Harrison Hydra-Gen Operation And Installation Manual Download Page 1

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Harrison Hydra-Gen

Hydraulic Driven AC Generator System

Operation and Installation Guide

For Harrison Hydra-Gen Model(s):

15.0 NCM – 16F
20.0 NCM – 16F

(01-31-2013) - Spec. B

For technical assistance contact:

Harrison Hydra-Gen, Ltd.

14233 West Rd.

Houston, Texas 77041

(281) 807-4420 Ph.
(800) 723-3334 Toll

(281) 807-4815 Fax

www.harrisonhydragen.com

Summary of Contents for Hydra-Gen

Page 1: ...n and Installation Guide For Harrison Hydra Gen Model s 15 0 NCM 16F 20 0 NCM 16F 01 31 2013 Spec B For technical assistance contact Harrison Hydra Gen Ltd 14233 West Rd Houston Texas 77041 281 807 4420 Ph 800 723 3334 Toll 281 807 4815 Fax www harrisonhydragen com ...

Page 2: ... proof of purchase information verification WARRANTY REGISTRATION CARD FORM NO WR 1 COMPANY NAME _______________________________________________________________ ADDRESS ________________________________________________________________________ CITY ____________________________________ STATE _________________ ZIP _________ CONTACT _______________________________ PHONE NO ___________________________ G...

Page 3: ...iii Place Stamp Here Harrison Hydra Gen Ltd 14233 West Rd Houston TX 77041 Please cut card along dotted line fold and secure with tape before mailing FOLD HERE CUT HERE ...

Page 4: ...e Motor 6 Pump Requirements 6 Dimension Drawings 7 Hydraulic Pump Information 8 80CC KAWASAKI PUMP 8 Installation Guide 9 Installation Cleanliness 9 Hydraulic Oil Requirements 9 Hydraulic Pump Mounting 10 Fretting 10 PUMP Mounting Locations 11 Soft Start Wiring 12 Key Points 12 Generator Tray Mounting and Airflow 13 Hydraulic Reservoir Mounting 14 Hydraulic Connections 14 Hose Specifications 14 Ke...

Page 5: ...ion Graph 9 Figure 6 Pump Mounting L Bracket Front View 11 Figure 7 Pump Mounting L Bracket Rear View 11 Figure 8 Pump Case Drain Orientation 12 Figure 9 Good Generator Airflow Installation 13 Figure 10 NCM Plumbing Diagram 16 Figure 11 Hydraulic Circuit Diagram 17 Figure 12 Meter Display Cutout Dimensions 18 Figure 13 Meter Display 18 Figure 14 Summary of Electrical Connections 19 Figure 15 Elect...

Page 6: ...ing parts present potential hazards that may result in serious personal injury Take care in following these recommended procedures Do not work on this equipment when mentally or physically fatigued Always wear safety glasses ELECTRICAL SHOCK Disengage power before moving protective shields or touching electrical equipment Use rubber insulating mats placed on dry wood platforms over floors that are...

Page 7: ...HYDRAULIC FLUID UNDER PRESSURE Hydraulic fluid can penetrate the skin which can result in possible blood poisoning Always shut down the primary engine driving the hydraulic pump before loosening or tightening any fittings CLEAN UNIT AND SURROUNDING AREA Keep the unit and surrounding area clean Remove all accumulated grease and oil from the unit Do not store anything in the generator compartment Bo...

Page 8: ...W Harrison Hydra Gen hydraulic generators are comprised of several components A general hydraulic and electrical component overview for our generator is described below Hydraulic Pump The hydraulic pump sends hydraulic fluid oil to the motor at a constant flow under varying engine speeds Motor The hydraulic motor drives the alternator Alternator An AC brushless revolving field alternator provides ...

Page 9: ...4 GENERATOR ORDERING CODE ...

Page 10: ...5 HYDRAULIC PUMP ORDERING CODE ...

Page 11: ...n is limited to just 4 Insulation Class H 200 C Slot Insulation Varnish Additional Marine Coating Power Factor Pf 1 0 unity for single phase units 0 8 for three phase units HYDRAULIC SYSTEM Type of oil Use only premium hydraulic fluid with anti wear anti foam and anti rust additives Optimum operating viscosity is 80 170 SUS Viscosity should never exceed 4 600 SUS at the coldest startup temperature...

Page 12: ...7 DIMENSION DRAWINGS Figure 1 Generator Tray Dimension Drawing Figure 2 Reservoir Dimension Drawing ...

Page 13: ...ment 80 CC Min Max Temperature 4 204 F Pump Weight 78 lbs Maximum Input Torque 295 ft lbs Pump Shaft SAE C Spline or Keyed Maximum Pressure 5200PSI Rotation CW or CCW Maximum Vacuum 10 0 in Hg Note Consult Harrison Hydra Gen factory for pump speeds above 3000 rpm Figure 3 80cc Kawasaki Pump ...

Page 14: ...to be used in the generator system Dextron III does not fall in this category Dextron is formulated to operate in transmissions The weight of the oil is determined by the climate the system is operating in Using an AW46 will provide good protection in most year round US climate conditions A graph of ISO Oil Grades versus applicable fluid temperatures is shown below The lowest allowed cold start te...

Page 15: ...Chelsea PTOs such as the constant mesh series have the option to install grease fitting which allows grease to be pumped into this area without removing the pump Consult your PTO manufacturer for availability We strongly suggest this option for constantly engaged PTOs since it greatly reduces maintenance time MAINTENANCE CONSIDERATIONS Even the best lubricant is eventually pushed out of the connec...

Page 16: ...ansmission service manual TRANSMISSION MOUNTING Before mounting the pump to the transmission obtain approval from the manufacturer Verify the extra weight does not exceed the recommended stress on the transmission In most cases a pump mounting bracket can be built to fasten to the bolt pattern off the rear of the transmission In some cases there is no room for a direct mount and the pump will need...

Page 17: ... the soft start solenoid activates 3 seconds after the PTO has been engaged If there are any secondary or remote switches be sure that they cannot be activated prior to 3 seconds of PTO engagement 3 All PTO manufacturers require PTO engagement below 1000 rpm High speed engagement will cause catastrophic damage to the PTO and or the pump A high speed lock out may be prudent Consult with your PTO ma...

Page 18: ...ns An intake shroud may be necessary for certain installations If the system oil temperature exceeds 180 F check the inlet and exhaust for restrictions If the inlet air temperature is above 120 F this may be an indication that the hot exhaust air is re circulating into the intake and additional baffling is necessary Figure 9 Good Generator Airflow Installation An installation with good airflow all...

Page 19: ...an specified above This is to ensure an adequate hydraulic fluid flow rate to the pump Contact the Harrison Hydra Gen factory at 1 800 723 3334 for assistance HOSE SPECIFICATIONS Suction Hose 16 Wire Inserted Suction Hose Must be rated for suction Max Operating Pressure 60 psi Vacuum Service sizes 12 64 28 in Hg Approved Example SAE100R4 Route from the reservoir outlet to the pump inlet Pressure H...

Page 20: ...a radiator hose clamp is only 50 psi This type of clamp will not carry the required pressure rating therefore a crimped hose end must be used All fittings are JIC 37 Flare See the hydraulic schematics on the following pages for hose routing It is important not to cross hoses during installation We recommend marking and capping plugging hose ends before routing hoses It is very easy to mix them up ...

Page 21: ...16 PLUMBING DIAGRAMS Figure 10 NCM Plumbing Diagram ...

Page 22: ...17 HYDRAULIC CIRCUIT DIAGRAM COOLER FILTER CHECK VALVE MANIFOLD MOTOR ASSEMBLY PUMP ASSEMBLY HYDRAULIC CIRCUIT 12 VDC COOLER Figure 11 Hydraulic Circuit Diagram ...

Page 23: ...t hole shown in the figure below is required for the meter display Figure 12 Meter Display Cutout Dimensions Follow these steps to install the meter display 1 Locate a suitable location for the display and cut the cutout hole and drill the 4 10 32 mounting screw holes 2 Route the 12 conductor extension cable from the generator to the meter Plug the cable in to the generator supplied connector and ...

Page 24: ...e followed in order to ensure personal protection WARNING FAULTY ELECTRICAL GROUNDING CAN LEAD TO FIRE OR ELECTROCUTION RESULTING IN SEVERE PERSONAL INJURY OR DEATH GROUNDING MUST BE DONE IN ACCORDANCE WITH APPLICABLE CODES Generators mounted permanently on a mobile vehicle must be grounded securely to the vehicle frame In addition the neutral conductor of the generator output must be grounded at ...

Page 25: ...LU YLW ORG RED BLK 1 2 3 4 5 6 7 8 9 10 11 12 12 Pin To Meter RED WHT BLK BLK L1 WHT N GRN GND Thermostat N O Cooler Fan YLW BLK RED RED RED BLK Thermostat N O Cooler Fan 25A Fuse 25A Fuse BLK BLU VERT EXHAUST FAN ASSEMBLY RED YLW BLU Low Oil Level Switch N O Optional F F Hz Hz 4 3 VAR VAR AVR Module Cut for 60Hz YLW RED RED BLK CUSTOMER CONNECTION RED 12AWG WHT or YLW 12AWG 30A Fuse BLK 12AWG 30A...

Page 26: ...voir using a clean funnel Fill the reservoir to the full mark on the sight glass Do not overfill 3 Fill the pump case with filtered oil 4 Loosen the hydraulic hose connections at the pump inlet pump case drain and pressure hose One turn should be enough 5 If there is no free flow of oil at the pump pressurize the reservoir maximum pressure 5 psi to force oil throughout the system until there is oi...

Page 27: ... of the hydraulic pump flow 1 Turn OFF the main line circuit breaker and remove any loads on the generator 2 Start the vehicle s engine 3 Engage the PTO 4 Set the vehicle s engine rpm at high idle and let the hydraulic oil temperature warm up to a minimum of 100 F 5 Turn the generator ON and check the frequency on the display module If frequency is not set at 61 5 Hz proceed to the next step CAUTI...

Page 28: ...iliar with the procedure for starting and stopping the generator system METER DISPLAY MODULE The FRC generator display module is designed to display AC generator data per NFPA 1901 Integrated warnings can alert the operator if a critical condition needs an appropriate action AC VOLTS AMPS LINE 1 AMPS LINE 2 FREQUENCY MODE 1 800 723 3334 6 0 5 0 2 2 0 2 4 0 Figure 18 Meter Display Module Excessive ...

Page 29: ... connections Visually inspect the generator for debris or greasy soil build up This can impede airflow and cause premature generator failure Blow out the heat exchanger fins and the inside of the alternator with an air hose Do not use water to clean the inside of the alternator If the alternator has been submerged in water the windings must be dried before use Immersion in salt water requires clea...

Page 30: ...st be registered within thirty 30 days of initial startup on FORM NO WR 1 to be provided and completed by the seller 2 Harrison s sole liability and Purchaser s sole remedy for a failure of goods under this warranty and for any and all other claims arising out of the purchase and use of the goods including negligence on the part of the manufacturer shall be limited to the repair or replacement of ...

Page 31: ...ber Supplier Phone Number Air gun hose cleaning system UC EL 1 1 4 Ultra Clean Technologies 800 791 9111 Spline lubricant grease gun tube 379831 Chelsea 662 895 1101 Oil Reservoir Filter Element WO206 2200 Harrison Hydra Gen 800 723 3334 ...

Page 32: ...C Meter Display Package Harrison Hydra Gen Part Number FR800 4812 The FRC meter kit consists of the following components Qty Description 1 Display Unit 1 Alarm Buzzer 1 Voltage Transformer 1 Oil Temperature Sensor 2 Current Transformer ...

Page 33: ...EMBLY FILTER ASEMBLY PART WO990 110 O RING 63 09 X 3 53 NBR 70 O RING 22 X 3 5 NBR 70 O RING 82 14 X 3 53 NBR 70 FILTER ELEMENT WO206 2200 CAP BOLTS QTY 4 FILTER CAP FILTER HOUSING ELEMENT SHIELD Filter Assembly Part WO206 1100 ...

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