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INSTRUCTION AND MAINTENANCE MANUAL FOR JABIRU 2200

1. 9 3 1 ENGINE MODELS 20000 E a E RA 9 3 1 1 LPS EEN EE 9 3 1 2 TEE e EE EE E 9 3 1 3 2200C ntm ties E EN WE E 9 3 1 4 PLU GEET 9 3 2 GENERAL SPECIFICATIONS A EQUIPMENT 3 Lseseeeeeseeeeeeeennneeennn nnne nennen nenne nennen entrain tenen nena 9 3 3 PERFORMANCE scsi lira MEET ce BE 10 3 3 1 Engine Ee E Ei TEE E i E BE 10 c EA EE A d d A EE ET ME 11 3 5 BT le EE D d E D Ee E 11 3 5 1 RUN P OHO TENE HN EM eet n 11 3 5 2 Normal Operations aA eene ia oe ER becas A rrer Fo loe ERE Ese e Ua en 11 3 6 GOQUING SYSTEM E RERUMS OE m 11 3 7 OPERATING SPEEDS AND LIMITS 5 ssessesseseseesee eene enne nennen nennen benennen tenen nnne nnns estet attese nna 12 3 7 1 Ground Operating LIMIS io DEET usua auge aaa 12 3 7 2 In Flight Operating LTS Precise eegene rosse ede IY 12 3 8 PROPELLER SELECTION SPECIFICATIONS ccoooccccoccccnnccconnconnnccnononnnnn coran cnn derrame cnn n rra n rra n caen nr nanncnnnnes 12 3 9 DIMENSIONS ccoo il 13 3 10 DENOMINATION OF CYLINDERS cocccccocccconcnconncconnconnn conan cnn n cnn rre 13 3 11 DISTRIBUTOR CYLINDER Map 14 3 12 POWER CURVE EE pia 14 4 OPERATING INSTRUCTIONS eat eee D 16 4 sIPRE START GHECKS icf E E E DE 16 4 2 STARTING PROCEDURE 12 debe seer eet tre etia Sco apts oad ees ee hoe ened ne need be AE 16 4 2 1 Gold Engine ET EE nis et E 16 4 2 2 Warm Engine 4 d
2. A 4 4 L OPTIONAL FRONT 7 1 73 uw BED MOUNT J Figure 1 Drawing 9404041 1 Engine Dimensions 3 10 Denomination Of Cylinders gd Drawing 9483093 1 Figure 2 Cylinder Denomination amp Firing Order Cylinder Firing Order 1 3 2 4 This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ee 50 o o Ter Ga Page 0015 L Miles Manuals_For_Products Engine_Manuals 2200_engine_manuals Hydraulic_Lifters Working copiesJEM2204 10 I amp M unsigned doc Jabiru Aircraft pty a ELA Instruction amp Maintenance Manual Jabiru 2200 Aircraft Engine Hydraulic Valve Lifter Models 3 11 Distributor Cylinder Map NW NOTE 1 ALL DISTRIBUTORS SHOWN LOOKING FROM THE PROP DRIVE END OF THE ENGINE 2 EXHAUST amp INTAKE REFER TO THE POSITION OF THE SPARK PLUGS IN THE CYLINDER ON THE EXHAUST OR INTAKE SIDE OF THE HEAD EXHAUST INTAKE EXHAUST INTAKE 4 4 1 BLANK ZO ct O pa MO BLANK E b dl 3 6 CYLIN
3. Instruction amp Maintenance Manual Jabiru 2200 Aircraft Engine Hydraulic Valve Lifter Models 5 9 5 ING El E TEE 22 5 9 6 Returning Engine to Service After Temporary Storage sss eene 22 5 9 7 New Engine SIOFage uiii cr eim bet eb tee ds teer ei inest ste cerebri 23 5 9 8 Operation in WAC HS nS 23 5 9 9 CarburettOr Jong 24 5 9 9 1 Icing Due to Water In RU EE E E 24 5 9 9 2 Icing Due to High Air Humidity 0 00 eee e eee eeeeeneeeeeeeaeeeeenaeeeeneacatensaaeeedenaeeeeneaeeeeesaaeeesenaeeeeseeeeeseaaes 24 E IMAINTENANCE 2 Ba sas en ec E E 25 6 1 LUBRICATION SYSTEM RE E suas arenae aaa airi EARE 25 6 2 AIR INTAKE FILTER E E EE EE EE 25 6 3 CARBURETOR ADJUSTMENT EE 25 6 4 COMPRESSION CHECK EE 26 6 4 1 Compression Gauge ooi E optatis iode etae co a eit 26 6 4 2 Pressure Differential Test esos eire nenne 26 6 5 A A S era caesa iren id ae 27 6 5 1 High Tension Lead Connection 27 6 5 2 rine M EE 28 6 6 EXHAUST SYSTEM Lm 28 6 7 BOLTS AND NUTS E em EE E duet una ra ia readin a dE 28 6 8 TAPPET ADJUSTMENT HYDRAULIC VALVE LIFTERS nennen nennen nnns nnn nnn nnn nnns 28 6 9 VALVE ROCKERS RM T qd ME D WE 30 6 10 HEAD BOLTS A EE desde WE 30 6 11 TACHOMETER AND DGENDER Dheeeeeeessusnnseeceecececssnduasecsecepecssesnaeseeeceeeesseeaeseeeeeeseseees 30 6 12 ADDITIONAL CHECKS POSTV8ERVICE E 30 6 12 1 Propeller fii il oP EN eae EE ee ee ieee 30 E e
4. 1 Update Torque Values 2 Update Propeller Installation Details 3 Update Maintenance Schedule Oct 2006 4 Add tolerance to servicing intervals Jan 2007 5 Add hydraulic lifter maintenance requirement Jul 2008 6 Add additional hydraulic lifter information Nov 2008 7 Add new engine storage details Dec 2009 8 Prop flange fitting details added May 2010 9 Starter motor overhaul prop strike details added Jun 2010 10 Remove overhaul information ref overhaul manual Apr 2011 This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled enson 5 0 7 o o w oueon isumeenors Page soss L files Manuals_For_Products Engine_Manuals 2200_engine_manuals Hydraulic_Lifters Working copies JEM2204 10_1 amp M_unsigned doc Jabiru Aircraft pty a ELA Instruction amp Maintenance Manual Jabiru 2200 Aircraft Engine Hydraulic Valve Lifter Models 2 Description 2 1 Model All Jabiru 2200 Engine Models from S No 2068 on 2 2 General Information WARNING Jabiru Aircraft Pty Ltd has devoted significant resources and testing to develop the Jabiru 2200 aircraft engine This engine is intended to be installed in accordance with the details given in the INSTALLATION MANUAL FOR JABIRU 2200 AIRCRAFT ENGINE document No JEM2202 Any other uses or applications may be extremely hazardous leading to property damage or injury or death of
5. for leaks 21 Check for oil Fill if needed 2 3L oil 2 43 US quarts 22 Wind over to get oil pressure gt 23 Start and inspect for leaks This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled anson 5 0 7 o o w Serrat museos page s7orss L Miles Manuals_For_Products Engine_Manuals 2200_engine_manuals Hydraulic_Lifters Working copies WEM2204 10_l amp M_unsigned doc Jabiru Aircraft pty Lia gt ELA Instruction amp Maintenance Manual Jabiru 2200 Aircraft Engine Hydraulic Valve Lifter Models No Operation Tools Required 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 Check Head bolt tensions torqued to 20 ft Ib 27 At25 hours inspect engine installation Change oil and filter Cut filter open and inspect Check engine leak down 28 f 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 or seek advice from Jabiru Aircraft or local authorized representative 7 5 Prop Strike Inspection After ground contact with the propeller check the crankshaft and prop flange for run out as shown below Figure 8 Dial Indicator Position for Crankshaft amp Prop Flange Run Out e Remove one spark plug from each head e
6. 51 12 2 1 LOW Oil EE GE EE 51 12 2 2 Flicking Of Oil Pressure Gage 51 1223 O A Hem E ns eI ee ites 51 UU NEN VUE a aiT 51 12 2 5 Magneto CHECKS i vice teh aei E GE 51 12 2 6 Rough Cylinder Running eese rn 51 LEE ee Ac MERE 51 12 2 8 Eimil llOlls eornm tesi GE D 51 13 AIRWORTHINESS LIMITATIONS SECTION eeeeeeeeeeeeeeeee enne nennen nnn nnne nnn 52 14 NEW ENGINE JABIRU S LIMITED EXPRESS WARRANTY cere 53 15 JABIRU S LIMITED EXPRESS WARRANTY CLAIM FORM eene 55 1 1 Table of Figures Figure 1 Drawing 9404041 1 Engine Dmmensions ANE 13 Figure 2 Cylinder Denomination Firing Order 13 Figure 3 Distributor Cylinder Map 14 Figure 4 POWE CUVE sci C 14 Figure 5 Power Curve 2200C 2200B Enges 15 Figure 6 High Tension Lead Connections drehen nnne t ettet rene n nens 27 Figure 7 Cam Identification Markings nennen inneren nennt nnns t eren entres enne 29 Figure 8 Dial Indicator Position for Crankshaft amp Prop Flange Run Out 38 Figure 9 Head Bolt Locations een 40 Figure 10 Oil System Schematic 0 cccccinncconncconaccconcccnnrcc ronca 42 1 2 List of Effective Pages This manual is revised as a complete document All pages must display the same revision number Issue Notes
7. 1 Run in Period Oil Weight 80 100 120 et 17 C to 25 C 15 C to 35 C Above 35 C pl peratu 1 to 77 F 59 to 95 F 95 F 3 5 2 Normal Operations Oil Weight Wan W100 W120 Outside Ar Tembard iro 17 C to 25 C 15 C to 35 C Above 35 C H 1 to 77 F 59 to 95 F 95 F 3 6 Cooling System Free air cooled Ensure that Ram air ducts are correctly fitted amp located The required pressure drop across the cylinders at 1 3 V clean stall speed is 4 3 cm 1 7 water gauge minimum A minimum of 6cm 2 4 is recommended at cruise speed This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled SEENEN 7o svo maran tindoy ors Pag ors LMiles Manuals_For_Products Engine_Manuals 2200_engine_manuals Hydraulic_Lifters Working copiesJEM2204 10 I amp M unsigned doc Jabiru Aircraft pty a ELA Instruction amp Maintenance Manual Jabiru 2200 Aircraft Engine Hydraulic Valve Lifter Models 3 7 Operating Speeds and Limits 3 7 1 Ground Operating Limits Idle Speed Nom 900 RPM set while engine is hot Oil Pressure Idle Min 80kPa 11 psi Max 525kPa 76 psi Oil Temperature Max 100 C 212 F Max CHT 180 C 356 F Note If ground temperature limits are reached shut the engine down or cool it by pointing the aircraft into wind 3 7 2 In Flight Operating Limits Maximum Speed 3300 RPM Maximum Continuous
8. 12 2 7 Carby Breather e Carburetors have a brass fitting for venting This is must be connected to a fitting screwed into filtered side of the carby heat box 12 2 8 Limitations e Jabiru recommend TBO of 2000 hrs with a Top End overhaul at 1000 or when engine condition indicates the need for overhaul earlier CAREFULLY READ MANUALS SUPPLIED This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled eme e s e z o o w oueon museos Page stats LMilesManuals For ProductsEngine Manuals 2200 engine manualsWydraulic LiftersWorking copies WEM2204 10_l amp M_unsigned doc Jabiru Aircraft pty a ELA Instruction amp Maintenance Manual Jabiru 2200 Aircraft Engine Hydraulic Valve Lifter Models 13 Airworthiness Limitations Section The Airworthiness Limitations Section is CASA Approved There are no Airworthiness Limitations pertaining to the Jabiru 2200C engine ee DDR beer Dinh Nguyen Delegate of the Authority This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ee 50 7 9 mer mor Ga ops Pago Set L Miles Manuals_For_Products Engine_Manuals 2200_engine_manuals Hydraulic_Lifters Working copiesJEM2204 10 I amp M unsigned doc Jabiru Aircraft pty a ELA Instruction amp Maintenance Manual Jabiru 2200 Aircraft
9. Carefully sand off paint on crank diameter and prop flange where dial indicator will be located e Position dial indicator onto crank as shown above and eliminate main bearing clearance by bearing down on crank when rotating Rotate crankshaft to measure crankshaft run out This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled won e e v eo w meman wuesoy ors Page 20015 LAfiles Manuals For ProductsEngine Manuals2200 engine manualsMydraulic LiftersWorking copieslJEM2204 10_18M_unsigned doc Jabiru Aircraft pty a ELA Jabiru 2200 Aircraft Engine Instruction amp Maintenance Manual Hydraulic Valve Lifter Models normally expect to see 0 01 0 03 mm but if run out exceeds of 0 08 mm the crankshaft must be replaced e Position dial indicator onto prop flange as shown above eliminate end float by either pulling or pushing flange when rotating Rotate prop flange to measure the face run out normally expect to see 0 02 0 06 mm but if run out exceeds 0 08 mm then replace the prop flange Note f the crankshaft run out exceeds the above limit the engine has to be stripped and the crankshaft replaced The flywheel retaining cap screws 6 need to be replaced after any prop strike Even if the above run out requirements are met and depending on the severity of the prop strike it could be prudent that an engine strip be perfo
10. DNIMOOT NAAOHS SHOLNEIYLSIC gt LON FTON oL L ISNVHX4 bp Figure 6 High Tension Lead Connections 5 2 o9 5 c o o c 2 o o E o o D 2 c o E 2 o o jo o lt o 2 ral rol bo D Oo c 9 o c E x o o c O DN o 2 o o 2 Ke s D o x c o o E o 2 o E jo i c o o 2 a c o E gt Q o o 2 lt E Page 27 of 55 Issued By DPS eo ea ENEE RE gine_Manuals 2200_engine_manuals Hydraulic_Lifters Working copiesJEM2204 10 I amp M unsigned doc LMilesManuals For Products En Jabiru Aircraft pty a ELA Jabiru 2200 Aircraft Engine Instruction amp Maintenance Manual Hydraulic Valve Lifter Models Figure 6 above shows the High Tension lead connections between the distributors and the spark plugs 6 5 2 Spark Plugs e Do not use steel or brass brushes for cleaning amp never sandblast plugs e Clean with plastic brush in a solvent e Check electrode gap amp if necessary adjust to 0 55 0 6mm 0 022 0 024 by carefully bending the electrode e Recommended Plugs NGK D9EA e Use suitable anti seize on thread IMPORTANT Only tighten spark plugs on cold engine amp only to the torque values shown in Section 9 using appropriate anti seize compound Note When plugs are removed from a warm engine the inspection of the tip of the spark plug can be used to indicate the hea
11. EE min EE tc EE 16 4 3 WARMING UP PERIOD GROUND TEST 16 44 TAKE DE Poma ol Al eerta ateliers 16 45 JENGINESTOP eJ aeM ieiunia been itr i re es 17 4 6 ENGINE STOP AND START DURING FLIGHT occccccnnccocncnnnncnnnnoonnonononoconnodonononnnnnnonnnonnnnnnnnnnnonanennnnnnnonenos 17 5 CHECKS ON ENGINE amp INSTALLATION ccce eee eene 18 5 1 DAILY GHECKS 1 oo ss M T EE 18 RT le lee Ter ee ob tes ee eed ee eee 19 5 3 CHECK AFTER INITIAL 10 HOURS cia er eee tr ec nee cen bec enc eec n Pn e 19 5 4 CHECK AFTER INITIAL 25 HOURS oococccccccccnnonononnnnnnnnonononononnnnnnnononnnnnnnnnnnnnnnononnnsnnnnnnnnnnnnnnnnnnnnnnnnannnnnnnnnns 20 59 SO HOWRS CHECK qe 20 5 5 100 HOURS CHECK irre irte dE ST 20 bu 200 HOURS CHECK nitet rt na 20 5 8 ENGINE OVERHAU LS 000 1 Sessa centi pete dett D eiue doter peste 21 5 9 ENGINE PRESERVATION 22 3 2 25 2 2 e nies e ege 21 5 9 1 ere Ei m 21 5 9 2 Returning Engine to Service From Flyable Ztorage sd 21 5 9 3 Re ee CEET EE 21 5 9 4 Inspection D ring TEE 22 This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled eso 5 0 7 o o w oueon isumeenors Peces L files Manuals_For_Products Engine_Manuals 2200_engine_manuals Hydraulic_Lifters Working copies WEM2204 10_l amp M_unsigned doc Jabiru Aircraft pty a ELA
12. Hydraulic Valve Lifter Models e The following are recommended IN ADDITION to the normal engine maintenance program e Where the maintenance requirements listed below differ from those of a third party supplier the lesser time interval should be used i e if the table below calls for the propeller to be re balanced annually but the propeller manufacturer recommends balancing every 100 hours or 6 months then the propeller manufacturer s recommendations should be used e Visual inspections of the propeller and propeller flange installation should check for excess metal oxide appears as rust or black chaffing dust originating from the flange This is often an early indication of movement between the parts and potential failure Oil leaks etc in this area and around the flywheel must be addressed quickly as they can both cause and mask other problems Annual Inspection Each 500 Hours Each 100 Hours Each 50 Hours 1 Spinner spinner flange amp hardware W Check condition 2 Propeller general condition visual hand check n i i 3 Propeller blade pitch tracking 4 Propeller mounting hardware bolts nuts bushes etc tension amp condition check 5 Propeller balance si 6 Propeller flange installation visual inspection N N no disassembly required 7 Propeller flange screws REPLACE Refer to engine overhaul manual for guidance 8 Propeller fla
13. 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 Limited Express 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 LIMITED EXPRESS WARRANTY ON JABIRU REPLACEMENT PARTS As a part of its Limited Express Warranty JABIRU warrants in respect of JABIRU parts and accessories required as replacement parts that 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 Limited Express Warranty does not cover those parts listed as exclusions above and is subject to the same general exclusions This document is
14. a gt ELA Instruction amp Maintenance Manual Jabiru 2200 Aircraft Engine Hydraulic Valve Lifter Models 4 CYLINDER POWER CURVE 65 0 450 60 0 1 400 55 0 350 50 0 300 45 0 POWER z 250 E 7 TORQUE 40 0 200 35 0 150 30 0 25 0 q 100 20 0 50 1500 1700 1900 2100 2300 2500 2700 2900 3100 3300 RPM Figure 5 Power Curve 2200C 2200B Engines Note Multiply Kilowatts kW by 1 341 to get Horesepower hp i e 63 5 kW x 1 341 85 hp This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ee 5 0 o o Ter a Page 1505 L Miles Manuals_For_Products Engine_Manuals 2200_engine_manuals Hydraulic_Lifters Working copiesJEM2204 10 I amp M unsigned doc Jabiru Aircraft pty a ELA Instruction amp Maintenance Manual Jabiru 2200 Aircraft Engine Hydraulic Valve Lifter Models 4 OPERATING INSTRUCTIONS To ensure that the engine operates reliably carefully observe all of the operating amp maintenance instructions 4 1 Pre Start Checks e Daily Checks See Paragraph 5 1 e Move throttle position to FULL amp check for ease of movement over the entire range Return to idle before attempting to start engine 4 2 Starting Procedure Notes e Activate Starter for a maximum of 20 seconds followed by a cooling per
15. anson e s e z o o w SMerezn museos Page ators LMilesManuals For ProductsEngine Manuals 2200 engine manualsWydraulic LiftersWorking copies WEM2204 10_l amp M_unsigned doc Jabiru Aircraft pty Lia ELA Instruction amp Maintenance Manual Jabiru 2200 Aircraft Engine Hydraulic Valve Lifter Models rocker by hand There should be no free rotation of the rocker Press down on the pushrod end of the rocker the lifter should feel hard with minimal movement possible under thumb pressure Note that the correct method for finding this point is to turn the crank until the valve is fully open then turning the crankshaft through one complete revolution to rotate the cam lobe away from the lifter e OR after the service idle the engine listen for loud tapping noises and feel for rough running This must be carried out with the cowls removed Note that due to the need to have a person at the controls of the aircraft this is a two person job CAUTION Whenever the engine is running there must be a qualified person inside the aircraft at the controls Under NO circumstances run the engine without a qualified person at the controls e Troubleshooting information is given in Section 12 1 11 e Air can be caught inside the lifters after maintenance Running the engine at a high idle approx 1500 RPM will expel the air but may take up to 15 minutes When fitting lifters after inspection or maintenance they should
16. be filled by injecting oil into the hole in the side of the lifter Care must be taken to ensure all air is removed e Several different hydraulic lifters have been used in Jabiru 2200 engines The cam P No fitted to the engine must be known when ordering replacement lifters This information can be found from the engine s S No or from its overhaul records e The type of lifter must be matched correctly to the cam design Use of mismatched parts will cause reduced engine power and possible engine damage e Figure 7 shows identification markings on a P No 4A432A0D cam it has two rings machined at the oil pump end and two small spots machined at the drive gear end Similarly P No 4A430A0D cams are marked with one ring and one spot Engines assembled with these cam types must use a Jabiru P No PE4A001 Hydraulic Lifter These cams are standard in engines with S No 224 2850 8 22C 001 onwards e Cams manufactured without any identification rings or spots must use a Jabiru P No 4A294C0D Hydraulic Lifter e The different types of Hydraulic Lifter are not marked and the difference requires disassembly and careful measuring using a micrometer to detect Accordingly care must be taken to ensure different types of lifter are not confused during maintenance Cam identification markings Figure 7 Cam Identification Markings This document is controlled while it remains on the Jabiru server Once this no longer appl
17. influenced by condition 7 2 1 Full Overhaul e Full overhauls must be carried out as detailed in the latest approved revision of the Jabiru Engine Overhaul Manual e During a full overhaul all parts are cleaned measured inspected and recorded in the prescribed build sheets in the manual Parts that are replaced during a full overhaul include Pistons gudgeons and circlips rings main bearings conrod bearings thrust bearings conrod bolts all orings gaskets and seals fuel pump valves induction hoses rubber oil feed tees spark plugs rotors head bolts intake exhaust studs fuel hose oil filter oil hoses flywheel bolts prop flange bolts woodruff key oil pump crankcase through bolts and crankcase studs Cylinder heads and dizzy shafts are usually replaced at a full overhaul depending on condition e As apart of the overhaul process the engine must be run in Again the procedure given in the Jabiru Engine Overhaul Manual must be used Details are given in that manual however note that if the run in is performed on the ground large air cooling ducts and a large oil cooler must be used The engine can also be run in in the aircraft in the air with caution using the run in program as the guide Section 11 1 Early Operation of an engine must be understood Initial performance data must be recorded New engines and engines overhauled by Jabiru Aircraft Australia are dispatched already run in no further running in is require
18. meeting the specification detailed in Para 2 5 e DO NOT drain the oil cooler during a normal oil change The cooler holds only a small amount of old oil which has negligible effect on the new oil Taking the hoses on amp off the cooler can prematurely age the oil lines and lead to hoses slipping off the cooler 6 2 Air Intake Filter e Clean filter by removing from the intake housing amp blowing compressed air against the direction of the intake flow e For operation in heavy dust conditions clean air filter at shorter intervals than recommended for normal conditions e Aclogged filter will reduce engine performance as well as promote premature engine wear 6 3 Carburetor Adjustment e Idle stop screw is a 7mm screw against throttle lever Adjust its position to adjust engine idle speed e Standard idle mixture screw position is 1 1 4 turns out Fine adjustment may be necessary to give a smooth idle e The mixture is set by selecting jet sizes As supplied the engine has jets to suit a majority of installations however the mixture may be affected by running a propeller which does not meet the requirements listed in the installation manual or by ambient temperature extremes If an engine is to used in these situations an EGT gauge should be fitted and monitored against the limits specified above CAUTION Do not change carburetor settings without consulting with Jabiru Aircraft or our local authorised representative If EGT rea
19. necessary changes to the TBO Limit due to operational experience will be announced by Jabiru in a Service Bulletin 5 9 Engine Preservation The following procedures assume that the engine is installed in a Jabiru 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 Note Failure to store the engine for a long period of time in excess of 90 days without taking the preventative measures as outlined in the manual will affect claims upon Jabiru s Limited Express Warranty 5 9 1 Flyable Storage e Flyable storage is defined as a maximum of 30 days non operational storage e Ensure that the engine has been stopped by turning off the fuel valve ensuring all fuel is drained from the carburettor bowl e Fit covers to engine induction air inlet and exhaust outlets to minimize moisture ingress to cylinders e 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 Note that intake amp exhaust covers should be removed before performing this task CAUTION Ensure that the Master and Ignition Switches are OFF before turning engine 5 9 2 Returning Engine to Service From Flyable St
20. 00 engine manualsWydraulic LiftersWorking copies WEM2204 10_l amp M_unsigned doc Jabiru Aircraft pty a ELA Instruction amp Maintenance Manual Jabiru 2200 Aircraft Engine Hydraulic Valve Lifter Models 11 2 2 Oil e Use anon compounded AVIATION oil Aero Shell 100 Mobil Red Band EXXON Aviation Oil 100 BP Aviation Oil 100 e Use for 20 25 hours then drain and replace with a compounded AVIATION oil Aero Shell W100 Aero Shell 15W50 for cooler climates Mobil Aero 100 SAE 50 EXXON Aero Elite 100 BP Aero Oil D100 BP Multigrade Aero Oil D SAE 20 W 50 Aero Shell W 100 Plus e The normal running oils are detergent and ashless dispersant types See MAINTENANCE SECTION 5 3 e Oil capacity The new engine will hold 2 3 litres with an oil cooler On subsequent oil changes the engine will hold approx 2 2 litres e Do not use any type of automotive oil Aviation oils have been blended specifically for the difficult operating conditions found in an air cooled aero engine operation and using automotive will be extremely detrimental to its operation e 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 a small amount of aluminium but definitely no metal If bearing metal is present contact the Jabiru Service Department 11 2 3 Engine Cooling e Avoid prolonged groun
21. DER ENGINE 3 FIRING ORDER 1 4 5 2 3 6 FIRING ORDER 1 2 INTAKE EXHAU ST y p sar Xx 1 4 Tx J Ok AL ON 3 UE ON 3 ON 5 ON 5 6 7 o a B o 6 a a o A d d oZ NOA NS SS 6 CZ oe O 4 CYLINDER ENGINE 3 2 3 2 8 CYLINDER ENGINE FIRING ORDER 1 5 8 3 2 6 7 4 Jw 2 310306 dq DIMENSIONS THIS DRAWING IS COPYRIGHT AND MUST NOT BE SCALE 1 29 9 05 Geesse IN MILLIMETRES PO NOT SCALE Baesch COPIED WITHOUT THE CONSENT OF AVTECH PTY LTD NTS Jigs DATE LIMITS NA DRAWN DS UNO TITLE DWG No N A delicia JABIRU ENGINE DISTRIBUTOR CYLINDER 4A266A0D 2 p APRE MAP ALL ENGINES Se Ea Figure 3 Distributor Cylinder Map 3 12 Power Curve POWER CURVE 70 0 450 65 0 400 60 0 350 55 0 300 50 0 S 4 259 E POWER 45 0 902 TORQUE 40 0 200 35 0 150 30 0 100 25 0 20 0 50 1500 1700 1900 2100 2300 2500 2700 2900 3100 3300 RPM Figure 4 Power Curve This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ee s e 7 9 meram Ga ops Page ois LMilesManuals For Products Engine Manuals2200 engine manuals Wydraulic LiftersWorking copiesJEM2204 10 I amp M unsigned doc Jabiru Aircraft pty
22. E C E ob DEE EE 31 Got RUEl Sy SOM E E Sas Nas D 31 6 13 SPECIAL MAINTENANCE GUIDANCE sescecesceeeesceneneceeeeceseaeeeeeaseseeeeesachesuenessaeeneeeeeeesensnenessaeeneaes 31 6 13 1 Special Maintenance Non Approved Propellers eese eene eene nnne nnn nnne nnn nnn nnns 31 6 14 ENGINE INSPECTION CHART een 33 T SERVICE amp REPAIR c 35 7 1 SERVICE INTERVAL TOLERANCE ENEE 35 7 2 ENGINE OVERHAUL AND TBO seinen radesss sisse ser ssssa isses isse raa nn assis nn 35 7 2 1 Tele nnnm 35 7 2 2 TOD End ele EE DEE 35 7 3 ENGINE REMOVAL PROCEDURE eege SE lesse eausa seva n e Seege 36 7 4 ENGINE INSTALLATION eege t E a aia 37 7 5 PROP STRIKE INSPECTION cocos i iaa il ideada 38 8 NOTES BEFORE STARTING ENGINE ccsseeeeceeeeeeeeeeeeseeeeeeeeeeeneeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 40 9 TABLE OF LUBRICANTS rusia ls 42 10 TORQUE SPECIFICATION FOR BOLTS amp NUTS eese nnn 43 10 1 PRESCRIBED SEALANTS AND PRIMERS tene rennen nennen nennen 43 10 2 ELECTRICAL SYSTEMS SPECIFICATIONS ccccssccecsesseeeesebecedecsseeeessseeessseeeesseeeeesseeeeess 43 11 OPERATING NOTES QUICK REFERENCE GUIDE cere 44 11 1 NEW ENGINE NOTES xit ee eo rte ada 44 11 2 NORMAL OPERATION NOTES eunti ee aet xen n o rr re e Fete E AE an 45 Tf12 f Regular Checks iste tuti ee E EE 45 T1 2 227 el iu us ERU URL S Mte seta Ul
23. Engine Hydraulic Valve Lifter Models 14 New Engine Jabiru s Limited Express Warranty New Jabiru Aircraft Engines are covered by Jabiru s Limited Express Warranty Details of this warranty are given below NOTE JABIRU S LIMITED EXPRESS WARRANTY IS EXCLUSIVE EXPRESSLY GIVEN AND HAS BEEN ACCEPTED IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED ORAL OR WRITTEN INCLUDING WITHOUT LIMITATION ANY WARRANTY OF MERCHANTABILITY FITNESS FOR A PARTICULAR PURPOSE OR OTHER WARRANTIES IMPLIED IN LAW THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THAT WHICH IS DESCRIBED IN JABIRU S LIMITED EXPRESS 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 i Before the engine has operated a total of 200 hours or ii Within twelve 12 months of the date of delivery of the engine to the first retail purchaser 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 The engine has been updated in accordance with JABIRU Service Bulletins before operation and 5 The engine has been stored in accordance with the Engine Preservation instruction in the Jabiru Instruction amp
24. INSTRUCTION AND MAINTENANCE MANUAL FOR JABIRU 2200 AIRCRAFT ENGINE DOCUMENT No JEM2204 10 BIKE This Manual has been prepared as a guide to correctly operate maintain and service the Jabiru 2200 engine It is the owner s responsibility to regularly check the Jabiru web site at www jabiru net au for applicable Service Bulletins and have them implemented as soon as possible Failure to do this may render the aircraft un airworthy and void Jabiru s Limited Express Warranty This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled Should you have any questions or doubts about the contents of this manual please contact Jabiru Aircraft Pty Ltd Applicable to Jabiru 2200 Models from S No 2068 and above Hydraulic Lifter Type Jabiru Aircraft pty a ELA Instruction amp Maintenance Manual Jabiru 2200 Aircraft Engine Hydraulic Valve Lifter Models 1 Table of Contents T TABLE OFCONTENTS cuencia te 2 1 1 TABLE OF FIGURES cocina di dd 4 1 2 LISTOF EFFECTIVE TEE E DEE 4 2 DESCRIP e ee E D 5 2 1 A D 5 2 2 GENERAL INFORMATION ascos iar c eec e een ge eee ee cec nec dh Den ec eb 5 2 3 GENERAL DESCHIPTION 6 2 4 DETAILS ND E 8 2 5 MANUFACTURER EE WE EE 8 2 6 ENGINE eSI 8 2 7 ADDITIONAL SERVICE INFORMATION e ennnennennnnnnne deseri rines siis isse n nisssas sss inseri s snas sss esseri s anna 8 3 SPECIFICATIONS
25. Jabiru server Once this no longer applies the document becomes uncontrolled anson e s e z o e w T saaenm museos Page roots LMilesManuals For ProductsEngine Manuals 2200 engine manualsWydraulic LiftersWorking copies WEM2204 10_l amp M_unsigned doc Jabiru Aircraft pty a ELA Instruction amp Maintenance Manual Jabiru 2200 Aircraft Engine Hydraulic Valve Lifter Models 4 5 Engine 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 2000 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 Do not apply the starter motor if the propeller is windmilling This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled anson 5 0 7 6 e ro T saaenm sesgos Page Vote L Miles Manuals_For_Products Engine_Manuals 2200_engine_manuals Hydraulic_Lifters Working copies WEM2204 10_l amp M_unsigned doc Jabiru Aircraft pty a ELA Instruction amp Maintenance Manual Jabiru 2200 Aircraft Engine Hydraulic Valve Lifter Mode
26. Maintenance Manual and 6 JABIRU has determined that the defect complained of is one of workmanship and is not caused by i Misuse or abuse of the engine such as by operation outside the approved Flight Manual or Maintenance and Operation Manual etc or by neglect ii Improper installation including overheating iii Operation of the engine after it is known to be defective iv Accident or deliberate act v Atmospheric fallout or flood hail salt wind etc vi Failure to carry out proper maintenance service vii Use of incorrect types and or grades of fuel oil or lubricants vii Alteration or modification of the engine by any party not authorised in writing by JABIRU ix The fitting of parts or accessories not marketed by JABIRU x Any work carried out on the engine by someone other than an Authorised JABIRU Service Centre or someone else authorised by JABIRU in writing xi The use of any engine oil or fuel additives or oil stabilisers eme e s e z o o w T saaenm museos Page moris LMilesManuals For ProductsEngine Manuals 2200 engine manualsWydraulic LiftersWorking copies WEM2204 10_l amp M_unsigned doc Jabiru Aircraft pty a ELA Instruction amp Maintenance Manual Jabiru 2200 Aircraft Engine Hydraulic Valve Lifter Models 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 Limited Express
27. Speed 3300 RPM Idle Speed 900 RPM set while engine is hot Oil Pressure Normal Operations Min 220 kPa 31 psi Max 525kPa 76 psi Idle Min 80 kPa 11 psi Starting amp Warm up Max 525 kPa 76 psi Oil Temperature Min 15 C 59 F Max 118 OC 244 F Oil Continuous Temperature 80 100 C 176 212 F Max CHT Climb 200 C 392 F Max Continuous CHT Cruise 180 C 356 F Notes Time with CHT at between 180 C and 200 C is not to exceed 5 Minutes Read Cylinder Head Temperature CHT under the spark plug nearest to the exhaust on the hottest cylinder EGT Continuous Limits EGT Mid Range Cruise Min 680 720 C 1256 1328 F EGT Above 70 Power Min 640 680 C 1184 1256 F Note An EGT gauge is not included as standard equipment on the Jabiru 2200 engine though a system can be supplied as an option 3 8 Propeller Selection amp Specifications WARNING Correct propeller selection tuning and maintenance are vital for the safe operation of this engine The guidance given herein and in the Engine Installation Manual must be adhered to for safe operation e Many propeller brands and models are not approved by Jabiru Aircraft Operators may choose to use these propellers however they do so at their own risk For information on which propellers are approved please contact Jabiru P L or our local representative e Propeller selection is discussed in detail in the Jabiru 2200 Engi
28. 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 Limited Express 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 Limited Express Warranty repairs do not extend the original Limited Express 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 Limited Express Warranty Consequential damages and freight costs are also not covered by this Limited Express Warranty JABIRU makes no representation that this engine is suitable for installation in any particular aircraft and the responsibility for determining such suitability rests with the Buyer Under no condition shall JABIRU or a JABIRU Authorised Service Centre be liable for any contingent costs through the engine or aircraft being out of service for whatever reason 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 endeavor is made to ensure that
29. a ME este HERE alee O eub toda e Peu einige 46 11 2 3 Engine Cooling iei eae rra LEUR ota a prse TG EE 46 I1 2 4 Consumables iiu ido eee de rni tenere dd GE eas te nest eco acne dan 47 IEEE S lujo EE EAE 47 12 TROUBLE SHOOTING E D ee 48 12 1 TROUBLESHOOTING TABLES ederet c e a Pee eet e eds 48 12 14 Engine Wont SIart EEN orare DEE 48 12 1 2 Engine Idles Unsteadily After Warm Up Period Smoky Exhaust essen 48 12 1 8 Engine Runs Erratically or Misfires Occasionally esses deseen nnne 48 12 1 4 Engine Runs Too Hot Oil Temperature Above 110 C G320E 49 12 1 5 Unsatisfactory Power Output 49 This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled mension 5 0 7 o o w preon isumeenors Pape Sots LMfiles Manuals_For_Products Engine_Manuals 2200_engine_manuals Hydraulic_Lifters Working copies WEM2204 10_l amp M_unsigned doc Jabiru Aircraft pty a ELA Instruction amp Maintenance Manual Jabiru 2200 Aircraft Engine Hydraulic Valve Lifter Models 12 16 Ee 49 12 1 7 Engine Keeps Running with Ignition On 49 121 8 Excessive Oil Gornlsumplioh ii EE 49 121 9 Knocking Under Loa e e eat see tna few EE 50 12 1 10 Engine Hard to Start at Low Temperature 50 12 111 Hydraulic Valve a eio d dengue A iia 50 12 2 TROUBLESHOOTING QUICK GUIDE
30. air of cylinder head necessar 4 Cil leaks Seal leaks This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled anson e s e z o o w T saaenm museos Page doors LMilesManuals For ProductsEngine Manuals 2200 engine manualsWydraulic LiftersWorking copiesJEM2204 10 l amp M unsigned doo Jabiru Aircraft pty a ELA Jabiru 2200 Aircraft Engine Instruction amp Maintenance Manual Hydraulic Valve Lifter Models 12 1 9 Knocking Under Load EA Possible Cause 1 Octane rating of fuel too low Use fuel with higher octane rating Spark plug fitted without sealing washer Ensure one sealing washer on each plug Heavy carbon deposits Remove cylinder heads amp in combustion chamber remove deposits Determine oil consumption Notes 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 can cause piston damage 12 1 E Engine Hard to Start at Low Temperature Possible Cause Ree speed too low 2 High oil pressure At very low temperatures a pressure reading of up to around 500 kpa doesnt necessarily indicate a malfunction Low battery charge Fit fully charged battery 12 1 11 Hydraulic Valve Lifters Symptoms Possible Cause Remedy Soft lifter s due to li
31. anmed Clean or renew float valve 113 Jets in carb clogged Clean jets 14 Water in carb Drain amp clean carb fuel line amp filter Water EE 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 12 1 2 Engine Idles Unsteadily After Warm Up Period Smoky Exhaust Choke activated Close choke Float valve dirty jammed or worn Clean or renew float valve 3 Intake manifold leak Tighten all connections renew faulty items 12 1 3 Engine Runs Erratically or Misfires Occasionally EM Possible Cause 1 Spark plug failure Faulty HT leads Faulty ignition unit 4 Clogged fuel filter Renew fuel filter This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled eme e s e z o o w T saaenm museos Pueri LMilesManuals For ProductsEngine Manuals 2200 engine manualsWydraulic LiftersWorking copiesJEM2204 10 l amp M unsigned doo Jabiru Aircraft pty a ELA Instruction amp Maintenance Manual Jabiru 2200 Aircraft Engine Hydraulic Valve Lifter Models 12 1 4 Engine Runs Too Hot Oil Temperature Above 110 C 230 F Possible Cause Remedy 11 Too much oil in crankcase Check oil level amp adjust if necessar Low o
32. burettor 6 Bearing Crankshaft 2 5 Manufacturer Jabiru Aircraft Pty Ltd P O Box 5792 Bundaberg West Queensland 4670 2 6 Engine Manuals JEM2204 Instruction and Maintenance Manual JEM2202 Installation Manual JEM2203 Parts Book JEMO001 Overhaul Manual All manuals are available on the Jabiru web site www jabiru net au 2 7 Additional Service Information Occasionally new or expanded service information will be made available to customers in the form of Jabiru Service Bulletins or Jabiru Service Letters Jabiru distributes this information to owners of certain types of Jabiru product However it is strongly recommended that owners and operators regularly visit the Jabiru Australia website www jabiru net au or the website of their local Jabiru representative to check for new or updated additional service information This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled eme 5 0 7 o o w oueon isumeenors Pape sors L files Manuals_For_Products Engine_Manuals 2200_engine_manuals Hydraulic_Lifters Working copies WEM2204 10_l amp M_unsigned doc Jabiru Aircraft pty a gt ELA Instruction amp Maintenance Manual Jabiru 2200 Aircraft Engine Hydraulic Valve Lifter Models 3 Specifications 3 1 Engine Models 3 1 1 2200J The Jabiru 2200J Engine is certified to the CS 22 Subpart H Design Standard b
33. ce if necessary This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled eme e s e z o o w Meran museos Page ots L Miles Manuals_For_Products Engine_Manuals 2200_engine_manuals Hydraulic_Lifters Working copies WEM2204 10_l amp M_unsigned doc Jabiru Aircraft pty a ELA Instruction amp Maintenance Manual Jabiru 2200 Aircraft Engine Hydraulic Valve Lifter Models e Remove warning placard from propeller e Remove inlet amp exhaust covers e Remove clean and gap spark plugs e Drain all oil before rotating While spark plugs are removed rotate propeller several revolutions using the starter to clear excess corrosion inhibitor from cylinders CAUTION Ensure that the Master and Ignition Switches are OFF e Install spark plugs torque to 11 Nm 8 ft Ibs e Check fuel filter replace if necessary e f returning to service after indefinite storage fill fuel tank with correct grade of fuel e Check fuel tank and fuel lines for moisture and sediment Drain enough fuel to eliminate any moisture and sediment e Check fuel tank breather is clear e Perform a thorough pre flight inspection e Start and warm engine 5 9 7 New Engine Storage e n many cases new or overhauled engines may be stored for some months or years before being installed in an aircraft All engines are treated with corrosion inhibitor by Jabiru Ai
34. celeration behavior to maximum RPM 10 seconds max iii Check temperatures amp pressures iv Stop Engine anson e s e z o o w T saaenm museos Page 19018 L Miles Manuals_For_Products Engine_Manuals 2200_engine_manuals Hydraulic_Lifters Working copies WEM2204 10_l amp M_unsigned doc Jabiru Aircraft pty a ELA Instruction amp Maintenance Manual Jabiru 2200 Aircraft Engine Hydraulic Valve Lifter Models 5 4 Check After Initial 25 Hours Details of specific operations are shown in Chapter 6 Maintenance of this manual e Remove engine cowlings e Check engine mounts e Thoroughly check engine for missing or loose bolts nuts pins etc e Check fit of cooling air ducts baffles Check the engine including oil cooler for signs of abrasion against cowls and ducts e Check induction and exhaust flange for loose bolts e Check safety wires ignition wiring hose connections e Oil Change Refer to Chapter 6 Maintenance for details Use normal aviation running oil e Change oil filter Inspect old filter for excessive contamination metal filings etc e Retorque cylinder head bolts at 20 ft lbs in diagonal pattern e Check exhaust system check exhaust cap screw tensions e Check fuel system for leaks amp abrasion e Check wiring for damage amp for tightness e Test run engine v Turn engine on starter with both ignitions OFF until oil pressure registers vi Start engine Observe starti
35. controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled eme e s e z e o w T saaenm museos Page stots LMilesManuals For ProductsEngine Manuals 2200 engine manualsWydraulic LiftersWorking copies WEM2204 10_l amp M_unsigned doc Jabiru Aircraft pty a ELA Instruction amp Maintenance Manual Jabiru 2200 Aircraft Engine Hydraulic Valve Lifter Models 15 Jabiru s Limited Express Warranty Claim Form FROM DATE ENGINE PARTS AIRFRAME PARTS ENGINE NUMBER AIRFRAME KIT NUMBER PART NUMBER TOTAL HOURS OWNER PREVIOUS OWNER PART DESCRIPTION CLAIM FAULTY GOODS RETURNED YES COURIER Co REF NO NO ALL GOODS THAT ARE BOXED AND HAVE TO PASS THROUGH CUSTOMS HAVE TO BE CLEANED AND FREE FROM CONTAMINATION WITH A 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 THIS CLAIM FORM IS NOT COMPLETELY AND CORRECTLY COMPLETED WARRANTY MAY BE REFUSED OFFICE USE ONLY APPROVED NOT APPROVED REASON PRINTED NAME SIGNED DATED This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled eme 5 0 7 6 e ro Tsaaenm museos Page zs L Miles Manuals_For_Products Engine_Manuals 2200_engine_manuals Hydraulic_Lifter
36. craft Engine Hydraulic Valve Lifter Models 8 Notes Before Starting Engine Jabiru Aircraft Pty Ltd 2200 Hydraulic Lifter Engine WARNING This engine has been run in and is ready for flight This engine uses hydraulic lifters for valve operation 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 2 3 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 Note Cylinder heads have a 1 8 NPT plug to be unscrewed to uncover head bolt No 5 After torquing reset plug CAUTION Do not over tighten Over tightening will eventually loosen fit between plug amp head to the point where the plug will not be secure Figure 9 Head Bolt Locations gt If the engine is run on the ground before flight use minimum power settings and minimum time to avoid overheating If the engine is to be run at more than idle power on the ground extra large cooling ducts and oil cooler will be required gt For the first 25 hours of operation add 2 2 litres of Shell 100 oil After 25 hours drain oil check torque of cylinder head bolts to 20 f
37. d 7 2 2 Top End Overhaul e Top End Overhauls must be carried out as detailed in the latest approved revision of the Jabiru Engine Overhaul Manual e Parts replaced include Conrod bearings pistons gudgeon pins and circlips rings valves all relevant O rings and gaskets head bolts spark plugs induction hose joiners rotors relevant cap screws and fuel line Other parts for inspection measure and clean or replace are oil pump starter alternator fuel pump coils ignition leads oil seals induction and exhaust capscrews carby heads and barrels e As apart of the overhaul process the engine must be run in Again the procedure given in the Jabiru Engine Overhaul Manual must be used Details are given in that manual however note that if the run in is performed on the ground large air cooling ducts and a large oil This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled anson 5 0 7 6 e i Tsaaenm museos Page zs L Miles Manuals_For_Products Engine_Manuals 2200_engine_manuals Hydraulic_Lifters Working copies WEM2204 10_l amp M_unsigned doc Jabiru Aircraft pty a Mox Instruction amp Maintenance Manual Jabiru 2200 Aircraft Engine Hydraulic Valve Lifter Models cooler must be used The engine can also be run in in the aircraft in the air with caution using the run in program as the guide Section 11 1 Early Opera
38. d and assembled in a very modern factory in Bundaberg where each engine is run in on a Dynometer and calibrated before delivery The crankcase halves cylinder heads crankshaft starter motor housings gearbox cover the gearbox powers the distributor rotors and coil mounts together with many smaller components are machined from solid The sump oil pan is the only casting The cylinders are machined from bar 4140 chrome molybdenum alloy steel with the pistons running directly in the steel bores The crankshaft is also machined from 4140 chrome molybdenum alloy steel the journals of which are precision ground prior to being Magnaflux inspected The camshaft is manufactured from 4140 chrome molybdenum alloy steel with nitrided journals amp cams The propeller is direct crankshaft driven and does not use a reduction gearbox This facilitates its light weight design and keeps maintenance costs to a minimum The crankshaft features a removable propeller flange which enables the easy replacement of the front crankshaft seal and provides for a propeller shaft extension to be fitted should this be required for particular applications Cylinder heads are machined from solid aluminium billet thereby providing a substantive quality trail to material source Connecting rods are machined from 4140 alloy steel and the 45mm big end bearings are of the automotive slipper type Many components of the engines are sourced from outside suppliers These item
39. d running at elevated RPM Engine can be over heated during ground operations remember air ducts are designed for in flight cooling Ground running at high power settings for more than a few minutes requires the use of special oversize air ducts and oil cooler e Do not apply full power until CHT has reached at least 100 C 212 F e ALWAYS TAKE OFF AT FULL POWER especially when the engine is new e For the first few take offs climb at a higher airspeed than normal to assist engine cooling Reduce power at cross wind leg and shallow climb lower nose e 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 e RETORQUE heads on annual inspection e The ducts supplied with the engine need to be fitted See Installation manual Occasionally periodic research and development dictates that changes must occur to cooling ducts The ducts supplied with new engines will the latest types and may differ to those supplied with older engines This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled anson e s e z o o w T saaenm museos Page doors LMilesManuals For ProductsEngine Manuals 2200 engine manualsWydraulic LiftersWorking copies WEM2204 10_l amp M_unsigned doc Jabiru Aircraft pty a ELA Instruction amp Maintenance Manual Jabiru 2200 Aircraft Eng
40. dings fall outside the range given above contact Jabiru Aircraft or our local authorised representative e The carburetor automatically adjusts the mixture to account for altitude This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled eme e s e z o o w T saaenm museos Page zs LMilesManuals For ProductsEngine Manuals 2200 engine manualsWydraulic LiftersWorking copies WEM2204 10_l amp M_unsigned doc Jabiru Aircraft pty a ELA Instruction amp Maintenance Manual Jabiru 2200 Aircraft Engine Hydraulic Valve Lifter Models IMPORTANT e Check carburetor joints for degradation e Check carburetor linkage for full amp free movement correct positioning of stops and security 6 4 Compression Check 6 4 1 Compression Gauge e Measure compression using a compression tracer Readings are taken with fully open throttle valve at engine oil temperature between 30 amp 70 C 90 to 160 F e f readings are below 6 bar 90 psi a check of the pistons cylinders valves amp cylinder heads must be undertaken 6 4 2 Pressure Differential Test e Check using a pressure loss or leakage tester eg SUN or BOSCH tester max allowable pressure loss is 25 As an alternative to a compression test a pressure differential test Leak down can be carried out This is a much better test of the condition of rings bore head sealing and valv
41. e This is the normal test used in aviation and requires specific equipment The test is carried out with the engine in warm to hot condition Input pressure is best set at 80 PSI a second gauge reads the differential This is done with piston on TDC on the firing stroke Note that the propeller needs to be restrained A differential of lower than 80 60 or generally a 25 loss indicates a problem Problems can be better identified using the leak down i Blow by through the crankcase vent indicates worn rings or bore ii Leaking from carby indicates a poor intake valve seal iii Leaking from exhaust indicates a poor exhaust valve seal iv Head leak indicates poor head to cylinder seal With the problem narrowed down correction work can more easily be carried out e A Pressure Differential Tester can be made by placing an orifice of 1 mm ID and 3mm length between two pressure gauges This will give the same result as with the above instrument Max pressure drop is 2596 CAUTION Poor compression can be an indication of a serious problem For example continued operation with poor compression due to a poorly sealing valve can lead to eventual valve failure and heavy damage to the piston con rod barrel and head If low compression is found which cannot be solved by reference to the Troubleshooting section below please contact Jabiru Aircraft or our local authorized representative This document is controlled while it remains on the Jab
42. ed if it comes into contact with alcohol leading to leaks f Prevent condensation of humidity ie avoid temperature differences between the aircraft amp fuel 5 9 9 2 Icing Due to High Air Humidity 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 CAUTION When using auto fuels ensure all components of the fuel delivery system are cooled to prevent fuel vaporization This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled eme e s e z o o w Sweat museos Page zz LMilesManuals For ProductsEngine Manuals 2200 engine manualsWydraulic LiftersWorking copies WEM2204 10_l amp M_unsigned doc Jabiru Aircraft pty a ELA Instruction amp Maintenance Manual Jabiru 2200 Aircraft Engine Hydraulic Valve Lifter Models 6 MAINTENANCE 6 1 Lubrication System e Oil Change as required Oil Filter Change as required Visual Check for Leaks e Drain the oil while engine is still warm e Change the oil filter at every 50 hourly inspection e Fill with oil approx 2 3 litres e Check oil level then run the engine The MAX mark must not be exceeded after the engine has been run to ensure that all lines filters etc are full e Use only registered brand oils
43. emains on the Jabiru server Once this no longer applies the document becomes uncontrolled L Miles Manuals_For_Products Engine_Manuals 2200_engine_manuals Hydraulic_Lifters Working copiesJEM2204 10 I amp M unsigned doc Dated Apr 2011 Issued By DPS Page 36 of 55 Jabiru Aircraft pty a ELA Jabiru 2200 Aircraft Engine Instruction amp Maintenance Manual Hydraulic Valve Lifter Models 7 4 Engine Installation No Operation Tools Required 1 Fit engine to engine mount 2 Torque engine mount bolts 7 16 Tube Socket 7 16 Ring Open End Spanner 3 Fit muffler if not already fitted and fit carburettor 3 16 Ball End Allen Key heat muff and hose 4 Connectleft and right ignition coils leads 5 Connect Tacho sender 6 Connect exhaust gas temp if fitted 7 Connect cylinder head sender 18mm Spark Plug socket 8 Connect hourmeter Screw Driver 9 Connect oil temp gauge sender 10 Connect oil pressure gauge sender 11 Connect starter 7 16 Ring Open End Spanner 12 Connect Battery Earth lead first 10mm Ring Open End Spanner 13 Connect fuel line Screw Driver 14 Connect Oil Breather Screw Driver 15 Connect Choke Cable Long Nose Pliers 16 Connect Throttle Cable Long Nose Pliers 17 Connect Air Inlet Screw Driver 18 Fit Propeller and spinner 7 16 Ring Open End Spanner 7 16 Torque Wrench Phillips Screw Driver 19 Fit Cooling Ducts 3 16 Allen Key 20 Prime Fuel system with electric pump and inspect
44. engine particularly the cylinder heads and barrels The fitment of these ducts is a great bonus for the home builder or engine installer as they remove the need to design and manufacture baffles and the establishment of a plenum chamber which is the traditional method of cooling air cooled aircraft engines The fact that these baffles and plenum chamber are not required also 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 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 drawn 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 t
45. fter fault Replace lifter s Soft lifter s due to low oil See Low Oil Pressure section pressure above Run engine Up to 15 minutes Engine noisy tapping at idle running may be required to H TP completely expel air from the Soft lifter s due to air in lifter lifter OR Remove lifter and manually fill with oil Soft or stuck hydraulic lifter s Replace lifter s Soft lifter s due to low oil See Low Oil Pressure section Reduced engine power do Ge operating oil pressure pide eee holding within limits P Replace lifter s Excess metal in oil filter Cam Lifter damage insager Mer and Cam working surfaces Replace if damaged Notes Refer to Section 6 8 for additional details on hydraulic lifter maintenance requirements This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled eme 5 0 7 6 e ro oueon museos Page soorss L Miles Manuals_For_Products Engine_Manuals 2200_engine_manuals Hydraulic_Lifters Working copiesWEM2204 10_l amp M_unsigned doc Jabiru Aircraft pty a ELA Instruction amp Maintenance Manual Jabiru 2200 Aircraft Engine Hydraulic Valve Lifter Models 12 2 Troubleshooting Quick Guide 12 2 1 Low Oil Pressure e A sudden drop of pressure usually is caused by a piece of foreign matter lodging under the relief valve Simply remove oil filter and cooler adapt
46. he Jabiru aircraft have been measured at 62dB at 1000 full power flyover For those owners wanting to fit vacuum instruments to their aircraft the Jabiru engine design includes an optional vacuum pump drive direct mounted through a coupling on the rear of the crankshaft The Jabiru engine is manufactured within an Australian Civil Aviation Safety Authority CASA approved Quality Assurance System to exacting standards Jabiru recommend a TBO of 2000 hours with a top end overhaul done at 1000 hours or when engine condition indicates the need to overhaul earlier This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled menson 5 0 7 o o w Swereaw owoey 0Ps Pape Tots LaifilesMManuals_For_ProductsiEngine_Manualsi2200_engine_manualsiHydraulic_LifterslWWorking copies WEM2204 10_l amp M_unsigned doc Jabiru Aircraft pty a ELA Instruction amp Maintenance Manual Jabiru 2200 Aircraft Engine Hydraulic Valve Lifter Models 2 4 Details 4 Stroke 4 Cylinder Horizontally Opposed 1 Central Camshaft Push Rods Over Head Valves OHV Hydraulic Valve Lifters with Automatic Adjustment Ram Air Cooled Wet Sump Lubrication Direct Propeller Drive Dual Transistorised Magneto Ignition Integrated AC Generator Electric Starter Mechanical Fuel Pump Naturally Aspirated 1 Pressure Compensating Car
47. he idle cannot be set on the DYNO Adjust throttle stop to obtain 900 950 RPM when engine is warm before first flight e Do not Baby a new engine 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 Early running of an engine should include periods at high RPM and power settings e Failure to operate at realistic power settings could be detrimental to engine condition amp long term performance e Always take off using full power especially when the engine is new e Avoid heat build up monitor CHT and oil temps Note that Initial temps will be elevated due to the friction of a new engine Careful monitoring by the pilot is needed during this initial period to ensure long life of the engine and its components e CIRCUIT WORK is a good sequence for initial run in work i Abbreviate circuits initially ii Step climbs and climb at shallow angles amp higher airspeeds iii Do not carry out glide approaches iv Gradually reduce power v Avoid sudden heating up and sudden cooling down e When you change oil from the run in type to the normal oil at or around 25 hrs replace oil filter This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes unco
48. hin this manual e Fuel Consumption 21 L hr Takeoff Max Continuous Rating e Oil Consumption 0 1 L hr max This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled anson 5 e z o e w oueon museos Page tors L files Manuals_For_Products Engine_Manuals 2200_engine_manuals Hydraulic_Lifters Working copies WEM2204 10_l amp M_unsigned doc Jabiru Aircraft pty a ELA Instruction amp Maintenance Manual Jabiru 2200 Aircraft Engine Hydraulic Valve Lifter Models 3 4 Fuel Fuel AVGAS 100 LL amp AVGAS 100 130 Leaded and Unleaded Automotive Gasoline above 95 Octane RON may be used if AVGAS is not available Detailed fuel information is available in Jabiru Service Letter JSLOO7 Current Jabiru Service Bulletins amp Letters available at www jabiru net au Oil The following chart is intended to assist in choosing the correct grade of oil and must be considered as a guide only Multiviscosity grades can also be used as indicated Average Mineral Ashless Dispersant Ambient Temperature Grades Grades Above 35 C 95 F SAE 60 SAE 60 15 C to 35 C 59 to 95 F SAE 50 SAE 50 17 C to 25 C 1 to 77 F SAE 40 SAE 40 Equivalence of SAE and commonly used Commercial Grade designations SAE 20 30 40 50 60 Commercial 55 35 80 100 120 3 5 Lubricant 3 5
49. ies the document becomes uncontrolled mension e e v eo w meman wuesoy ors Page 20015 Lifiles Manuals_For_Products Engine_Manuals 2200_engine_manuals Hydraulic_Lifters Working copieslJEM2204 10_18M_unsigned doc Jabiru Aircraft pty a ELA Instruction amp Maintenance Manual Jabiru 2200 Aircraft Engine Hydraulic Valve Lifter Models e Hydraulic Lifters can be bled back while installed by using a suitable tool to push rocker pushrod assembly back to enable a small gap on rocker to valve tip Total bleed back is less than 2 mm More details are given in the engine overhaul manual Hydraulic lifters can be removed for inspection using the following method e Remove the rocker pivot shaft rockers and pushrods from the cylinder to be inspected e Remove the pushrod tube retaining circlips from the cylinder head and slide the pushrod tubes out through the head e Remove the hydraulic lifter adaptors from the crankcase e Remove the lifters Whenever lifters are removed the working face of the cam and the lifter should be inspected for damage If damage is found contact Jabiru Aircraft P L or our local representative for further guidance 6 9 Valve Rockers e The condition of the bushes fitted to the valve rockers must be monitored This can be done by a visual inspection with the rocker cover removed check for visible movement of the rocker on the shaft visible degradation of the bush mate
50. il level 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 Faulty bearings If metallic particles are present in oil complete engine overhaul necessary 7 Faulty oil temperature gauge Exchange gauge 12 1 5 Unsatisfactory Power Output PossibleCaue Remedy 1 Ignition failure Check ignition circuits check wiring and pick uM ups replace ignition units 6 Leak in air intake Check and tighten all connections check carby sockets Carby diaphragm damage 8 Hydraulic Lifter stuck collapsed Replace lifter s 12 1 6 Low Oil Pressure am Possible Cause Remedy Insufficient oil in sump Check oil level amp replenish as necessary High oil temperature Refer to Para 10 4 3 Faulty pressure gauge sender or wiring Check gauge sender amp wiring Renew as necessary Faulty crankshaft bearings Engine overhaul 5 Relief valve not sealing Inspect replace back after cleaning 12 1 7 Engine Keeps Running with Ignition Off Possible Cause 11 Idle speed too high Adjust to proper idle speed 200 RPM 2 Faulty ignition switch Check switch amp cables Repair replace as necessar 3 Overheated engine Conduct cooling run at 900 RPM 12 1 8 Excessive Oil Consumption PossibleCause Remedy Worn valve guides Rep
51. ine Hydraulic Valve Lifter Models 11 2 4 Consumables e Filters Regular inspections 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 air filter e Spark Plugs NGK D9EA are recommended Refer to main body of this manual for plug gap Remember that plugs are installed at around 8 ft Ib or given 1 2 turn after contact with head 18mm Plug spanner used 11 2 5 Starting e A warm idle of around 900 RPM will automatically create the right starting environment As the engine is run in on a dynamometer the Idle set screw may have to be adjusted to give 900 RPM idle when warm e Normal start requires the application of choke with the throttle closed With the throttle on the idle stop the butterfly in the throat body will be slightly cracked The engine will be difficult to start if throttle is cracked open too far e After the engine stars the choke should be pushed off The choke is only used for a cold start Prolonged cranking with choke on will flood the intake system making starting difficult Should this occur leave the aircraft to sit for approx 10 minutes or alternatively clear the system on full throttle momentarily mags off e f the Cranking speed is too slow poor battery or starter fault the ignitions will not fire preventing starting If jump starting is necessary it point towards poor battery condition or faulty alternato
52. iod of 1 minute e When engine runs adjust the throttle to achieve smooth running at approximately 1200 RPM Deactivate Choke Check Oil Pressure has risen within 5 seconds if not shut down e lt is strongly recommended to crank the engine to obtain oil pressure following an oil change before starting 4 2 1 Cold Engine Fuel Tap OPEN Choke ON HOLD in cold conditions less than 20 C Fuel Pump ON for 10 seconds then off Throttle CLOSED to stop cracked throttle degrades choke Master ON Ignition BOTH ON Starter PRESS 4 2 2 Warm Engine As for cold start with the following differences Choke OFF Throttle Slightly Cracked from off position approx 2 4 3 Warming Up Period Ground Test Start the warming up period with the engine running at 1200 RPM Continue at 2000 RPM depending on ambient temperature until oil temperature reaches 15 C 59 F Check the two ignition circuits at 2000 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 212 F DO NOT apply full power until Oil Temperature reaches 50 C 104 F DO NOT allow cylinder heads to rise above 150 C 302 F during ground running 4 4 Take Off Climb with the engine at maximum continuous power Observe Oil amp Cylinder Head Temperatures amp Oil Pressure Max RPM at Full Throttle is 3300 RPM Limits must not be exceeded This document is controlled while it remains on the
53. ion 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 Output 14 2 VDA at 2750 RPM Tacho Coil Resistance 160 to 170R Gap 0 4 This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled ee 50 o o Tier Ga ors Pao et L Miles Manuals_For_Products Engine_Manuals 2200_engine_manuals Hydraulic_Lifters Working copiesJEM2204 10 I amp M unsigned doc Jabiru Aircraft pty a ELA Jabiru 2200 Aircraft Engine Instruction amp Maintenance Manual Hydraulic Valve Lifter Models 11 Operating Notes Quick Reference Guide 11 1 New Engine Notes e This engine has been ground run to a specific run in program and is ready for flight e The engine has been NHIBITED However if you intend to store it for any length of time please refer to Section 5 7 3 of INSTRUCTION AND MAINTENANCE MANUAL Removing spark plugs and turning over will help periodically e Before initial start add oil to engine 2 3 litres with cooler remove one plug per head and turn the engine over on the starter to remove excess inhibitor Once oil pressure is obtained replace plugs and continue start up sequence e Remove ALL plastic bungs on engine before starting EXHAUST 4 CARBY 2 OIL VENT 1 FUEL PUMP 1 e VARY your RPM when flying with a new engine e T
54. iru server Once this no longer applies the document becomes uncontrolled eme e s e z o o w oueon museos Page abate LMilesManuals For ProductsEngine Manuals 2200 engine manualsWydraulic LiftersWorking copies WEM2204 10_l amp M_unsigned doc Jabiru Aircraft pty Lia o E En o co UI g D o EE 2 os RS A 3 53 g CH ot e a Instruction amp Maintenance Manual Ignition System 6 5 High Tension Lead Connections 6 5 1 I1SnVHX3 9 E c 8 t HAQHO ONIHIJ 0 S AA SINIDN3 TIV dein aaa dd Een c Q0v99cvr VIN aroma CAONITAD HOLNEIYLSIC INIONI FCIHISVE Loun us mii vaa el NE 26 982 O10 N O V 31V Sei OUT Ald HOALAY dO LNASNOO JHL LNOHLIM datdoo SIYLINWITIIN NI soez ar 39 LON SAW ONY JHSIMAdOO SI ONIMVEG SIHL Vd HO31AV SOS JON OO a e N3MIG E e NOLLO3POYd soe z mw T 7 9 C 8 8 HACHO SNIHIJ ANIONS H3CNITAO 8 359V LNI 1SAWHX3 3MVINI cl HACHO 9NIHld 3NION3 H3QNITAO E 3NION3 H3ONITAO 9 y JNVLNI NV 18 KO Anne A 33V LNI lSnvHX34 QvaH 3HL 40 3018 3XV1NI HO LSNWHXS SHL NO Y30NI749 SHLNI SOMId NEVAS 3HL 20 NOLLISOd SHL OL 43434 3XVLNI L80VHX3 2 dNISN3 JHL 3O QN3 SAIC dOHd SHL WOYS
55. ls 5 CHECKS ON ENGINE amp INSTALLATION 5 1 Daily Checks e Ensure free movement of throttle amp choke cables e Check Oil Level replenish if necessary i Check oil level by screwing in cap fully before withdrawing ii Oil level should be between the MAX amp MIN marks but must never be below the MIN mark iii Before long periods of operation ensure that the level is at least at the mid position iv Difference in the oil quantity between MAX amp MIN mark is 300 mL 0 317 US Quarts v See section 11 1 for first 25 hours of Operation vi Overfilling is detrimental to the engine e Check lubrication amp fuel system for leaks i Visually inspect for signs of leakage on the ground where the aircraft was parked overnight ii Inspect the oil cooler for leaks through the cowl opening iii Visually inspect the underside of the aircraft for fresh oil or fuel residue e Check exhaust system for security i Wriggle the exhaust tail pipes by hand checking for excessive movement rubbing on cowls or unusual noises e 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 refer to Trouble Shooting section of this Manual for corrective action CAUTION Prior to pulling through the propeller by hand both ignition circuits amp the Master Switch must be switched OFF the brakes applied and the
56. ls 2200 engine manualsWydraulic LiftersWorking copies WEM2204 10_l amp M_unsigned doc Jabiru Aircraft pty a ELA Instruction amp Maintenance Manual Jabiru 2200 Aircraft Engine Hydraulic Valve Lifter Models 9 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 80 100 120 Outside Air Temp 17 C to 25 C 15 C to 35 C Above 35 C Normal Operations Oil W80 W100 W120 Outside Air Temp 17 C to 25 C 15 C to 35 C Above 35 C Note Multigrade aviation oils are also available ANKCAS L FILTER RELIEF VALVE OIL TO COOLER FROM OIL PUMP OIL RETURN FROM COOLER FI OIL FROM COOLER Y Coll FILTER OL RETURN FROM ot COOLER ADAPTOR RELIEF VALVE HOUSING Figure 10 Oil System Schematic This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled Dated Apr 2011 Issued By DPS Page 42 of 55 REVISION L Miles Manuals_F
57. lth of the engine e Brown to Dark Brown Plug amp calibration is correct e Velvet Black Mixture too rich Check choke Insufficient air intake Check for clogged air filter e Oily Glossy Coating Misfiring Too much oil in combustion chamber Worn cylinder 8 piston rings e Whitish with Melt Droplets Mixture too lean Leaking valves CAUTION This guide is only relevant when running the engine on AVGAS Unleaded fuels give different plug colours which are generally unsuitable for use in evaluating engine tuning 6 6 Exhaust System e Visual check for damage rubbing leaks amp general condition 6 7 Bolts and Nuts e Check for tightness re torque if necessary see Section 9 Note Cylinder Base Nuts are factory set and must NOT be checked for tension at periodic service intervals 6 8 Tappet Adjustment Hydraulic Valve Lifters e The Hydraulic Valve Lifters used in the engine automatically adjust for any valve movement so periodic adjustment of the valve clearances is not required however the valve lifters are a serviceable item and some monitoring is required to ensure they are working properly e EITHER Remove each rocker cover and check that each lifter has not collapsed This is done by turning the crankshaft so that the valve is fully in the closed position then feeling the This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled
58. mp M_unsigned doc Jabiru Aircraft pty a ELA Instruction amp Maintenance Manual Jabiru 2200 Aircraft Engine Hydraulic Valve Lifter Models Operators using non approved parts do so at their own risk Jabiru Aircraft strongly recommend operators using non approved parts follow a system of extra preventative maintenance checks to monitor their engine This should be based on Section 6 13 1 below Airworthiness and issues when claiming upon Jabiru s Limited Express Warranty may also result 6 12 2 Engine Carburettor carburetor heat system carburetor attachment Air filter Engine baffles and air ducts Front crankcase seal Hoses lines and fittings Intake system Exhaust system including muffler springs and heat muff Ignition harness spark plugs coils distributor caps and rotors Electrical wiring starter solenoid and electrical connections Fuel pump Engine controls and linkages Engine mount rubbers amp mount structure Oil system tubes and hoses oil cooler Oil amp filter change and filter inspection if due Firewall Engine cowlings and clips All SCAT Hoses and Clamps 6 12 3 Fuel System Fuel filter Fuel drain valve Carburetor bowl Fuel tank vent cap and placards Fuel shut off valve and placards Electronic fuel boost pump and fittings Fuel lines and connectors fire sleeves 6 13 Special Maintenance Guidance e This manual has been prepared to provide instruction amp mai
59. n Preventive Concentrate or similar engine preservative CAUTION Ensure that the Master and Ignition Switches are OFF e Install spark plugs and connect leads e Seal exhaust pipes Attach a red streamer to each seal e DO NOT seal fuel tank breather e Attach a warning placard to the propeller stating that vents and breathers have been sealed and prop should not be turned e The engine must not be started with the seals in place 5 9 4 Inspection During Storage e Generally inspect airframe and clean as necessary e Inspect the interior of at least one cylinder through the spark plug hole for corrosion at least once a month e f at the end of the 90 day period the aircraft is to be continued in non operational storage repeat Steps 1 5 above most will only need to be checked 5 9 5 Indefinite Storage For indefinite storage treat the engine as per Temporary Storage Section above In Addition e Drain fuel tank 8 ensure carburettor bowl is empty by running engine with fuel valve off until it stops or by draining the bowl manually e Long term storage Flood the cylinder sump with corrosion inhibitor Periodically remove one spark plug per head turn engine over then replace spark plugs 5 9 6 Returning Engine to Service After Temporary Storage After temporary storage the procedures for returning the aircraft to service are as follows e Check battery charge level and install e Check carburettor air filter and servi
60. ne Installation Manual e 2 bladed fixed pitch wooden propellers manufactured by reputable companies are recommended by Jabiru Aircraft e All propellers must be maintained in accordance to the propeller manufacturer s requirements in conjunction with Jabiru Aircraft P L requirements e A maximum moment of inertia of 0 25 kgm is recommended for the propeller assembly anson 5 0 7 6 2 ro I saaen sesgos Page ots L files Manuals_For_Products Engine_Manuals 2200_engine_manuals Hydraulic_Lifters Working copies WEM2204 10_l amp M_unsigned doc Jabiru Aircraft pty a EZ Instruction amp Maintenance Manual Jabiru 2200 Aircraft Engine Hydraulic Valve Lifter Models 3 9 Dimensions OPTIONAL FRONT Pd BED MOUNT E og EI E E DIMENSIONS
61. ng warm up amp acceleration behavior to maximum RPM 10 seconds max vii Check temperatures amp pressures vii Stop Engine 5 5 50 Hours Check e Details of specific operations are shown in Maintenance section of this manual e Conduct the items shown under 25 Hour Check above include oil and filter change 5 6 100 Hours Check e Details of specific operations are shown in Maintenance section of this manual e Conduct the items shown under 25 and 50 Hour Checks include oil and filter change e Renew spark plugs 5 7 200 Hours Check e Details of specific operations are shown in Maintenance section of this manual This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled anson e s e z o o w T saaenm museos Page mors LMilesManuals For ProductsEngine Manuals 2200 engine manualsWydraulic LiftersWorking copies WEM2204 10_l amp M_unsigned doc Jabiru Aircraft pty a ELA Instruction amp Maintenance Manual Jabiru 2200 Aircraft Engine Hydraulic Valve Lifter Models e Conduct the items shown under 25 50 and 100 Hour Checks 5 8 Engine Overhauls e The Overhaul Manual for the Jabiru 2200 and 3300 engines must be referred to for engine overhaul procedures e The overhaul work must be carried out to Jabiru specifications at an approved aeronautical service facility or by an approved Jabiru Service Centre e f
62. nge run out check E per prop strike inspection detailed below 9 Crank run out check per prop strike inspection detailed below Flywheel Screws REPLACE 10 E l Refer to engine overhaul manual for guidance This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled anson e s e z o o w Meran museos Page seors L files Manuals_For_Products Engine_Manuals 2200_engine_manuals Hydraulic_Lifters Working copies JEM2204 10_1 amp M_unsigned doc Jabiru Aircraft pty a ELA Instruction amp Maintenance Manual Jabiru 2200 Aircraft Engine Hydraulic Valve Lifter Models 6 14 Engine Inspection Chart Note READ ALL INSPECTION RQUIREMENTS PARAGRAPHS PRIOR TO USING THESE CHARTS Annual Inspection Each 200 Hours Each 100 Hours Each 50 Hours PROPELLER 11 Spinner i B 12 Spinner Flange i ii a 18 Spinner screws i i 14 Propeller li 15 Propeller bolts nuts Tension id S 16 Spinner Prop Tracking KR ij li ENGINE amp ENGINE COMPARTMENT Check for oil fuel exhaust amp induction leaks then clean entire engine amp compartment before inspection e Check flywheel screw tensions to 24lb ft Carburetor air filter Check amp replace if required e Engine baffles and air ducts e Cylinders ki e Crankcase amp front crankcase seal e Fuel hoses lines and fi
63. ntenance requirements for operating a Jabiru engine As much as possible the information contained herein applies to all engines however the following paragraphs detail additional maintenance recommendations for certain engines 6 13 1 Special Maintenance Non Approved Propellers e As noted operators who choose to fit a non approved propeller to their Jabiru engine do so at their own risk and a system of additional maintenance is recommended to monitor the engine for possible detrimental effects e This section has been added to the manual to help guide such maintenance However as we cannot anticipate every combination of engine airframe and propeller this is strictly of an informational basis It is not a complete or inclusive maintenance schedule rather an overall guide directing which areas are likely to need additional attention WARNING Using a non approved propeller may lead to unforeseen operational airworthiness safety financial or legal problems Jabiru Aircraft accept no responsibility for such issues This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled anson e s e z o o w T saaenm museos Page stots L Miles Manuals_For_Products Engine_Manuals 2200_engine_manuals Hydraulic_Lifters Working copies WEM2204 10_l amp M_unsigned doc Jabiru Aircraft pty a ELA Instruction amp Maintenance Manual Jabiru 2200 Aircraft Engine
64. ntrolled eme e s e z o o w T saaenm museos Page stots LMilesManuals For ProductsEngine Manuals 2200 engine manualsWydraulic LiftersWorking copiesJEM2204 10 l amp M unsigned doo Jabiru Aircraft pty a ELA Instruction amp Maintenance Manual Jabiru 2200 Aircraft Engine Hydraulic Valve Lifter Models 11 2 Normal Operation Notes The following are tips to ensure a long life They are intended to bring attention to important aspects of caring for a Jabiru 2200 engine For details on the required work refer to the main body of this manual 11 2 1 Regular Checks e With ignition and master OFF and throttle closed turn the prop by hand and observe engine for odd noises or heavy movements e Turn the engine over by hand before starting to check for regular compressions If irregular one cylinder with lower compression than others a leak down or similar pressure differential test should be done If the results show a low compression cylinder contact Jabiru Aircraft or our authorized local representative e Compression Test Condition of compression can be gauged by testing the engine with a compression gauge The test is carried out with the engine warm wide open throttle ignitions OFF Turn over on starter A reading below 90 PSI may indicate removal of head and possibly cylinder e Pressure Differential Test As an alternative to a compression test a pressure differential test Leak down can be car
65. oc Jabiru Aircraft pty a ELA Jabiru 2200 Aircraft Engine Instruction amp Maintenance Manual Hydraulic Valve Lifter Models 5 9 9 Carburettor Icing It is important to distinguish between two kinds of icing Icing due to water in fuel and i Icing due to high air humidity 5 9 9 1 Icing Due to Water in fuel 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 a 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 COOC a IMPORTANT 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 CAUTION Do not add any form of alcohol including automotive fuels with Ethanol or similar additives to a Jabiru Aircraft fiberglass fuel tank unless directed otherwise by the aircraft operating manual The sealant used in some older tanks will be damag
66. or if fitted Remove matter by depressing plunger or removing relief mechanism Replace and check operation by ground run If low pressure persists the problem will need further investigation e High oil temperature can cause low oil pressure Ensure oil temperature remains within limits at all times The fitting of an approved oil cooler is strongly recommended Overfilling the sump with oil can cause high oil temperature 12 2 2 Flicking Of Oil Pressure Gauge e t is not uncommon for the Jabiru 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 12 2 3 CHT e lf the gauge is not reading the cause can be cause by a break in the sender wires or incorrect polarity e High readings can result from a poorly centred sender under the spark plug e Normal cruise CHT should not exceed 150 C and climb must not exceed 200 C Air ducts supplied at present give results below these figures 12 2 4 RPM e Tacho s may need adjustment when a new engine is fitted Inducted magnet sender units require coil gap to flywheel tags of 014 or 35mm 12 2 5 Magneto Checks e Possible causes of abnormal drop could be loose leads faulty leads rotor buttons coil gaps spark plugs 12 2 6 Rough Cylinder Running e Check plugs ignition coils and the induction system for looseness
67. or_Products Engine_Manuals 2200_engine_manuals Hydraulic_Lifters Working copiesJEM2204 10 I amp M unsigned doc Jabiru Aircraft pty a ELA Jabiru 2200 Aircraft Engine Instruction amp Maintenance Manual Hydraulic Valve Lifter Models 10 TORQUE SPECIFICATION FOR BOLTS amp NUTS Part Nom Dia mm Torque l nm_ ft lbs Spark Plugs 12mm 11 8 Cylinder Head Bolts 516 34 24 Flywheel Gear Bolts 516 34 24 Crankshaft Prop Flange Cap Screws 3 8 40 30 Lockwire for std length flange only l Tappet Cover Cap Screws 1 4 7 5 Starter Motor Bolts 1 4 11 8 Carburettor Flange Bolts 1 4 11 8 Alternator amp Coil Mount Bolts 1 4 14 10 Propeller Bolts 1 4 9 5 7 Initially head bolts are assembled at 24 Ft Lb After 25 hours head bolts can be checked at 20 Ft Lb 10 1 PRESCRIBED SEALANTS AND PRIMERS Item Sealant Engine Mount Bolts Loctite 243 Spark Plugs NGK D9EA Spark Plug Lubricant Loctite Nickel Anti Seize Prop Mount Loctite 620 Flywheel Crank bolts Loctite 620 Tighten to finger tight to seat then with plug socket turn an additional 1 2 turn 8 ft lbs for a new plug sii All gasket areas use Loctite Gasket Eliminator 515 De LOCTITE CURE ACCELERATOR 7471 used on threads before LOCTITE 10 2 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 Ignit
68. orage After flyable storage returning the engine to service is accomplished by performing a thorough pre flight inspection Ensure all protective covers are removed from the intake amp exhaust 5 9 3 Temporary Storage e Temporary storage is defined as aircraft in non operational status for a maximum of 90 days nominal depending on ambient temperature humidity etc e Disconnect or remove battery This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled enson 5 0 7 6 e ro T saaenm museos Pueri L Miles Manuals_For_Products Engine_Manuals 2200_engine_manuals Hydraulic_Lifters Working copies WEM2204 10_l amp M_unsigned doc Jabiru Aircraft pty a ELA Jabiru 2200 Aircraft Engine Instruction amp Maintenance Manual Hydraulic Valve Lifter Models e Treat as for flyable storage see details above plus i For temporary storage fill fuel tank with correct grade of fuel to prevent moisture accumulation Then e Disconnect spark plug leads and remove spark plugs from each cylinder e Using a spray atomiser spray corrosion inhibitor through the spark plug hole with the piston down then rotate until both valves are open and re spray to coat the induction and exhaust system When all cylinders are treated leave prop horizontal and retreat each cylinder NOTE Use Shell Aero fluid 2UN MIL C 6529C Type 1 Corrosio
69. persons on or in the vicinity of the vehicle Jabiru Aircraft Pty Ltd does not support the use of this engine in any applications which do not meet the requirements of the INSTALLATION MANUAL FOR JABIRU 2200 AIRCRAFT ENGINE Any non compliant installation may render the aircraft un airworthy and will void any warranty issued by Jabiru The Jabiru 2200 aircraft engine is designed to be operated and maintained only in strict accordance with this instruction and maintenance manual Any variation of any kind including alteration to any component at all whether replacement relocation modification or otherwise which is not strictly in accordance with this manual may lead to dramatic changes in the performance of the engine and may cause unexpected engine stoppage engine damage or harm to other parts of the aircraft to which it may be fitted and may lead to injury or death Jabiru Aircraft Pty Ltd does not support any modifications to the engine its parts or components Any such actions may render the aircraft un airworthy and will void any warranty issued by Jabiru Maintenance and modification cannot be supervised by the manufacturer Maintenance requires extreme cleanliness exact parts precise workmanship and proper consumables It is your responsibility to ensure absolute attention to detail no matter who may become involved in work on this engine Your safety your life and your passenger s lives rely on precise and accurate following of ins
70. r charging Further testing would then be required in these areas to identify the problem This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled eso e s e z o o w Sweat museos Page zs LMilesManuals For ProductsEngine Manuals 2200 engine manualsWydraulic LiftersWorking copies WEM2204 10_l amp M_unsigned doc Jabiru Aircraft pty a ELA Jabiru 2200 Aircraft Engine Hydraulic Valve Lifter Models Instruction amp Maintenance Manual 12 Trouble Shooting 12 1 Troubleshooting Tables 12 1 1 Engine Won t Start Possible Cause Remedy 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 No fuel in tank Refuel 15 Wrongly connected high tension leads Connect as shown on leads 6 Starting Speed too low faulty or discharged Recharge or replace battery battery 17 Coil to Magnet gap too wide Adjust to 0 25mm 0 010 High tension leads loose or damaged Check or renew connections 91 Dampnessin distributors Thoroughly dry internally Bd id plugs damp due to condensation Thoroughly dry both inside and outside of lugs 11 Plug face wet by fuel due to excessive Dry spark plugs trace possible faults in fuel actuation of choke or overflow of carb system or over flow of carb Float valve dirty or j
71. rcraft Australia before shipping from the factory however this treatment is roughly equivalent to that described in Section 5 9 3 above It is intended for a maximum life of approximately 90 days though the exact effective life of the treatment depends on the ambient temperature humidity etc e If an engine is to be stored before use the owner must i Install the engine within 90 days nominally of the engine leaving the factory or ii Repeat the Temporary Storage procedures given in Section 5 9 3 at a suitable interval 90 days nominally depending on ambient temperature humidity etc and periodically inspect the engine in accordance with Section and 5 9 4 or iii Treat and maintain the engine for Indefinite Storage per Section 5 9 5 above e When the engine is to be run the storage measures must be reversed as detailed in the appropriate sections above 5 9 8 Operation in Winter e t 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 given in the Engine Specifications above Follow the following advice for operation at extremely low temperatures This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled eme e s e z o o w T saaenm smeemoPs Pueri LMilesManuals For ProductsEngine Manuals 2200 engine manualsWydraulic LiftersWorking copies WEM2204 10_l amp M_unsigned d
72. reduced intervals e After the initial 10 hours check in accordance with para 5 3 e After the initial 25 hours check in accordance with para 5 4 e After 50 hours of operation check in accordance with para 5 5 amp thereafter after each 50 hours of operation e After 100 hours of operation check in accordance with para 5 6 and thereafter after each 100 hours of operation e After 200 hours of operation check in accordance with para 5 7 and thereafter after each 200 hours of operation e At TBO overhaul in accordance with the latest approved revision of the Jabiru Engine Overhaul Manual 5 3 Check after initial 10 Hours e Details of specific operations are shown in Maintenance section of this manual e Remove engine cowlings e Check engine mounts e Thoroughly check engine for missing or loose bolts nuts pins etc e Check fit of cooling air ducts baffles Check the engine including oil cooler for signs of abrasion against cowls and ducts e Check induction and exhaust flange for loose bolts e Check safety wires ignition wiring hose connections e Retorque cylinder head bolts at 20 ft lbs in diagonal pattern e Check exhaust system check exhaust cap screw tensions e Check fuel system for leaks amp abrasion e Check wiring for damage amp for tightness e Test run engine i Turn engine on starter with both ignitions OFF until oil pressure registers ii Start engine Observe starting warm up amp ac
73. rial etc e This should be done as a part of the hydraulic lifter inspections noted above 6 10 Head Bolts e Head bolts are torqued to 20 ft lb when cold e Carry out this adjustment after five hours of operation and again after ten hours of operation The bolts should thereafter be checked annually or as specified below 6 11 Tachometer and Sender e 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 e Tachometer sender gap is 0 4mm 0 016 The sender must have at least 60 covered by the tags fitted to the gearbox side of the flywheel e Ensure both tags are equal distance from sender 6 12 Additional Checks Post Service e Check engine for ease of starting Conduct idle test run Checklist of engine inspection 6 12 1 Propeller e Check spinner spinner flange screws prop tension spinner and prop tracking CAUTION The maintenance schedules given in this manual are designed for engines which use a propeller and propeller flange approved by Jabiru Aircraft Australia This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled anson 5 0 7 6 2 ro SMererzn museos Page soorss L Miles Manuals_For_Products Engine_Manuals 2200_engine_manuals Hydraulic_Lifters Working copies WEM2204 10_l a
74. ried out This is a much better test of the condition of rings bore head sealing and valve This is the normal test used in aviation and requires specific equipment The test is carried out with the engine in warm to hot condition Pressure input of 80 PSI a second gauge reads the differential This is done with piston on TDC on the firing stroke Note that the propeller needs to be restrained A differential of lower than 80 60 indicates a problem Problems can be better identified using the leak down v Blow by through the crankcase vent indicates worn rings or bore vi Leaking from carby indicates a poor intake valve seal vii Leaking from exhaust indicates a poor exhaust valve seal viii Head leak indicates poor head to cylinder seal With the problem narrowed down correction work can more easily be carried out e Your Tension Wrench should be accurate It should be a good brand and have had some method of calibration Even new wrenches can be un calibrated and can vary to manufacturers claims e The Coil Gap can be adjusted easily by cutting a 15mm wide strip of plastic or thin card thickness 010 Place between magnets on flywheel and coil Check both sides that is each coil to each magnet 4 checks This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled eme e s e z o o w T saaenm museos Pueri LMilesManuals For ProductsEngine Manuals 22
75. rmed and the crankshaft MPI tested as internal damage may have occurred and can only be revealed by stripping the engine The decision to run an engine after a prop strike and after carrying out the above run out checks rests with the owner If you have any doubt about the action to take then consult the Jabiru factory or your Authorised Jabiru dealer for advice Engines running a non Jabiru propeller especially composite propellers must check the tension of the 6 flywheel cap screws at each service to determine that the cap screws meet the torque requirement if not then replace the cap screws and apply Loctite to the screws on assembly 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 If a crankshaft has been severely stressed but measurements and MPI testing indicates a sound item it is Jabiru policy to not re use but replace with a new crankshaft This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled eme e s e z o o w Meran museos Page soorss LMilesManuals For ProductsEngine Manuals 2200 engine manualsWydraulic LiftersWorking copies WEM2204 10_l amp M_unsigned doc Jabiru Aircraft pty a ELA Instruction amp Maintenance Manual Jabiru 2200 Air
76. s 75 Power a 13 I hr 3 5 US gal hr Fuel AVGAS 100 130 MOGAS with RON Octane Rating 95 or above may be used if AVGAS is not available Oil Aero Oil W Multigrade 15W 50 or equivalent Lubricant complying with MIL L 22851C or Lycoming Spec 301F or Teledyne Continental Spec MHF 24B Oil Capacity 2 3 L 2 2 quarts Spark Plugs NGK D9EA Automotive Electrode Gap 0 55 0 6mm 0 022 0 024 Generator Jabiru permanently excited single phase AC generator with rectifier regulator Carburettor d BING constant depression Type 94 40 A Air Intake Filter folder paper cartridge type A Fuel Filtration 0 1 mm 100 Micron maximum particle size Fuel Pump f Camshaft driven diaphragm type Starting System Electric 12 V 1 5 kW Oil Filter a RYCO Z 386 or equivalent 3 3 Performance Static sea level ratings under the following conditions e International Standard Atmospheric conditions at sea level e Aircraft service equipment drives unloaded Vacuum Pump not fitted e Full rich fuel air mixture e Maximum cylinder head temperature e Standard Jabiru air filter and cold air e Standard exhaust muffler 3 3 1 Engine Ratings Table 1 Engine Ratings Model 2200C 2200B All Other 2200 Models 60 kW 80 hp 3300 RPM ISO 63 kW 85 hp 3300 RPM ISO menu rower STD Conditions STD Conditions Note These apply only to engines meeting the configurations detailed wit
77. s Working copiesWEM2204 10_l amp M_unsigned doc
78. s include camshaft followers and the bendix gear in the starter motor The ignition coils are also sourced from outside suppliers and are modified by Jabiru for their own particular application An integral alternator using rare earth magnets provides alternating current for battery charging and electrical accessories The alternator is attached to the flywheel and is driven directly by the crankshaft The ignition system is a transistorised electronic system two fixed coils mounted adjacent to the flywheel are energised by rare earth magnets attached to the flywheel The passing of the coils by the magnets creates the high voltage current which is then transported by high tension leads to the centre post of two automotive type distributors which are simply rotors and caps before distribution to automotive spark plugs two in the top of each cylinder head The ignition system is fixed timing and therefore removes the need for timing adjustment The ignition system is fully redundant self generating and does not depend on battery power The crankshaft is designed with a double bearing at the propeller flange end and a main bearing between each big end it therefore does not have flying webs 48mm main bearings are also of the automotive slipper type Thrust bearings are located fore and aft of the front double bearing allowing either tractor or pusher installation Pistons are manufactured to Jabiru design by a major manufacturer they are fitted
79. t Ibs gt Use 2 2 litres of W100 oil for normal operation or W80 oil for cold weather operation Shell also manufacture a multigrade oil Aeroshell 15W50 which is particularly suited for operations in cold climates This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled eme 5 0 7 6 2 ro Tsaaenm museos Page soorss L Miles Manuals_For_Products Engine_Manuals 2200_engine_manuals Hydraulic_Lifters Working copies WEM2204 10_l amp M_unsigned doc Jabiru Aircraft pty a ELA Instruction amp Maintenance Manual Jabiru 2200 Aircraft Engine Hydraulic Valve Lifter Models CAUTION 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 Jabiru s Limited Express warranty gt Operate engine only on AVGAS 100LL or highest octane available MOGAS Min octane 95 RON Failure to do so could result in engine damage and void Jabiru s Limited Express Warranty CAUTION USE OF OIL FUEL ADDITIVES VOIDS JABIRU S LIMITED EXPRESS WARRANTY This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled eme e s e z o e w Sweat sweemoPs Page eris LMilesManuals For ProductsEngine Manua
80. tandard Modern Jabiru 2200A Engines are rated at 63kW 85hp Nominally this applies to engines with a serial number above approximately 22A 2068 however any engine which meets a certain configuration for example after an overhaul will produce this power level The power difference compared to older models is due to minor evolutionary changes to the engine design 3 2 General Specifications amp Equipment A Displacement 2200 cc Bore j 97 5 mm Stroke 74 mm Compression Ratio 8 1 Direction of Rotation of Prop Shaft a Clockwise Pilot s view Tractor Applications Ramp Weight 61 kg 134 Ibs Complete including Exhaust Carburettor Starter Motor Alternator amp Ignition System gnition Unit Jabiru dual ignition breakerless transistorized Battery independent Ignition Timing a 25 BTDC Firing Order 1 3 2 4 DC Output 10 Amps up to engine S No 22A 2661 17 Amps engine S No 22A 2661 and 22C 001 onwards Fuel Consumption This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled eso 5 0 7 o o w preon isueenors Pape ootss L files Manuals_For_Products Engine_Manuals 2200_engine_manuals Hydraulic_Lifters Working copies WEM2204 10_l amp M_unsigned doc Jabiru Aircraft pty a ELA Instruction amp Maintenance Manual Jabiru 2200 Aircraft Engine Hydraulic Valve Lifter Model
81. throttle closed WARNING A hot engine may fire with the ignition s switched OFF DO NOT TURN OVER A HOT ENGINE BY HAND CAUTION A common cause of low compression is poorly sealing valves Continued operation in this condition will result in damage to valves valve seats valve guides amp overhead gear e Prior to takeoff follow the Starting amp Warm Up procedure observe the engine behavior amp throttle response e Check temperatures amp pressures Conduct a short ground test at full power a few seconds consult aircraft Flight Manual NOTE Prolonged running at full power on the ground can cause engine overheating amp damage unless special oversized air ducts and oil coolers are used This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled anson e s e z o o w Tsaaenm museos Page toris LMilesManuals For ProductsEngine Manuals 2200 engine manualsWydraulic LiftersWorking copies WEM2204 10_l amp M_unsigned doc Jabiru Aircraft pty a ELA Instruction amp Maintenance Manual Jabiru 2200 Aircraft Engine Hydraulic Valve Lifter Models 5 2 Periodic Checks e Basic Inspection Checklists are given below Note that depending on the aircraft s use some items may need checking at more frequent intervals than those specified For example when operating from dusty dirt runways the air cleaner will need attention at
82. tion of an engine must be understood Initial performance data must be recorded New engines and engines overhauled by Jabiru Aircraft Australia are dispatched already run in no further running in is required 7 3 No 1 10 11 12 13 14 15 16 17 18 19 Engine Removal Procedure Operation Remove Spinner and Propeller Remove Carby Heat hose from hot air muff on muffler Remove Air Inlet Hose from Carburettor and blank off Carburettor and Air Cleaner Disconnect Throttle Cable Disconnect Choke Lever Remove Oil Breather Line Remove Fuel Line from Fuel Pump and plug Fuel Line and Fuel Pump Remove starter Motor Cable from Solenoid Disconnect Earth at Battery Remove Oil Pressure Gauge Lead Remove Oil Temperature Gauge Lead Remove Hourmeter Lead if fitted Remove Cylinder Head Temperature Gauge Lead Remove Exhaust Gas temperature Gauge Lead Remove Tacho Lead Remove Left and Right Ignition Coil Leads Remove Muffler Assy Undo Engine Mount Bolts Remove Engine from Engine Mount Frame Tools Required Phillips Screwdriver 7 16 Socket 7 16 Spanner Flat bladed Screwdriver Flat bladed Screwdriver 2 Plugs Long Nose Pliers Long Nose Pliers Flat bladed Screwdriver Flat bladed Screwdriver 1 4 Plugs 7 16 R OE spanner 10mm R OE Screwdriver disconnect at cold junction 3 16 Ball End Allen Key 7 16 Tube Socket 7 16 Spanner This document is controlled while it r
83. tructions in this manual In exchange for the engine manual provided by Jabiru Aircraft Pty Ltd Jabiru hereby agree to waive release and hold Jabiru harmless from any injury loss damage or mishap that I my spouse heirs or next of kin may suffer as a result of my use of any Jabiru product except to the extent due to gross negligence or willful misconduct by Jabiru understand that proper skills and training are essential to minimize the unavoidable risks of property damage serious bodily injury and death that arise from the use of Jabiru products This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled enson 5 e z s e w SMeea isumeenors Peto LMilesManuals For ProductsEngine Manuals 2200 engine manualsWydraulic LiftersWorking copiesJEM2204 10 l amp M unsigned doo Jabiru Aircraft pty a ELA Instruction amp Maintenance Manual Jabiru 2200 Aircraft Engine Hydraulic Valve Lifter Models 2 3 General Description It is said that aircraft are designed around available engines Jabiru believe that the Jabiru range of very light engines offers opportunities for light aircraft designers to develop a new generation of light aircraft Jabiru engines are designed to be manufactured in small batch quantities using the very latest Computer Numerically Controlled CNC machine tools All Jabiru engines are manufacture
84. ttings i S e Intake and exhaust systems S e Ignition harness distributor caps amp rotors 2 2 S Note if any screws rotate they must be removed crankshaft and screw threads cleaned then re installed with fresh Loctite 620 Use no more than the size of a match head Do not remove all flywheel screws at once or loss of valve timing may occur This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled wwe s 9 7 o vo Oaea mnzn tindoy ors Page mors LMilesManuals For ProductsEngine Manuals 2200 engine manualsWydraulic LiftersWorking copiesJEM2204 10 I amp M unsigned doc Jabiru Aircraft pty a ELA Instruction amp Maintenance Manual Jabiru 2200 Aircraft Engine Hydraulic Valve Lifter Models Annual Inspection Each 200 Hours Each 100 Hours Each 50 Hours Spark plugs li e Compression check or leak down check KR KR e Electrical wiring i i e Fuel pump i e Engine controls and linkages n R e Engine mounts mount structure a j e Starter solenoid and electrical connections il e Coils and electrical connections ii Carburettor heat system i i e Throttle and linkage Carburettor E e Oil system tubes and hoses i i Firewall E e Engine cowlings and clips t T i e Exhaust system incl
85. uding muffler i S e Cylinder Head bolt tension i n Hydraulic Lifter amp Rocker Inspection H Section 6 8 amp 6 9 above e Oil amp filter change d e SCAT hose condition i ij Fuel System 1 Fuel filters drain valves carburetor bowl i 2 Electronic fuel boost pump and fittings KR 3 Fuel lines and connectors i P 4 Fire sleeves il anson 5 0 7 6 e ro T saaenm museos Page tots L Miles Manuals_For_Products Engine_Manuals 2200_engine_manuals Hydraulic_Lifters Working copiesWEM2204 10_l amp M_unsigned doc Jabiru Aircraft pty a ELA Jabiru 2200 Aircraft Engine Instruction amp Maintenance Manual Hydraulic Valve Lifter Models 7 SERVICE amp REPAIR 7 1 Service Interval Tolerance e A tolerance of plus or minus 3 hours is allowable on all service intervals set within this manual 7 2 Engine Overhaul and TBO e 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 e The engine must be sent in a complete state with logbook to Jabiru or the Approved Service Centre after reaching the TBO limit e Changes to TBO due to operational experience will be advised by Jabiru via Service Bulletin e Engines have full overhauls at 2000 hours with a Top End being done at around 1000 hours This is also subject to certain conditions overhauls are
86. with 3 rings the top rings being cast iron to complement the chrome molybdenum cylinder bores Valves are 7mm stem dia which are purpose manufactured for the Jabiru engine The valve gear includes pushrods from the hydraulic cam followers to forged steel valve rockers mounted on a shaft through a Teflon coated bronze steel bush Valve guides are manufactured from aluminium bronze as is found in larger aero engines and high performance racing engines This document is controlled while it remains on the Jabiru server Once this no longer applies the document becomes uncontrolled eme 5 e z s e w preon isumeenors Pape cots LMilesManuals For ProductsEngine Manuals 2200 engine manualsWydraulic LiftersWorking copies WEM2204 10_l amp M_unsigned doc Jabiru Aircraft pty a ELA Instruction amp Maintenance Manual Jabiru 2200 Aircraft Engine Hydraulic Valve Lifter Models Replaceable valve seats are of nickel steel and are shrunk into the aluminium cylinder heads The valve gear is lubricated via the hollow pushrods An internal gear pump is driven directly by the camshaft amp provides engine lubrication via an oil circuit which includes an automotive spin on filter oil cooler and in built relief valve The standard engines are supplied with two Ram air 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
87. y the Civil Aviation Safety Authority of Australia The CASA Type Certificate Number for the 2200J Engine is 160 2 Specifications of the engine are available on the Type Certificate Data Sheet attached to the Type Certificate At the time of writing copies of all Type Certificates for Jabiru products are available from the CASA website http www casa gov au casadata cota aust htm 3 1 2 2200B The Jabiru 2200B Engine has been certified as a part of the Jabiru J160 C Aircraft The CASA Type Certificate Number for the J160 C Aircraft is VA 515 2200B engines with a serial number of 22B001 and above are Manufacturer Certified to the ASTM F2339 design standard 3 1 3 2200C The Jabiru 2200C Engine is certified to the CS 22 Subpart H Design Standard by the Civil Aviation Safety Authority of Australia The CASA Type Certificate Number for the 2200C Engine is VE 501 Specifications of the engine are available on the Type Certificate Data Sheet attached to the Type Certificate At the time of writing copies of all Type Certificates for Jabiru products are available from the CASA website http www casa gov au casadata cota aust htm The Jabiru 2200C Engine is rated at 60kW 80 hp 2200C engines with a serial number of 22C001 and above are Manufacturer Certified to the ASTM F2339 design standard 3 1 4 2200A 2200A engines with a serial number of 22A1845 and above are Manufacturer Certified to the ASTM F2339 design s

INSTRUCTION AND MAINTENANCE MANUAL FOR JABIRU 2200

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