
FOR
JABIRU 3300 AIRCRAFT ENGINE
This Manual has been prepared as a guide to correctly operate, maintain and
service the Jabiru 3300 engine.
Should you have any questions or doubts about the contents of this manual, please contact
Jabiru Aircraft Pty Ltd.
Page No: 1
Issue No: 1
Date: 031100
Issued By: PJA

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Summary of Contents for Jabiru 3300

  • Page 1 JABIRU 3300 AIRCRAFT ENGINE This Manual has been prepared as a guide to correctly operate, maintain and service the Jabiru 3300 engine. Should you have any questions or doubts about the contents of this manual, please contact Jabiru Aircraft Pty Ltd.

  • Page 2: Table Of Contents

    Table of Contents Paragraph Description Page Table of Contents List of Amendments Description Denomination of Cylinders Technical Data Dimensions & Weights Normal Equipment Performance Data Fuel Consumption Fuel & Lubricant Cooling System Operating Speeds & Limits Performance Graphs Operating Instructions Pre-Start Checks Starting Procedure Warm-Up Period, Ground Test...
  • Page 3 Service & Repair Engine Overhaul and TBO Engine Removal Procedure Disassembly 3300 Engine Overhaul 1 Subassembly A - Crankshaft Prop Mount and Con rods 2 Subassembly B - Crankcase and Camshaft 3 Subassembly C - Pistons, Cylinders and Cylinder Heads 4 Subassembly D - Sump and Oil Pump 5 Subassembly E - Flywheel and Ignition Coils &...

  • Page 4: List Of Amendments

    List of Amendments Page Amendment Date Issue Page No: 4 Issue No: 1 Date: 031100 Issued By: PJA...
  • Page 5 Pressure Compensating Carburettor (Bing Type 94/40) It is said that "aircraft are designed around available engines". Jabiru believe that the Jabiru range of very light engines will now offer new opportunities for light aircraft designers, to develop a new generation of light aircraft.
  • Page 6 The ignition coils are also sourced from Honda, but are modified by Jabiru for their own particular application. An integral alternator using rare earth magnets, provides alternating current for battery charging and electrical accessory drive. The alternator is attached to the flywheel and is driven directly by the crankshaft.
  • Page 7 The engine is fitted with a 1 kw starter motor, which is also manufactured by Jabiru and provides very effective starting. The engine has very low vibration levels, however it is also supported by four large rubber shock mounts attached to the engine mounts at the rear of the engine.

  • Page 8: Denomination Of Cylinders

    1.1 Denomination of Cylinders Page No: 8 Issue No: 1 Date: 031100 Issued By: PJA...

  • Page 9: Technical Data

    Camshaft driven diaphragm type Starting System: Electric 12 V / 1.0 kW 2.3 Performance Data Maximum 90 kW (120 hp) @ 3300 RPM ISO STD Conditions 2.4 Fuel Consumption Fuel Consumption @ Takeoff/Max Continuous Rating 28.5 litres/hr 2.5 Fuel and Lubricant Fuel: AVGAS 100 LL &...

  • Page 10: Cooling System

    The required pressure drop across the cylinders at 1.3 Vs in take off configuration is 4.3 cm (1.7") water gauge, minimum. 2.7 Operating Speeds and Limits Maximum continuous speed 2750 RPM Maximum 3300 RPM ISO STD Conditions Idle Speed: 650 RPM Oil Pressure: Normal Operations 220 kPa (31 psi) 525 kPa (76 psi)

  • Page 11: Performance Graphs

    3.0 PERFORMANCE GRAPHS Page No: 11 Issue No: 1 Date: 031100 Issued By: PJA...

  • Page 12: Operating Instructions

    4.0 OPERATING INSTRUCTIONS To ensure that the engine operates reliably, carefully observe all of the operating & maintenance instructions. 4.1 Pre-Start Checks Daily Checks (See Paragraph 5.1) Move throttle position to FULL & check for ease of movement over the entire range. 4.2 Starting Procedure Fuel Tap OPEN...

  • Page 13: Engine Stop

    & with choke for a cold engine. Note: Engine cools quickly with propeller stopped in flight. Choke will therefore normally be needed to restart. Addition} Early Operation of Engine JABIRU ENGINE NOTES NEW ENGINE NOTES: This engine has been ground run to a specific run in program and is ready for flight.
  • Page 14 2. Add 3.2 Litres (without oil cooler) 3.4 Litres (with an oil cooler) 3. Avoid prolonged ground running at elevated RPM. Engine can be over heated, remember air ducts are designed for in flight cooling. NOTE: remove ALL plastic bungs on engine. EXHAUST (4) CARBY (2) OIL VENT (1) FUEL PUMP (1) 4.
  • Page 15 13. When you change oil from the “run in” type to the “normal” oil at or around 25 hrs replace oil filter. You may want to cut the filter open for inspection. It is usual in Jabiru engines to find a small amount of aluminium but definitely no metal. If bearing metal is present contact the Jabiru Service Department.
  • Page 16 Easiest method of setting valves requires you to pull the prop until exhaust valve on No.1 cylinder is fully depressed. Note the O’clock position. Rotate prop 360 and adjust valve. (This puts the cam and lifter at 180 to the peak lift). Repeat for each valve. Heads and valves should be done at least twice at 5 hrs and 10 hrs on a new engine.
  • Page 17 Jabiru engines. 2. FLICKING OF OIL PRESSURE GAUGE It is not uncommon for the Jabiru engine to display flicking of the needle pointer for brief periods but still within normal operating regions. If it continues, check continuity of sender lead and or possible sender change.
  • Page 18 8. LIMITATIONS Warranty notes follow. Jabiru recommend TBO of 1000 hrs. A guaranteed fixed price overhaul exists through the Jabiru factory. Warranty is 200 hours or 12 months which ever comes first.

  • Page 19: Checks On Engine & Installation

    5.0 CHECKS ON ENGINE & INSTALLATION 5.1 Daily Checks * Ensure free movement of throttle & choke cables. * Check Oil Level, replenish if necessary. Oil level should be between the MAX & MIN marks - but must never be below the MIN mark. Before long periods of operation, ensure that the level is at least at the mid position.

  • Page 20: Check After Initial 25 Hours

    After the initial 25 hours, check in accordance with para. 5.3. After 50 hours of operation, check in accordance with para. 5.4 & thereafter after each 50 hours of operation. After 100 hours of operation, check in accordance with para. 5.5 and thereafter after each 100 hours of operation.

  • Page 21: Hours Check

    * Check clearance on throttle valve shaft. If radial clearance exceeds 0.5mm (0.020"), repair carburettor. The overhaul work must be carried out to Jabiru specifications at an approved aeronautical service facility or by an approved Jabiru Service Centre. If necessary, changes to the TBO Limit due to operational experience, will be announced by Jabiru in a Service Bulletin.

  • Page 22: Engine Preservation

    5.7 Engine Preservation The following procedures assume that the engine is installed in a Jabiru LSA airframe. For other aircraft types, refer to the manufacturer's service manual. If the engine is not fitted to an airframe, ignore those items referring to the airframe.
  • Page 23 NOTE: Use Shell Aero fluid 2UN (MIL-C-6529C Type 1) Corrosion Preventive Concentrate or similar engine preservative. CAUTION Ensure that the Master and Ignition Switches are OFF! 3. Install spark plugs and connect leads. 4. Seal exhaust pipes. Attach a red streamer to each seal. DO NOT seal fuel tank breather.

  • Page 24: Operation In Winter

    9. If returning to service after indefinite storage, fill fuel tank with correct grade of fuel. 10. Check fuel tank and fuel lines for moisture and sediment. Drain enough fuel to eliminate any moisture and sediment. 11. Check fuel tank breather is clear. 12.
  • Page 25 Re 2) Carburettor icing due to humidity may occur in the carburettor venturi & leads to performance loss due to changes in the mixture. The only effective remedy is to preheat the intake air by use of the Carburettor Heat Control.

  • Page 26: Maintenance

    6.0 MAINTENANCE 6.1 Lubrication System Oil Change, Oil Filter Change, Visual Check for Leaks. * Drain the oil while engine is still warm. * Change the oil filter at 100 hour inspection. * Fill with oil. Capacity is 3.5 litres (3.69 US Quarts) * Check oil level.

  • Page 27: Spark Plugs

    If readings are below 6 bar (90 psi) a check of the pistons, cylinders, valves & cylinder heads must be undertaken. Alternatives: * Pressure loss or leakage tester eg SUN or BOSCH tester; max. allowable pressure loss is 25%. * Checking by commonly used pressure difference method; place orifice of 1 mm ID and 3mm length between the two pressure gauges.

  • Page 28: Tappet Adjustment

    6.8 Tappet Adjustment Tappets must be adjusted to: Inlet 0.254mm (.010") Exhaust 0.254mm (.010") Adjust the tappets when the engine is cold. Head torqued to 24 ft lb. when cold. Carry out this adjustment after five hours of operation and again after ten hours of operation. At the 25 hour inspection this is done again.

  • Page 29: Service & Repair

    These are carried out only by the manufacturer, Jabiru Aircraft Pty Ltd or by a specifically approved Jabiru Engine Service Centre (contact Jabiru for details). The engine must be sent in a complete state, with logbook, to Jabiru (or the Approved Service Centre) after reaching the TBO limit.

  • Page 30: Engine Removal Procedure

    ENGINE REMOVAL PROCEDURE Operation Tools Remove Spinner and Propeller Phillips Screwdriver 1/2" Socket 1/2" Spanner If fitted, remove Carby Heat hose from Hot Box Muffler Screwdriver Remove Air Inlet Hose from Carburettor and blank Screwdriver off Carburettor and Air Cleaner 2 Plugs Disconnect Throttle Cable Long Nose Pliers...

  • Page 31: Disassembly

    ENGINE DISASSEMBLY Operation Tools Mount Engine on an engine stand in vertical position Remove Spark Plugs Spark Plug Socket Remove Oil Pressure Sensor 17mm Spanner Remove Oil Filter Oil Pressure Valve may be removed by removing Snap Ring Pliers snap ring (1) Extract Valve Seat (1), Valve (1), Spring (1) Remove Oil Pump Assembly (Housing, Rotor, Stator 1/4"...
  • Page 32 Remove Sump 3/16" Allen Key Remove Exhaust and Induction Pipes 3/16" Allen Key Remove Tappet Covers 3/16" Allen Key Remove Rocker, Rocker Shafts and Push Rods 3/16” Allen Key Remove Cylinder Head 1/4" Allen Key 1/2" Socket Remove Push Rod Tubes Remove Cylinder 7/16"...
  • Page 33 Remove Thrust Washers (front and rear) - 2 without tang on right half case - 2 with tang on left half case Note - visually check for marks or scratches - keep matched to their seats Remove Main Bearing Inserts (16) Note - visually check for marks or scratches - keep matched to seats...

  • Page 34: 3300 Engine Overhaul

    3300 ENGINE OVERHAUL Inspection and Assembly of Sub-Assemblies Sub-Assembly A - Crankshaft, Prop Mount and Con Rods. Sub-Assembly B - Crankcase and Camshaft. Sub-Assembly C - Pistons, Cylinders and Cylinder Heads. Sub-Assembly D - Sump and Oil Pump Sub-Assembly E - Flywheel, Ignition Coils and Alternator...

  • Page 35: Subassembly A - Crankshaft Prop Mount And Con Rods

    Jabiru 3300 Component Inspection and Assembly Procedure 7.4.1 Sub-Assembly A - Crankshaft, Prop Mount and ConRods Remove welsh plugs from crankshaft Clean conrods and crankshaft Note - Make sure all old loctite is removed from threads Strip paint off prop flange and crankshaft.
  • Page 36 Drawing 9478083 Clean and visually inspect camshaft. Measure journal diameter. Measure lobe lift. Drawing 9433064 Inspect fuel pump lobe for wear. Spray camshaft rear gears and bolts with Loctite 7471 Primer. Fit gears and new bolts. Use Loctite 620 torque to 12 ft lbs & Lock Wire. Fit end welsh plug.
  • Page 37 Drawing 9448064 Stage Inspection by 2nd person of Sub-Assembly Page No: 37 Issue No: 1 Date: 031100 Issued By: PJA...

  • Page 38: Subassembly B - Crankcase And Camshaft

    3300 Component Inspection and Assembly Procedure 7.4.2 Sub-Assembly B – Crankcase and Camshaft Clean crankcase, remove old Loctite and clean oil gallerys. Visually inspect crankcase. Fit inner stud O Rings with a small smear of rubber grease. Inspect all studs for tightness threads and stretching Check oil suction pipe for security, replace o ring.
  • Page 39 Drawing 9441064 Make spacers as per drawing. Drawing 9442064 Join crankcase halves. Put through studs in case. Note the cylinders by themselves can be used as spacers. It is just a bit harder to measure the main tunnels. Fit old nuts and torque to 40 NM (30 ft/lbs) in two stages. Measure main tunnel and cam tunnel and record in build sheet.

  • Page 40: Subassembly C - Pistons, Cylinders And Cylinder Heads

    Jabiru 3300 Component Inspection and Assembly Procedure 7.4.3 Sub-Assembly C - Pistons, Cylinders and Cylinder Heads Cylinder Head Clean Up Clean oil off heads. Dip heads in a cold dip solvent (i.e. Redik dkt Degreaser - Decarboniser - Paint stripper) as per manufactures instructions to remove all carbon deposits.
  • Page 41 Drawing 9446064 Mount head up and cut seats as per drawing. Drawing 9445064 Note - When cutting seats cut enough to clean up but try to remove as little as possible. This will give maximum number of overhauls on heads. Page No: 41 Issue No: 1 Date: 031100...
  • Page 42 Use ground and serviceable valves to check seat contact. Note - If machine has a vacuum tester, vacuum test valves. Heads of valves must be above the level of the combustion chamber. If they are below, the valve seats and valves must be replaced. Measure valve stem for wear.
  • Page 43 Drawing 9443064 Inspect valve spring seats, valve spring retainers and valve collets. Replace any that show signs of wear. Lube valves well. Install valves, valve spring seats, springs, retainers and collets. Drawing 9447064 Install Push Rod Tube O'Rings with a small amount of rubber grease. Page No: 43 Issue No: 1 Date: 031100...
  • Page 44 Rocker Assembly Disassemble and clean off all carbon. Inspect rocker tip for wear. Replace any with excessive wear. Measure bushes and record on build sheet. If over service limits, replace. Drawing 9449064 Clean off old Loctite from rocker bore. Press in Bushes. These are a 15mm wide glasier type bush. Measure rocker shafts for wear and inspect for scratching, scuffing etc.
  • Page 45 Drawing 9449064 Put capscrew through clamp hole and check rocker end float. Must be 0.1 to 0.4mm (0.004" to 0.010"). Face off outside bushes to adjust. Clean up, oil well and reassemble. Cylinders Clean and visually inspect. Mount cylinders in honing machine by base and hone with Sunnen mm 33-J85 Stone Drawing 9436064 Page No: 45...
  • Page 46 Oil Rings and pistons and bore well. Fit front piston pin circlip. (vi) Fit cylinder base O Ring. (vii) Seal up in plastic bags ready for final assembly. Jabiru 3300 Component Inspection and Assembly Procedure Page No: 46 Issue No: 1 Date: 031100 Issued By: PJA...

  • Page 47: Subassembly D - Sump And Oil Pump

    7.4.4 Sub-Assembly D - Sump and Oil Pump Sump Clean sump and remove all gasket eliminator. Inspect oil pick up. Remove induction O Rings. Inspect carburettor coupling replace if it is damaged or showing signs of deterioration. Note: It is very important that the carburettor and coupling are free of oil.
  • Page 48 Page No: 48 Issue No: 1 Date: 031100 Issued By: PJA...

  • Page 49: Alternator Operation

    Jabiru 3300 Component Inspection and Assembly Procedure 7.4.5 Sub-Assembly E - Flywheel & Ignition Coils & Alternator & Alternator Operation Flywheel Inspection Inspect ring gear for damaged teeth Use a spring scale and a prop cap screw as per drawing to test ignition magnet strength.
  • Page 50 Ignition Coil Inspection Using a multimeter measure the primary resistance (from the earth terminal to the iron core). It should be 0.8 R to 1.0 R. Drawing 9439064 Measure the secondary resistance (from the high tension lead to the iron core) it should be between 5.9 KR to 7.1 KR.
  • Page 51 Use multimeter to test resistance of windings. Resistance should be 0.5 to 1.1 R. Use multi meter to test resistance to ground. Resistance should be infinite. Permanent Magnet Alternator (PMA) Operation (1) Master Switch (3) Main Bus Bar (5) Battery (7) Regulator (2)Voltage Reference Line (4) Fusible Link...
  • Page 52 Page No: 52 Issue No: 1 Date: 031100 Issued By: PJA...
  • Page 53 2. Regulator The regulator performs rectification and voltage regulation. The regulator converts A.C. into D.C. which flows through the power consuming circuits and the battery, and also charges the battery. If however, the battery voltage exceeds a certain level, the D.C. is cut off from the charging circuit to prevent over charging.

  • Page 54: Subassembly F - Gear Case

    Jabiru 3300 Component Inspection and Assembly 7.4.6 Sub-Assembly F - Gear Case Remove distributor shaft seals and rotor seal and discard. Inspect Distributor shaft posts for signs of leaking. Note: If there is no signs of leaking don't disassemble. But if it is leaking disassemble and clean off old master gasket.

  • Page 55: Carburettor Operation

    7.4.7 Sub-Assembly G - Fuel Pump and Carburettor and Carburettor Operation Fuel Pump The fuel pump on the 3300 engine is replaced as a complete unit at overhaul. It can be inspected for faults by removing the top half. Things to look for are:...
  • Page 56 selected so that foreign bodies greater than 0.1mm are filtered out and the fuel supply is not impeded to too great an extent. The float needle (42) contains a spring-loaded plunger which contacts the float hinge. This absorbs vibrations on the float (40). In addition the float needle (42) is connected to the float hinge by the retaining spring (43) to prevent it from moving between float and valve seat and thus reducing the fuel supply.
  • Page 57 The plunger (13) is located centrally in the cover (20) which is secured to the carburettor housing by screws (21). The diaphragm (16) is connected to the plunger (13) by a retaining ring (17) and four screws (18) and washers (19) each. The vacuum in the choke tube acts on the top of the diaphragm and the plunger via a bore (U) in the plunger (13) and attempts to lift the plunger against its own weight and spring (22).
  • Page 58 IDLING SYSTEM During idling and low-load running the throttle valve (23) is closed to such an extent that the air flow underneath the plunger (13) no longer forms a sufficient vacuum. The fuel is then supplied via an auxiliary system, the idling system, which consists of the idling jet (5), the idling air jet (LLD) - no spare part - and the mixture control screw (7) which is sealed off against the carburettor housing by the rubber ring (9) and secured by spring (8) to prevent it from becoming slack.
  • Page 59 mixture bypasses the main carburettor to flow into the intake manifold of the engine direct. During starting the throttle valve has to be closed to make sufficient vacuum available for the starting carburettor. When the engine is at a standstill and also during normal operation the fuel level in the float chamber compartment incorporating the riser will be the same as in the rest of the float chamber.
  • Page 60 Disassemble carburettor Using over haul kit replace all components Record jet size Record needle position Reassemble carburettor Page No: 60 Issue No: 1 Date: 031100 Issued By: PJA...
  • Page 61 Jabiru 3300 Component Inspection and Assembly 7.4.8 Sub-Assembly H - Final Assembly Crankcase Joining Photocopy Degree Wheel (increase by 226% to bring to full size) then glue to stiff cardboard and cut out. Drawing 9427063 Page No: 61 Issue No: 1...
  • Page 62 Stand crankshaft (Sub assembly A) up vertically, mounted on the prop flange as per drawing. Drawing 9478083 Page No: 62 Issue No: 1 Date: 031100 Issued By: PJA...
  • Page 63 Apply Loctite 515 to left side of the crankcase. Fit cam shaft to left side Inspect Bearing shell in position Loctite on all areas O Rings in Piston/Cylinder Assembly complete Thrust washers in position Dowels in Lifter are in with moly grease on faces You will need 1) An extra person 4 7/16 Ring Open End spanners...
  • Page 64 Torque up by hand lightly. Turn engine so that No. 3 & 4 conrod are out. Repeat procedure on No. 3 & 4. Repeat for conrod No. 5 & 6. Torque to 15 ft lbs then 30 ft lbs. Note: Keep an eye on the amount of thread through each nut. Both sides should have approx 2 turns hanging out.
  • Page 65 Zero the indicator at T.D.C. Fix a wire pointer of the oil seal bolt hole and roughly set to T.D.C. Turn 1/4 turn backwards then forward until the piston is 2mm from T.D.C. Note degrees. Turn past T.D.C. to 2mm down from T.D.C. Note degrees. Add two together then divide by 2 and set pointer at this (with piston down 2mm) Note: The crank is mounted to turn the engine in direction of...
  • Page 66 Note: Make sure outside of tubes are smooth or it will damage the O Rings. Oil Push rods and fit. Note: Make sure ball end of push rod is in the socket of the lifter. It also helps if the lifter is on the base circle of the lobe. It is a good ides to fit heads No.
  • Page 67 Drawing 9430064 Page No: 67 Issue No: 1 Date: 031100 Issued By: PJA...
  • Page 68 Drawing 9431064 Note: When gear case goes on Make sure No. 1 is 25 o before T.D.C. compression. Both valves should be seated. The rotors point to the No. 1 position on the rotor caps. Fit cap screws with loctite 242 and torque. Fit flywheel so that magnets line up to where coils are positioned Note: The small hole in the flywheel will line up with the hole in the crankcase.
  • Page 69 Fit Carburettor assembly Note: It is very important to make sure hose clamp is at the outside end of coupling, the coupling and carby are free of oil and the carburettor goes fully into coupling. Fit Fuel Pump Assembly Note: Use loctite 242 on cap screws. Use molybdenum disulphide grease on push rod.

  • Page 70: Run In

    The Jabiru engine is run in on a DYNOMOMETER and cooled with fan driven air. In the absence of a DYNO controlled run, engines can be run in in the airframe. Very large air ducts must be constructed to get adequate airflow for cooling in the static situation.
  • Page 71 Engine Installation Operation Tools Fit engine to engine mount Torque engine mount bolts up 7/16 Tube Socket 7/16 Ring Open End Spanner Fit muffler (if not already fitted) and fit carburettor 3/16 Ball End Allen heat muff and hose. Connect left and right ignition coils leads Connect Tacho sender Connect exhaust gas temp (if fitted) Connect cylinder head sender...

  • Page 72: Prop Strike Inspection

    If an engine stoppage due to force is not recorded in the logbook and not advised to Jabiru, the liability for all subsequent and consequential damage will remain with the owner. This applies to both prior to and after engine overhaul.
  • Page 73 * Run In Programme * Post Run Checklist Photocopy all documents and use photocopies to fill in. When complete, fax to Jabiru Aircraft so all documents can be kept up to date. This helps us provide a better service to our customers if we know what our engine is in and what has been done to it.
  • Page 74 Jabiru Aircraft Pty Ltd WARNING This engine has been run in and is ready for flight. DO NOT GROUND RUN THIS ENGINE This engine has been inhibited and the oil system drained. Before first start of new engine, remove 1 spark plug from each head.
  • Page 75 Jabiru 3300 – Component Assembly Procedure Subassembly A – Crankshaft, Propeller Mount Flange and Conrods Details Sign Sign Date Inspect for Burrs, Oil Holes, Chamfers; Clean Crankshaft, Conrods and Propeller Mount Plate Inspect Oil Holes and Insert Welch Plugs Measure Crankshaft (refer to...
  • Page 77 Jabiru 3300 – Component Assembly Procedure Subassembly B – Crankcase and Camshaft Assembly Details Sign Date Inspect case, deburr, clean, check oil holes Fit inner stud “O” rings Fit all studs Fit outer oil suction and conrod welch plugs Fit oil relief valve, oil pressure sender and...
  • Page 79 Jabiru 3300 – Component Assembly Procedure Subassembly C – Pistons, Cylinders and Cylinder Heads Details Sign Date Clean and deburr all parts Record all measurements Install pushrod tube “O” Rings Check valve seats, fit spring retainers, install valves Fit intake pipes to heads Complete rocker shafts and rocker assemblies Fit cylinder base “O”...
  • Page 80 I hereby certify that the above listed parts conform with the dimensions, have been engraved, and installed as recorded. Signed ____________ Date ____________ For Jabiru Aircraft Pty Ltd Certificate of Approval #3501 Page No: 80 Issue No: 2 Date: 031100...
  • Page 81 Jabiru 3300 – Component Assembly Procedure Subassembly D - Sump Details Sign Date Deburr and wash sump, inspect for defects Fit oil temperature sender I hereby certify that the subassembly has been completed using the approved procedures and data; and is fit for installation.
  • Page 82 Component Register and Parts Inspection Record Subassembly D – Sump Batch ____________ Serial No. ____________ Date ____________ Description Part No Batch Item Details Sump 4635072 I hereby certify that the above listed parts conform with the dimensions, have been engraved, and installed as recorded. Signed ____________ Date ____________ Page No: 82 Issue No: 2...
  • Page 83 Jabiru 3300 – Component Assembly Procedure Subassembly E – Flywheel and Ignition Coils Details Sign Date Deburr and Clean Fit magnets using silastic Using loctite 620 fit the ring gear Fit the alternator rotor Fit the plugs to the ignition coils I hereby certify that the subassembly has been completed using the approved procedures and data;...
  • Page 84 I hereby certify that the above listed parts conform with the dimensions, have been engraved, and installed as recorded. Signed ____________ Date ____________ For Jabiru Aircraft Pty Ltd Certificate of Approval #3501 Page No: 84 Issue No: 2 Date: 031100...
  • Page 85 Jabiru 3300 – Component Assembly Procedure Subassembly F – Gear Case Details Sign Sign Date Deburr, clean and inspect all of the gears Measure the shaft post internal diameters and the distributor shaft diameters Using loctite 515 fit the shaft posts to the gear...
  • Page 86 I hereby certify that the above listed parts conform with the dimensions, have been engraved, and installed as recorded. Signed ____________ Date ____________ For Jabiru Aircraft Pty Ltd Certificate of Approval #3501 Page No: 86 Issue No: 2 Date: 031100...
  • Page 87 Jabiru 3300 – Component Assembly Procedure Subassembly G – Fuel Pump and Carburettor Details Sign Date Fuel Pump – Disassembly Drill hole in spacer and insert breather Final assembly checked for correct flow Drill and tap upper half for 90o elbow and fit...
  • Page 88 Jabiru 3300 – Component Assembly Procedure Subassembly H – Final Assembly Details Sign Sign Date Apply Loctite 515 to crankcase halves; lubricate where necessary Locate camshaft and crankshaft in crankcase half Stage 3 Stage Inspection Pre-joining Crankcase Locate crankcase half over crankshaft and...
  • Page 89 Page No: 89 Issue No: 2 Date: 031100 Issued By: PJA...
  • Page 91 Noises Manifold Sealing Oil Pressure and Temp Prop Tacho Check alternator Charging Voltage Jabiru 3300 – Engine Post Run Procedure SIGN DATE 1. Heads retorqued 32 Nm (24 ft/lb). Valves Adjusted. 2. Check induction/exhaust bolts. 3. Any changes to be made.

  • Page 92: Table Of Lubricants

    8.0 TABLE OF LUBRICANTS Use only oils of registered brands meeting the specification detailed at para. 2.5. Acceptable engine lubricating oils: Run in Period -17 o C to 25 o C 15 o C to 35 o C Above 35 o C Outside Air Temp Normal Operations W100...
  • Page 93 9.0 TORQUE SPECIFICATION FOR BOLTS & NUTS Part Nom. Dia (mm) Torque nm (ft.lbs) Spark Plugs 12mm 11 (8) Cylinder Head Bolts 5/16" 34 (24) Crankcase Main Studs 3/8" 40 (30) Flywheel/Gear Bolts 1/4" 20 (15) 5/16” 24 (18) Crankshaft Prop Flange Cap Screws 3/8"...

  • Page 94: Prescribed Sealants And Primers

    PRESCRIBED SEALANTS AND PRIMERS Item Sealant Main Bearing Studs Loctite 620 Conrod Bolts Loctite 620 Oil Pump Bolts Loctite 243 Sump Plate Bolts Loctite 243 Engine Mount Bolts Loctite 243 Gearbox Cover Bolts Loctite 243 Spark Plugs NGK D9EA* Spark Plug Lubricant Loctite “Nickel Anti-Seize”...

  • Page 95: New Tolerances

    NEW TOLERANCES (All Dimensions are in Millimetres) Crankshaft Mains Journals 47.938 to 47.918 Big Ends Journals 44.998 to 45.000 Thrust Face 56.95 to 57.05 Crankcase Main Bearings 47.975 to 48.005 Cam Bearings 20.00 to 20.020 Cam Thrust Face 14.95 to 15.10 Lifter Bores 9.000 to 9.050 Crank Thrust...

  • Page 96: Maximum Allowable Clearances (Wear Limits)

    MAXIMUM ALLOWABLE CLEARANCES (Wear Limits) (All Dimensions are in Millimetres) Mains 0.10 Big Ends 0.10 Little Ends 0.03 Camshaft Journals 0.08 Crank End Float 0.80 Cam End Float 0.50 Lifter - Crankcase 0.12 Piston/Cylinder 0.15 Ring Side Clearance 0.05 Pin/Piston 0.04 Ring End Gap 1.20...
  • Page 97 ELECTRICAL SYSTEMS SPECIFICATIONS (All Dimensions are in Millimetres) Ignition Primary Resistance 8.8R to 1.0R Secondary Resistance 5.9kR to 7.1kR Coil Gap 0.27 Plug Gap 0.55 Ignition Harness Resistance 6.7kR per 300mm of length Alternator Coil Resistance 0.2 to 0.3 at 20 Coil Earth Resistance Infinite A.C.

  • Page 98: Trouble Shooting

    10.0 TROUBLE SHOOTING 10.1 Engine Won't Start Possible Cause Remedy Ignition OFF Switch ON Spark plug gap too large Adjust gap to 0.6-0.7mm or renew plugs Closed fuel tap or clogged filter Open tap, renew filter, check fuel system for leaks No fuel in tank Refuel Wrongly connected high tension leads...

  • Page 99: Engine Runs Too Hot, Oil Temperature Above 110 O C (230 O F)

    10.4 Engine Runs Too Hot - Oil Temperature Above 110 o C (230 Possible Cause Remedy Too much oil in crankcase Check oil level & adjust if necessary Low oil level Check oil level & add oil if necessary Poor quality oil Oil change, use specified oil Clogged oil filter Change filter...

  • Page 100: Excessive Oil Consumption

    10.8 Excessive Oil Consumption Possible Cause Remedy 1) Worn, broken or wrongly fitted piston rings Repair/engine overhaul necessary 2) Poor oil quality Oil change, use specified oil 3) Worn valve guides Repair of cylinder head necessary 4) Oil leaks Seal leaks 10.9 Knocking Under Load Possible Cause Remedy...
  • Page 101 Warranty repairs do not extend the original warranty. Due to the substantial number of problems that can arise due to installation errors, JABIRU shall not be liable for any labour and/or service charges for removal, reinstallation and adjustment which are the responsibility of the buyer and are not covered by this Warranty.
  • Page 102 JABIRU product or in connection with the supply of any JABIRU product, which is at variance with any written statement assertion or undertaking on any of these subjects given or made by JABIRU in its published sales literature, and the company does not accept any such unauthorised action.
  • Page 103 JABIRU WARRANTY: CLAIM FORM FROM:__________________________________DATE:____________ ENGINE PARTS: AIRFRAME PARTS: ENGINE NUMBER:_________________ AIRFRAME KIT NUMBER:__________ PART NUMBER:___________________ TOTAL HOURS:____________________ OWNER:__________________________ PREVIOUS OWNER:________________ PART DESCRIPTION:___________________________________________________ _______________________________________________________________________ CLAIM:________________________________________________________________ FAULTY GOODS RETURNED: YES COURIER Co. REF NO:__________ ALL GOODS THAT ARE BOXED AND HAVE TO PASS THROUGH CUSTOMS...

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