Home

INSTALLATION MANUAL FOR JABIRU 5100 AIRCRAFT ENGINE

1. 14 Figure 11 lgnition Coil Cooling TUDO meristation odie 15 Figure 12 Starter Wiring Detalls oia baca 16 Figure 13 Tachometer Sender InstallatiON cccoooccccccoconoconcnnnnnnncnnononoconcnconononononcnnonnnnnnnnnnnnnnnnrnnonnnnnnonnnnnnnnnranenananess 17 Figure 14 Tachometer 17 Figure 15 Oil Temperature Sender 18 Figure 16 Oil Temperature nnns enn 18 Figure 17 Oil Pressure Sender 19 Figure 18 Oil Pressure Connections 19 Figure 19 Voltage Gauge CONNECtIONS cccccoccccccocncccncncoconnncnnncnnonnrnnn nennen nennen nnn nnne RR RR nn RR sara suisse snas ranae sr rasan nnns 19 Figure 20 CHT Sender Thermocouple Installation 20 Figure 21 CHT Terminal InstelldliOlls tls os cu US sand 21 Figure 22 CHT Gauge nennen nennen nenne nnne R RRE RR nnn nn enn 21 Figure 23 RG400 Co Axial Antenna Cable 22
2. hir filter box Air filter box Figure 30 Air Intake Connections sew DIT TT TII 55 Jabiru Aircraft pty Lta a N Installation Manual Jabiru 5100 Aircraft Engine Figure 31 Air Filter Box Plumbing Incorrect Correct plumbing sharp lips amp abrupt corners rounded amp smoothed off Gradual bends 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 33 Typical Cobra Head Installation on a Jabiru Aircraft mew DIT TT TI enes Jabiru Aircraft pty Lta n o Installation Manual Jabiru 5100 Aircraft Engine Firewall Carburettor Cobra Head Duct Figure 34 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 520 kg hr 1150 Ib h 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 taken from outside the cowl 7 4 Ram Air Bleed e The hot air mixer box filter box must have a Ram Air Bleed flap incorporated e This flap prevents excess ram air p
3. 48 Ee EC AMA PP etree ene ener m 49 Figure 53 Outlet Restriction Caused By Flange On Lower 49 Figure 54 Cooling pressure measurement sssssssssssssssssesesee nennen nnne nnns A 50 Figure 55 Air duct pressure TAPPING 2 eon ne ida 51 Figure 56 Augmentor Exhaust System RR RR RR 52 S7 MIRAS QUAN un aa ds 53 mew DIT TT TII III EE 5 Installation Manual Jabiru 5100 Aircraft Engine 1 2 List of Effective Pages Jabiru Aircraft pty Lta The dates of issue for original 8 revised pages are gt LI I I II I I lI LI Ll Ll Ll Ll Ll Ll Ll 21 10 08 21 10 08 21 10 08 21 10 08 21 10 08 21 10 08 21 10 08 21 10 08 21 10 08 21 10 08 21 10 08 21 10 08 21 10 08 21 10 08 21 10 08 21 10 08 21 10 08 21 10 08 21 10 08 21 10 08 21 10 08 21 10 08 21 10 08 21 10 08 21 10 08 21 10 08 21 10 08 21 10 08 21 10 08 21 10 08 21 10 08 21 10 08 21 10 08 21 10 08 21 10 08 21 10 08 21 10 08 21 10 08 21 10 08 21 10 08 LI 2 2 2 2 2 2 2 2 2 21 10 08 21 10 08 21 10 08 21 10 08 21 10 08 21 10 08 21 10 08 21 10 08 21 10 08 21 10 08 21 10 08 21 10 08 21 10 08 21 10 08 21 10 08 The installation of an aircraft engine into an airf
4. nnne nnns 37 Figure 39 Fuel Connections General ccccccssscccceececceeececcescecceuececceueeecsueeessueeecsegeeessueeesseeeessuaeeesseeesseueeesseseeessaeeessaneeesas 38 Figure 40 SCAT Hose 38 Figure 41 Balance Tube P 38 Figure 42 Control Connections to 1 39 Figure 43 Cowl Airflow Best Viewed in 43 Figure 44 Cowl Airflow Black amp White Versi0N coooocccccooccncconcnncononconoronononcnnononononnnnnnnoncnnnnnnrnnronnrnnnnnnrnnrnnnrnrnnnnnnnnannnns 43 AG alo AI ATION PROPANO OPORTUNA 44 Figure 46 Front On View Into Ram Air 45 Figure 47 Coil Cooling Detail oocccococococonnococonnnonoconocononcononnnnnnnrnnnnn nro nnne nn nnnne sara saa saris aan rn 46 Figure 48 Oil Cooler Duct Design 47 Figure 49 Cooler Cire ova Ei 47 Figure 50 Lip to aid cooling as installed on a 1 48 Figure 51 Affect of Angle of Attack Cowl Outlets
5. bcm REL n I A 3 Figure 4 Engine Mount Point Locations e Each engine mounting point is rubber mounted to damp the engine vibrations The correct installation of these rubbers is shown below in Figure 4 5 mew DIT TT TII IIem EE Jabiru Aircraft pty Lta Mn Installation Manual Jabiru 5100 Aircraft Engine Parts List PART NUMBER 2 009 R amp UPG 10712N RUBBER ISOLATOR FEMALE 3 0029 __ R amp UPG10722NRUBBERISOLATORMALE 4 4094224 WASHER ENGINE MOUNT Bj HE AN960 416 1 4 FLAT WASHER 4840014 PLATE ENGINE MOUNT RUBBER 8 CYL 7 AN4 31A BOLT 8 MS21045 428 1 4 HIGH TEMP LOCK NUT eu as Bx Figure 5 Engine Mount Assembly DIT TT TT I II9ewems Pane Jabiru Aircraft pty ta Mn Installation Manual Jabiru 5100 Aircraft Engine 3 Controls This section comprises of the mechanical controls and electrical switches 3 1 Throttle and Choke e The 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 6 A 7mm spanner is required e The cables used must have an adequate radius wherever they turn a corner Ben
6. Measured with sensor ring fitted under exhaust spark plug Jabiru Aircraft pty Lta Ne Installation Manual Jabiru 5100 Aircraft Engine 1 4 Dimensions OB US NOR 9 Figure 1 Drawing W5000510 Engine Dimensions DIT TT TII IIIem STE Jabiru Aircraft pty Lta Mn Installation Manual Jabiru 5100 Aircraft Engine 1 4 1 Denomination Of Cylinders Cylinder Firing Order 1 5 8 3 2 6 7 4 Figure 2 Cylinder Firing Order 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 B 4 6 CYLINDER ENGINE 2 CYLINDER ENGINE FIRING ORDER 1 4 5 2 3 6 FIRING ORDER 1 2 EXHAUST INTAKE 4 CYLINDER ENGINE FIRING ORDER 1 3 2 4 8 CYLINDER ENGINE FIRING ORDER 1 5 8 3 2 6 7 4 A C N 010 786 973 TRE Teen HINKLER AIRPORT JABIRU ENGINE DISTRIBUTOR CYLINDER 4A266A0D 2 MAP ALL ENGINES SEE Figure 3 Distributor Cylinder Map mew DIT T TT eean EE Jabiru Aircraft py gt Lu Installation Manual Jabiru 5100 Aircraft Engine 2 Engine Mount The design of the engine mount must balance many requirements e The mount must be strong enough to carry the loads applied by the weight and powe
7. j i A gt e 5 O Lavas B HS Q er usns Tog Y HOLIMS ui IN3WLISVdNO2 vr A 3WOS O0 Ald HOSLAY 30 1N3SNOO LNOHLIM E gt nolLoaroud TWOS LON 00 NI SNOISN3AId Em CU ICI DO WEM REVISION Jabiru Aircraft pty Lta Mn Installation Manual Jabiru 5100 Aircraft Engine 6 Fuel Supply System 6 1 Fuel Tank e The 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 e A Fuel filter capable of preventing the passage of particles larger than 0 1mm 100um must be installed between the fuel tank outlet and the fuel pump e filter must be present in the system for fuel flow test The size of the filter should give consideration to allow adequate flow with a used filter Ryco 215 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 require that all fittings in the fuel system on the engine side of the firewall must be fire resistant 6 3 Mechanical Fuel Pump e mechanical fuel pump is mounted on the engine crankcase and is camshaft driven It is desig
8. 2 Stetit ab cec cut see eu Gane iii 24 oT MEM AP 24 00 E Ogg TN 24 A fe ee 28 ES dito baaa 29 7 1 29 7 2 Intake Hose 8 Air Filter BOX cooocccconccccnccocnccocnoconocconcnnnnonnnonannonannonnnnnnnnonannnnannnnnnnnnnnenaness 29 A E 31 o AP dre 31 MEE XMAS Em 32 io lol d PO7Uo0 U0 0O 0QOO eo A 33 10 Engine Installation Procedure lessen 35 11 BEE TFI EO eec vi PA 40 12 RUINS secreciones ici 41 12 1 A A 41 ne nee eee ee ee 42 13 1 udcciaiseio 42 13 2 FOW Ae NUIT TT TT 44 13 3 Air niers Ram Air DUCTS M H 45 13 4 E r E E E E EEE E E EE EE 46 13 5 AP OUG e nE A E E A E E E EAE E 47 13 6 Cooling System Testing Evaluati0ON ooocccoccccoccccccnccncncnncncnanonnnnnnnnnnonnnonnnonnnncnannnnaninos 50 13 7 o el e BIER 51 13 8 Amphibian or Seaplane Installations ccooocccocnccocnoconnoconccnonoconnncannonanconancnnnnonanoss 51 13 9 Slow Speed InstallatioNsS ccooccoconcoconccconiconnncannocanocnnncnnnnonannonannnnnnonnnnnnannnnannnnaninos 52 14 Appendix A
9. Figure 19 Voltage Gauge Connections mew DIT TT TII A Jabiru Aircraft pty Lta o Installation Manual Jabiru 5100 Aircraft Engine 5 8 5 Cylinder 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 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 miss read and show high CHT s Figure 21 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
10. Wiring Diagrams 93 15 Appendix B Jabiru Engine Installation occocconconccnocnonionioncnnonnccnononnnnnonos 54 15 1 Normal Operation ci 54 16 Engine Installation CMOCKIISE amonio indiana 55 eson TE Jabiru Aircraft py 9 Installation Manual Jabiru 5100 Aircraft Engine 1 1 Table of Figures Figure 1 Drawing W5000510 Engine Dimensions occcooccconcncnncnncnccnnnncnnnncncnncnnnncnnnncnnonrnnonnrr nne nnne nennen nnne rn nnns nnne nn 7 Figure eU e uipepormec E 8 Figure 3 Distributor Cylinder 8 Figure 4 Engine Mount Point Locations aiiia 9 5 Engine WIOUNUASSOMDIY NR tirada tail 10 Figure 6 Choke and Throttle Connections to 11 Figure 7 Crankcase Breather 1 nennen enhn nenne nnns 12 Figure 8 Ignition amp Alternator Detail ooocccoonncccconcnncnccnncnonnnononnnnonnrcnnnnnrnnnnnrnnonnnnnnnnnrnnn nen nnns nnns 13 Figure 9 Electrics Installation to FIS Wal Ad A aa ia 14 Figure 10 Regulator Plug Wiring
11. 1 3 1 Ratings RPM Maximum 3000 RPM RPM Maximum Continuous 3000 RPM RPM Recommended Cruise 2 50 RPM 3000 RPM Power Rating 180 hp 3000 RPM 1 3 2 Fuel Fuel Pressure to Carburettor Maximum 20 kPa 3 psi Fuel Pressure to Carburettor Minimum 10 kPa 1 5 psi Recommended Fuel Grade Avgas 100LL 8 Avgas 100 130 Note Leaded and Unleaded Automotive Gasoline above 100 Octane RON may be used however due to the lack of a strong quality control system for automotive fuels Jabiru Aircraft recommend using AVGAS wherever possible 1 3 3 Cil OM CAD AGINY 5 5 Litres Oil Minimum Temperature for Take Off 50 C 122 F Oil Maximum Peak Oil Temperature 118 C 244 F Oil Maximum Continuous Oil Temperature 80 C 100 C 176 F 212 F Oil Pressure Normal Operations Min 220 kPa 32 psi Max 525 kPa 76 psi Oil Pressure uicta ca Min 80 kPa 12 psi Oil Pressure Starting amp Warm Up Max 525 kPa 76 psi mew DIT TT TI II I9ems TEE Jabiru Aircraft py MN Installation Manual Jabiru 5100 Aircraft Engine Oil Consumption sosisini a 0 1 L hr max O
12. 5 HOLES FIT STATIC PRESSURE TUBE INDEXED 90 AS DETAILED THRU FIREWALL Pam AND CONNECT V gt cpm a a T 6 STEEL TUBE 0 8 WALL T STATIC PRESSURE TON PRESSURE DIFFERENCE BRAZE OR SOLDER END CLOSED Py j c _ Tum WAT APTA o A na ae or Yaa ee DETAIL STATIC PRESSURE TUBE ARALDITE STATIC TUBE SCALE roer FOTO MVA 1 230407 amp PVC TUBE TO FIREWALL yn eu ISS DATE P L mte DWG NO A C N 010 786 973 E CEN pruta 16 00 1 m mm HINKLER AIRPORT JABIRU ENGINE COOLING AIR PRESSURE DIFFERENTIALS 21 MATERIAI APPR BUNDABERG Figure 54 Cooling pressure measurement CONOCIO 55 Jabiru Aircraft pty Lta Ne A Installation Manual Jabiru 5100 Aircraft Engine Figure 55 Ram Air duct pressure tapping 13 7 Pusher Installations e For pusher installations 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 e The propeller can be used to suck air out of the cowls using the following as a guide Wherever possible the cowl outlets should be vertical openings with lips that come close to propeller as close a possible without the blades hitting the cowls ii The propeller blade must
13. 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 is strongly recommended Compared to other grades of wire aircraft grade can carry higher currents for the same physical size and weight The insulation used on aircraft grade wire is also frame resistant and is designed for better resistance to damage caused by chaffing or rubbing 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 be laid out in bundles and supported along their length to prevent failures due to fatigue DIT TLL LL A 16 o Jabiru Aircraft pty Lta Mn um Installation Manual Jabiru 5100 Aircraft Engine 5 8 Instruments 5 8 1 Electronic Tachometer e General wiring information for the Tachometer is given in the Wiring Diagram Figure 24 Detailed instructions for its installation are supplied by the instrument manufacturer e The tachometer picks up on 2 metal tabs attached to the inside of the flywheel e The Pickup used is a Magnetic Induction sender ty
14. Figure 24 A a PEE E E E E A 23 Figure 25 Mechanical Fuel PUMP ETT m da 24 Figure 26 Carburettor or dato 25 Figure 27 Carburettor Intake amp Balance Tube 26 Figure 29 Carburettor E e Ta 26 Figure 29 Needle Jet Jabiru Needle ocooocccccoocococononccoconoconcnnoconononnnrnnnnonrnnnnnnnnnnnrnnnrnnnnnnnrnnnnnnnnrnnnrnnnnnonnnnnnnnnrarenananess 27 Figure 30 Air Intake 29 Figure 31 Air Filter Box Plumbing 30 Figure 32 Air Filter Box Plumbing 30 Figure 33 Typical Cobra Head Installation on a Jabiru Aircraft cooooncccconccnnoncnncnonnnnonnnnnnnnncnnonononnnnnrnnnnnnrnnonnnrnnonarnnonnnnnnss 30 Figure 34 Cobra Head for Installations with Minimum Carburettor 31 Figure 35 Fe AIP A PS oe o A II So nn A 31 Figure 36 Schematic Propeller amp Spinner Installati0N oocccconccconnncconcconnnononnconononnnnnnonnnnnnnnnnnnnnnncnnnnnnnnnnnnnnnnncnnnnnenans 34 Figure 7 Engine Mount Detalla airada dias 36 Figure 38 Engine Mount nn rn nn rn nn rn nn Eee nnne nnne e rina nsn rns rris er rne
15. STARTER LOOM WIRING MAIN BUS INST BUS B e 7 5 43 2 5 1 SOLENOID MAIN BUS INST BUS O O000000 EARTH BUS PEDI Ss v EE 1110987654321 OOOO OOOO OC 11109 8 7 65 4 4 2 1 OFF ON OFF ON OFFI ON ON OFFI ON OFF ON OFFI ON OFF ON OFF ES Xm Cee ed C 2 EA SS O 754 M FUEL MAIN RADIO FUEL MAIN RADIO E PUMP FUSE INS PUMP FUSE INST IGN 1 IGN 2 STARTER MASTER STROBE FUEL FUSE IGN 1 IGN 2 STARTER MASTER STROBE FUEL FUSE FUSE PUMP PUMP WIRING A BE Ur
16. and rich A high power mixture Parallel end for full power View looking through A needle jet N N eedle Jet Needle Figure 29 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 ETE Jabiru Aircraft py gt Lu Installation Manual Jabiru 5100 Aircraft Engine 6 5 2 Carburettor Tuning e The mixture supplied to the engine by the carburettor is affected by a large number of variables including l Ambient temperature ii Propeller size coarse or fine and loading iii 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 hoses forward of the firewall require fire resistant sheathing visible as an orange covering the fuel lines in Figure 25 above Note that the sheathing should be extended past the hos
17. be connected to the air box in a location where the air 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 e drip 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 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 e 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 T 1 1 H gt 4 D ES ES 2226 La I T 3 Fuel bowl clip Fuel bowl Drip deflector Figure 26 Carburettor Installation DIT TT TII ETE Jabiru Aircraft pty Lta Installation Manual Th Air filter Balance tube 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 El nipple T L Sense port 5 Poor location for Su balance tube A n p Figure 27 Carburettor Intake amp Balance Tube Detail 6 5 1 Carburettor Operat
18. 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 C and you want to flying in up to 35 C weather in 35 C all your engine temps will be approximately 20 C higher Check you have sufficient margin for all conditions you plan to fly in engine gets too hot during testing don t push it Something needs to be changed e For low speed cooling a lip on the front edge cowl outlet can add up to 20mm of pressure drop at 65kts a lip 25mm deep at 60 to the airflow shown in Figure 50 e Refer to Figure 20 CHT terminals must be placed correctly or inaccurate too high readings can result i t D Mica va P CRA P DM CONSENT OF VTECH o a PIE D MENSIO N gt IN MILIMETR ES DO NOT SCALE PROJECTION En t CDAD A f TUBE MOU NTED Fl USI 1 WITI x RAM AIR DUCT SPARK PLUG RAM AIR DUCTS BETWEEN SPARK PLUGS 4 a Ij E N i 6 mm CLEAR PVC TUBE lt 6 mm STEEL TUBE BENT 90 LOCATION OF TUBE IN RAM f DEGREES AND ARALDITED TO ete _ AIR DUCT ON BOTH SIDES RAM AIR DUCT WITH TAIL FACING AFT TO CONNECT FIT STATIC TUBE AS DETAILED IN FRONT OF OIL COOLER CONNECT TO CLEAR PVC TUBE MANOMETER c m DRILL THRU 1 0
19. have significant pitch and chord in the section that 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 e Augmentor type exhausts Figure 56 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 e The position of the cowl 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 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 e 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 requiremen
20. o A MASTER WIRING mo MAIN BUS INST BUS 3 STARTER E OOOOOO SOLENOID E STARTER BATTERY EARTH BUS i 11109 8 65943 2 1 O O EARTH BUS MAIN BUS INST BUS 00000000000 11109876543 2 1 76143 21 43 21 0000 LACK BLACK d d ff ff dd tf J fq ON OFF OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF i L E E FUEL MAIN RADIO E FUSE INST FUEL MAN RADIO IGN 1 2 STARTER PUMP FUSE ou ML SE ilc GN 1 IGN 2 STARTER MASTER STROBE FUEL Figure 57 Wiring Details me T 55 Jabiru Aircraft py gt Lu Installation Manual Jabiru 5100 Aircraft Engine 15 Appendix B Jabiru Engine Installation 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 Normal Operation Data e following are typical values for the engine when installed uro mE E 750 850 R
21. oil cooler be closed as a Starting point e The propeller rush of air from the aircraft s speed make it easier to get air into the cowl than to get it out e Too much 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 its 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 overheating of cylinders or oil CONOCI paoe ae orsa Jabiru Aircraft pty Lta Installation Manual Jabiru 5100 Aircraft Engine High pressure air entering Balanced Flow Air from ram air ducts cowl through ram air ducts
22. the fuel pump 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 7 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 muff to carburettor heat inlet on the hot air mixer box and from the hot air mixer box to carburettor similar to what is shown in Figure 40 e Fit throttle cable to carburettor with 5 16 washers one washer either side of cable end fitting to align cable Use R clip to assemble Figure 42 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 6 e Connect the fuel balance tube from the nipple on the carburettor to a fitting on the filtered air side of the air mixer box e Fit cylinder head temperature CHT sensor The CHT 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 hea
23. 010 to 0 012 e When installing new ignition coils the output leads go in the direction of prop rotation See Figure 8 Ram air cooling duct Coil cooling tube Ignition coil E y V Figure 11 Ignition Coil Cooling Tube ib 5 4 Starter Motor e The starter is mounted on the top of the engine and drives the ring gear on the flywheel e he 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 e cable from Battery to starter should be minimum 16mm copper e Wiring details are shown in Figure 24 5 5 Starter Solenoid e The starter Solenoid is mounted on the firewall as shown in Figure 9 e The Solenoid body forms a part of the electrical circuit and MUST be earthed to function correctly as shown in Figure 13 DIT TT T TII A Jabiru Aircraft py gt Lu Installation Manual Jabiru 5100 Aircraft Engine SOLENOID BODY START BUTTON x TO MAIN POWER BUS EARTH CONNECTION BETWEEN SOLENOID amp IAG VIA REWALL SHE POS Figure 12 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
24. 13 4 Oil Cooling e The dipstick cap must be screwed fully in before removal for reading oil level e The oil cooler is plumbed to either side of the crankcase 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 dont have an oil cooler you can t fly if it warms up You can always block off the air flow to the oil cooler in cold conditions e In continuous operation oil temperatures between 80 C and 90 C 176 F 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 amp loss e Hoses should be nominally 10mm 3 8 bore e Hoses must be changed every 2 years or if visible degradation cracking hardening is visible at inspection e air 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 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 improv
25. 3 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 single 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 insta
26. ALVEw14NPT_ 1 6 1 8 j HOSETTOCRANKCASE 1 9 jJHOSECRANKCASETOT jHOSETTOCOOLER 2 NOTE FREE FLOW DIRECTION OF CHECKVALVE 8 CYL OIL CIRCUIT SCHEMATIC 4A480A0D 1 Figure 49 Oil Cooler Circuit 13 5 Air Outlet 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 e 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 e 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 e Figure 50 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 CONOCI ETE Jabiru Aircraft pty Lta Shaun Installation Manual Jabiru 5100 Aircraft Engine e Figure 51 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 that the aircraft will normally experience e Figure 52 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 Dee
27. Detail View Location Figure 53 Outlet Restriction Caused By Flange On Lower Firewall mew DIT TL LL LL T 55 Jabiru Aircraft pty Lta Installation Manual Jabiru 5100 Aircraft Engine 13 6 Cooling System Testing amp Evaluation e For new installations the pressure drop across both Ram air ducts must be checked e following is a guide to evaluating an engine installation to see if it meets minimum cooling requirements e The 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 a U and half filled with water if the water is hard to see add a bit of food colouring e For ram air duct pressure connect one side of U to a static port inside the ram air 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 tubes several measurements can be taken in one flight e Details of a typical static probe are shown in Figure 54 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
28. INSTALLATION MANUAL FOR JABIRU 5100 AIRCRAFT ENGINE DOCUMENT No JEM5103 1 This Manual is a guide to correctly install the Jabiru 5100 engine into an airframe If you have any questions or doubts about the contents please contact Jabiru Aircraft P L Applicable to Jabiru 5100cc Enginers S No 51001 Onwards Jabiru Aircraft py 9 Installation Manual Jabiru 5100 Aircraft Engine MEN a A 3 te ic PR mmm 4 is 5 1 1 MOOG A 5 Te 5 e less gt nee eee 5 UM DRIER UNUM 7 21 9 XA T m 11 x Thone and scenic ii pibe tii 11 32 gnillonr amp Starter ao torso oia 11 4 Engine Crankcase Breather Catch Bottle amp Dipstick 12 OCU Te GU OTS 13 O A 13 RoUe ee 13 A o AA 14 Emm 15 ui geo ioo 15 S c 16 ad Rm uem 16 DO MSM CIS toto ton ree bno 17 59 Radio Frequency RF Noise Reduction cooccccooccccoccncconcnccnncnonnncnonnnononncnnonannnonnrnnnnnnncnnnnnos 21 oO Fuel Supply T 24 6 1 A qu 24 oT MEE A 24 6 3 Mechanical Fuel PUMP
29. LU T AT A AT AR 00 UR 47 AF AF AT AI 49 JONY IJ OSNILNNOW dOdd LIVWHSANV4O d 4 Z G t a r S108 H3TI3dOHd s ONIN3IHSIL MOJ JONINOIS v TRE E Nouosroyd LON O0 S3HI3NTIM 38 ON ISPA ON DRDS S DNO Si REVISION Jabiru Aircraft py gt Lu Installation Manual Jabiru 5100 Aircraft Engine 10 Engine Installation Procedure e Attach male engine mount rubbers to all engine mount pins on the engine mount Place an AN4 31A bolt through each mount e With the Back of the Aircraft Supported amp the wheels chocked lift the engine onto the engine mount e Insert female engine mount rubbers into the engine mount plate lugs then fit the engine mount washer 74 washer amp Heat Proof nut e To 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 37 e Tighten nuts until firm Engine mount washer will touch the engine mount pin as the rubbers compress e Connect the fuel line to fuel pump Refer to Figure 37 Ensure the fireproof sleeve is in place e Ensure the fuel line from fuel pump to the carburettor is connected amp 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 leading from
30. NING 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 pump with engine off then mechanical fuel pump with engine on then combine with electrical boost pump as well before first flight e A 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 5100 engine this equates to approximately 70 Litres per hour e The Bing carburettor has a Balance tube also known as a sense tube that 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 27 shows the tube installation Note that the balance tube must not
31. PM Take Off POWER 2650 Full gt 3000 RPM Cruise At 75 2 50 RPM OIl SS SG naar UIN MG D RE 400 kPa 58 psi Oil Temperature 80 C 175 F Oil Temperature 95 203 F Ne Rr 121 C 250 F A 177 C 350 F EGT spe 650 C 1202 F CUS EG P nadia picas 690 C 1274 F T 55 Jabiru Aircraft pty Lta ees Installation Manual Jabiru 5100 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 instruments i e resistive or voltage type Sender units used chosen to suit typ
32. SHER ENGINE MOUNT 5 AN960 216 1 4 FLAT WASHER PLATE ENGINE MOUNT RUBBER 8 CYL BOLT 114 HIGH TEMP LOCK NUT ex eu eee lea ua lia m Figure 38 Engine Mount Detail mew DIT TT TII paoe ar orsa Jabiru Aircraft pty Lta Fuel line from firewall fitting to mechanical fuel pump Fuel line from mechanical fuel pump to carburettor Figure 39 Fuel Connections General SCAT hose from SCAT hose from hot air NACA inlet to air box muff on exhaust to air box ME 1 P ev 5 Figure 40 SCAT Hose Detail Balance tube connecting filtered side of air mixer box to nipple on carburettor sew DIT TT Jabiru Aircraft pty Lta M Installation Manual Jabiru 5100 Aircraft Engine Throttle Cable Ends Carburettor end Throttle lever end Throttle cable connected Se A T Figure 42 Control Connections to Carburettor CONOCIO EEE Jabiru Aircraft py gt Za WN Installation Manual Jabiru 5100 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 e Once past the initial 25 30 hours ensure the oil used meets the specifications given
33. UE FROM ALTERNATOR 2 2 RED 7 BATTERY 2 N TO LOW VOLTAGE WARNING LIGHT ES TELLOW VOLTAGE CONTROL IO MAIN BUS REGULATOR PLUG WIRING Figure 10 Regulator Plug Wiring Details 5 3 Ignition e The ignition unit has dual breakerless transistorised ignition with the magnets mounted on the flywheel and the coils mounted on the alternator mount plate Figure 8 shows the coils of a Jabiru engine however the position of the coils and the magnets on the flywheel are slightly different for the 5100 engine e The current from the coils flows to the distributor from where it is distributed to the spark plugs Jabiru Aircraft pty Lta M Installation Manual Jabiru 5100 Aircraft Engine e The 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 24 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 he 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
34. above e Oil 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 mew DIT TT TT Paseo orsa Jabiru Aircraft py gt Lu Installation Manual Jabiru 5100 Aircraft Engine 12 Auxiliary Units 12 1 Vacuum Pump For 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 e The pad and spline are SAE Standard CONOCIO Jabiru Aircraft py gt Lu Installation Manual Jabiru 5100 Aircraft Engine 13 Cooling Systems 13 1 General Principles e 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 lil Is simple to build install and maintain IV Produces minimum drag V Requires no pilot attention vi Is not affected by rain dirt or insects sticking to it Vil And weighs next to nothing For the sake of the follo
35. and oil cooler mixing Cowl 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 es gt Un Balanced Flow Air leaking past cylinder heads reduces air flow rate reduces air flow rate through oil cooler XS through cylinder heads Figure 43 Cowl Airflow Best Viewed in Colour High pressure air entering Balanced Flow 7 from ram air ducts cowl through ram air ducts lt and oil cooler mixing T Cowl outlet sucks air out of the cowls Low pressure air flows out High temperature air __ under cylinder heads Air entering cowl through oil cooler Un Balanced Flow ndi AA A AA RR en di E E utat TTE Air leaking past cylinder heads BN reduces air flow rate through oil cooler Air leaking past oil cooler reduces air flow rate through cylinder heads Figure 44 Cowl Airflow Black amp White Version mew DIT Pane orsa Jabiru Aircraft py gt Lu Installation Manual Jabiru 5100 Aircraft Engine 13 2 Flow Visualisation e 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 45 shows two schoolrooms drawn as if seen fr
36. ator is mounted on the alternator mount plate at the back of the engine The alternator mount plate is also the mount for the ignition coils and the vacuum pump e Note The electrical system is Negative Earth Specifications Power Max 200W Continuous Engine S No 2662 onwards tw 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 Figure 8 Ignition amp Alternator Detail 5 2 Regulator e 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 20A fuse or circuit breaker may be used between the regulator amp battery e The regulator is equipped to illuminate a Low Voltage Warning Light Refer to Figure 10 for plug pin details pase Jabiru Aircraft pty Lta Ne A o Installation Manual Jabiru 5100 Aircraft Engine Firewall Starter Solenoid Power Earth cables to starter motor Regulator Plug Regulator Grey finned block PAN Figure 9 Electrics Installation to Firewall BLACK TO BATTERY PALE BLUE lt FROM ALTERNATOR 1 Y PALE BL
37. 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 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 lt Cold Junction Plug terminal under spark plug CHT Thermocouple Cold Junction Spark Plug Terminal Figure 20 CHT Sender Thermocouple Installation CONOCIO Pane 20 Jabiru Aircraft pty Lta Mn Installation Manual Jabiru 5100 Aircraft Engine CHT TERMINAL TERMINAL NOT CENTRED UNDER PLUG SPARK PLUG r d CENTRED UNDER Sc d Figure 21 CHT Terminal Installation Cylinder Head Temp ia d Figure 22 CHT Gauge Connections 5 8 6 Exhaust Gas Temperature Gauge e 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 a common problem with aircraft Symptoms include y Ra
38. 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 57 is provided connecting the carburettor to the rest of the engine so the throttle and choke cables are connected to earth through this wire e It is normal amp unavoidable that the engine s ignition system produces some RF noise This can minimised by l Ensuring all spark plug gaps are set properly Il Ensure ignition coil gaps are set properly iii 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 To counteract RF noise Jabiru Aircraft run shielded wiring on all radio and intercom wiring In our experience the Earth Return method of shielding where the shield for the wire is also used to form the earth connection does not work as well as the 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 aircraft s earth system at one end only e The cable used for the Antenna should be high quality such as RG400 Shown in Figure 2
39. ding the cables too sharply will increase the cable friction making it difficult to use the control accurately This is a particular problem for the throttle cable as it will make setting the idle accurately very difficult e Jabiru engines are run in 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 6 must be adjusted as a part of the engine installation process gt Idle stop screw Throttle Cable connected to throttle arm Cable mount bracket Choke Cable connected to throttle arm Adjustors to fine tune choke A and throttle operation Figure 6 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 The ignition switches and starter system wiring are connected as shown by the circuit diagram Figure 57 e Section 5 gives details of the electrical systems for the engine mew Pane orsa Jabiru Aircraft pty Lta o Installation Manual Jabiru 5100 Aircraft Engine 4 Engine Crankcase Breather Catch Bottle 4 Dipstick e The Jabiru 5100 engine has a crankcase breather connection built into the dipstick housing This is to be connected as shown in Figure 7 below e he catch bottle is designed to catch most oil vapour from the crankcase breather air It mus
40. dio squelch setting needs to be high ii Excess noise in the background during transmissions iii oqueals or other feedback noises heard during transmission IV Intermittent static or noise breaking through the squelch e 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 lf the aircraft has a metallic firewall it can be used as a shield to block the majority of RF noise To 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 DIT TT TII IIeeme Pane 2 orsa Jabiru Aircraft py gt Za WN Installation Manual Jabiru 5100 Aircraft Engine Suppressor for each wire The wiring diagram in Figure 24 shows suppressors in schematic form These suppressors are readily available at local electronics stores e A 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
41. e 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 e The pressure differential between the inside the cooling ducts and the cowl outlet must not be lower than 60mm 2 4 water gauge when the aircraft s speed is 1 3 times the stall speed 1 3 x Vs e 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 diameter are required to provide cooling air to the ignition coils Figure 47 e Foran 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 e Gull Wing baffles can be used to fine tune the restriction to airflow caused by the engine and this in tur
42. e 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 e 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 DIT TT TII Jabiru Aircraft py gt Lu Installation Manual Jabiru 5100 Aircraft Engine 7 Air Intake System 7 1 Intake Air Heating e he Jabiru 5100 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 Box 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 The hose type recommended for induction systems is SCAT aircraft type WARNING SKEET type which has an inner liner must NOT be used Over time the inne
43. e or other reference Make sure you are comparing equivalent pitch units when specifying a propeller mm A ETE WALI 0917 ASSY MANNIdS dOHd ses a 0 _ NO H3NNIdS 0917 dogeg ive SNINSTIY H3NNIdS 0917 YIHSYM VFc ZLO SE LEV MIJIS 3NIHOVIN ISOC69T CS F O v YI433 CLE 982 010 NIY m mul Id HOJLAY p E d0068 Yt CI EX Ses 1602015 z NOLYTIVISNI LAN jJOHONY a Mm Z sovoso e do 108 VL VvNV ADOTAN SZcr S9 0csM AAH M3HSVM N lov Hd 120 S S dOYd Hsna 20889F 0006897 4 v ASSY AJHSYM 31118431138 1130 Page 34 of 55 INNON 3lv ld SNIMDVE W3NNIdS 0917 TC LGA S2 EE Adv el HOHONVY 80 1690 LSW Q ui OL WALI 39313 O c lt e LO mo 2 gt 3noHOl 1034400 304 SIHL 38 LSNW 7 SNOLLOd4Id 3150949 NI 33754 SIJHSVM LON YY NOILIIS ve ince ates Dated June 2009 AAA TIM i Figure 36 Schematic Propeller amp Spinner Installation YANNIdS NI S310H 03180344 48 0314907 SLNN YOHONY Jabiru Aircraft pty Lta Installation Manual A EN MU 4 A HU EE HN LN AT AR ZZZ NT A UU T 4
44. ed 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 48 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 48 shows an oil cooler installation of a Jabiru 2200 it shows the cooler 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 e The maximum hose length from the engine crankcase outlet to the oil cooler inlet must not exceed 900 mm total and also for the hoses from the oil cooler back to the engine must not exceed 900 mm total e The checkvalve opening pressure must be set to 70 kPa 10 PSI above the pressure drop of the oil cooler between the inlet and outlet ports with hot oil e Note the free flow direction is from the left side of the crankcase to the right side of the crankcase Jabiru Aircraft pty Lta Controlled gap leaking air over the sump and lower parts of the engine Airflow in Oil Cooler a PENES EI 3 4 4 NPT FEMALE 3 WAY 4 NIPPLEMM4 4NPT J1 5 CHECKV
45. en 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 e 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 36 to allow for expansion and contraction of Jabiru wooden propellers e The propeller must be carefully selected to match the airframe and the engine Propellers up to 1778mm 70 in diameter and 1778mm 70 in pitch may be used The propeller flange is drilled with 6 holes at 120 65mm 4 75 PCD e The Jabiru Engine does not have a hydraulic pressure supply or a governor mounting pad required for a hydraulic constant speed or variable propeller e Propellers with excess pitch can cause high temperatures and engine damage Nominally all propellers must be able to obtain 2650rpm static and 3000rpm wide open throttle straight and level e Do not cruise or climb in the range 2100rpm 2400rpm 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 lin
46. ical 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 ES LIEST PEPE OLEA ES 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 ETE
47. il Standatrd pas Aero Oil W Multigrade 15W 50 or equivalent complying with EEEE HOA MIL L 22851C A Lycoming Spec 301F or Teledyne Continental Spec MHF 24B 1 3 4 Additives Note No Oil or fuel additives should be used Use of oil or fuel additives will void warranty 1 3 5 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 6 Exhaust Gas Temperature EGT EGT Mid Range 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 1 3 7 Ground Running Limitations Ground Idle 900 RPM set while engine is hot Ground Oil Pressure Idle Startup Min kPa 11 psi A Max 525 kPa 76 psi Ground Oil Max 100 C 212 F Ground Maximum Cylinder Head Temperature 180 C 356 F Note If ground temperature limits are reached shut the engine down or cool it by pointing the aircraft into wind
48. ion Diaphragm spring Diaphragm Needle carrier RE Air density sense port Needle Idle circuit inlet aperture Atomiser Air density sense port Needle Jet Jet Carrier Idle Jet Figure 28 Carburettor Schematic DIT TT TII EEE Jabiru Aircraft py gt Za WN Installation Manual Jabiru 5100 Aircraft Engine e The 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 e 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 29 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
49. is controlled by the main jet located upstream of the needle jet in this circuit e he 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 e To achieve a good mixture with the type of load applied by a propeller the Jabiru needle uses two stage taper and a straight tip The more gradual taper at the upper end of the needle gives a leaner mixture in low power cruise settings and at lower RPM where the 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 e The transition from lean cruise mixtures to richer full power mixture will occur at around 2800 3000 rpm 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 Needle Slow linear taper for Needle Jet cross lt cruise power amp below section view NI Steeper linear taper for transition between lean cruise mixture
50. lled 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 noises Outer shield layer Inner shield layer Black outer insulation TT Figure 23 RG400 Co Axial Antenna Cable DIT TT TT II Ieeme ETE ANIONS HIONAD 8 ONIMIM IVOIJLOFT eze sez oio Nov e 9 133 5 TUNG LJvOMNM 0371130 SINIANALSNI 8 IJ3NNOOM3INI v46 43 OW 1000 BS 10 56 60 0r SNIMWHO M3d SY 3346 OL SNM NOUVTIVISNI OIOV INMMAISNI JO DNd SY YISNLIVINAWA AB 03MAdNS SHOSN3S ONV AV 1305 Wauy WNOLLIIS X OS WA 91 TEVI 1 Z qaivis 3SIMY3HLO SSTINN 6 91 91 6G ZZ 2345 OMY 914 mi ine LO LO uc N O 65 A O c O 4 hm LO o 2 gt did 143 dari HOLAS INSNI 4 01 3511 x O SION 335 O kanva HOSN35 l VOL 3613 a O J INANNHLSN y SoMd WHvds O MOSN3S uosuas E TET 00 00 00 00 00 00 es e a N gt s a NOLLINS 3 il 5 gt LL cC Jil amp 5 Ug P o O c El O a
51. mended e The 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 earth e The temperature sender is a brass fitting installed in the engine sump beside the drain plug e The oil temperature relies on a good earth connection between the sensor the engine and the airframe earth terminal If there is excess resistance at any of these points gauge reading errors will occur Oil Temperature sender with wire connected Engine sump drain plug Figure 16 Oil Temperature Connections DIT TT TT I Jabiru Aircraft py gt Lu Installation Manual Jabiru 5100 Aircraft Engine 5 8 3 Oil Pressure Gauge e An electric oil pressure sender is fitted to the engine and wired to an Oil Pressure Gauge Jabiru Part No PI10762N is the recommended gauge e 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 Y Oil filter Oil Temperature sender with wire connected kPa x 100 A a 3 y 2 7 ke Figure 18 Oil Pressure Connections 5 8 4 Voltage Gauge Optional e A voltage gauge can be connected to the aircraft systems e he gauge has 2 pins one marked which is connected to power and one un marked which is connected to earth
52. n 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 Hole in ram air duct to blow cool air over the crankcase Gull Wing baffles fitted between cylinders u Figure 46 Front On View Into Ram Air Duct Pane as orsa Jabiru Aircraft pty ta Ne A Installation Manual Jabiru 5100 Aircraft Engine s ot TS E 2 Pipes blowing cool air over the ignition coils 29 SP 4 m 4 p f F y 7 2 in 64 i NP ur if E Q
53. ned to supply fuel at the pressure described in the following paragraph e airworthiness categories require that a backup fuel pump be fitted in case the primary pump fails Jabiru Aircraft recommend fitting an electrical boost pump If fitted this pump must also fulfil the fuel input criteria for the carburettor given below e Some airworthiness categories also require an additional drip tray be fitted to the fuel pump This optional tray is shown in Figure 25 Fuel line from pump to carburettor Fuel Pump Fuel line from firewall fitting to fuel pump Fuel pump drip tray Optional Figure 25 Mechanical Fuel Pump 6 4 Fuel Flow Meters e 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 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 DIT T TT TII Pane 20 of Jabiru Aircraft pty Lta Mn Installation Manual Jabiru 5100 Aircraft Engine WAR
54. om above Each room represents an engine and oil cooler inside a cowling l There are two doors in the inlet side of the room and one on the outlet side ii oeveral desks are placed in the room representing the engine cylinders and the oil cooler Ili otudents walk through from left to right representing the airflow 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 e The 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 homework but if they are slowed down anywhere else it only reduces the amount of students that can get through the room e lf 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
55. p Outlet give better pressure differentials and are less affected by aircraft angle of attack than horizontal Long Outlet e Figure 52 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 e 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 53 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 Line shows direction of ambient airflow Figure 51 Affect of Angle of Attack on Cowl Outlets mew DIT TT 55 Jabiru Aircraft pty Lta _ A Installation Manual Jabiru 5100 Aircraft Engine Figure 52 Cowl Outlet Geometry Firewall Fange an fuselage
56. pe lt is a passive device requiring no external power e They Pickup outputs a voltage in response to variations in their self induced magnetic field caused by proximity to moving ferrous metal parts the tags fitted to the rear of the flywheel e he 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 e 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 14 Tachometer Connections DIT TT TI II Ieeme Jabiru Aircraft pty ta Mn Installation Manual Jabiru 5100 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 recom
57. 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 vary between different heads Partition Cylinder head desks Oil cooler desks Desk CD otudents carrying homework Partitions are used to force 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 amp jostling at the exit Outlet door is parallel to the flow of students in the corridor causing restriction amp jostling at the exit Figure 45 Flow Visualisation AECI Jabiru Aircraft pty Lta Mn Installation Manual Jabiru 5100 Aircraft Engine 13 3 Air Inlet amp Ram Air Ducts e he engine should be installed using RAM AIR ducts provided with the engine e 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 th
58. r 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 30 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 e 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 34 e The 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 Rough entry into hose high 7 Smooth entry into hose no j turbulence and pressure difference y A turbulence or pressure difference Balance tube Balance tube Hose bunched covering sense ports 8 adding turbulence amp swirl Cobra Head duct f fitted to carburettor Y
59. r of the engine e The mount must be stiff enough that the engine does not sag move too much when power is applied e 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 e 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 its position must be calculated to place the centre of gravity of the aircraft CG in the right spot e 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 e The final design of the engine mount is a compromise and sometimes special parts will be required to make it work Figure 4 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 2 located at the rear of the engine and 2 located at the front as shown in Figure 14 FRONT ENGINE MOUNT PINS REAR ENGINE MOUNT PIN Saw ae 2
60. rame is a serious undertaking and should not be attempted by any person without a high level of engineering competence This manual does not cover all levels of detail and assumes a high level of engineering competence by the person installing the engine They should have professional assistance from industry experienced personnel to assist and check all aspects of the installation to ensure all criteria are met even TAT TL EII TE Jabiru Aircraft py gt Lu Installation Manual Jabiru 5100 Aircraft Engine 1 Description 1 1 Model This Manual applies to all Jabiru 5100 Engine Models from S No 51001 on note some illustrations and photographs are of different model engines and are for illustration only 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 e 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
61. ressure in the induction system 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 35 Ram Air Bleed mew T 55 Jabiru Aircraft py 9 Installation Manual Jabiru 5100 Aircraft Engine 8 Exhaust System e An exhaust system is provided with the engine the outlet tubes to be TIG welded to the muffler body to suit the installation NOTE Drilled ends of outlet pipe go inside the muffler cavity and welded around the entry point e Muffler Volume Capacity litres per side e Back pressure at Takeoff Performance Max 0 2 bar 2 9 psi Readings taken 70mm from muffler flange connections e Exhaust Gas Temperature EGT limits are given in Section 1 3 6 ETE Jabiru Aircraft py gt Lu Installation Manual Jabiru 5100 Aircraft Engine 9 Propeller amp Spinner e 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 prov
62. t be monitored in service and periodically emptied of waste oil e Figure 52 shows more clearly the outlet from the catch bottle 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 or low pressure partial vacuum area the pressure inside the crankcases will also change with unpredictable effects on engine oil consumption and oil flow within the engine This is because several areas of the engine are lubricated via low pressure or spray oil feeds 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 f attached to firewall Hose to outlet Figure 7 Crankcase Breather Installation mew DIT TT pase Jabiru Aircraft pty Lta Ne um Installation Manual Jabiru 5100 Aircraft Engine 5 Electrical Equipment 5 1 Alternator e The alternator fitted to the Jabiru 5100 engine is a single phase permanently excited with a regulator e The rotor is mounted on the flywheel and the st
63. t of the engine Refer to Figure 20 e he Oil Temperature Sensor used is VDO 320 028 which is located in the bottom of the sump as shown Figure 15 e The oil pressure sensor is located at the base of the oil filter and this can be seen in Figure 17 The sensor used is VDO 360 001 e he exhaust gas probe used on 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 e he Tachometer sensor used is a 6 35 22 mm analogue magnetic pick up and is fitted to a bracket on the alternator housing Refer to Figure 13 The sensor picks up on 2 tags fitted behind the flywheel DIT TT ETE Jabiru Aircraft pty Lta Installation Manual Jabiru 5100 Aircraft Engine G Clamp with Deep long swivel removed reach socket AS A PA um r 72 Por n lt a Heat proof nut Figure 37 Engine Mount Detail CONOCIO ETE Jabiru Aircraft pty Lta Installation Manual Jabiru 5100 Aircraft Engine Parts List ITEM 1 3 WA
64. ts 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 56 may be required CONOCIO CEET Jabiru Aircraft pty ta NA A Installation Manual Jabiru 5100 Aircraft Engine Air is sucked out of the cowl and entrained with the exhaust inside the augmentor tube gt AMBIENT AIR SS gt EXHAUST UNS Figure 56 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 e n some of these 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 In these cases large ram air ducts are used and the rest of the engine is exposed to the propeller wash for cooling mew DIT TT TI TILI Ieeme ETE Jabiru Aircraft py gt Lu Installation Manual Jabiru 5100 Aircraft Engine 14 Appendix A Wiring Diagrams M S ON
65. wing discussion a gap is considered an opening roughly large enough to slide two fingers into around 13mm by 32mm 0 5 by 1 74 e 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 52 e Each cowl cylinder head Inlet of a Jabiru Aircraft has an area of approximately 10 500mm 16 25 in Oil cooler inlets have an area of approximately 12 500mm 19 4 in This gives a required total outlet area of approximately 100 500mm 155 in These sizes are based on a Jabiru Aircraft Inlet and outlet sizes required will vary depending on the aircraft s speed drag and the positions of the inlets and outlets the areas given should be used as a guide and starting point only e Ageneralised picture of the airflow and air temperature is shown in Figure 43 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 Sometimes air leaking through controlled gaps such as the holes in the front of the ram air ducts Figure 46 or the gaps between cylinders can have beneficial effects However it is recommended that gaps around the engine and

INSTALLATION MANUAL FOR JABIRU 5100 AIRCRAFT ENGINE

Contents

Download Pdf Manuals

Related Search

Related Contents