Jabiru 2200 Installation Manual
  1. Manuals
  2. Brands
  3. Jabiru Manuals
  4. Engine
  5. 2200
  6. Installation manual

Jabiru 2200 Installation Manual

Hide thumbs Also See for 2200:
Table of Contents

Advertisement

Quick Links

Download this manual See also: Maintenance Manual
INSTALLATION MANUAL
FOR
JABIRU 2200 AIRCRAFT ENGINE
This Manual has been prepared as a guide to correctly install the Jabiru 2200 engine into an
airframe.
Should you have any questions or doubts about the contents of this manual, please contact
Jabiru Aircraft Pty Ltd.
Applicable to Jabiru 2200cc Enginers, S/No. 2068 Onwards (Hydraulic Lifter Type)

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the 2200 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Jabiru 2200

Summary of Contents for Jabiru 2200

  • Page 1 INSTALLATION MANUAL JABIRU 2200 AIRCRAFT ENGINE This Manual has been prepared as a guide to correctly install the Jabiru 2200 engine into an airframe. Should you have any questions or doubts about the contents of this manual, please contact Jabiru Aircraft Pty Ltd.

  • Page 2: Table Of Contents

    Auxiliary Units ______________________________________________________ 27 Appendix A – Wiring Diagrams _________________________________________ 28 Appendix B – Supplemantay Information _________________________________ 29 Appendix C – Jabiru Engine Installation Tips _____________________________ 30 Appendix D _________________________________________________________ 33 Typical Installation – Jabiru Engine _____________________________________ 35 Dated : March 2006...
  • Page 3 Jabiru Aircraft Pty Ptd Installation Manual Jabiru 2200 Aircraft Engine Table of Figures Figure 1. Drawing 9404041/1 Engine Dimensions ....................... 9 Figure 2. Cylinder Firing Order ........................... 10 Figure 3. Engine Mount Point Locations ........................12 Figure 4 Engine Mount Assembly ..........................13 Figure 5.

  • Page 4: List Of Effective Pages

    Jabiru Aircraft Pty Ptd Installation Manual Jabiru 2200 Aircraft Engine List of Effective Pages The dates of issue for original & revised pages are: Page Revision Date Page Revision Date 29/6/05 29/6/05 29/6/05 29/6/05 29/6/05 29/6/05 29/6/05 29/6/05 29/6/05 29/6/05...

  • Page 5: Description

    Jabiru Aircraft Pty Ptd Installation Manual Jabiru 2200 Aircraft Engine Description Model All Jabiru 2200 Engine Models from S/No 2068 on. Details 4 Stroke 4 Cylinder Horizontally Opposed 1 Central Camshaft Push Rods Over Head Valves (OHV) Hydraulic Valve Lifters with Automatic Adjustment...

  • Page 6: Specifications

    • International Standard Atmospheric conditions at sea level. • Aircraft service equipment drives unloaded. (Vacuum Pump not fitted) • Full rich fuel/air mixture. • Maximum cylinder head temperature. • Standard Jabiru air filter and cold air. • Standard exhaust muffler. 3.2.1 Engine Ratings •...

  • Page 7: Operating Limitations

    Jabiru Aircraft Pty Ptd Installation Manual Jabiru 2200 Aircraft Engine Operating Limitations Continuous 3300 RPM / Full Throttle Recommended Cruise: 2750 RPM – 3100 RPM Engine Cooling Maximum Cylinder Head Temperatures measured under exhaust spark plug. Maximum Peak Temperature 200ºC (392°F) Continuous Operation 180ºC (356°F)
  • Page 8 Jabiru Aircraft Pty Ptd Installation Manual Jabiru 2200 Aircraft Engine 4.5.3 Pressure • Normal Operations: Min 220 kPa (32 psi) Max 525 kPa (76 psi) • Idle: Min 80 kPa (12 psi) • Starting & Warm Up: Max 525 kPa (76 psi)

  • Page 9: Dimensions

    Jabiru Aircraft Pty Ptd Installation Manual Jabiru 2200 Aircraft Engine Dimensions Figure 1. Drawing 9404041/1 Engine Dimensions Dated : March 2006 Page: 9 REVISION \\Gateway\library\files\engine_manuals\2200_engine_manuals\Hydraulic_Lifters\Working copies\HL_Installation_Manual_2200_Rev_0.doc Print Date: 3/8/2006 1:56:00 PM...

  • Page 10: Denomination Of Cylinders

    Jabiru Aircraft Pty Ptd Installation Manual Jabiru 2200 Aircraft Engine Denomination Of Cylinders Figure 2. Cylinder Firing Order Cylinder Firing Order: 1 – 3 – 2 – 4 Dated : March 2006 Page: 10 REVISION \\Gateway\library\files\engine_manuals\2200_engine_manuals\Hydraulic_Lifters\Working copies\HL_Installation_Manual_2200_Rev_0.doc Print Date: 3/8/2006 1:56:00 PM...
  • Page 11 Jabiru Aircraft Pty Ptd Installation Manual Jabiru 2200 Aircraft Engine Figure 3. Distributor Cylinder Map Dated : March 2006 Page: 11 REVISION \\Gateway\library\files\engine_manuals\2200_engine_manuals\Hydraulic_Lifters\Working copies\HL_Installation_Manual_2200_Rev_0.doc Print Date: 3/8/2006 1:56:00 PM...

  • Page 12: Engine Mount

    Jabiru Aircraft Pty Ptd Installation Manual Jabiru 2200 Aircraft Engine Engine Mount The design of the engine mount must not only take into account the structural loadings but must make allowances for accessibility of components and the removal of equipment located at the rear of the engine.
  • Page 13 Jabiru Aircraft Pty Ptd Installation Manual Jabiru 2200 Aircraft Engine Figure 5 Engine Mount Assembly Corrections of the engine alignment may be made using spacers under the rubber cushions. The maximum spacer thickness on any one mount is 3mm. Dated : March 2006...

  • Page 14: Controls

    Jabiru Aircraft Pty Ptd Installation Manual Jabiru 2200 Aircraft Engine Controls This section comprises of the mechanical controls and electrical switches. Throttle and Choke Provisions for the connection of the throttle and choke are made on the carburettor. Note: Since a pressure compensating carburettor is used there is no mixture control.

  • Page 15: Instruments

    White Oil Temperature Gauge Sensor (S) to Oil Temperature Sensor (Lower Left Eng Sump) 9.1.3 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. 9.1.3.1 Oil Pressure Wiring...
  • Page 16 Exhaust Gas Temperature Gauge An optional Exhaust Gas Temperature Gauge can be fitted. The probe should be positioned 100mm from the port flange on the exhaust pipe of a convenient cylinder. Jabiru Part No. PI0325N is the recommended gauge. Dated : March 2006...
  • Page 17 Jabiru Aircraft Pty Ptd Installation Manual Jabiru 2200 Aircraft Engine Dated : March 2006 Page: 17 REVISION \\Gateway\library\files\engine_manuals\2200_engine_manuals\Hydraulic_Lifters\Working copies\HL_Installation_Manual_2200_Rev_0.doc Print Date: 3/8/2006 1:56:00 PM...

  • Page 18: Electrical Equipment

    10.1 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 with the stator mounted on the alternator mount plate at the back of the engine. The alternator mount plate is also the mount for the ignition coils and the vacuum pump.

  • Page 19: Starter Motor

    Jabiru Aircraft Pty Ptd Installation Manual Jabiru 2200 Aircraft Engine 10.3.2 Transistorised Ignition 2 Wiring No. 2 Switch – Upper to Right Transistorised Ignition No. 2 Switch – Lower to Earth Switch Open for Ignition ON, closed for Ignition OFF.
  • Page 20 Jabiru Aircraft Pty Ptd Installation Manual Jabiru 2200 Aircraft Engine Main Fuse to Master Switch (Lower) Master Switch (Upper) to Main Bus Main Bus to Red on Regulator 10.6.4 Fuel Pump Wiring Main Bus to Fuel Pump Fuse Fuel Pump Fuse to Fuel Pump Switch (Lower)

  • Page 21: Fuel Supply System

    11.4.1 Carburettor Tuning Late in 2004 Jabiru Aircraft introduced a new system of needles and jets to the 2200 engine. The new configuration lowers fuel consumption and is now standard. Details of the configuration are given below:...

  • Page 22: Fuel Lines

    Jabiru Needle P/No. 4A138A0D Needle Note that the needle used is a proprietary item developed by Jabiru specifically for use on the 2200 engine. From S/N 2161 main jet 225 needle jet 280. Engine tuning may be significantly affected by extreme ranges of climate or propellers which incur RPM values outside suggested figures (Appendix C).

  • Page 23: Air Intake System

    Jabiru Aircraft Pty Ptd Installation Manual Jabiru 2200 Aircraft Engine 12 Air Intake System 12.1 SCAT HOSE Remove at each 50 hourly inspection one end of each scat hose. Inspect for holes, leaks and condition of helical wound in a wire former. Replace if any signs of corrosion is evident.

  • Page 24: 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.

  • Page 25: Cooling Systems

    • The dipstick cap must be screwed fully in before removal for reading oil level. • An oil cooler adapter is supplied with the engine and is fitted under the oil filter. • Oil coolers are available from Jabiru Aircraft. • Unless operating in environments of low temperatures, oil coolers are mandatory.

  • Page 26: Propeller Selection

    • Do not cruise or climb in the range 2100rpm – 2400rpm. • Maximum moment of inertia 0.25 kgm2 Applications outside this range should be referred to Jabiru. Engine MUST NEVER BE RUN WITHOUT THE PROPELLER. Damage will occur in this state.

  • Page 27: Auxiliary Units

    Jabiru Aircraft Pty Ptd Installation Manual Jabiru 2200 Aircraft Engine 16 Auxiliary Units 16.1 Vacuum Pump For the installation of an artificial horizon and/or a direction gyro a vacuum pump is necessary. A Tempest 212CW (or equivalent) vacuum pump can be fitted to the alternator mounting plate and directly coupled to the crankshaft.

  • Page 28: Appendix A - Wiring Diagrams

    Jabiru Aircraft Pty Ptd Installation Manual Jabiru 2200 Aircraft Engine 17 Appendix A – Wiring Diagrams Figure 8 – Wiring Details Dated : March 2006 Page: 28 REVISION \\Gateway\library\files\engine_manuals\2200_engine_manuals\Hydraulic_Lifters\Working copies\HL_Installation_Manual_2200_Rev_0.doc Print Date: 3/8/2006 1:56:00 PM...

  • Page 29: Appendix B - Supplemantay Information

    Nippon Denso type, P/No. 4933023. The following optional equipment may be driven by or fitted to the engine subject to the type number being included in the approved Jabiru Aircraft Pty Ltd engine specification:- Vacuum Pump Tempest 212CW (or equivalent) vacuum pump fitted to the alternator mounting plate and directly coupled to the crankshaft.

  • Page 30: Appendix C - Jabiru Engine Installation Tips

    • Carby tuning must not be altered other than with advice from Jabiru Aircraft. If in doubt, contact Jabiru Aircraft or our local representative.

  • Page 31: Fuel Pump

    Jabiru Aircraft Pty Ptd Installation Manual Jabiru 2200 Aircraft Engine 19.6 Fuel Pump • Ensure boost pump is not capable of more than 3 lb (20 kPa) pressure. 19.7 • 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 32 “Cobra Head” made by Jabiru Aircraft be used. This will prevent air turbulence in front of the 2 sense holes on the intake of the carby. Turbulence next to these sense holes can cause the engine to run “out of tune”...

  • Page 33: Appendix D

    CHT’s • Engines are jetted to a standard and must not be changed without discussion with Jabiru Aircraft or local representative. • All figures given at sea level and at summer temp of around 25 ˚C O.A.T 20.3...
  • Page 34 Jabiru Aircraft Pty Ptd Installation Manual Jabiru 2200 Aircraft Engine Dated : March 2006 Page: 34 REVISION \\Gateway\library\files\engine_manuals\2200_engine_manuals\Hydraulic_Lifters\Working copies\HL_Installation_Manual_2200_Rev_0.doc Print Date: 3/8/2006 1:56:00 PM...

  • Page 35: Typical Installation - Jabiru Engine

    Jabiru Aircraft Pty Ptd Installation Manual Jabiru 2200 Aircraft Engine 21 Appendix E - Typical Installation Gradual bends only in SCAT hose Glass duct removes sharp corner in SCAT tube Glass duct prevents bunched SCAT hose from blocking sensor holes on carburettor inlet Figure 9.
  • Page 36 Jabiru Aircraft Pty Ptd Installation Manual Jabiru 2200 Aircraft Engine Oil cooler “soft” Ram air ducts fixed to mounted Torque on propeller engine with rocker cover rubber grommets bolts 6 ft.lb cap screws front & rear. Figure 11. Engine Installation #1...
  • Page 37 Jabiru Aircraft Pty Ptd Installation Manual Jabiru 2200 Aircraft Engine Figure 13. Coil Cooling Detail #2 21.1 Engine Installation Procedure Male rubber Female rubber Washer – engine engine mount engine mount mount spacer Washer – engine mount Air duct Spring...
  • Page 38 Pty Ptd Installation Manual Jabiru 2200 Aircraft Engine d) To 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 & clamping the rubber mount assembly using a G-clamp with the swivel taken off the ball.

  • Page 39: Figure 16 Lower Engine Mount Detail

    Jabiru Aircraft Pty Ptd Installation Manual Jabiru 2200 Aircraft Engine Deep long reach socket G-Clamp with swivel removed Figure 16 Lower Engine Mount Detail Dated : March 2006 Page: 39 REVISION \\Gateway\library\files\engine_manuals\2200_engine_manuals\Hydraulic_Lifters\Working copies\HL_Installation_Manual_2200_Rev_0.doc Print Date: 3/8/2006 1:56:00 PM...
  • Page 40 Jabiru Aircraft Pty Ptd Installation Manual Jabiru 2200 Aircraft Engine Dated : March 2006 Page: 40 REVISION \\Gateway\library\files\engine_manuals\2200_engine_manuals\Hydraulic_Lifters\Working copies\HL_Installation_Manual_2200_Rev_0.doc Print Date: 3/8/2006 1:56:00 PM...

  • Page 41: Figure 17. Engine Mount Detail

    Jabiru Aircraft Pty Ptd Installation Manual Jabiru 2200 Aircraft Engine Figure 17. Engine Mount Detail Fuel line from firewall fitting to mechanical fuel pump Fuel line from mechanical fuel pump to carburettor Figure 18. Fuel Connections General Fuel line from firewall...

  • Page 42: Figure 20. Oil Collector Bottle

    Jabiru Aircraft Pty Ptd Installation Manual Jabiru 2200 Aircraft Engine j) Ensure the fuel line from fuel pump to the carburettor is connected & protected by fireproof sleeve. k) Ensure that the fuel overflow line is in place, and secured to vent overboard.

  • Page 43: Figure 21. Hot Air Plumbing – Incorrect

    Jabiru Aircraft Pty Ptd Installation Manual Jabiru 2200 Aircraft Engine Incorrect plumbing – Note sharp lips Figure 21. Hot Air Plumbing – Incorrect Correct plumbing – sharp lips & abrupt corners rounded & smoothed off. Figure 22 Hot Air Plumbing – Correct...
  • Page 44 Jabiru Aircraft Pty Ptd Installation Manual Jabiru 2200 Aircraft Engine SCAT hose from NACA inlet to mixer box SCAT hose from hot air muff on exhaust to mixer box Figure 23. SCAT Hose Detail #1 Dated : March 2006 Page: 44 REVISION \\Gateway\library\files\engine_manuals\2200_engine_manuals\Hydraulic_Lifters\Working copies\HL_Installation_Manual_2200_Rev_0.doc...
  • Page 45 Jabiru Aircraft Pty Ptd Installation Manual Jabiru 2200 Aircraft Engine Dated : March 2006 Page: 45 REVISION \\Gateway\library\files\engine_manuals\2200_engine_manuals\Hydraulic_Lifters\Working copies\HL_Installation_Manual_2200_Rev_0.doc Print Date: 3/8/2006 1:56:00 PM...
  • Page 46 Figure 25. Control Connections to Carburettor p) Fit throttle cable to carburetor. 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.
  • Page 47 Balance tube nipple Figure 27. Carburettor Balance Tube Nipple s) Fit cylinder head temperature (CHT) sensor. The CHT sensor used in Jabiru aircraft is a J-type thermocouple located under the rear spark plug of No: 4 cylinder. The VDO 310 980 Cylinder Head Temperature Gauge Kit is compatible with this sensor and is installed as standard equipment in Jabiru Aircraft.
  • Page 48 The sensor used is VDO 360 001 v) The exhaust gas probe used on Jabiru engines is a VDO 310 306 Pyrometer which is supplied as a complete kit. The probe is mounted in a fitting which is welded to an...
  • Page 49 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.

Table of Contents