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Ecofly M 160/1 manual

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Table of contents for the manual

  • Page 1

    Manual Smart M 160/1 Engine Manufacturer: Ecofly GmbH , Germany[...]

  • Page 2

    Manual Smart M160 / 1 – UL - Engine July 05 Ecofly GmbH Page 1 Table of Contents 1. Technical Concept .................................................................... 1 1.1. Description ....................................................................... 2 1.2. Engine Layout / Dimensions .............................................. 3 2. [...]

  • Page 3

    Manual Smart M160 / 1 – UL - Engine July 05 Ecofly GmbH page 1 1. Technical C oncept Our engine is a seri es - produced automobile engine from the smart car with belt drive for use as a stationary engine or as an un certified power train for sports aircraft. Engine RPM is reduced with the help of a toothed belt drive . Car - like vibration dampin[...]

  • Page 4

    Manual Smart M160 / 1 – UL - Engine July 05 Ecofly GmbH pag e 2 1.1. Description o 3 - cylinder series engine with turbocharger ; 60KW / 74KW o Fully electronic sequenti al injection o Lambda sensor controlled 3 - way catalytic converter integrated into muffler ( o ption al ) o Electronic knock control using knock sensor o Power control using red[...]

  • Page 5

    Manual Smart M160 / 1 – UL - Engine July 05 Ecofly GmbH pag e 3 o Flanged gearbox wi th bearing - mounted drive shaft o Toothed belt drive with adjustable belt tension o CNC machined propeller bearing and shaft o Centrifugal clutch with metal bushings to reduce torsional vibration o Elastically suspended mounting plate for sensors , relay box a n[...]

  • Page 6

    Manual Smart M160 / 1 – UL - Engine July 05 Ecofly GmbH page 4[...]

  • Page 7

    Manual Smart M160 / 1 – UL - Engine July 05 Ecofly GmbH page 5 2. Technic al Data 2.1. Technical Dat a / Key Features 60 KW 74 KW Capacity (cm ³) 698 Stroke / Bo re (mm) 68 / 66 Compression ratio 9 . 5 ( - 0 . 4) : 1 C ylinder s / V alves 3 c ylinder s ; 2 valves per cylinder Spark plugs ( per cylinder ) 2 Engine weight per DIN (kg) 57 M ax. tor[...]

  • Page 8

    Manual Smart M160 / 1 – UL - Engine July 05 Ecofly GmbH page 6 2.2. Performance and Torque Curve for 60KW Engine[...]

  • Page 9

    Manual Smart M1 60 / 1 – UL - Engine July 05 Ecofly GmbH page 7 2.3. Performance and Torque Curve for 74KW Engine[...]

  • Page 10

    Manual Smart M160 / 1 – UL - Engine July 05 Ecofly GmbH page 8 2.4. Fuels / Fuel System Use only unleaded, min. 95 octane fuel ( unleaded S uper = standard automotive fuel ). Do not use any fuel additives ! Remarks : o Leaded fuels damage not only the catalytic converter but also the l ambda sensor ! The general rule also for engines not fitted w[...]

  • Page 11

    Manual Smart M160 / 1 – UL - Engine July 05 Ecofly GmbH page 9 2.5. Lubricants The oil tank has a capacity of about 3 . 2 l. Replace the oil filter when changing the oil. Use suction to withdraw spent oil completely. E cofly will install an oil bleed screw upon request. The difference between the maximum and minimum oil level amounts to about 0 .[...]

  • Page 12

    Manual Smart M160 / 1 – UL - Engine July 05 Ec ofly GmbH page 10 2.6. Cooling S ystem / Coolant The coolant is a 50:50 mixt ur e of water and antifreeze/anti corrosive fluid . A 50:50 mixture provides frost protection down to - 37°C. At temperatures as low as - 45°C , increase the ratio of the anti freeze /anticorrosive fluid to 55% but not hig[...]

  • Page 13

    Manual Smart M160 / 1 – UL - Engine July 05 Ecofly GmbH page 11 Note : o Ensure that the drive axes are perfectly p arallel . o Misalignments will provoke damage o NEVER assemble the propeller axle without locating pins . o Do not insert any s pacer s to extend the engine - propeller distance: this will increase the bending load on the gears beyo[...]

  • Page 14

    Manual Smart M160 / 1 – UL - Engine July 05 Ecofly GmbH page 12 The diagram below indicates normal temperatures against RPM . The minim um permissible oil pressure is a function of the oil temperature and RPM . See diagram below ( applies to engines when new ) In the engines that have been in operation for longer per iods, the indicated values ca[...]

  • Page 15

    Manual Smart M160 / 1 – UL - Engine July 05 Ecofly GmbH page 13 3.2. H eight The turbocharger is configured such that the engine will deliv er 60/74 KW of power up to 2500m height . Reduce power setting above 2400 m so that the turbocharger does not exceed its maximum rotational speed . As a thumb rule : Reduce power by 50 RPM ( i.e. by about 1%)[...]

  • Page 16

    Manual Smart M160 / 1 – UL - Engine July 05 Ecofly GmbH page 14 3.5. ECU / Rela y B ox Install the ECU so that the rear of the ECU is ventilated by cool ambient air . This arrangement is necessary to drain the heat from active components . Max. t emperatur e on ECU housing : 90°C . Install the relay box a nd contacts such that they are protected[...]

  • Page 17

    Manual Smart M160 / 1 – UL - Engine July 05 Ecofly GmbH page 15 4.2. Takeoff Always set full power for takeoff . In addition to observing temperatures, mon itor especially the indicated oil and manifold pressure . Leave engine at full power until you reach safe flying altitude; since the engine regulates itself, it is not necessary to power down [...]

  • Page 18

    Manual Smart M160 / 1 – UL - Engine July 05 Ecofly GmbH page 16 5.2. Checks after first 25h rs ( in addition to 5.1.) o Check the entire power train for loose or missing nuts and screws. Replace or tighten as necessary. o Check belt, belt tension, propeller drive and propeller bearings o Check air filter o Change oil, renew oil filter o Clean and[...]

  • Page 19

    Manual Smart M160 / 1 – U L - Engine July 05 Ecofly GmbH page 17 5.5. Checks after 1500h rs or 15 years We recommend full engine overhaul after 1500h rs. Contact your engine service station . Since these engines ar e produced in large numbers, it may be cheaper to buy a new engine ( crankcase with power plant a nd cylinder head ) and install it a[...]

  • Page 20

    Manual Smart M160 / 1 – UL - Engine July 05 Ecofly GmbH page 18 6.7. Torque Table All M6 in a luminium: 12 ± 1 Nm All M8 in a luminium: 20 ± 1,6 Nm Engine frame strut to cylinder head : 23 ± 2 Nm Alternator to aggregate frame : 28 ± 2 Nm Starter to crankcase / gearbox : 20 ± 1,6 Nm Mitnehmerscheibe to crankshaft (M10*1): 47Nm ± 2Nm, angle o[...]