Manual Smart M 160/1 Engine Manufacturer: Ecofly GmbH, Germany
November 05 Manual Smart M160 / 1– UL- Engine Ecofly GmbH Page 0 Table of Contents 1. 2. 3. 4. 5. 6. 7. Technical Concept .................................................................... 1 1.1. Description....................................................................... 2 1.2. Engine Layout / Dimensions .............................................. 3 Technical Data ......................................................................... 5 2.1. Technical Data / Key Features ............
November 05 1. Manual Smart M160 / 1– UL- Engine Ecofly GmbH page 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.
November 05 Manual Smart M160 / 1– UL- Engine Ecofly GmbH page 2 1.1.
November 05 o o o o o o Manual Smart M160 / 1– UL- Engine Ecofly GmbH Flanged gearbox with bearingmounted drive shaft Toothed belt drive with adjustable belt tension CNC machined propeller bearing and shaft Centrifugal clutch with metal bushings to reduce torsional vibration Elastically suspended mounting plate for sensors , relay box and ECU 4-point engine mount 1.2.
November 05 Manual Smart M160 / 1– UL- Engine Ecofly GmbH page 4
November 05 2. Manual Smart M160 / 1– UL- Engine Ecofly GmbH page 5 Technical Data 2.1. Technical Data / Key Features 60 KW Capacity (cm³) Stroke / Bore (mm) Compression ratio Cylinders / Valves Spark plugs (per cylinder) Engine weight per DIN (kg) Max. torque (Nm) Max. power output (kW) Max. continuous RPM Max. short-time RPM Max. manifold pressure (bar) Charge air control Oil pump Ventilation Fuel injection / injection pressure Fuel Lambda sensor Anti-knock control Max.
November 05 Manual Smart M160 / 1– UL- Engine Ecofly GmbH 2.2.
November 05 Manual Smart M160 / 1– UL- Engine Ecofly GmbH 2.3.
November 05 Manual Smart M160 / 1– UL- Engine Ecofly GmbH page 8 2.4. Fuels / Fuel System Use only unleaded, min. 95 octane fuel (unleaded Super = standard automotive fuel).
November 05 Manual Smart M160 / 1– UL- Engine Ecofly GmbH page 9 2.5. Lubricants The oil tank has a capacity of about 3.2l. Replace the oil filter when changing the oil. Use suction to withdraw spent oil completely. Ecofly will install an oil bleed screw upon request. The difference between the maximum and minimum oil level amounts to about 0.5l. Note: While topping up oil, ensure that the oil level NEVER exceeds the max. level indicated on the dip stick. Withdraw excess oil by suction if necessary.
November 05 Manual Smart M160 / 1– UL- Engine Ecofly GmbH page 10 2.6. Cooling System / Coolant The coolant is a 50:50 mixture of water and antifreeze/anticorrosive fluid. A 50:50 mixture provides frost protection down to -37°C. At temperatures as low as -45°C, increase the ratio of the antifreeze /anticorrosive fluid to 55% but not higher, since otherwise heat drain will be impeded. Use only antifreeze/anticorrosive fluids recommended by Mercedes -Benz.
November 05 Manual Smart M160 / 1– UL- Engine Ecofly GmbH page 11 Note: o Ensure that the drive axes are perfectly parallel. o Misalignments will provoke damage o NEVER assemble the propeller axle without locating pins . o Do not insert any spacers to extend the engine-propeller distance: this will increase the bending load on the gears beyond permissible limits ! Note that a new belt will initially lose some rubber; this is not indicative of unusual wear.
November 05 Manual Smart M160 / 1– UL- Engine Ecofly GmbH page 12 The diagram below indicates normal temperatures against RPM. The minimum 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 periods, the indicated values can be lower by about 10%. For instance: At 2000 RPM: At 4000 RPM: At 5500 RPM: Min. oil pressure 2.
November 05 Manual Smart M160 / 1– UL- Engine Ecofly GmbH page 13 3.2. Height The turbocharger is configured such that the engine will deliver 60/74KW of power up to 2500m height. Reduce power setting above 2400m 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%) for every 100m increase in height above 2400m. For example, at 3000m, reduce power by 300 RPM (6*50=300).
November 05 Manual Smart M160 / 1– UL- Engine Ecofly GmbH page 14 3.5. ECU / Relay Box 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. temperature on ECU housing: 90°C. Install the relay box and contacts such that they are protected from spray. Moisture will cause contact problems! 4.
November 05 Manual Smart M160 / 1– UL- Engine Ecofly GmbH page 15 4.2. Takeoff Always set full power for takeoff. In addition to observing temperatures, monitor 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! 4.3. Flight Set the desired engine RPM in flight, taking care to avoid as far as possible, RPM ranges where engine running is not smooth.
November 05 5. Manual Smart M160 / 1– UL- Engine Ecofly GmbH page 16 Checks 5.1.
November 05 Manual Smart M160 / 1– UL- Engine Ecofly GmbH page 17 5.4. Checks after 300hrs / 3 years (in addition to 5.1. & 5.3.) o o o o o Renew spark plugs Check compression Renew coolant Until and such time long-term tests are concluded, we strongly recommend renewing the belt to be on the safe side. Contact Ecofly GmbH. after completion of long-term tests we expect a renewal of the belt every 600h (check in advance with Ecofly GmbH) 5.5.
November 05 Manual Smart M160 / 1– UL- Engine Ecofly GmbH page 18 6.7.
