Jabiru Aircraft
Pty Ltd
Instruction & Maintenance Manual
Jabiru 2200 Aircraft Engine
Hydraulic Valve Lifter Models
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Dated : June 2010
Issued By: DPS
Page: 8 of 116
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General Description
It is said that "aircraft are designed around available engines".
Jabiru believe that the Jabiru range of very light engines offers opportunities for light
aircraft designers to develop a new generation of light aircraft.
Jabiru engines are designed to be manufactured in small batch quantities using the very
latest Computer Numerically Controlled (CNC) machine tools. All Jabiru engines are
manufactured and assembled in a very modern factory in Bundaberg where each engine
is run in on a Dynometer and calibrated before delivery. The crankcase halves, cylinder
heads, crankshaft, starter motor housings, gearbox cover (the gearbox powers the
distributor rotors) and coil mounts
– together with many smaller components are machined
from solid. The sump (oil pan) is the only casting. The cylinders are machined from bar
4140 chrome molybdenum alloy steel, with the pistons running directly in the steel bores.
The crankshaft is also machined from 4140 chrome molybdenum alloy steel, the journals
of which are precision ground prior to being Magnaflux inspected. The camshaft is
manufactured from 4140 chrome molybdenum alloy steel
– with nitrided journals & cams.
The propeller is direct crankshaft driven and does not use a reduction gearbox. This
facilitates its light-weight design and keeps maintenance costs to a minimum. The
crankshaft features a removable propeller flange which enables the easy replacement of
the front crankshaft seal and provides for a propeller shaft extension to be fitted, should
this be required for particular applications. Cylinder heads are machined from solid
aluminium billet, thereby providing a substantive quality trail to material source.
Connecting rods are machined from 4140 alloy steel and the 45mm big end bearings are
of the automotive slipper type.
Many components of the engines are sourced from outside Suppliers. These items include
camshaft followers, and the bendix gear in the starter motor. The ignition coils are also
sourced from outside Suppliers, and are modified by Jabiru for their own particular
application.
An integral alternator using rare earth magnets provides alternating current for battery
charging and electrical accessories. The alternator is attached to the flywheel and is
driven directly by the crankshaft. The ignition system is a transistorised electronic system;
two fixed coils mounted adjacent to the flywheel are energised by rare earth magnets
attached to the flywheel. The passing of the coils by the magnets creates the high voltage
current which is then transported by high tension leads to the centre post of two
automotive type distributors (which are simply rotors and caps) before distribution to
automotive spark plugs, two in the top of each cylinder head. The ignition system is fixed
timing and, therefore, removes the need for timing adjustment. The ignition system is fully
redundant, self-generating and does not depend on battery power.
The crankshaft is designed with a double bearing at the propeller flange end and a main
bearing between each big end; it therefore does not have flying webs. 48mm main
bearings are also of the automotive slipper type. Thrust bearings are located fore and aft
of the front double bearing allowing either tractor or pusher installation.
