Jabiru 3300, Installation Manual

Page 1: ... a guide to correctly install the Jabiru 3300 engine into an airframe If you have any questions or doubts about the contents please contact Jabiru Aircraft P L Applicable to Jabiru 3300cc Engines S No 33A961 Onwards Hydraulic Lifter Type Including 33A927 33A928 33A947 33A948 33A949 33A950 ...

Page 2: ... 2 Fuel Filtration 27 5 3 Mechanical Fuel Pump 27 5 4 Fuel Flow Meters 27 5 5 Carburettor 27 5 6 Fuel Lines 31 6 Air Intake System 32 6 1 Intake Air Heating 32 6 2 Intake Hose Air Filter Box 32 6 3 Air Filter 34 6 4 Ram Air Bleed 34 7 Exhaust System 35 8 Propeller Spinner 35 9 Engine Installation Procedure 37 10 Before First Start 42 11 Auxiliary Units 42 11 1 Vacuum Pump 42 12 Cooling Systems 43 ...

Page 3: ...gure 30 Carburettor Intake Balance Tube Detail 29 Figure 31 Carburettor Schematic 29 Figure 32 Needle Jet Jabiru Needle 30 Figure 33 Air Intake Connections 32 Figure 34 Air Filter Box Plumbing Incorrect 33 Figure 35 Air Filter Box Plumbing Correct 33 Figure 36 Typical Cobra Head Installation on a Jabiru Aircraft 33 Figure 37 Cobra Head for Installations with Minimum Carburettor Clearance 34 Figure...

Page 4: ... 12 4 14 8 09 32 4 14 8 09 52 4 14 8 09 13 4 14 8 09 33 4 14 8 09 53 4 14 8 09 14 4 14 8 09 34 4 14 8 09 54 4 14 8 09 15 4 14 8 09 35 4 14 8 09 55 4 14 8 09 16 4 14 8 09 36 4 14 8 09 56 4 14 8 09 17 4 14 8 09 37 4 14 8 09 57 4 14 8 09 18 4 14 8 09 38 4 14 8 09 19 4 14 8 09 39 4 14 8 09 20 6 1 9 15 40 4 14 8 09 Issue Notes Rev 0 Original Issue Rev 1 Rev 2 Rev 3 Re Format Rev 4 Rev 5 Change drawing ...

Page 5: ...allation are duplicated below for all other information please refer to the Instruction Maintenance Manual 1 4 Manuals Instruction and Maintenance Manual Installation Manual Parts Catalogue 1 5 Specifications All information given in this manual assumes static sea level ratings under the following conditions International Standard Atmospheric conditions at sea level Aircraft service equipment driv...

Page 6: ...ical installation in a Jabiru Aircraft Values will differ for other installations 1 5 3 Fuel Fuel Consumption 35 L hr Takeoff Rating Fuel Consumption 24 L hr 75 nominal power setting Fuel Pressure to Carburettor Maximum 20 kPa 3 psi Fuel Pressure to Carburettor Minimum 5 kPa 0 75 psi Recommended Fuel Grade Avgas 100LL Avgas 100 130 Note Leaded and Unleaded Automotive Gasoline above 95 Octane RON m...

Page 7: ...364 F EGT Max Above 70 Power 700 C 1292 F EGT Min Above 50 Power 600 C 1112 F Note An EGT gauge is included as standard equipment on the Jabiru factory built aircraft for other installations it is required equipment 1 5 8 Ground Running Limitations Ground Idle Speed 900 RPM set while engine is hot Ground Oil Pressure Idle Startup Min 80 kPa 11 psi Max 525 kPa 76 psi Ground Oil Temperature Max 100 ...

Page 8: ...Jabiru Aircraft Pty Ltd Installation Manual Jabiru 3300 Aircraft Engine REVISION 0 1 2 3 4 5 6 7 Dated 1 st Dec 2016 Page 8 of 56 1 6 Dimensions Figure 1 Drawing W000509 2 Engine Dimensions ...

Page 9: ...llation Manual Jabiru 3300 Aircraft Engine REVISION 0 1 2 3 4 5 6 7 Dated 1 st Dec 2016 Page 9 of 56 1 6 1 Denomination Of Cylinders Figure 2 Cylinder Firing Order Cylinder Firing Order 1 4 5 2 3 6 Figure 3 Distributor Cylinder Map ...

Page 10: ...ight spot The mount must be designed to allow enough room for the air intake to the Carburettor as well as accessories like vacuum pumps Access for maintenance must also be considered The final design of the engine mount is a compromise and sometimes special parts will be required to make it work For example to give a good CG location the engine may have to be mounted as close to the firewall as p...

Page 11: ...ft Pty Ltd Installation Manual Jabiru 3300 Aircraft Engine REVISION 0 1 2 3 4 5 6 7 Dated 1 st Dec 2016 Page 11 of 56 Figures 5 6 Typical Upper Engine Mount Air Intake Installation Custom air intake tube Cobra Head ...

Page 12: ...use the control accurately This is a particular problem for the throttle cable as it will make setting the idle accurately very difficult All Jabiru engines are run in on a Dynamometer before delivery It is impossible to accurately set the idle RPM when the engine is on the dynamometer so the Idle Stop Screw shown in Figure 7 must be adjusted as a part of the engine installation process Figure 7 C...

Page 13: ...e assessed and oriented so that the crankcase of the engine is exposed to pressure close to ambient If the breather is open to a high or low pressure partial vacuum area the pressure inside the crankcases will also change with unpredictable effects on engine oil consumption and oil flow within the engine This is because several areas of the engine are lubricated via low pressure or spray oil feeds...

Page 14: ...so the mount for the ignition coils and the vacuum pump Note The electrical system is Negative Earth The Alternator stator leads must be of different lengths at least 25mm difference This helps to ensure an electrical short between the two leads cannot take place between connectors see Figure 10 Specifications Power Max 200W Continuous Figure 9 Ignition Alternator Detail Figure 10 Alternator leads...

Page 15: ...put 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 regulator battery The regulator is equipped to illuminate a Low Voltage Warning Light Refer to Figure 12 for plug pin details Figure 11 Electrics Installation to Firewall Figure 12 Regulator Plug Wiring Details Star...

Page 16: ...e ignition coils is approximately 70 C This should be checked by the installer It is recommended that pipes of 12mm dia be fitted to the top rear of each air duct directing air onto the coils for cooling purposes Coil gaps are set at 0 25mm to 0 30mm 0 010 to 0 012 When installing new ignition coils the output leads go in the directon of prop rotation RHS coil output lead is up LHS coil output lea...

Page 17: ...Wiring Practices Using aircraft grade wiring is strongly recommended Compared to other grades of wire aircraft grade can carry higher currents for the same physical size and weight The insulation used on aircraft grade wire is also frame resistant and is designed for better resistance to damage caused by chaffing or rubbing Care should be taken to identify each wire via labels or similar This make...

Page 18: ...nder must be adjusted to have approximately a 0 4mm gap between the tip of the sender and the tag Note that due to normal bearing clearances the crankshaft moves slightly when the engine is running so if this gap is set too small the sender will hit the tag The sender is fragile and most times damage like this means that the sender must be replaced If the gap is different for each of the two tags ...

Page 19: ...ed to power one S which is connected to the sensor and one un marked which is connected to earth The temperature sender is a brass fitting installed in the engine sump beside the drain plug The oil temperature relies on a good earth connection between the sensor the engine and the airframe earth terminal If there is excess resistance at any of these points gauge reading errors will occur Figure 17...

Page 20: ...e gauge has 3 pins one marked which is connected to power one S which is connected to the sensor and one un marked which is connected to earth Figure 19 Oil Pressure Sender Figure 20 Oil Pressure Connections 4 8 4 Voltage Gauge Optional A voltage gauge can be connected to the aircraft systems The gauge has 2 pins one marked which is connected to power and one un marked which is connected to earth ...

Page 21: ...10732N is the recommended gauge Care must be taken when installing the spark plug terminal the terminal must be aligned with the spark plug If the terminal is not aligned the spark plug seal will be poor and hot combustion gasses can leak out These very hot gases will cause the thermocouple to mis read and show high CHT s Figure 23 shows properly and improperly fitted CHT terminals If thermocouple...

Page 22: ...ioned 120mm from the port flange on the exhaust pipe of each cylinder It is important that this distance is accurately measured Accurate positioning allows true comparison between cylinders As the EGT probes as also thermocouples as with the CHT do not cut the wires shorter 4 8 7 Engine monitoring systems When installing Engine monitoring systems always follow the manufactures instructions There i...

Page 23: ...d from each ignition coil to the distributor must be firmly fitted to the distributor iv Ensure Distributor caps and rotors are in good condition To counteract RF noise Jabiru Aircraft run shielded wiring on all radio and intercom wiring In our experience the Earth Return method of shielding where the shield for the wire is also used to form the earth connection does not work as well as the Farada...

Page 24: ...t Pty Ltd Installation Manual Jabiru 3300 Aircraft Engine REVISION 0 1 2 3 4 5 6 7 Dated 1 st Dec 2016 Page 24 of 56 Figure 25 RG400 Co Axial Antenna Cable Inner shield layer Outer shield layer Black outer insulation ...

Page 25: ...Jabiru Aircraft Pty Ltd Installation Manual Jabiru 3300 Aircraft Engine REVISION 0 1 2 3 4 5 6 7 Dated 1 st Dec 2016 Page 25 of 56 Figure 26 Wiring Diagram ...

Page 26: ...Jabiru Aircraft Pty Ltd Installation Manual Jabiru 3300 Aircraft Engine REVISION 0 1 2 3 4 5 6 7 Dated 1 st Dec 2016 Page 26 of 56 Figure 27 Wiring Diagram Key ...

Page 27: ... is designed to supply fuel at the pressure described in the following paragraph Many airworthiness categories require that a backup fuel pump be fitted in case the primary pump fails Jabiru Aircraft recommend fitting an electrical boost pump If fitted this pump must also fulfil the fuel input criteria for the carburettor given below Some airworthiness categories also require an additional drip tr...

Page 28: ...o known as a sense tube which connects the carburettor to the air box The tube runs from a nipple on the carburettor to the airspace in the air box on the clean side of the air filter This tube is part of a system or ports which tells the carburettor how hard the engine is working and controls how the carburettor varies the fuel air mixture delivered to the engine Tuning issues and poor running wi...

Page 29: ... 31 Carburettor Schematic Idle circuit inlet aperture Needle carrier Needle Atomiser Needle Jet Jet Carrier Idle Jet Air density sense port Air density sense port Diaphragm Diaphragm spring Balance tube nipple Sense ports Fuel inlet nipple Sense port Air filter Correct location for balance tube connection on Clean side of air filter in an area where the air is relatively slow moving Poor location ...

Page 30: ...ich puts a very non linear load on the engine to double the RPM of a propeller a lot more than double the power has to be applied To achieve a good mixture with the type of load applied by a propeller the Jabiru needle uses two stage taper and a straight tip The more gradual taper at the upper end of the needle gives a leaner mixture in low power cruise settings and at lower RPM where the propelle...

Page 31: ...ive can provide assistance during this phase 5 6 Fuel Lines Fuel lines are nominally 6mm bore All hoses forward of the firewall require fire resistant sheathing visible as an orange covering on the fuel lines in Figure 28 above Note that wherever possible the sheathing should be extended past the hose clamp The ends of the sheath must be held in place using safety wire to prevent the sheathing mov...

Page 32: ...wirl and turbulence to the air flowing into the carburettor Connecting the hose directly to the carburettor can cause the hose to bunch up and cover the sense ports A Cobra Head duct or similar is recommended to prevent this Sharp corners inside the air filter box cause turbulence and a pressure drop The pressure drop means that the carburettor balance tube pressure reading is inaccurate while the...

Page 33: ...Plumbing Incorrect Figure 35 Air Filter Box Plumbing Correct Figure 36 Typical Cobra Head Installation on a Jabiru Aircraft Correct plumbing sharp lips abrupt corners rounded smoothed off Glass Cobra Head removes a sharp corner in SCAT tube Glass duct prevents bunched SCAT hose from blocking sensor holes on carburettor inlet Gradual bends only in SCAT hose ...

Page 34: ... if the engine is to be used in a dusty environment Air flow should be as direct as possible no tight bends and air taken from outside the cowl Current air filter is RAF 17 Repco 6 4 Ram Air Bleed The hot air mixer box filter boxes manufactured by Jabiru Aircraft have a Ram Air Bleed flap incorporated This flap prevents excess ram air pressure in the induction system If the engine ever backfires t...

Page 35: ...e characteristics are known when installed with a Jabiru engine within the range of typical pitch setting angles specified Wooden propellers require periodic inspections to maintain proper attachment bolt tension Typically every 50 or 100 hours depending on the propeller manufacturer s recommendations Belleville washers may be used as shown in Figure 39 to allow for expansion and contraction of Ja...

Page 36: ...Jabiru Aircraft Pty Ltd Installation Manual Jabiru 3300 Aircraft Engine REVISION 0 1 2 3 4 5 6 7 Dated 1 st Dec 2016 Page 36 of 56 Figure 39 Jabiru Propeller Spinner Installation ...

Page 37: ... is in place and vents overboard Fit Scat hoses from NACA duct to Air Inlet Housing Assembly from hot air muff to carburettor heat inlet on the hot air mixer box and from the hot air mixer box to carburettor shown in Figure 44 Fit throttle cable to carburettor Note that Jabiru Aircraft kits come with a throttle cable cut to length and with the correct end fitting attached Engines used in firewall ...

Page 38: ...up on 2 tags fitted behind the flywheel Figure 40 Engine Accessory Pack Contents Figure 41 Upper Lower Engine Mount Detail Air duct Spring Rivet Propeller guide bush Washer engine mount spacer Washer engine mount Male rubber engine mount Female rubber engine mount Lock wire to attach ram air cooling ducts Spring mounting bracket Exhaust spring Washer Belleville washer Deep long reach socket G Clam...

Page 39: ...Jabiru Aircraft Pty Ltd Installation Manual Jabiru 3300 Aircraft Engine REVISION 0 1 2 3 4 5 6 7 Dated 1 st Dec 2016 Page 39 of 56 Figure 42 Engine Mount Detail ...

Page 40: ...onnections General Figure 44 SCAT Hose Detail Figure 45 Balance Tube Detail Fuel line from firewall fitting to mechanical fuel pump Fuel line from mechanical fuel pump to carburettor SCAT hose from NACA inlet to air box SCAT hose from hot air muff on exhaust to air box Balance tube connecting filtered side of air mixer box to nipple on carburettor ...

Page 41: ...on Manual Jabiru 3300 Aircraft Engine REVISION 0 1 2 3 4 5 6 7 Dated 1 st Dec 2016 Page 41 of 56 Figure 46 Control Connections to Carburettor Jabiru Aircraft Throttle cable connected Kit Throttle Cable Carburettor end Throttle lever end ...

Page 42: ...o Oil Cooling section above for allowable oil operating temperature ranges Do not overfill the engine this may result in high oil temperatures Check for contact of engine cooler or ducts on cowl Any contact will cause excessive vibration if the oil cooler is rubbing it will eventually fail leak 11 Auxiliary Units 11 1 Vacuum Pump For the installation of an artificial horizon and or a direction gyr...

Page 43: ...nt only A generalised picture of the airflow and air temperature is shown in Figure 47 Most of the time air leaking through gaps instead of flowing though a cylinder head oil cooler or similar is waste air it does not transfer heat and does not cool the engine Sometimes air leaking through controlled gaps such as the holes in the front of the ram air ducts Figure 50 or the gaps between cylinders c...

Page 44: ...rm air flows out Balanced Flow Un Balanced Flow Un Balanced Flow Air leaking past oil cooler reduces air flow rate through cylinder heads Air leaking past cylinder heads reduces air flow rate through oil cooler Air entering cowl through oil cooler High pressure air entering cowl through ram air ducts Air from ram air ducts and oil cooler mixing High temperature air under cylinder heads Cowl outlet...

Page 45: ...oor Gaps can leave room for students to pass without picking up homework Given a group of desks as shown students can follow many paths through them from front to rear from top to bottom or any combination Slowing down the students as they pass through the desks means they will pick up their homework but if they are slowed down anywhere else it only reduces the amount of students that can get thro...

Page 46: ...ng The ducts may require to be increased in size and additional baffles provided for best cooling Tubes of approximately 12mm diameter are required to provide cooling air to the ignition coils Figure 51 For an air cooled engine it is entirely normal for there to be significant differences in the temperature of each cylinder head Often the head which is hottest in the climb will not be the hottest ...

Page 47: ...t with the curved edge hold it against the rear of the duct inlet with the curve towards the top rear of the duct and mark around the bottom of the duct then cut to shape Figure 53 refers Tape the air dam into place Mix a small batch of 5 minute Epoxy and flock and use it to fix the air dam into place Leave to cure then sand away any rough edges Remove the masking tape and roughen the underside of...

Page 48: ...least 60mm 2 4 water pressure between the air flowing into the cooler and the air flowing out of the cowls should provide sufficient oil cooling if using a standard Jabiru oil cooler Section 12 1 noted that air leaking through gaps in the cooling system ducts is generally waste air not contributing to cooling though it noted that there were exceptions to this rule Oil cooling is the feature of eng...

Page 49: ...ow well it is cooled The shape of the outlet of the cowls controls how effectively air is sucked out of the cowling and is arguably the single most important aspect of cowling design As noted above as a rule of thumb the cowl outlet area should be at least 3 times the combined area of all the cowl inlets Figure 56 shows a small lip added to the rear of the cowls of a Jabiru Aircraft This lip gives...

Page 50: ...e the depth and area of the cowl outlet and also provides mounting points for the rudder pedals This type of feature is not mandatory for good engine cooling but it does help An alternative is to make the bottom corner of the firewall as smooth and rounded as possible to help airflow and minimise the outlet restriction Some aircraft types have a flange running around the firewall Particularly on m...

Page 51: ... probe inside the cowl near the outlet For the pressure drop across the oil cooler plumb a static probe against the front of the cooler and a static probe inside the cowl near the outlet The further the probe is in front of the cooler the less the static pressure that will be measured so place the probe no more than 5mm in front of the cooler and parallel to it Using multiple U tubes several measu...

Page 52: ... to the airflow shown in Figure 56 Refer to Figure 22 CHT terminals must be placed correctly or inaccurate too high readings can result Figure 60 Cooling pressure measurement Figure 61 Ram Air duct pressure tapping 12 7 Pusher Installations For pusher installations the details given above hold though some changes are necessary for the different configuration Versions of Jabiru ram air ducts are av...

Page 53: ...ires relatively high power settings for long periods and this is often the most critical condition for cooling systems in these aircraft Increased duct size scooping more air through the engine may be necessary For amphibian or seaplane aircraft using a pusher engine installation the methods outlined above can use the propeller to suck air out of the cowls but ultimately the effect is limited and ...

Page 54: ...Jabiru Aircraft Pty Ltd Installation Manual Jabiru 3300 Aircraft Engine REVISION 0 1 2 3 4 5 6 7 Dated 1 st Dec 2016 Page 54 of 56 13 Appendix A Wiring Diagrams Figure 63 Wiring Details ...

Page 55: ...e so installations must be designed referencing the information given in the main body of this manual 14 1 Known Airframe Engine Details Jabiru SP 2 Seater Propeller 60 x 53 1525mm x 1346mm or 60 x 48 1525mm x 1219mm 14 2 Normal Operation Data The following are typical values for the engine when installed in a Jabiru SP Idle Hot 900 950 RPM Take Off Power 2800 RPM 60 x 53 Propeller 2900 RPM 60 x 4...

Page 56: ...on aircraft Control cables set up to work in the correct direction Heat muffs for carb and cabin heat included Outlet positioned correctly ELECTRICAL SYSTEMS Noise levels satisfactory Correct sized circuit beakers used COOLING Connections for power earth correct size Cowl inlet outlet ratio correct Correct type of sender units used for instruments i e resistive or voltage type Cowl inlets located ...