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Table of Contents
Summary of Contents for HFE INTERNATIONAL GENPOD 70
- Page 1 GENPOD HFE INTERNATIONAL OWNER’S MANUAL HFEDCN0418 Revision A...
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Page 2: Table Of Contents
CONTENTS SPECIFICATIONS ........2 SAFETY PRECAUTIONS ......4 FUEL REQUIREMENTS ....... 5 COMPONENT IDENTIFICATION ....6 INSTALLATION AND STARTING ....9 INSTALLATION .....................9 THROTTLE AND ENABLE SETUP ................11 ENGINE STARTING ..................... 11 STARTING AGAIN AFTER FIRST START ..............12 INTERFACE SPECIFICATIONS .... -
Page 3: Specifications
SPECIFICATIONS Metric Value (SI) Value (SAE) Actual displacement 70 cc 4.27 in Momentary Peak Power @ rated 4.5 kW@ 9000 RPM 6.0 hp @ 9000 RPM Max Continuous Power 3.71 kW@ 7000 RPM 5 hP @ 7000 RPM Peak Torque @ RPM 5 N-m @ 7500 RPM 3.7 ft-lb @ 7500 RPM Max Torsional Impulse... -
Page 5: Safety Precautions
SAFETY PRECAUTIONS General Safety Read and understand this Owner’s Manual before operating your engine. You can help prevent accidents by being familiar with the controls and observing safe operating procedures. Operator’s Responsibility: 1. The operator should know how to stop the engine quickly in case of an emergency. 2. -
Page 6: Fuel Requirements
FUEL REQUIREMENTS Engine Oil This engine was calibrated using Red Line 2 Stroke Racing oil at a mix ratio of 40:1. This oil type and mix ratio should be maintained to ensure that the fuel injection system and engine operates as designed. If Redline oil is not available, use an equivalent 2T quality two stroke oil for best results. -
Page 7: Component Identification
COMPONENT IDENTIFICATION Note: Non-leaded fuels will not require cylinder dressing and may be used continuously until the suggested TBO. Fuel Filter Engine Connector Display for Fuel Connector GenPod Status Generator Connector Figure 1. GenPod Connections and Components Air Filter Figure 2. GenPod Air Filter... - Page 8 Throttle Servo Fuel Fitting Injector MAP Fitting Figure 3. Intake Assembly Components Figure 4. Intake Gasket Order...
- Page 9 Status Display Faults: Engine Hour Meter CHT - Cylinder Head Temperature Sensor Fault Engine Speed (RPM) MAT- Manifold air Temperature Engine Status (Enabled / Sensor Fault Disabled) TPS - No Throttle Command given or throttle command error Battery - Power to GenPod Fault Codes will display in the too high or too low.
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Page 10: Installation And Starting
INSTALLATION AND STARTING INSTALLATION 1. Install the GenPod Interface to your aircraft with 4x M5 flat head screws, ensuring that the attachment can handle up to 23 kg (50 lbs.) of thrust and vibration torque impulses as high as 30 N-m (22 ft-lbs). Permanently Install GenPod Mounting... - Page 11 that there are no sharp edges that the wire harness can chafe on and that the fuel line cannot kink when engine is installed. Connect main harness and PMU inside the aircraft. You may cut and adjust the harness inside the aircraft as needed. Use Mil Spec connectors or similar. Install Engine and fuel connector to the back of the GenPod as shown.
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Page 12: Throttle And Enable Setup
THROTTLE AND ENABLE SETUP 1. Throttle commands use a standard PWM signal. Expected pulse width range from 900µs for closed throttle and 2100µs for wide open throttle. 2. (Throttle kill) When the pulse width from the receiver falls below 960µs (5% throttle), the ECM will remove power to both the injector and ignition system thus stopping the operation of the engine. -
Page 13: Starting Again After First Start
STARTING AGAIN AFTER FIRST START 1. Verify that the throttle setting is at about 30%. 2. The engine should be started using an external hand held starter, or using a built-in starting alternator. Flip starting is an additional option but is not recommended due to possible injuries. -
Page 14: Interface Specifications
INTERFACE SPECIFICATIONS Signal Inputs/Outputs for GenPod Pin Signal Color Description TACH OUT Brown +5V logic-level digital output. This pin has a maximum continuous load of ±20mA. Output signal has a 50% duty cycle. Blue RS-232 Transmit CAN HI White CAN bus signal High ENABLE Green Engine enable signal from Auto Pilot. - Page 15 POWER MANAGEMENT UNIT NODE 1 Signal Color Description AC IN 1 3 Phase input 30VAC to 85 VAC AC IN 2 YELLOW 3 Phase input 30VAC to 85 VAC AC IN 3 BLUE 3 Phase input 30VAC to 85 VAC BATTERY + System battery positive.
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Page 17: Maintenance
MAINTENANCE Torque Specifications Table 2. Torque Specifications Description Torque Type Spark Plug 10 N-m (90 in-lb) NGK CM-6 Prop Bolts 7.3 N-m (65 in-lb) M5 x 70 mm Spinner Bolts 3.4 N-m (30 in-lb) M5 x 120 mm Muffler Bolts 6.8 N-m (60 in-lb) M5 x 20 mm Throttle Body Mounting Bolts... -
Page 18: Fuel Filter Replacement
Fuel Filter Replacement Seal O-ring Figure 7. Push-to-Connect Seal The Genpod is supplied with 2 filters: One 250 micron filtration element that is green and one 48 micron filtration element that is blue. Fuel filters are designed to be installed with a push to connect fitting. - Page 19 Air Filter Replacement WARNING: Air filter installation is critical for protecting the throttle body from foreign objects and dust that may jam the throttle barrel. Make sure the air filter is installed at all times! Replace air filter as needed by unscrewing the hose clamp and pulling the filter off of the throttle body.
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Page 20: Troubleshooting
TROUBLESHOOTING Engine Does Not Start No spark at spark plug(s) Fault Potential Cause Corrective Action Power GenPod power is not 12 V or does Repair or diagnose Power Supply. not have enough current capacity Verify GenPod connector is fully when engine is cranking seated. - Page 21 Miss-firing but not starting (spark is working) Fault Potential Cause Corrective Action Start Rotation Direction Wrong Engine is being turned the wrong If externally started, change rotation for starting. (Review the manual starter to turn opposite label on the engine for correct prop direction.
- Page 22 Lack of “full power” and/or unstable running Fault Potential Cause Corrective Action Engine running well but full power is Various external causes See “Power Worksheet” To determine not as high as expected. if engine is at max power. Engine cuts out at Wide Open Return GenPod to HFE Ignition Coil Failure...
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Page 23: Max Power Worksheet
MAX POWER WORKSHEET Power Available Worksheet Multiply the following percentages together to acquire the total power loss. Use the graphs provided in this section to determine the CHT, MAT electrical power draw, and altitude corrections below. Table 5. Power Available Calculator CHT % MAT % Electrical Draw... - Page 24 What is the altitude you are at when doing the max power check? Use this chart to determine what the engine can output at various altitudes. Determine how much electrical power you are drawing from the generator and PMU system when you are doing the max power test.
- Page 25 When the engine is being tested, record the value for Manifold Air Temperature and use it to determine what the engine power output would be from this chart.
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Page 26: Parts List
PARTS LIST Coming soon. -
Page 27: Warranty
WARRANTY Thank you for choosing an HFE International. Your Total satisfaction is our #1 priority. If you have any questions on the installation and operation of this engine, please contact us directly. Please have your GenPod serial number on hand when calling for service. - Page 28 GenPod System Warranty Your GenPod system is covered with a 1 year warranty by HFE International starting from the date of shipment. This warranty covers defects in workmanship and materials only to include Fuel Pump, wiring, ECM and throttle body.
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