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Instruction and Maintenance 3300

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1. Sh OV ND HA gt _ int N ays N Ne a DP C Gl L ea ae Be AE a c pe COTTA TTT TTT TTT gg Cc N WY CTS nm e id Vioad EA a LL Li a Ar eee a ATE JNIONA gt 9JH93 P EPS JRE N XY CCC wr dS JANIONS AAOENOAZ 4 QG4R509 5 Page No 89 Issue No 2 Date 031100 DATE NA n SI c Issued By PJA Jabiru 3300 Aero Engine Ground Test Form
2. g 94470641 2 VALVE ASSEMBLY Drawing 94470641 2 Page No 43 Issue No 2 Date 240103 Issued By PJA C4 Install Push Rod Tube O Rings with a small amount of rubber grease Rocker Assembly C5 1 Disassemble and clean off all carbon 2 Inspect rocker tip for wear Replace any with excessive wear 3 Measure bushes and record on build sheet 4 If over service limits replace E SOCKET i m ROCKER ASSY SPECIAL PUNCH j FA OR SOCKET 4A y Drawing 9449064 1 ROCKER BUSH REMOVAL Drawing 9449064 5 Clean off old Loctite from rocker bore 6 Press in Bushes These are a 15mm wide glasier type bush 7 Measure rocker shafts for wear and inspect for scratching scuffing etc Record in Build Sheet Bush join goes to top of the rocker Page No 44 Issue No 2 Date 240103 Issued By PJA ia T x x X OCKER amp BUSH ASSEMBLY AFIT ORNCS FIRST THEN INSERT SHAFT Drawing 9449064 1 ROCKER ASSEMBLY Drawing 9449064 12 Put capscrew through 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
3. Serial Date Start Time Temp Wind QNH Humidity Operator Finish Time Block Total Seq Time Duration Condition RPM Rec RPM CHT 1 CHT2 CHT3 CHT 4 EGT Oil Temp Oil Press Current 1 3 Start and Idle 1400 2 30 sec 1 Take Off Power Full 2000 3 1 2 15 Power 2600 2000 4 1 2 Take Off 2700 2000 5 15 sec 2 2700 2000 6 2 715 Power 2600 7 1 Cooling Run 2000 8 2 715 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 ies 2000 2700 Mins 11 3 Cooling Run 1200 Record of Replenishments Max RPM Record of Maintenance or Adjustment Start Fuel Quantity Low Idle RPM Fuel Added Charge Rate Finish Fuel Quantity Fuel Used During Block Oil Added I hereby certify that this engine has been tested in accordance with the approved procedures and the Jabiru Aircraft Pty Ltd Engines Division Policy and Procedures Manual and is fit for use Signed Page No 90 Issue No 2 Date Date 031100 Issued By PJA Run In Checks 1 Preliminary Paperwork Complete Sufficient Fuel Correct Oil Level All Connections Correct and Secure 2 Start Run Start Time End Time 3 Ignition Checks repeat a couple of times for each side Left Side 1000 2000 rpm Right Side 1000 2000 rpm 4 Oil Leaks Check Visually 5 Instruments Working and Correct Range 6 Idle Check idle screw 650 Low Idle 2700 High Idle
4. Page No 85 Issue No 2 Date 031100 Issued By PJA Com ponentRegisterand Parts Inspection Record Subassembly F Gear Case Batch Serial No Date Description Part No Batch Item Details aaa eed oe SS aeeT Dia Distributor Mount Spacer 1 4632074 2 4632074 Distributor Drive Shaft 1 4653184 2 4653184 eer ol gee eee ees Gear Housing 4631073 Distributor Gear 1 4333054 2 4333054 Thereby certify that the above listed parts conform with the dimensions have been engraved and installed as recorded Signed ____ Date For Jabiru Aircraft Pty Ltd Certificate of Approval 3501 Page No 86 Issue No 2 Date 031100 Issued By PJA Jabiru 3300 Component Assembly Procedure Subassembly G Fuel Pump and Carburettor No Details Sign Date G1 Fuel Pump Disassembly G2 Drill hole in spacer and insert breather G3 Final assembly checked for correct flow G4 Drill and tap upper half for 900 elbow and fit G5 Clean and reassemble G6 Carburettor needle position G7 Fit fuel line G8 Remove bow and check jet size G9 Reassembly bowl G10 Fuel pump and carby engraved I hereby certify that the subassembly has been completed using the approved procedures and data and is fit for installation Signed Date For Jabiru Aircraft Pty Ltd Certificate of Approval 3501 Notes Page No 87 Issue No 2 Date 031100 Issu
5. JOIN ps9 REF ALTERNATOR CORE ASSEMBLY 3 MAGNET 2 2 ALTERNATOR BODY MAGNET RETAINER DESCRIPTION QTY Issue No 2 RNATOR BODY AS Date 240103 SEMBLY Issued By PJA 2 Regulator BATTERY lt EGULATOR The regulator performs rectification and 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 level the D C is cut off from the charging circuit to prevent over charging Single Phase Diagram It is our preference to wire positive and negative of the regulator direct to the battery FUEL MAIN RADIO DUMP FUSE INST FUSE FUSE Page No 53 Issue No 2 Date 240103 Issued By PJA 7 4 6 F1 F2 F3 F4 F5 F6 F7 F8
6. 10 11 12 13 14 15 16 17 18 19 Page No 31 ENGINE DISASSEMBLY Operation Mount Engine on an engine stand in vertical position Remove Spark Plugs Remove Oil Pressure Sensor Remove Oil Filter Oil Pressure Valve may be removed by removing snap ring 1 Extract Valve Seat 1 Valve 1 Spring 1 Remove Oil Pump Assembly Housing Rotor Stator amp Backing Plate Remove 4 capscrews in front oil seal carrier and break seal on crankcase Remove Fuel Line and Carburettor Remove Fuel Pump Gasket and Push Rod Remove Distributor Cap Clamps Caps and Rotors Remove Starter Motor Remove Alternator Mount Remove Ignition Coils from Alternator Mount Remove Flywheel Remove Gearbox Cover Remove Engine Mount Plate Remove Crankshaft Timing Gear Remove Lower Induction Pipes Issue No 2 Date 240103 Tools Spark Plug Socket 17mm Spanner Snap Ring Pliers 1 4 Allen Key 3 16 Allen Key Screwdriver 1 4 Allen Key 5 32 Allen Key 3 16 Allen Key 7 16 Socket 5 16 Ring O End Spanner 3 16 Allen Key 1 4 Allen Key 3 16 Allen Key 1 4 amp 3 16 Allen Key Screwdriver Issued By PJA 20 Remove Sump 3 16 Allen Key 21 Remove Exhaust and Induction Pipes 3 16 Allen Key 22 Remove Tappet Covers 3 16 Allen Key 23 Remove Rocker Rocker Shafts and Push Rods 3 16 Allen Key 24 Remove Cylinder Head 1 4 Allen Key 1 2 Socket 25 Remove Push Rod Tubes 26 Remove C
7. e O O O O oOo oOo oo j 12 12 12 12 12 13 13 13 14 14 14 15 16 16 16 17 20 21 21 21 21 21 22 22 22 23 23 Issued By PJA 6 10 Additional Checks 23 7 0 Service amp Repair 24 7 1 Engine Overhaul and TBO 24 7 2 Engine Removal Procedure 25 73 Disassembly 26 74 3300 Engine Overhaul 29 1 Subassembly A Crankshaft Prop Mount and Con rods 30 2 Subassembly B Crankcase and Camshaft 33 3 Subassembly C Pistons Cylinders and Cylinder Heads 35 4 Subassembly D Sump and Oil Pump 42 5 Subassembly E Flywheel and Ignition Coils amp Alternator amp Alternator Operation 44 6 Subassembly F Gear Case 49 7 Subassembly G Fuel Pump amp Carburettor amp Carburettor Operation 50 8 Subassembly H Final assembly of subassemblies 56 9 Runin 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 and Primers 88 9 2 New Tolerances 89 9 3 Maximum Allowable Clearances Wear Limits 90 9 4 Electrical System Specifications 91 10 0 Trouble Shooting 92 10 1 Engine Won t Start 92 10 2 Engine Idles Unsteadily After Warm Up Period Smoky Exhaust Emission 92 10 3 Engine Runs Erratically or Misfires Occasionally 92 10 4 Engine Runs Too Hot Oil Temperature above 110 C 230 F 93 10 5 Unsatisfactory Power Output 93 10 6 Low Oil Pressure 93 10 7 Engine Keeps Runnin
8. 7 4 1 Sub Assembly A Crankshaft Prop Mount and ConRods Al 1 Remove welsh plugs from crankshaft 2 Clean conrods and crankshaft Note Make sure all old loctite is removed from threads 3 Strip paint off prop flange and crankshaft 4 Magnet particle inspect crankshaft prop flange cam and conrods A2 Measure crankshaft and record in Build Sheet A3 Inspect Oil Holes for Cleanliness and insert new front welsh plugs 2 off and rear welsh plug A4 Inspect prop flange Paint prop flange and end of crankshaft to prevent rusting AS 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 Ibs with new bolts 4 Measure Big End Bearings Record in Build Sheet check crush 5 Measure Piston Pin Bore Record in Build Sheet 6 Remove caps and check bearing back contact Must be at least 90 7 Remove all blue and thoroughly clean surfaces Refit bearing shells 8 Clearance as close to or at 0 05mm A6 Temporarily mount prop flange to crankshaft and mount to stand vertically Flange is removed later to fit front oil seal A7 1 Spray conrod bolts and conrod bolt threads with Loctite 7471 primer and allow to dry 2 Mount conrods to crankshaft Use plenty of oil on journals Closest to prop flange is number 1 Pins to prop drive Use Loctite 620 on rods and bolts torque up to 24 NM 18ft lbs 3 Wipe off excess loctite at the basis of the cap screws on
9. Page No 57 Issue No 2 Date 240103 Issued By PJA A rubber ring 11 seals the nozzle stock 10 off from the carburettor housing to avoid any fuel being drawn in via the thread and thus bypassing the main jet IDLING SYSTEM During idling and low load running the throttle valve 23 is closed to such an extent that the air flow underneath the plunger 13 no longer forms a sufficient vacuum The fuel is then supplied via an auxiliary system the idling system which consists of the idling jet 5 the idling air jet LLD no spare part and the mixture control screw 7 which is sealed off against the carburettor housing by the rubber ring 9 and secured by spring 8 to prevent it from becoming slack The fuel passes through the idling jet 5 whose bore will determine the amount of fuel Behind the jet bore the fuel mixes with air which is supplied via cross ducts in the jet throat from the idling air channel the amount of air admitted being determined by the size of the idling air jet at the inlet of this duct This initial mixture then flows through the idling outlet bore LA the cross sectional area of which can be adjusted by the mixture control screw 7 it then reaches the choke tube via bypass or transition passages BP where it is mixed further with pure air Idling should always be with the engine at operating temperature First the mixture control screw 7 is turned fully clockwise and then backed off by the number of turns
10. is pressed against the seat of the float needle valve thus preventing any further supply of fuel When the engine draws in fuel from the carburettor the level in the float chamber 44 drops and so does the float The float needle then opens the valve again and allows fuel to flow in from the tank The float needle valve regulates the fuel supply in conjunction with the float but it does not act as a stop valve when the engine is at a standstill Minute foreign bodies may be deposited between valve Page No 55 Issue No 2 Date 240103 Issued By PJA seat and needle tip thus preventing complete closure of the valve When stopping the engine therefore the fuel cock on the tank should always be closed In addition the fuel should be filtered before it reaches the carburettor The filter should be selected so that foreign bodies greater than 0 1mm are filtered out and the fuel supply is not impeded to too great an extent The float needle 42 contains a spring loaded plunger which contacts the float hinge This absorbs vibrations on the float 40 In addition the float needle 42 is connected to the float hinge by the retaining spring 43 to prevent it from moving between float and valve seat and thus reducing the fuel supply Spring and retaining guide make a considerable contribution towards keeping the fuel level in the float chamber constant When fitting a new float the fuel level must be adjusted When doing this care must be taken to e
11. jammed or worn Clean or renew float valve 3 Intake manifold leak Tighten all connections renew faulty items 10 3 Engine Runs Erratically or Misfires Occasionally Possible Cause 1 Spark plug failure Check plugs clean inside amp outside adjust electrode gap If necessary renew plugs Faulty HT leads Dry damp leads renew damaged leads Faulty ignition unit Clogged fuel filter Renew fuel filter Page No 99 Issue No 2 Date 031100 Issued By PJA 10 4 Engine Runs Too Hot Oil Temperature Above 110 C 230 F Possible Cause Too much oil in crankcase Low oil level Remedy Check oil level amp adjust if necessary Check oil level amp add oil if necessary Poor quality oil Oil change use specified oil Clogged oil filter Change filter Excessive piston blow by Common reason worn or sticking piston rings complete engine overhaul necessary If metallic particles are present in oil complete engine overhaul necessary Exchange gauge Remedy Check ignition circuits check wiring and pick ups replace ignition units Check oil level amp adjust if necessary Check fuel supply system Re fuel with specified fuel Re adjust throttle fitting Check and tighten all connections check carby sockets renew diaphragm Remedy Check oil level amp replenish as necessary Refer to Para 10 4 Check gauge sender amp wiring Renew as necessary Engine overhaul
12. 2 The rotors point to the No 1 position on the rotor caps Fit cap screws with loctite 242 and 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 gear if it has been moved for cam timing Put loctite 262 on new flywheel cap screws and torque to 24 nm 18 ft lbs b Fit coil mount posts and alternator mount c Fit coils and set gap to 0 25mm 0 010 Note A strip of 0 25mm 0 010 card is best because it is now magnet Coil direction lead follows prop rotation Page No 68 Issue No 2 Date 240103 Issued By PJA H13 Fit Carburettor assembly Note Itis very important to make sure hose clamp is at the outside end of coupling the coupling and carby are free of oil and the carburettor goes fully into coupling H14 Fit Fuel Pump Assembly Note Use loctite 242 on cap screws Use molybdenum disulphide grease on push rod Oil Pump HI5S a Put loctite 515 on back face of oil pump backing plate and fit b Fit woodruff key c Fit inner gear to camshaft d Fit outer gear to housing and fill with oil e Fit O Ring f Fit Oil pump on Use loctite 242 on cap screws Note When torquing up rotate engine carefully to ensure oil pump is not binding If oil pump binds it can sheer the end of camshaft H16 Fit exhaust system Use a little anti seize on cap screws and shake proof washers F
13. 240103 Issued By PJA E5 1 Use multimeter to test resistance of windings Resistance should be 0 5to 1 1 R 2 Use multi meter to test resistance to ground Resistance should be infinite Permanent Magnet Alternator PMA Operation 1 Master Switch 3 Main Bus Bar 5 Battery 7 Regulator KT hi L ee LI Ta mle pu Ea ys 1 A AA y re rah d B j eee 2 Voltage Reference Line 4 Fusible Link 6 Permanent Magent Alternator 8 Charge Lamp The charging system 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 pole 3 phase rotating magnet type generator It is a simple construction consisting of a stator and rotor The rotor is made up of permanent magnets alternator body and magnet retainer mounted on the flywheel The stator has 12 poles with coils and is mounted on the rear plate the stator goes inside the rotor 2 Later engines use a single phase alternator of similar construction and a single phase regulator s n 164 Page No 51 Issue No 2 Date 240103 Issued By PJA Page No 52 Dre WIE INSULATE I 50 AND INSULATION E TO EXTEND AS SH TERMINAL E FOR C 5 HIN THE SINGLE INSULATION VN AND TERMINATE ENDS
14. Issued By PJA Check for tightness re torque if necessary see para 9 0 6 8 Tappet Adjustment Tappets must be adjusted to Inlet 0 254mm 010 Exhaust 0 254mm 010 Adjust the tappets when the engine is cold Head torqued to 24 ft lb when cold Carry out this adjustment after five hours of operation and again after ten hours of operation At the 25 hour inspection this is done again CAUTION Continued operation with incorrectly adjusted tappets will result in damage to valves valve seats valve guides amp overhead gear 6 9 Tachometer and Sender Many apparent engine problems can be caused through inaccurate tachometers Where engine performance is observed to be outside limits the tachometer should be checked against a calibrated instrument Tachometer sender gap is 0 4mm 0 016 When using the 2 tags behind the flywheel sender must have at least 60 covering by tag Ensure both tags are equal distance from sender 6 10 Additional Checks Check engine for ease of starting Conduct idle test run Page No 28 Issue No 2 Date 240103 Issued By PJA 7 0 SERVICE amp REPAIR 7 1 Engine Overhaul and TBO These are carried out only by the manufacturer 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 Service Centre after reaching the TBO limit Changes to the TBO
15. Screw Driver 19 Fit Cooling Ducts 3 16 Allen Key 20 Prime Fuel system with electric pump and inspect for leaks 21 Check for oil Fill if needed 3 5L oil 3 69 US quarts 22 Wind over to get oil pressure 23 Start and inspect for leaks 24 Test Fly Note First flight is a test flight so fly conservatively 25 Remove Cowls and inspect for anything loose rubbing or leaking 26 After 5 and 10 hours and possibly 15 hours retorque heads and adjust valves Inspect engine installation 27 After 25 hours retorque heads 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 very hot conditions If it is still using oil remain on run in oil Refer to nearest Jabiru service centre for more advice 7 6 Prop Strike Inspection After ground contact of a wooden propeller check the crankshaft flange for run out at the front seal surface If run out is evident the engine will have to be stripped and crankshaft checked for cracks If an engine stoppage due to force is not recorded in the logbook and not advised to Jabiru the liability for all subsequent and consequential damage will remain with the owner This applies to both prior to and after engine overhaul 7 7 Build Sheets and Run In Programme Page No 72 Issue No 2 Date 240103 Issued By PJA Included with the bui
16. Seals Crankshaft amp Camshaft Disassembly 44 Remove Bolts from Conrod Note Rods will need to be heated Big End Bolts are Discarded on Removal 45 Remove Rod Bearing Inserts Note visually inspect for marks and scratches keep matched to their seats 46 Remove Camshaft Gears Discard Camshaft Bolts Remove welsh plug in rear of camshaft Page No 33 Issue No 2 Date 240103 Valve Spring Compressor Internal Circlip Pliers 1 4 Allen Key 3 8 Ratchet Hot Air Gun Rags Issued By PJA 7 4 3300 ENGINE OVERHAUL Inspection and Assembly of Sub Assemblies 1 Sub Assembly 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 Ignition Coils and Alternator 6 Sub Assembly F Gear Case 7 Fuel Pump and Carburettor 8 Final Assembly of Sub assemblies 9 Run In 10 Engine Can be run in statically using suitable mount structure and very large specially constructed air ducts Or in the airframe in flight with extreme care Run In Program can be found at the end of the build sheets See also early run notes section 4 7 11 The overhaul of any engine is an exacting science Approved Jabiru service centres as well as Jabiru Aircraft Pty Ltd can provide this service Page No 34 Issue No 2 Date 240103 Issued By PJA Jabiru 3300 Component Inspection and Assembly Procedure
17. Vc PULL SQUARE TO FLYWHEEL Ss WITH SPRING SCALE _LOCKWIRE TO FORM LOOP Drawing 9437064 1 MAGNET PULL TEST FLYWHEEI Drawing 9437064 E3 Use spring scale and prop cap screw as in E2 to test alternator magnets Pull off should be 1 5 to 2 5 kg 3 3 to 5 5 Ibs y ALTERNATOR ASSEMBLY y ALTERNATOR MAGNET m PROP FLANGE CAP SCREW r Li Ty Wx ae K Te e cs ES i g _ N PULL PARALLEL TO FLYW FACE WITH SPRING SCAL L LOCKWIRE TO FORM LOOP FLYWHEEL Drawing 9438064 1 MAGNET PULL TEST ALTERNATIOR Drawing 9438064 Page No 49 Issue No 2 Date 240103 Issued By PJA Ignition Coil Inspection E4 1 Using a multimeter measure the primary resistance from the earth terminal to the iron core It should be 0 8 R to 1 0 R IGNITION COIL ios a RESISTANCE PROBES Drawing 9439064 1 IGNITION PRIMARY RESISTANCE Drawing 9439064 2 Measure the secondary resistance from the high tension lead to the iron core it should be between 5 9 KR to 7 1 KR 9064 1 IGNITION SECONDARY RESISTANCE Drawing 9439064 Alternator Inspection Page No 50 Issue No 2 Date
18. and exhaust 0 010 cold Use 3 4 litres of W100 oil for normal operation or W80 oil for cold weather operation J J Shell also manufacture a multigrade oil Aeroshell 15W50 which is particularly suited for operations in cold climates UNDER NO CIRCUMSTANCES USE AUTOMOTIVE OIL IN THIS ENGINE Use only oils which are designed for Air Cooled Aero Engines Some brands of automotive oils have been shown to cause very rapid cylinder wear This will not be covered under warranty Operate engine only on AVGAS 100LL or highest octane available MOGAS above 95 octane containing lead Failure to do so could result in engine damage and void warranty USE OF OIL FUEL ADDITIVES VOID WARRANTY Page No 74 Issue No 2 Date 240103 Issued By PJA Jabiru 3300 Component Assembly Procedure Subassembly A Crankshaft Propeller Mount Flange and Conrods No Details Sign Sign Date Al Inspect for Burrs Oil Holes Chamfers Clean Crankshaft Conrods and Propeller Mount Plate A2 Inspect Oil Holes and Insert Welch Plugs A3 Measure Crankshaft refer to Goods Inwards Inspection Sheet A4 Inspect and Measure Propeller Mount Flange A5 Inspect and Measure Conrods refer to Goods Inwards Inspection Sheet Mount Propeller Mount Flange to crankshaft Torque to 30ft Ibs Lockwire Fit the Conrods to the Crankshaft Use Loctite 620 on the bolts and torque to 18ft lbs Stage A8 Stage Inspection of Assembly 1 Conrods Cran
19. due to operational experience will be advised by Jabiru through Service Bulletins We recommend engines prior to 118 have TBO at 1000 hours Engines after can be extended to 2000 hours with the Top End done at 1000 hours conditions apply Page No 29 Issue No 2 Date 240103 Issued By PJA 7 2 ENGINE REMOVAL PROCEDURE No Operation 1 Remove Spinner and Propeller 2 If fitted remove Carby Heat hose from Hot Box Muffler 3 Remove Air Inlet Hose from Carburettor and blank off Carburettor and Air Cleaner 4 Disconnect Throttle Cable 5 Disconnect Choke Lever 6 Remove Oil Breather Line 7 Remove Fuel Line from Fuel Pump and plug Fuel Line and Fuel Pump 8 Remove Starter Motor Cable from Solenoid 9 Disconnect Earth at Battery 10 Remove Oil Pressure Gauge Lead 11 Remove Oil Temperature Gauge Lead 12 Remove Hourmeter Lead 13 Remove Cylinder Head Temperature Gauge Lead 14 Remove Exhaust Gas temperature Gauge Lead 15 Remove Tacho Lead 16 Remove Left and Right Ignition Coil Leads 17 Remove Air Ducts 18 Remove Muffler Assy 19 Undo Engine Mount Bolts 20 Remove Engine from Engine Mount Frame Page No 30 Issue No 2 Date 240103 Tools Phillips Screwdriver 1 2 Socket 1 2 Spanner Screwdriver Screwdriver 2 Plugs Long Nose Pliers Long Nose Pliers Screwdriver Screwdriver 1 4 Plugs 7 16 R OE 10mm R OE Screwdriver 3 16 Ball End Allen Key 7 16 Tube Socket 7 16 Spanner Issued By PJA 7 3 No
20. earlier carbies we supplied a kit for this purpose as no internal carby fitting was installed 8 LIMITATIONS Warranty notes follow Jabiru recommend TBO of 1000 hrs A guaranteed fixed price overhaul exists through the Jabiru factory Warranty is 200 hours or 12 months which ever comes first CAREFULLY READ MANUALS SUPPLIED Page No 18 Issue No 2 Date 240103 Issued By PJA 5 0 CHECKS ON ENGINE amp INSTALLATION 5 1 Daily Checks Ensure free movement of throttle amp choke cables Check Oil Level replenish if necessary Oil level should be between the MAX amp MIN marks but must never be below the MIN mark Before long periods of operation ensure that the level is at least at the mid position Difference in the oil quantity between MAX amp MIN mark is 0 75 litres 0 792 US Quarts See section 4 7 for first 25 hrs of operation Check Oil Level by screwing in cap fully before withdrawing Check security of spark plugs leads amp electrical connections Check lubrication amp fuel system for leaks Check exhaust system for security amp leaks With Ignition amp Master OFF and throttle closed turn propeller by hand amp 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 pulling through the propeller by hand both ignition circuits amp the Master must be switched OFF the brakes appl
21. engraved and installed as recorded Signed _ Date For Jabiru Aircraft Pty Ltd Certificate of Approval 3501 Page No 80 Issue No 2 Date 031100 Issued By PJA Jabiru 3300 Component Assembly Procedure Subassembly D Sump No Details 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 installation Signed Date For Jabiru Aircraft Pty Ltd Certificate of Approval 3501 Notes Page No 81 Issue No 2 Date 031100 Issued By PJA Com ponentRegisterand Parts Inspection Record Subassembly D Sump Batch Serial No Date Description Part No Batch Item Details B 4635072 I hereby certify that the above listed parts conform with the dimensions have been engraved and installed as recorded Signed Date Page No 82 Issue No 2 Date 031100 Issued By PJA Jabiru 3300 Component Assembly Procedure Subassembly E Flywheel and Ignition Coils No Details Sign Date El Deburr and Clean 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 using the approved procedures and data and is fit for installation Signed Date
22. ensures a cleaner engine installation which in turn facilitates maintenance and inspection of the engine and engine component So the hard work of engine installation has largely been done for you by the Jabiru design team RAMAIR ducts are available for tractor or pusher configurations Special ducts are available for certain installations Page No 6 Issue No 1 Date 031100 Issued By PJA The engine is fitted with a 1 5 kw starter motor which is also manufactured by Jabiru and provides very effective starting The engine has very low vibration levels however it is also supported by four large rubber shock mounts attached to the engine mounts at the rear of the engine An optional bed mount is available The fuel induction system comprises a BING pressure compensating carburettor Following carburation the fuel air mixture is transported through a swept plenum chamber bolted to the sump casting in which the mixture is warmed prior to entering short induction tubes attached to the cylinder heads An effective stainless steel exhaust 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 owners wanting to fit vacuum instruments to their aircraft the Jabiru engine design includes a vacuum pump drive direct mounted through a coupling on the rear of the crankshaft The Jabiru engine is manufactured
23. oil well and reassemble Cylinders C6 1 Clean and visually inspect 2 Mount cylinders in honing machine by base and hone with Sunnen mm 33 J85 Stone i BARREL HONE PATTERN SN Le 5 J Drawing 9436064 3 Measure and record in Build Sheet Page No 45 Issue No 2 Date 240103 Issued By PJA Pistons C7 C8 4 6 7 1 3 1 Bead blast cylinder outer to remove all old paint and rust Etch prime and paint with high temperature black paint Run 5 16 UNF Tap through head threads to remove all beads and to insure that head bolts torque up fully Clean in kero then in hot soapy water to remove all honing oil etc Note Once cleaned oil up cylinders straight away Store in a cool dry place in a sealed container Clean oil out of pistons Dip Pistons in cold dip solvent i e Redik DKT degreaser decarboniser paint stripper as per manufacturers instructions to remove all carbon Note The head of the piston can be bead blasted but never bead blast the ring grooves piston skirt and piston pin bores 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 0 080 perspex can also be used as it is kinder to the pistons Clean thoroughly 2 3 4 Page No 46 Visually inspect pistons for cracks or damage Measure pi
24. temp initially es pecially during the first few hours of operation Remember engines need to be flown T hey are designed for this purpose Do not use full power before CHT reaches 100 C Page No 14 Issue No 2 Date 240103 Issued By PJA The purpose of breaking in an engine correctly is to ensure a long reliable life All moving parts need freeing up especially piston rings to cylinder walls This is best accomplished when the greatest B M E P Break Mean Effective Pressure occurs That is at 75 power and above Careful monitoring by the pilot is needed during this initial period to ensure long life of the engine and its components Failure to operate at realistic power settings could be detrimental 11 Do not use any type of automotive oil These oils have not been blended for the purpose of air cooled aero engine operation and will be detrimental to its operation 12 Use AVGAS 100 LL or the highest Octane Mogas above 95 containing lead Engines not shimmed on the cylinder base should only be run on AVGAS 13 When you change oil from the run in type to the normal oil at or around 25 hrs replace oil filter You may want to cut the filter open for inspection It is usual in Jabiru engines to find asmall amount of aluminium but definitely no metal If bearing metal is present contact the Jabiru Service Department 14 With ignition and master OFF and throttle closed turn the prop by hand and obs erve engine for
25. the end caps wa Page No 35 Issue No 2 Date 240103 Issued By PJA A8 l 3 4 5 6 7 Page No 36 Ba E Se EE MATCH CONROD amp CAP NUMBERS ima Y os Samat ti rte 7 f DC M DEGREE WHEEL J 3 THIS S RANK VIEWED J 20M NGIN DECREE WHEEL b U ah NG ap i pau paeo Drawing 9478083 Drawing 9478083 Clean and visually inspect camshaft Measure journal diameter Measure lobe lift A LIFT MEASUREMENT Drawing 9433064 Inspect fuel pump lobe for wear Spray camshaft rear gears and bolts with Loctite 7471 Primer Fit gears and new bolts Use Loctite 620 torque to 8 ft lbs amp Lock Wire Fit end welsh plug Issue No 2 Date 240103 Issued By PJA j SPACER OUTER TIMING GEAR HEX BOLT ee WELSH PLUG ave IN END OF 8 npn CAM SHAFT i wees PP a 2 a INNER TIMING GEAR IA CAM SHAFT 1 SAIR PIN TO ALIGN ALIGN OUTER CE S AS CLOSE AS HOLES Drawing 9448064 A9 Stage Inspection by 2nd person of Sub Assembly Page No 37 Issue No 2 Date 240103 Issued By PJA 7 4 2 Bl B2 B3 B4 B5 B6 3300 Component Inspection and As
26. used a bolt on swept chamber and new induction pipes Oil Pump D5 1 Inspect oil pump inner and outer for damage to rotor surfaces 2 Measure rotor clearance OUTER CLEARANCE m INNER CLEARANCE Drawing 9440064 1 OIL PUMP CLEARANCES Drawing 9440064 Housing to Outer Rotor clearance 0 07mm to 0 14mm 0 003 to 0 006 Inner Rotor to Outer Rotor 0 07mm to 0 14mm 0 003 to 0 006 Page No 47 Issue No 2 Date 240103 Issued By PJA Fit Inner Rotor into Outer Rotor Using straight edge check end clearance 3 End Clearance 0 03mm to 0 006mm 0 0015 to 0 003 y STRAIGHT EDG m CLEARANC OIL PUMP GEAR SET PE om PUMP HOUSING m EARANCE Drawing 9428064 1 OIL PUMP END C Page No 48 Issue No 2 Date 240103 Issued By PJA Jabiru 3300 Component Inspection and Assembly Procedure 7 4 5 Sub Assembly E Flywheel amp Ignition Coils amp Alternator amp Alternator Operation Flywheel Inspection El 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 to 5 5 Ibs 77 FLYWHEEL ASSEMBLY POLE PLATE PROP FLANGE CAP SCREW oo NG Sx gt JE Lf l A pn l m jj me Bae ace Pe a N
27. within an Australian Civil Aviation Safety Authority CASA approved Quality Assurance System to exacting standards Jabiru recommend a TBO of 1000 hours for engines to s n 118 A Guaranteed Fixed Price Overhaul Plan is offered with both engines Contact your regional distributor or Jabiru Aircraft for details Top End overhauls are also available on later model engines From s n 118 TBO has been extended to 2000 hours with Top End at 1000 conditions apply Jabiru engine Warranty is 200 hours or 12 months whichever comes first from date of sale or from date of independently verified first flight Conditions Apply Page No 7 Issue No 1 Date 031100 Issued By PJA 1 1 Denomination of Cylinders Page No 8 Issue No 1 Date 031100 Issued By PJA 2 0 TECHNICAL DATA 2 1 Dimensions and Weights Bore Stroke Displacement Compression Ratio Direction of Rotation on Prop Shaft Engine Curb Weight 97 5 mm 74mm 3314 cc 7 8 1 s n 224 on is 8 1 Clockwise Pilot s view tractor applica
28. 2 45 to 2 55 15 18 to 15 25 8 965 to 8 990 97 51 to 97 53 0 01 to 0 02 22 990 to 23 000 0 400 to 1 000 97 59 to 97 61 106 450 to 106 500 6 970 to 6 990 6 970 to 6 990 7 040 to 7 050 7 040 to 7 050 39 to 42 14 940 to 14 970 15 00 to 15 03 Imm Date 031100 Issued By PJA 9 3 MAXIMUM ALLOWABLE CLEARANCES Wear Limits All Dimensions are in Millimetres Mains Big Ends Little Ends Camshaft Journals Crank End Float Cam End Float Lifter Crankcase Piston Cylinder Ring Side Clearance Pin Piston Ring End Gap Inlet Valve Guide Exhaust Valve Guide Min Spring Length Distributor Shaft Post Distributor Shaft End Float Cylinder Dia at Half stroke Rocker Shaft Rocker Arm Oil Pump Gears Bearing Clearances main Big Ends 0 10 0 10 0 03 0 08 0 80 0 50 0 12 0 15 0 05 0 04 1 20 0 12 0 15 39 5 0 15 1 20 97 65 0 18 0 15 0 04 0 09 typical 0 04 0 06 typical Note Variation can occur overall tolerances may be acceptable with advice from Jabiru Aircraft Pty Ltd Page No 97 Issue No 2 Date 031100 Issued By PJA 9 4 ELECTRICAL SYSTEMS SPECIFICATIONS All Dimensions are in Millimetres Ignition Primary 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 20 C Coil Earth Resistance Infinite A C Output 40 VAC at 2750 RPM D C Outp
29. 7 General Running Smoothness Noises Manifold Sealing 8 Oil Pressure and Temp 9 Prop Tacho 10 Check alternator Charging Voltage Jabiru 3300 Engine Post Run Procedure SIGN DATE 1 Heads retorqued 32 Nm 24 ft lb Valves Adjusted 2 Check induction exhaust bolts 3 Any changes to be made 4 Rerun check for oil leaks and or any modifications made oil pressure leaks etc 5 Check charging rate of alternator Volts 6 Leak Down 80 80 80 80 80 80 Cyl 1 2 3 4 5 6 7 Che k all_ phper E 8 Drain fuel oil Prepare for Shipment Page No 91 Issue No 2 Date 031100 Issued By PJA 8 0 TABLE OF LUBRICANTS Use only oils of registered brands meeting the specification detailed at para 2 5 Acceptable engine lubricating oils Run in Period Oil 80 Outside Air Temp 170C to 25 C Normal Operations Oil W80 Outside Air Temp 170C to 25 C Page No 92 Issue No 2 100 15 C to 35 C W100 15 C to 35 C Date 031100 120 Above 35 C W120 Above 350C Issued By PJA yOldvdv Yd YaN 10 gt D A 4 AMWA Y OL _ NaAlda 110 umto00 wows T0 Pro NX T SANS ONOTY AYSTIVI Tio WOds NNl 10 YJ0NI
30. F If readings are below 6 bar 90 psi a check of the pistons cylinders valves amp cylinder heads must be undertaken Alternatives Pressure loss or leakage tester eg SUN or BOSCH tester max allowable pressure loss is 25 Checking by commonly used pressure difference method place orifice of 1 mm ID and 3mm length between the two pressure gauges This will give the same result as with the above instrument Max pressure drop is 25 6 5 Spark Plugs Do not use steel or brass brushes for cleaning amp never sandblast plugs Clean with plastic brush in a solvent Check electrode gap amp if necessary adjust to 0 55 0 6mm 0 022 0 024 by carefully bending the electrode Recommended Plugs NGK D9EA use suitable anti seize lubricant IMPORTANT Only tighten spark plugs on cold engine amp only to the torque values shown in para 9 0 using appropriate anti seize compound Note When plugs are removed from a warm engine the following are indicators Light Coloured to Brown Plug amp calibration is correct Velvet Black Mixture too rich Check choke Insufficient air intake Check for clogged air filter Oily Glossy Coating Misfiring Too much oil in combustion chamber Worn cylinder amp piston rings Whitish with Melt Droplets Mixture too lean Leaking valves 6 6 Exhaust System Visual check for damage leaks amp general condition 6 7 Bolts and Nuts Page No 27 Issue No 2 Date 240103
31. F9 F10 F11 F12 Jabiru 3300 Component Inspection and Assembly Sub Assembly F Gear Case Remove distributor shaft seals and rotor seal and discard Inspect Distributor shaft posts for signs of leaking Note If there is no signs of leaking don t disassemble But if it is leaking disassemble and clean off old master gasket Inspect surfaces and reassemble Clean gear case distributor shaft and engine mount plate Measure distributor shafts and record on build sheet Measure distributor shaft posts and record in build sheet Fit shafts into gearcase and using a straight edge and feeler gauge measure end float Record in build sheet Visually inspect gears for wear Fit seals to gear case Use suitable seal lubricant Lube shafts and fit to gear case Fit rotors Rotors are glued onto shafts this process prevents movement of the rotor Visually inspect engine mount plate for 1 Damaged Threads 2 Wear from distributor shafts Seal up and store for final assembly Note It is recommended that rotors are attached with a small amount of Silastic or 5 Minute Araldite Flox mix This will prevent them from loosening This still allows Rotors to be removed when necessary Page No 54 Issue No 2 Date 240103 Issued By PJA Jabiru 3300 Component Inspection and Assembly 7 4 7 Sub Assembly G Fuel Pump and Carburettor and Carburettor Operation Fuel Pump The fuel pump on the 3300 engine is replaced as a complete un
32. For Jabiru Aircraft Pty Ltd Certificate of Approval 3501 Notes Page No 83 Issue No 2 Date 031100 Issued By PJA Com ponentRegisterand Parts hspection Record Subassembly E Flywheel Assy Batch Serial 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 dimensions have been engraved and installed as recorded Signed _ Date For Jabiru Aircraft Pty Ltd Certificate of Approval 3501 Page No 84 Issue No 2 Date 031100 Issued By PJA Jabiru 3300 Component Assembly Procedure Subassembly F Gear Case No Details Sign Fl Deburr clean and inspect all of the gears F2 Measure the shaft post internal diameters and the distributor shaft diameters F3 Using loctite 515 fit the shaft posts to 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 clearance of distributor shaft to case flange Stage 2 F8 Stage Inspection of Assembly Sign Date I hereby certify that the subassembly has been completed using the approved procedures and data and is fit for installation Signed Date For Jabiru Aircraft Pty Ltd Certificate of Approval 3501 Notes
33. INSTRUCTION AND MAINTENANCE 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 the contents of this manual please contact Jabiru Aircraft Pty Ltd Page No 1 Issue No 1 Date 031100 Issued By PJA Paragraph 1 0 1 1 2 0 2 1 2 2 23 2 4 2 5 2 6 2 7 3 0 4 0 4 1 4 2 4 3 4 4 4 5 4 6 4 7 5 0 5 1 5 2 5 3 5 4 5 5 5 6 5 7 5 8 6 0 6 1 6 2 6 3 6 4 6 5 6 6 6 7 6 8 6 9 Page No 2 Table of Contents Description Table of Contents List of Amendments Description Denomination of Cylinders Technical Data Dimensions amp Weights Normal Equipment Performance Data Fuel Consumption Fuel amp Lubricant Cooling System Operating Speeds amp Limits Performance Graphs Operating Instructions Pre Start Checks Starting Procedure Warm Up Period Ground Test Take Off Engine Stop Engine Stop amp Start During Flight Addition Early Operation of Engine Checks on Engine amp Installation Daily Checks Periodic Checks Check After Initial 25 Hours 50 Hours Check 100 Hours Check TBO Engine Preservation Operation in Winter Maintenance Lubrication System Air Intake Filter Carburettor Adjustment Compression Check Spark Plugs Exhaust System Bolts amp Nuts Tappet Adjustment Tachometer and Sender Issue No 1 Date 031100
34. Inspect replace back after cleaning Possible Cause Remedy 1 Idle speed too high Adjust to proper idle speed 900 RPM 2 Faulty ignition switch Check switch amp cables Repair replace as necessary 3 Overheated engine Page No 100 Issue No 2 Conduct cooling run at 900 RPM Date 031100 Issued By PJA 10 8 Excessive Oil Consumption Worn broken or wrongly fitted piston rings Repait engine overhaul necessary Poor oil quality Oil change use specified oil Worn valve guides Repair of cylinder head necessary Oil leaks Seal leaks 10 9 Knocking Under Load Possible Cause Remedy 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 amp in combustion chamber remove deposits Determine oil consumption 10 10 Engine Hard to Start at Low Temperature Possible Cause Remedy Starting speed too low Preheat engine 2 High oil pressure At very low temperatures a pressure reading of up to around 500 kpa doesn necessarily indicate a malfunction Low battery charge Fit fully charged battery Note running this engine on low octane fuel will cause piston damage and in extreme cases failure of the top ring gland or holed piston due to detonation Changing the engine tuning to a leaner air fuel mix will also cause pis
35. PRESCRIBED SEALANTS AND PRIMERS Spark Plug Lubricant Prop Mount Flywheel Camshaft Spark Plugs NGK D9EA Item Sealant Main Bearing Studs Loctite 620 Conrod Bolts Loctite 620 Oil Pump Bolts Loctite 243 Sump Plate Bolts Loctite 243 Engine Mount Bolts Loctite 243 Gearbox Cover Bolts Loctite 243 Loctite Nickel Anti Seize Loctite 262 Loctite 262 Loctite 262 Tighten to finger tight to seat then with plug socket turn an additional 1 2 turn 8 ft lbs for a new plug All gasket areas use Loctite Gasket Eliminator 515 Issue No 2 Date 031100 Issued By PJA 9 22 NEW TOLERANCES All Dimensions are in Millimetres Crankshaft Mains Journals Big Ends Journals Thrust Face Crankcase Main Bearings Cam Bearings Cam Thrust Face Lifter Bores Crank Thrust Con Rods Big Ends Little Ends Length Between Bore Radius Cam Shaft Journals Valve Lift Fuel Pump Lift Thrust Faces Lifter Stems Dia Sidering Clearance Pin Dia Ring End Gap Pistons Dia Length over flanges Cylinder Bore Stem Dia Inlet Stem Dia Exhaust Guide I D Inlet Guide I D Exhaust Spring Free length Valve Shaft dia Shaft Post I D Shaft End Float Distributor Page No 96 Issue No 2 47 938 to 47 918 44 998 to 45 000 56 95 to 57 05 47 975 to 48 005 20 00 to 20 020 14 95 to 15 10 9 000 to 9 050 56 65 to 56 85 45 028 to 45 070 23 005 to 23 015 74 485 to 74 498 19 96 to 19 97 6 900 to 7 100
36. RS TDC MARK Pi A THIS SIDE CRANK FROM TOP OF ENGIN ape lt DECREE WHEEL SS Drawing 9478083 Drawing 9478083 Page No 62 Issue No 2 Date 240103 ON DEGREE WHEEL VIEWED NE Issued By PJA H2 H3 H4 H5 H6 Page No 63 c b c a b c a b Apply Loctite 515 to left side of the crankcase Fit cam shaft to left side Inspect 1 Bearing shell in position 2 Loctite on all areas 3 O Rings in 4 Piston Cylinder Assembly complete 5 Thrust washers in position 6 Dowels in T Lifter are in with moly grease on faces You will need 1 An extra person 2 4 7 16 Ring Open End spanners 3 2 9 16 Ring Open End spanners 4 2 3 8 Plain grade 5 nuts 5 2 3 8 Belleville Washers 6 26 through stud nuts MS21042L6 7 10 through studs 8 Torque wench 9 7 16 x 3 8 drive 2 extension snap on no fres 14 10 Long Nose Pliers Note An extra person makes it easier to bolt up and also can cross check work Stage Inspection Oil all bearing crank and camshaft Fit halves over crankshaft assembly and squeeze up by hand Using spacers and plain nuts on rear studs and belleville washers and MS21042L6 nuts on the front studs pull the crankcase together but don t do up tight Remove rear nuts Put all through studs in a b c Fit piston cylinder assemblies to No 1 amp 2 conrods Fit circlips cross check circlips for corre
37. S AYNSSENd TO dNMd WO Woes X71009 OL 10 O SNIVA INVES SATA any Ya 10 OIL Date 031100 Issued By PJA Issue No 2 Page No 93 9 0 TORQUE SPECIFICATION FOR BOLTS amp NUTS Part Spark Plugs Cylinder Head Bolts Crankcase Main Studs Flywheel Gear Bolts Crankshaft Prop Flange Cap Screws Lockwire Oil Pump Cap Screws Tappet Cover Cap Screws Starter Motor Bolts Carburettor Flange Bolts Engine Mount Plate Bolts Gearbox Cover Bolts Alternator amp Coil Mount Bolts Sump Cap Screws Conrod Bolts Propeller Bolts Camshaft Gear Bolts Lockwire Page No 94 Issue No 2 Nom Dia mm 12mm 5 16 3 8 1 4 5 16 3 8 5 16 1 4 5 16 1 4 1 4 5 16 1 4 1 4 1 4 5 16 1 4 1 4 Date 031100 Torque nm ft lbs 11 34 40 20 24 40 20 7 20 11 14 16 14 14 14 24 8 24 30 15 18 30 15 5 15 8 10 12 10 10 10 18 9 5 7 16 12 Issued By PJA KK Page No 95 9 1
38. 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 from solid bar 4140 chrome molybdenum alloy steel the journals of which are precision ground prior to being Magnaflux inspected The camshaft is manufactured of 4140 steel and hardened using a nitriding process 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 which is purchased directly from one of Australia s largest aluminium companies as is all alloy used in the engine thereby providing a substantive quality trail to material source Conrods are machined from 4140 alloy steel the 45mm big end bearings are of the automotive slipper type Various components of the engines are sourced from many Suppliers These items include camshaft followers and the bendix gear in the starter motor The ignition coils are also Page No 5 Issue No 1 Date 031100 Issued By PJA sourced from outside Suppliers and are modified by Jabiru for their own particular application An integral alternator using r
39. arance exceeds 0 5mm 0 020 repair carburettor The overhaul work must be carried out to Jabiru specifications at an approved aeronautical service facility or by an approved Jabiru Service Centre If necessary changes to the TBO Limit due to operational experience will be announced by Jabiru in a Service Bulletin Page No 21 Issue No 2 Date 240103 Issued By PJA 5 7 Engine Preservation The following procedures assume that the engine is installed in a Jabiru LSA airframe For other aircraft types refer to the manufacturer s service manual If the engine is not fitted to an airframe ignore those items referring to the airframe 5 7 1 Flyable Storage Flyable storage is defined as a maximum of 30 days non operational storage Ensure that the engine has been stopped by turning off the fuel valve thereby not leaving any fuel in the carburettor bowl Every 7th day the propeller should be rotated through 5 revolutions without running the engine Leave the propeller in the horizontal position to ensure even distribution of liquids in the wood If left in the vertical position liquids will drain to the lower tip resulting in an unbalanced 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 pre flight inspection Ensure all protective covers are removed 5 7 3 Temporary or Indef
40. are earth magnets provides alternating current for battery charging and electrical accessory drive 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 It is suppressed to prevent radio interference 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 for and aft of the front double bearing allowing either tractor or pusher installation Pistons are sourced in Australia and are re machined to include a piston pin circlip groove They are fitted with 3 rings the top rings being cast iron to complement the chrome molybdenum cylinder bores Valves are 7mm stem dia which are purpose manufactur
41. biru engine to display flicking of the needle pointer for brief periods but still within normal operating regions If it continues check continuity of sender lead and or possible sender change We are assuming oil level is OK 3 CHT Possible not reading can be cause by a break in the sender wires or incorrect polarity High readings can result with poorly centred sender under the spark plug Normal cruise CHT should not Page No 17 Issue No 2 Date 240103 Issued By PJA exceed 150 C and climb must not exceed 175 C Air ducts supplied at present give results below these figures 4 RPM Tacho s may need adjustment when anew engine is fitted Inducted magnet sender units require coil gap to flywheel gear teeth of 014 or 35mm Tacho s using this sender require a pot adjustment access through outside of case Tacho s using the magneto as sender requires a sequence of operation for correction T his information can be faxed if required Later engines use 2 tags under the ring gear in conjunction with the induction sender 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 system for looseness 7 CARBY BREATHER Later model carbies have a brass fitting for venting This is easily connected via a clear plastic hose to a fitting s crewed into the carby heat box On
42. commended Plug gap of around 022 to 024 Remember plugs are installed at around 8 ft Ib or given 1 2 turn after contact with head 18mm Plug spanner us ed COMPRESSION TESTING Condition of compression can be done by a compression gauge Wide open throttle engine warm Turn over on starter Below 90 PSI would indicate removal of head and possibly cylinder PRESSURE DIFFERENTIAL TEST Leak down This is a much better test for condition of rings bore head sealing and valve Engine in warm to hot condition This is the normal test used in aviation requiring specific equipment for the job Pressure input of 80 PSI a second gauge reads the differential when supplying 80 PSI This is done with piston on TDC on the firing stroke Prop needs to be restrained The differential cut off is 80 60 Problems can be better identified eg BLOW BY CRANKCASE VENT RINGS BORE SEAL LEAKING FROM CARBY INTAKE VALVE SEAL LEAKING FROM EXHAUST EXHAUST VALVE SEAL HEAD LEAK HEAD GASKET OR HEAD TO CYLINDER SEAL Correction work can then be carried out ah al sly Page No 16 Issue No 2 Date 240103 Issued By PJA COIL GAP Best done with a piece of plastic or thin card of a thickness 010 Cut into a strip approximately 15mm wide Place between magnets on flywheel and coil STARTING A warm idle of around 650 RPM will automatically create the right starting environment Idle set screw may have to be adjusted Carby has been factory set N
43. ct fit Push cylinders home Put cylinder base nuts MS21042L6 on Using 2 7 16 ring spanners do up each side together If one nut goes on more than 3 turns put the 3 8 plain nut on top of it and use a 9 16 ring spanner to hold the nut locking up the stud Issue No 2 Date 240103 Issued By PJA Torque up by hand lightly d Turn engine so that No 3 amp 4 conrod are out Repeat procedure on No 3 amp 4 Repeat for conrod No 5 amp 6 H7 a Torque to 15 ft lbs then 30 ft Ibs 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 Timing timing marks on cam gear are on 2 teeth crank gear has one mark H8 a Fit crankshaft gear as drawing and put one bolt in crankshaft to hold gear x f ALIGN MARKS ON GEARS Drawing lt 1 TIMING GEAR ALIGNMENT MViavy Iug ITI LUUT b Mount a dial indicator on cylinder with the plunger on the center of the piston Page No 64 Issue No 2 Date 240103 Issued By PJA c d e g h Head Fitting H9 a b c Page No 65 Zero the indicator at T D C Fix a wire pointer of the oil seal bolt hole and roughly set to T D C Turn 1 4 turn backwards then forward until the piston is 2mm from T D C Note degrees Turn past T D C to 2mm down from T D C Note degrees Add two toget
44. e Stop In normal conditions cooling down the engine during descent amp taxiing will permit the engine to be stopped by switching OFF the ignitions 4 6 Engine Stop and Start During Flight Reduce power to 1000 RPM to cool engine for 30 seconds then to idle Switch ignitions OFF Starting procedure is the same as ground starting without choke for a warm engine amp with choke for a cold engine Note Engine cools quickly with propeller stopped in flight Choke will therefore normally be needed to restart 4 7 Addition Early Operation of Engine JABRU ENG WE NOTES NEW ENGINE NOTES This engine has been ground run to a specific run in 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 and turning over will help periodically Before initial start oil engine 3 4 litres with cooler remove one plug per head activate starter to remove excess inhibitor Once oil pressure is obtained replace plugs and continue start up s equence The following are tips to ensure along life 1 OIL Use anon compounded AVIATION oil Aero Shell 100 Mobil Red Band BP Aviation Oil 100 Use for 20 25 hours Drain and replace with a compounded oil Aero Shell W100 Aero Shell 15W50 for cooler climates Mobil Aero 100 SAE 50 BP Aero Oil DIOOAP Multigrade Aero Oil D SAE 20 W 50 Aero Sh
45. ed for the Jabiru engine The valve gear includes pushrods from the camshaft from the camshaft followers to valve rockers which are CNC machined from steel plate induction hardened and polished on contact surfaces and mounted on a shaft through a teflon bronze steel bush Valve guides are manufactured from aluminium bronze as is found in larger aero engines and high performance racing engines Replaceable valve seats are of nickel steel and are shrunk into the aluminium cylinder heads The valve gear is lubricated from the oil gallery Engines use solid lifters and require periodic checking of rocker to valve clearance An internal gear pump direct mounted on the camshaft and incorporating a small automotive spin on filter provides engine lubrication An oil cooler adapter is provided Most installations require an oil cooler to meet oil temperature limits The standard engines are supplied with two RAMAIR cooling ducts which have been developed by Jabiru to facilitate the cooling of the engine and direct air from the propeller to the critical areas of the engine particularly the cylinder heads and barrels The fitment of these RAMAIR cooling ducts is a great bonus for the home builder or engine installer as they obviate the need to design and manufacture baffles and the establishment of a plennum chamber which is the traditional method of cooling air cooled aircraft engines The fact that these baffles and plennum chamber are not required also
46. ed By PJA Jabiru 3300 Component Assembly Procedure Subassembly H Final Assembly No Details Sign H1 Apply Loctite 515 to crankcase halves lubricate where necessary H2 Locate camshaft and crankshaft in crankcase half Stage 3 Stage Inspection Pre joining Crankcase H3 Locate crankcase half over crankshaft and camshaft H4 Tension front 2 and rear 2 studs H5 Fit oil pump assembly and front seal housing H6 Place all through bolts in crankcase H7 Fit piston and 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 24 ft lbs H11 Fit push rod and valve gear Set gap to 0 10 0 25mm H12 Check camshaft timing DEGREES H13 Fit fuel pump H14 Fit engine mount plate and gearbox housing H15 Fit flywheel alternator mount plate and ignition coils and lead H16 Fit carby assembly H17 Fit exhaust system Sign Date I hereby certify that the subassembly has been completed using the approved procedures and data and is fit for installation Signed Date For Jabiru Aircraft Pty Ltd Certificate of Approval 3501 Notes Page No 88 Issue No 2 Date 031100 Issued By PJA
47. ee Paragraph 5 1 Move throttle position to FULL amp check for ease of movement over the entire range 4 2 Starting Procedure Fuel Tap OPEN Choke ON in cold conditions Fuel Pump ON for 10 seconds then off Throttle CLOSED to Stop Master ON Ignition BOTH ON Starter PRESS Attention Activate Starter for a max 20 seconds followed by a cooling period of 1 minute When engine runs adjust throttle to achieve smooth running at approximately 1000 RPM Deactivate Choke Check Oil Pressure has risen within 5 seconds if not shut down It is strongly advised to close choke while cranking on first attempt To much choke will cause over fuelling and loss of start It is strongly recommended to crank the engine to obtain oil pressure following an oil change before starting 4 3 Warming Up Period Ground Test Start the warming up period with the engine running at 1000 RPM Continue at 1400 RPM depending on ambient temperature until oil temperature reaches 15 C 59 F Check the two ignition circuits at 1600 RPM Note RPM with only one ignition should not drop by more than 100 RPM DO NOT apply full power until CHT reaches 100 C 2120F DO NOT allow cylinder heads to rise above 150 C during ground running 4 4 Take Off Climb with the engine at maximum continuous power Observe Oil amp Cylinder Head Temperatures amp Oil Pressure Limits must not be exceeded Page No 12 Issue No 2 Date 240103 Issued By PJA 4 5 Engin
48. ell W 100 Plus The normal running oils are detergent and ashless dis pers ant types See MAINTENANCE SECTION 5 3 Page No 13 Issue No 2 Date 240103 Issued By PJA Add 3 2 Litres without oil Cooler 3 4 Litres with an oil cooler Avoid prolonged ground running at elevated RPM Engine can be over heated remember air ducts are designed for in flight cooling NOTE remove ALL plastic bungs on engine EXHAUST 4 CARBY 2 OIL VENT 1 FUEL PUMP 1 DOTAKE OFF AT FULL POWER For the first few take offs climb at a higher airspeed Reduce power at cross wind leg and shallow climb lower nose VARY your RPM when flying Avoid high nose altitude continual climbs The higher the climb out speed the better for engine cooling No low speed high nose altitude climb outs Ring bedin is accomplished better at 75 power and above Avoid heat build up Monitor CHT and oil temps Vary RPM Initial temps will be elevated due to friction of anew engine 10 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 s udden heating up and sudden cooling down RETORQUE heads as suggested on warning sheet 24 ft Ib and 010 valve clearance all done cold Subs equent torquing of around 22 to 24 seems to helpin settling down head bolts and heads Don t BABY YOUR ENGINE but monitor carefully CHT and oil
49. fitting rest of heads Put loctite 262 on rocker cap screw and torque to 8 ft lbs f Torque heads to 16 nm then 34 nm 12 ft Ibs then 24 ft Ibs g Adjust all valves to 0 25 mm 0 010 Note Valves must be adjusted with the lifter 180 to the peak lift to 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 important to make sure the sump is level with the rear crank case face b Fit induction pipes to heads before fitting heads c Fit lower pipes and hoses later engines S N 68 on had a bolt on swept Plenium chamber Gear Case and Rear H11 Pagel a Insure Gear case is fitted up Backing plate is ready All bolts are ready Loctite 515 Loctite 242 Loctite 262 b Turn engine around until it is 25 B T D C No 1 compression c Put loctite 515 on crankcase Fit engine mount plate Make sure 2 inside cap screws are in Use loctite 242 on all cap screws d Put loctite on gear case and point rotors to No 1 position n CAP 5 C NTO REAR 3y PJA Drawing 9430064 Page No 67 Issue No 2 Date 240103 Issued By PJA Drawing 9431064 2 REAR PLATE GEAR HOUSING amp Drawing 9431064 Note When gear case goes on 1 Make sure No 1 is 25 before T D C compression Both valves should be seated
50. g with Ignition OFF 93 10 8 Excessive Oil Consumption 94 10 9 Knocking Under Load 94 10 10 Engine Hard to Start at Low Temperature 94 11 0 Engine Warranty Form 95 96 Page No 3 Issue No 1 Date 031100 Issued By PJA List of Amendments Page Amendment Date Issue Page No 4 Issue No 1 Date 031100 Issued By PJA 1 0 DESCRIPTION OF DESIGN 4 Stroke 6 Cylinder Horizontally Opposed One Central Camshaft Pushrods OHV Ram Air Cooled Wet Sump Lubrication Direct Propeller Drive Dual Transistorised Magneto Ignition Integrated AC Generator Electric Starter Mechanical Fuel Pump Pressure Compensating Carburettor Bing Type 94 40 ae eS SS SS SS SS SS SS SS e It is said that aircraft are designed around available engines Jabiru believe that the Jabiru range of very light engines will now offer new 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 The vast majority of the components are manufactured in Southern Queensland in a network of high technology small companies The crankcase halves cylinder crankshaft starter motor housings gearbox cover the gearbox powers the distributor rotors and coil mounts together with many smaller components are machined using the latest CNC machine tools The sump oil pan is the only casting
51. h 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 need to be checked 5 7 5 Returning Engine to Service After temporary storage the procedures for returning the aircraft to service are as follows 1 Check battery and install 2 Check carburettor air filter and service if necessary 3 Remove warning placard from propeller 4 Remove materials used to cover openings 5 Remove clean and gap spark plugs 6 While spark plugs are removed rotate propeller several revolutions to clear excess preservative oil from cylinders CAUTION Ensure that the Master and Ignition Switches are OFF 7 Install spark plugs torque to 11 Nm 8 ft lbs 8 Check fuel filter replace if necessary Page No 23 Issue No 2 Date 240103 Issued By PJA 9 If returning to service after indefinite storage fill fuel tank with correct grade of fuel 10 Check fuel tank and fuel lines for moisture and sediment Drain enough fuel to eliminate any moisture and sediment 11 Check fuel tank breather is clear 12 Perform a thorough pre flight inspection 13 Start and warm engine 5 8 Operation in Winter It is recommended to carry out an engine service prior to the start of the cold season For selection of oil consult the table of lubricants at Paragraph 2 5 Follow the following advice for operation at extremely low temperatures 5 8 1 Carburetto
52. has started it is not supplied with an excessively rich mixture and stalled The starting carburettor is therefore matched to any given engine by modifying the starting jet and matching the space behind it The starting carburettor is secured to the carburettor housing by four screws 51 and protected against ingress of dirt and water by the seal 50 between the two The starting shaft is also sealed against the starting carburettor housing by a rubber ring 49 Nadelstellung Carburettor Overhaul Page No 59 Issue No 2 Date 240103 Issued By PJA Note As a guide to overhaul read carburettor operation Gl Disassemble carburettor G2 Using over haul kit replace all components G3 Record jet size G4 Record needle position G5 Reassemble carburettor Page No 60 Issue No 2 Date 240103 Issued 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 cardboard and cut out BER LULL Drawing 9427063 Page No 61 Issue No 2 Date 240103 Issued By PJA b Stand crankshaft Sub assembly A up vertically mounted on the prop flange as per drawing MATCH CONROD amp C
53. her then divide by 2 and set pointer at this with piston down 2mm Note The crank is mounted to turn the engine in direction of rotation turn crankcase anti clockwise viewed from rear Repeat again to check Note Itis important to find T D C accurately as it is the datum for setting the cam timing and ignition timing Set dial indicator up to measure lift on No 1 exhaust Set to 0 on max lift Turn 1 4 turn backwards then turn until 0 5mm 0 020 from peak note degrees continue turning until 0 5mm 0 020 after peak Note Always turn in direction of rotation to eliminate back lash in gears Calculate total degrees and divide by 2 to find peak Peak should be 709 72 after B D C The cam shaft gear has 22 teeth and 6 bolt holes so if it needs adjusting Move the gear around and re check Record final measurement in build sheet Insure All O Rings are place and greased Have all head bolts Head Gaskets Push rod tubes Push Rods Rocker Blocks Loctite 515 Loctite 626 Fit heads by hand Push the push rod tube through the head and all the way home Fit circlips Issue No 2 Date 240103 Issued By PJA Note Make sure outside of tubes are smooth or it will damage the O Rings d Oil Push rods and fit Note Make sure ball end of push rod is in the socket of the lifter It also helps if the lifter is on the base circle of the lobe e It is a good ides to fit heads No 3 amp 4 with rocker gear before
54. ied throttle closed amp the cockpit attended by a trained person WARNING A hot engine may fire with the ignition s switched OFF CAUTION Continued operation with incorrectly adjusted tappets will result in damage to valves valve seats valve guides amp overhead gear Head torque and valve adjustment at 5 10 hrs from initial start up Continual operation with leaky valves will result in engine damage Prior to takeoff follow the Starting amp Warm Up procedure observe the engine behaviour amp throttle response Check temperatures amp pressures Conduct a short ground test at full power a few seconds Max consult aircraft Flight Manual NOTE Any prolonged running at full power on the ground can cause serious damage to the engine Operation of the engine with partially sealing exhaust gaskets will cause engine damage Page No 19 Issue No 2 Date 240103 Issued By PJA 5 2 Periodic Checks After the initial 25 hours check in accordance with para 5 3 After 50 hours of operation check in accordance with para 5 4 amp thereafter after each 50 hours of operation After 100 hours of operation check in accordance with para 5 5 and thereafter after each 100 hours of operation At TBO overhaul in accordance with para 5 6 5 3 Check After Initial 25 Hours Details of specific operations are shown in Chapter 6 Maintenance Remove engine cowlings check engine mounts Thoroughly check engine for miss
55. ing or loose bolts nuts pins etc amp for abrasions Check induction and exhaust flange for loose bolts Check safety wires cooling air ducts amp baffles ignition wiring amp hose connections Oil Change 3 5 litres normal aviation oil Change oil filter First 25 hours only Inspect old filter Retorque cylinder head bolts 24 ft Ibs in diagonal pattern Check tappet clearance and adjust as necessary refer Para 6 8 0 010 cold inlet and exhaust Check exhaust system Check exhaust cap screw tensions and gasket condition Check fuel system for leaks amp abrasion Check wiring for damage amp for tightness Engine test run Observe starting warm up amp acceleration behaviour to maximum RPM 10 seconds max Check temperatures amp pressures Engine stop Page No 20 Issue No 2 Date 240103 Issued By PJA 5 4 50 Hours Check Details of specific operations are shown in Chapter 6 Maintenance Conduct the items shown under 25 Hour Check at para 5 3 5 5 100 Hours Check Details of specific operations are shown in Chapter 6 Maintenance Conduct the items shown under 25 Hour Check at para 5 3 Renew spark plugs if necessary 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 clearance on throttle valve shaft If radial cle
56. inite Storage Temporary storage is defined as aircraft in non operational status for a maximum of 90 days Treat as for flyable storage see Paragraph 5 7 1 plus For temporary storage fill fuel tank with correct grade of fuel to prevent moisture accumulation For indefinite storage drain fuel tank ensure carburettor bowl is empty by running engine with fuel valve off until it stops or by draining bowl Then 1 Disconnect spark plug leads and remove spark plugs from each cylinder 2 Using a spray atomiser spray the oil through the spark plug hole with the piston down then rotate until both valve are open and respray to coat the induction and exhaust system When all cylinders are treated leave prop horizontal and retreat each cylinder Page No 22 Issue No 2 Date 240103 Issued By PJA NOTE Use Shell Aero fluid 2UN MIL C 6529C Type 1 Corrosion Preventive Concentrate or similar engine preservative CAUTION Ensure that the Master and Ignition Switches are OFF 3 Install spark plugs and connect leads 4 Seal exhaust pipes Attach a red streamer to each seal DO NOT seal fuel tank breather 5 Attach a warning placard to the propeller stating that vents and breathers have been sealed and prop should not be turned The engine must not be started with the seals in place 5 7 4 Inspection During Storage 1 Inspect the interior of at least one cylinder through the spark plug hole for corrosion at least once a mont
57. ion and Repair C21 2 3 4 5 Page No 40 Inspect cylinder head for flatness If sealing surface show signs of leakage it may need refacing When refacing remove only the minimum to clean up Measure valve guide wear If wear is excessive remove guides Measure valve guide bore in the head The new guide must have at least 0 05mm 0 002 interference on the outside diameter Note The standard guide has no dimples in top P N 4518064 In P N 4519064 Ex 0 05mm 0 002 has one dimple 0 05mm 0 004 has two dimples 0 05mm 0 006 has three dimples Press guides back in Note Oil hole must go up Special note Guides Guides are installed at 7 05mm bore diameter Guides from 7 08mm can cause oil usage in the engine Max valve stem to guide clearance is 0 12mm Issue No 2 Date 240103 Issued By PJA 5 Page No 41 SPECIAL TOOL FOR VALVE GUIDE FITTING VALVE GUIDE INCLIN Fa 13 REF 4 064 SA 944606 Drawing Drawing 9446064 Mount head up and cut seats as per drawing ED BASE VALVE GUIDE REPLACEMENT ad 549 50 1 34 po Ve 5 a 300 one 57 18 0 5 1 1 10 0 02 N 1 0 YO 0 04 T Ls on VALVE SEAT DETAILS EXHAUST VALV INLET Drawing 9445064 i P e ai s O E SEAT DETAILS Note When cutting seats cut enough to clean up but try to remove as little as possible This wil
58. ised Service Centre be liable for any contingent costs through the engine or aircraft being out of service for whatever reason Page No 102 Issue No 1 Date 031100 Issued By PJA SPECIAL NOTICE TO OWNERS AVAILABILITY OF SERVICE AND PARTS AFTER WARRANTY JABIRU Aircraft Pty Ltd maintains a substantial stock of spare parts and operates a Service Exchange Programme in respect to some components Every endeavour is made to ensure that JABIRU carries adequate stocks of service parts and that Authorised Service Agents are equipped to provide satisfactory service but JABIRU does not make any promise that after the expiration of the warranty such parts or service will be available or available at any specific location or at any particular time UNAUTHORISED STATEMENTS IN RELATION TO JABIRU PRODUCTS No JABIRU Authorised Service Centre or other person is authorised 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 connection with the supply of any JABIRU product which is at variance with any written statement assertion or undertaking on any of these subjects given or made by JABIRU in its published sales literature and the company does not accept any such unauthorised action WARRANTY ON JABIRU REPLACEMENT PARTS JABIRU warrants in respect of JABIRU parts and accessories required as replacement parts that
59. it at overhaul It can be inspected for faults by removing the top half Things to look for are 1 Stuck or leaking valves 2 Torn diaphragm 3 Weak springs 4 Broken actuating lever Carburettor Operation The BING constant depression carburettor type comprises a cross draught butterfly valve carburettor with variable choke tube double float system arranged centrally below the carburettor venturi and a rotary valve type starting carburettor It features a throttle slide which is suspended from a roller diaphragm and projects into the venturi It changes the smallest cross section choke tube of the venturi as a function of the vacuum at this point MOUNTING The carburettor is secured to the engine using a 52mm push on connection which takes a flexible connecting piece with clamps On the intake side the carburettor is provided with a socket having a diameter of 55mm and a 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 centrally below the carburettor choke tube so that the carburettor can be tilted very far in all directions without impairing operation The object of the float is to maintain the fuel level in the float chamber 44 constant When the fuel has reached a specified level in the float chamber then the float 40 mounted on pin 41 is lifted until the float needle 42
60. it will make good by repair or at its option by replacement any defect occurring in any such JABIRU parts and accessories within twelve 12 months from the date of acquisition Normal wear and tear is excluded This warranty does not cover those parts listed as exclusions in the New Engine Warranty and is subject to the same general exclusions Page No 103 Issue No 1 Date 031100 Issued By PJA Shane JAB RU WARRANTY CLAM FORM FROM DATE ENGINE PARTS J AIRFRAME PARTS m ENGINE NUMBER AIRFRAME KIT NUMBER PART NUMBER TOTAL HOURS OWNER PREVIOUS OWNER PART DESCRIPTION CLAIM FAULTY GOODS RETURNED YES J COURIER Co REF NO No q ALL GOODS THAT ARE BOXED AND HAVE TO PASS THROUGH CUSTOMS HAVE TO BE CLEANED AND FREE FROM CONTAMINATION WITH A STATEMENT ATTACHED SPECIFING HOW THEY WERE CLEANED AND THAT THEY ARE FREE OF DIRT AND GRASS SEEDS IF THEY ARE NOT CLEANED TO CUSTOMS SATISFACTION AN EXTRA CLEANING CHARGE WILL APPLY IF WARRANTY CLAIM IS NOT COMPLETELY AND CORRECTLY COMPLETED WARRANTY MAY BE REFUSED OFFICE USE ONLY APPROVED NOT APPROVED d REASON PRINTED NAME SIGNED DATE Page No 104 Issue No 1 Date 031100 Issued By PJA
61. ivery system are cooled to prevent fuel vaporization Page No 25 Issue No 2 Date 240103 Issued By PJA 6 0 MAINTENANCE 6 1 Lubrication System Oil Change Oil Filter Change Visual Check for Leaks Drain the oil while engine is still warm Change the oil filter at 100 hour inspection Fill with oil Capacity is 3 5 litres 3 69 US Quarts check oil level with dipstick screwed right in before removing to check Check oil level The MAX mark must not be exceeded Use only registered brand oils meeting the specification detailed in Para 2 5 6 2 Air Intake Filter Clean filter by removing from the intake housing amp blowing compressed 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 engine performance as well as promote premature engine wear 6 3 Carburettor Adjustment Idle stop screw is 7mm Open idle mixture screw approximately 1 1 4 turns fine adjust for a smooth idle The determination of the main jet is carried out on a dyno at 107 ft above Mean Sea Level IMPORTANT Check amp oil carburettor joints amp linkage 6 4 Compression Check Page No 26 Issue No 2 Date 240103 Issued By PJA Measure compression using a compression tracer Readings are taken with fully open throttle valve at engine oil temperature between 30 amp 70 degrees C 90 to 160 degrees
62. kshaft I hereby certify that the subassembly has been completed using the approved procedures and data and is fit for installation Signed Date For Jabiru Aircraft Pty Ltd Certificate of Approval 3501 Notes Page No 75 Issue No 2 Date 240103 Issued By PJA Com ponentRegisterand Parts Inspection Record Subassembly A Crankshaft Propeller Mount Flange and Conrods Batch __ SerialNo __ Date Description PartNo Batch Item Details Mains Big End T A TO E 71s 4 Crankshaft 4629072 Propeller Mount Flange 4662084 B E Dia D Conrod 1 4651183 7 vl 8 MES ee 2 4651183 i ee 3 4651183 Se ee ee 4 4651183 gt gt gt _ ee a 5 4651183 6 4651183 Conrod SHCS 5 16 x 1 UNF Bearings ACL 4B8290 I hereby certify that the above listed parts conform with the dimensions have been engraved and installed as recorded Signed _ Date _ gt For Jabiru Aircraft Pty Ltd Certificate of Approval 3501 Page No 76 Issue No 2 Date 031100 Issued By PJA Jabiru 3300 Component Assembly Procedure Subassembly B Crankcase and Camshaft Assembly No Details Sign Date Bl Inspect case deburr clean check oil holes B2 Fit inner stud O rings B3 Fit all studs B4 Fit outer oil suction and co
63. l give maximum number of overhauls on heads Issue No 2 Date 240103 Issued By PJA 6 Use ground and serviceable valves to check seat contact Note If machine has a vacuum tester vacuum test valves 7 Heads of valves must be above the level 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 If margin is too small replace valves INLET VALVE 0 6 MIN EXHAUST VALVE 1 0 MIN f 0 024 7 0 040 Ss a gt wo S a w fo 9444064 1 VALVE DETAILS Drawing 9444064 C3 1 Clean heads and valves ready for assembly 2 Measure valve springs Replace if they are shorter than service limits 40 0mm 41 8mm 1 580 1 688 Page No 42 Issue No 2 Date 240103 Issued By PJA A 0 10 20 30 40 50 69 70 830 90 bliin outlay aula oe oe 5 i E SPRING MEASUREMENT Drawing 9443064 3 Inspect 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 Note All engines have same spring retainer on exhaust and inlet VALVE SPRING COLLETS
64. ld sheets are Pre Run Check List Run In Programme Post Run Checklist 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 know what our engine is in and what has been done to it Fax Number Within Australia 07 4155 2669 Outside Australia 61 74155 2669 Page No 73 Issue No 2 Date 240103 Issued By PJA Jabiru Aircraft Pty Ltd WARNING This engine has been run in and is ready for flight DO NOT GROUND RUN THIS ENGINE This engine has been inhibited and the oil system drained Before first start of new engine remove 1 spark plug from each head Add the required run in oil to sump 3 4 litres engine must have oil cooler fitted Press starter to obtain oil pressure and to throw out excess inhibiting oil in cylinders Replace plugs NOTE ALL plastic bungs must be removed At each 5 hours for first 15 hours check tappet clearances 0 010 cold and cylinder head bolt torque 24 ft lbs 32nm Note New style heads have a 1 8 NPT plug to be unscrewed to uncover head bolt No 5 joo 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 Ibs and check valve clearances inlet
65. mbly C Pistons Cylinders and Cylinder Heads No Details Sign Date Cl Clean and deburr all parts C2 Record all measurements C3 Install pushrod tube O Rings C4 Check valve seats fit spring retainers 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 Install piston assembly to cylinder just clear of the oil ring I hereby certify that the subassembly has been completed using the approved procedures and data and is fit for installation Signed Date For Jabiru Aircraft Pty Ltd Certificate of Approval 3501 Notes Page No 79 Issue No 2 Date 031100 Issued By PJA Com ponentRegisterand Parts Inspection Record Subassembly C Pistons Cylinders and Cylinder Heads Batch Serial No Date Description Part No Batch Item Details Guides Inlet Outlet Head 1 4657082 2 4657082 3 4657082 4 4657082 5 4657082 6 4657082 Cylinder 1 4554062 2 4554062 3 4554062 4 4554062 5 4554062 6 4554062 Piston 1 4685083 2 4685083 3 4685083 4 4685083 5 4685083 6 4685083 Rockers LH 4647084 RH 464808N Gudgeon Pin 4299054 I hereby certify that the above listed parts conform with the dimensions have been
66. nrod welch plugs B5 Fit oil relief valve oil pressure sender and pressure switch B6 Fit bearing shells 16 B7 Assemble and torque to 30 ft Ibs B8 Measure main tunnel and camshaft bearings B9 Measure Cam Follower Bores B10 Fit Lifters Bll Check Camshaft End Float B12 Check Crankshaft End Float I hereby certify that the subassembly has been completed using the approved procedures and data and is fit for installation Signed Date For Jabiru Aircraft Pty Ltd Certificate of Approval 3501 Notes Page No 77 Issue No 2 Date 031100 Issued By PJA Com ponentRegisterand Parts Inspection Record Subassembly B Crankcase and Camshaft Assy Batch Serial No Date Description Part No Batch Item Details Crankcase LS 4621072 Crankcase 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 B Crankshaft Gear 4643084 LHS Main Bearings 5M1869 RHS Page No 78 I hereby certify that the above listed parts conform with the dimensions have been engraved and installed as recorded Signed _ Date __ For Jabiru Aircraft Pty Ltd Certificate of Approval 3501 Issue No 2 Date 031100 Issued By PJA Jabiru 3300 Component Assembly Procedure Subasse
67. nsure that the fuel needle spring is not compressed by the float weight It is therefore advisable to put the carburettor in a horizontal position until the float just contacts the float needle In this position the point on the float hinge is set in such a way that the float top edges are parallel to the top edge of the float chamber The float chamber 44 is secured to the carburettor housing by a spring yoke 45 A seal 46 is provided between float chamber and carburettor housing The space above the fuel level is connected to atmosphere by two ducts When these ducts are blocked an air cushion forms above the fuel The fuel will not lift the float sufficiently to close the needle valve and the carburettor overflows The float chamber 44 incorporates an overflow pipe to allow fuel to drain off if the specified level in the float chamber is 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 sectional area in the choke tube which is opened by the throttle valve 23 The throttle valve is secured to the valve shaft 24 by two screws 25 The end projecting from the carburettor housing carries the throttle levers 27 28 which are secured by the nut 3 and washer 29 to which the Bowden cable operating the throttle shaft is attached The sealing ring 26 provides the seal between valve shaf
68. odd noises or heavy movements Check for regular compressions if irregular firstly check tappet adjustment Operation with incorrectly adjusted tappets with result in damage to valves valve seats guides and overhead gear HEAD TORQUING VALVE SETTING Your tension wrench should be accurate It should have had some method of calibration They can vary to manufacturers claims 24 ft Ib on head bolts 010 on valve clearance cold Engines use a 9 16 thin walled or tubed socket and a blade screwdriver Page No 15 Issue No 2 Date 240103 Issued By PJA Easiest method of setting valves requires you to pull the prop until exhaust valve on No 1 cylinder is fully depressed Note the O clock position Rotate prop 360 and adjust valve This puts the cam and lifter at 180 to the peak lift Repeat for each valve Heads and valves should be done at least twice at 5 hrs and 10 hrs on anew engine You may also adjust each cylinders valves on the firing stroke Firing order 145236 at TDC Remember to go over exhaust cap screws They are fitted with shakeproof washers to prevent loos ening AIR DUCTS Periodic research and development does cause at time changes to occur Ones supplied need to be fitted See instructions manual FILTERS Inspections down the track are a must for fuel and air filters Conditions will dictate when changed The air box has a rubber flap to give partial inspection of filter SPARK PLUGS NGK D9EA are re
69. ormal start requires throttle closed that is the idle criteria has just cracked the butterfly in the throat body and also apply choke The engine is difficult to start if throttle is cracked open somewhat As the engine is cranked the choke should be pushed off Engine should fire The choke is only used for a cold start Prolonged cranking with choke will only flood the intake system making starting difficult Should this occur leave or clear the system on full throttle momentarily mags off Cranking speed if too slow poor battery or starter fault will prevent magneto operation Jump starting with care will point towards poor battery 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 It is unusual for a problem to occur however a few of common type are listed 1 LOW OIL PRESSURE A sudden drop of pressure usually is caus ed by a small piece of foreign matter being lodged under the relief valve Simply remove oil filter and cooler adaptor if fitted Remove matter by depressing plunger or removing relief mechanism Replace and check operation by groundrun If low pressure persists the problem will need further inves tigation We strongly recommend the fitting of an approved oil cooler to Jabiru engines 2 FLICKING OF OIL PRESSURE GAUGE It is not uncommon for the Ja
70. ot authorised in writing by JABIRU G 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 or someone else authorised by JABIRU in writing k the use of any engine oil or fuel additive s or oil stabiliser s BY JABIRU or as otherwise decided by JABIRU MAKING GOOD THE DEFECT BY REPAIR OR AT THE OPTION OF JABIRU BY REPLACEMENT Excluded from this Warranty are service items such as engine tuning adjustments replacement of air and oil filters spark plugs etc which are required as part of normal engine maintenance This Warranty is given to the person who is entitled to possession of the engine whether as owner lessee or otherwise and is given in addition to all right conferred by law on that person Warranty repairs do not extend the original warranty Due to the substantial number of problems that can arise due to installation errors JABIRU shall not be liable for any labour and or service charges for removal reinstallation and adjustment which are the responsibility of the buyer and are not covered by this Warranty Consequential damages and freight costs are also not covered by this Warranty JABIRU makes no representation that this engine is suitable for installation in any particular aircraft and the responsibility for determining such suitability rests without the Buyer Under no condition shall JABIRU or a JABIRU Author
71. process to form minute fuel droplets and thus favourably affects the fuel distribution in the intake manifold and combustion in the engine The conical section of the jet needle 4 which is secured to the plunger 13 with the retaining spring 14 and the serrated washer 15 engages into the needle jet 3 Depending on the dimension of the flat cone at the end of the jet needle the annular gap between jet needle and needle jet is enlarged or decreased and thus the fuel supply is throttled to a lesser or greater extent The jet needle 4 can be located in the plunger 13 in four different positions which similarly to the jet needle cone affect the amount of fuel drawn in For example needle position 3 means that the jet needle has been suspended from the retaining spring 14 with the third notch from the top To achieve the height adjustment the jet needle is turned through 90 and pushed up or down the retaining spring engaging the next notch in the jet needle If the needle is suspended higher up this will result in a richer mixture and vice versa In short the main regulating system is set using main jets and needle jets of various diameters and also jet needles plungers and pistons of various types Between main jet 1 and nozzle stock 10 a washer 12 is provided which together with the float chamber forms an annular gap In particularly severe operating conditions this ensures that the fuel is not spun away from the main jet
72. quired 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 Maximum Idle Speed Oil Pressure Normal Operations Min Max Idle Min Starting amp Warmup Max Oil Temperature Min Max Continuous Temperature Max Cylinder Head Temperature Continuous Page No 10 Issue No 2 2750 RPM 3300 RPM ISO STD Conditions 700 800 RPM HOT 220 kPa 31 psi 525 kPa 76 psi 80 kPa 11 psi 525 kPa 76 psi 15 C 59 F 118 C 244 f 80 100 C 1769 2120F 175 OC 3480F reading on the sensor spot of the hottest cylinder 150 C 302 F Max Date 031100 Issued By PJA 3 0 PERFORMANCE GRAPHS sq qi enbso ZA ES gt gt S D oO c c N lt 7 KS J 7 Li E Cr Oo 5 C5 E lajs _ 2 T N T lt N h gt oma gt T 5 Q 2 NI oe i gt D A D foe ea gt S C N laa i S x C_ Lx 2 LS 2 5 gt gone 2 gt T D gt J la Se Page No 11 Issue No 2 Date 240103 Issued By PJA 4 0 OPERATING INSTRUCTIONS To ensure that the engine operates reliably carefully observe all of the operating amp maintenance instructions 4 1 Pre Start Checks Daily Checks S
73. r Icing It is important to distinguish between two kinds of icing 1 Icing due to water in fuel and 2 Icing due to high air humidity Re 1 Water in fuel will accumulate at the lower parts of the fuel system amp can lead to freezing of fuel lines filters or jets Remedies are Drain using fuel tank water drain Ensure fuelling without traces of water If in doubt use a chamois as a filter Install a generously sized water separator Ensure that fuel lines do not permit the accumulation of water Add up to 2 isopropyl to fuel Note Addition of alcohol raises vapour pressure and may aggravate vapour lock in warm weather this practice should be used only when needed and not in warm weather Prevent condensation of humidity ie avoid temperature differences between the aircraft amp fuel IMPORTANT Page No 24 Issue No 2 Date 240103 Issued By PJA Fuels containing alcohol always carry a small amount of water in solution In situations where there are changes in temperature or where there is an increase in alcohol content water or a mixture of water amp alcohol may settle amp could cause problems Re 2 Carburettor icing due to humidity may occur in the carburettor venturi amp 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 fuels ensure all components of the fuel del
74. rawing 9441064 1 Make spacers as per drawing L DRILL 10 DIA Drawing 9442064 1 SPACER FOR MEASURING CRANKCASE Drawing 9442064 2 Join crankcase halves 3 Put through studs in case Note the cylinders by themselves can be used as spacers It is just a bit harder to measure the main tunnels 4 Fit old nuts and torque to 40 NM 30 ft Ibs in two stages Measure main tunnel and cam tunnel and record in build sheet 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 surfaces Refit bearing shells Measure cam lifters and bores and record on build sheet Check Lifter face for excessive scuffing Oil and refit Use a small amount of Molybdenum disulphide grease on lifter faces Check cam shaft end float in both halves Record in build sheet Check crankshaft end float in both halves and record in build sheet Page No 39 Issue No 2 Date 240103 Issued By PJA Jabiru 3300 Component Inspection and Assembly Procedure 7 4 3 Sub Assembly C Pistons Cylinders and Cylinder Heads Cylinder Head Clean Up Cl 1 Clean oil off heads 2 Dip heads in a cold dip solvent i e Redik dkt Degreaser Decarboniser Paint stripper as per manufactures instructions to remove all carbon deposits 3 Note The heads can be bead blasted but care must be taken 4 Wire buff valves 5 Clean all other parts Cylinder Head Inspect
75. ront Seal amp Flange H17 a Remove from vertical stand and mount on engine mount stand b Remove prop flange c Clean off oil from sealing surfaces d Use loctite 515 on crankshaft seal carrier to crankface and loctite on cap screws Put a little grease on seal Install seal e Prime crankshaft and new prop flange bolts with loctite primer Using loctite 262 fit flange and torque to 40 nm 30 ft Ibs f Wire flange If for any reason the prop flange has been damaged or become detached flywheel capscrews must be replaced Page No 69 Issue No 2 Date 240103 Issued By PJA 7 4 9 Engine Run In The Jabiru engine is run in on a DYNOMOMETER and cooled with fan driven air In the absence of a DYNO controlled run engines can be run in in the airframe Very large air ducts must be constructed to get adequate airflow for cooling in the static situation The flying air ducts must not be used for this purpose Extreme care must be taken with the cylinder head temps if run in is done in the airframe Engine run in procedure allows progressive build up of the B M E P break mean effective 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 in detail after the engine build sheets All engines are run in before delivery including overhauled engines as well When delivered they are ready for flight R
76. sembly Procedure Sub Assembly B Crankcase and Camshaft 1 Clean crankcase remove old Loctite and clean oil gallerys 2 Visually inspect crankcase Fit inner stud O Rings with a small smear of rubber grease Inspect all studs for tightness threads and stretching 1 Check oil suction pipe for security replace o ring 2 Fit all dowels lightly Lubricate o rings before fitting dowel Fit oil relief valve assembly oil pressure sender and front plug hourmeter switch 1 Lightly blue bearing shells and one crankcase half 2 Fit hearino shells LS CRANK CASE OIL PUMP __ RELIEF VALVE CAVITY SPRING Se ee RELIEF POPPET m CIRCLIP 78 LPS TH l Ap l Drawing 9435064 1 OIL RELIEF VALVE ASSEMBLY To increase oil pressure one or two AN4 washers can be placed behind the relief valve spring Note relief washer should have a bevel to except plunger Page No 38 Issue No 2 Date 240103 Issued By PJA B7 B8 B9 B10 B11 B12 5 HOLE BEARING POSITION amp TYPE D
77. specified for the particular engine Turning in clockwise direction results in a leaner mixture and turning in anti clockwise direction in a richer mixture The idling setting quoted serves as a guide only The optimum will generally differ slightly First select the desired idling speed by using the idling stop screw 34 When subsequently adjusting the mixture 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 was noticed To facilitate the idling setting on engines having several carburettors where it is important that they are evenly adjusted it is possible to connect a pressure gauge in the simplest case a U tube pressure gauge to a nipple below the throttle valve shaft bearing point which is normally closed off by screw 39 To select the idling speed the idling screw 34 is in this case adjusted until the same vacuum is indicated for all carburettors By slightly opening the throttle valve via a turning handle or the accelerator it is also possible to adjust Bowden cables or linkages evenly by making this vacuum comparison STARTING CARBURETTOR BING constant depression carburettor is provided with a rotary valve starting carburettor as an aid for staring a cold engine using a Bowden cable A disc 47 resting against the carburettor housing is turned via a shaft in the starting carburet
78. stons and record in build sheet ae eee 1 50 7 a ie S l l t j MEASURE DIA AT d POSITION TO PIN 7 4 K Drawing 9434064 i Clean inhibitor off new rings ii Measure end gap of rings in the cylinder and record in build sheet iii Fit rings with dots up Note End of oil ring expanded must be butted together Piston and rings must be orientated with joins opposite and not in thrust line iv Fit pistons in cylinders Oil Ring should only just enter so piston pin can be fitted later Note Arrows on inside of pistons point in direction of rotation Oil Rings and pistons and bore well Also notch on the crown faces the Propeller Flange Also notch on piston crown faces prop v Fit front piston pin circlip vi Fit cylinder base O Ring Issue No 2 Date 240103 Issued By PJA vii Seal up in plastic bags ready for final assembly Jabiru 3300 Component Inspection and Assembly Procedure 7 4 4 Sub Assembly D Sump and Oil Pump Sump D1 1 Clean sump and remove all gasket eliminator 2 Inspect oil pick up D2 Remove induction O Rings D3 Inspect carburettor coupling replace if it is damaged or showing signs of deterioration Note It is very important that the carburettor and coupling are free of oil If there is any 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
79. t and housing The retaining arm 31 attached to the carburettor housing by means of screws 32 and washers 33 engages the notch in the valve shaft and thus prevents it from moving in axial direction The return spring 35 whose action opposes the Bowden cable is attached between a bent over tab at the lower end of the retaining arm and the throttle lever 28 If the throttle valve 23 is opened while the engine is running the increased air flow in the choke tube results in a vacuum building up at the outlet of the needle jet 3 which draws fuel from the float chamber through the jet system At low speeds and in particular in the case of four stroke engines this vacuum is not sufficient for an adequate fuel supply it must therefore be increased artificially by using a pressure regulator For this purpose the BING constant depression carburettor type 94 is provided with a plunger 13 operating in conjunction with a diaphragm 16 which reduces the cross sectional area or the needle Page No 56 Issue No 2 Date 240103 Issued By PJA jet outlet by virtue of its own weight or in some applications with the additional pressure from a spring 22 and thus increases air velocity and vacuum at this point The plunger 13 is located centrally in the cover 20 which is secured to the carburettor housing by screws 21 The diaphragm 16 is connected to the plunger 13 by a retaining ring 17 and four screws 18 and washers 19 each The vacu
80. tions 81 kg 178 Ib complete with Engine Oil Exhaust 2 2 Normal Equipment Ignition Unit Ignition Timing Firing Order Spark Plugs Electrode Gap Generator DC Output Carburettor Air Intake Filter Fuel Filtration Fuel Pump Starting System 2 3 Performance Data Maximum 2 4 Fuel Consumption Fuel Consumption Takeoff Max Continuous Rating 2 5 Fuel and Lubricant and Starter Motor Jabiru dual ignition breakerless transistorised Battery Independent 25 degrees BTDC 1 4 5 2 3 6 NGK D9EA 0 55 0 6mm 0 022 0 024 Jabiru permanently excited three phase or single phase AC generator with rectifier regulator 20 amps continuous BING constant depression type 94 40 1 x folded paper cartridge 0 1 mm 100 Micron maximum particle size Camshaft driven diaphragm type Electric 12 V 1 5 kW 90 kW 120 hp 3300 RPM ISO STD Conditions 28 5 litres hr Fuel AVGAS 100 LL amp AVGAS 100 130 Page No 9 Issue No 2 Date 031100 Issued By PJA Leaded and Unleaded Automotive Gasoline above 95 Octane Ron Run in Period Oil 80 Outside Air Temp 170C to 25 C 1 to 77 F Normal Operations Oil W80 Outside Air Temp 179C to 25 C 1 to 77 f 2 6 Cooling System 100 120 15 C to 35 C Above 35 C 59 to 95 F Above 95 F W100 W120 15 C to 35 C Above 35 C 59 to 95 F Above 95 F Free air cooled Ensure that baffles are correctly fitted amp located The re
81. ton and engine damage Page No 101 Issue No 2 Date 031100 Issued By PJA JABIRU AIRCRAFT PTY LTD NEW_ ENGINE WARRANTY Jabiru Aircraft Pty Ltd hereinafter JABIRU warrants that it will make good without charge any defect which appears in this engine Provided 1 the defect has been notified in writing to JABIRU a before the engine has operated a total of 200 hours or b within twelve 12 months of the date of delivery of the engine to the first retail purchaser or from the date of independent Authority authenticated first flight whichever comes first and 2 the engine has been delivered to a JABIRU Approved Service Centre or such other service facility as advised by JABIRU and 3 the engine has been installed in an aircraft type in accordance with a JABIRU approved installation system and 4 JABIRU has determined that the defect complained of is one of workmanship and is not caused by a misuse or abuse of the engine such as by operation outside the approved Flight Manual or Maintenance and Operation Manual etc or by neglect b improper installation including overheating c operation of the engine after it is known to be defective d accident or deliberate act e atmospheric fallout or flood hail salt wind etc f failure to carry out proper maintenance service g use of incorrect types and or grades of fuel oil or lubricants h alteration or modification of the engine by any party n
82. tor housing 48 so that the starting carburettor chamber into which air enters from the air filter side of the carburettor is connected to the engine side of the carburettor via a duct The airport in the disc 47 is shaped in such a way that depending on the disc position more or less air is drawn in At the same time the disc opens the fuel system of the starting carburettor via bores matched to the disc position The fuel flows from the float chamber through the starting jet into the Page No 58 Issue No 2 Date 240103 Issued By PJA vented starting chamber also contained in the float chamber 44 and from there through a riser where it is pre mixed with air via transverse bores into the starting carburettor There it forms a particularly rich mixture with the air drawn in and this mixture bypasses the main carburettor to flow into the intake manifold of the engine direct During starting the throttle valve has to be closed to make sufficient vacuum available for the starting carburettor When the engine is at a standstill and also during normal operation the fuel level in the float chamber compartment incorporating the riser will be the same as in the rest of the float chamber When starting with opened up starting carburettor the fuel will initially be 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
83. um in the choke tube acts on the top of the diaphragm and the plunger via a bore U in the plunger 13 and attempts to lift the plunger against its own weight and spring 22 The considerably lower vacuum between air filter and carburettor is applied to the underside of the diaphragm via duct V as a reference pressure If the throttle valve 23 is opened when the plunger 13 is closed then a vacuum will build up in the small cross section at the bottom of the plunger 13 which is sufficient to provide a supply of fuel The weight of the plunger 13 and the force of the spring 22 are matched in such a way that this vacuum will be maintained with increasing speed until the plunger has fully opened the carburettor cross section From this point onwards the carburettor acts as a throttle valve carburettor with fixed choke tube The vacuum increases with increasing speed The space in the cover 20 above the plunger guide is vented through bore D Its diameter is designed in such a way that it acts as a restrictor for air flowing in and out and therefore acts as a vibration damper for the plunger On its way from the float chamber to the choke tube the fuel passes through the main jet 1 the jet carrier 10 and the needle jet 3 as it leaves the needle jet it is pre mixed with 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
84. un Procedure 1 Mount Engine on test rig See engine installation 2 Fill with non detergent oil 3 Remove spark plugs and wind over until oil pressure is reached 4 Fit plugs and cooling ducts 5 Run in Follow run in program 6 Cool down at least 12 hours 7 Retorque heads 8 Adjust valves 9 Rerun 10 Check leak down Note There is a run in program and run in checklist to fill out Page No 70 Issue No 2 Date 240103 Issued By PJA 7 5 1 Engine Installation Operation Fit engine to engine mount 2 Torque engine mount bolts up 3 Fit muffler if not already fitted and fit carburettor heat muff and hose 4 Connect left and right ignition coils leads 5 Connect Tacho sender 6 Connect exhaust gas temp if fitted 7 Connect cylinder head sender 8 Connect hourmeter 9 Connect oil temp gauge sender 10 Connect oil pressure gauge sender 11 Connect starter 12 Connect Battery 13 Connect fuel line 14 Connect Oil Breather 15 Connect Choke Cable 16 Connect Throttle Cable 17 Connect Air Inlet 18 Fit Propeller and spinner Page No 71 Issue No 2 Date 240103 Tools 7 16 Tube Socket 7 16 Ring Open End Spanner 3 16 Ball End Allen Key 18mm Spark Plug socket Screw Driver 7 16 Ring Open End Spanner 10mm Ring Open End Spanner Screw Driver Screw Driver Long Nose Pliers Long Nose Pliers Screw Driver 7 16 Ring Open End Spanner Issued By PJA Phillips
85. ut 14 2 VDA at 2750 RPM Tacho Coil Resistance 160 to 170R Gap 0 4 Page No 98 Issue No 2 Date 031100 Issued By PJA 10 0 TROUBLE SHOOTING 10 1 Engine Won t Start Possible Cause Remedy 1 Ignition OFF Switch ON 2 Spark plug gap too large Adjust gap to 0 6 0 7mm or renew plugs 3 Closed fuel tap or clogged filter Open tap renew filter check fuel system for leaks 4 No fuel in tank Refuel 5 Wrongly connected high tension leads Connect as shown on leads 6 Starting Speed too low faulty or discharged Recharge or replace battery battery 7 Coil to Magnet gap too wide Adjust to 0 4mm 0 016 8 High tension leads loose or damaged Check or renew connections 9 Dampness in distributors Thoroughly dry internally 10 _ Spark plugs damp due to condensation Thoroughly dry both inside and outside of plugs 11 Plug face wet by fuel due to excessive actuation Dry spark plugs trace possible faults in fuel system of choke or overflow of carb or over flow of carb 12 Float valve dirty or jammed Clean or renew float valve 13 JJets in carb clogged Clean jets 14 Water in carb Drain amp clean carb fuel line amp filter Water drain fuel tank 15 Insufficient compression Trace pressure loss amp repair if necessary 16 Engine damage Inspect oil strainer filter amp oil filter for metallic particles If present an engine overhaul may be necessary Possible Cause Remedy 1 Choke activated Close choke 2 Float valve dirty
86. ylinder 7 16 Crowsfoot Removal of Piston 27 Remove Wrist Pin Circlip 28 Remove Wrist 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 Nuts on Front 2 studs 7 16 Socket 32 Double check that every bolt is removed and sump gear case engine mount plate oil pump and Front Oil Seal Carrier is removed 33 Tap Crankcase slightly and open Crankcase by Soft Faced Hammer removing half Crankcase 34 Remove both Crankcase Halves of Crankshaft and Remove Cam Shaft 35 Remove Valve Lifters 12 z Note Keep valve lifters matched to each Crankcase half Page No 32 Issue No 2 Date 240103 Issued By PJA 36 Remove Thrust Washers front and rear 2 without tang on right half case 2 with tang on left half case Note visually check for marks or scratches keep matched to their seats 37 Remove Main Bearing Inserts 16 Note visually check for marks or scratches keep matched to seats 38 Remove Crankcase dowels Remove O Rings and Discard Note do not attempt to remove studs as they are loctited in with 620 loctite 39 Remove Oil Gallery Plugs and Oil Pressure Sender Remove Oil Relief Valve Cylinder Head Disassembly 40 Remove Valve Springs and Valves 41 Remove Push Rod Circlips and O Rings Gearbox Cover Disassembly 42 Remove Distributor Shafts 43 Remove Oil

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