Smart power LI-10 User manual

9991051 Rev. E
The...liberator®
HYDRAULIC GENERATOR PLUS
RESCUE TOOL PUMP SYSTEM
OWNER’S MANUAL
MODEL#: LI-10, LI-15, LI-20, and LI-25

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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 ..............................................................................................................17
Hose Installation Guidelines..............................................................................................22
Operation ..........................................................................................................................29
Special Operating Instructions ..........................................................................................34
Maintenance Instructions ..................................................................................................35
Troubleshooting Guide......................................................................................................39
Pump Adjustment..............................................................................................................46
Doc. 9991051 Rev. E
ECO # 16219

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A. C. MODULAR GENERATOR SYSTEM Page 2 of 49
WARNING:
Do not install or operate the liberator (LI) system without completely reading both this
manual and the XRT 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 Systems®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 Systems®hydraulic generators, as well as all generators, must be sufficiently
protected from the environment to prevent damage to the stator. Smart Power Systems®
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) or to the rescue tool system 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  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 or the XRT rescue tool pump 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 A.C. modular generator system or the XRT rescue tool pump
without hydraulic fluid. FOR A.C. Modular Generator System ONLY: A) Always
maintain a fluid level between ½ to ¾ full in the sight plug. B) When installing the system,

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A. C. MODULAR GENERATOR SYSTEM Page 4 of 49
fill the pump case with a minimum of 1 pint 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.
Use only hoses that meet or exceed the minimum requirements specified in this manual
for the A.C. modular generator system. Reference the XRT manual for the hose
requirements for the XRT system. 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 around 5000 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 / Rescue Tool Pump 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 from no-load to
full load, handling electrical loads of 10,000, 15,000, 20,000, or 25,000 watts, depending
on model.
The XRT rescue tool pump is a dual level hydraulic pump designed to operate one, two or
three hydraulic extrication tools at the same time.
How our System works:
A generator driven by a hydraulic motor delivers the electrical power. In addition, a rescue
tool pump is driven by the generator as its drive shaft is directly coupled to the generator
shaft. The motor turns at 1800 RPM 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.
NOTE: The rescue tool pump has a separate hydraulic circuit with its own filtering,
cooling and control components.
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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CASE DRAIN
xy
RESERVOIR
PUMP
PROPORTIONAL
VALVE
CASE DRAIN
MOTOR
COOLER
FILTER
BOOST BLOCK
VENTURI BOOST
CHECK
VALVE
IN
BP
REG
Hydraulic schematic for LI 10, LI-15, LI-20, and LI-25
generator system (excluding Rescue tool pump 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 8505034 (LI-15)
P/N 8505033 (LI-20, LI-25)
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
Electrical Wiring Diagram for LI10, LI-15, LI-20, and LI-25 generator systems (excluding Rescue tool pump system)
Figure 2

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System Specifications
MODEL OF
GENERATOR
LI-10
LI-15
LI-20
LI-25
Generator
Type
Speed
Frequency
Voltage
Amperage
Output
Power
AC Inductive
1800 RPM
60 Hz
240 VAC or
120/240 VAC
42A @ 240 VAC or
84A @ 120 VAC
10 KW continuous
12 KW peak
AC Inductive
1800 RPM
60 Hz
240 VAC or
120/240 VAC
63A @ 240 VAC or
125A @ 120 VAC
15 KW continuous
16.5 KW peak
AC Inductive
1800 RPM
60 Hz
240 VAC or
120/240 VAC
84A @ 240 VAC or
167A @ 120 VAC
20 KW continuous
22 KW peak
AC Inductive
1800 RPM
60 Hz
240 VAC or
120/240 VAC
105A @ 240 VAC or
209A @ 120 VAC
25 KW continuous
27 KW peak
Hydraulic
Motor
Max. Speed
Piston type, 30cc
4000 RPM
Piston type, 30cc
4000 RPM
Piston type, 40cc
4000 RPM
Piston type, 40cc
4000 RPM
Hydraulic
Pump
Operating
Speed
(For 5KW max.
output)
Operating
Speed
(For full output)
Standard Shaft
Optional Shaft
Mounting
Flange
Displacement
Continuous
Pressure (Max)
Peak Pressure
Standard
Rotation
Pump
Dry Weight:
Piston w/pressure
compensated control
800-3000 RPM
continuous duty
SAE ‘C’ Flange
1-1/4”-keyed (1.229”)
SAE ‘C’ Flange
1-1/4” 14-tooth spline
SAE ‘C’ bolt mount
80cc per revolution
5100 psi (347 bar)
4600 psi (315 bar)
Engine right-hand
rotation (opposite
engine rotation
available upon request)
77 lbs
Piston w/pressure
compensated control
800-3000 RPM
continuous duty
SAE ‘C’ Flange
1-1/4”-keyed (1.229”)
SAE ‘C’ Flange
1-1/4” 14-tooth spline
SAE ‘C’ bolt mount
80cc per revolution
5100 psi (347 bar)
4600 psi (315 bar)
Engine right-hand
rotation (opposite
engine rotation
available upon request)
77 lbs
Piston w/pressure
compensated control
1200-3000 RPM
continuous duty
SAE ‘C’ Flange
1-1/4”-keyed (1.229”)
SAE ‘C’ Flange
1-1/4” 14-tooth spline
SAE ‘C’ bolt mount
80cc per revolution
5100 psi (347 bar)
4600 psi (315 bar)
Engine right-hand
rotation (opposite
engine rotation
available upon request)
77 lbs
Piston w/pressure
compensated control
950-3000 RPM
continuous duty
(See Note )
1200-3000 RPM
continuous duty
SAE ‘C’ Flange
1-1/4”-keyed (1.229”)
SAE ‘C’ Flange
1-1/4” 14-tooth spline
SAE ‘C’ bolt mount
80cc per revolution
5100 psi (347 bar)
4600 psi (315 bar)
Engine right-hand rotation
(opposite engine rotation
available upon request)
77 lbs
Table 1

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MODEL OF
GENERATOR
LI-10
LI-15
LI-20
LI-25
Oil Cooler
Dimensions (Core)
7.5”D x 18.9” W
x 27.25”L
7.5”D x 18.9” W x
27.25”L
7.5”D x 18.9” W x
32.3”L
7.5”D x 18.9” W x 32.3”L
Fan
Voltage
Amperage
16 Inch Pusher
12 Volts DC
22 Amps
16 Inch Pusher
12 Volts DC
22 Amps
16 Inch Pusher
12 Volts DC
22 Amps
16 Inch Pusher
12 Volts DC
22 Amps
Filter
10 Micron
10 Micron
10 Micron
10 Micron
Hydraulic Oil
(recommended)
(alternate)
Maximum Viscosity
Minimum Viscosity
Op. Temp. range
(deg. F.)
Dexron III
ISO Approved
Hydraulic Fluid
4650 SUS (1000
cSt)
55 SUS (10 cSt)
-13° F to 195° F
Dexron III
ISO Approved Hydraulic
Fluid
4650 SUS (1000 cSt)
55 SUS (10 cSt)
-13° F to 195° F
Dexron III
ISO Approved
Hydraulic Fluid
4650 SUS (1000 cSt)
55 SUS (10 cSt)
-13° F to 195° F
Dexron III
ISO Approved Hydraulic
Fluid
4650 SUS (1000 cSt)
55 SUS (10 cSt)
-13° F to 195° F
Hoses
Motor Inlet
All Others
JIC STD
6000 psi, SAE
1250 psi, SAE
JIC STD
6000 psi, SAE
1250 psi, SAE
SAE
6000 psi, SAE
1250 psi, SAE
SAE
6000 psi, SAE
1250 psi, SAE
Fittings
SAE
SAE
SAE
SAE
Dry Weight
(without pump)
485 lbs
485 lbs
580 lbs
715 lbs
Dimension of Tray
Asm.
40.5” L x 19” W
x 22” H
(Including
Reservoir)
46” L x 19” W x 22” H
(Including Reservoir)
48” L x 19” W x 22” H
(Including Reservoir)
48” L x 19” W x 22” H
(Including Reservoir)
Ambient Operating
Temperature
Range
0F to 120F
0F to 120F
0F to 120F
0F to 120F
Table 1 (cont.)
Note : The recommended PTO ratio is 1.29 : 1 (129%).
The recommended engine idle speed with this PTO is 750 RPM.
This will result in a 968 RPM pump drive input, thereby insuring 5KW
of available power at engine idle. If full output is required at idle speed, then a higher PTO
ratio must be chosen to create 1200 RPM pump drive at idle speed; however care must
be taken to prevent higher engine speeds from creating a pump speed that exceeds the
pump’s maximum speed.

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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: 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 speed
must be in the range specified in Table 1 for your model generator.
Example: For an LI-10 System that is to operate at 650 RPM engine speed:
PTO Ratio = 800 RPM ÷ 650 RPM = 1.23 or use the recommended 129% PTO ratio
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 a SAE ‘C’2 bolt flange.

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The pumps supplied by Smart Power Systems®for Models LI-10, LI-15, LI-20, and LI-
25 have either the standard 1-1/4” keyed shaft, or, the optional 1-1/4” shaft with a 14-
tooth spline.
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.
Obtain the following hoses of the necessary length for the installation of the A.C.
Modular Generator System ONLY!
5. Note: See XRT manual for rescue tool system hose requirements:
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 (LI-10): 1/2”SAE 100R9AT-8 4000 PSI rated hose (use
Parker 10643-8-8 hose ends or equivalent). Note: Maximum hose length is 20’.
Pump outlet hose (LI-15/20/25): 1/2”, 6000 PSI rated hose (use Parker P/N 701-
8
Hose with Parker 1JS70-8-8 hose fittings or equivalent). 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. SPS models LI-10, LI-15, LI-20, and LI-25 can be mounted on top of a vehicle, in
the open, without requiring any additional coverings. Reference Figure 3, Figure 4
and Figure 5 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].
WARNING: Additional considerations must be made for mounting the XRT
reservoir and the other rescue tool components. Reference the
XRT manual for further instructions PRIOR to installation.

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Bottom view of LI-10, LI-15, LI-20, and LI-25 tray assemblies showing minimum clearance
for proper ventilation and the three possible air vent options (LI-20 shown)
Figure 3
Front view of LI-10, LI-15, LI-20, and LI-25 tray assemblies showing tray dimensions
and minimum clearance for proper ventilation (LI-20 shown)
Figure 4

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Side view of LI-10, LI-15, LI-20, and LI-25 tray assemblies showing tray dimensions
and minimum clearance for proper ventilation
Figure 5

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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 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 1500047C
Figure 6

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Installation Guide
For A.C. Modular Generator System (Reference XRT Manual for Installation Guide of
rescue tool pump system)
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 LI-10, LI-15, LI-20, and LI-25 tray assemblies (LI-20 shown)
Figure 7

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A. C. MODULAR GENERATOR SYSTEM Page 18 of 49
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.

Smart Power Systems®
A. C. MODULAR GENERATOR SYSTEM Page 19 of 49
LI-10, LI-15, LI-20, and LI-25 tray assemblies disassembled into base tray assembly
(with diamond plate cover added), cooler/fan enclosure and reservoir
Figure 9
6. Mount Command & Control Center:
a. Create hole pattern as shown in Figure 10.
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 harness.