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Smart power LI-10 Owner's Manual

Hydraulic generator plus rescue tool pump system
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®
The...liberator
HYDRAULIC GENERATOR PLUS
RESCUE TOOL PUMP SYSTEM
OWNER'S MANUAL
MODEL#: LI-10, LI-15, LI-20, and LI-25
9991051 Rev. E

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  • Page 1 ® The...liberator HYDRAULIC GENERATOR PLUS RESCUE TOOL PUMP SYSTEM OWNER’S MANUAL MODEL#: LI-10, LI-15, LI-20, and LI-25 9991051 Rev. E...

  • Page 2: Table Of Contents

    ® 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 ......................17 Hose Installation Guidelines ....................22 Operation ..........................
  • Page 3 ® 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.
  • Page 4 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 (231) 832-5525 before proceeding. Damage to the generator from improper pump adjustment will void the system’s warranty.
  • Page 5 ® Smart Power Systems 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.

  • Page 6: Disclaimer

    ® 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...

  • Page 7: Description Of Product

    ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 6 of 49 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.
  • Page 8 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 7 of 49 BOOST BLOCK FILTER VENTURI BOOST RESERVOIR COOLER CHECK VALVE MOTOR PROPORTIONAL VALVE PUMP CASE DRAIN CASE DRAIN Hydraulic schematic for LI 10, LI-15, LI-20, and LI-25 generator system (excluding Rescue tool pump system)
  • Page 9 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 8 of 49 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...

  • Page 10: System Specifications

    ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 9 of 49 System Specifications MODEL OF LI-10 LI-15 LI-20 LI-25 GENERATOR Generator AC Inductive AC Inductive AC Inductive AC Inductive Type Speed 1800 RPM 1800 RPM 1800 RPM 1800 RPM...
  • Page 11 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 10 of 49 MODEL OF LI-10 LI-15 LI-20 LI-25 GENERATOR Oil Cooler 7.5”D x 18.9” W 7.5”D x 18.9” W x 7.5”D x 18.9” W x 7.5”D x 18.9” W x 32.3”L Dimensions (Core) x 27.25”L...

  • Page 12: Pre-Installation Guide

    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.
  • Page 13 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’.
  • Page 14 (but not taut) between connections. Do not exceed hose lengths of 20 feet. 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.
  • Page 15 Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 14 of 49 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...
  • Page 16 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 15 of 49 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...
  • Page 17 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 16 of 49 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.

  • Page 18: Installation Guide

    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...
  • Page 19 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 18 of 49 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.
  • Page 20 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 Mount Command & Control Center: a.
  • Page 21 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 20 of 49 3.375 .208 CLEARANCE HOLE 1.688 FOR #10 SCREW 4 PL. 2.000 1.688 3.375 Hole pattern for Command & Control Center Figure 10 Flush the hoses with fresh hydraulic fluid (Dexron III). Install hoses and tighten hose ends, using the Hose Installation Guidelines.
  • Page 22 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 21 of 49 Hose connection locations for LI-10 tray assembly Figure 11A Hose connection locations for LI-15, LI-20, and LI-25 tray assemblies (LI-20 shown) Figure 11B...

  • Page 23: Hose Installation Guidelines

    ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 22 of 49 WARNING: Never operate the system with the pump case drain plugged. Damage to the pump seals will result. To do so will void the system’s warranty. Lubricate hose fitting o-rings ONLY on the A.C. modular generator system with clean hydraulic fluid (Dexron III) before installation to prevent damage to them.
  • Page 24 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 the system’s warranty. Replacement breakers must be obtained from Smart Power ® Systems...
  • Page 25 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 24 of 49 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.
  • Page 26 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 25 of 49 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.
  • Page 27 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 26 of 49 Enabling System Purge Option The purge option can also be set by performing the following steps: Step 5: Press On/Off Step 3: Hold Mode until  appears.
  • Page 28 (231) 832-5525 for more information. Also verify that the air passing through the cooler and the fan is not restricted. WARNING: The SPS Model LI-10, LI-15, LI-20, and LI-25 have been pre-set at the factory to provide correct frequency and voltage. No pump adjustment is required.
  • Page 29 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 28 of 49 Set “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”...

  • Page 30: Operation

    ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 29 of 49 Operation For A.C. Modular Generator System (Reference XRT Manual for Operation Instructions of rescue tool pump system) The Command & Control Center will show the generator’s output voltage, frequency, current, and system run time whenever the Command &...
  • Page 31 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 30 of 49  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”...
  • Page 32 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 31 of 49 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.
  • Page 33 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 32 of 49 output (electrical PLUS hydraulic) of the system in kilowatts (reference Figure 21). The  indicates the system The system controller is configured to operate a generator controller is configured to...
  • Page 34 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 33 of 49 d. . If the system measures a continuous current draw exceeding the generator’s maximum output rating, the generator will automatically shut down in 30 minutes unless the shutdown is overridden.

  • Page 35: Special Operating Instructions

    ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 34 of 49 b. Note the  and  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”...

  • Page 36: Maintenance Instructions

    ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 35 of 49 Measured oil Message advising the temperature in oil is cold (less than degrees fahrenheit 40  F) Example of Command & Control Center when operating with cold hydraulic fluid...
  • Page 37 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 36 of 49 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.
  • Page 38 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 37 of 49 Press Mode until  and  are displayed Time Since last Oil Filter Change in Hours. Example of oil filter run time display Figure 25 The Command & Control Center will flash a fault when 250 hours have passed since the previous filter change.
  • Page 39 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 38 of 49 will be removed and replaced by another screen. The fault has been cleared and the timer reset. c. When the fault has been cleared, the system automatically enters purge mode to purge any entrapped air from the hydraulic lines (see Figure 13).

  • Page 40: Troubleshooting Guide

    ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 39 of 49 Troubleshooting Guide For A.C. Modular Generator System (Reference XRT Manual for Troubleshooting Guide of rescue tool pump system) Diagnostic: The Command & Control Center will display certain faults that can assist a service technician in trouble shooting a problem with the generator system.
  • Page 41 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 40 of 49 Diagnostic Faults: The following is a list of the diagnostic faults, with a brief explanation of each. String Class Meaning  Alarm The control valve feedback is invalid, indicating the system is not under control.
  • Page 42 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 41 of 49 Note: The fault “Classes” are defined in the table below: Class Meaning Service Warning Normal maintenance needs to take place. Alarm A condition requires the immediate attention of the operator.
  • Page 43 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 42 of 49 After correcting any problems, again operate the generator twenty minutes to purge air out of the hydraulic fluid. Note that any bubbles seen in the reservoir indicate leakage in the pump inlet line.
  • Page 44 This indicates overheating or aging. Drain and flush the system. g. Fill with new, clean hydraulic fluid. ® h. Adjust pump, if necessary, only after contacting Smart Power Systems at (231) 832-5525. Low Hydraulic Fluid Level In Reservoir: Low hydraulic fluid level in reservoir can be caused by leaking fittings, hoses or pipes.
  • Page 45 The resistance between wires 1 and 2, and wires 3 and 4 should ® be essentially 0 ohms. Contact Smart Power Systems at (231) 832-5525 if any problems are found.
  • Page 46 The generator speed may be incorrect. The generator output should be ® between 59-63 Hz. 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 ®...

  • Page 47: Pump Adjustment

    ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 46 of 49 Pump Adjustment For A.C. Modular Generator System (Reference XRT Manual for Pump Adjustment of rescue tool pump system) WARNING: The SPS Electronic Controlled Generators have been pre-set at the factory to provide correct frequency and voltage, no pump adjustments are required.
  • Page 48 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 47 of 49 The Pump Set option can be accessed by performing the following steps: Step d: After selecting Step b: Hold Mode until , Press On/Off until Amps Line 1 Blinks .
  • Page 49 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 48 of 49 Adjust pump compensator: a. Reference Figure 30. b. Loosen the flow control pressure jam nut. c. While monitoring the generator’s output voltage, slowly rotate the flow control set screw with a 4mm hex wrench.
  • Page 50 ® Smart Power Systems A. C. MODULAR GENERATOR SYSTEM Page 49 of 49 Disable the generator Pump Set option. After the pump has been properly adjusted, disable the Pump Set option by performing the following steps: Step c: After selecting Step a: Hold Mode until , Press On/Off until...

This manual is also suitable for:

Li-15Li-20Li-25

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