HFE GENPOD 100 User manual

OWNER’S
MANUAL
HFE INTERNATIONAL
GENPOD®100
HFEDCN0543
Revision B

1
SPECIFICATIONS........................................2
SAFETY PRECAUTIONS ..............................4
FUEL REQUIREMENTS ...............................5
COMPONENT IDENTIFICATION..................6
INSTALLATION AND STARTING..................9
INSTALLATION.....................................................................................................9
THROTTLE, COMMUNICATION, AND ENABLE SETUP..........................................11
ENGINE STARTING.............................................................................................12
STARTING AGAIN AFTER FIRST START................................................................12
REMOVING THE ENGINE....................................................................................13
INTERFACE SPECIFICATIONS....................14
MAINTENANCE .......................................18
Torque Specifications........................................................................................18
Maintenance Schedule......................................................................................18
Fuel Filter Replacement.....................................................................................19
TROUBLESHOOTING................................21
MAX POWER WORKSHEET......................24
PARTS LIST..............................................27
WARRANTY.............................................28
Document Revision Table
Rev
Description of change
Revised by
Revision
Date
Approved By
Approved
Date
A
Initial Release
KGRATIEN
2021/03/11
DRB
2021/03/11
B
Revised Warm Up CHT
TWEST
2021/07/20
KGRATIEN
2021/07/20
CONTENTS

2
SPECIFICATIONS
Metric
Value (SI)
Value (SAE)
Actual displacement
100 cc
6.1 in3
Momentary Peak Power @ rated
RPM
6.1 kW @ 9000 RPM
8.2 hP @ 9000 RPM
Max Continuous Power
5.5 kW @ 7000 RPM
7.3 hP @ 7000 RPM
Peak Torque @ RPM
7.7 NM @ 6500 RPM
5.7 ft lbs @ 6500 RPM
Max Torsional Impulse
16 NM
11.8 ft lbs
Cruise BSFC @ RPM
564 g/kW-hr @ 6500 RPM
0.93 lb/hP-hr @ 6500 RPM
Idle BSFC @ RPM
708 g/kW-hr @ 3500 RPM
1.16 lb/hP-hr @ 3500 RPM
Do Not Exceed Max RPM
9000 RPM
9000 RPM
Rated (useable) Max RPM
7500 RPM
7500 RPM
Standard Operating RPM Range
2500 –7000 RPM
2500 -7000 RPM
Full System Weight with mufflers
5.54 kg
12.2 lb
Full System Power to Weight
Ratio
1.1 kW/kg
0.67 hp/lb.
Generator Operating RPM
3500 RPM to 8000 RPM
3500 RPM to 8000 RPM
Nominal Current Draw (12V)
0.5 A
0.5 A
Maximum Current Draw (12V)
1 A
1 A
Rated Max CHT
130 °C
270 °F
Do Not Exceed CHT
190 °C
375 °F
CHT after warm up
65 °C
150 °F
Rated Ambient Minimum
-18 °C
0 °F
Rated Ambient Maximum
49 °C
120 °F
Nominal Dynamic Compression
9 bar
130 psi
Compression Ratio
8.5 : 1
8.5 : 1
Time between overhauls
300 Hrs
300 Hrs
Sound Level
TBD
TBD

3

4
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. A safety zone of 3 feet around the propeller should be established in which no person
or object is allowed to enter. Install a guard around the propeller when appropriate.
WARNING
1. Observe all safety precautions when working around the propeller.
2. Exhaust contains poisonous carbon monoxide, a colorless and odorless gas.
Breathing carbon monoxide can cause loss of consciousness and may lead to death.
3. Never run your engine in an enclosed space. Always allow for appropriate
ventilation.
4. Observe precaution around the muffler. The exhaust system gets hot enough to
ignite some materials.
5. Keep flammable materials away from the engine.
6. Gasoline is extremely flammable and is explosive under certain conditions. Do not
smoke or allow flames or sparks where the engine is operating.
SAFETY
PRECAUTIONS

5
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.
Oil Brand:
Red Line
Oil Type:
2 Stroke Racing Oil
Mix Ratio: 40:1
40 parts gasoline to one part oil by
volume.
Fuel Recommendations
The engine was calibrated with standard 87 octane gasoline. Customers may use higher
octane fuel if desired. Non-leaded fuels recommended.
Leaded Fuels Warning: When using leaded fuels, the result will be shorter TBO’s as a
result of lead oxide coking on cylinder and exhaust ports. Leaded fuels will require cylinder,
piston, and port, dressing and inspection every 50 to 100 hours (depending on use case).
Cylinder dressing and cleaning should be done by a trained professional or by HFE
International.
Note: Non-leaded fuels will not require cylinder dressing and may be used continuously until
the suggested TBO.
FUEL
REQUIREMENTS

6
Figure 1. GenPod® Connections and Components
Figure 2. GenPod®Air Filter
COMPONENT
IDENTIFICATION
Fuel Filter
Engine Connector
Generator
Connector
Fuel Connector
Air Filter
Display for
GenPod®
Status
Decompression
Valves

7
Figure 3. Intake Assembly Components
Figure 4: Intake Assembly Components
Throttle Servo
Injector
MAP Fitting
Fuel Fitting

8
Status
Display
Engine Hour Meter
Engine Speed (RPM)
Engine Status (Enabled /
Disabled)
Fault Codes will display in the
place of the standard display.
Faults:
CHT - Cylinder Head
Temperature Sensor Fault
MAT- Manifold air Temperature
Sensor Fault
TPS - No Throttle Command
given or throttle command error
Battery - Power to GenPod®is
too high or too low. See Signal
input limits.
RPM - Crank position sensor
error.
Pump - Fuel pressure problem
NOTE: display data will only show in CAN BUS communication mode

9
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) to include a safety factor.
Figure 5. GenPod®Mounting Interface
INSTALLATION
AND STARTING
Permanently Install
GenPod®Mounting
Interface on Aircraft
with 4x M5 Flat Head
Screws
This Side Up
Allow 4 inches clearance or
more inside the vehicle for
wire strain relief