Jabiru 2200, Installation Manual

Page 1: ...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 Appli...

Page 2: ..._______________________________________________ 14 9 Instruments___________________________________________________________ 15 10 Electrical Equipment _________________________________________________...

Page 3: ...Detail 2 35 Figure 10 Engine Installation 1 36 Figure 11 Coil Cooling Detail 1 36 Figure 12 Coil Cooling Detail 2 37 Figure 13 Engine Accessory Pack Contents 37 Figure 14 Upper Engine Mount Detail 38...

Page 4: ...00 PM 1 2 List of Effective Pages The dates of issue for original revised pages are Page Revision Date Page Revision Date 1 0 29 6 05 21 0 29 6 05 2 0 29 6 05 22 0 29 6 05 3 0 29 6 05 23 0 29 6 05 4...

Page 5: ...ails 4 Stroke 4 Cylinder Horizontally Opposed 1 Central Camshaft Push Rods Over Head Valves OHV Hydraulic Valve Lifters with Automatic Adjustment Ram Air Cooled Wet Sump Lubrication Direct Propeller D...

Page 6: ...Fuel Consumption 75 Power 13 l hr 3 5 US gal hr Fuel AVGAS 100 130 MOGAS with RON Octane Rating 95 or above may be used if AVGAS is not available Oil Aero Oil W Multigrade 15W 50 or equivalent Lubric...

Page 7: ...Peak Temperature 200 C 392 F Continuous Operation 180 C 356 F 4 3 Fuel 4 3 1 Specifications Avgas 100LL Avgas 100 130 Leaded and Unleaded Automotive Gasoline above 95 Octane RON 4 4 Pressure to Carbu...

Page 8: ...006 Page 8 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 4 5 3 Pressure Normal Operatio...

Page 9: ...Engine REVISION 0 1 2 Dated March 2006 Page 9 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...

Page 10: ...0 1 2 Dated March 2006 Page 10 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 6 Denomin...

Page 11: ...200 Aircraft Engine REVISION 0 1 2 Dated March 2006 Page 11 Gateway library files engine_manuals 2200_engine_manuals Hydraulic_Lifters Working copies HL_Installation_Manual_2200_Rev_0 doc Print Date 3...

Page 12: ...e 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...

Page 13: ...ibrary 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 Figure 5 Engine Mount Assembly Corrections of the...

Page 14: ...doc Print Date 3 8 2006 1 56 00 PM 8 Controls This section comprises of the mechanical controls and electrical switches 8 1 Throttle and Choke Provisions for the connection of the throttle and choke...

Page 15: ...uge uses an electric probe mounted in the base of the sump Jabiru Part No PI10752N is recommended 9 1 2 1 Oil Temperature Wiring Black Oil Temperature Gauge Negative to Earth Red Oil Temperature Gauge...

Page 16: ...instrument These must be installed as per directions If cable is too long it must be looped as many times as necessary and strapped behind the instrument panel DO NOT CUT TO LENGTH Ensure that wire is...

Page 17: ...n Manual Jabiru 2200 Aircraft Engine REVISION 0 1 2 Dated March 2006 Page 17 Gateway library files engine_manuals 2200_engine_manuals Hydraulic_Lifters Working copies HL_Installation_Manual_2200_Rev_0...

Page 18: ...regulator output voltage is 14 volts 0 8 volt Recommended wiring of regulator is positive and negative of the regulator directly to the battery A 20A fuse or circuit breaker may be used between the re...

Page 19: ...ry to the motor The cable from Battery to starter should be minimum 16mm 2 copper 10 4 1 Starter Wiring Starter Button Switch lower to Main Bus Starter Button Switch upper to Start Solenoid through Gr...

Page 20: ...ed on Regulator 10 6 4 Fuel Pump Wiring Red Main Bus to Fuel Pump Fuse Red Fuel Pump Fuse to Fuel Pump Switch Lower Red Fuel Pump Switch Upper to fuel Pump Red Wire Black Fuel Pump Black Wire to Earth...

Page 21: ...ut criteria for the carburettor given below 11 4 Carburettor A Bing constant depression type 94 40 is used This carburettor has a minimum delivery pressure of 5 kPa 0 75 Psi and a maximum pressure of...

Page 22: ...ru 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 outsi...

Page 23: ...for holes leaks and condition of helical wound in a wire former Replace if any signs of corrosion is evident 12 2 Air Filter The induction system must not cause positive RAM induction pressure as this...

Page 24: ...rformance 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...

Page 25: ...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 operat...

Page 26: ...e carefully selected to match the airframe and the engine Propellers up to 1727mm 68 in diameter and between 762mm 30 and 1219mm 48 in pitch may be used The propeller flange is drilled with 6 holes at...

Page 27: ...copies HL_Installation_Manual_2200_Rev_0 doc Print Date 3 8 2006 1 56 00 PM 16 Auxiliary Units 16 1 Vacuum Pump For the installation of an artificial horizon and or a direction gyro a vacuum pump is...

Page 28: ...ft Engine REVISION 0 1 2 Dated March 2006 Page 28 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...

Page 29: ...dle jet 276 Idle jet 45 Fuel Pump Mechanical Jabiru P N PG10332N Ignition System Jabiru dual magneto high voltage transistorised contactless P N PI10522N Spark Plugs NGK D9EA Alternator Integrated Jab...

Page 30: ...rop tach 19 3 Cooling Cowls should have adequate entry and exit areas As a general guide cowl outlets should have approximately 3 times as much area as the inlets Care must be taken not to flood the c...

Page 31: ...ng in very cold ambient temperatures Refer to Oil Cooling section above for allowable oil operating temperature ranges Do not overfill the engine this may result in high oil temperatures 19 8 Fuel Avg...

Page 32: ...rubbing it will eventually fail leak 19 15 Warranty Damage caused by overheating due to poor installation techniques would not be covered under warranty Operation of the engine on non approved oils a...

Page 33: ...protection to the scat hose attachment short glass tube or Jabiru produced adaptor Air vent for the carburettor bowl must be routed to the filtered side of the air box Engines must be fitted with an...

Page 34: ...n Manual Jabiru 2200 Aircraft Engine REVISION 0 1 2 Dated March 2006 Page 34 Gateway library files engine_manuals 2200_engine_manuals Hydraulic_Lifters Working copies HL_Installation_Manual_2200_Rev_0...

Page 35: ...PM 21 Appendix E Typical Installation Figure 9 Intake Detail 1 Figure 10 Intake Detail 2 Glass duct removes a sharp corner in SCAT tube Glass duct prevents bunched SCAT hose from blocking sensor holes...

Page 36: ...ydraulic_Lifters Working copies HL_Installation_Manual_2200_Rev_0 doc Print Date 3 8 2006 1 56 00 PM Figure 11 Engine Installation 1 Figure 12 Coil Cooling Detail 1 Torque on propeller bolts 6 ft lb R...

Page 37: ...ote that an engine mount spacer washer is fitted between the male rubber the lower engine mount pins Refer to Figure below b With the Back of the Aircraft Supported the wheels chocked lift the engine...

Page 38: ...ee Photo Start nuts on both upper mount bolts e Once bolts of the upper rubbers are started continue lowering the front of the engine align the lower engine mount pins with the engine backing plate f...

Page 39: ...N 0 1 2 Dated March 2006 Page 39 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 Figure 1...

Page 40: ..._manuals 2200_engine_manuals Hydraulic_Lifters Working copies HL_Installation_Manual_2200_Rev_0 doc Print Date 3 8 2006 1 56 00 PM LOWER ENGINE MOUNT CONFIGURATION APPLICABLE JABIRU 2200 AND 3300 ENGI...

Page 41: ...3 8 2006 1 56 00 PM Figure 17 Engine Mount Detail Figure 18 Fuel Connections General Figure 19 Fuel Connection Detail i Connect the fuel line to fuel pump Refer to photo Ensure the fireproof sleeve i...

Page 42: ...Oil Collector Bottle l Fit the oil over flow bottle to the firewall by drilling and Riveting oil bottle holder in place using 73AS 6 6 rivets Refer to photo m Connect the oil breather line from the en...

Page 43: ...ibrary 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 Figure 21 Hot Air Plumbing Incorrect Figure 22 Hot...

Page 44: ...rch 2006 Page 44 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 Figure 23 SCAT Hose Deta...

Page 45: ...n Manual Jabiru 2200 Aircraft Engine REVISION 0 1 2 Dated March 2006 Page 45 Gateway library files engine_manuals 2200_engine_manuals Hydraulic_Lifters Working copies HL_Installation_Manual_2200_Rev_0...

Page 46: ...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...

Page 47: ...ance 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...

Page 48: ...320 028 which is located in the bottom of the sump as shown in photo Figure 29 Oil Pressure Sensor u The oil pressure sensor is located at the base of the oil filter and this can be seen in photo The...

Page 49: ...tting 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...