Jabiru 2200 Instructions for use

INSTRUCTION AND MAINTENANCE MANUAL
FOR
JABIRU 2200 AIRCRAFT ENGINE
DOCUMENT No. JEM2204-9
This Manual has been prepared as a guide to correctly operate, maintain and
service the Jabiru 2200 engine.
It is the owner's responsibility to regularly check the Jabiru web site at
www.jabiru.net.au for applicable Service Bulletins and have them
implemented as soon as possible. Failure to do this may render the
aircraft un-airworthy and void Jabiru’s Limited, Express Warranty.
This document is controlled while it remains on the Jabiru server. Once
this no longer applies the document becomes uncontrolled.
Should you have any questions or doubts about the contents of this manual, please
contact Jabiru Aircraft Pty Ltd.
Applicable to Jabiru 2200 Models from S/No 2068 and above (Hydraulic Lifter Type)

Jabiru Aircraft Pty Ltd
Instruction & Maintenance Manual
Jabiru 2200 Aircraft Engine
Hydraulic Valve Lifter Models
This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled.
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1Table of Contents
1TABLE OF CONTENTS...........................................................................................................2
1.1 TABLE OF FIGURES.................................................................................................................................5
1.2 LIST OF EFFECTIVE PAGES .....................................................................................................................6
2DESCRIPTION.........................................................................................................................7
2.1 MODEL...................................................................................................................................................7
2.2 GENERAL INFORMATION..........................................................................................................................7
2.3 GENERAL DESCRIPTION..........................................................................................................................8
2.4 DETAILS...............................................................................................................................................10
2.5 MANUFACTURER...................................................................................................................................10
2.6 MANUALS.............................................................................................................................................10
3SPECIFICATIONS .................................................................................................................11
3.1 ENGINE MODELS ..................................................................................................................................11
3.1.1 2200J ........................................................................................................................................................11
3.1.2 2200B........................................................................................................................................................11
3.1.3 2200C........................................................................................................................................................11
3.1.4 2200A........................................................................................................................................................11
3.2 GENERAL SPECIFICATIONS &EQUIPMENT..............................................................................................11
3.3 PERFORMANCE ....................................................................................................................................12
3.3.1 Engine Ratings.........................................................................................................................................12
3.4 FUEL....................................................................................................................................................13
3.5 LUBRICANT...........................................................................................................................................13
3.5.1 Run in Period ............................................................................................................................................13
3.5.2 Normal Operations....................................................................................................................................13
3.6 COOLING SYSTEM ................................................................................................................................13
3.7 OPERATING SPEEDS AND LIMITS...........................................................................................................14
3.7.1 Ground Operating Limits...........................................................................................................................14
3.7.2 In-Flight Operating Limits..........................................................................................................................14
3.8 PROPELLER SELECTION &SPECIFICATIONS...........................................................................................14
3.9 DIMENSIONS.........................................................................................................................................15
3.10 DENOMINATION OF CYLINDERS .........................................................................................................16
3.11 DISTRIBUTOR CYLINDER MAP............................................................................................................16
3.12 POWER CURVE.................................................................................................................................17
4OPERATING INSTRUCTIONS...............................................................................................18
4.1 PRE-START CHECKS ............................................................................................................................18
4.2 STARTING PROCEDURE ........................................................................................................................18
4.2.1 Cold Engine...............................................................................................................................................18
4.2.2 Warm Engine ............................................................................................................................................18
4.3 WARMING UP PERIOD,GROUND TEST ..................................................................................................18
4.4 TAKE-OFF............................................................................................................................................19
4.5 ENGINE STOP.......................................................................................................................................19
4.6 ENGINE STOP AND START DURING FLIGHT ............................................................................................19
5CHECKS ON ENGINE & INSTALLATION.............................................................................20
5.1 DAILY CHECKS.....................................................................................................................................20
5.2 PERIODIC CHECKS ...............................................................................................................................21
5.3 CHECK AFTER INITIAL 10 HOURS...........................................................................................................21
5.4 CHECK AFTER INITIAL 25 HOURS ..........................................................................................................22
5.5 50 HOURS CHECK ................................................................................................................................22
5.6 100 HOURS CHECK ..............................................................................................................................23
5.7 TBO....................................................................................................................................................23
5.8 ENGINE PRESERVATION........................................................................................................................23
5.8.1 Flyable Storage.........................................................................................................................................23
5.8.2 Returning Engine to Service From Flyable Storage..................................................................................24
5.8.3 Temporary Storage ...................................................................................................................................24
5.8.4 Inspection During Storage.........................................................................................................................25
5.8.5 Indefinite Storage......................................................................................................................................25
5.8.6 Returning Engine to Service After Temporary Storage.............................................................................25

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Hydraulic Valve Lifter Models
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5.8.7 New Engine Storage .................................................................................................................................26
5.8.8 Operation in Winter ...................................................................................................................................26
5.8.9 Carburettor Icing .......................................................................................................................................26
5.8.9.1 Icing Due to Water in fuel......................................................................................................................26
5.8.9.2 Icing Due to High Air Humidity. .............................................................................................................27
6MAINTENANCE.....................................................................................................................28
6.1 LUBRICATION SYSTEM ..........................................................................................................................28
6.2 AIR INTAKE FILTER ...............................................................................................................................28
6.3 CARBURETOR ADJUSTMENT..................................................................................................................28
6.4 COMPRESSION CHECK..........................................................................................................................29
6.4.1 Compression Gauge: ................................................................................................................................29
6.4.2 Pressure Differential Test:.........................................................................................................................29
6.5 IGNITION SYSTEM.................................................................................................................................30
6.5.1 High-Tension Lead Connections...............................................................................................................30
6.5.2 Spark Plugs...............................................................................................................................................31
6.6 EXHAUST SYSTEM................................................................................................................................31
6.7 BOLTS AND NUTS .................................................................................................................................31
6.8 TAPPET ADJUSTMENT /HYDRAULIC VALVE LIFTERS...............................................................................31
6.9 HEAD BOLTS........................................................................................................................................33
6.10 TACHOMETER AND SENDER...............................................................................................................33
6.11 ADDITIONAL CHECKS –POST SERVICE ..............................................................................................33
6.11.1 Propeller....................................................................................................................................................34
6.11.2 Engine.......................................................................................................................................................34
6.11.3 Fuel System..............................................................................................................................................34
6.12 ENGINE INSPECTION CHART..............................................................................................................35
7SERVICE & REPAIR..............................................................................................................37
7.1 SERVICE INTERVAL TOLERANCE............................................................................................................37
7.2 ENGINE OVERHAUL AND TBO...............................................................................................................37
7.2.1 Full Overhaul.............................................................................................................................................37
7.2.2 Top End Overhaul.....................................................................................................................................38
7.3 ENGINE REMOVAL PROCEDURE ............................................................................................................38
7.4 ENGINE DISASSEMBLY....................................................................................................................39
7.5 2200 ENGINE OVERHAUL................................................................................................................42
7.5.1 Jabiru 2200 Component Inspection and Assembly Procedure .................................................................43
7.5.1.1 Sub-Assembly A - Crankshaft, Prop Mount and Con-Rods...................................................................43
7.5.1.2 Sub-Assembly B –Crankcase and Camshaft.......................................................................................45
7.5.1.3 Crankcase Decking / Machining............................................................................................................48
7.5.1.4 Sub-Assembly C - Pistons, Cylinders and Cylinder Heads...................................................................48
7.5.1.5 Sub-Assembly D - Sump and Oil Pump................................................................................................54
7.5.1.6 Sub-Assembly E –Flywheel, Ignition Coils, Alternator & Alternator Operation.....................................55
7.5.1.7 Permanent Magnet Alternator (PMA) Operation ...................................................................................58
7.5.1.8 Regulator...............................................................................................................................................59
7.5.1.9 Sub-Assembly F - Gear Case ...............................................................................................................60
7.5.1.10 Sub-Assembly G - Fuel Pump, Carburetor and Carburetor Operation..............................................60
7.5.1.11 Sub-Assembly H - Final Assembly....................................................................................................65
7.5.1.12 Engine Run In ...................................................................................................................................74
7.6 ENGINE INSTALLATION..........................................................................................................................75
7.7 PROP STRIKE INSPECTION....................................................................................................................76
7.8 STARTER MOTOR OVERHAUL................................................................................................................77
7.8.1 Starter motor disassembly and inspection ................................................................................................77
7.8.2 Reassembly ..............................................................................................................................................78
7.9 BUILD SHEETS AND RUN IN PROGRAMME ..............................................................................................78
8NOTES BEFORE STARTING ENGINE..................................................................................79
9SERVICE DOCUMENTATION ...............................................................................................81
9.1 SUBASSEMBLY A–COMPONENT ASSEMBLY PROCEDURE ......................................................................81
9.2 SUBASSEMBLY A–COMPONENT REGISTER &PARTS INSPECTION RECORD............................................82
9.3 SUBASSEMBLY B–COMPONENT ASSEMBLY PROCEDURE ......................................................................83
9.4 SUBASSEMBLY B–COMPONENT REGISTER &PARTS INSPECTION RECORD............................................84
9.5 SUBASSEMBLY C–COMPONENT ASSEMBLY PROCEDURE......................................................................85
9.6 SUBASSEMBLY C–COMPONENT REGISTER AND PARTS INSPECTION RECORD........................................86

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Instruction & Maintenance Manual
Jabiru 2200 Aircraft Engine
Hydraulic Valve Lifter Models
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9.7 SUBASSEMBLY D–COMPONENT ASSEMBLY PROCEDURE......................................................................87
9.8 SUBASSEMBLY D–COMPONENT REGISTER AND PARTS INSPECTION RECORD........................................88
9.9 SUBASSEMBLY E–COMPONENT ASSEMBLY PROCEDURE ......................................................................89
9.10 SUBASSEMBLY E–COMPONENT REGISTER AND PARTS INSPECTION RECORD ....................................90
9.11 SUBASSEMBLY F–COMPONENT ASSEMBLY PROCEDURE...................................................................91
9.12 SUBASSEMBLY F–COMPONENT REGISTER AND PARTS INSPECTION RECORD.....................................92
9.13 SUBASSEMBLY G–COMPONENT ASSEMBLY PROCEDURE ..................................................................93
9.14 SUBASSEMBLY H–COMPONENT ASSEMBLY PROCEDURE ..................................................................94
10 JABIRU 2200 ENGINE RUN-IN & TESTING .........................................................................95
10.1 RUN-IN SCHEDULE............................................................................................................................95
10.2 JABIRU 2200A AERO ENGINE GROUND TEST FORM...........................................................................96
10.3RUN-IN CHECKS ...............................................................................................................................97
10.4 JABIRU 2200 –ENGINE POST RUN PROCEDURE ................................................................................97
11 TABLE OF LUBRICANTS......................................................................................................98
12 TORQUE SPECIFICATION FOR BOLTS & NUTS ................................................................99
12.1 PRESCRIBED SEALANTS AND PRIMERS.................................................................................100
12.2 NEW TOLERANCES....................................................................................................................101
12.3 MAXIMUM ALLOWABLE CLEARANCES (WEAR LIMITS).............................................................102
12.4 ELECTRICAL SYSTEMS SPECIFICATIONS...............................................................................103
13 OPERATING NOTES –QUICK REFERENCE GUIDE......................................................... 104
13.1 NEW ENGINE NOTES.......................................................................................................................104
13.2 NORMAL OPERATION NOTES...........................................................................................................105
13.2.1 Regular Checks.......................................................................................................................................105
13.2.2 Oil............................................................................................................................................................106
13.2.3 Engine Cooling........................................................................................................................................106
13.2.4 Consumables ..........................................................................................................................................107
13.2.5 Starting....................................................................................................................................................107
13.2.6 Trouble Shooting.....................................................................................................................................107
14 TROUBLE SHOOTING........................................................................................................108
14.1 TROUBLESHOOTING TABLES............................................................................................................108
14.1.1 Engine Won't Start ..................................................................................................................................108
14.1.2 Engine Idles Unsteadily After Warm-Up Period: Smoky Exhaust ...........................................................108
14.1.3 Engine Runs Erratically or Misfires Occasionally....................................................................................108
14.1.4 Engine Runs Too Hot - Oil Temperature Above 110oC (230oF).............................................................109
14.1.5 Unsatisfactory Power Output ..................................................................................................................109
14.1.6 Low Oil Pressure.....................................................................................................................................109
14.1.7 Engine Keeps Running with Ignition Off..................................................................................................109
14.1.8 Excessive Oil Consumption ....................................................................................................................109
14.1.9 Knocking Under Load..............................................................................................................................110
14.1.10 Engine Hard to Start at Low Temperature...............................................................................................110
14.1.11 Hydraulic Valve Lifters ............................................................................................................................110
14.2 TROUBLESHOOTING QUICK GUIDE...................................................................................................111
14.2.1 Low Oil Pressure.....................................................................................................................................111
14.2.2 Flicking Of Oil Pressure Gauge...............................................................................................................111
14.2.3 CHT.........................................................................................................................................................111
14.2.4 RPM ........................................................................................................................................................111
14.2.5 Magneto Checks .....................................................................................................................................111
14.2.6 Rough Cylinder Running.........................................................................................................................111
14.2.7 Carby Breather........................................................................................................................................111
14.2.8 Limitations...............................................................................................................................................111
15 AIRWORTHINESS LIMITATIONS SECTION.......................................................................112
16 NEW ENGINE –JABIRU’S LIMITED, EXPRESS WARRANTY...........................................113
17 JABIRU’S LIMITED, EXPRESS WARRANTY: CLAIM FORM.............................................116

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Jabiru 2200 Aircraft Engine
Hydraulic Valve Lifter Models
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1.1 Table of Figures
Figure 1. Drawing 9404041/1 Engine Dimensions............................................................15
Figure 2. Cylinder Denomination & Firing Order................................................................16
Figure 3. Distributor Cylinder Map.....................................................................................16
Figure 4. Power Curve.......................................................................................................17
Figure 5. Power Curve, 2200C, 2200B Engines................................................................17
Figure 6. High-Tension Lead Connections ........................................................................30
Figure 7. Cam Identification Markings ...............................................................................33
Figure 8. Drawing 9429063 –Crank & Rod Assembly ......................................................44
Figure 9. Drawing 9433064 –Cam Lift Measurement.......................................................44
Figure 10. Drawing 9448064 –Cam Gear Assy................................................................45
Figure 11. Drawing 9435064 –Oil Pressure Relief Valve Assy.........................................46
Figure 12. Drawing 9441064 –Crankcase Bearings .........................................................46
Figure 13. Drawing 9442064 –Crankcase Spacer............................................................47
Figure 14. Drawing 944064 –Valve Guide Replacement..................................................49
Figure 15. Valve Seats ......................................................................................................49
Figure 16. Drawing 9444064 –Valve Details.....................................................................50
Figure 17. Drawing 9443064 –Valve Spring Measurement ..............................................51
Figure 18. Drawing 9447064 –Valve Assy........................................................................51
Figure 19. Drawing 9449064 –Rocker Bush Removal......................................................52
Figure 20. Drawing 9A011A0D –Rocker Shaft Install.......................................................52
Figure 21. Drawing 9436064 –Barrel Hone ......................................................................53
Figure 22. Drawing 9434064 –Piston Diameter................................................................54
Figure 23. Drawing 9440064 –Oil Pump Clearances.......................................................55
Figure 24. Drawing 9428064 –Oil Pump End Clearance..................................................55
Figure 25. Drawing 9437064 –Magnet Pull Test Flywheel................................................56
Figure 26. Drawing 9438064 –Magnet Pull Test Alternator..............................................56
Figure 27. Drawing 9439064 –Ignition Primary Resistance..............................................57
Figure 28. –Ignition Secondary Resistance ......................................................................57
Figure 29 –Alternator Circuit Diagram ..............................................................................58
Figure 30. –Alternator Core Assy......................................................................................59
Figure 31. Regulator Wiring...............................................................................................59
Figure 32 –Carburetor Details ..........................................................................................65
Figure 33. Drawing 9427063 –Degree Wheel ..................................................................66
Figure 34. Drawing 9429063 –Crank & Rod Assy ............................................................67
Figure 35. Drawing 9432064 –Timing Gear Alignment.....................................................69
Figure 36. Drawing 9430064 –Rear Plate Through Bolts .................................................71
Figure 37. Drawing 9431064 –Gearbox & Distributor Rotors............................................72
Figure 38 Dial Indicator Position for Crankshaft & Prop Flange Run Out..........................76
Figure 39 –Head Bolt Locations .......................................................................................79
Figure 40. Drawing 9486091 –Run-In Schedule...............................................................95
Figure 41. Oil System Schematic ......................................................................................98

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Instruction & Maintenance Manual
Jabiru 2200 Aircraft Engine
Hydraulic Valve Lifter Models
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1.2 List of Effective Pages
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Issue Notes:
1
Update Torque Values
2
Update Propeller Installation Details
3
Update Maintenance Schedule
4
Add tolerance to servicing intervals
5
Add hydraulic lifter maintenance requirement
6
Add additional hydraulic lifter information
7
Add new engine storage details
8
Prop flange fitting details added
9
Starter motor overhaul, prop strike details added

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2Description
2.1 Model
All Jabiru 2200 Engine Models from S/No 2068 on.
2.2 General Information WARNING:
Jabiru Aircraft Pty Ltd has devoted significant resources and testing to develop the
Jabiru 2200 aircraft engine. This engine is intended to be installed in accordance with
the details given in the “INSTALLATION MANUAL FOR JABIRU 2200 AIRCRAFT
ENGINE”, document No. JEM2202. Any other uses or applications may be extremely
hazardous, leading to property damage, or injury or death of persons on or in the
vicinity of the vehicle. Jabiru Aircraft Pty Ltd does not support the use of this engine in
any applications which do not meet the requirements of the “INSTALLATION MANUAL
FOR JABIRU 2200 AIRCRAFT ENGINE”. Any non-compliant installation may render the
aircraft un-airworthy and will void any warranty issued by Jabiru.
The Jabiru 2200 aircraft engine is designed to be operated and maintained only in strict
accordance with this instruction and maintenance manual. Any variation of any kind,
including alteration to any component at all, whether replacement, relocation,
modification or otherwise which is not strictly in accordance with this manual may lead
to dramatic changes in the performance of the engine and may cause unexpected
engine stoppage, engine damage or harm to other parts of the aircraft to which it may
be fitted and may lead to injury or death. Jabiru Aircraft Pty Ltd does not support any
modifications to the engine, its parts, or components. Any such actions may render the
aircraft un-airworthy and will void any warranty issued by Jabiru.
Maintenance and modification cannot be supervised by the manufacturer. Maintenance
requires extreme cleanliness, exact parts, precise workmanship and proper
consumables. It is your responsibility to ensure absolute attention to detail no matter
who may become involved in work on this engine. Your safety, your life and your
passenger’s lives rely on precise and accurate following of instructions in this manual.
In exchange for the engine manual provided by Jabiru Aircraft Pty. Ltd. (“Jabiru”) I
hereby agree to waive, release, and hold Jabiru harmless from any injury, loss, damage,
or mishap that I, my spouse, heirs, or next of kin may suffer as a result of my use of any
Jabiru product, except to the extent due to gross negligence or willful misconduct by
Jabiru. I understand that proper skills and training are essential to minimize the
unavoidable risks of property damage, serious bodily injury and death that arise from
the use of Jabiru products.

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Hydraulic Valve Lifter Models
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2.3 General Description
It is said that "aircraft are designed around available engines".
Jabiru believe that the Jabiru range of very light engines offers opportunities for light
aircraft designers to develop a new generation of light aircraft.
Jabiru engines are designed to be manufactured in small batch quantities using the very
latest Computer Numerically Controlled (CNC) machine tools. All Jabiru engines are
manufactured and assembled in a very modern factory in Bundaberg where each engine
is run in on a Dynometer and calibrated before delivery. The crankcase halves, cylinder
heads, crankshaft, starter motor housings, gearbox cover (the gearbox powers the
distributor rotors) and coil mounts –together with many smaller components are machined
from solid. The sump (oil pan) is the only casting. The cylinders are machined from bar
4140 chrome molybdenum alloy steel, with the pistons running directly in the steel bores.
The crankshaft is also machined from 4140 chrome molybdenum alloy steel, the journals
of which are precision ground prior to being Magnaflux inspected. The camshaft is
manufactured from 4140 chrome molybdenum alloy steel –with nitrided journals & cams.
The propeller is direct crankshaft driven and does not use a reduction gearbox. This
facilitates its light-weight design and keeps maintenance costs to a minimum. The
crankshaft features a removable propeller flange which enables the easy replacement of
the front crankshaft seal and provides for a propeller shaft extension to be fitted, should
this be required for particular applications. Cylinder heads are machined from solid
aluminium billet, thereby providing a substantive quality trail to material source.
Connecting rods are machined from 4140 alloy steel and the 45mm big end bearings are
of the automotive slipper type.
Many components of the engines are sourced from outside Suppliers. These items include
camshaft followers, and the bendix gear in the starter motor. The ignition coils are also
sourced from outside Suppliers, and are modified by Jabiru for their own particular
application.
An integral alternator using rare earth magnets provides alternating current for battery
charging and electrical accessories. The alternator is attached to the flywheel and is
driven directly by the crankshaft. The ignition system is a transistorised electronic system;
two fixed coils mounted adjacent to the flywheel are energised by rare earth magnets
attached to the flywheel. The passing of the coils by the magnets creates the high voltage
current which is then transported by high tension leads to the centre post of two
automotive type distributors (which are simply rotors and caps) before distribution to
automotive spark plugs, two in the top of each cylinder head. The ignition system is fixed
timing and, therefore, removes the need for timing adjustment. The ignition system is fully
redundant, self-generating and does not depend on battery power.
The crankshaft is designed with a double bearing at the propeller flange end and a main
bearing between each big end; it therefore does not have flying webs. 48mm main
bearings are also of the automotive slipper type. Thrust bearings are located fore and aft
of the front double bearing allowing either tractor or pusher installation.

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Pistons are manufactured to Jabiru design by a major manufacturer, they are fitted with 3
rings, the top rings being cast iron to complement the chrome molybdenum cylinder bores.
Valves are 7mm (stem dia) which are purpose manufactured for the Jabiru engine.
The valve gear includes pushrods from the hydraulic cam followers to forged steel valve
rockers mounted on a shaft through a Teflon coated bronze-steel bush. Valve guides are
manufactured from aluminium/bronze, as is found in larger aero engines and high
performance racing engines. Replaceable valve seats are of nickel steel and are shrunk
into the aluminium cylinder heads. The valve gear is lubricated via the hollow pushrods.
An internal gear pump is driven directly by the camshaft & provides engine lubrication via
an oil circuit which includes an automotive spin-on filter, oil cooler and in-built relief valve.
The standard engines are supplied with two Ram-air cooling ducts, which have been
developed by Jabiru to facilitate the cooling of the engine and direct air from the propeller
to the critical areas of the engine, particularly the cylinder heads and barrels. The fitment
of these ducts is a great bonus for the home builder or engine installer, as they remove
the need to design and manufacture baffles and the establishment of a plenum chamber,
which is the traditional method of cooling air-cooled aircraft engines. The fact that these
baffles and plenum chamber are not required also ensures a "cleaner" engine installation,
which in turn facilitates maintenance and inspection of the engine and engine component.
So the hard work of engine installation has largely been done for you by the Jabiru design
team. RAMAIR ducts are available for tractor or pusher configurations. Special ducts are
available for certain installations.
The engine is fitted with a 1.5 kW starter motor, which is also manufactured by Jabiru and
provides very effective starting. The engine has very low vibration levels, however it is also
supported by four large rubber shock mounts attached to the engine mounts at the rear of
the engine. An optional bed mount is available.
The fuel induction system comprises a BING pressure compensating carburettor.
Following carburation, the fuel/air mixture is drawn through a swept plenum chamber
bolted to the sump casting, in which the mixture is warmed prior to entering short induction
tubes attached to the cylinder heads.
An effective stainless steel exhaust and muffler system is fitted as standard equipment,
ensuring very quiet operations, which in the Jabiru aircraft have been measured at 62dB
at 1000' full power flyover.
For those owners wanting to fit vacuum instruments to their aircraft the Jabiru engine
design includes an optional vacuum pump drive, direct mounted through a coupling on the
rear of the crankshaft.
The Jabiru engine is manufactured within an Australian Civil Aviation Safety Authority
(CASA) approved Quality Assurance System to exacting standards.
Jabiru recommend a TBO of 2000 hours, with a top end overhaul done at 1000 hours, or
when engine condition indicates the need to overhaul earlier.

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2.4 Details
-4 Stroke
-4 Cylinder Horizontally Opposed
-1 Central Camshaft
-Push Rods
-Over Head Valves (OHV)
-Hydraulic Valve Lifters with Automatic Adjustment
-Ram Air Cooled
-Wet Sump Lubrication
-Direct Propeller Drive
-Dual Transistorised Magneto Ignition
-Integrated AC Generator
-Electric Starter
-Mechanical Fuel Pump
-Naturally Aspirated –1 Pressure Compensating Carburettor
-6 Bearing Crankshaft
2.5 Manufacturer
Jabiru Aircraft Pty Ltd,
P.O. Box 5792,
Bundaberg West,
Queensland 4670
2.6 Manuals
Instruction and Maintenance Manual
Installation Manual
Parts Catalogue
All manuals are available on the Jabiru web site www.jabiru.net.au

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3Specifications
3.1 Engine Models
3.1.1 2200J
- The Jabiru 2200J Engine is certified to the CS-22 Subpart H Design Standard by the
Civil Aviation Safety Authority of Australia.
- The CASA Type Certificate Number for the 2200J Engine is 160-2. Specifications of
the engine are available on the Type Certificate Data Sheet attached to the Type
Certificate.
- At the time of writing, copies of all Type Certificates for Jabiru products are available
from the CASA website - http://www.casa.gov.au/casadata/cota/aust.htm
3.1.2 2200B
- The Jabiru 2200B Engine has been certified as a part of the Jabiru J160-C Aircraft.
- The CASA Type Certificate Number for the J160-C Aircraft is VA-515.
- 2200B engines with a serial number of 22B001 and above are Manufacturer Certified
to the ASTM F2339 design standard.
3.1.3 2200C
- The Jabiru 2200C Engine is certified to the CS-22 Subpart H Design Standard by the
Civil Aviation Safety Authority of Australia.
- The CASA Type Certificate Number for the 2200C Engine is VE-501. Specifications of
the engine are available on the Type Certificate Data Sheet attached to the Type
Certificate.
- At the time of writing, copies of all Type Certificates for Jabiru products are available
from the CASA website - http://www.casa.gov.au/casadata/cota/aust.htm
- The Jabiru 2200C Engine is rated at 60kW (80 hp).
- 2200C engines with a serial number of 22C001 and above are Manufacturer Certified
to the ASTM F2339 design standard.
3.1.4 2200A
- 2200A engines with a serial number of 22A1845 and above are Manufacturer Certified
to the ASTM F2339 design standard.
- Modern Jabiru 2200A Engines are rated at 63kW (85hp). Nominally, this applies to
engines with a serial number above approximately 22A-2068, however any engine
which meets a certain configuration (for example, after an overhaul) will produce this
power level. The power difference compared to older models is due to minor,
evolutionary changes to the engine design.
3.2 General Specifications & Equipment
- Displacement : 2200 cc
- Bore : 97.5 mm
- Stroke : 74 mm
- Compression Ratio : 8 :1
-Direction of Rotation
of Prop Shaft : Clockwise –Pilot’s view – Tractor Applications
- Ramp Weight : 61 kg (134 lbs) Complete including Exhaust,
Carburettor, Starter Motor, Alternator & Ignition
System.
- Ignition Unit : Jabiru dual ignition - breakerless transistorized.

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Battery independent
- Ignition Timing : 25oBTDC
- Firing Order : 1 –3 –2 –4
- DC Output : 10 Amps up to engine S/No. 22A-2661
17 Amps engine S/No. 22A-2661 and 22C-001 onwards
-Fuel Consumption
@ 75% Power : 13 l/hr (3.5 US gal/hr)
- Fuel : AVGAS 100/130. MOGAS with RON Octane
Rating 95 or above may be used if AVGAS is
not available.
- Oil : Aero Oil W Multigrade 15W-50, or equivalent
Lubricant complying with MIL-L-22851C, or
Lycoming Spec. 301F, or Teledyne –
Continental Spec MHF-24B
- Oil Capacity : 2.3 L (2.2 quarts)
- Spark Plugs : NGK D9EA –Automotive
Electrode Gap: 0.55 - 0.6mm (0.022" - 0.024")
- Generator : Jabiru, permanently excited single phase
AC generator with rectifier/regulator
- Carburettor : BING constant depression Type 94/40
- Air Intake Filter : folder paper cartridge type
- Fuel Filtration : 0.1 mm (100 Micron) maximum particle size.
- Fuel Pump : Camshaft driven diaphragm type
- Starting System : Electric 12 V / 1.5 kW
- Oil Filter : RYCO Z 386 or equivalent
3.3 Performance
Static sea level ratings under the following conditions:-
International Standard Atmospheric conditions at sea level.
Aircraft service equipment drives unloaded. (Vacuum Pump not fitted)
Full rich fuel/air mixture.
Maximum cylinder head temperature.
Standard Jabiru air filter and cold air.
Standard exhaust muffler.
3.3.1 Engine Ratings
Table 1 –Engine Ratings
Model:
2200C, 2200B
All Other 2200 Models
Maximum Power
60 kW (80 hp) @ 3300 RPM - ISO
STD Conditions
63 kW (85 hp) @ 3300 RPM -
ISO STD Conditions
Note: These apply only to engines meeting the configurations detailed within this manual.
Fuel Consumption 21 L/hr @ Takeoff/Max Continuous Rating
Oil Consumption 0.1 L/hr (max)

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3.4 Fuel
Fuel: AVGAS 100 LL & AVGAS 100/130
Leaded and Unleaded Automotive Gasoline above 95 Octane RON may be
used if AVGAS is not available
Detailed fuel information is available in Jabiru Service Letter JSL007.
Current Jabiru Service Bulletins & Letters available at www.jabiru.net.au
Oil: The following chart is intended to assist in choosing the correct grade of oil
and must be considered as a guide only. Multiviscosity grades can also be
used as indicated
Average
Ambient Temperature
Mineral
Grades
Ashless Dispersant
Grades
Above 35°C (95°F)
SAE 60
SAE 60
15°C to 35°C
(59°to 95°F)
SAE 50
SAE 50
-17°C to 25°C
(1°to 77°F)
SAE 40
SAE 40
Equivalence of SAE and commonly used Commercial Grade designations:
SAE:
20
30
40
50
60
Commercial:
55
35
80
100
120
3.5 Lubricant
3.5.1 Run in Period
Oil Weight:
80
100
120
Outside Air Temperature
-17°C to 25°C
(1°to 77°F)
15°C to 35°C
(59°to 95°F)
Above 35°C
(95°F)
3.5.2 Normal Operations
Oil Weight:
W80
W100
W120
Outside Air Temperature
-17°C to 25°C
(1°to 77°F)
15°C to 35°C
(59°to 95°F)
Above 35°C
(95°F)
3.6 Cooling System
Free air cooled. Ensure that Ram-air ducts are correctly fitted & located.
The required pressure drop across the cylinders at 1.3 Vs(clean stall speed) is 4.3 cm
(1.7") water gauge, minimum. A minimum of 6cm (2.4”) is recommended at cruise speed.

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3.7 Operating Speeds and Limits
3.7.1 Ground Operating Limits
Idle Speed 900 RPM (set while engine is hot)
Oil Pressure –Idle Min 80 kPa (11 psi)
Max 525 kPa (76 psi)
Oil Temperature: Max. 100°C (212°F)
Max. CHT 180oC (356oF)
Note: If ground temperature limits are reached, shut the engine down or cool it by
pointing the aircraft into wind.
3.7.2 In-Flight Operating Limits
Maximum Speed 3300 RPM
Maximum Continuous Speed 3300 RPM
Idle Speed 900 RPM (set while engine is hot)
Oil Pressure –Normal Operations Min 220 kPa (31 psi)
Max 525 kPa (76 psi)
–Idle Min 80 kPa (11 psi)
–Starting & Warm up Max 525 kPa (76 psi)
Oil Temperature: Min 15°C (59°F)
Max. 118 oC (244°F)
Oil Continuous Temperature 80 - 100°C (176°- 212°F)
Max. CHT (Climb) 200°C (392°F)
Max Continuous CHT (Cruise) 180oC (356oF)
Notes: - Time with CHT at between 180°C and 200°C is not to exceed 5 Minutes
- (Read Cylinder Head Temperature –CHT –under the spark plug nearest
to the exhaust on the hottest cylinder).
EGT Continuous Limits:
EGT (Mid-Range / Cruise): Min 680° - 720°C (1256° - 1328°F)
EGT (Above 70% Power): Min 640° - 680°C (1184° - 1256°F)
Note: An EGT gauge is not included as standard equipment on the Jabiru 2200 engine,
though a system can be supplied as an option.
3.8 Propeller Selection & Specifications
WARNING:
Correct propeller selection, tuning and maintenance are vital for the safe operation
of this engine. The guidance given herein and in the Engine Installation Manual
must be adhered to for safe operation.
Propeller selection is discussed in detail in the Jabiru 2200 Engine Installation Manual.
Many propeller brands and models are not approved by Jabiru Aircraft. Operators
may choose to use these propellers, however they do so at their own risk. For
information on which propellers are approved, please contact Jabiru P/L or our local
representative.
2-bladed, fixed-pitch wooden propellers manufactured by reputable companies are
recommended by Jabiru Aircraft.

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All propellers must be maintained in accordance to the propeller manufacturer’s
requirements in conjunction with Jabiru Aircraft P/L requirements.
A maximum moment of inertia of 0.25 kgm2is recommended for the propeller
assembly.
3.9 Dimensions
Figure 1. Drawing 9404041/1 Engine Dimensions

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3.10 Denomination Of Cylinders
Figure 2. Cylinder Denomination & Firing Order
Cylinder Firing Order: 1 –3 –2 –4
3.11 Distributor Cylinder Map
Figure 3. Distributor Cylinder Map

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3.12 Power Curve
POWER CURVE
20.0
25.0
30.0
35.0
40.0
45.0
50.0
55.0
60.0
65.0
70.0
1500 1700 1900 2100 2300 2500 2700 2900 3100 3300
RPM
kW
50
100
150
200
250
300
350
400
450
Nm
POWER
TORQUE
Figure 4. Power Curve
4 CYLINDER POWER CURVE
20.0
25.0
30.0
35.0
40.0
45.0
50.0
55.0
60.0
65.0
1500 1700 1900 2100 2300 2500 2700 2900 3100 3300
RPM
kW
50
100
150
200
250
300
350
400
450
Nm
POWER
TORQUE
Figure 5. Power Curve, 2200C, 2200B Engines
Note: Multiply Kilowatts (kW) by 1.341 to get Horesepower (hp).
i.e. 63.5 kW x 1.341 = 85 hp.

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4OPERATING INSTRUCTIONS
To ensure that the engine operates reliably, carefully observe all of the operating &
maintenance instructions.
4.1 Pre-Start Checks
Daily Checks (See Paragraph 5.1)
Move throttle position to FULL & check for ease of movement over the entire range.
Return to idle before attempting to start engine.
4.2 Starting Procedure
Note: Activate Starter for a maximum of 20 seconds, followed by a cooling period of 1
minute.
When engine runs, adjust the throttle to achieve smooth running at approximately
1200 RPM. Deactivate Choke. Check Oil Pressure has risen within 5 seconds - if
not, shut down. It is strongly advised to close choke while cranking on first attempt.
Too much choke will cause over fueling in the venturi (“flooding” the engine) and
loss of start.
4.2.1 Cold Engine
Fuel Tap OPEN
Choke ON (in cold conditions less than 20°C)
Fuel Pump ON for 10 seconds then off
Throttle CLOSED to Stop
Master ON
Ignition BOTH ON
Starter PRESS
After an oil change, it is strongly recommended to crank the engine with the ignitions OFF
to obtain oil pressure before turning ignitions ON and attempting to start.
4.2.2 Warm Engine
As for cold start, with the following differences:
Choke OFF
Throttle Slightly “Cracked” from off position (approx 2%).
4.3 Warming Up Period, Ground Test
Start the warming up period with the engine running at 1200 RPM. Continue at 2000 RPM
depending on ambient temperature, until oil temperature reaches 15°C (59°F). Check the
two ignition circuits at 2000 RPM. Note: - RPM with only one ignition should not drop by
more than 100 RPM.
DO NOT apply full power until CHT reaches 100 °C (212°F)
DO NOT apply full power until Oil Temperature reaches 50°C (104°F)
DO NOT allow cylinder heads to rise above 150°C (302°F) during ground running.

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4.4 Take-Off
Climb with the engine at maximum continuous power. Observe Oil & Cylinder Head
Temperatures & Oil Pressure.
Limits must not be exceeded ! ( Max. continuous RPM at Full Throttle is 3300 RPM ).
4.5 Engine Stop
In normal conditions, cooling down the engine during descent & taxiing will permit the
engine to be stopped by switching OFF the ignitions.
4.6 Engine Stop and Start During Flight
Reduce power to 2000 RPM to cool engine for 30 seconds, then to idle. Switch ignitions
OFF. Starting procedure is the same as ground starting, without choke for a warm engine
& with choke for a cold engine. Note: Engine cools quickly with propeller stopped in flight.
Choke will therefore normally be needed to restart.

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5CHECKS ON ENGINE & INSTALLATION
5.1 Daily Checks
Ensure free movement of throttle & choke cables.
Check Oil Level, replenish if necessary.
i) Check oil level by screwing in cap fully before withdrawing
ii) Oil level should be between the MAX & MIN marks - but must never be below
the MIN mark.
iii) Before long periods of operation, ensure that the level is at least at the mid
position.
iv) Difference in the oil quantity between MAX & MIN mark is 0.5 litres (0.528 US
Quarts).
v) See section 13.1 for first 25 hours of Operation.
vi) Overfilling is detrimental to the engine.
Check lubrication & fuel system for leaks.
i) Visually inspect for signs of leakage on the ground where the aircraft was
parked overnight
ii) Inspect the oil cooler for leaks through the cowl opening
iii) Visually inspect the underside of the aircraft for fresh oil or fuel residue.
Check exhaust system for security.
i) Wriggle the exhaust tail pipes by hand, checking for excessive movement,
rubbing on cowls or unusual noises.
With Ignition & Master OFF, and throttle closed, turn propeller by hand & observe
engine for odd noises or heavy movements. Check for regular compression. If
irregular, refer to Trouble Shooting section of this Manual for corrective action.
CAUTION:
Prior to pulling through the propeller by hand, both ignition circuits & the Master
Switch must be switched OFF, the brakes applied and the throttle closed.
WARNING
A hot engine may fire with the ignition/s switched OFF.
DO NOT TURN OVER A HOT ENGINE BY HAND
CAUTION:
A common cause of low compression is poorly sealing valves. Continued operation in this
condition will result in damage to valves, valve seats, valve guides & overhead gear.
Prior to takeoff - follow the Starting & Warm Up procedure, observe the engine
behavior & throttle response.
Check temperatures & pressures. Conduct a short ground test at full power (a few
seconds) (consult aircraft Flight Manual).