A.C. MODULAR
GENERATOR SYSTEM
OWNERS MANUAL
MODEL#: LR-6.2 (60 Hz), LR-8 (60 Hz) and
LR-6.2 (50 Hz)
Smart Power® Systems
A. C. MODULAR GENERATOR SYSTEM
Page 1 of 49
Table of Contents
Section Page
Disclaimer .......................................................................................................................... 5
Description of Product ...................................................................................................... 6
System Specifications ...................................................................................................... 9
Pre-Installation Guide ..................................................................................................... 11
Installation Guide ............................................................................................................ 15
Hose Installation Guidelines .......................................................................................... 17
The Auto-Start Option ..................................................................................................... 23
Operation ......................................................................................................................... 24
Special Operating Instructions ...................................................................................... 33
Maintenance Instructions ............................................................................................... 34
Troubleshooting Guide ................................................................................................... 38
SPS Model Matrix ............................................................................................................ 44
Component Part Number Lists ...................................................................................... 45
LR-6.2 and LR-8 Assembly drawing .............................................................................. 46
LR-6.2 and LR-8 Assembly drawing .............................................................................. 47
Manufacturers Limited Warranty ................................................................................... 48
Doc. 9991032 Rev. G
ECO #15660
Smart Power® Systems
A. C. MODULAR GENERATOR SYSTEM
Page 2 of 49
WARNING:
Do not install or operate the A.C. modular generator system without reading this entire
manual.
The A.C. modular generator system will generate enough voltage to produce a fatal
electrical shock. Do not perform any wiring installations or modifications while the system
is operating. Never touch any live connections while the system is operating. Never
operate the system with the generator wiring enclosure open. Install and secure cover
before operating.
The installation of the Smart Power® A.C. modular generator system is to be done in
accordance with applicable sections in the National Fire Protection Association’s
document NFPA 1901, National Electrical Code®, and/or other applicable, recognized
electrical codes and by a certified electrician.
Never directly expose the generator to any liquids, especially water, oil, or solvents.
Electrical shock, fire and/or damage to the generator can occur and will void the system’s
warranty.
Smart Power hydraulic generators, as well as all generators, must be sufficiently protected
from the environment to prevent damage to the stator. Smart Power stators go through a
very important double-dip coating process prior to generator assembly, however, exposure
to direct water sprays can cause the stator to electrically short. Generator damage and
electrical shock can occur.
Caution should be taken during truck pressure washing, since water damage to the
generator can occur if directly sprayed with high water pressure. Though Smart Power
generators are enclosed as much as possible, direct spray through the cooler, fan or open
lid can still cause such damage.
Excessive road spray/salt can also cause an electrical short of the stator in the generator
and can also shorten the generator’s operating life. To prevent this type of damage, do not
mount the system where it will be exposed to road spray.
Evidence of water damage, road spray/salt infiltration, and improper mounting will void the
generator warranty.
Avoid physical contact with any of the components of the A.C. modular generator system
during its operation or immediately after its use. The components of this system will get
hot enough to cause burns and could ignite combustible materials.
Do not mount or locate anything inside of the framework. System overheating could result
and void the system’s warranty.
Smart Power® Systems
A. C. MODULAR GENERATOR SYSTEM
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Never operate the system with leaks of any type. Clean up any hydraulic fluid that is
spilled or has leaked out of the system. Hydraulic fluid is combustible, and ignition may
occur.
With the exception of oil filter periodic replacement, never modify or remove any of the
components within the tray assembly.
Never modify or remove any of the components within the pump. This includes all fittings
that are originally provided with the A.C. modular generator system.
Never attempt any adjustments or repairs to the A.C. modular generator system while the
vehicle engine is running and the PTO is engaged.
Never operate the system with the hydraulic fluid exceeding 175°F. Above this
temperature, hydraulic fluid can rapidly oxidize and deteriorate causing generator
performance problems. Operating the system while the hydraulic fluid is above 175°F will
void the system’s warranty.
Hydraulic fluid is combustible and toxic. In the event of human contact with hydraulic fluid,
generously flush body part (eyes, skin, etc.) with running water. Avoid inhalation of any oil
mist or vapor. Do not ingest hydraulic fluid. In case of fire, use foam, dry chemical or
carbon dioxide to extinguish flame.
Do not exceed the wattage rating of the generator. The generator may be permanently
damaged and the generator and hydraulic components may reach temperatures that could
cause severe burns upon human contact with the components. Operating the generator
system at wattages above the system’s rating will void the system’s warranty.
Disengage the system immediately if a hydraulic fluid leak is detected. Operation of the
A.C. modular generator system with low fluid level will result in permanent damage to the
hydraulic components in the system and will void the system’s warranty.
Do not attempt to operate the generator with the tray assembly top lid open. Do not
tamper with the top lid interlock switch or the hydraulic fluid level sensor.
Never attempt to operate the system without hydraulic fluid. Always maintain a fluid level
between ½ to ¾ full in the sight gage. When installing the system, fill the hoses with
hydraulic fluid (Dexron III) before engaging the system. Failing to do so will void the
system’s warranty.
Operating the A.C. modular generator system in the presence of flammable vapors may
result in an explosion.
Use only hoses that meet or exceed the minimum requirements specified in this manual.
A ruptured hose can cause personal injury and/or damage to the generator system.
Smart Power® Systems
A. C. MODULAR GENERATOR SYSTEM
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Do not operate the system under electrical load with air in the hydraulic fluid (the system
will make a growling sound). Do not allow anything to contact the hydraulic hoses that will
cause a kink, pinch or chaffing. The A.C. modular hydraulic system generates hydraulic
pressures approaching 3600 psi. A ruptured hose may result from abrasion, discharging
hot, high-pressure hydraulic fluid, which can cause serious personal injury, fire, and/or
damage to the system.
Never remove the guards on the generator to expose the rotating fan or motor coupling.
Personal injury will result if fingers, hair or loose clothing come in contact with rotating
components.
Smart Power® Systems
A. C. MODULAR GENERATOR SYSTEM
Page 5 of 49
Disclaimer
Although SPS has taken all reasonable care to ensure that the information contained in
this installation manual (including without limitation, references, databases, resources,
specifications, illustrations and instructions) was accurate in all material respects at the
time of publication, SPS PROVIDES NO ASSURANCE, REPRESENTATION,
WARRANTY OR GUARANTEE, expressed or implied (including third party liability), with
regard to this manual, including without limiting the generality of the foregoing, with regard
to its accuracy, reliability or completeness. The entire information contained in this
installation manual is provided by SPS “AS IS” and without warranty of any kind, express
or implied, including (but not limited to) any implied warranties or merchantability, fitness
for any particular purpose, or non-infringement. Accordingly, by using the SPS unit and
this information, you agree that, to the greatest extent permitted by law, SPS (including,
without limitation, its subsidiaries, affiliates, agents, officers, directors, employees and
insurers) is not and will not be liable for losses or damages resulting from this installation
manual, its use, any information contained therein or the installation of the SPS unit.
This installation manual contains references to certain database and resources. As SPS
has no control over these database and resources, you acknowledge and agree that SPS
is not responsible or liable for any content, advertising, products, information or other
materials on or available from such database or resources. You further acknowledge and
agree that SPS shall not be responsible or liable, directly or indirectly, for any damage or
loss caused or alleged to be caused by or in connection with use of or reliance on any
such content, information goods or services available on or through any such database or
resources. All product illustrations and specifications are based upon current information
at the time of publication. Although descriptions are believed correct, complete accuracy
cannot be guaranteed. SPS reserves the right to make changes of any kind at any time,
without notice or obligation, in the information contained on this installation manual. All
data and information of any kind are subject to change without notice and SPS assumes
no obligation to update or correct information in this manual.
As some states do not allow the exclusion or limitation of liability for consequential or
incidental damages, the limitation contained herein may not apply to you. In such states,
SPS’ liability is limited to the greatest extent liability limitation is permitted by applicable
law.
Smart Power® Systems
A. C. MODULAR GENERATOR SYSTEM
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Description of Product
Hydraulic Generator Applications:
This heavy-duty electronically controlled generator system has been designed to meet the
most demanding mobile applications. The 60 Hz systems provide 120/240 volt AC @ 6200
or 8000 watts depending on model. The 50 Hz system provides 110/220 volt AC @ 6200
watts.
How our System works:
A generator driven by a hydraulic motor delivers the electrical power. The motor turns at
3000 RPM for the 50 Hz system and at 3600 RPM for the 60 Hz systems as controlled by
the flow of hydraulic fluid through an electrically controlled proportional valve. The
proportional valve is directly driven by the system controller. The gear pump delivers fluid
to the proportional valve through supplied PTO mounted to the vehicle’s transmission.
Heat generated in the hydraulic fluid as it passes through the various components in the
system is cooled by a heat exchanger and fan. A filter removes impurities in the fluid. A
venturi boost assembly monitors the volume of oil in the hydraulic circuit and feeds the
system from the reservoir as needed.
Essentially, the only system maintenance required is periodic replacement of the hydraulic
fluid filter and adding hydraulic fluid to maintain the fluid level (when the hydraulic fluid is
between 70° and 80° F, it should be at the ¾ mark on the sight gauge).
Generator hydraulic and electrical schematics: see Figure 1, and Figure 2.
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A. C. MODULAR GENERATOR SYSTEM
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BOOST BLOCK
FILTER
CASE DRAIN
COOLER
CHECK
VALVE
MOTOR
VENTURI BOOST
x
y
BP
REG
PROPORTIONAL
VALVE
IN
Hydraulic schematic for LR-6.2 and LR-8 generator system
Figure 1
RESERVOIR
PUMP
Smart Power® Systems
A. C. MODULAR GENERATOR SYSTEM
Page 8 of 49
Electrical schematic for LR-6.2 and LR-8 generator systems
Figure 2
MODEL OF
GENERATOR
LR-6.2 (60 Hz)
LR-
8 (60 Hz)
LR-
6.2 (50 Hz)
Generator
Hydraulic
Hydraulic
Type
Speed
Frequency
Voltage
Amperage
Output
Power
Motor
Maximum
Speed
Motor Shaft
Size
Pump
Operating
Pump Speed
Engine Max
Engage Speed
Displacement
Continuous
Pressure (Max)
Peak Pressure
Smart Power® Systems
A. C. MODULAR GENERATOR SYSTEM
System Specifications
AC Inductive
3600 RPM
60 Hz
240 VAC or
120/240 VAC
52A @ 120 VAC or
26A @ 240 VAC
6.2 KW continuous
7.5 KW peak
Gear Type, 8cc
4000 RPM
0.626 inches
9 tooth spline
Gear Type, 23cc
1670-1800 RPM
continuous duty
1500 RPM
23cc per revolution
3408 psi (235 bar)
3698 psi (255 bar)
AC Inductive
3600 RPM
60 Hz
240 VAC or
120/240 VAC
66A @ 120 VAC or
33A @ 240 VAC
8 KW continuous
9 KW peak
Gear Type, 8cc
4000 RPM
0.626 inches
9 tooth spline
Gear Type, 23cc
1670-1800 RPM
continuous duty
1500 RPM
23cc per revolution
3408 psi (235 bar)
3698 psi (255 bar)
Table 1
Page 9 of 49
AC Inductive
3000 RPM
50 Hz
220 VAC or
110/220 VAC
56A @ 110 VAC or
28A @ 220 VAC
6.2 KW continuous
7.25 KW peak
Gear Type, 8cc
4000 RPM
0.626 inches
9 tooth spline
Gear Type, 23cc
1525-1625 RPM
continuous duty
1500 RPM
23cc per revolution
3408 psi (235 bar)
3698 psi (255 bar)
Smart Power® Systems
MODEL OF GENERATOR
LR-6.2
, LR-8
Fan
Hydraulic Oil
Hoses
Dry Weight
Dimension of Tray Asm.
Ambient Operating
A. C. MODULAR GENERATOR SYSTEM
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12 Inch Pusher
Voltage
Amperage
Filter 10 Micron
(recommended)
(alternate)
Maximum Viscosity
Op. Temp. range
(deg. F.)
Pump Output
All Others
12 Volts DC
22 Amps
Dexron III
ISO Approved Hydraulic Oil
4600 SUS (1000mm2/S)
60 SUS (10mm2/S)
-13° F to 195° F
JIC STD
3600 psi, SAE
1250 psi, SAE
Fittings SAE
LR-6.2 190 lbs
(without pump)
Temperature Range
LR-8 220 lbs
33 ¾” L x 15 ¾” W x 13 ¾” H
(Including Reservoir)
0°F to 120°F
Table 1 (cont.)
Smart Power® Systems
A. C. MODULAR GENERATOR SYSTEM
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Pre-Installation Guide
Pre-Installation Check List
WARNING:
Never exceed 1500 RPM engine speed when the PTO is engaged. Doing so will void
the system’s warranty.
Do not approach a running A.C. modular generator when wearing long, loose items
such as hair, jewelry, ties, clothing, etc. Direct contact with a rotating drive shaft
can cause serious personal injury and/or damage to the system.
1. Obtain the following hoses of the necessary length for the installation:
a) Pump inlet hose: 1” SAE 100R1AT-16 hose (use Parker hose ends P/N 10643-
16-16). Note: Maximum hose length is 20’.
b) Pump outlet hose: 5/8” SAE 100R13-10 rated to 4000 PSI (use Parker hose
ends, part number 10671-10-10). Note: Maximum hose length is 20’.
WARNING:
Do not install hose ends until proper hose length has been determined.
Never install a hose in a location where it will rub against another surface or
abrasion member.
Do not position hoses with tight bend radii. Consult the hose manufacturers
installation guidelines. Tight bends may kink and cause serious damage to the
system and will void the system’s warranty.
Use caution when tightening the hose ends to prevent the hose from becoming
twisted.
Never install a 90° fitting at the pump inlet or outlet. Avoid the use of flow
restricting fittings.
Do not form loops in the hose that may collect air or kink. Run hoses as straight as
possible (but not taut) between connections.
Do not exceed hose lengths of 20 feet.
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A. C. MODULAR GENERATOR SYSTEM
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2. SPS models LR-6.2 and LR-8 can be mounted on top of a vehicle, in the open,
without requiring any additional coverings. Reference Figure 3 and Figure 4 for the
minimum clearances around the perimeter of the generator’s tray assembly. Also,
do not position any obstructions directly in front of the system’s oil cooler. If the
system cannot be installed without maintaining the minimum clearances as
indicated, or if you have any questions relative to the installation of these systems,
contact Smart Power® Systems at (231) 832-5525.
12" MINIMUM OBSTRUCTION
FREE CLEARANCE
OIL FILTER
ACCESS PANEL
Front view of LR-6.2 and LR-8 tray assemblies
showing minimum clearance for proper ventilation
Figure 3
Smart Power® Systems
A. C. MODULAR GENERATOR SYSTEM
6" MINIMUM OBSTRUCTION
FREE CLEARANCE
1" MAXIMUM SETBACK FROM
FRONT OF COMPARTMENT
Page 13 of 49
Side view of LR-6.2 and LR-8 tray assemblies
showing minimum clearance for proper ventilation
Figure 4
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A. C. MODULAR GENERATOR SYSTEM
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WARNING:
Do not mount the tray assembly in any location that is not well ventilated. External
heat sources elevating the hydraulic fluid and/or the generator temperature will
result in premature wear and degraded system performance and void the system’s
warranty.
3. The tray assembly must be mounted in a position that is higher than the pump. If
the pump inlet hose is 10’ in length or less, the tray and reservoir assemblies must
be a minimum of 12” higher than the pump. If the pump inlet hose is longer than
10’, elevate the tray and reservoir assemblies an additional 12” for every additional
10’ of pump inlet hose length. See below for examples of minimum tray assembly
elevations above the pump:
Pump inlet hose length
Minimum tray and reservoir elevation
(above pump)
0 – 10 ft. 12 inches
15 ft. 18 inches
20 ft. 24 inches
4. Locate a position to mount the SPS Command & Control Center. The ideal location
for the Command & Control Center will be in an area that is easily seen and
accessed by the generator operator. When the generator system is in use, the
Command & Control Center will continuously show the status of the generator,
including faults (warnings) if they occur. The Command & Control Center can also
be used to engage and disengage the generator. The Command & Control Center
is water sealed, and operates on low voltages so pump house mounting is
permissible. A 15 ft. water sealed harness is provided to connect the Command &
Control Center to the system controller mounted within the generator tray assembly.
See Figure 5 for the dimensions of the Command & Control Center.
4.25
1.375 .45
4.25
Command & Control Center, P/N 1500047B
Figure 5
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A. C. MODULAR GENERATOR SYSTEM
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Installation Guide
1. Refer to the Chelsea PTO Installation Instructions (provided) to mount the
PTO/pump unit on Ford Torqshift Transmission.
2. Locate and bore mounting holes for generator tray assembly as shown in Figure 6.
Maintain minimum clearances as indicated in Figure 3 and Figure 4.
Hole pattern for mounting LR-6.2 LR-8 tray assemblies
Figure 6
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A. C. MODULAR GENERATOR SYSTEM
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3. Mount the tray assembly as high as possible within the structure of the vehicle. The
ideal location for the generator is at the top of the truck in the dunnage area. The
manufacturer must also take sufficient precautions to ensure that the generator is
not mounted in the path of the deck gun/water cannon.
4. Mount the hydraulic generator tray securely to vehicle. Secure the generator to the
floor of the enclosure using mounting hardware (not included), as shown in Figure
7.
1/2-13UNC Screw
1/2” Flat Washer Generator Tray
Dunnage Area
Floor
1/2” Flat Washer 1/2” Lock Washer
1/2-13UNC Nut
Figure 7
WARNING:
Never mount the Generator on its side or upside down. Always mount the generator
upright with its base horizontal. Improper mounting will lead to poor performance
and damage to the system and will void the system’s warranty.
Never operate an AC modular generator system that is not secured in place;
damage will result.
Do not mount the hydraulic pump or tray assembly in any location that is not well
ventilated. External heat sources elevating the hydraulic fluid and/or the generator
temperature will result in premature wear and degraded system performance and
void the system’s warranty.
5. Mount Command & Control Center:
a. Create hole pattern as shown in Figure 8.
b. Mount Command & Control Center to vehicle using #10 stainless steel
fasteners.
c. Connect Command & Control Center to system controller unit using p/n
3722004 harnesses.
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A. C. MODULAR GENERATOR SYSTEM
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3.375
1.688
1.688
3.375
.208
CLEARANCE HOLE
FOR #10 SCREW
4 PL.
2.000
Hole pattern for Command & Control Center
Figure 8
6. Flush the hoses with fresh hydraulic fluid (Dexron III). Install hoses and tighten hose
ends, using the Hose Installation Guidelines. See Figure 31 and for connection
locations.
WARNING:
Lubricate hose fitting O-rings with clean hydraulic fluid (Dexron III) before
installation to prevent damage to them.
Hose Installation Guidelines
Never install a hose without first flushing it with clean hydraulic fluid to remove any
debris.
Never install a hose in a location where it will rub against an abrasive surface or
sharp edge or corner.
Do not position hoses with tight bend radii. Tight bends may kink and cause
serious damage to the system. Consult the hose manufacturer’s guidelines when
installing hoses.
Use caution when tightening the hose ends to prevent the hose from becoming
twisted.
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A. C. MODULAR GENERATOR SYSTEM
Page 18 of 49
Never install a 90° fitting at the pump outlet or inlet.
Never use an inlet line fitting less than 1”.
Never install a hose tightly between connections. Leave length for the hoses to
expand.
Do not form loops in the hose that may collect air or cause kinking. Run hose as
straight as possible (but not taut) between connections.
To keep debris out of hoses while being positioned, cover the ends.
Do not bundle installed hoses tightly together with banding. Hoses must have
freedom to expand.
Do not operate the system with external stresses applied to the hydraulic hoses.
The A.C. modular hydraulic system generates hydraulic pressure approaching 3500
psi. A ruptured hose may result, causing personal injury or damage to the system.
Do not put any substance into the reservoir other than clean, fresh Dexron III
hydraulic fluid. Doing so will void the system’s warranty.
7. Connect the vehicle’s breaker panel to the generator output. The generator is prewired to supply 120/240 VAC for 60 Hz systems or 110/220 VAC for 50 Hz system,
with the generator frame bonded to ground. Route the generator output
conduit/wiring to the breaker panel, and carefully cut the conduit to length without
cutting the wire insulation. A conduit connector has been provided to connect the
conduit to the breaker panel. Connect the (4) four generator output wires to the
breaker panel as follows (see Figure 2 for electrical schematic and wiring diagram):
60 Hz Systems 50 Hz System
Phase A: Black wire (120 VAC) Phase A: Black wire (110 VAC)
Phase B: Red wire (120 VAC) Phase B: Red wire (110 VAC)
Neutral: White wire Neutral: White wire
Ground: Green wire Ground: Green wire
To completely utilize the generator’s output capabilities, the 120 VAC for 60 Hz
systems or 110 VAC or 50 Hz system loads must be equally divided between the
generator’s two main windings. Before wiring the vehicle, calculate the wattage of
each 120 VAC for 60 Hz systems or 110 VAC for 50 Hz system load that will be
connected to the generator. Next, create two groups of loads based on total
wattage (add the individual wattage of each load together). Exchange loads
between the two groups until the total wattage of the two groups is as close as
possible to being equal. Wire the system with one group connected to Phase A
(BLACK) and neutral, with the other group connected to Phase B (RED) and
neutral.
ALTERNATE CONFIGURATION: 120 VAC for 60 Hz systems or 110 VAC for 50
Hz system only: If the application requires 120 VAC for 60 Hz systems or 110 VAC
Smart Power® Systems
110V
A. C. MODULAR GENERATOR SYSTEM
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for 50 Hz system only, the generator terminal strip should be configured as depicted
below. This method ensures balanced loading of the generator, fully optimizing the
system’s capabilities. Make the following wire connections at the terminal strip:
a) place one jumper between wire 1 and wire 3.
b) place the second jumper between wire 2 and wire 4.
c) connect the phase wire from the breaker box to either wire 1 or wire 3.
d) connect the neutral wire from the breaker box to either wire 2 or wire 4.
e) connect the ground wire from the breaker box to the green wire.
60 Hz 50 Hz
WARNING:
To ensure proper voltage regulation, during the operation of generator system, the
load difference between Phase A and Phase B must never exceed 20%. Damage to
generator system caused by operating it with an unbalanced load will void the
system’s warranty.
Wiring of the A.C. modular generator system and electrical distribution throughout
the vehicle must be done in accordance with applicable sections in the National Fire
Protection Association’s document NFPA 1901, the National Electrical Code® and/or
other applicable, recognized electrical code and by a certified electrician.
Smart Power® Systems’ A.C. modular generators are supplied with the neutral
bonded to ground. Refer to National Fire Protection Association’s document NFPA
1901, National Electrical Code
, and/or other applicable recognized electrical codes
before wiring an SPS A.C. modular generator system.
Never wire any loads to the generator’s output without a circuit breaker in series
with the load. Damage to the generator, to the components within that circuit,
electrical shock, or fire may result if a short occurs in an unprotected circuit. Run
all 120 VAC and 240 VAC electrical connections between the generator and the
distribution panel in conduit. Bypassing the SPS factory installed breaker will void
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A. C. MODULAR GENERATOR SYSTEM
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the system’s warranty. Replacement breakers must be obtained from Smart Power®
Systems approved sources only.
Do not perform any wiring installations or modifications while the system is
operating. The A.C. modular generator system will generate enough voltage to
produce a fatal shock.
Never touch any live connections while the system is operating.
Never operate the system with the generator cover removed.
8. Connect 12 VDC (vehicle battery positive) to the generator’s system controller input
(reference Figure 2). Connect the RED wire from the system controller, marked
“Vehicle +12V supply” to the vehicle’s ignition circuit through a 30 amp fuse.
Connect the BLACK wire to the vehicle’s ground (vehicle battery negative).
WARNING:
12 volts DC must be directly applied to the generator system controller whenever
the hydraulic pump is engaged. Failure to do so may cause excessive fluid
temperature, damaging the system components and will void the warranty.
Never come near a running fan with loose items such as long hair, clothing, jewelry,
ties, items that can fall out of pockets, etc.
Do not attempt to operate the generator with the tray assembly top lid open.
Serious personal injury may result if clothing, fingers or other body parts come in
contact with rotating fan blades.
Never operate the system with fan disabled or removed, or with the lid open.
System over-heating will result and this will void the system’s warranty.
Improper wiring of the generator system to the vehicle may discharge the vehicle
battery, cause a fire, or cause improper operation of the generator system.
9. Bleed air from the hydraulic system:
a. Turn off the generator’s main power breaker. See Figure 9.
b. Fill the Gen-set reservoir with fresh Dexron III hydraulic fluid until the sight
gauge is full. As hydraulic fluid begins to fill the hoses, maintain the level of fluid
in the reservoir.
c. Start the vehicle and allow the engine to idle.
d. Ensure the generator purge option is enabled.
Note: The generator is shipped from the factory with the purge option enabled.
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The system controller has been designed to provide a purge option. With this
option applied, the generator will turn at a reduced speed to minimize wear to
the system’s hydraulic components while purging air from the system. Once
enabled, the purge option will remain set until automatically reset by the system
controller. The system controller will reset the option once the following two
conditions are met:
1. The hydraulic system has been purged for a total of at least 30 minutes.
2. Of those 30 minutes, at least 20 minutes occurred with the generator on.
Main power breaker
Figure 9
WARNING:
Never operate the system without the filler/breather plug installed. Contaminants
may enter the hydraulic fluid through the filler opening, causing premature wear on
the hydraulic components and void the system’s warranty.
Never apply a load to the generator while there is air trapped in the hydraulic fluid.
Damage to the system’s hydraulic components, as well as ruptured hoses, may
result and void the system’s warranty.
Always run the purge cycle after installation, after replacing the hydraulic fluid and
the filter, or after making any other repairs that may allow air into the hydraulic
system. Failure to do so will void the system’s warranty.
Smart Power® Systems
Step 4: Press mode to
until
y
appears.
A. C. MODULAR GENERATOR SYSTEM
Page 22 of 49
Enabling System Purge Option
The purge option can also be set by performing the following steps:
Step 3: Hold Mode
until Amps Line 1
Blinks 88. Release
switch so
appears.
0Pt
Step 5: Press On/Off
PvrG
make
appear.
Figure 10
1. If the Command & Control Center is dark, press the Mode switch to put
the display into Normal mode.
2. If the Display looks like Figure 11, The purge option is enabled.
3. Otherwise, press and hold the Mode switch until the Amps Line 1 field
begins blinking 88 (more than 10 seconds). Release the switch so 0Pt
appears. Reference Figure 10.
4. Press (and release) the Mode switch until PvrG appears.
5. Press the On/Off switch until a y appears, indicating Purge option is
Active.
6. Return to system purge display by pressing the Mode switch repeatedly
until the screen shown in Figure 11 is displayed. Purge will still be active.
Indicates whether the
generator is 0n or
0ff
Example of display with purge option set
Figure 11
e. Engage the Power Take-Off (PTO). (Note: Pump may sound rough for a few
minutes due to entrapped air.).
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f. Check for hydraulic fluid leaks, all hose connections must be tight. Monitor the
hydraulic fluid level, adding fluid as needed to keep the level in the sight
gauge full.
g. After 10 minutes, the system controller will automatically switch the generator to
“0N”. Check to see that the generator is turning (The frequency display should
indicate 0n). If it is not, press the On/Off switch on the Command & Control
Center to start the generator.
h. After the generator has been operated for 20 minutes with the generator on, the
system controller will automatically disable the purge option.
i. Turn on the generator’s main power breaker
Verify that the generator’s output frequency is 59-62 Hz for 60 Hz systems or 49-52
Hz for 50 Hz system. If the frequency is not within that range, contact Smart Power
Systems at (231) 832-5525 for more information.
10. Prior to applying full load, and after the oil temperature is above 100°F verify proper
operation of the cooler fan by feeling for airflow being pulled into the cooler and
pushed out by the fan. If the air is not being pulled through the cooler face, contact
Smart Power® Systems at (231) 832-5525 for more information. Also, verify that
the air passing through the cooler and the fan is not restricted.
WARNING:
Improper ventilation will result in system overheating, reduced performance and
possible damage to the system and/or cause personal injury. If the system is
installed such that improper ventilation exists, the system’s warranty will be voided.
The Auto-Start Option
If the auto-start option is enabled, the generator will begin generating electricity
whenever the PTO is engaged. If the auto-start option is disabled, the generator
will not output electricity after PTO engagement until the “on/off” switch is pressed.
Select the auto-start function by performing the following steps:
Smart Power® Systems
appears
A. C. MODULAR GENERATOR SYSTEM
Page 24 of 49
Step b: Hold Mode until
Amps Line 1 Blinks 88.
Release switch so
AStr
and
appear.
0Pt
Step c: Press On/Off
until the desired value
Figure 12
Enabling Auto-Start Option
a. If the Command & Control Center is dark, press the Mode switch to put the
Command & Control Center into Normal mode.
b. Press and hold the Mode switch until the Amps Line 1 field begins blinking 88
(more than 10 seconds). Release the switch so 0Pt and AStr appear.
Reference Figure 12.
c. Press the On/Off switch until the desired value appears. A y means Auto-Start
is enabled, an n means Auto-Start is disabled.
d. Return to Normal mode by pressing Mode.
Operation
1. The Command & Control Center will show the generator’s output voltage,
frequency, current, and system run time whenever the Command & Control Center
is in the Normal mode. To access Normal mode, press the Mode switch repeatedly
until the correct information is displayed (reference Figure 13).
Smart Power® Systems
Mode Switch Status Light
On/Off Switch Status Light
A. C. MODULAR GENERATOR SYSTEM
Page 25 of 49
Example of Command & Control Center in normal mode
Figure 13
2. The PTO driving the SPS hydraulic pump must be engaged for the system to
generate electricity.
3. The Command & Control Center is equipped with two Smart Touch switches,
labeled “Mode” and “On/Off” respectively. These switches do not require pressure
to be activated, but instead sense the presence or absence of your fingertip. The
decimal points in the “Amps Line 1” and “Amps Line 2” fields of the Command &
Control Center are used to indicate the status of the Mode and On/Off switches
respectively (reference Figure 14).
Switch Status Lights
Figure 14
Normally, the status lights will be off. When a switch is pressed, the
corresponding light will be illuminated. When a status light is flashing,
the corresponding switch is calibrating, and the switch should not be
pressed. The system controller will ignore the switch while it is
calibrating.
Smart Power® Systems
Temperature in degrees
A. C. MODULAR GENERATOR SYSTEM
Page 26 of 49
4. If the system controller is powered on, but the generator is not running and no
buttons are pressed for 5 minutes, the system will enter Quiescent mode. In
Quiescent mode all displays are blank to conserve power. To return to Normal
mode from Quiescent mode, press the Mode switch.
5. Whenever the PTO is engaged and the system controller is in Normal or Quiescent
mode, the generator can be switched from an “off” state to an “on” state, and viceversa, by pressing the “on/off” switch on the Command & Control Center. If the
PTO is not engaged, the hydraulic pressure is too low, or the generator enclosure
cover is not closed when the “on/off” switch is pressed, the following two screens
will be displayed alternately (reference Figure 15):
Example of low hydraulic pressure display
Figure 15
6. If the system controller has been set to “auto-start”, the generator will begin to
produce power whenever the PTO is engaged. See installation instructions for the
directions to select the “auto-start” options.
7. Additional Information provided by the Command & Control Center:
a. When the Command & Control Center is in Normal mode, pressing the Mode
switch once will display the oil temperature (reference Figure 16).
Displayed Oil
Fahrenheit
Example of oil temperature display
Figure 16
Smart Power® Systems
configured to operate a generator
whose maximum output is this
A. C. MODULAR GENERATOR SYSTEM
Page 27 of 49
b. When the Command & Control Center is in Normal mode, pressing the Mode
switch twice will cause the amount of time since the oil filter was last changed to
be displayed (reference Figure 17):
Time Since last Oil Filter
Change in Hours.
Example of oil filter run time display
Figure 17
c. When the Command & Control Center is in Normal mode, pressing the Mode
switch three times will cause the configuration of the generator system controller
to be displayed. The “Lr” indicates the controller is configured to run an LR-
series generator, and the number displayed corresponds to the maximum power
output of the generator in kilowatts (reference Figure 18).
The Lr indicates the system
controller is configured to
operate an LR-series
Generator
d. If there are no active faults, pressing the Mode switch once more will return the
Command & Control Center to its normal mode. If there are active faults, they
will be displayed in succession, one each time you press the Mode switch.
See Diagnostics in the trouble shooting section for more information on faults.
The system controller is
number (in kW).
Example of configuration display
Figure 18
Smart Power® Systems
A. C. MODULAR GENERATOR SYSTEM
Page 28 of 49
8. If the system measures a hydraulic oil temperature that exceeds 175°F (79°C), the
system will begin displaying an alarm. If the system measures a hydraulic oil
temperature that exceeds 180°F (82°C), the generator will automatically shut down
in 30 minutes unless the shutdown is overridden. If the temperature of the hydraulic
oil is measured at or above 220°F, the system will immediately shut down whether
or not the high temperature oil warning is overridden. To override the shutdown,
perform the following steps:
Note: The system must measure a hydraulic oil temperature that exceeds 180°F for
this procedure to work.
Step a: Press Mode to
rvn
cause
n
labels to appear.
and the
y
and
Step b: Press On/Off to
answer “yes” and make
the next screen appear.
Example of Command & Control Center in hot oil fault override
Figure 19
a. From the Normal mode display, press Mode, as if you wanted to display the oil
temperature. The screen shown in Figure 19 will be displayed instead, asking if
you want to “Run hot.” This screen will also be displayed if you attempt to start
the generator with the condition present.
b. Note the y and n labels below the Mode and On/Off switches. Press the On/Off
switch to answer “yes” and proceed to the next screen, or press Mode to answer
“no” and proceed to the oil temperature display.
Smart Power® Systems
A. C. MODULAR GENERATOR SYSTEM
Page 29 of 49
Step c: Press On/Off to
answer “yes” and
override the shutdown.
Example of Command & Control Center
in hot oil fault override confirmation
Figure 20
c. If your answer was “yes” in the previous step, the confirmation screen shown in
Figure 20 will be displayed. Again note the y and n labels below the Mode and
On/Off switches. Press the On/Off switch to answer “yes” and override the
shutdown. Press Mode to answer “no” and proceed to the oil temperature
display.
Note: The hydraulic oil is rated for operation at temperatures between -19°F
and 175°F. If you override the system and command it to operate at oil
temperatures above 195°F, the system output power may degrade and you will
void the system’s warranty.
9. If the system detects an insufficient level of hydraulic fluid in the reservoir, it will
begin displaying an alarm. If the generator was running when the fault is detected,
it will automatically be shut down in 30 minutes unless the shutdown is overridden.
To override the shutdown, perform the following steps:
Note: The oil level in the reservoir must be low for this procedure to work.
Step a: Press Mode to
rvn
cause
n
labels to appear.
and the
y
and
Step b: Press On/Off to
answer “yes” and make
the next screen appear.
Example of Command & Control Center in low oil fault override
Figure 21
Smart Power® Systems
A. C. MODULAR GENERATOR SYSTEM
Page 30 of 49
a. From the Normal mode display, press Mode, as if you wanted to display the oil
temperature. The screen shown in Figure 21 will be displayed instead, asking if
you want to “Run [with the] Oil Lo[w].” This screen will also be displayed if you
attempt to start the generator with the condition present.
b. Note the y and n labels below the Mode and On/Off switches. Press the On/Off
switch to answer “yes” and proceed to the next screen, or press Mode to answer
“no” and proceed to the oil temperature display.
Step c: Press On/Off to
answer “yes” and
override the shutdown.
Example of Command & Control Center
in low oil fault override confirmation
Figure 22
c. If your answer was “yes” in the previous step, the confirmation screen shown in
Figure 22 will be displayed. Again note the y and n labels below the Mode and
On/Off switches. Press the On/Off switch to answer “yes” and override the
shutdown. Press Mode to answer “no” and proceed to the oil temperature
display.
Note: If you override the system and command it to operate with insufficient
hydraulic fluid, the system output power may degrade and you will void the
system’s warranty.
10. If the system determines the hydraulic fluid temperature sensor is faulty, it will begin
displaying an alarm. If the generator was running when the fault is detected, it will
automatically be shut down in 30 minutes unless the shutdown is overridden. To
override the shutdown, perform the following steps:
Note: The alarm must be active for this procedure to work.
Smart Power® Systems
A. C. MODULAR GENERATOR SYSTEM
Page 31 of 49
Step a: Press Mode to
rvn
cause
n
labels to appear.
and the
y
and
Step b: Press On/Off to
answer “yes” and make
the next screen appear.
Example of Command & Control Center in temperature sensor fault override
Figure 23
a. From the Normal mode display, press Mode, as if you wanted to display the oil
temperature. The screen shown in Figure 23 will be displayed instead, asking if
you want to “Run [with a] bad tsns [temperature sensor].” This screen will also
be displayed if you attempt to start the generator with the condition present.
b. Note the y and n labels below the Mode and On/Off switches. Press the On/Off
switch to answer “yes” and proceed to the next screen, or press Mode to answer
“no” and proceed to the oil temperature display.
Step c: Press On/Off to
answer “yes” and
override the shutdown.
Example of Command & Control Center
in temperature sensor fault override confirmation
Figure 24
c. If your answer was “yes” in the previous step, the confirmation screen shown in
Figure 24 will be displayed. Again note the y and n labels below the Mode and
On/Off switches. Press the On/Off switch to answer “yes” and override the
shutdown. Press Mode to answer “no” and proceed to the oil temperature
display.
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A. C. MODULAR GENERATOR SYSTEM
Page 32 of 49
Note: If you override the system and command it to operate with a faulty
temperature sensor, the system may overheat and you will void the system’s
warranty.
11. If the system determines the generator output voltage is out of range, it will begin
displaying an alarm. This fault can be detected only when the generator is
operating, and will automatically shut down the generator after 30 minutes unless
the shutdown is overridden. To override the shutdown, perform the following steps:
Note: The alarm must be active for this procedure to work.
Step a: Press Mode to
rvn
cause
n
labels to appear.
and the
y
and
Step b: Press On/Off to
answer “yes” and make
the next screen appear.
Example of Command & Control Center
in voltage range fault override
Figure 25
a. From the Normal mode display, press Mode, as if you wanted to display the oil
temperature. The screen shown in Figure 25 will be displayed instead, asking if
you want to “Rvn [with] bad UOLt[age].”
b. Note the y and n labels below the Mode and On/Off switches. Press the On/Off
switch to answer “yes” and proceed to the next screen, or press Mode to answer
“no” and proceed to the oil temperature display.
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A. C. MODULAR GENERATOR SYSTEM
Page 33 of 49
Step c: Press On/Off to
answer “yes” and
override the shutdown.
Example of Command & Control Center
in voltage range fault override confirmation
Figure 26
c. If your answer was “yes” in the previous step, the confirmation screen shown in
Figure 26 will be displayed. Again note the y and n labels below the Mode and
On/Off switches. Press the On/Off switch to answer “yes” and override the
shutdown. Press Mode to answer “no” and proceed to the oil temperature
display.
Note: If you override the system and command it to operate with voltage out of
range, the system may damage the equipment it is powering and you will void
the system’s warranty.
Special Operating Instructions
Cold Weather Procedure:
If the generator system is “started” when the hydraulic oil temperature is below 40°F, the
following message will be displayed on the Command & Control Center (reference Figure
27):
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A. C. MODULAR GENERATOR SYSTEM
Page 34 of 49
Message advising the
oil is cold (less than
40°F)
Measured oil
temperature in
degrees fahrenheit
Example of Command & Control Center
when operating with cold hydraulic fluid
Figure 27
Operating Modes when the system START button is activated (or when the system is in
“autostart”):
• When the meter displays hydraulic oil temperatures below 20°F, the hydraulic
system will bypass the generator motor and the generator will not produce
power. This mode warms the hydraulic oil.
• When the meter displays hydraulic oil temperatures between 20° and 40°F, the
generator rotor will turn at a reduced RPM and the generator will not produce
power. This warms the hydraulic oil to 40°F.
• When the meter displays hydraulic oil temperatures that exceed 40°F, the
system will then commence full power generating operations.
Maintenance Instructions
WARNING:
Do not perform maintenance while system is running.
1. Perform regular, periodic checks to verify:
a. The cooler, the cooler fan and generator vents are not plugged by debris.
b. There are no fluid leaks within the framework of the generator, along the hoses,
or at the pump.
c. The hoses are not cut, chaffed, bulged or kinked.
d. That no electrical connections are loose.
e. That the hydraulic fluid level in the reservoir is between ½ to ¾ full in the sight
gage and the hydraulic fluid is clean and bright red in color.
f. That the bolts mounting the pump to the PTO are not loose.
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A. C. MODULAR GENERATOR SYSTEM
Page 35 of 49
g. If the hydraulic fluid appears dirty or black in the reservoir sight gage, replace
the fluid and filter immediately. Also, if the hydraulic fluid sustains a temperature
over 175° F, replace the fluid immediately. Oxidation can occur naturally over
time and can be accelerated with over temperature operation, affecting
generator output. Always change the filter when the hydraulic fluid is changed.
WARNING:
When adding or replacing hydraulic fluid, always use clean, new Dexron III fluid.
Do not power wash the generator. Doing so will void the system’s warranty.
Do not allow liquid to enter the generator.
If the outside of the generator requires cleaning, wipe surface with a damp cloth.
Clean the Command and Control Center using soap and water with a soft cloth only.
Improper cleaning, handling and use that may scratch, gouge, chip, fade or
otherwise damage the metallic coating and display surfaces are not covered under
the device warranty.
2. Replace the oil filter after every 250 hours of operation, or every three (3) years
(whichever comes first). Use Dexron III fluid and one of the following filters:
Hydac 0080 MA010 P
Puralator 20101
Fram P-1653-A (10 Micron 8 GPM)
WIX 51551 (10 Micron 8 GPM)
Lubricate the oil filter gasket with Dexron III before installation to permit
proper sealing of the filter.
WARNING:
Do not by-pass the filter or alter filtration plumbing in any way. Doing so will void
the system’s warranty.
3. The system controller automatically records the time from the previous filter change.
The hours since the previous filter change can be accessed using the Command &
Control Center by pressing the Mode switch until the following screen appears
(reference Figure 28):
Smart Power® Systems
,
Procedure will also work
A. C. MODULAR GENERATOR SYSTEM
Page 36 of 49
Press Mode until FLt
and Xr are displayed
Time Since last Oil Filter
Change in Hours.
Example of oil filter run time display
Figure 28
4. The Command & Control Center will flash a fault when 250 hours have passed
since the previous filter change. After replacing the filter, this fault can be removed
from the Command & Control Center, and the filter run time can be reset by
performing the following steps:
Step a: Press Mode until
0IL
and
,
FILt
appear.
InF
in the Oil Filter Hours
Information display
Step b: Hold Mode switch
down and press On/Off three
times in a row to clear the
Example of oil filter service warning display
Figure 29
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A. C. MODULAR GENERATOR SYSTEM
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a. Press the Mode switch repeatedly until one of the screens shown in Figure 29
appears.
b. While holding the Mode switch down, press and release the On/Off switch three
times in succession, then release the Mode switch. The Oil Filter Fault display
will be removed and replaced by another screen. The fault has been cleared
and the timer reset. Note: Perform this step every time the filter is changed.
c. When the timer has been reset, the system automatically enters purge mode to
purge any entrapped air from the hydraulic lines. See Figure 11. The system
must be purged for 30 minutes.
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A. C. MODULAR GENERATOR SYSTEM
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Troubleshooting Guide
Diagnostic:
The Command & Control Center will display certain faults that can assist a service
technician in trouble shooting a problem with the generator system. When these faults
occur, the fault message will periodically flash on the Command & Control Center,
interrupting the normal display. Reference Figure 30 for an example of an over-current
fault.
The faults can also be accessed by repeatedly pressing the mode switch. After displaying
the oil temperature, oil filter time, and configuration, the next display will be the first active
fault. Each time the Mode switch is pressed; the next fault will be displayed. When there
are no more faults to display, the Command & Control Center will return to Normal mode.
Example of high current in Line 1 fault display
Figure 30
Smart Power® Systems
String
Class
Meaning
Service Warning
Alarm
Shutdown
Override
A. C. MODULAR GENERATOR SYSTEM
Page 39 of 49
Diagnostic Faults:
The following is a list of the diagnostic faults, with a brief explanation of each.
uLu CTrL
xI Cvrr
bAd (r 1
bAd (r 2
bAd uoLT
xoT <Temp> Alarm Oil temperature is getting too high (>175° F). Measured
xoT <Temp> Override Oil Temperature is too high (>180° F). Measured Temperature
Add 0il l0
xoT <Temp> Shutdown Oil Temperature dangerous (>220° F). Measured Temperature
bAd Ind
bAd tSnS
bAd Alrt
bAd dISP
LS FAn
0IL FILT
Alarm The control valve feedback is invalid, indicating the system is not
under control. Voltage and/or Frequency may be out of
specifications.
Alarm Overcurrent condition. The line in which the overcurrent
condition exists is indicated by the location of the “xI” string: If in
the “Amps Line 1” field, the overcurrent is in line 1; If in the
“Amps Line 2” field, the overcurrent is in line 2.
Alarm Current sensor fault on line 1. The indicated current may be
incorrect.
Alarm Current sensor fault on line 2. The indicated current may be
incorrect.
Override Voltage Sensor Fault. The indicated voltage may be incorrect.
Temperature in the “Hours” field
in the “Hours” field
Override Oil level in reservoir is low. Add oil to clear the error.
in the “Hours” field
Alarm Indicator Light Ground Fault. The indicator light may not
function properly.
Override Temperature Sensor Fault. The indicated oil temperature may
be incorrect.
Alarm Buzzer Ground Fault. The audible alert buzzer may not function
properly.
Alarm Display Ground Fault. The Command & Control Center may not
operate properly.
Alarm Low Side Fan Short. The Fan may not operate properly
Service
Warning
Service Warning: Change the Oil Filter
Note: The fault “Classes” are defined in the table below:
Table 2
Class Meaning
Normal maintenance needs to take place.
A condition requires the immediate attention of the operator.
A condition causes the immediate shutdown of the generator.
A condition that will cause the generator to be shut down in 30
minutes unless explicitly overridden by the operator.
Table 3
Hydraulic Problems:
1. Cavitation:
Cavitation is caused by trying to pump more fluid than is available at the
pump inlet due to system restrictions. Pump cavitation sounds like “marbles”
passing through the pump. Conditions frequently associated with cavitation are the
following:
a. Too many restrictive fittings such as elbows and reducers on the pump inlet
hose.
b. Tight bends or kinks in pump inlet hose and/or tubing.
c. Insufficient tray height above the pump, resulting in low head pressures.
d. Under sized pump inlet hose (minimum pump inlet hose size is 1”).
e. Excessive long inlet hose (may be corrected by using larger hose).
f. Cold hydraulic fluid.
Finding the cause and correcting it should stop cavitation.
Install a 0-25 psig gauge in line between inlet hose fitting and pump inlet port.
Engage PTO. Operate genset with no load for thirty minutes to purge air out of the
system. Observe the pressure reading. If the pressure is not positive, system
repair/rework is required.
2. Aeration:
Aeration results from air being drawn into the system through leak paths or a
low fluid condition. Aeration makes a “growling” sound and produces visible
bubbles in the fluid stream and/or reservoir. Conditions frequently associated with
aeration are the following:
a. Air leaks in the pump inlet flow path.
b. Low fluid level allowing air to be drawn into the system.
Verify there are no air bubbles in the fluid by viewing inside the reservoir. If there
are air bubbles, check fluid level, tighten all fittings, and look for cracked fittings or
hose leaks on the pump inlet line. Replace any suspect parts and adjust fluid level.
After correcting any problems, again operate the generator thirty minutes to purge
air out of the hydraulic fluid. Note that any bubbles seen in the reservoir indicate
leakage in the pump inlet line.
Smart Power® Systems
A. C. MODULAR GENERATOR SYSTEM
Page 40 of 49
Smart Power® Systems
A. C. MODULAR GENERATOR SYSTEM
3. System Overheating:
System overheating may be caused by re-circulation of hot air through oil cooler,
dirty or obstructed oil cooler fins, restricted hydraulic fluid flow, excessive generator
load, restricted airflow, previously overheated (old) fluid, non-functional fan, or
improperly adjusted pump.
a. Check the oil cooler fins for debris or damage. Clean and/or replace cooler.
b. Verify that the generator load is not excessive.
c. Verify that there is proper ventilation.
d. Verify that the DC fan motor is operating properly.
e. Verify that warm air from the fan outlet is not being re-circulated through the
cooler.
f. Check the hydraulic fluid to see if it is black or darkened. This indicates
overheating or aging. Drain and flush the system.
g. Fill with new, clean hydraulic fluid.
4. Low Hydraulic Fluid Level In Reservoir:
Low hydraulic fluid level in reservoir can be caused by leaking fittings, hoses or
pipes.
a. Check all the fittings for leaks. Tighten any loose fittings that are found (but do
not over-tighten).
b. Replace defective fittings.
c. Check all tubing for leaks. Repair or replace as necessary.
Electrical Problems
1. No Output Voltage:
a. No output voltage may be caused by excessive current draw opening the circuit
breakers. (The circuit breakers can be found mounted on the generator wiring
enclosure.) Remove all electrical loads from the generator and reset breaker(s).
Re-engage electrical load in increments. If possible, monitor current draw with
the Command & Control Center to determine which portion of the load is
causing the breaker to open.
b. The PTO will not engage or is faulty. Contact Smart Power® Systems.
c. The generator’s system controller has lost power (reference Figure 2). The
Command & Control Center would stay dark even after the mode and/or on/off
switch is pressed. Verify that the vehicle +12V supply has both +12 volts and
ground. If 12 volts is not available check the vehicle for a blown fuse or a
loose/open electrical connection.
Page 41 of 49
Smart Power® Systems
A. C. MODULAR GENERATOR SYSTEM
Page 42 of 49
d. The stator field may be shorted or open. With a flashlight, check the generator
windings visible through the ventilation slots. If the windings appear burnt in any
area, the generator must be replaced. If the windings are not burnt, disconnect
wires 1, 2, 3, and 4 from the terminal strip located in the generator wiring
enclosure and make resistance measurement. The resistance between wires 1
and 2, and wires 3 and 4 should be between essentially 0 ohms. Contact Smart
Power® Systems at (231) 832-5525 if any problems are found.
WARNING:
Do not attempt to measure stator field resistance while the system is operating.
Electrical shock may occur.
e. The exciter field may be shorted or open. With a flashlight, check the generator
windings visible through the ventilation slots. If the windings appear burnt in any
area, the generator must be replaced. If the windings are not burnt, disconnect
the exciter field from the field capacitor. Measure the resistance of the exciter
field using an ohmmeter. The resistance of the exciter field should be between
.27 and .29 ohms. Contact Smart Power® Systems at (231) 832-5525 if the
resistance is outside this range.
WARNING:
Do not attempt to measure the exciter field resistance while the system is operating.
Electrical shock may occur.
f. Exciter field capacitor may be faulty. Disconnect the exciter field from the field
capacitor. Using a screwdriver, short leads of capacitor together to discharge
capacitor. Measure capacitance using a capacitance meter. Capacitor should
have capacitance between 47 and 53 microfarads.
WARNING:
Do not attempt to test the field capacitor with the system running. Electrical shock
may occur.
g. The generator drive motor or coupling is faulty. Observe the generator while the
system is engaged. If the coupling is not turning, or if it is turning but the
generator is not, one or more of the coupling components may be damaged and
must be replaced. Also, verify that the coupling halves are mating. If the
coupling halves are not mating, remove the hydraulic motor from the generator
to inspect coupling and the rubber insert between the coupling halves. Replace
components as necessary, reposition and tighten coupling set screw so both
halves of the coupling are mating correctly.
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A. C. MODULAR GENERATOR SYSTEM
Page 43 of 49
h. The pump is faulty. If no faults are found in steps a. through g., the problem is
likely to be a non-functional pump. Contact Smart Power® Systems at (231)
832-5525 for further instructions.
2. Output voltage exceeds 260 volts or falls below 220 volts AC on a 240 volt line
for 60 Hz systems OR output voltage exceeds 240 volts or falls below 200
volts AC on a 220 volt line for 50 Hz system:
a. Verify that the hydraulic system is not overheating by viewing the temperature
as displayed by the Command & Control Center. The temperature should not
exceed 175° F. If the temperature is greater than 175° F, follow instructions for
system overheating (see hydraulic problems).
b. The hydraulic pump speed may be too low. Verify that the engine speed is in
the required range (see Table 1). Adjust the engine speed if necessary.
c. The generator speed may be incorrect. The generator output should be
between 59-61 Hz for 60 Hz systems or 49-52 Hz for 50 Hz system. If it is not,
contact Smart Power® Systems at (231) 832-5525 for further instructions.
d. If the problem is not detected by performing steps a. through c., contact Smart
Power® Systems.
3. Generator Noise:
Generator noise can be caused by defective generator bearings or a faulty
generator/hydraulic motor coupling.
a. Contact Smart Power® Systems if bearings need replacement.
b. Check the generator/hydraulic motor coupling and replace it if necessary.
If problems occur other than those listed call Smart Power® Systems (231) 8325525 for additional assistance.
Smart Power® Systems
COMMAND & CONTROL
RANGE
PUMP DISP.
SHAFT
SHAFT ROTATION
MOTOR DISP.
A. C. MODULAR GENERATOR SYSTEM
SPS Model Matrix
SPS MODEL MATRIX ER - LR SERIES
Page 44 of 49
DESCRIPTION
PARENT P/N
1700806
1700808 GENERATOR, LR-8, W/PTO PUMP, 2004-2010
1701806 GENERATOR, LR-6, W/PTO PUMP, 2011-CUR
1701808
1751806 GENERATOR, LR-6.2, 50 Hz W/PTO PUMP, 2011-CUR
GENERATOR, LR-6, W/PTO PUMP, 2004-2010
GENERATOR, LR-8, W/PTO PUMP, 2011-CUR
CC
CENTER P/N
1500047B 8570106 8510051
1500047B 8570108 8510051 FIXED 23 S R 8
1500047B 8570106 8510141 FIXED 23 S R 8
1500047B 8570108 8510141
1500047B 8575106 8510051 FIXED 23 S R 8
TRAY ASM P/N
PUMP ASM P/N
WR=WIDE RANGE
STD=STANDARD RANGE
XWR=EXTENDED WIDE RANGE
FIXED 23 S R 8
FIXED 23 S R 8
K=KEYED S=SPLINED (STD)
R=CW (STD), L=CCW
Table 4
CC
MANUAL P/N
POWER OUTPUT KILOWATTS
6.2
8
6.2
8
6.2
9991032
9991032
9991032
9991032
9991032
Smart Power® Systems
ITEM NO.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
BREATHER
A. C. MODULAR GENERATOR SYSTEM
Component Part Number Lists
(Reference Figure 31 and Figure 32)
Page 45 of 49
PR. SW.,
FAN
CONT.
PARENT
1700806
1700808
1701806
1701808
1751806
GENER-
ATOR
1500088
1500052
1500088
1500052
1500089
OIL
COOLER
ASM,
FAN
ASM,
FILTER
8591003 3401121 8590012 8594019 8573001 8590000 8574401
8591003 3401121 8590012 8594019 8573001 8590000 8574401
8591003 3401121 8590012 8594019 8573001 8590000 8574401
8591003 3401121 8590012 8594019 8573001 8590000 8574401
8591003 3401121 8590012 8594019 8573001 8590000 8574401
SHADED COLUMNS HAVE DIFFERING PART NUMBERS
TRAY
FILTER
ELEMENT
Table 5
HOUSING
BOOST
HYD.
MOTOR
8505009
8505009
8505009
8505009
8505009
GAUGE,
FLUID
LEVEL
PLUG
OIL RES.
8594660 8574404 8572003
8594660 8574404 8572003
8594660 8574404 8572003
8594660 8574404 8572003
8594660 8574404 8572003
ASM,
PTO/PUMP
8510051
8510051
8510141
8510141
8510141
ELEC.
CONT.
UNIT
PROP.
CONT.
VALVE
8505028 8594463
8505028 8594463
8505029 8594463
8505029 8594463
8505040 8594463
OIL FILTER
ACCESS PANEL
Smart Power® Systems
A. C. MODULAR GENERATOR SYSTEM
CONNECTOR:
12V POWER
RESERVOIR DRAIN
(3/8" HOSE)
BOOST BLOCK OUTLET
(1" HOSE TO PUMP INLET)
Page 46 of 49
CONNECTOR:
REMOTE ENABLE / BUZZER
CONNECTOR:
COMMAND AND CONTROL CENTER
VALVE INLET
(5/8" HOSE FROM PUMP OUTLET)
LR-6.2 and LR-8 Assembly drawing
Figure 31
14
Smart Power® Systems
A. C. MODULAR GENERATOR SYSTEM
Page 47 of 49
15
5
1
10
12
9
8
3
6
4
7
THIS VIEW SHOWN WITH LID REMOVED
11
LID LATCH
(2 EA)
2
LR-6.2 and LR-8 Assembly drawing
Figure 32
Smart Power® Systems
A. C. MODULAR GENERATOR SYSTEM
Page 48 of 49
Manufacturers Limited Warranty
Smart Power® Systems Hydraulic Generator
Coverage period
Provided such goods are operated and maintained in accordance with SPS’s
written instructions, SPS warrants the hydraulic generators manufactured or
supplied by it will be free from defects in material and workmanship for a period
of five (5) years or one thousand (1,000) hours, whichever comes first, from the
date of delivery to the first purchaser. In the case of generators used for rental or
demonstration purposes, this warranty coverage period begins on the date the
generator is first used for such rental or demonstration purposes. This warranty
is extended to all subsequent owners of the generator during the coverage period.
Repair or replacement parts are warranted for ninety (90) days from date of purchase,
excluding labor and travel expenses. Any part repaired or replaced during the warranty
period assumes the remainder of the warranty or ninety (90) days, whichever is greater.
Smart Power® Systems responsibilities
SPS’s obligation under the terms of this warranty is limited to the repair or replacement, at
its option, of the generator or parts of the generator that do not conform to this warranty.
SPS will pay parts costs and reasonable labor expenses (up to the maximum time of two
(2) hours @ $65/hour) associated with the removal, repair and reinstallation of the
generator into the customer’s equipment. For the first two (2) years of coverage, SPS will
pay travel time up to two and one-half (2.5) hours @ $65/hour and mileage cost up to one
hundred (100) miles @ $0.25/mile, if such work is done by an SPS distributor or other
service representative designated by SPS.
Owner’s responsibilities
The owner is obligated to operate and maintain the generator in accordance with the
recommendations published by SPS in the owners manual. The owner is responsible for
the costs associated with such maintenance and any adjustments that may be required.
All claims must be brought to the attention of SPS or an authorized distributor or its
designated service representative within a reasonable time, within fifteen (15) days after
discovery that the generator fails to meet this warranty.
The owner is responsible for payment of any of the following expenses that might be
incurred as a result of a failure under the terms of this warranty:
1. Rental equipment used to replace the equipment being repaired.
2. Telephone or other communication expenses.
3. Living and travel expenses of the person making the repair (other than those
outlined above).
4. The premium costs for overtime labor requested by the owner.
Smart Power® Systems
A. C. MODULAR GENERATOR SYSTEM
Page 49 of 49
5. The cost of airfreight or other extraordinary expenses for shipment of parts over and
above premium surface transportation.
Limitation
SPS is not responsible for the repair of generators that is required because of normal
wear, accident, misuse, abuse, improper installation, corrosion, lack of maintenance,
unauthorized modifications, the use of add-on or modified parts, improper storage or
negligence. The warranty is void if the generator is (a) not properly ventilated as
described in the Owners Manual or (b) is exposed (due to improper installation or location)
to water, salt or abrasive particles such as dirt or heavy dust.
The Owners Manual must be completely followed or the Warranty is void.
Normal wear
This warranty will not cover repair where normal use has exhausted the life of a part or
generator. Generators, like all mechanical devices, need periodic parts replacement and
service to perform well. It should be remembered that the service life of any generator is
dependent on the care it receives and the conditions under which it has to operate. Some
applications are very dusty or dirty, which can cause excessive wear when ingested. Such
wear, when caused by dirt, dust or other abrasive material that has entered the generator
because of improper installation/location is not covered by warranty.
THERE IS NO OTHER EXPRESS WARRANTY.
IMPLIED WARRANTIES, INCLUDING MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PUROSE, ARE LIMITED TO PERIODS OF WARRANTY SET FORTH
ABOVE. TO THE EXTENT PERMITTED BY LAW, ANY AND ALL IMPLIED
WARRANTIES ARE EXCLUDED. NOTE: Some states and provinces do not allow
limitations on how long an implied warranty lasts, so the above limitations may not apply to
you.
IN NO EVENT IS SPS LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.
NOTE: Some states or provinces do not allow the exclusion or limitation of incidental or
consequential damages, so the above limitation or exclusion may not apply to you.
This warranty gives you specific legal rights, and you may also have other rights that may
vary from state to state or province.
No person is authorized to give any other warranties or to assume any other liabilities on
SPS’s behalf, unless made or assumed in writing by an officer of SPS, and no person is
authorized to give any warranties or assume any other liability on behalf of seller unless
made or assumed in writing by seller.
Contact your SPS distributor for questions regarding your warranty rights and responsibilities at (231) 8325525; or visit our website at
www.smartpower.com
.
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