Jabiru 3300, Instruction And Maintenance Manual

Page 1: ...NTENANCE 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...

Page 2: ...ks 12 4 2 Starting Procedure 12 4 3 Warm Up Period Ground Test 12 4 4 Take Off 12 4 5 Engine Stop 13 4 6 Engine Stop Start During Flight 13 4 7 Addition Early Operation of Engine 13 5 0 Checks on Engi...

Page 3: ...65 7 5 Engine Installation and First 25 hours 66 7 6 Prop Strike Inspection 67 7 7 Build Sheets and Run in programme 68 8 0 Table of Lubricants 86 9 0 Torque Specifications 87 9 1 Prescribed Sealants...

Page 4: ...Page No 4 Issue No 1 Date 031100 Issued By PJA List of Amendments Page Amendment Date Issue...

Page 5: ...he sump oil pan is the only casting The cylinders are machined from solid bar 4140 chrome molybdenum alloy steel with the pistons running directly in the steel bores The crankshaft is also machined fr...

Page 6: ...enum cylinder bores Valves are 7mm stem dia which are purpose manufactured for the Jabiru engine in England The valve gear includes pushrods from the camshaft from the camshaft followers to valve rock...

Page 7: ...xhaust and muffler system is fitted as standard equipment ensuring very quiet operations which in the Jabiru aircraft have been measured at 62dB at 1000 full power flyover for 2200 engine For those ow...

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

Page 9: ...BTDC Firing Order 1 4 5 2 3 6 Spark Plugs NGK D9EA Electrode Gap 0 55 0 6mm 0 022 0 024 Generator Jabiru permanently excited three phase or single phase AC generator with rectifier regulator DC Outpu...

Page 10: ...correctly fitted located 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...

Page 11: ...Page No 11 Issue No 1 Date 031100 Issued By PJA 3 0 PERFORMANCE GRAPHS...

Page 12: ...iod of 1 minute When engine runs adjust throttle to achieve smooth running at approximately 1200 RPM Deactivate Choke Check Oil Pressure has risen within 5 seconds if not shut down 4 3 Warming Up Peri...

Page 13: ...program and is ready for flight It has been INHIBITED however if you intend to store for any length of time please refer to 5 7 Section 3 of INSTRUCTION AND MAINTENANCE MANUAL Removing spark plugs an...

Page 14: ...e climb outs 7 8 CIRCUIT WORK is possibly a good sequence for initial run in work Abbreviate circuits initially step climb climb shallow No glide approaches Gradually reduce power Avoid sudden heating...

Page 15: ...prop by hand and observe engine for odd noises or heavy movements Check for regular compressions if irregular firstly check tappet adjustment Operation with incorrectly adjusted tappets with result i...

Page 16: ...inspection of filter SPARK PLUGS NGK D9EA are recommended Plug gap of around 022 to 024 Remember plugs are installed at around 8 ft lb or given 1 2 turn after contact with head 18mm Plug spanner used...

Page 17: ...tery condition or faulty alternator charging Further testing would then be required in these areas to identify the problem POSSIBLE PROBLEMS See Trouble Shooting Section of 10 0 of Maintenance Manual...

Page 18: ...uired 5 MAGNETO CHECKS Possible causes of abnormal drop could be loose leads faulty leads rotor buttons coil gaps spark plugs 6 ROUGH CYLINDER RUNNING Check plugs valve clearance and the induction sys...

Page 19: ...nd throttle closed turn propeller by hand observe engine for odd noises or heavy movements Check for regular compression If irregular firstly check tappet adjustment see para 6 8 IMPORTANT Prior to pu...

Page 20: ...gs check engine mounts Thoroughly check engine for missing or loose bolts nuts pins etc for abrasions Check induction and exhaust flange for loose bolts Check safety wires cooling air ducts baffles ig...

Page 21: ...essary 5 6 TBO Details of specific operations are shown in Chapter 6 Maintenance Engine Overhaul in accordance with Service Bulletins Conduct the items shown under 25 Hour Check at para 5 3 Check clea...

Page 22: ...propeller CAUTION Ensure that the Master and Ignition Switches are OFF 5 7 2 Returning Engine to Service After flyable storage returning the engine to service is accomplished by performing a thorough...

Page 23: ...hrough the spark plug hole for corrosion at least once a month 2 If at the end of the 90 day period the aircraft is to be continued in non operational storage repeat Steps 1 4 above most will only nee...

Page 24: ...d 2 Icing due to high air humidity Re 1 Water in fuel will accumulate at the lower parts of the fuel system can lead to freezing of fuel lines filters or jets Remedies are Drain using fuel tank water...

Page 25: ...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 WARNING When using auto...

Page 26: ...essed air against the direction of the intake flow For operation in heavy dusty conditions clean air filter at shorter intervals than recommended for normal conditions A clogged filter will reduce eng...

Page 27: ...solvent Check electrode gap if necessary adjust to 0 55 0 6mm 0 022 0 024 by carefully bending the electrode Recommended Plugs NGK D9EA IMPORTANT Only tighten spark plugs on cold engine only to the to...

Page 28: ...he 25 hour inspection this is done again CAUTION Continued operation with incorrectly adjusted tappets will result in damage to valves valve seats valve guides overhead gear 6 9 Tachometer and Sender...

Page 29: ...r 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 Servi...

Page 30: ...l Breather Line Screwdriver 7 Remove Fuel Line from Fuel Pump and plug Fuel Screwdriver Line and Fuel Pump 1 4 Plugs 8 Remove Starter Motor Cable from Solenoid 7 16 R OE 9 Disconnect Earth at Battery...

Page 31: ...cking Plate 8 Remove 4 capscrews in front oil seal carrier and break 3 16 Allen Key seal on crankcase 9 Remove Fuel Line and Carburettor Screwdriver 10 Remove Fuel Pump Gasket and Push Rod 1 4 Allen K...

Page 32: ...ist Pin keep pin matched with its piston 29 Remove Piston Rings keep rings matched with its piston 30 Repeat Operations 27 30 on other pistons if required Crankcase Disassembly 31 Remove main Stud Nut...

Page 33: ...ove Oil Gallery Plugs and Oil Pressure Sender Remove Oil Relief Valve Cylinder Head Disassembly 40 Remove Valve Springs and Valves Valve Spring Compressor 41 Remove Push Rod Circlips and O Rings Inter...

Page 34: ...mbly A Crankshaft Prop Mount and Con Rods 2 Sub Assembly B Crankcase and Camshaft 3 Sub Assembly C Pistons Cylinders and Cylinder Heads 4 Sub Assembly D Sump and Oil Pump 5 Sub Assembly E Flywheel Ign...

Page 35: ...aft to prevent rusting A5 1 Magnet Particle Inspect conrods for cracks 2 Fit bearings with a light smear of bearing blue on back of shells 3 Torque Caps to 18 lbs with new bolts 4 Measure Big End Bear...

Page 36: ...visually inspect camshaft 2 Measure journal diameter 3 Measure lobe lift Drawing 9433064 4 Inspect fuel pump lobe for wear 5 Spray camshaft rear gears and bolts with Loctite 7471 Primer 6 Fit gears an...

Page 37: ...Page No 37 Issue No 1 Date 031100 Issued By PJA Drawing 9448064 A9 Stage Inspection by 2nd person of Sub Assembly...

Page 38: ...ankcase B2 Fit inner stud O Rings with a small smear of rubber grease B3 Inspect all studs for tightness threads and stretching B4 1 Check oil suction pipe for security replace o ring 2 Fit all dowles...

Page 39: ...unnel and cam tunnel and record in build sheet B9 1 Disassemble 2 Remove shells and check back contact must be at least 90 3 Check mating surface on crankcase 4 Remove all blue and thoroughly clean su...

Page 40: ...spect cylinder head for flatness If sealing surface show signs of leakage it may need refacing When refacing remove only the minimum to clean up 2 Measure valve guide wear 3 If wear is excessive remov...

Page 41: ...0 Issued By PJA Drawing 9446064 5 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 maxim...

Page 42: ...evel of the combustion chamber If they are below the valve seats and valves must be replaced 8 Measure valve stem for wear Record in build sheet if within limits or replace valves 9 Grind valve seats...

Page 43: ...pect valve spring seats valve spring retainers and valve collets Replace any that show signs of wear 4 Lube valves well Install valves valve spring seats springs retainers and collets Drawing 9447064...

Page 44: ...for wear Replace any with excessive wear 3 Measure bushes and record on build sheet 4 If over service limits replace Drawing 9449064 5 Clean off old Loctite from rocker bore 6 Press in Bushes These ar...

Page 45: ...gh 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 13 Clean up oil well and reassemble Cylinders C6 1 Clean and visually inspect 2 Mount cyl...

Page 46: ...iston skirt and piston pin bores 3 Use an old ring to clean carbon out of ring grooves but care must be taken not to scratch grooves Any scratching will cause Gas Leakage past the rings A piece of 2mm...

Page 47: ...ny oil present at all it is possible for the carburettor to slip out of the coupling D4 Fit new induction O Rings to Induction Pipes Engines from S N 68 used a bolt on swept chamber and new induction...

Page 48: ...Page No 48 Issue No 1 Date 031100 Issued By PJA...

Page 49: ...tor Operation Flywheel Inspection E1 Inspect ring gear for damaged teeth E2 Use a spring scale and a prop cap screw as per drawing to test ignition magnet strength Pull off should be 1 5 to 2 5 kg 3 3...

Page 50: ...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 2 Measure the secondary resistance from the high tension lead to the ir...

Page 51: ...ystem supplies electrical devices and also charges the battery while the engine runs It consists of a Permanent Magnet Alternator PMA and a Regulator 1 This permanent magnet alternator PMA is a 12 pol...

Page 52: ...Page No 52 Issue No 1 Date 031100 Issued By PJA...

Page 53: ...nd 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...

Page 54: ...spect surfaces and reassemble F3 Clean gear case distributor shaft and engine mount plate F4 Measure distributor shafts and record on build sheet F5 Measure distributor shaft posts and record in build...

Page 55: ...length of 12mm for connecting an air filter or intake silencer FUEL INTAKE CONTROL The float 40 of the carburettor consists of two plastic float elements joined by a metal hinge The float is arranged...

Page 56: ...exceeded substantially due to a leaking needle valve MAIN REGULATING SYSTEM WITH PRESSURE REGULATOR The amount of mixture drawn in by the engine and thus its performance is determined by the cross se...

Page 57: ...air which is brought in from the air filter via an air duct Z and the atomiser 2 in an annular flow around the needle jet This air flow assists the atomising process to form minute fuel droplets and...

Page 58: ...e control screw starting from the basic setting a speed drop will be noticed in both directions The optimum setting will generally be found half way between the two settings at which this speed drop w...

Page 59: ...e drawn in from this compartment which forms a very rich mixture The fuel supplied subsequently will only be the amount allowed through by the starting jet This ensures that once the engine has starte...

Page 60: ...Page No 60 Issue No 1 Date 031100 Issued By PJA G1 Disassemble carburettor G2 Using over haul kit replace all components G3 Record jet size G4 Record needle position G5 Reassemble carburettor...

Page 61: ...ssued By PJA Jabiru 3300 Component Inspection and Assembly 7 4 8 Sub Assembly H Final Assembly Crankcase Joining H1 a Photocopy Degree Wheel increase by 226 to bring to full size then glue to stiff ca...

Page 62: ...Page No 62 Issue No 1 Date 031100 Issued By PJA b Stand crankshaft Sub assembly A up vertically mounted on the prop flange as per drawing Drawing 9478083...

Page 63: ...fres 14 10 Long Nose Pliers Note An extra person makes it easier to bolt up and also can cross check work H3 a Stage Inspection b Oil all bearing crank and camshaft c Fit halves over crankshaft assemb...

Page 64: ...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 b Put anti sabotarge Paint on nuts STAGE INSPECTION Camshaft Tim...

Page 65: ...timing and ignition timing g Set dial indicator up to measure lift on No 1 exhaust Set to 0 on max lift h Turn 1 4 turn backwards then turn until 0 5mm 0 020 from peak note degrees continue turning u...

Page 66: ...ensure it is on the base circle Sump and Induction H10 a Fit sump using loctite 515 on faces and loctite 242 on threads Note Because the engine mount plate goes on the sump and crankcase it is importa...

Page 67: ...Page No 67 Issue No 1 Date 031100 Issued By PJA Drawing 9430064...

Page 68: ...torque H12 a 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 It may not line up with the hole in the...

Page 69: ...ll with oil e Fit O Ring f Fit Oil pump on Use loctite 242 on cap screws Note When torqued up rotate engine carefully to ensure oil pump is not binding If oil pump binds it can sheer the end of camsha...

Page 70: ...tive pressure in the cylinders while carefully limiting the heat build up In essence short amounts of hard work increasing in intensity while limiting the heat build up is the format This can be seen...

Page 71: ...ct Tacho sender 6 Connect exhaust gas temp if fitted 7 Connect cylinder head sender 18mm Spark Plug socket 8 Connect hourmeter Screw Driver 9 Connect oil temp gauge sender 10 Connect oil pressure gaug...

Page 72: ...adjust valves and inspect engine installation Change oil and filter Cut filter open and inspect Check engine leak down 28 If oil consumption is stable fill with W100 W80 in cold conditions and W120 in...

Page 73: ...cklist 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...

Page 74: ...ead bolt No 5 After torquing reset plug with Loctite 243 For the first 25 hours of operation add 3 4 litres of Shell 100 oil After 25 hours drain oil retorque cylinder head bolts to 24 ft lbs and chec...

Page 75: ...et A4 Inspect and Measure Propeller Mount Flange A5 Inspect and Measure Conrods refer to Goods Inwards Inspection Sheet A6 Mount Propeller Mount Flange to crankshaft Torque to 30ft lbs Lockwire A7 Fit...

Page 76: ...h Item Details Mains Big End 1 2 3 4 1 2 3 4 Crankshaft 4629072 Propeller Mount Flange 4662084 5 6 5 6 B E Dia Conrod 1 4651183 7 8 2 4651183 3 4651183 4 4651183 5 4651183 6 4651183 Conrod SHCS 5 16 x...

Page 77: ...oil relief valve oil pressure sender and pressure switch B6 Fit bearing shells 16 B7 Assemble and torque to 30 ft lbs B8 Measure main tunnel and camshaft bearings B9 Measure Cam Follower Bores B10 Fi...

Page 78: ...e RS 4622072 1 2 3 4 5 6 7 8 Camshaft 4625072 Studs Long Barrel 4291044 Cam Tunnel Studs Short Barrel 4292044 Cam Studs Front 4293044 1 2 3 4 5 6 7 Outer Gear 4333054 Inner Gear 4066123 Cam Followers...

Page 79: ...iners install valves C5 Fit intake pipes to heads C6 Complete rocker shafts and rocker assemblies C7 Fit cylinder base O rings C8 Fit front circlip C9 Check ring end gaps fit rings to pistons C10 Inst...

Page 80: ...4657082 3 4657082 4 4657082 5 4657082 6 4657082 Bore Length Cylinder 1 4554062 2 4554062 3 4554062 4 4554062 5 4554062 6 4554062 Ring Gap Dia Top Bottom Piston 1 4685083 2 4685083 3 4685083 4 4685083...

Page 81: ...ils Sign Date D1 Deburr and wash sump inspect for defects D2 Fit oil temperature sender I hereby certify that the subassembly has been completed using the approved procedures and data and is fit for i...

Page 82: ...ord 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 dim...

Page 83: ...ean E2 Fit magnets using silastic E3 Using loctite 620 fit the ring gear E4 Fit the alternator rotor E5 Fit the plugs to the ignition coils I hereby certify that the subassembly has been completed usi...

Page 84: ...No ____________ Date ____________ Description Part No Batch Item Details Flywheel 4626173 Ring Gear 4066423 Coil 1 PI10522N 2 PI10522N I hereby certify that the above listed parts conform with the di...

Page 85: ...the gear housing F4 Fit the distributor shaft seals and rear crankshaft seal F5 Fit shafts to gears with 24 hour araldite F6 Fit the distributor shafts and gears to the gear housing F7 Check end clear...

Page 86: ...Part No Batch Item Details Dia Distributor Mount Spacer 1 4632074 2 4632074 Distributor Drive Shaft 1 4653184 2 4653184 Gear Housing 4631073 Distributor Gear 1 4333054 2 4333054 I hereby certify that...

Page 87: ...correct flow G4 Drill and tap upper half for 90o elbow and fit G5 Clean and reassemble G6 Carburettor needle position G7 Fit fuel line G8 Remove bowl and check jet size G9 Reassembly bowl G10 Fuel pum...

Page 88: ...cylinder assemblies and check circlips Stage 4 Stage Inspection Piston Circlips H8 Tension the cylinder base studs to 25 ft lbs then 30 ft lbs H9 Fit sump H10 Fit heads to cylinder torque 12 ft lbs 2...

Page 89: ...Page No 89 Issue No 2 Date 031100 Issued By PJA...

Page 90: ...00 6 2 75 Power 2600 7 1 Cooling Run 2000 8 2 75 Power 2600 9 3 Cooling Run 2000 10 Max Cont Power 2 1 2 2600 2000 2600 Mins 2 2 1 2000 2600 2700 Mins 2 3 2000 2600 Mins 2 3 2000 2700 Mins 11 3 Coolin...

Page 91: ...nd Correct Range 6 Idle Check idle screw 650 Low Idle 2700 High Idle 7 General Running Smoothness Noises Manifold Sealing 8 Oil Pressure and Temp 9 Prop Tacho 10 Check alternator Charging Voltage Jabi...

Page 92: ...oils of registered brands meeting the specification detailed at para 2 5 Acceptable engine lubricating oils Run in Period Oil 80 100 120 Outside Air Temp 17oC to 25oC 15oC to 35oC Above 35oC Normal Op...

Page 93: ...20 15 5 16 24 18 Crankshaft Prop Flange Cap Screws Lockwire 3 8 40 30 Oil Pump Cap Screws 5 16 20 15 Tappet Cover Cap Screws 1 4 7 5 Starter Motor Bolts 5 16 20 15 Carburettor Flange Bolts 1 4 11 8 E...

Page 94: ...ump 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 Prop Mount Loctite 262 Flywheel Loctite 2...

Page 95: ...15 Length Between 74 485 to 74 498 Bore Radius Cam Shaft Journals 19 96 to 19 97 Valve Lift 6 900 to 7 100 Fuel Pump Lift 2 45 to 2 55 Thrust Faces 15 18 to 15 25 Lifter Stems 8 965 to 8 990 Pistons D...

Page 96: ...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: ...rimary 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 20o C Coil...

Page 98: ...b Dry spark plugs trace possible faults in fuel system or over flow of carb 12 Float valve dirty or jammed Clean or renew float valve 13 Jets in carb clogged Clean jets 14 Water in carb Drain clean ca...

Page 99: ...Too much oil in crankcase Check oil level adjust if necessary 3 Insufficient fuel supply Check fuel supply system 4 Fuel not according to specifications Re fuel with specified fuel 5 Incorrect throttl...

Page 100: ...edy 1 Octane rating of fuel too low Use fuel with higher octane rating 2 Spark plug fitted without sealing washer Ensure one sealing washer on each plug 3 Heavy carbon deposits Remove cylinder heads i...

Page 101: ...party not authorised in writing by JABIRU i the fitting of parts or accessories not marketed by JABIRU j any work carried out on the engine by someone other than an Authorised JABIRU Service Centre o...

Page 102: ...d or permitted to give or make any statement assertion or undertaking in relation to the quality performance characteristics descriptions or fitness for any purpose of any JABIRU product or in connect...

Page 103: ..._____________________________ FAULTY GOODS RETURNED YES COURIER Co REF NO __________ NO ALL GOODS THAT ARE BOXED AND HAVE TO PASS THROUGH CUSTOMS HAVE TO BE CLEANED AND FREE FROM CONTAMINATION WITH A...