Smart power HR-15 User manual

A.C. MODULAR
GENERATOR SYSTEM
OWNERS MANUAL
MODELS#: HR-15 60 Hz
HR-12 50 Hz
9991041 Rev. H

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A. C. MODULAR GENERATOR SYSTEM Page 1 of 53
Table of Contents
Section Page
Disclaimer..........................................................................................................................5
Description of Product......................................................................................................6
System Specifications....................................................................................................10
Pre-Installation Guide.....................................................................................................12
Installation Guide............................................................................................................18
Hose Installation Guidelines .......................................................................................... 23
Operation......................................................................................................................... 31
Special Operating Instructions ......................................................................................37
Maintenance Instructions...............................................................................................38
Troubleshooting Guide...................................................................................................41
SPS Model Matrix............................................................................................................48
Pump Adjustment............................................................................................................49
Doc. 9991041 Rev. H
ECO #16138

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A. C. MODULAR GENERATOR SYSTEM Page 2 of 53
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.

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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 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 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.
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 pump case with
2 pints of 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.

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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 a kink, pinch or chaffing. The A.C. modular hydraulic system generates hydraulic
pressures approaching 4000 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:
These heavy-duty electronically controlled generator systems have been designed to meet
the most demanding mobile applications. The HR-15 provides 15000 watts @ 120/240
VAC @ 60 Hz. The HR-12 provides 12000 watts @ 115/230 VAC @ 50 Hz.
How Our System Works:
A generator driven by a hydraulic motor delivers the electrical power. The motor turns at
1800 RPM for the HR-15, or 1500 RPM for the HR-12, 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 driven by an 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 between ½ and ¾ full in the
sight gage.
Generator hydraulic and electrical schematics: see Figure 1 and Figure 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
Hydraulic schematic for HR-15/HR-12 generator system
Figure 1

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PROP. CONTROL VALVE
P/N 8594452
ASM, OIL TEMP. SENSOR
P/N 3310736
INDICATOR BULB
REMOTE ENB. SW.
NOT PROVIDED
BUZZER
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
VEHICLE +12V SUPPLY
VEHICLE GROUND
SYSTEM CONTROLLER
P/N 8505038 (HR-15)
P/N 8505042 (HR-12)
BROWN/WHITE
RED
ORANGE
BLACK
ORANGE
GREY
YELLOW
PURPLE
BLACK/WHITE
GREEN/WHITE
YELLOW
BLACK/YELLOW
BLACK
GREEN
PINK
BLUE PRESSURE SWITCH
P/N 8594019
YELLOW
PURPLE/YELLOW
ASM, OIL LEVEL SENSOR
P/N 3320106
SPS DISPLAY WIRE HARNESS
P/N 3722004
COMMAND & CONTROL CENTER
P/N 1500047
+
-
FAN MOTOR
CURRENT TRANS.
P/N 1500035
WHITE/RED
WHITE/BLUE
PINK
BLUE
PURPLE/WHITE
RED/WHITE
BLUE/WHITE
ORANGE/WHITE CIRCUIT BREAKER
GENERATOR
OUTPUT
LOGIC HI L1
LOGIC LO L2
F1
F2
ASM, FIELD CONTROL
P/N 3100308
VAC
FIELD WINDING
RED
BLACK
CIRCUIT BREAKER
CURRENT TRANS.
P/N 1500035
GENERATOR
WINDING A
WINDING B
FIELD
T1
T2
T3
T4
GENERATOR
OUTPUT
GENERATOR
OUTPUT
GENERATOR
OUTPUT
RED
GREEN
WHITE
BLACK
VEHICLE
+12V SUPPLY
VEHICLE
+12V SUPPLY
VEHICLE
+12V SUPPLY
Electrical schematic for HR-15/HR-12 generator system

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Figure 2

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System Specifications
Model of generator
HR-15
HR-12
Generator Type
Speed
Frequency
Voltage
Amperage
Motor Starting
Voltage Regulation
Power
AC Inductive
1800 RPM
60 Hz
120/240 VAC
125A @ 120 VAC
-or-63A @ 240 VAC
300 percent surge
Electronic
15 kW continuous, 16.5 kW
peak
AC Inductive
1500 RPM
50 Hz
115/230 VAC
106A @ 115 VAC
–or- 53A @ 230 VAC
300 percent surge
Electronic
12 kW continuous, 13 kW peak
Hydraulic Motor
Maximum Speed
Motor Shaft Size
Port Size
Piston, 30cc
6300 RPM
1.181 inches (keyed)
SAE ½”
Piston, 30cc
6300 RPM
1.181 inches (keyed)
SAE ½”
Hydraulic Pump
Operating Speed
Standard Shaft
Mounting Flange
Displacement
Continuous Pressure (Max)
Peak Pressure
Standard Rotation
Piston w/pressure compensated
control
800-3000 RPM
SAE C 1.25” Keyed
SAE C-2 bolt mount
80cc per revolution
4600 psi (320 bar)
5075 psi (350 bar)
Engine right-hand rotation
(opposite engine rotation
available upon request)
Piston w/pressure compensated
control
800-3000 RPM
SAE C 1.25” Keyed
SAE C-2 bolt mount
80cc per revolution
4600 psi (320 bar)
5075 psi (350 bar)
Engine right-hand rotation
(opposite engine rotation
available upon request)
Dry Weight of Hydraulic Pump
77 lbs.
77 lbs.
Oil Cooler
Dimensions
Inlet/Outlet Fittings
2.25”D x 24” W x 15” W
SAE-12
2.25”D x 24” W x 15” W
SAE-12
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 Fluid (recommended)
Alternate Hydraulic Fluid
Maximum Viscosity
Op. Temp. range (deg. F.)
Dexron III
ISO Approved Hydraulic Fluid
4600 SUS (1000mm2/S)
60 SUS (10mm2/S)
-13° F to 195° F
Dexron III
ISO Approved Hydraulic Fluid
4600 SUS (1000mm2/S)
60 SUS (10mm2/S)
-13° F to 195°F
Hoses
Motor Inlet
All Others
JIC STD
4000 psi, SAE
1250 psi, SAE
JIC STD
4000 psi, SAE
1250 psi, SAE
Table 1

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System Specifications (cont.)
Model of generator
HR-15
HR-12
Fittings
SAE
SAE
Dry Weight (without pump)
442 lbs.
442 lbs.
Dimension of Tray Asm.
34.5” L x 19” W x 22” H
(Including Reservoir)
34.5” L x 19” W x 22” H
(including Reservoir)
Ambient Operating
Temperature Range
0F to 120F
0°F to 120°F
Table 1 (cont.)
System Requirements
Power Take-Off Attachment
Pump must be remote mounted and driven
by the PTO via a drive shaft.
Power Take-Off Rotation
Engine rotation (systems for opposite
engine rotation available upon request).
Power Take-Off Speed (extended range)
800 to 3000 RPM
Table 2

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Pre-Installation Guide
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: K3VL80/B-10R
A left hand rotating pump will have the letter “L” in its part number.
Example: K3VL80/B-10L
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.
2. 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 output
speed must be between 800 to 3,000 RPM for normal operation.
Example: For a HR-15 system, that is to operate at 650 RPM engine
speed: PTO Ratio = 800 RPM ÷ 650 RPM = 1.23 or 123%
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. The hydraulic pump used for the SPS 12 kW and 15kW systems is too heavy to
mount directly onto a PTO. The pump must be mounted remotely with a bracket to
either the vehicle’s transmission or the vehicle’s chassis, and driven by a drive

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shaft. Contact the PTO manufacturer and/or the drive shaft manufacture for
installation instructions for remote mounting a hydraulic pump.
4. Verify that the drive shaft selected will couple to both the PTO and the SPS
supplied pump. Pumps supplied by Smart Power®Systems for this system have an
SAE C, 1.25” keyed shaft.
WARNING:
The installer must provide guarding to prevent damage to the pump seals from road
debris. 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.
5. Obtain the following hoses of the necessary length for the installation:
a) Pump inlet hose: 1” SAE 100R1AT-16 hose with 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.
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. 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.
6. Mounting considerations:
The SPS models HR-12 and HR-15 have been specifically designed to be mounted
on top of a vehicle, in the open, without requiring any additional coverings.
Reference Figure 3, Figure 4, and Figure 5 for minimum clearances around the
perimeter of the generator’s tray assemble. Also, do not position any obstructions
directly above the system’s oil cooler. If a system cannot be installed without
maintaining the minimum clearances as indicated, or if you have any questions
relative to the installation of a HR-12 or a HR-15, contact Smart Power®Systems at
[phone].

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Bottom view of HR12/HR-15 tray assembly showing minimum clearance
for proper ventilation
Figure 3
End view of HR-12/HR-15 tray assembly showing minimum clearance
for proper ventilation

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Figure 4
Left side view of HR-12/HR-15 tray assembly showing minimum clearance
for proper ventilation
Figure 5
WARNING:
Do not mount the hydraulic pump, tray assembly or reservoir 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

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a. 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 6 for the dimensions of the
Command & Control Center.
Command & Control Center, P/N 1500047
Figure 6

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Installation Guide
1. Mount the pump securely to the Power Take-Off (PTO). This may require attaching
a mounting bracket to the PTO housing prior to mounting the pump.
WARNING:
Always mount the hydraulic pump in a position with the pump controls up.
Mounting the pump in any other orientation will not allow hydraulic fluid in the
pump to reach the correct level before starting, causing premature wear of the
pump, thus voiding the system’s warranty. The pump and undercarriage
components will corrode if they are left unprotected. It is advisable to paint them
before completing the installation.
2. Locate and bore mounting holes for generator tray assembly as shown in Figure 7.
Maintain minimum clearances as indicated in Figure 3, Figure 4, and Figure 5.
Hole pattern for mounting HR-12/HR-15 tray assembly
Figure 7

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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
8.
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 8
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, cooler/fan assembly 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. If desired, reservoir and cooler/fan assemblies can be remote mounted. Contact
Smart Power Systems at [phone] to review remote mounting applications
and to order remote mounting kit, PN 1500065.