Ecofly Smart M 160/1, Manual

Page 1: ...Manual Smart M 160 1 Engine Manufacturer Ecofly GmbH Germany ...

Page 2: ... Oil 11 3 2 Height 13 3 3 Manifold Temperature 13 3 4 Manifold Pressure 13 3 5 ECU Relay Box 14 4 Engine Operation 14 4 1 Ignition Warming up 14 4 2 Takeoff 15 4 3 Landing 15 4 4 Switching off 15 5 Checks 15 5 1 Daily Checks 15 5 2 Checks after first 25hrs in addition to 5 1 16 5 3 Checks after 100hrs 1 year in addition to 5 1 16 5 4 Checks after 300hrs 3 years in addition to 5 1 5 3 16 5 5 Checks...

Page 3: ...ristics of the aircraft must not be affected by engine failure proof of which must be produced during aircraft certification Therefore aircraft equipped with this engine must only be flown over such terrain and at altitudes and speeds so that in the event of sudden engine failure safe landing is always possible responsibility for which rests with the pilot Local regulations may apply For Germany s...

Page 4: ...o Dual ignition for maximum smoothness single circuit o Manifold pressure controlled by variable valve timing intercooler o Water cooled turbocharger housing with pressurised lubrication o Thermostat controlled water cooling o Oil circuit with wet sump o Overhead camshaft with maintenance free chain drive o Maintenance free valve control with hydraulic valve play compensators o All aluminium crank...

Page 5: ... 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 and ECU o 4 point engine mount 1 2 Engine Layout Dimensions ...

Page 6: ...Manual Smart M160 1 UL Engine July 05 Ecofly GmbH page 4 ...

Page 7: ...nuous running Max continuous RPM 5800 RPM Max short time RPM 6000 RPM Max manifold pressure bar 0 9 0 1 0 2 1 3 0 1 0 1 Charge air control Map guided Oil pump Chain driven external gear pump wet sump Ventilation Integrated full and partial load ventilation Fuel injection injection pressure Bosch EV6 3 8 bar via intake manifold max 4 8 bar Fuel Min RON 95 super unleaded Lambda sensor Bosch LSF4 Ant...

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 M160 1 UL Engine July 05 Ecofly GmbH page 7 2 3 Performance and Torque Curve for 74KW Engine ...

Page 10: ...ionally o Unleaded Super Plus RON 98 at very high ambient temperatures and limited cooling of charge air this fuel grade might even result in slightly higher performance o We also recommend sulphur free fuels such as Shell Optimax RON 99 very environment friendly and extremely knock resistant o All other fuels even aviation grade fuels will cause irreparable damage to the engine sooner or later o ...

Page 11: ... excess oil by suction if necessary The air exhaust system of this engine is sensitive to excess oil excessive oil levels may even result in irreparable damage to the engine Minimum requirements Use only branded oils of API grade SG and higher Recommended Semi synthetic or synthetic oils are recommended The best oils currently on the market are classified SJ API The best oil you can use for this e...

Page 12: ...pecial measures to ensure that air taken in is not inadvertently preheated by the cooler or the exhaust Since carburettor icing cannot occur in this engine by design being an injection system preheated air is not merely superfluous it actually reduces engine performance If the intake temperature is too high the ECU will automatically reduce engine power output WHICH MAY GIVE RISE TO DANGEROUS SITU...

Page 13: ...f an aircraft when the engine is idling not even when the propeller has stopped turning Always switch off the engine before getting out of the cockpit 3 Operating Limits While the engine is rated for maximum power output of 60 74KW we recommend that the engine power is suitably adjusted for cruise flight to conserve fuel Note that the engine is completely unsuited for aerobatic manoeuvres Do not c...

Page 14: ...gines that have been in operation for longer periods the indicated values can be lower by about 10 For instance At 2000 RPM Min oil pressure 2 0 bar oil temperature 110 C if oil temperature is higher oil pressure will be lower At 4000 RPM Min oil pressure 2 9 bar oil temperature 125 C if oil temperature is higher oil pressure will be lower At 5500 RPM Min oil pressure 3 3 bar oil temperature 135 C...

Page 15: ...ngine power output is lower at 45 55 C while at 60 C the ECU will sharply lower manifold pressure Use Super Plus 98 RON fuel at very high ambient temperatures to prevent the anti knocking system from scaling back ignition If necessary use an electric fan to support cooling in cases where air flow is poor e g in trike applications In general allow uniform air flow on the surface of the intercooler ...

Page 16: ... On Ignition On Starter Operate As soon as the engine starts throttle up sufficiently so that the engine runs smoothly in conjunction with the resonance frequency of the cell propeller Never operate the engine for long periods at low RPM with stationary propeller so as to provoke overheating situations If water temperature touches 100 C on ground increase engine RPM to 2000 for better cooling Allo...

Page 17: ...on to cool the exhaust manifold in order to prevent oil coking After stationary full load operation it is sensible to allow the engine to run for two minutes with propeller engaged at about 2000 RPM to allow it to cool down 5 Checks 5 1 Daily Checks o Remove cowling completely top and bottom halves o Check engine frame and bearing seats gearbox for cracks o Check bearing washers for cracks replace...

Page 18: ...r drive and propeller bearings o Check belt tension must yield 5 10mm in a cold engine when pressed down with a finger adjust if necessary o Change oil renew oil filter o Renew fuel filter o Carefully check fuel system and lines for signs of brittleness check all guides joints and connectors renew ageing components where necessary o Clean air filter renew if necessary o Check for dirt in the inter...

Page 19: ...ll it along with a new e gas unit and turbocharger If the belt pulleys are not severely damaged you will only need to replace three bearings in the gearbox 6 Maintenance Contact Ecofly GmbH until long term tests are concluded If necessary detailed maintenance instructions can be obtained from any smart center website 6 1 Oil Circuit In process 6 2 Air intake Air filter Oil in intake system In proc...

Page 20: ...6 nut 16 Nm 1 Nm Lambda sensor in turbocharger housing 50 Nm 5 Nm Knock sensor to crankcase 20 Nm 1 6 Nm Fuel distributor on manifold M6 8 5 Nm 0 5 Nm Pressure sensor on manifold 5 5 Nm 0 5 Nm E Gas Drosselklappensteller an Saugrohr 8 5 Nm 0 5 Nm Oil line to Turbo screw M8 1 10 Nm 1 Nm Water line to turbocharger M12 5 1 5 19 Nm 1 Nm Spark plugs 20 Nm 2 Nm Drive wheel to crankshaft extension 180 Nm...