Manual
Smart M 160/1
Engine
Manufacturer: Ecofly GmbH, Germany
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. Technical Data ......................................................................... 5
2.1. Principal Dimensions / Data............................................... 5
2.2. Performance and Torque Curve for 60KW Engine ............... 6
2.3. Performance and Torque Curve for 74KW Engine ............... 7
2.4. Fuels / Fuel System.......................................................... 8
2.5. Lubricants ........................................................................ 9
2.6. Cooling system and Coolant .............................................10
2.7. Manifold Intake ................................................................10
2.8. Propeller Gear .................................................................10
3. Operating Limits ......................................................................11
3.1. Water / 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 after 1500hrs or 15 years .....................................17
6. Maintenance............................................................................17
6.1. Oil Circuit ........................................................................17
6.2. Air intake / Air fi lter (Oil in intake system?).........................17
6.3. Compression ...................................................................17
6.4. Spark Plugs.....................................................................17
6.5. Belt Tension ....................................................................17
6.6. Extending Engine Life......................................................17
6.7. Torque Table ...................................................................18
7. Document Version History ........................................................18
Manual Smart M160 / 1– UL- Engine
July 05
1. Technical Concept
Our engine is a series -produced automobile engine from the smart car with belt
drive for use as a stationary engine or as an uncertified power train for sports
aircraft.
Engine RPM is reduced with the help of a toothed belt drive.
Car-like vibration damping is achieved by using a centrifugal clutch with soft
torsion coupling.
Note:
Since this engine is a variant of a serially produced stationary engine, it does not
meet the safety requirements of certified aircraft engines. The engine may
therefore only be used in aircraft types where sudden engine failure does not
endanger safety.
This means that the glide and landing characteristics 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, see Civil Aviation Act (Luft VO) § 6.
The user acknowledges by signing below that engine failure is possible at any
time because the engine is used for a purpose other than designed.
Place......................................... Date:....................................
Signature:..................................................................................................
Furthermore, any modifications to the engine and/or drive pose potential safety
risks. As such, distributors are advised to not undertake any changes prior to
qualified engineering analysis and exhaustive testing!
Any irregularities, anomalies and damage must be immediately reported to the
distributor!
Ecofly GmbH page 1
Signature:....................................................
Manual Smart M160 / 1– UL- Engine
July 05
1.1. Description
Ecofly GmbH page 2
o 3-cylinder series
engine with
turbocharger;
60KW / 74KW
o Fully electronic
sequential
injection
o Lambda sensor
controlled 3-way
catalytic
converter
integrated into
muffler (optional)
o Electronic knock
control using
knock sensor
o Power control
using redundant
potentiometer
and e-gas
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 crankcase
o Belt-driven water pump and alternator
o Electrical starter
o Electrical fuel pump
o Electronic engine control unit (ECU) with relays and 2 sets of cables
Manual Smart M160 / 1– UL- Engine
July 05
o Flanged gearbox with 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 and ECU
o 4-point engine mount
1.2. Engine Layout / Dimensions
Ecofly GmbH page 3
July 05
Manual Smart M160 / 1– UL- Engine
Ecofly GmbH page 4