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INSTALLATION MANUAL FOR JABIRU 3300 AIRCRAFT ENGINE

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1. MAIN BUS INST BUS 7654321 4321 STARTER 0009 SOLENOID MAIN BUS 0000000 FARTH BUS Ss _ 9500190110191 1110987654321 1110 9 8 7 6 5 4 4 2 4 L 54 0808 ON OFF ON OFF ON OFF ON OFF ON OFF Aah 1 2 m zii po 1 7 4 S FUEL RADIO E FUEL RADIO _ PUMP FUSE INST PUMP FUSE INST IGN 1 IGN 2 STARTER MASTER STROBE FUEL FUSE IGN 2 STARTER MASTER STROBE EL FUSE is PUMP lt EGULATOR WIRING Wy K MASIER WIRING Wi MAIN BUS INST BUS E 7654321 4 3 2 1 T 000000 5 STARTER BATTERY EARTH BUS 13 10 9 6 7 65 43 27 1 EARTH BUS MAIN BUS INST BUS 11109 87 6543 21 7 6 435 21 4321 2000 00600 BLACK 4 id 1 ji ff 1 ON OFF OFF ON OFF ON OFF ON OFF ON OFF OFF ON
2. ENGINE MOUNT POINTS f CLE ee 58 Let FN y H Figure 4 Engine Mount Point Locations Each engine mounting point is rubber mounted to damp the engine vibrations The correct installation of these rubbers is shown below in Figure 4 If required corrections of the engine angle or propeller position can be made by fitting spacers under the rubber cushions The maximum spacer thickness on any one mount is 3mm enson s 2 5 T Torre ZME Jabiru Aircraft ta Mn Installation Manual Jabiru 3300 Aircraft Engine Custom air intake tube Cobra Head ms f LI Figures 5 amp 6 Typical Upper Engine Mount Air Intake Installation PIN ENGINE MOUNT BREAK ALI 88 SHARP CORNERS 60 he 1 5 PN 6 55 R3 1 i eS 18 14 id 17 20 38 M gt MACHINE UNLESS SHOWN OTHERWISE 5 CS1020 CS10
3. 31 Figure 37 Cobra Head for Installations with Minimum Carburettor 32 Figure 38 Ram Alr Ble NR T 32 Figure 39 Jabiru Propeller amp Spinner nennen nnn nnn nnns nnn 35 Figure 40 Engine Accessory Pack Conte nnt ccccccccccsssseecceeeeeeeeeeeecceceeeeaeeseceeeeeseeeeeeceeeeesseeaseeeeeeeeseaesseeeeeeessaaaeeeeeeeeesaas 37 Figure 41 Upper amp Lower Engine Mount 37 Figure 42 Engine Mount 38 Figure 43 Fuel Connections 39 miele SCAT Hose Detall AER 39 Figure 45 Balance Tube Detail 39 Figure 46 Control Connections to 40 Figure 47 Cowl Airflow Best Viewed in 0 aa ar nnn 44 Figure 48 Cowl Airflow Black amp White nennen nenne nnns nnns nnn 44 Fig re 49 Flow VISUAIISAU ON te 45 Figure 50 Front On View Into Harm
4. 47 13 5 A E 48 13 6 Cooling System Testing amp 51 13 7 52 13 8 Amphibian Seaplane Installations esses 52 13 9 Slow Speed 5 nennen nennen 53 14 Appendix A Wiring 54 15 Appendix B Jabiru Aircraft 55 15 1 Known Airframe Engine nnns 55 15 2 Normal Operation Data sseesessssssssssseeeeee nennen nnn nnne nennen nnns nnns nsns 55 16 Engine Installation 14 16 56 15515 T TT T osos ZHE Jabiru Aircraft pty C Installation Manual Jabiru 3300 Aircraft Engine 1 1 Table of Figures Figure 1 Drawing W000509 2 Engine 7 Figure 2 Cylinder Firing 8 Figure 3 Distributor Cylinder MAD m 8 Figure 4 Engine Mount Point Locations 9 Figures 5 amp 6 Typical Upper Engine
5. Addy 01 759 OL 51 CISVHOYNd ALO 538 ON 7009096 INQOIN WARREN xdv SINA 1108 1 c ON OMA JILL HOJLAV 3199 Ee JiVN34 INNON NOIHSNO 21 0194 2 LO E 601100 nigavr NI SNOLLVTIVLISNI 3NI9N3 0022 0022 NOIHSND 22 0194 e OG NOILVUNYIANOD 3NISN3 9IMOT i M3HSVM 91 7 O96NV E v 9 ONG LAN P zvOlZSN 9 __ O lt WN LL 300501 M3OVdS MN3HSVM 2 amp gt 2 LAVHOUIV NUldver NI SNOILVTIVLSNI 3NI9N3 0088 0022 NOILVYNSIANOD LNnOIN J 22 97 ASSY M INNON 27 Pa 4 LL 40080 gt 5 e jlVid 3NION3 Figure 42 Engine Mount Detail pe 48 Installation Manual 5 gt jmd duum lt 2 ASSV M INNON 9 p INNON 3NION3 411 Ald HO3IAV 49 IN3SNOO LNOHLIM
6. SNOTSNSINIG 931909 48 LON ISNA 1H9lMAdOO SI SNIMVSO SIHL Ai L JOS LON OQ REVISION Fuel line from firewall fitting to mechanical fuel pump Fuel line mechanical fuel Jabiru Aircraft pty ta pump to carburettor gt Figure 43 Fuel Connections General SCAT hose from SCAT hose from hot air inlet to air muff on exhaust to air box 1725 Figure 44 SCAT Hose Detail Balance tube connecting filtered side of air mixer box to nipple on carburettor Figure 45 Balance Tube Detail Pesas T Jabiru Aircraft pty ta Mn Installation Manual Jabiru 3300 Aircraft Engine Kit Throttle Cable Carburettor end Throttle lever end Jabiru Aircraft Throttle cable connected Figure 46 Control Connections to Carburettor T T T Ion T rmm Jabiru Aircraft pty Mn Installation Manual Jabiru 3300 Aircraft Engine 11 Before First Start e Expel inhibiting oil from cylinders and pressure up wind engine on starter until a the oil pressure gauge shows a reading before first start e Ensure correct run in type oil is used for the first 25 30 hours to ensure proper ring bedding in Once past the initial 25 30 hours ensure the oil used meets the specifications
7. Figure 52 Oil Cooler Duct Design T esce Pae ar or se 2 1 Jabiru Aircraft Installation Manual Jabiru 3300 Aircraft Engine gt PART Ne DESCRIPTION THIS DRAWING 15 COPYRIGHT AND MUST NOT BE COPIED DIMENSIONS IN MILIMETRES N C PROJECTION dp 1 1129013 BOTTOM COWL 3300 OIL COOLER ADAPTOR QTY 1 1 1 484006 us coor 6 4826004 BAFFLE on COOLER 22011 OL HOSE 1 5 P 20086N HOSETAIL 2 THREADED ADAPTOR 3 4 UNF m PG0138N 85228 O RING urbem load 236 2386 ou i REFER TO DETAIL VIEW 14 REFER DETAIL 18 PHC6T16N GENERAL VIEW 16 x 3 4 2200 ENGINE INSTALLATION SHOWN OIL COOLER OF 3300 I8 THE SAME WITH LONGER COWLS TO SUIT ENGINE SCREWS INTO 1 5 CRANKCASE AIR IN REF 7 PLACE amp TRIM INTAKE DUCT OF COWL TO FIT FRONT OF SUMP amp OL COOLER N AN3 BOLT 1 4 BUNDY TUBE SPACER 12mm SM 1 ao 5 OIL COOLER 4 AK AIR OUT INTO NN REF 27 EAS RX DETAIL VIEW OIL COOLER INSTALLATION PENNY SA SO es Y WAS X WAN NOS HOLD FIRE SLEEVE TO USING SAFETY WIRE 230804 1 AR FLOWING TH
8. sense ports 8 adding 2 turbulence amp swirl 7 ff Cobra Head duct fitted to carburettor AVO Airfilter box Air filter box Figure 33 Air Intake Connections T Jabiru Aircraft le Installation Manual Jabiru 3300 Aircraft Engine Figure 34 Air Filter Box Plumbing Incorrect Correct plumbing sharp lips amp abrupt corners rounded amp smoothed off Gradual bends only in SCAT hose Glass Cobra Head removes a sharp corner in SCAT tube Glass duct prevents bunched SCAT hose from blocking sensor holes on carburettor inlet Figure 36 Typical Cobra Head Installation on a Jabiru Aircraft S Peman mer Jabiru Aircraft py Installation Manual Jabiru 3300 Aircraft Engine Firewall Carburettor Cobra Head Duct Figure 37 Cobra Head for Installations with Minimum Carburettor Clearance 7 3 Air Filter e The induction system must not cause positive RAM induction pressure as this will have an unpredictable affect the fuel air mixture supplied to the engine e The filter must be capable of supplying 250 kg hr 550 pph of air e filter may have to be changed at regular intervals if the engine is to be used in a dusty environment e Air flow should be as direct as possible no tight bends and air t
9. Min 680 720 1256 1328 F Above 70 Power Min 640 680 1184 1256 Note An EGT gauge is not included as standard equipment on the Jabiru 3300 engine though a system can be supplied as an option 1 3 8 Ground Running Limitations Ground Idle 900 RPM set while engine is hot Ground Oil Pressure Idle Startup Min 80 kPa 11 psi Max 525 kPa 76 psi Ground Oil Max 100 C 212 F Ground Maximum Cylinder Head Temperature 180 C 356 Note If ground temperature limits are reached shut the engine down or cool it by pointing the aircraft into wind Measured with sensor ring fitted under exhaust spark plug enson 18 15121111 ZE Jabiru Aircraft pty ta _ Installation Manual Jabiru 3300 Aircraft Jabiru 3300 Aircraft Engine 1 4 Dimensions OPTIONAL FRONT BED MOUNT OPTIONAL FRONT BED MOUNT DIMENSIONS eSI DRAWING IS COPYRIGHT AND MUST NOT BE SCALE 1 1030702 PROJECTION BH IN MILLIMETRES DO NOT SCALE Av TECH P L eSI WITHOUT THE CONSENT OF AVTECH PTY LTD NTS DATE A C N 010 788 973 HINKLER AIRPORT BUNDABERG 4670 GENERAL IOLEHANCES WHOLE NOS 05 mem dH No a ENGINE ASSY JABIRU 3300A WO00509 2 1 op 1 93 Figu
10. and cutting the wire upsets the instrument s calibration e Ensure that wire is not chaffing on the fibreglass air duct or cooing fins e No power connection is required the instrument reads directly off the voltage created by the thermocouple wire e Temperature of the cold junction for best results should be around 50 C Ensure cold junction is mounted as far from the thermo couple probe as possible Cold Junction Plug terminal under spark plug CHT Thermocouple Cold Junction Spark Plug Terminal Figure 22 CHT Sender Thermocouple Installation ew 15151511 T T escis Jabiru Aircraft pty Installation Manual Jabiru 3300 Aircraft Engine ee oni d CHT TERMINAL N TERMINAL NOT CENTRED UNDER A Dg a SPARK PLUG 5 350 600 Cylinder Head Temp Figure 24 CHT Gauge Connections 5 8 6 Exhaust Gas Temperature Gauge optional Exhaust Gas Temperature Gauge can be fitted The probe should be positioned 100mm from the port flange on the exhaust pipe of a convenient cylinder Jabiru Part No PIO325N is the recommended gauge 5 9 Radio Frequency RF Noise Reduction e RF noise is acommon problem with aircraft Symptoms include Radio squelch setting needs to be high Excess noise in the background during transmissions lii Squeals or other feedback noises heard during transmission IV Intermittent static or noise bre
11. 60 x 53 Propeller 3300 RPM 60 x 48 Propeller Cruise At 75 2 50 2850 RPM Sic E 400 kPa 58 psi Oil Temperature Cruise 80 C 175 F Oil Temperature 95 203 Cruise 121 250 F ere gp 177 C 350 F eu EGT 650 C 1202 690 1274 Mechanical Fuel Pump Pressure 3 1 6 20 kPa T Jabiru Aircraft pty ta eos Installation Manual Jabiru 3300 Aircraft Engine 16 Engine Installation Checklist LI LI LI LI LI LI LI LI LI LI LI LI LI LI LI LI LI ENGINE MOUNT Positions engine for correct aircraft CG Positions engine for correct thrust line Sufficient strength Sufficient stiffness Provides access for maintenance Provides clearance the engine and mount are not rubbing on other parts of the aircraft ENGINE CONTROLS Control cables bend radii sufficient Control cables not rubbing on other parts Control cables set up to work in the correct direction ELECTRICAL SYSTEMS Correct sized circuit beakers used Connections for power amp earth correct size Correct type of sender units used for instr
12. AI DUCK Eo aeui esu Ap 46 Fig re 51 Coil Cooling 47 Figure 52 COG er DUCT Desig RT 47 meradiet 48 Figure 54 to aid cooling as installed on a 49 Figure 55 Affect of Angle of Attack Outlets nennen nnn nennen sns naar nnn nnns nana 49 Figure 56 Cowl OUIET GeOMe _ _ ______ 49 Figure 57 Outlet Restriction Caused By Flange Lower 50 Figure 58 Cooling pressure nennen nnne 51 Figure 59 Ram Air duct pressure tapping 52 Figure 60 Augmentor Exhaust System 5 CENE 54 12851511 Torre ZHE Jabiru Aircraft pty C Installation Manual Jabiru 3300 Aircraft Engine 1 2 List of Effective Pages The dates of issue for original amp revised pages are Page Revision Date Page Revision Date Page Revision Date 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 24 6 08 O1 O1 OF O1 OF 1 1
13. Gas Temperature limits are given in Section 1 3 7 oleje T Jabiru Aircraft pty Mn Installation Manual Jabiru 3300 Aircraft Engine Propeller amp Spinner The hub of the propeller must be drilled with holes to match the flange e Fixed pitch wooden propellers are preferred To safely use a propeller made of metal or composite a crankshaft vibration resonance survey has to be conducted to ensure that there are no damaging vibrations Note that this refers to each new propeller design using composite or metal blades once proven the propellers do not need to be tested for each individual installation However due to their inherent vibration damping qualities wooden propellers can be used without this testing Wooden propellers require periodic inspections to maintain proper attachment bolt tension Typically every 50 or 100 hours depending on the propeller manufacturer s recommendations e Belleville washers may be used as shown in Figure 39 to allow for expansion and contraction of Jabiru wooden propellers he propeller must be carefully selected to match the airframe and the engine Propellers up to 1778 70 in diameter and between 762mm 30 and 1397mm 55 in pitch may be used The propeller flange is drilled with two sets of holes which can be used for propeller mounting 6 holes at both 101 6mm 4 PCD and 111 12mm 4 3 8 PCD total of 1
14. Head Temperature Gauge e he Cylinder Head Temperature Gauge uses a thermocouple which is installed to the exhaust spark plug of the hottest cylinder of the engine e The head temperatures of air cooled engines are typically quite variable differences of 50 C 90 F between the hottest and coolest head are not uncommon Refer to Section 13 for additional information on cooling e For a new installation an audit must be done to establish which is the hottest cylinder The CHT thermocouple probe is then fitted under the exhaust spark plug on that cylinder Cylinder number 4 often runs hottest in normal tractor installations however for new installations this MUST be checked and confirmed Jabiru Part No PI10732N is the recommended gauge e Care must be taken when installing the spark plug terminal the terminal must be aligned with the spark plug If the terminal is not aligned the spark plug seal will be poor and hot combustion gasses can leak out These very hot gases will cause the thermocouple to mis read and show high CHT s Figure 23 shows properly and improperly fitted CHT terminals e Loom and Thermocouple sensor are supplied with the instrument These must be installed as per the instrument manufacturer s directions If cable is too long it must be looped as many times as necessary and strapped behind the instrument panel DO NOT CUT TO LENGTH The Thermocouple sensor works by reading small voltages generated by the sensor wires
15. OFF OFF OFF J PPS dts FUEL MAIN RADIO 1 PUMP FUSE INST FUSE PUE GN 1 IGN 2 STARTER MASTER STROBE FUEL pyjoe PUMP Figure 61 Wiring Details 21 T T T Dom T me Jabiru Aircraft pty C Installation Manual Jabiru 3300 Aircraft Engine Appendix B Jabiru Aircraft Installation The following information describes the installation and performance of a Jabiru SP Aircraft fitted with the 3300 engine he information given can be used to estimate the performance of different designs though obviously there will be differences depending on how similar the aircraft is to the Jabiru described below e Poor installations will result in poor performance so installations must be designed referencing the information given in the main body of this manual 15 1 Known Airframe Engine Details Jabiru SP 2 Seater Propeller 60 x 53 1525mm 1346mm 60 x 48 1525mm x 1219mm 15 2 Normal Operation Data following are typical values for the engine when installed a Jabiru SP ja c 900 950 RPM Take Off 2800 RPM 60 x 53 Propeller 2900 RPM 60 x 48 Propeller Full Power S amp L cccccceceseeeeeeeeeeeesaeesseeeeeeeesssaeeeees 3200 RPM
16. build install and maintain IV Produces minimum drag Requires no pilot attention vi Is not affected by rain dirt or insects sticking to it vii And weighs next to nothing e For the sake of the following discussion is considered an opening roughly large enough to slide two fingers into around 13mm by 32mm 0 5 by 1 he total area of the air intakes combined cylinder head and oil cooling openings should generally be no more than one third the total area of the cowl outlet the outlet area must be a minimum of about 3 times as large as the total area of the inlets This assumes that the outlet area is oriented effectively see Figure 56 e Each cylinder head Inlet of a Jabiru Aircraft has an area of approximately 10 500mm 16 25 Oil cooler inlets have an area of approximately 12 500mm 19 4 This gives a required total outlet area of approximately 100 500 155 These sizes are based on Jabiru Aircraft Inlet and outlet sizes required will vary depending on the aircrafts speed drag and the positions of the inlets and outlets the areas given should be used as a guide and starting point only Ageneralised picture of the airflow and air temperature is shown in Figure 47 e Most of the time air leaking through gaps instead of flowing though a cylinder head oil cooler or similar is waste air it does not transfer heat and does not cool the engine Som
17. on the filtered air side of the air mixer box e Fit cylinder head temperature CHT sensor The sensor used in Jabiru aircraft is a J type thermocouple The VDO 310 980 Cylinder Head Temperature Gauge Kit is compatible with this sensor and is installed as standard equipment in Jabiru Aircraft Note that to ensure an accurate temperature reading it is important to have the cold junction for the CHT the plug between the stiff thermocouple wires and the normal plastic insulated gauge wires located away from the heat of the engine Refer to Figure 22 he Oil Temperature Sensor used is a VDO 320 028 which is located in the bottom of the sump as shown Figure 17 e The oil pressure sensor is located at the base of the oil filter and this can be seen in Figure 19 The sensor used is VDO 360 001 e he exhaust gas probe used Jabiru engines is a VDO 310 306 Pyrometer which is supplied as a complete kit The probe is mounted in a fitting which is welded to an exhaust pipe Note that this fitting is not standard The installation of the fitting is best done at the time of order though if required the exhaust pipe may be returned to Jabiru and the fitting added Note that in this case it will normally take around 2 weeks before the pipe is returned to you The fitting is welded to the pipe 100mm down from the exhaust manifold mounting plate Jabiru Aircraft pty ta Installation Manu
18. shape of the taper of the needle controls the mixture at a given throttle setting The needle used in Jabiru engines been optimized for use with a propeller which puts a very non linear load on the engine to double the RPM of a propeller a lot more than double the power has to be applied o achieve a good mixture with the type of load applied by a propeller the Jabiru needle uses two stage taper and a straight tip The more gradual taper at the upper end of the needle gives a leaner mixture in low power cruise settings and at lower RPM where the propeller is using relatively little power The sharper taper at the lower end ramps up rapidly to a much richer mixture at higher power settings The straight tip of the needle is used when the throttle is wide open and the engine s mixture is being controlled by the main jet This rich mixture at full power protects the engine from detonation he transition from lean cruise mixtures to richer full power mixture will occur at around 2800 3000 rpm on 4 and 6 cylinder engines when fitted with an appropriate propeller For most efficient operation the transition must be above cruise rpm The transition can clearly be seen by changes in the EGT Jabiru 3300 needle shown with 3 shallow grooves machined above taper Jabiru Needle gt olow linear taper for 4 cruise power amp below Needle Jet cross section view NI Steeper linear taper for transit
19. the weight and power of the engine The mount must be stiff enough that the engine does not sag or move too much when power is applied The mount must position the engine at the correct height and angle so that the engine s thrust line suits the aircraft In most installations Jabiru Engines need to have their thrust axis offset to the right tractor installations by between 1 and 2 The mount must position the engine at the right place The weight of the engine is a very significant part of the overall aircraft weight and it s position must be calculated to place the centre of gravity of the aircraft CG in the right spot The mount must be designed to allow enough room for the air intake to the Carburettor as well as accessories like vacuum pumps Access for maintenance must also be considered The final design of the engine mount is a compromise and sometimes special parts will be required to make it work Figure 6 shows the installation of a Jabiru 8 cylinder engine into a Van s RV 6 To give a good CG location the engine had to be mounted as close to the firewall as possible This meant that custom air intake tubes had to be developed to get the intake air to the carburettor with a minimum disturbance and turbulence The engine has four engine mounting points located at the rear of the engine shown in Figure 1 or Figure 4 from which the engine is to be mounted An optional bed mount may be fitted
20. 1 OF1 OF O1 01 01 01 OF OF 1 1 OF 01 OF 01 1 OF 01 O1 01 OF OF O1 OF C1 OF 1 OF 01 C1 C1 01 Issue Notes ans 12851511 T Torre Jabiru Aircraft pty C Installation Manual Jabiru 3300 Aircraft Engine 1 Description 1 1 Model This Manual applies to all Jabiru 3300 Engine Models but particularly those from S No 961 on Details for operating and servicing are supplied in the Engine Instruction amp Maintenance Manual Only those details relevant for installation are duplicated below for all other information please refer to the Instruction amp Maintenance Manual 1 2 Manuals Instruction and Maintenance Manual Installation Manual Parts Catalogue 1 3 Specifications All information given in this manual assumes static sea level ratings under the following conditions e International Standard Atmospheric conditions at sea level Aircraft service equipment drives unloaded Vacuum Pump not fitted e Full rich fuel air mixture e Standard Jabiru air filter and hot air mixer box assembly e Standard exhaust muffler e Jabiru Propeller e Jabiru Airframe 1 3 1 Engine Models he 3300L engine has a maximum continuous RPM rating of 2850RPM The engine may be operated at engine speeds above 2850RPM for up to 10 minutes All other engine specifications and li
21. 2 holes he Jabiru Engine does not have a hydraulic pressure supply or a governor mounting pad required for a hydraulic constant speed or variable propeller Propellers with excess pitch can cause high temperatures and engine damage Nominally all propellers must be able to obtain 2800rpm static and 3150rpm to 3300rpm wide open throttle straight and level However in some particularly low drag airframes it may be necessary to use a propeller which does not achieve 2800 static rom In these cases propellers should be chosen based on their RPM at wide open throttle straight and level flight Donotcruise or climb in the range 2100rpm 2400rpm Maximum moment of inertia 0 3 e Applications outside this range should be referred to Jabiru WARNING Engine MUST NEVER BE RUN WITHOUT THE PROPELLER Damage Will occur in this state Pitch measurements are taken from the angle of the rear face of the prop blade Other propeller manufacturers may specify pitch measured from the blade mean chord line or other reference Make sure you are comparing equivalent pitch units when specifying a propeller o i e s smesso WALI 1 1 13865 0917 ASSY M3NNIdS ONY awas oN Va noa we JILL 55 2 HINNIJS 0917 404681 9 2 21 VPZ ZLO SEIEV soz
22. 30 STEEL TO PSJED 07 445 SECTION AA ENGINE MOUNT PLATE WASHER ENGINE MOUNT ENGINE MOUNT W ASSY aste 8 8 MC SEE DETAII PIN ENG MOUNT Y el 6 DRILL 06 55 pn ER gt p CS1030 STEEL TO PSJED 07 1 X 45 ALUMINIUM GRADE 2011 16 MOUNT BUSH FIREWALL SECTION WASHER ENGINE MOUNT 9467073 1 Figure 7 Engine Mount Assembly 128231 T T T Peemans T mm 5 Jabiru Aircraft pty Installation Manual Jabiru 3300 Aircraft Engine 3 Controls This section comprises of the mechanical controls and electrical switches 3 1 Throttle and Choke e he throttle and choke cables both attach to the cable mount arm fitted to the carburettor e Note Since a pressure compensating carburettor is used there is no mixture control e The cables for the choke and throttle can be adjusted using the adjuster screws and nuts shown in Figure 8 A 7mm spanner is required he cables used must have an adequate radius wherever they turn a corner Bending the cables too sharply will increase the cable friction making it difficult to use the control accurately This is a particular problem
23. 5 Ns 19 Figure 22 CHT Sender Thermocouple Installation 20 Figure 23 CHT Terminal instalation m 21 Figure 24 CHT Gauge _ __ ______ 21 Figure 25 RG400 Co Axial Antenna Cable ains 22 Figure 26 Wirmo Diagram 23 Figure 27 111116 24 Figure 29 Mechanical Fuel PUMP __ ___ _ __________ ___ 25 Figure 2 niic 26 Figure 30 Carburettor Intake 4 Balance Tube nnn nnn nsn nna 27 Figure 31 Carburettor m m 27 Figure 32 Needle Jet Jabiru nennen 28 Fig te 33 Alr Intake CONIC gt 30 Figure 34 Air Filter Box Plumbing Incorrect 31 Figure 35 Air Filter Box Plumbing 31 Figure 36 Typical Cobra Head Installation on a Jabiru Aircraft
24. 8 Amphibian or Seaplane Installations e Water taxiing requires relatively high power settings for long periods and this is often the most critical condition for cooling systems in these aircraft Increased duct size scooping more air through the engine may be necessary e For amphibian or seaplane aircraft using a pusher engine installation the methods outlined above can use the propeller to suck air out of the cowls but ultimately the effect is limited and can conflict with cooling requirements in other modes of flight For these installations some form of active venting for the cowls such as flaps fans or an augmentor type exhaust system See Figure 60 may be required 15151311 escis Page 52 or Jabiru Aircraft pty Lia C Installation Manual Jabiru 3300 Aircraft Engine Air is sucked out of the cowl and entrained with the exhaust inside the augmentor tube gt AMBIENT AIR S gt EXHAUST XM Figure 60 Augmentor Exhaust System 13 9 Slow Speed Installations e Installations where the cruise speed is below around 70 80 knots are considered slow speed installations e Jabiru ram air ducts are available for slow speed installations These are larger than the ducts used for faster aircraft e Increased duct size scooping more air through the engine may be necessary for slow speed installations e Increased outlet size and more aggressive outlet lips may be required n some of t
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26. INSTALLATION MANUAL FOR JABIRU 3300 AIRCRAFT ENGINE DOCUMENT JEM3302 3 This Manual is a guide to correctly install the Jabiru 3300 engine into an airframe If you have any questions or doubts about the contents please contact Jabiru Aircraft P L Applicable to Jabiru 3300cc Enginers S No 33A961 Onwards Hydraulic Lifter Type Including 33A927 33A928 33A947 33A948 33A949 33A950 Jabiru Aircraft pty _ Installation Manual Jabiru 3300 Aircraft Engine 0217 mtm 3 12 SIGOPS CUI c 4 2 0 E E E S E 5 5 MEN 5 5 1 4 WINNS 7 2 ENGINE MOUN n ___________ _ ____4_64_ 9 MEET 11 SEEN 11 32 Starner eii mE E TO D 11 4 Engine Crankcase Breather Catch Bottle Dipstick 12 13 Oe FANON RURSUS 13 S 13 s CMM 14 21 402 them 15 ee 15 50 AUG T 16 16 o _ __ __ _____ _____ 17 59 Radio Frequency
27. Mount Air Intake Installation 10 Figure 7 Engine Mount Assembly 10 Figure 8 Choke and Throttle Connections to 11 Figure 9 Crankcase Breather 1 12 Figure 10 Ignition amp Alternator 13 Figure 11 Electrics Installation to 14 Figure 12 Regulator Plug Wiring 14 Figure 13 oreniedeviieeelcaiic 15 Figure 14 Starter Wiring a rris snas n rrr ns 16 Figure 15 Tachometer Sender Installation cccccccccccccsseseeececeeeeeeeeeeeeeeeeeeaeeseeceeeeesseeeeeeeeeeeeseeeeeceeeeeseesaseeeeeeesseeaeeeeeeeeeeaas 17 Figure 16 Tachometer 2 ausus Uva ncc dc quiu n us dans Uma du dre 17 Figure 17 Oil Temperature Sender 18 Figure 18 Oil Temperature 18 Figure 19 Oil Pressure Sender 19 Figure 20 01 5 5 TREE ERR T 19 Figure 21 VOllage Gauge
28. ONTROL MAIN BUS REGULATOR PLUG WIRING Figure 12 Regulator Plug Wiring Details 5 3 Ignition e The ignition unit is a dual breakerless transistorised ignition with the magnets mounted on the flywheel and the coils mounted on the alternator mount plate Figure 10 shows the coils of a Jabiru 6 cylinder engine e The current from the coils flows to the distributor from where it is distributed to the spark plugs 18855111 T rmm Jabiru Aircraft ta Installation Manual Jabiru 3300 Aircraft Engine he ignition is turned OFF by grounding the coils via the ignition switches This is the reverse of most electrical systems when the ignition switch is in the open not connected position the coil is LIVE and will fire Wiring details are shown in Figure 26 e The ignition is timed to 25 BTDC Ignition timing is fixed it is set by the position of the flywheel magnets relative to the crankshaft e The temperature limit for the ignition coils is approximately 70 C This should be checked by the installer It is recommended that pipes of 12mm dia be fitted to the top rear of each air duct directing air onto the coils for cooling purposes e Coil gaps are set at 0 25mm to 0 30mm 0 010 to 0 012 e When installing new ignition coils the output leads go in the directon of prop rotation 5 coil output lead is up LHS coil output lead goes down See Figure 10 A Ram air coolin
29. RF Noise Reduction 21 FUEL 5 25 FUT K ee 25 6 2 FuelFiltration sisse nennen nnne nnnm nnn nnns nans 25 6 3 Mechanical Fuel mtt 25 64 PuelFl w Meters 25 bud E 25 A suse 29 30 T IC 30 7 2 Hose Air Filter nnne nennen nnns ann nnns 30 lt e 32 O 32 mmm 33 2161 34 10 Engine Installation esas suem 36 CROPS FSi D 41 12 Units 42 12 1 ___ _ _ __ 42 13 43 13 1 43 13 2 45 13 3 Air niere Ram 46 13 4 2 80760 __
30. RU Pee N 0 75 BETWEN END OF SLEEVE m 2 AND END OF OIL HOSE lt RUBBER MOUNT 1 1 5 03 DETAIL VIEW OL COOLER INSTALLATION VAR DATE MM qus Joa os DETAIL VIEW OIL COOLER HINKLER COOLER INSTALLATION 2 21 4A018A0D 5 MOUNTING DETAILS REFER PART ORAWNGS arem BUNDABERG Figure 53 Oil Cooler Installation 3 5 Air Outlet As the sections above describe getting air out of the cowling is often the factor limiting how much air can be pushed through the engine and how well it is cooled The shape of the outlet of the cowls controls how effectively air is sucked out of the cowling and is arguably the single most important aspect of cowling design As noted above as a rule of thumb the cowl outlet area should be at least 3 times the combined area of all the cowl inlets Figure 54 shows a small lip added to the rear of the cowls of a Jabiru Aircraft This lip gives a large improvement to pressure differentials and engine cooling Figure 55 shows an aircraft at varied angles of attack to the surrounding air The cowl inlets and outlets must both be designed to work effectively at all angles which the aircraft will normally experience Figure 56 shows two different cowl outlets one is basically an opening in the flat bottom of the cowl while for the other the opening is oriented at 90 to the airflow direction Vertical orientations De
31. aken from outside the cowl Current air filter is RAF 17 Repco 7 4 Ram Air Bleed e he hot air mixer box filter boxes manufactured by Jabiru Aircraft have a Ram Air Bleed flap incorporated e This prevents excess ram air pressure in the induction system f the engine ever backfires the flap also acts as a relief valve to let the excess pressure escape without damaging the induction system Rubber flap covers holes amp prevents excess bust etc entering airbox Vent holes to release pressure on un filtered side of airbox Figure 38 Ram Air Bleed ew Jabiru Aircraft pty C Installation Manual Jabiru 3300 Aircraft Engine 8 Exhaust System e Anexhaust system is provided with the engine Both Pusher and Tractor systems are available e Muffler Volume Capacity 5 litres Back pressure at Takeoff Performance Max 0 2 bar 2 9 psi Readings taken 70mm from muffler flange connections Only complete mufflers supplied with Jabiru Aircraft are welded all others require tail pipes to be TIG welded to the muffler body NOTE Drilled ends of pipes go inside muffler cavity The tail pipes go completely through the muffler body and are welded on both top and bottom e When fitting the muffler one or more of the exhaust pipes can be loosened at the connection to the cylinder head to allow easy fit of the muffler They then must be tightened e Exhaust
32. aking through the squelch RF noise is a complex problem and is influenced by many different factors The following points do not contain everything there is to know about RF noise but they are given as recommendations of general good practice to minimise it s effect e Ensure all connections particularly engine earths are clean and un corroded e fthe aircraft has metallic firewall it can be used as a shield to block the majority of RF noise be most effective any wire that passes through the firewall should be fitted with a Ferrite Bead also known as a Suppressor or RF Suppressor Bundles of wires can have a single large Suppressor fitted rather than a T T T T Jabiru Aircraft pty C Installation Manual Jabiru 3300 Aircraft Engine ouppressor for each wire The wiring diagram in Figure 26 shows suppressors in schematic form These suppressors are readily available at local electronics stores Noise Filter can be fitted to the radio s power supply Again these filters are readily available from local electronics stores The manufacturer s instructions must be followed for installation e Cables passing through the firewall such as throttle cables choke carburettor heat and cabin heat cables can transmit RF noise back into the cabin This can be minimised by earthing the cables at ONE end On the Jabiru Engine an earth wire Shown in Figure 27 is provided connectin
33. al Jabiru 3300 Aircraft Engine he Tachometer sensor used is 6 35 x 22 mm analogue magnetic pick up and is fitted to a bracket on the alternator housing Refer to Figure 15 The sensor picks up on 2 tags fitted behind the flywheel Male rubber engine mount Female rubber Washer engine engine mount mount spacer Washer engine mount me Propeller guide bush Lock wire eo ore RON attach ram air cooling ducts Bikes Spring 1 1 IM 2k f Mee PE MEDS wes Exhaust fies PL i spring ET 5 RO xS e ae x man y Se A E a 2 deo Belleville washer 24 Washer o ac a Ter EP dp AE Rp dee SIS Figure 40 Engine Accessory Pack Contents G Clamp with Deep long Engine mount Female engine Male engine swivel removed reach socket washer mount rubber mount rubber Figure 41 Upper 4 Lower Engine Mount Detail T T ar or se 1
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35. e to the lack of a strong quality control system for automotive fuels Jabiru Aircraft recommend using AVGAS wherever possible 1 3 4 Cil 3 5 Litres Oil Minimum Temperature for Take Off 50 122 F Oil Maximum Peak Oil Temperature 118 C 244 F Oil Maximum Continuous Oil Temperature 80 100 176 F 212 Oil Pressure Normal Operations Min 220 kPa 32 psi ERR Max 525 kPa 76 psi Oil Pressure Idle Min 80 kPa 12 psi Oil Pressure Starting amp Warm Up Max 525 kPa 76 psi Oil Consumption 0 1 L hr max ES Aero Oil W Multigrade 15W 50 or equivalent complying with MIL L 22851C Lycoming Spec 301F E Teledyne Continental Spec MHF 24B 1 3 5 Additives Note No Oil or fuel additives should be used Use of oil or fuel additives will void warranty 1 3 6 Cylinder Head Temperature CHT Maximum Peak Cylinder Head Temperature 200 C 392 F Maximum Continuous Temperature 180 C 356 F Note Time with CHT at between 180 C and 200 C is not to exceed 5 Minutes 1 3 7 Exhaust Gas Temperature EGT Mid Range
36. eometry T T T Peemans T rmm Jabiru Aircraft pty C Installation Manual Jabiru 3300 Aircraft Engine Firewall Flange on Gm 2 Figure 57 Outlet Restriction Caused Flange On Lower Firewall seo T Jabiru Aircraft pty ta Installation Manual Jabiru 3300 Aircraft Engine 13 6 Cooling System Testing amp Evaluation e For new installations new designs rather than new aircraft of a known type the pressure drop across both air ducts must be checked The following is a guide to evaluating an engine installation to see if it meets minimum cooling requirements he easiest way to measure the air pressure drop across the engine and oil cooler is using a U tube manometer using water It is basically a piece of clear tube bent into and half filled with water if the water is hard to see add a bit of food colouring For ram air duct pressure connect one side of to a static port inside the ram duct and the other to a static probe inside the cowl near the outlet For the pressure drop across the oil cooler plumb a static probe against the front of the cooler and a static probe inside the cowl near the outlet The further the probe is in front of the cooler the less the static pressure that will be measured so place the probe no more than 5mm in front of the cooler and parallel to it e Using multiple U tub
37. ep Outlet give better pressure differentials and are less affected by aircraft angle of attack than horizontal Long Outlet Figure 56 also shows the lower firewall section of a Jabiru Aircraft The lower part of the fuselage has two large ramps moulded in which increase the depth and area of the cowl outlet and also provides mounting points for the rudder pedals This type of feature is not mandatory for good engine cooling but it does help An alternative is to make the bottom corner of the firewall as smooth and rounded as possible to help airflow and minimise the outlet restriction Some aircraft types have a flange running around the firewall Particularly on metal types this flange is a useful way of mounting the cowls However if the flange runs across the edge of the firewall where the cowl outlet is located then it causes a significant flow restriction Figure 57 shows a drawing of the lower section of a firewall with a flange of this type Wherever possible flanges across the cowl outlet should be avoided Alternatively a fairing can be built inside the cowl to smooth airflow over the lip amp reduce flow restriction REVISION 123 Dated July 2008 Page 48 of 56 Jabiru Aircraft pty 772 Installation Manual Jabiru 3300 Aircraft Engine m 1 ti 1 NN am Line shows direction of ambient airflow die Detail View Location 4 2 Figure 56 Outlet G
38. er are required to provide cooling air to the ignition coils Figure 51 e For an air cooled engine it is entirely normal for there to be significant differences in the temperature of each cylinder head Often the head which is hottest in the climb will not be the hottest during cruise amp descent This is only a problem if the hotter heads exceed the engine s set limits Gull Wing baffles can be used to fine tune the restriction to airflow caused by the engine and this in turn affects the volume of air flowing through the engine and into the cowls Fitting the baffles will give a higher restriction as it forces air to flow through the small gaps between fins Leaving the baffles out provides larger gaps and a higher volume of relatively cool air blows through these gaps into the Hot zone immediately under the cylinder heads Wherever possible it is recommended to leave the baffles out However compared to an installation with the Gull Wings fitted a significantly larger volume of air must be sucked out of the cowl outlet This often requires a larger cowl outlet or a larger lip on the existing outlet Pressure differentials must be maintained e Check for contact of engine cooler or ducts on cowl Any contact will cause excessive vibration amp if the oil cooler is rubbing it will eventually fail amp leak Front baffle in duct to prevent air slipping Rear baffle to direct air under cylinder amp head into rear cylinder head Ho
39. erheating of cylinders or oil T T Peman T rmm 5 Jabiru Aircraft pty ta Installation Manual High pressure air entering Balanced Flow Air from ram air ducts cowl through ram air ducts and cooler mixing owl outlet sucks air out of the cowls Low pressure warm air flows out High temperature air _ under cylinder heads Air entering cowl through oil cooler Un Balanced Flow Air leaking past cylinder heads Air leaking past oil cooler 7 reduces air flow rate through oil cooler 95 reduces air flow through cylinder heads Figure 47 Cowl Airflow Best Viewed in Colour High pressure air entering Balanced Flow Air from ram air ducts cowl through ram air ducts and oil cooler mixing STR 2 High temperature air under cylinder heads Cowl outlet sucks out of the cowls Low pressure warm air flows out Air entering cowl through oil cooler 29 Un Balanced Flow Un Balanced Flow SRE KIS Air leaking cylinder heads reduces air flow rate Air leaking past oil cooler through oil cooler reduces air flow rate through cylinder heads Fi ure 48 Cowl Airflow Black amp White Version T Ion T rmn Jabiru Aircraft pty C Installation Ma
40. es several measurements can be taken in one flight e Details of a typical static probe are shown in Figure 58 e Note that probes must be fitted in the same place each time to ensure you get consistent measurements Some hints e Usually the most critical situation for cooling is climb however this is not always true so check all situations e The change in air temperature is approximately the same as the change in engine temp For example if you did all your testing in 15 and you want to flying in up to 35 weather in 35 all your engine temps will be approximately 20 C higher Check you have sufficient margin for all conditions you plan to fly in fthe engine gets too hot during testing don t push it Something needs to be changed For low speed cooling a lip on the front edge cowl outlet can add up to 20mm of pressure drop at 65kts lip 25mm deep at 60 to the airflow shown in Figure 54 Refer to Figure 22 CHT terminals must be placed correctly or inaccurate too high readings can result THIS DRAWING 15 Ci IGHT AND MUST NOT COPIED mem DX zz du i COEN DIMENSIONS IN MILIMETRES scale mius MOUNTED FLUSH WITH INSIDE OF BOTH X SPARK PLUG RAM AIR DUCTS BETWEEN SPARK PLUGS RAM AIR DUCT 53 Ww t 3 pi A 2 6 mm CLEAR PVC TUBE lt 6
41. etimes air leaking through controlled gaps such as the holes in the front of the ram air ducts Figure 50 or the gaps between cylinders can have beneficial effects However it is recommended that gaps around the engine and oil cooler be closed as a starting point The propeller amp rush of air from the aircraft s speed make it easier to get air into the cowl than to get it out oomuch air flowing through the oil cooler can restrict airflow through the cylinder heads amp vice versa e The pressure difference between the low pressure outlet area of the cowls and the high pressure inlet areas controls the amount of air flowing through the engine The pressure differential testing described in Section 13 5 gives target pressures e During developmental work it is strongly recommended that each cylinder head has it s own temperature sensor Modifications to cowls etc can have unpredictable effects and normally a change will affect each cylinder head differently i e head 4 may cool down while head 3 heats up e Testing of an installation in a Jabiru Aircraft showed that the heat radiating from the engine exhaust system normally has a minimal effect Wrapping the exhaust in insulation etc does not produce a measurable temperature reduction during taxi or in the air WARNING The limits in the Specification Sheet contained in Appendix B must be strictly adhered to Warranty will not be paid on engine damage attributed to ov
42. for the ignition coils and the vacuum pump e Note The electrical system is Negative Earth Specifications Power 200W Continuous l Wire to ignition switch Ignition coil 1 of 2 Alternator rotor mounted on flywheel Alternator stator mounted on alternator mount plate fixed to rear of engine Ignition magnets mounted on flywheel 5 Figure 10 Ignition amp Alternator Detail 5 2 Regulator The regulator has been selected to match the voltage and current of the integral alternator Only Jabiru Part No PI10652N should be used The regulator output voltage is 14 volts 0 8 volt e Recommended wiring of regulator is positive and negative of the regulator directly to the battery A 20A fuse or circuit breaker may be used between the regulator amp battery The regulator is equipped to illuminate Low Voltage Warning Light Refer to Figure 12 for plug pin details T T T Ion T me Jabiru Aircraft pty Mn Installation Manual Jabiru 3300 Aircraft Engine Firewall Starter Solenoid Power Earth cables to starter motor Regulator Plug Regulator Grey finned block AA Figure 11 Electrics Installation to Firewall BLACK BATTERY FROM ALTERNATOR 1 BLUE FROM ALTERNATOR 2 _ RED BATTERY GREEN LOW VOLTAGE WARNING LIGHT YELLOW VOLTAGE C
43. for the throttle cable as it will make setting the idle accurately very difficult e All Jabiru engines are run in on a Dynamometer before delivery It is impossible to accurately set the idle RPM when the engine is on the dynamometer so the Idle Stop Screw shown in Figure 8 must be adjusted as a part of the engine installation process Idle stop screw Throttle Cable connected to throttle arm Cable mount bracket Choke Cable connected to throttle arm Adjustors to fine tune choke S and throttle operation A Figure 8 Choke and Throttle Connections to Carburettor 3 2 Ignition amp Starter Systems e The only electrical controls for the Jabiru Engine are the ignition switching and the start button e he ignition switches and starter system wiring are connected as shown the circuit diagram Figure 27 e Section 5 gives details of the electrical systems for the engine T T T Ion T mer Jabiru Aircraft ta Installation Manual Jabiru 3300 Aircraft Engine 4 Engine Crankcase Breather Catch Bottle amp Dipstick he Jabiru 3300 engine has a crankcase breather connection built into the dipstick housing This is to be connected as shown in Figure 9 below The catch bottle is designed to catch most oil vapour from the crankcase breather air It must be monitored in service and periodically emptied of waste oil e Figure 56 shows more clearly the outlet from the catch b
44. fuel pump to the carburettor is connected 4 protected by fireproof sleeve e Ensure that the fuel overflow line is in place and secured to vent overboard This is the small clear hose shown leading from the fuel pump in Figure 41 e Fit the oil over flow bottle to the firewall by drilling and Riveting oil bottle holder in place using 73AS 6 6 rivets Refer to Figure 9 e Connect the oil breather line from the engine breather e Ensure that the oil overflow line is in place and vents overboard e Fit Scat hoses from NACA duct to Air Inlet Housing Assembly from hot air to carburettor heat inlet on the hot air mixer box and from the hot air mixer box to carburettor shown in Figure 44 e Fit throttle cable to carburettor Note that Jabiru Aircraft kits come with a throttle cable cut to length and with the correct end fitting attached Engines used in firewall forward kits will be supplied with a length of throttle cable with end the builder must cut the cable to length and fit the carburettor end fitting 5 16 washers are used on the cable end fitting one washer either side of cable end fitting to align cable Use R clip to assemble Figure 46 refers e Fit choke cable to carburettor Use an R clip to assemble Note that the fuel line from the fuel pump to the carburettor passes between the choke and throttle cables The choke is shown in Figure 8 e Connect the fuel balance tube from the nipple on the carburettor to a fitting
45. g duct Coil cooling tube Ignition coil E y y Figure 13 Ignition Coil Cooling Tube 5 4 Starter Motor e The starter is mounted on the top of the engine and drives the ring gear on the flywheel The motor is activated by engaging the starter button the master switch has to be ON which trips the solenoid hence current flows from the battery to the motor he cable from Battery to starter should be minimum 16mm e Wiring details are shown in Figure 26 5 5 Starter Solenoid The starter Solenoid is mounted on the firewall as shown in Figure 11 e he Solenoid body forms a part of the electrical circuit and MUST be earthed to function correctly T Ion T me Jabiru Aircraft pty me Installation Manual Jabiru 3300 Aircraft Engine SOLENOID BODY START BUTTON TO MAIN POWER BUS POS Figure 14 Starter Wiring Details 5 6 Battery e The battery should be of a light weight 12V 20 Ah type able to accept a charging voltage up to 14 V 0 8V and a 30 AMP Input e For optimum starting the battery used must have a high Cranking Amp Capacity also known as Pulse Amp Capacity The standard battery used by Jabiru Aircraft has a Pulse Amp rating of 625 Amps Batteries with higher Pulse Amp ratings may be used and will improve engine starting in colder climates 5 7 Wiring Practices e Using aircraft grade wiring i
46. g the carburettor to the rest of the engine so the throttle and choke cables are connected to earth through this wire t is normal amp unavoidable that the engine s ignition system produces some noise This can be minimised by Ensuring spark plug gaps are set properly Ensure ignition coil gaps set properly lii Ensure all high tension leads Spark plug leads are firmly fitted at both ends to the spark plug and to the distributor In addition the lead from each ignition coil to the distributor must be firmly fitted to the distributor IV Ensure Distributor caps and rotors are in good condition e o counteract RF noise Jabiru Aircraft run shielded wiring on all radio and intercom wiring In our experience the Earth Return method of shielding where the shield for the wire is also used to form the earth connection does not work as well as the Faraday Cage where the shield is a shield only it is not a part of the circuit method of shielding e Earth Loops where a wire is connected to earth at both ends can introduce RF noise into the system All shields should be connected to the aircrafts earth system at one end only e The cable used for the Antenna should be high quality such as RG400 Shown in Figure 25 This cable has a double layer of shielding and better RF insulation than other cable types Note that the coaxial cable included in most antenna kits tends to have a sin
47. given above e coolers are mandatory unless operating in very cold ambient temperatures Refer to Oil Cooling section above for allowable oil operating temperature ranges e Do not overfill the engine this may result in high oil temperatures e Check for contact of engine cooler or ducts on cowl Any contact will cause excessive vibration amp if the oil cooler is rubbing it will eventually fail amp leak 21 T Ion T mer Jabiru Aircraft pty dL Installation Manual Jabiru 3300 Aircraft Engine 12 Auxiliary Units 12 1 Vacuum Pump the installation of an artificial horizon and or a direction gyro a vacuum pump is necessary A Tempest 212CW or equivalent vacuum pump can be fitted to the alternator mounting plate and directly coupled to the crankshaft The drive pad is dry The pad and spline are SAE Standard e For later engines S No 1522 and onwards the vacuum pump drive spline is an option extra not included with the standard engine it must be ordered separately oj efe T esce Page Jabiru Aircraft pty C Installation Manual Jabiru 3300 Aircraft Engine 13 Cooling Systems 13 4 General Principles An ideal cooling system l Controls engine temperatures through speeds ranging from taxiing on the ground through to Vye ii Controls the engine temperatures through a wide range of angles of attack iii Is simple to
48. gle layer of insulation BNC connectors are recommended for most applications and wherever possible crimped connectors which require a special crimper to assemble should be used Crimped connectors are much less prone to RF leakage or assembly issues than other types such as screw together BNC connectors e Wires and antenna cables must be routed carefully Bending or coiling Co axial cable such as is used for antennas sharply will significantly degrade the cable s RF shielding and must be avoided wherever possible Coiling antenna cables or any wire carrying current Sensor wires carry very low current so are generally exempt from this requirement into loops can induce RF noise in other systems GPS antennas in particular are powered both the antenna and any excess antenna cable must be positioned carefully as far away from the radios antennas and intercom as possible e While not a part of the engine installation strobes can produce significant RF noise Most brands of strobes require that the box containing the strobe head unit electronics is earthed and this is essential to minimise noise The cables used for the strobe lights themselves must be shielded and the shield must be earthed properly at ONE end only The Box containing the strobe electronics can also be installed on the engine side of the firewall to further reduce RF noise The strobe units manufacturer normally provides good instructions for minimising their effect on radio
49. hese installations where the airframe has a lot of drag it is preferable to do away with cowls altogether and run an open installation Aircraft such as the Thruster Vision Drifter X Air and some RANS models are examples of this n these cases large ram air ducts are used and the rest of the engine is exposed to the propeller wash for cooling T sme Jabiru Aircraft pty ta Installation Manual Jabiru 3300 Aircraft Engine 14 Appendix A Wiring Diagrams WIRING STARTER LOOM WIRING
50. ion between lean cruise mixture and rich A high power mixture Parallel end for full power View looking through 2 0 needle jet N N M eedle Jet 227772 22277 Needle Figure 32 Needle Jet Jabiru Needle e Because of the way the carburettor uses the sense ports and balance tube to regulate the mixture it is sensitive to the way the intake air moves and to the conditions of the intake system e Section 7 below contains information on setting up the induction system ew T Page 09 or se Jabiru Aircraft pty Mn Installation Manual Jabiru 3300 Aircraft Engine 6 5 2 Carburettor Tuning he mixture supplied to the engine by the carburettor is affected by a large number of variables including Ambient temperature li Propeller size coarse or fine and loading lil Whether the engine is cowled or open by affecting the temperature of the induction pipes and carburettor IV The airframe type V The intake system e Because of these factors we recommend that whenever a new engine installation is being developed that the engine be fitted with EGT probes and the tuning checked e Jabiru Aircraft or our local representative can provide assistance during this phase 6 6 Fuel Lines e Fuel lines are nominally 6mm bore e All hoses forward of the firewall require fire resistant sheathing visible as an orange covering on the fuel lines i
51. ir is moving fast rapid flows produces pressure changes and boundary layer effects which mean the balance tube gives the carburettor bad information which can cause poor mixture control and running issues Adrip deflector to deflect overflowing fuel from the exhaust system is supplied as standard equipment on the engine e Because idle adjustments cannot accurately be made on the dynamometer where every engine is run before delivery some adjustment of the 7mm idle set screw may be required A hot idle of around 900RPM is desirable Fitting an earth strap from carby to crankcase is recommended to eliminate possible radio interference Balance tube Idle screw Vent tube from mechanical fuel pump Fuel bowl clip Fuel bowl Drip deflector Figure 29 Carburettor Installation T pecie Jabiru Aircraft pty ta Installation Manual Jabiru 3300 Aircraft Engine Tt Balance tube EN Air filter nipple Correct location for balance tube connection on Clean side of air filter in an area where the air is Sense ports relatively slow moving Fuel inlet vex c Sense port oon Poor location for T balance tube nun u Figure 30 Carburettor Intake amp Balance Tube Detail 6 5 1 Carburettor Operation Diaphragm spring Diaphragm Needle carrier Air density sense port Needle Idle circu
52. it inlet aperture Atomiser lt Air density sense port Needle Jet Jet Carrier Idle Jet Figure 31 Carburettor Schematic T ossis Jabiru Aircraft pty Mn Installation Manual Jabiru 3300 Aircraft Engine he Bing altitude compensating carburettor uses bowl float level and two main air circuits the idle and the needle main to control the mixture Both circuits use jets to meter the rate at which fuel is allowed to flow The jets are small brass parts with precisely controlled openings both the size of the opening and the shape surrounding the opening affect fuel flow rate which can be changed to adjust engine mixture he main and idle jets have simple fixed apertures while the effective size of the needle jet aperture varies depending on the diameter of the needle Figure 32 below shows three different throttle settings in the needle jet and the corresponding difference in aperture On the left is a low power setting where the needle jet is nearly completely blocked by the needle The middle throttle setting corresponds approximately to a high cruise power setting The gap between the needle and the sides of the jet is much larger The final setting corresponds approximately to wide open throttle The needle jet is now effectively not there and the amount of fuel flowing is controlled by the main jet located upstream of the needle jet in this circuit he
53. le in ram air duct to blow cool air over the crankcase Gull Wing baffles fitted between cylinders il patti uU N UNO V UC EN aay WS Ere Figure 50 Front On View Into Ram Air Duct T T Ion T m Jabiru Aircraft pty Installation Manual Jabiru 3300 Aircraft Engine Pipes blowing cool air over the ignition coils _ 9 Figure 51 Coil Cooling Detail 13 4 Oil Cooling e The dipstick cap must be screwed fully in before removal for reading oil level e oil cooler adapter is supplied with the engine amp fits under the oil filter The cooler be plumbed either way to the adaptor flow direction is not important Oil coolers are available from Jabiru Aircraft e Unless consistently operating in low temperatures oil coolers are mandatory Note if you fly in cold weather and don t have an oil cooler you can t fly if it warms up You can always block the oil air off in cold conditions n continuous operation oil temperatures between 80 and 90 1764 194 F are desirable 70 C 158 F is the minimum allowable temperature for continuous running and 100 C 212 F is the maximum allowable temperature for continuous running e Over filling with oil is not desirable It can cause elevated temperatures amp excessive oil use 4 loss Hoses should be nominally 10mm 3 8 bore Hoses m
54. llations the details given above hold though some changes are necessary for the different configuration e Versions of Jabiru ram air ducts are available for high speed and low speed pusher installations The propeller can be used to suck air out of the cowls using the following as a guide l Wherever possible the cowl outlets should be vertical openings with lips that come close to the propeller as close a possible without the blades hitting the cowls The propeller blade must have significant pitch and chord in the section which passes over the outlets iii The cowl openings should each be reasonably small As each blade passes the opening it will create a suction in the cowl behind it but if the cowl opening is large this effect will be dissipated Alternatively larger openings can be divided up by fitting louvers or vanes Augmentor type exhausts Figure 60 can also be used to suck air out of the cowlings e In pusher installations the inlets into the cowl are harder to get right than in a tractor installation Intake ducts should be as straight as possible with no sharp corners or other restrictions to the flow he position of the air inlets is critical inlets on the upper surface of the aircraft are generally in low pressure zones while those on the underside are normally in high pressure zones Depending where the inlet is located the area ratio between inlet and outlets may need to be modified 13
55. mitations are identical to other 3300 models such as the 3300A e The 3300L uses the same parts Parts Books Servicing Maintenance and Overhaul Information as other 3300 models e Unless specifically stated otherwise all Service Letters Service Bulletins Manufacturer Safety Directions and other service information issued for Jabiru 3300 engines is applicable to 33001 models 1 3 2 Engine Ratings Table 1 Engine Ratings Models 3300L Other 3300 Models 90 kW 120 hp 3300 RPM ISO STD Conditions 35 L hr Takeoff Rating 35 L hr Fuel Consumption 26 L hr Continuous Rating Takeoff Max Continuous Rating Oil Consumption 0 1 L hr max Note that fuel and oil consumption figures are based on a typical installation in a Jabiru Aircraft Values will differ for other installations 1 3 3 Fuel ck 35 L hr Takeoff Rating Fuel 24 L hr 75 nominal power setting s 2 5 T THE Jabiru Aircraft pty Mn Installation Manual Jabiru 3300 Aircraft Engine Fuel Pressure to Carburettor Maximum 20 kPa 3 psi Fuel Pressure to Carburettor Minimum 5 kPa 0 75 psi Recommended Fuel Grade Avgas 100LL amp Avgas 100 130 Note Leaded and Unleaded Automotive Gasoline above 95 Octane RON may be used however du
56. mm STEEL TUBE BENT 90 LOCATION OF TUBE IN RAM DEGREES AND TO AIR DUCT ON BOTH SIDES RAM AIR DUCT WITH TAIL FACING AFT TO CONNECT TO PCV TUBE LR FIT STATIC TUBE AS DETAILED IN FRONT OF OIL COOLER AND CONNECT TO CLEAR PVC TUBE MANOMETER ed d 4 f 7 nr s 1 rDRILL THRU 91 0 INDEXED AT 90 FIT STATIC PRESSURE TUBE AS DETAILED THRU FIREWALL T y ON 5 N f J AND CONNECT MANOMETER M 96 STEEL TUBE 0 8 WALL STATIC PRESSURE ION PRESSURE DIFFERENCE BRAZE OR SOLDER END CLOSED OT N nm WATE Vp or om mr N DETAIL STATIC PRESSURE TUBE ARALDITE STATIC TUBE SE amp PVC TUBE TO FIREWALL ZAJ TITLE ud d 1 1 JABIRU ENGINE COOLING AIR PRESSURE DIFFERENTIALS PAOT6AQU T AVTECH P L A C N 010 786 973 HINKLER AIRPORT BUNDABERG Figure 58 Cooling pressure measurement T T T mer Jabiru Aircraft ta Mn Installation Manual Jabiru 3300 Aircraft Engine Figure 59 Ram Air duct pressure tapping 13 7 Pusher Installations e For pusher insta
57. n Figure 28 above Note that wherever possible the sheathing should be extended past the hose clamp The ends of the sheath must be held in place using safety wire to prevent the sheathing moving and exposing the fuel line e Fuel lines between moving sections such as between engine and firewall should be flexible SAE standard automotive rubber hoses are adequate provided they are protected with fire resistance sheathing In many countries including Australia standard airworthiness requirements state that all flexible hoses must be changed every two years though if there are visible signs of degradation Such as cracking or hardening the hose should be changed immediately o efo esce J Page 20 or se Jabiru Aircraft pty Mn Installation Manual Jabiru 3300 Aircraft Engine 7 Air Intake System 7 1 Intake Air Heating he Jabiru 3300 engine can experience carburettor icing in some conditions Jabiru Aircraft strongly recommend that a system for heating engine intake air be included in the induction system design 7 2 Intake Hose amp Air Filter e Jabiru Aircraft recommend that engine intake air be drawn from outside the cowl wherever possible e Due to the way the carburettor works as described above it is sensitive to the air flowing into it Turbulence swirl and sharp edges all affect the mixture metering system of the carburettor e he hose type recommended for induction sys
58. na REVISION Jabiru Aircraft pty Installation Manual Jabiru 3300 Aircraft Engine 6 Fuel Supply System 6 1 Fuel Tank e he fuel tank must be fitted with an outlet strainer of between 8 and 16 mesh per inch with a minimum total mesh area of 5 cm e Ensure the fuel tank is properly vented 6 2 Fuel Filtration Fuel filter capable of preventing the passage of particles larger than 0 1 100um must be installed between the fuel tank outlet and the fuel pump e The filter must be present in the system for the fuel flow test The size of the filter should give consideration to allow adequate flow with a used filter Z15 disposable paper element automotive filter has been used successfully Note that this filter or any other filter with a plastic body must not be used on the engine side of the firewall regulations and common sense both require that all fittings in the fuel system on the engine side of the firewall must be fire resistant 6 3 Mechanical Fuel Pump he mechanical fuel pump is mounted on the engine crankcase and is camshaft driven lt is designed to supply fuel at the pressure described in the following paragraph Many airworthiness categories require that a backup fuel pump be fitted case the primary pump fails Jabiru Aircraft recommend fitting an electrical boost pump If fitted this pump must also fulfil the fuel input criteria for
59. noises Black nsulation Juter shield layer Inner shield layer imm Figure 25 RG400 Co Axial Antenna Cable Page 22 or Jabiru Aircraft pty ta 2 11398 6 QOvr9cNvv 551 cin 80 6 9 1 31608 9002 1 82 wa 93144435 09 Lf Vid HO3LAV wma gaTOLll1fn4dlno N3342 3000410107 5 35 SHOSS 3 99 5 ADNVD OF H 9L 1 2 SALON 33 O p lt o 5 Q 520114 5 0102105 4314915 2 2 1 1 45 OHOVLI 6l 9 1 339435 OHOVL LINA INO 9413 HONGYHL 5 18 JHM 903 1 SNILLIJ 30044344 350 51300094 59 310 iz HOLIMS 35055344 H Installation Manual 4 31V08 LON S3ML3AFTIN SNOISN3WIO v L398NI HLA GALLI 38 07088 S3HI A 3000 3HIM 1538 is 1 Hv amp SNE NIVIA SOINOIAY 2 T C SAF H DOES 199 Qna 1328 NI 03117130 SLNSWNYLSNI 9 0081906 23dS S YSYNLOYSNNYA OL NOLLVTTZLSNI H30NOdSN HL S 00711907E S
60. nual Jabiru 3300 Aircraft Engine 13 2 Flow Visualisation In designing the cooling system the designer must have a basic understanding of how air flows and behaves inside the cowl The pictures below are intended to explain it in simple terms e Figure 49 shows two schoolrooms drawn as if seen from above Each room represents an engine and oil cooler inside a cowling There are two doors in the inlet side of the room and one on the outlet side ii Several desks are placed in the room representing the engine cylinders and the oil cooler iii otudents walk through from left to right representing the air flow through the cowls IV On each desk is a pile of homework papers representing heat generated by the engine e Air always takes the path of least resistance It tries to escape quickly to the playground without taking the homework he desks and doorways form restrictions If the desks are too close not enough students can pass through If the desks are too far apart some students will not pick up their homework If the inlet doorways are too large then there will be a traffic jam trying to get out of the outlet door e Gaps can leave room for students to pass without picking up homework e Given a group of desks as shown students can follow many paths through them from front to rear from top to bottom or any combination e Slowing down the students as they pass through the desks means they will pick up their homewo
61. oiz 2 NOLYTIYLSNI LAN jMOHONY 8 ZL 35 ANIHOWW 190697250 09080 Wa viva 7 O W 43434 1708 82 49 0251 80889 20680 09968 v ALNO AAH 3 1738 ASSY YSHSVM 1 31138 1 140 122 5 5 doud 3lv ld Page 35 of 56 Q W3NNIdS 0917 TC 2 5 Adv 21 201690 25 N E aj OL WALI 39313 9039 p lt e o 5 Q 1933305 404 SIHL 38 15 SNOLO34MIK 3llSOddO NI 3994 SH3HSVM SALON NOILOAS gt 5 e Jabiru Propeller amp Spinner Installation Figure 39 g3NNldS 5310 939 344 0349307 51 Jabiru Aircraft pty ta Installation Manual eis JONY IJ SNINNOW dOdd LWHSANVHS g Hi3TI3dOHd SNINSLHDIL 8504 32 31035 V TNI 5 beanies 11935 LON 00 SIMLINMIW NI SNOISN3HIQ REVISION Jabiru Aircraft pty C Installation Manual Jabiru 3300 Aircraft Engine 10 Engine Installation Procedure e Attach male engine mount rubbers to all engine mount pins on the engine mount Place an 4 31 bolt through each mount No
62. ottle the catch bottle outlet is secured in the cowl outlet The position of this outlet and the catch bottle itself must be assessed and oriented so that the crankcase of the engine is exposed to pressure close to ambient If the breather is open to a high low pressure partial vacuum area the pressure inside the crankcases will also change with unpredictable effects on engine oil consumption and oil flow within the engine This is because several areas of the engine are lubricated via low pressure or spray oil feeds and drained by gravity pressure differences cause airflow changes and modified airflow can significantly affect the oil feeds in these areas e When installed in a tail dragger aircraft re calibration of the dipstick will be required by the owner so that it can be read accurately with the aircraft sitting on it s wheels Hose from engine Hose from engine to catch bottle Catch bottle attached to firewall Hose to outlet Figure 9 Crankcase Breather Installation Jabiru Aircraft pty Installation Manual Jabiru 3300 Aircraft Engine o Electrical Equipment 5 1 Alternator e he alternator fitted to the Jabiru 3300 engine is a single phase permanently excited with a regulator e The rotor is mounted the flywheel and the stator is mounted on the alternator mount plate at the back of the engine The alternator mount plate is also the mount
63. re 1 Drawing Engine Dimensions seo T osos Jabiru Aircraft pty Installation Manual Jabiru 3300 Aircraft Engine 1 4 1 Denomination Of Cylinders Drawing 9476083 Figure 2 Cylinder Firing Order Cylinder Firing Order 1 4 5 2 3 6 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 EXHAUST 6 CYLINDER ENGINE gt CYLINDER ENGINE FIRING ORDER 1 4 5 2 3 6 FIRING ORDER 1 2 INTAKE EXHAUST EXHAUST INTAKE gt 8 CYLINDER ENGINE FIRING ORDER 1 5 8 3 2 6 7 4 210306 SCALE 1 29 9 05 A C N 010 786 973 DAL ENDURO JABIRU ENGINE DISTRIBUTOR CYLINDER 4A266A0D 2 MAP ALL ENGINES SET OF 7 Ad Figure 3 Distributor Cylinder Map T T Torre ZE Installation Manual 2 Engine Mount The design of the engine mount must balance many requirements eos Jabiru 3300 Aircraft Engine Jabiru Aircraft pty ta The mount must be strong enough to carry the loads applied by
64. rk but if they are slowed down anywhere else it only reduces the amount of students that can get through the room If the exit becomes jammed with people installing bigger inlet doors will not increase the number of students passing through the room Exits should be as clear and free of obstructions as possible to let people out e Students will often have a preferred desk to take their homework from meaning that some cylinder heads will have more heat removed than others temperatures will wary between different heads Desk 888 SM 9 89 otudents carrying 98889 8 homework 1 9 8 884 68 6 6 8888 Students in the 2448 8 8 8 8 8 8 8 corridor 8 8 7 9 68 4 A A 8 9 9 9 9 8 4 8 8 59 86 8 8 8 8 8 8 ee A 9 8 8 9 8 2 6 Partitions are used to force the students to walk No partitions are used so students walk around through the desks the desks instead of through them Each student picks up the homework Most students don t come close enough to a desk Outlet door is 90 to the flow of students in the to pick up the homework corridor there is no restriction 4 jostling at the exit door is parallel to the flow of students in the corridor causing restriction amp jostling at the exit Figure 49 Flow Visualisation 51 21 T T Dom T rmm Jabiru Aircraft ta In
65. s strongly recommended Compared to other grades of wire aircraft grade can carry higher currents for the same physical size and weight The insulation used on aircraft grade wire is also frame resistant and is designed for better resistance to damage caused by chaffing or rubbing e Care should be taken to identify each wire via labels or similar This makes troubleshooting electrical issues much easier Wherever possible wires should be identified as carrying Power or Earth This can be done by using different colour connectors or applying rings of coloured heat shrink during assembly Again this step simplifies troubleshooting or later modification e Wires should laid out in bundles and supported along their length to prevent failures due to fatigue 21 T T T Ionen T mr Jabiru Aircraft pty Installation Manual Jabiru 3300 Aircraft Engine 5 8 Instruments 5 8 1 Electronic Tachometer General wiring information for the Tachometer is given in the Wiring Diagram Figure 26 Detailed instructions on it s installation are supplied by the instrument manufacturer The tachometer picks up on 2 metal tabs attached to the inside of the flywheel The Pickup used is a Magnetic Induction sender type It is a passive device requiring no external power They Pickup outputs a voltage in response to variations in their self induced magnetic field caused by proximity to moving ferrous metal par
66. stallation Manual Jabiru 3300 Aircraft Engine 13 3 Inlet amp Ram Air Ducts he engine should be installed using RAM AIR ducts provided with the engine The ram air ducts are screwed to the engine using the normal rocker cover screws Note that if the duct is not fastened to the engine then air pressure at high speed can lift the ducts off the engine This will upset the pressure balance inside the cowl and impede cooling More importantly with some types of ducts the duct lifting will dislodge the spark plug high tension leads causing the engine to run roughly or stop e For best cooling on the ground during climb and low speed flight the propeller used must have significant pitch and blade area on the section immediately in front of the air inlets At low speeds the airflow does not have much energy and the acceleration and pressure provided by the propeller greatly assists in getting air into the ram air ducts e Each duct must have a 25mm hole at the inside top front to bleed air over the crankcase The pressure differential between the inside the cooling ducts and the cowl outlet must not be lower than 60mm 2 4 water gauge at when the aircraft s speed is 1 3 times the stall speed 1 3 x Vs he cooling ducts provided are a starting point in establishing effective engine cooling The ducts may require to be increased in size and additional baffles provided for best cooling e Tubes of approximately 12mm diamet
67. te that an engine mount spacer washer is fitted between the male rubber amp the lower engine mount pins Refer to Figure 42 below With the Back of the Aircraft Supported the wheels chocked lift the engine onto the engine mount e Insert the upper engine mount rubbers into the engine backing plate first by tilting the front of the engine up Once both upper rubbers are through the engine backing plate fit the female rubber engine mount spacer washer engine mount washer 4 washer amp Heat Proof nut place the nuts on the mount bolts the rubbers must be compressed Do this by using a deep reach Socket inside the engine mount pins amp clamping the rubber mount assembly using a G clamp with the swivel taken off the ball See Figure 41 Start nuts on both upper mount bolts Once bolts of the upper rubbers are started continue lowering the front of the engine amp align the lower engine mount pins with the engine backing plate Use the weight of the engine to compress the lower rubbers amp fit the nuts to the bolts he lower engine mount rubbers are assembled in the same way except the male engine mount rubber is fitted to the engine mount pins first Refer to Figure 42 below e Tighten nuts until firm Engine mount washer will touch the engine mount pin as the rubbers compress Connect the fuel line to fuel pump Refer to Figure 41 Ensure the fireproof sleeve is in place e Ensure the fuel line from
68. tems is SCAT aircraft type WARNING SKEET type which has an inner liner must NOT be used Over time the inner lining can detach and collapse blocking the hose SKEET hose should be used for positive pressure applications only e Tight corners in the hose as shown in Figure 33 can introduce both swirl and turbulence to the air flowing into the carburettor e Connecting the hose directly to the carburettor can cause the hose to bunch up and cover the sense ports A Cobra Head duct or similar is recommended to prevent this Sharp corners inside the air filter box cause turbulence and a pressure drop The pressure drop means that the carburettor balance tube pressure reading is inaccurate while the turbulence affects the readings at the carburettor sense ports Both items can cause power loss and rough running particularly at high power settings e For installations where there is very little room between the carburettor and the firewall a special duct has been developed to minimise pressure drop and turbulence shown in Figure 37 e he intake hose should align as closely as possible with the carburettor body having the intake duct come at the carburettor from one side encourages swirl and can give uneven mixture AT 0 Rough entry into hose 7 Smooth entry into hose no turbulence and pressure difference y turbulence or pressure difference Balance tube Balance tube Hose bunched covering
69. th e The temperature sender is a brass fitting installed in the engine sump beside the drain plug e The oil temperature relies a good earth connection between the sensor the engine and the airframe earth terminal If there is excess resistance at any of these points gauge reading errors will occur Oil Temperature sender with wire connected Engine sump drain plug Figure 18 Oil Temperature Connections 21 T Peman T mr Jabiru Aircraft pty Mn lt Installation Manual Jabiru 3300 Aircraft Engine 5 8 3 Oil Pressure Gauge e electric oil pressure sender is fitted to the engine for an Oil Pressure Gauge Jabiru Part No PI10762N is the recommended gauge he gauge has 3 pins one marked which is connected to power one S which is connected to the sensor and one un marked which is connected to earth Nm Oil filter Oil Temperature sender with wire connected kPa x TON 1 Figure 20 Pressure Connections 5 8 4 Voltage Gauge Optional Avoltage gauge can be connected to the aircraft systems he gauge has 2 pins one marked which is connected to power and one un marked which is connected to earth Figure 21 Voltage Gauge Connections 2 219 Jabiru Aircraft ta Installation Manual Jabiru 3300 Aircraft Engine 5 8 5 Cylinder
70. the carburettor given below e Some airworthiness categories also require an additional drip tray be fitted to the fuel pump This optional tray is shown in Figure 28 Fuel line pump m to carburettor lt a MA Fuel line from firewall fitting to fuel pump Fuel pump drip tray Optional Figure 28 Mechanical Fuel Pump 6 4 Fuel Flow Meters Where a Fuel Flow Meter is to be installed to the aircraft Jabiru Aircraft recommend that the flow transducer is not installed on the engine side of the firewall Most transducers are made of either plastic or light aluminium and are not fire resistant Regulations and common sense both require that every part of the fuel system on the engine side of the firewall must be fire resistant 6 5 Carburettor Bing constant depression type 94 40 is used This carburettor has a minimum delivery pressure of 5 kPa 0 75 Psi and a maximum pressure of 20 kPa 3 psi To confirm that the fuel system is capable of delivering this pressure a fuel flow test must be performed ww T esce Page 25 or Jabiru Aircraft ta Installation Manual Jabiru 3300 Aircraft Engine WARNING When using auto fuels the fuel delivery system must be designed to prevent fuel vaporization To check pressure insert a T piece between the mechanical pump amp carburettor Test boost p
71. ts such as the tags fitted to the rear of the flywheel The Tachometer sender must be adjusted to have approximately a 0 4mm gap between the tip of the sender and the tag Note that due to normal bearing clearances the crankshaft moves slightly when the engine is running so if this gap is set too small the sender will hit the tag The sender is fragile and most times damage like this means that the sender must be replaced If the gap is different for each of the two tags then one tag can be carefully bent to be the same as the other Ensure gauge is reading correctly While large errors will be obvious smaller errors are harder to pick and it is recommended to check the gauge reading with another instrument such as a hand held optical prop tach Tachometer Sender Connect to Red Wire of tachometer pick up Connect to Black wire of tachometer pick up Connect to Earth Bus Connect to positive such as the Instrument Wiring Bus Figure 16 Tachometer Connections ww T pecie Jabiru Aircraft pty Installation Manual Jabiru 3300 Aircraft Engine 5 8 2 Oil Temperature Gauge e The Oil Temperature Gauge uses an electric probe mounted in the base of the sump Jabiru Part No PI10752N is recommended he gauge has pins one marked which is connected to power one S which is connected to the sensor and one un marked which is connected to ear
72. uments i e resistive or voltage type Sender units used chosen to suit typical parameter ranges of a Jabiru Engine Aircraft grade wiring used CHT cold junction positioned correctly EGT probe located correctly Starter solenoid earthed Regulator earthed Battery mounted close to the engine Anti RF noise measures taken FUEL SUPPLY SYSTEM Electric backup pump installed Electric pump supply pressure within limits Fuel line bend radii sufficient All fittings fwd of firewall fireproof System designed to prevent vapour lock TE BESTE AIR INDUCTION SYSTEM Cobra Head fitted Duct to carburettor as direct as possible No sharp edges or sharp corners in system Carburettor heat system working correctly Backfire flap fitted to air box Drain holes drilled in air box Carburettor sense pipe connected correctly EGT s evaluated EXHAUST SYSTEM Sufficient clearance no rubbing on aircraft Heat muffs for carb and cabin heat included Outlet positioned correctly Noise levels satisfactory COOLING Cowl inlet outlet ratio correct Cowl inlets located amp shaped correctly Cowl outlets located amp shaped correctly Cowl inlets sealed Crankcase and coil cooling correct Pressure differentials correct Engine temperatures correct seo
73. ump with engine off then mechanical fuel pump with engine on then combine with electrical boost pump as well before first flight method for performing a fuel flow test is available from Jabiru if required In brief the fuel line is disconnected from the carburettor fuel is pumped into a calibrated container and the rate at which the fuel is pumped or drained for gravity fed systems without a pump is calculated e Most regulations require that the fuel system including pumps supplying the engine be capable of delivering 1 25 to 1 5 times the maximum flow rate required for the engine For a Jabiru 3300 engine this equates to approximately 44 to 53 Litres per hour see Section 1 3 3 The electric boost pump used on Jabiru Aircraft generally manages a flow rate of approximately 60 litres per hour he Bing carburettor has a Balance tube also known as a sense tube which connects the carburettor to the air box The tube runs from a nipple on the carburettor to the airspace in the air box on the clean side of the air filter This tube is part of a system or ports which tells the carburettor how hard the engine is working and controls how the carburettor varies the fuel air mixture delivered to the engine Tuning issues and poor running will result if this tube is blocked or connected to the wrong spot Figure 30 shows the tube installation Note that the balance tube must not be connected to the air box in a location where the a
74. ust be changed every 2 years or if visible degradation cracking hardening is visible at inspection A pressure drop of at least 60mm 2 4 water pressure between the air flowing into the cooler and the air flowing out of the cowls should provide sufficient oil cooling if using a standard Jabiru oil cooler e Section 13 1 noted that air leaking through gaps in the cooling system ducts is generally waste air not contributing to cooling though it noted that there were exceptions to this rule Oil cooling is the feature of engine installations that is most often improved by leaks like this A controlled amount of free air blowing over the sump crankcase and underside of the engine can significantly improve oil temperatures Figure 52 shows a duct of this type fitted to a Jabiru 6 cylinder engine However for this to work the cowl installation must be able to cope with the extra volume of air flowing into the cowl space the outlet area or outlet lip size may need to be increased to suck out the extra volume e Figure 53 shows oil cooler installation of a Jabiru 3300 Note Detail in the lower corner of the drawing which shows the cooler being fitted using rubber mounts This is very important as it insulates the cooler from engine vibrations coolers installed with a soft mount like this are much less likely to fail in service Controlled gap leaking air over the sump and lower parts of the engine Airflow in Oil Cooler

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