Smart power HR-6.2 User manual

9991035 Rev. N
A.C. MODULAR
GENERATOR SYSTEM
OWNERS MANUAL
MODEL#: HR-6.2, HR-8, HR-10 and HR-110

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A. C. MODULAR GENERATOR SYSTEM Page 1 of 56
Table of Contents
Section Page
Disclaimer..........................................................................................................................5
Description of Product......................................................................................................6
System Specifications......................................................................................................9
Pre-Installation Guide.....................................................................................................13
Installation Guide............................................................................................................20
Hose Installation Guidelines .......................................................................................... 25
Operation......................................................................................................................... 32
Special Operating Instructions ......................................................................................39
Maintenance Instructions............................................................................................... 40
Troubleshooting Guide...................................................................................................43
Pump Adjustment............................................................................................................ 52
SPS Model Matrix............................................................................................................56
Doc. 9991035 Rev. N
ECO # 16417

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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. Nevertouch 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
Systems®(SPS) 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.

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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 instructions within this manual, never modify or remove any of the
components within the tray assembly.
Never modify or remove any of the components within the pump or the controls mounted to
the pump. This includes all fittings and tubing that are originally provided with the A.C.
modular generator system.
Never make any adjustments to the pump other than for flow control. If it appears the pump
needs to be adjusted, contact Smart Power Systems®at [phone] before proceeding.
Damage to the generator from improper pump adjustment will void the system’s warranty.
Never attempt any adjustments or repairs to the A.C. modular generator system (other than
pump flow control) while the vehicle engine is running and the PTO is engaged.
Never operate the system with the hydraulic fluid exceeding 195  F. Above this temperature,
hydraulic fluid can rapidly oxidize and deteriorate causing generator performance problems.
Operating the system while the hydraulic fluid is above 195  Fwill 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 d
amaged 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 tamper with 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 plug.
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.
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

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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.

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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.

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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. It provides 120/240 volt AC @ 60 Hz, or 115/230 volt
AC @ 50hz from no-load to full load, handling electrical loads of 6200, 8000 and 10000
watts, depending on model.
How our System works:
A generator driven by a hydraulic motor delivers the electrical power. The motor turns at
3600 RPM for 60hz, or3000 RPM for 50hz 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 piston pump delivers fluid to the proportional valve through installer-
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: Reference Figures 1 and 2.

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CASE DRAIN
xy
RESERVOIR
PUMP
PROPORTIONAL
VALVE
CASE DRAIN
MOTOR
COOLER
FILTER
BOOST BLOCK
VENTURI BOOST
CHECK
VALVE
IN
BP
REG
Figure 1 –Hydraulic Generator Schematic for HR-6.2, HR-8, HR-10 and HR-110

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Figure 2 –Generator Electrical Schematic for HR-6.2, HR-8, HR-10 and HR-110

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System Specifications
MODEL OF
GENERATOR
HR-6.2
HR-8
HR-10
HR-110
Generator
Type
Speed
Frequency
Voltage
Amperage
Output
Power
AC Inductive
3600 RPM
60 Hz
120/240 VAC or
120 VAC
52A @ 120 VAC or
26A @ 240 VAC
6.2 KW continuous
7.5 KW peak
AC Inductive
3600 RPM
60 Hz
120/240 VAC or
120 VAC
67A @ 120 VAC or
34A @ 240 VAC
8 KW continuous
9 KW peak
AC Inductive
3600 RPM
60 Hz
120/240 VAC or
120 VAC
84A @ 120 VAC or
42A @ 240 VAC
10 KW continuous
12 KW peak
AC Inductive
3600 RPM
60 Hz
120/240 VAC or
120 VAC
84A @ 120 VAC or
42A @ 240 VAC
10 KW continuous
12 KW peak
50hz
Generator Type
Speed
Frequency
Voltage
Amperage
Power
Output
AC Inductive
3000 RPM
50Hz
230 VAC or
115/230 VAC
70A @ 115 VAC or
35A @ 230VAC
8 KW continuous
9 KW peak
Hydraulic
Motor
Maximum
Speed
Motor Shaft
Size
Port Size
Gear Type, 8cc
4000 RPM
0.626 inches
9 tooth spline
7/8” – 14 SAE
7/8” – 14 SAE
Gear, 8cc or 11cc 50hz
4000 RPM
0.626 inches
9 tooth spline
7/8” – 14 SAE
7/8” – 14 SAE
Gear Type, 11cc
4000 RPM
0.626 inches
9 tooth spline
7/8” – 14 SAE
7/8” – 14 SAE
Gear Type, 11cc
4000 RPM
0.626 inches
9 tooth spline
7/8” – 14 SAE
7/8” – 14 SAE

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Hydraulic
Pump
Operating
Speed
Standard Shaft
Optional Shaft
Mounting
Flange
Displacement
Continuous
Pressure (Max)
Peak Pressure
Standard
Rotation
Dry Weight
Piston w/pressure
compensated control
880-3000 RPM
continuous duty
SAE B 7/8”-13
Tooth Spline
SAE 1” parallel with key
SAE B-B 1” 15T Spline
SAE B-2 bolt mount
45cc per revolution
3500 psi (250 bar)
4600 psi (315 bar)
Engine right-hand
rotation (opposite
engine rotation
available upon request)
46 lbs
Piston w/pressure
compensated control
880-3000 RPM
continuous duty
SAE B 7/8”-13
Tooth Spline
SAE 1” parallel with key
SAE B-B 1” 15T Spline
SAE B-2 bolt mount
45cc per revolution
3500 psi (250 bar)
4600 psi (315 bar)
Engine right-hand
rotation (opposite
engine rotation
available upon request)
46 lbs
Piston w/pressure
compensated control
1100-3000 RPM
continuous duty
SAE B 7/8”-13
Tooth Spline
SAE 1” parallel with key
SAE B-B 1” 15T Spline
SAE B-2 bolt mount
45cc per revolution
3500 psi (250 bar)
4600 psi (315 bar)
Engine right-hand
rotation (opposite
engine rotation
available upon request)
46 lbs
Piston w/pressure
compensated control
850-2700 RPM
continuous duty
SAE B-B 1” 15
Tooth Spline
SAE 1¼” parallel with key
SAE B-2 bolt mount
60cc per revolution
3500 psi (250 bar)
4600 psi (315 bar)
Engine right-hand rotation
(opposite engine rotation
available upon request)
51 lbs

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Table 1
MODEL OF GENERATOR
HR-6.2, HR-8
HR-10, HR-110
Oil Cooler
Dimensions (Core)
9.75”D x 22.6” W x 2.25” H
9.75”D x 22.6” W x 2.25” H
Fan
Voltage
Amperage
12 Inch Pusher
12 Volts DC
22 Amps
12 Inch Pusher
12 Volts DC
22 Amps
Filter
10 Micron
10 Micron
Hydraulic Oil
(recommended)
(alternate)
Op. Temp. range
(deg. F.)
ISO Approved Hydraulic Fluid
Dexron III
-13° F to 195° F
ISO Approved Hydraulic Fluid
Dexron III
-13° F to 195° F
Hoses
Motor Inlet
All Others
3600 psi, SAE
1250 psi, SAE
3600 psi, SAE
1250 psi, SAE
Hose Fittings
JIC STD
JIC STD
Dry Weight
(without pump)
HR-6.2 255 lbs
HR-8 255 lbs
HR-10 280 lbs
HR-110280 lbs
Dimension of Tray Asm.
32” L x 13.5” W x 17” H
(Including Reservoir)
32” L x 13.5” W x 17” H
(Including Reservoir)
Ambient Operating
Temperature Range
0F to 120F
0F to 120F

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Table 1 (cont.)

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Pre-Installation Guide
Pre-Installation Check List
1. Verify that the Power Take Off (PTO) and the pump rotations match.
To identify the pump rotation, check the pump part number found on the metal tag
attached to side of the pump. A right hand rotating pump (the standard pump offered
by Smart Power®Systems), will have the letter “R” in its part number.
Example: A10VO (45 or 60) DFR-1/52 R PUC.
A left hand rotating pump will have the letter “L” in its part number.
Example: A10VO (45 or 60) DRF-1/52 L PUC.
Depending on genset model, a 45cc or 60cc pump is supplied. To determine the PTO
rotation, check the PTO manufacturer’s specification or observe the PTO when it is
engaged with the vehicle’s engine running.
A right hand rotating pump requires a PTO that turns counter-clockwise when looking
at the free end of the PTO shaft. A left hand rotating pump requires a PTO that turns
clockwise when looking at the free end of the PTO shaft.
WARNING:
Operating the pump with reverse rotation will damage the pump and void the
system’s warranty.
Verify that the PTO ratio is properly sized to provide adequate speed to the hydraulic
pump during normal operation of the generator system. The PTO speed must be
between the range specified in

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2. Table 1 for your model generator.
Example: For an HR-8 System that is to operate at 650 RPM engine speed:
PTO Ratio = 880 RPM ÷ 650 RPM = 1.35 or 135% (or higher)
WARNING:
Never exceed the maximum pump shaft speed. Pump failure or premature pump wear
will result. Doing so will void the system’s warranty.
3. Verify the combined weight of the pump and hoses filled with hydraulic fluid do not
exceed the PTO manufacturer’s weight restriction. If the pump weight does exceed
this restriction, the installer has two options: A) a bracket to support the pump can
be implemented, or B) the pump can be mounted to the vehicle chassis, connected
to the PTO with a drive shaft.
4. Verify that the pump shaft will mount to the PTO. Pumps supplied by Smart Power
Systems®have an SAE B 2 bolt flange. The standard pumps supplied by Smart
Power Systems®have either a SAE B 7/8” 13 tooth spline for Models HR-6.2, HR-8
and HR-10; OR a SAE B-B 1” 15 tooth spline on the HR-110 model.
Upon special order, a 1” keyed shaft or 1” 15 tooth spline is available on Models HR-
6, HR-8 and HR-10. A 1 ¼” keyed shaft is available on the HR-110 Model. Check
the PTO manufacturer’s specification to verify that the pump supplied with the system
will mount to the PTO installed on the vehicle.
Note: In some cases it may be necessary to mount the pump remote from the PTO
and drive it with a drive shaft. Contact the PTO manufacturer for information on the
proper mounting configuration under these conditions.
WARNING:
The installer must provide guarding to prevent damage to the pump seals from road
debris if the pump is remotely located. Also, properly sized and installed vibration
isolators must be used if the pump is mounted to the chassis. Failure to do either
will void the system’s warranty.
Never use an unbalanced drive shaft to drive a remotely located pump. An
unbalanced drive shaft will cause premature wear of the pump and 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.

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5. 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: 1/2” SAE 100R9AT-8 rated to 4000 PSI (use Parker hose ends,
part number 10643-8-8). Note: Maximum hose length is 20’.
c) Pump case drain hose: 5/8” SAE 100R1AT-10 (use Parker hose ends, part
number 10643-10-10). Note: Maximum hose length is 20’.

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WARNING:
Do not install hose ends until proper hose length has been determined.
Ensure debris is kept out of the hoses and hydraulic system prior to installation.
Never install a hose in a location where it will rub against another surface or abrasive
member.
Do not position hoses with tight bend radii. Consult the hose manufacturer’s
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.
Smart Power has fully tested and approved ISO fluids
ISO #32, #46 and #68 are approved for use in all Smart Power hydraulic generators.
Complete testing was performed using U.S. Oil Multi-Vis R Hydraulic Fluid under
controlled environments ranging from below freezing to above NFPA’s high temperature
requirements. The systems ran within our tight performance specifications using all three
listed grades.
ISO #32 is recommended when ambient temperatures are generally between 2 and 56°F.
ISO #46 is recommended when ambient temperatures are generally between 10 and
74°F.
ISO #68 is recommended when ambient temperatures are generally between 27 and
95°F.
For additional information on ISO fluids, contact U.S. Oils, or your local ISO grade fluid
supplier.
6. SPS models HR-6.2, HR-8, HR-10 and HR-110 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 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 [phone].

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MINIMUM
1.00
CLEARANCE
CLEARANCE
MINIMUM
.50
.50
MINIMUM
CLEARANCE
15.00
AIR VENT OPTION A
(IF AIR VENT OPTION B OR C IS USED
.50 CLEARANCE REQUIRED ON THIS SURFACE)
AIR VENT OPTION B
(IF AIR VENT OPTION A OR C IS USED
.50 CLEARANCE REQUIRED ON THIS SURFACE)
AIR VENT OPTION C
(IF AIR VENT OPTION A OR B IS USED
.50 CLEARANCE REQUIRED ON THIS SURFACE)
Figure 3 - HR-6.2, HR-8, HR-10 and HR-110 Bottom View
Figure 4 - HR-6.2, HR-8, HR-10 and HR-110 Front View

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Figure 5 - HR-6.2, HR-8, HR-10 and HR-110 End View

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WARNING:
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.
7. 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
8. Locate a position to mount the SPS Command & Control Center. The ideal location
for the Command & Control Center will be in an area that iseasily 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 theyoccur. The Command & Control Center can also beused 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 6 for the
dimensions of the Command & Control Center.
Figure 6 - Command & Control Center, P/N 1500047C