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Jabiru Engine
Jabiru Aircraft Engines – 4th Generation

Jabiru engines are designed to be manufactured in small batch quantities using the very latest Computer Numerically Controlled (CNC) machine tools. Majority of the components are machined in Southern Queensland in a network of small companies.

The crankshaft is forged from 4140 chrome molybdenum alloy steel, the journals of which are precision ground prior to being Magna flux inspected. 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 for and aft of the front double bearing allowing either tractor or pusher installation.

The propeller is directly 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.

The camshaft is provided by a specialist camshaft manufacturer.

Cylinder heads are cast aluminium and screwed to aluminium cylinders to form a one piece assembly. There are no cylinder head bolts that are needed to be re-torqued which reduces maintenance. The cylinder barrels are electrolytically coated with silicone carbide (ceramic) in a nickel matrix. This material is very hard wearing and has low friction qualities. The aluminium cylinders have a high heat dissipation rate which is 3 times the rate of the previous steel barrels. Also the aluminium cylinder bores are non-corrosive.

Con rods are forged from 4130 alloy steel, the 45mm big end bearings are of the automotive slipper type and easily replaced.

An integral alternator using rare earth magnets, provides alternating current for battery charging and electrical accessory drive. 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 dual ignition system is self-generating and does not depend on battery power.

Pistons are Jabiru designed. They are manufactured by a specialist piston manufacturer. They are fitted with 3 rings.

Valves are 7mm (stem dia) which are purpose manufactured for the Jabiru engine. The valve gear includes push rods from the roller follower. Valve rockers are forged, through hardened and mounted on a shaft through a pressure lubricated bush. Valve guides are manufactured from bronze. Valve seats are of nickel steel and are shrunk into the aluminium cylinder heads. The valve gear is lubricated from the oil gallery via the hollow push rods.

An internal gear pump, direct mounted on the camshaft and incorporating a small automotive spin-on filter, provides engine lubrication. An oil cooler adapter is provided. All installations require an oil cooler to meet oil temperature limits.

The standard engines are supplied with two RAMAIR 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 RAMAIR cooling ducts is a great bonus for the home builder or engine installer, as this obviate the need to design and manufacture baffles or establish a plenum chamber. A “cleaner” engine installation results, 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 1.2 kw starter motor. 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 pressure compensating carburettor. Following carburation, the fuel/air mixture is transported to a small plenum chamber in 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 quiet operations, which in the Jabiru aircraft have been measured at 62dB at 1000' full power flyover (for 2200 engine).

Jabiru engines are designed and manufactured to ASTM F2339 and within quality assurance standard ASTM F2279 as well as to Australian Civil Aviation Safety Authority (CASA) approved Quality Assurance System exacting standards. Jabiru also holds a Production Certificate and Type Certificate for the 2200C engine.
Engine Philosophy

It is said that "aircraft are designed around available engines".

Jabiru believe that the Jabiru range of very light engines will now offer new 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. The vast majority of the components are manufactured in Southern Queensland in a network of high technology small companies. The crankcase halves, cylinder, crankshaft, starter motor housings, gearbox cover (the gearbox powers the distributor rotors) and coil mounts together with many smaller components are machined using the latest CNC machine tools. The sump (oil pan) is the only casting.

The cylinders are machined from solid bar 4140 chrome molybdenum alloy steel, with the pistons running directly in the steel bores. The crankshaft is also machined from solid bar 4140 chrome molybdenum alloy steel, the journals of which are precision ground prior to being Magna flux inspected. The camshaft is provided by a specialist camshaft manufacturer.

The engine 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 which is purchased directly from one of Australia's largest aluminium companies, as is all alloy used in the engine, thereby providing a substantive quality trail to material source. Con rods are machined from 4130 alloy steel, the 45mm big end bearings are of the automotive slipper type.

An integral alternator using rare earth magnets, provides alternating current for battery charging and electrical accessory drive. 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. It is suppressed to prevent radio interference. 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 for and aft of the front double bearing allowing either tractor or pusher installation.

Pistons are made in Australia and are re-machined to include a piston pin cir clip groove. 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 in England.

The valve gear includes push rods from the camshaft from the camshaft followers to valve rockers which are CNC machined from steel plate, induction hardened and polished on contact surfaces and mounted on a shaft through an aluminium bronze 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 from the oil gallery.

An internal gear pump, direct mounted on the camshaft and incorporating a small automotive spin-on filter, provides engine lubrication. An oil cooler adapter is provided. Most installations require an oil cooler to meet oil temperature limits.

The standard engines are supplied with two RAMAIR 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 RAMAIR cooling ducts is a great bonus for the home builder or engine installer, as they obviate 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 kw starter motor, which is also manufactured by Jabiru and provides very effective starting in all conditions. 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 carburetor. Following carburation, the fuel/air mixture is transported to a small plenum chamber in 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 2200 engine).

For those owners wanting to fit vacuum instruments to their aircraft the Jabiru engine design includes a 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.
CAMit Pty Ltd, the company that supply the engine, hold a registered
AS/NZS ISO 9001:2000 Quality System.

Jabiru engine Warranty* is currently 200 hours or 12 months (which ever comes first) from date of retail sale to customer.

*Conditions apply