THE LIBERATOR ™ HYDRAULIC GENERATOR PLUS RESCUE TOOL PUMP SYSTEM OWNER’S MANUAL MODEL#: LI-15, LI-20, and LI-25
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 1 of 54 Table of Contents Section Page Disclaimer .......................................................................................................................... 5 Description of Product...................................................................................................... 6 System Specifications ...................................................................................................... 9 Pre-Installation Guide .
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 2 of 54 WARNING: Do not install or operate a 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.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 3 of 54 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.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 4 of 54 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.
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Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 6 of 54 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, or 20,000 watts, depending on model.
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Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 8 of 54 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 FAN MOTOR + VEHICLE +12V SUPPLY RED VEHICLE GROUND - ORANGE BLACK NOT PROVIDED BROWN/WHITE BUZZER GREY ORANGE YELLOW SPS DISPLAY WIRE HARNESS P/N 3722004 REMOTE ENB. SW.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 9 of 54 System Specifications MODEL OF GENERATOR Generator Type LI-15 LI-20 LI-25 AC Inductive AC Inductive AC Inductive Speed Frequency Voltage 1800 RPM 60 Hz 240 VAC or 120/240 VAC 1800 RPM 60 Hz 240 VAC or 120/240 VAC 1800 RPM 60 Hz 240 VAC or 120/240 VAC Amperage 42A @ 240 VAC or 83A @ 120 VAC 62A @ 240 VAC or 125A @ 120 VAC 84A @ 240 VAC or 167A @ 120 VAC 15 KW continuous 16.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 10 of 54 MODEL OF GENERATOR Oil Cooler Dimensions (Core) LI-15 LI-20 LI-25 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.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 11 of 54 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.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 12 of 54 The pumps supplied by Smart Power® Systems for Models 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 14tooth 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.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 13 of 54 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.
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Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 16 of 54 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.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 17 of 54 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.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 18 of 54 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.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 19 of 54 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.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 20 of 54 3.375 1.688 .208 CLEARANCE HOLE FOR #10 SCREW 4 PL. 2.000 1.688 3.375 Hole pattern for Command & Control Center Figure 10 7. Flush the hoses with fresh hydraulic fluid (Dexron III). Install hoses and tighten hose ends, using the Hose Installation Guidelines. See Figure 11 for connection locations. WARNING: The XRT rescue tool pump uses a different hydraulic fluid see the XRT manual for more information.
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Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 22 of 54 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. Hose Installation Guidelines For A.C.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 23 of 54 8. Connect the vehicle’s breaker panel to the generator output. The generator is prewired to supply 120/240 VAC, with the generator frame bonded to ground. Route the generator output conduit/wiring to the breaker panel, and carefully cut the conduit to length without cutting the wire insulation. A conduit connector has been provided to connect the conduit to the breaker panel.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 24 of 54 Do not perform any wiring installations or modifications while the system is operating. The A.C. modular generator system will generate enough voltage to produce a fatal shock. Never touch any live connections while the system is operating. 9. Connect 12 VDC (vehicle battery positive) to the generator’s system controller input (reference Figure 2).
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 25 of 54 controller. The system controller will reset the option once the following two conditions are met: 1. The hydraulic system has been purged for a total of at least 30 minutes. 2. Of those 30 minutes, at least 20 occurred with the generator on. Main power breaker (LI-20 Breaker shown without protective boot) Figure 12 WARNING: Never operate the system without the filler/breather plug installed.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 26 of 54 Enabling System Purge Option The purge option can also be set by performing the following steps: Step 5: Press On/Off until y appears. Step 3: Hold Mode until Amps Line 1 Blinks 88. Release switch so 0Pt appears. Step 4: Press mode to make Pvrg appear. Figure 13 1. If the Command & Control Center is dark, press the Mode switch to put the display into Normal mode. 2. If the Display looks like Figure 13, The purge option is enabled. 3.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 27 of 54 displays the string “0FF” as shown in Figure 14, press the On/Off switch to turn the generator off, if needed. g. Check for hydraulic fluid leaks, all hose connections must be tight. Monitor the hydraulic fluid level in both the A.C. modular generator system and the XRT system, adding fluid to both as needed. WARNING: The A.C. modular generator system and the XRT rescue tool pump use DIFFERENT hydraulic fluids. ONLY the A.C.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 28 of 54 12. 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” switch is pressed. Select the auto-start function by performing the following steps: Step b: Hold Mode until Amps Line 1 Blinks 88. Release switch so 0Pt and AStr appear.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 29 of 54 Operation For A.C. Modular Generator System (Reference XRT Manual for Operation Instructions of rescue tool pump system) 1A. The Command & Control Center will show the generator’s output voltage, frequency, current, and system run time whenever the Command & Control Center is in the Normal mode. To access Normal mode, press the Mode switch repeatedly until the correct information is displayed (reference Figure16A).
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 30 of 54 3. The Command & Control Center is equipped with two Smart Touch® switches, labeled “Mode” and “On/Off” respectively. These switches do not require pressure to be activated, but instead sense the presence or absence of your fingertip. The decimal points in the “Amps Line 1” and “Amps Line 2” fields of the Command & Control Center are used to indicate the status of the Mode and On/Off switches respectively (reference Figure 17).
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 31 of 54 6. If the system controller has been set to “auto-start”, the generator will begin to produce power whenever the PTO is engaged. See installation instructions for the directions to select the “auto-start” options. 7. Additional Information provided by the Command & Control Center: a. When the Command & Control Center is in Normal mode, pressing the Mode switch once will display the oil temperature (reference Figure 19).
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 32 of 54 power output (electrical PLUS hydraulic) of the system in kilowatts (reference Figure 21). The LI indicates the system controller is configured to operate an LI-series Generator The system controller is configured to operate a generator whose maximum output is this number (in kW). Example of configuration display Figure 21 d.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 33 of 54 d. HI Curr. 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. e. bAd uoLts. If the system measures an output voltage that is too low or too high the generator will automatically shut down in 30 minutes unless the shutdown is overridden. f. Bad tSnS.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 34 of 54 b. Note the y and n labels below the Mode and On/Off switches. Press the On/Off switch to answer “yes” and proceed to the next screen, or press Mode to answer “no” and proceed to the oil temperature display. Step c: Press On/Off to answer “yes” and override the shutdown. Example of Command & Control Center in hot oil fault override confirmation Figure 23 c.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 35 of 54 Measured oil temperature in degrees fahrenheit Message advising the oil is cold (less than 40°F) Example of Command & Control Center when operating with cold hydraulic fluid Figure 24 Operating Modes when the system START button is activated (or when the system is in “autostart”): • When the meter displays hydraulic oil temperatures below 20°F, the hydraulic system will bypass the generator motor and the generator will not produce power.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 36 of 54 e. That the hydraulic fluid level in the reservoir is between ½ to ¾ full in the sight gage and the hydraulic fluid is clean and bright red in color. f. That the bolts mounting the pump to the PTO are not loose. g. If the hydraulic fluid appears dirty or black in the reservoir sight gage, replace the fluid and filter immediately. Also, if the hydraulic fluid sustains a temperature over 175° F, replace the fluid immediately.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 37 of 54 Press Mode until FLt and Xr are displayed Time Since last Oil Filter Change in Hours. Example of oil filter run time display Figure 25 4. The Command & Control Center will flash a fault when 250 hours have passed since the previous filter change.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 38 of 54 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). The system must be purged for 30 minutes, 20 of which must be with the generator ON. Turn off the main power breaker during purge (see Figure 12).
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 39 of 54 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. When these faults occur, the fault message will periodically flash on the Command & Control Center, interrupting the normal display.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 40 of 54 Diagnostic Faults: The following is a list of the diagnostic faults, with a brief explanation of each.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 41 of 54 Note: The fault “Classes” are defined in the table below: Class Service Warning Alarm Shutdown Override Meaning Normal maintenance needs to take place. A condition requires the immediate attention of the operator. A condition causes the immediate shutdown of the generator. A condition that will cause the generator to be shut down in 30 minutes unless explicitly overridden by the operator. Table 3 Hydraulic Problems: 1.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 42 of 54 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. 3. Differential Pressure: Differential pressure between the inlet pressure and the case pressure over 7 psi causes the piston shoes to lift off the swash plate.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 43 of 54 4. System Overheating: System overheating may be caused by re-circulation of hot air through oil cooler, dirty or obstructed oil cooler fins, restricted hydraulic fluid flow, excessive generator load, restricted airflow, previously overheated (old) fluid, non-functional fan, or improperly adjusted pump. a. b. c. d. e. Check the oil cooler fins for debris or damage. Clean and/or replace cooler.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 44 of 54 Electrical Problems 1. No Output Voltage: a. No output voltage may be caused by excessive current draw opening the circuit breakers (the circuit breakers can be found mounted on the generator wiring enclosure). Remove all electrical loads from the generator and reset breaker(s). Re-engage electrical load in increments.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 45 of 54 g. The pump is faulty. If no faults are found in steps a. through g., the problem is likely to be a non-functional pump. Contact Smart Power® Systems at (231) 832-5525 for further instructions. 2. Output voltage exceeds 260 volts or falls below 220 volts AC on a 240 volt line: a. Verify that the hydraulic system is not overheating by viewing the temperature as displayed by the Command & Control Center.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 46 of 54 SPS Model Matrix SHAFT ROTATION R=CW (STD), L=CCW MOTOR DISP.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 47 of 54 SHAFT K=KEYED S=SPLINED (STD) SHAFT ROTATION R=CW (STD), L=CCW MOTOR DISP. CC # OF RESCUE TOOL OUTPUTS ELECTRICAL OUTPUT (KILOWATTS) HYDRAULIC OUTPUT (KILOWATTS) MANUAL P/N 8585060 8585060 8585060 8585060 8585060 8585060 8585060 8585060 8585060 8585060 8585060 8585060 8585060 8585060 8585060 8585060 8585060 8585060 8585060 8585060 8585060 8585065 8585065 8585065 8585065 8585065 8585065 NEXT SHEET PUMP DISP.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 48 of 54 PARENT P/N DESCRIPTION COMMAND & CONTROL CENTER P/N XRT KIT P/N TRAY ASM P/N PUMP ASM P/N RANGE STD=STANDARD RANGE WR=WIDE RANGE XWR=EXTENDED RANGE PUMP DISP. CC SHAFT K=KEYED S=SPLINED (STD) SHAFT ROTATION R=CW (STD), L=CCW MOTOR DISP.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 49 of 54 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. If it appears the pump need to be adjusted, contact SPS at (231) 832-5525 before proceeding.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 50 of 54 The Pump Set option can be accessed by performing the following steps: Step d: After selecting PSEt, Press On/Off until y appears. Step b: Hold Mode until Amps Line 1 Blinks 88. Release switch so 0Pt appears. Step c: Press mode twice to make PSEt appear. Enabling pump set option Figure 28 a. If the Command & Control Center is dark, press the Mode switch to put the Command & Control Center into Normal mode. b.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 51 of 54 2. 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. Adjust the flow control until the generator’s output frequency is 63 Hz. d. While keeping the setscrew from rotating, with the hex wrench, re-tighten the jam nut.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 52 of 54 3. 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 PSEt, Press On/Off until n appears. Step a: Hold Mode until Amps Line 1 Blinks 88. Release switch so 0Pt appears. Step b: Press mode twice to make PSEt appear. Disabling pump set option Figure 31 a.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM Page 53 of 54 Manufacturers Limited Warranty Smart Power® Systems Hydraulic Generator (NOTE: This warranty DOES NOT cover the XRT rescue tool pump, and its components or the rescue tools. Reference XRT manual for rescue tool pump warranty.
Smart Power® Systems A. C. MODULAR GENERATOR SYSTEM 3. 4. 5. Page 54 of 54 Living and travel expenses of the person making the repair (other than those outlined above). The premium costs for overtime labor requested by the owner. The cost of airfreight or other extraordinary expenses for shipment of parts over and above premium surface transportation.
