Jabiru 2200 User manual

INSTALLATION MANUAL
FOR
JABIRU 2200 AIRCRAFT ENGINE
This Manual has been prepared as a guide to correctly install the Jabiru 2200 engine into an
airframe.
Should you have any questions or doubts about the contents of this manual, please contact
Jabiru Aircraft Pty Ltd.
Applicable to Jabiru 2200cc Enginers, S/No. 2068 Onwards (Hydraulic Lifter Type)

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Installation Manual Jabiru 2200 Aircraft Engine
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1TABLE OF CONTENTS
1TABLE OF CONTENTS _________________________________________________ 2
2Description ____________________________________________________________ 5
3Specifications __________________________________________________________ 6
4Operating Limitations ___________________________________________________ 7
5Dimensions ____________________________________________________________ 9
6Denomination Of Cylinders ______________________________________________ 10
7Engine Mount_________________________________________________________ 12
8Controls______________________________________________________________ 14
9Instruments___________________________________________________________ 15
10 Electrical Equipment _________________________________________________ 18
11 Fuel Supply System___________________________________________________ 21
12 Air Intake System ____________________________________________________ 23
13 Exhaust System ______________________________________________________ 24
14 Cooling Systems _____________________________________________________ 25
15 Propeller Selection ___________________________________________________ 26
16 Auxiliary Units ______________________________________________________ 27
17 Appendix A – Wiring Diagrams _________________________________________ 28
18 Appendix B – Supplemantay Information _________________________________ 29
19 Appendix C – Jabiru Engine Installation Tips _____________________________ 30
20 Appendix D _________________________________________________________ 33
21 Typical Installation – Jabiru Engine _____________________________________ 35

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1.1 Table of Figures
Figure 1. Drawing 9404041/1 Engine Dimensions ....................................................................................................... 9
Figure 2. Cylinder Firing Order ................................................................................................................................... 10
Figure 3. Engine Mount Point Locations ..................................................................................................................... 12
Figure 4 Engine Mount Assembly ............................................................................................................................... 13
Figure 5. Wiring Diagram............................................................................................................................................ 18
Figure 6. Regulator Plug.............................................................................................................................................. 20
Figure 7 – Wiring Details ............................................................................................................................................ 28
Figure 8. Intake Detail #1 ............................................................................................................................................ 35
Figure 9. Intake Detail #2 ............................................................................................................................................ 35
Figure 10. Engine Installation #1................................................................................................................................. 36
Figure 11. Coil Cooling Detail #1................................................................................................................................ 36
Figure 12. Coil Cooling Detail #2................................................................................................................................ 37
Figure 13. Engine Accessory Pack Contents ............................................................................................................... 37
Figure 14. Upper Engine Mount Detail ....................................................................................................................... 38
Figure 16 Lower Engine Mount Detail ........................................................................................................................ 39
Figure 17. Engine Mount Detail .................................................................................................................................. 41
Figure 19. Fuel Connections General .......................................................................................................................... 41
Figure 18. Fuel Connection Detail............................................................................................................................... 41
Figure 20. Oil Collector Bottle .................................................................................................................................... 42
Figure 21. Hot Air Plumbing – Incorrect..................................................................................................................... 43
Figure 22 Hot Air Plumbing – Correct ........................................................................................................................ 43
Figure 24. SCAT Hose Detail #1................................................................................................................................. 44
Figure 23. Typical Hot Air Mixer Box ........................................................................................................................ 46
Figure 26. Control Connections to Carburettor............................................................................................................ 46
Figure 27. Balance Tube Detail #1 .............................................................................................................................. 47
Figure 29. Carburettor Balance Tube Nipple............................................................................................................... 47
Figure 31. Oil Temperature Sensor.............................................................................................................................. 48
Figure 32. Oil Pressure Sensor .................................................................................................................................... 48
Figure 33. Tachometer Sensor Installation. ................................................................................................................. 49

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1.2 List of Effective Pages
The dates of issue for original & revised pages are:
Page Revision Date Page Revision Date
1 0 29/6/05 21 0 29/6/05
2 0 29/6/05 22 0 29/6/05
3 0 29/6/05 23 0 29/6/05
4 0 29/6/05 24 0 29/6/05
5 0 29/6/05 25 0 29/6/05
6 0 29/6/05 26 0 29/6/05
7 0 29/6/05
8 0 29/6/05
9 0 29/6/05
10 0 29/6/05
11 0 29/6/05
12 0 29/6/05
13 0 29/6/05
14 0 29/6/05
15 0 29/6/05
16 0 29/6/05
17 0 29/6/05
18 0 29/6/05
19 0 29/6/05
20 0 29/6/05
Issue Notes:

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2Description
2.1 Model
All Jabiru 2200 Engine Models from S/No 2068 on.
2.2 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
2.3 Manufacturer
Jabiru Aircraft Pty Ltd,
P.O. Box 5186,
Bundaberg West,
Queensland 4670
2.4 Manuals
Instruction and Maintenance Manual
Installation Manual
Parts Catalogue

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3Specifications
3.1 General
- 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 Timing : 25oBTDC
- Firing Order : 1 – 3 – 2 – 4
- DC Output : 10 Amps
-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
3.2 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.
3.2.1 Engine Ratings
•Takeoff/Max Continuous 85 hp / 3300 RPM
•Fuel Consumption 21 L/hr @ Takeoff/Max Continuous Rating
•Oil Consumption 0.1 L/hr (max)

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4Operating Limitations
4.1 RPM
Continuous : 3300 RPM / Full Throttle
Recommended Cruise: 2750 RPM – 3100 RPM
4.2 Engine Cooling
Maximum Cylinder Head Temperatures measured under exhaust spark plug.
Maximum Peak Temperature 200ºC (392°F)
Continuous Operation 180ºC (356°F)
4.3 Fuel
4.3.1 Specifications
•Avgas 100LL & Avgas 100/130
•Leaded and Unleaded Automotive Gasoline above 95 Octane RON
4.4 Pressure to Carburettor (above ambient)
•Maximum 20 kPa (3 psi)
•Minimum 5 kPa (0.75 psi)
WARNING – When using auto fuels, ensure all components of the fuel delivery system
are cooled to prevent fuel vaporization.
4.5 Oil
4.5.1 Specifications
Aero Oil W Multigrade 15W-50,
or equivalent Lubricant complying with
MIL-L-22851C, or
Lycoming Spec. 301F, or
Teledyne - Continental Spec MHF-24B
4.5.2 Oil Temperature
•Minimum for Take-off Power 50°C (122°F)
•Maximum 118°C (244°F)
•Continuous 80°C – 100°C (176°F - 212°F)

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4.5.3 Pressure
•Normal Operations: Min 220 kPa (32 psi)
Max 525 kPa (76 psi)
•Idle: Min 80 kPa (12 psi)
•Starting & Warm Up: Max 525 kPa (76 psi)

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5Dimensions
Figure 1. Drawing 9404041/1 Engine Dimensions

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6Denomination Of Cylinders
Figure 2. Cylinder Firing Order
Cylinder Firing Order: 1 – 3 – 2 – 4

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Figure 3. Distributor Cylinder Map

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7Engine Mount
The design of the engine mount must not only take into account the structural loadings but
must make allowances for accessibility of components and the removal of equipment located
at the rear of the engine.
The engine has four engine mounting points located at the rear of the engine (refer to figure
1.0) from which the engine is to be mounted. An optional bed mount may be fitted.
Figure 4. Engine Mount Point Locations
The correct installation is shown below in Figure 4.0

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Figure 5 Engine Mount Assembly
Corrections of the engine alignment may be made using spacers under the rubber cushions.
The maximum spacer thickness on any one mount is 3mm.

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8Controls
This section comprises of the mechanical controls and electrical switches.
8.1 Throttle and Choke
Provisions for the connection of the throttle and choke are made on the carburettor.
Note: Since a pressure compensating carburettor is used there is no mixture control.
8.2 Master Switch, Ignition Switches and Starter Button
The switches are connected as shown by the circuit diagram, on Page 10.

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9Instruments
9.1 Electronic Tachometer
The tachometer picks up on 2 metal tabs attached to the inside of the flywheel. Pickup is of
induction sender type.
9.1.1 Tachometer Wiring
3 Tachometer Negative (3) to Earth
4 Tachometer Positive (4) to Instrument
8 Tachometer to Red Wire tachometer pick-up
7 Tachometer to Black Wire tachometer pick-up
9.1.2 Oil Temperature Gauge
The Oil Temperature Gauge uses an electric probe mounted in the base of the sump. Jabiru
Part No. PI10752N is recommended.
9.1.2.1 Oil Temperature Wiring
Black Oil Temperature Gauge Negative to Earth
Red Oil Temperature Gauge Positive to Instrument
White Oil Temperature Gauge Sensor (S) to Oil Temperature Sensor
(Lower Left Eng Sump)
9.1.3 Oil Pressure Gauge
An electric oil pressure sender is fitted to the engine for an Oil Pressure Gauge. Jabiru Part
No. PI10762N is the recommended gauge.
9.1.3.1 Oil Pressure Wiring
Black Oil Pressure Gauge Negative to Earth
Red Oil Pressure Gauge Positive to Instrument
White Oil Pressure Gauge Sensor (S) to Oil Pressure Sensor (Fwd Top Eng)
9.1.4 Cylinder Head Temperature Gauge
The Cylinder Head Temperature Gauge uses a thermocouple. An audit must be done to
establish the hottest cylinder and the thermocouple probe should be fitted under the exhaust

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spark plug on that cylinder. (Note that number 4 head runs hottest in normal tractor
installations.) Jabiru Part No. PI10732N is the recommended gauge.
9.1.4.1 Cylinder Head Temperature Wiring
Loom and sensor is supplied with the instrument. These must be installed as per directions.
If cable is too long it must be looped as many times as necessary and strapped behind the
instrument panel.
DO NOT CUT TO LENGTH
Ensure that wire is not chaffing on the fibreglass air duct or cooing fins.
No power connection is required.
9.1.4.2 CHT Sender
Temperature of the cold junction for best results should be around 50ºC. Ensure cold
junction is furthest from the thermo couple probe as possible.
9.1.5 Exhaust Gas Temperature Gauge
An 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.
PI0325N is the recommended gauge.

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Figure 6. Wiring Diagram
10 Electrical Equipment
10.1 Alternator
The alternator fitted to the Jabiru 2200 engine is a single phase, permanently excited with a
regulator. The rotor is mounted on the flywheel with the stator 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.
Specifications
Power (Max): 120W Continuous
Note: The electrical system is Negative Earth.
10.2 Regulator
The regulator has been selected to match the voltage and current of the integral alternator.
Only Jabiru Part No. PI10652N should be used. (The regulator output voltage is 14 volts +
0.8 volt.).
Recommended wiring of regulator is positive and negative of the regulator directly to the
battery. A 20A fuse or circuit breaker may be used between the regulator & battery
10.3 Ignition
The ignition unit has dual breakerless transistorised ignition with the magnets mounted on the
flywheel and the coils mounted on the alternator mount plate.
The current from the coils flows to the distributor from where it is distributed to the spark
plugs. (See also Regulator Wiring at Page 12.)
•The ignition is turned off by grounding the coils via the ignition switches.
•The ignition is timed to 25oBTDC
•The temperature limit for the ignition coils is 70oC. 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.
•Coil gaps are set at 0.25mm to 0.30mm (0.010” to 0.012”).
10.3.1 Transistorised Ignition 1 Wiring
No. 1 Switch – Upper to Left Transistorised Ignition
No. 1 Switch – Lower to Earth
Switch Open for Ignition ON, closed for Ignition OFF.

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10.3.2 Transistorised Ignition 2 Wiring
No. 2 Switch – Upper to Right Transistorised Ignition
No. 2 Switch – Lower to Earth
Switch Open for Ignition ON, closed for Ignition OFF.
10.4 Starter Motor
The starter is mounted on the top of the engine and drives the ring gear on the flywheel. The
motor is activated by engaging the starter button (the master switch has to be ON) which trips
the solenoid, hence current flows from the battery to the motor. The cable from Battery to
starter should be minimum 16mm2copper.
10.4.1 Starter Wiring
Starter Button Switch (lower) to Main Bus
Starter Button Switch (upper) to Start Solenoid (through Grommet)
10.5 Battery
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 10 AMP Input.
10.5.1 Battery Cables
Black Starter Motor Mount (Engine Rear) to Battery Negative
Red Battery Positive to Starter Solenoid
Red Starter Solenoid (Switched) to Starter Motor (Part of)
10.6 Additional Wiring Information
10.6.1 Engine Hourmeter Wiring
Red Hourmeter Positive to Positive
Black Oil Pressure Switch to Engine Sump Bolt
Black Hourmeter to Oil Pressure Switch (Fwd Eng Left)
10.6.2 Earth Wiring
Black Battery Earth Negative to Firewall Earth (Engine Bay)
Black Battery Earth Negative to Earth Bus
10.6.3 Master Wiring
Red Starter Solenoid to Main Fuse

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Red Main Fuse to Master Switch (Lower)
Red Master Switch (Upper) to Main Bus
Red Main Bus to Red on Regulator
10.6.4 Fuel Pump Wiring
Red Main Bus to Fuel Pump Fuse
Red Fuel Pump Fuse to Fuel Pump Switch (Lower)
Red Fuel Pump Switch (Upper) to fuel Pump (Red Wire)
Black Fuel Pump (Black Wire) to Earth Bus
10.6.5 Regulator
Pale Blue (No Coding) Pale Blue Wire Regulator plug to one Alternator Wire
Pale Blue (No Coding) Pale Blue Wire Regulator plug to the other Alt. Wire
Black Black Wire Regulator Plug to Earth
Red 10 g Positive to Red Wire Reg. Plug
Yellow 16g Positive to Yellow Wire Reg Plug
Green Not connected – can power a charging light.
Figure 7. Regulator Plug