The Kotuku kMAG Engine Management System for Lycoming O-Series Engines

The Kotuku kMAG is a compact and powerful engine management system designed specifically for Lycoming O-Series aircraft engines. It combines a complete engine control unit (ECU) with several other features into a single, integrated package.

Key features of the kMAG:

  • Compact design: The kMAG is a self-contained unit that is easy to install in your aircraft.

  • Generator: The built-in generator can power the ignition and injection systems down to 1500 RPM.

  • Electronic injection: The kMAG supports 4 channels of electronic fuel injection, compatible with the standard mechanical fuel pump on your Lycoming O-Series engine.

  • Waste-spark ignition: The system features 2 channels of waste-spark ignition with compact coil packs mounted on the rear of the kMAG.

  • Single connector: The kMAG uses a single, IP67 lockable connector for all connections.

  • Open-loop system: The kMAG is an open-loop system that does not require a throttle position sensor. However, normal aircraft operating procedures should always be followed when opening the throttle.

| Front | Rear | Side |

Optimum performance with CanFly Commander:

The kMAG can be configured using the CanFly Commander to achieve optimum performance for most aircraft. This software allows for:

Ignition features

  • Programmable ignition: Ignition timing can be programmed in 6 RPM and manifold pressure bands for precise tuning.

  • Non-critical installation: The CanFly Commander software simplifies installation by allowing configuration of the index setting.

  • Programmable dwell timing: The system features a modern high-energy spark system with programmable dwell timing.

  • Starting retard: The starting retard can be set to reduce cranking loads on the starter motor.

  • Battery usage: Battery power is only required for starting the engine. Self-contained unit: The kMAG is a self-contained unit that does not require external sensors on the firewall for timing.

  • Spark plugs: The system uses common automotive 14mm spark plugs and comes with two brass plug adapters per cylinder.

  • Spark plug wires: Spark plug wires are included in each kMAG kit.

Advanced injection features:

The kMAG offers advanced injection features for precise fuel control and engine performance:

  • Individual cylinder programming: Volumetric efficiency for each cylinder can be individually programmed in 6 RPM bands.

  • Flow rate adjustment: The flow rate for each injector can be adjusted to compensate for installation variations.

  • Dual ECU operation: Both ECUs operate in active mode, eliminating a single point of failure.

  • Battery and electric fuel pump: Battery power and an electronic fuel pump are only required for starting.

Other components

A CanFly system is provided with the fuel rail distribution block that has 2 pressure sensors. This is mounted to the top of the engine and the fuel lines are then run to the injectors.

| Side of Manifold | Top of Manifold |

| Installed Manifold | Injectors |

The builder is responsible for installing and routing the fuel lines to the distribution block, and to the supplied injectors.

Injectors

Kotuku can supply 3 different sizes of injectors depending on the model of engine to be used.

  • 350cc/Min: For O-235/O-290 engines.

  • 750cc/Min: For O-320/O-340/O-360 parallel valve engines.

  • 1000cc/Min : For O-360 Angle valve/O-375/O-390 and larger engines.

The injectors are all Bosch Motorsport EV-14 long nose injectors.

Cyl 1 Injector

CanFly® bus published data

A feature of the CanFly® system is that each unit published comprehensive information that can be displayed on a range of devices, or stored in a data logger. The kMAG publishes the following information continually:

Information Comment
Operational hours Hours that the ECU has be running (>50 rpm)
RPM ECU Rpm
MAP Manifold pressure
IAT Inlet air temperature
V Generator/bus voltage
Temp Current ECU temperature, max operating id 80°C
Max Temp Maximum recorded temperature
Fuel pressure Current fuel pressure at the distribution block
Mixture lever Current mixture position 0-100%
Ignition dwell Current ignition dwell
Ignition advance Current ignition advance
Injector dwell Dwell for each of the injector channels

The kMAG and kEDU cooperate and also generate the following data:

Information Comment
MAP Divergence Difference between each kMAG MAP reading
IAT Divergence Difference between each kMAG IAT reading
FUELP Divergence Difference between each kMAG Fuel Pressure
ADV Divergence Difference between each kMAG ignition advance

The kMAG and kEDU also generate alarms that can be shown on the engine instruments:

Alarm Comment
RPM Reported RPM divergence too great
MAP Reported MAP divergence too great
IAT Reported IAT divergence too great
Timing Divergence between the left and right ignition too great
ECU Temp The temperate on an ECU is too high
Fuel Pressure The fuel pressure is too high or too low

Standard parts

The kMAG is designed to use the standard Lycoming non-impulse gear drive part number LW-15659/68C19622. Generally one can be recovered from the right magneto in an installation while the second must be purchased. These are available from Aircraft Spruce.

The fuel pump, both electronic and mechanical must be 2Bar pumps. The Lycoming fuel pump LW15473 or other can be purchased from Aircraft Spruce.

The electonic fuel pump is used to start the engine, this differs from the standard Lycoming operation. A suitable pump is the Andair Fuel Boost Pump.