INSTRUCTION AND MAINTENANCE MANUAL FOR JABIRU 2200 ...

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Jabiru Aircraft Pty LtdInstruction & Maintenance ManualJabiru <strong>2200</strong> Aircraft EngineHydraulic Valve Lifter Models2.3 General DescriptionIt is said that "aircraft are designed around available engines".Jabiru believe that the Jabiru range of very light engines offers opportunities for lightaircraft designers to develop a new generation of light aircraft.Jabiru engines are designed to be manufactured in small batch quantities using the verylatest Computer Numerically Controlled (CNC) machine tools. All Jabiru engines aremanufactured and assembled in a very modern factory in Bundaberg where each engineis run in on a Dynometer and calibrated before delivery. The crankcase halves, cylinderheads, crankshaft, starter motor housings, gearbox cover (the gearbox powers thedistributor rotors) and coil mounts – together with many smaller components are machinedfrom solid. The sump (oil pan) is the only casting. The cylinders are machined from bar4140 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 journalsof which are precision ground prior to being Magnaflux inspected. The camshaft ismanufactured from 4140 chrome molybdenum alloy steel – with nitrided journals & cams.The propeller is direct crankshaft driven and does not use a reduction gearbox. Thisfacilitates its light-weight design and keeps maintenance costs to a minimum. Thecrankshaft features a removable propeller flange which enables the easy replacement ofthe front crankshaft seal and provides for a propeller shaft extension to be fitted, shouldthis be required for particular applications. Cylinder heads are machined from solidaluminium billet, thereby providing a substantive quality trail to material source.Connecting rods are machined from 4140 alloy steel and the 45mm big end bearings areof the automotive slipper type.Many components of the engines are sourced from outside Suppliers. These items includecamshaft followers, and the bendix gear in the starter motor. The ignition coils are alsosourced from outside Suppliers, and are modified by Jabiru for their own particularapplication.An integral alternator using rare earth magnets provides alternating current for batterycharging and electrical accessories. The alternator is attached to the flywheel and isdriven 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 magnetsattached to the flywheel. The passing of the coils by the magnets creates the high voltagecurrent which is then transported by high tension leads to the centre post of twoautomotive type distributors (which are simply rotors and caps) before distribution toautomotive spark plugs, two in the top of each cylinder head. The ignition system is fixedtiming and, therefore, removes the need for timing adjustment. The ignition system is fullyredundant, self-generating and does not depend on battery power.The crankshaft is designed with a double bearing at the propeller flange end and a mainbearing between each big end; it therefore does not have flying webs. 48mm mainbearings are also of the automotive slipper type. Thrust bearings are located fore and aftof the front double bearing allowing either tractor or pusher installation.This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled.REVISION 0 1 2 3 4 5 6 7 8 9 Dated : June 2010 Issued By: DPS Page: 8 of 116L:\files\Manuals_For_Products\Engine_Manuals\Transition\JEM2204-9_I&M_unsigned.docx
Jabiru Aircraft Pty LtdInstruction & Maintenance ManualJabiru <strong>2200</strong> Aircraft EngineHydraulic Valve Lifter ModelsPistons are manufactured to Jabiru design by a major manufacturer, they are fitted with 3rings, 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 valverockers mounted on a shaft through a Teflon coated bronze-steel bush. Valve guides aremanufactured from aluminium/bronze, as is found in larger aero engines and highperformance racing engines. Replaceable valve seats are of nickel steel and are shrunkinto 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 viaan 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 beendeveloped by Jabiru to facilitate the cooling of the engine and direct air from the propellerto the critical areas of the engine, particularly the cylinder heads and barrels. The fitmentof these ducts is a great bonus for the home builder or engine installer, as they removethe 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 thesebaffles 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 designteam. RAMAIR ducts are available for tractor or pusher configurations. Special ducts areavailable for certain installations.The engine is fitted with a 1.5 kW starter motor, which is also manufactured by Jabiru andprovides very effective starting. The engine has very low vibration levels, however it is alsosupported by four large rubber shock mounts attached to the engine mounts at the rear ofthe 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 chamberbolted to the sump casting, in which the mixture is warmed prior to entering short inductiontubes 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 62dBat 1000' full power flyover.For those owners wanting to fit vacuum instruments to their aircraft the Jabiru enginedesign includes an optional vacuum pump drive, direct mounted through a coupling on therear 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, orwhen engine condition indicates the need to overhaul earlier.This document is controlled while it remains on the Jabiru server. Once this no longer applies the document becomes uncontrolled.REVISION 0 1 2 3 4 5 6 7 8 9 Dated : June 2010 Issued By: DPS Page: 9 of 116L:\files\Manuals_For_Products\Engine_Manuals\Transition\JEM2204-9_I&M_unsigned.docx
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INSTRUCTION AND MAINTENANCE MANUAL FOR JABIRU 2200 ...

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