Setting the Standard in Mobile Power

Instruction Manual for Model

HYDRO 400X

Hydraulic Generator

Manufacturing of: Vehicle Mounted Generators • Hydraulic Generators

P.O. Box 582 • Chester, NY 10918 • 845-469-9151 • Fax: 845-469-7871 • Web Site/E-mail: www.fabcopower.com

Fabco Power

GENERAL INFORMATION

Instruction Manual

MODEL: HYDRO 400X

GENERATOR ............ BRUSHLESS

GENERATOR ............ 3600 (60 Hz)

GENERATOR VOLTAGE ............ 120 or 120/240

MOTOR STARTING ............ 300% SURGE

VOLTAGE REGULATOR ............ INHERENT

OUTPUT ............ 4000 WATTS CONTINUOUS

4500 WATTS PEAK AT

100°F OIL TEMPERATURE

HYDRAULIC MOTOR ............ GEAR TYPE WITH BUILT IN

FLOW CONTROL

FLOW CONTROL PRESSURE COMPENSATION

BY-PASS TYPE

MAXIMUM SPEED ............ 4200RPM

(3600 RPM IDEAL)

MOTOR SHAFT ............ ½ inch

PORT SIZE

INLET ............ 3/4 - 8 S.A.E.

RETURN ............ 7/8 - 10 S.A.E.

CASE DRAIN PORT ............ 7/16 - 4 S.A.E.

• Page 2 •

Fabco Power Instruction Manual

RECOMMENDATIONS

MODEL: HYDRO 400X

HIGH PRESSURE LINE ........................ ½ inch

LOW PRESSURE LINE .......................... ¾ inch

FLOW RATE .......................................... 8 to 25 GPM

(8 GPM IDEAL)

FOR BEST RESULTS KEEP HYDRAULIC OIL

TEMPERATURE BETWEEN 80°F AND 120°F.

DO NOT EXCEED 175°F.

AN OIL COOLER IS RECOMMENDED.

MAXIMUM BACK PRESSURE ............. 150 PSI

WILL OPERATE ON ANY 2500 PSI OPEN CIRCUIT

OR CLOSED LOOP SYSTEMS.

RECOMMEND FILTER ........................ 10m

RECOMMEND HYDRAULIC OIL ....... DEXTRON III A.T.F.

INSTALLATION TIPS

Excessive pressure in your return line will damage the hydraulic motor seal. High back pressure can be caused by

“spikes” sent back through the return from other equipment on a common return line. Another potential problem can develop if several pieces of equipment are connected to one “common” return line causing a high back pressure (150 PSI is the maximum). We recommend you run the return line from the generator back to the cooling tank with a separate line.

You can either run the 3/4 inch return line back to the tank or leave the 3/4 inch line connected to a common return and run a separate 3/8 inch line from the case drain (located at the bottom of the hydraulic motor) directly back to the tank. Either way you completely eliminate any problem of excessive return line pressure damaging your hydraulic motor.

• Page 3 •

Fabco Power Instruction Manual

Initial Installation and Start-Up

Be sure you set the hydraulic flow (GPM) to the generator at

Approximately 62.5 HZ or 3750 RPM with NO electrical load on the generator.

By using this setting you will have approximately 60HZ

(cycles) or 3600 RPM when you are running at full rated load.

One way this can be accomplished is by using a Photo

Tachometer on our generator coupling or generator cooling fan.

A Photo Tachometer is an inexpensive tool that can be purchased at McMasters, Grainger, Sears or any other electrical supplier.

• Page 4 •

Fabco Power Instruction Manual

TECHNICAL INFORMATION

These self-excited and self-regulating generators, although overall dimensions have been reduced to a minimum, are designed for high-level electrical performance and the maximum in operating reliability.

PRELIMINARY CHECKS: Before touching the machines, perform a thorough and in depth visual inspection, checking that components are correctly connected up and that no cables or terminals are broken or loose.

STARTING UP: Make sure, when starting up, that cooling air intake and discharge openings are free and unblocked. We also recommend (when the machine operates in a dusty environment) do periodic checks to make sure it is properly ventilated

THE IMPORTANCE OF SPEED: Frequency and voltage depend directly on rotation speed. This must be kept as constantly as possible on its nominal value no matter what the load. Drive motor speed control systems generally have a small drop in speed between no load and loaded conditions. We therefore recommend setting no load speed 3÷4% above nominal speed.

CHECKING VOLTAGE: All the machines are regulated during factory testing. If voltage readings differ from the value indicated on the name plate, this maybe caused by a mistaken reading or by a different rotation speed and we recommend regulating motor speed in order to have nominal RPM under loaded conditions.

CHECKING THE DIODES: For the ohmmeter test it is best to disconnect the diode from its circuit.

Measure continuity in one direction only. The test can also be made without disconnecting the diode form the circuit, using a 12V battery and a 45 watt light bulb (automobile light) as shown in the illustration.

The light should turn totally on only in one direction, as shown below.

WINDING RESISTANCE AT 20° C

ROOM TEMPERATURE

Size Stator

Ω

Rotor

Ω

Exciter

Ω

3.5

4.0

5.0

6.0

8.0

12.0

.506

.506

.506

.506

0.300

0.196

4.38

4.38

4.38

4.38

5.75

7.54

2.10

2.10

2.10

2.10

1.25

0.44

• Page 5 •

Fabco Power

CONNECT NEUTRAL

TO GROUND IF USING

Instruction Manual

ELECTRICAL CONNECTIONS

GROUND SCREW ON

GENERATOR FRAME.

USE GREEN WIRE

FOR GROUND IF

GROUND SCREW ON

GENERATOR FRAME.

USE GREEN WIRE

FOR GROUND IF

USING GFCI OUTLETS

• Page 6 •

Fabco Power Instruction Manual

PARTS BREAKDOWN

HYDRO 400X

No. PART # DESCRIPTION

1 572262 Louvered Panel

2 572268 Frame For Stator

3 572182 Drive End Bell

4 572235 Front Bearing

5 572184 Fan

6 572269 Rotor

8 572064 Rear Bearing

13 572186 User Terminal Board

15 572260 Cover

17 572288 Capacitor (31.5 mfd/w Tie Wraps)

19 572196 Diodes

20 572615 Pump Mount

21 572066 Coupling 24mm

22 572067 Spider

23 572068 Coupling ½

24 572173 Motor w/Flow Control

25 572128 Rails

26 572154 Mounts

27 572179 Flow Control Cartridge (8 GPM)

28 572261 Stud Cover

29 572263 Rubber Cup

30 572272 Fan Ring

572072 Seal For Hydraulic Motor

572274 Generator Complete

572159 Voltage Indicating Light

572158 Overload Protection Device

• Page 7 •

PART # OPTIONAL CONTROL PANEL

572227 Complete Control Panel

572228 Control Box (Shell)

572052 Volt Meter

572054 Receptacle 120 Volt

572100 Waterproof Recpt. Cover

572226 GFI Outlet 120 Volt

Fabco Power Instruction Manual

TROUBLE SHOOTING

PROBLEMS

ALTERNATOR EXCITATION

FAILURE

CAUSES

1.

2.

3.

Low Speed

Faulty capacitor

Faulty winding

HIGH NO-LOAD VOLTAGE

LOW NO-LOAD VOLTAGE

UNSTABLE VOLTAGE

PROPER NO-LOAD BUT LOW

LOADED VOLTAGE

1. Speed too high.

2. Capacitor with high capacity.

1. Speed too low.

2. Faulty rotary diodes.

3. Breakdown in windings.

4. Capacitor with high capacity.

1. Low loaded speed.

2. Load too large.

3. Rotary diodes short-circuited

1. Loose contacts.

2. Uneven rotation.

NOISY GENERATOR 1. Broken bearings.

2. Poor couplings.

• Page 8 •

REMEDIES

1. Check RPM and set at nominal value.

2. Check and replace.

3. Check that winding resistance is as shown in the tables.

1. Check and adjust RPM’s

2. Check and replace

1. Check and adjust RPM’s

2. Check and replace.

3. Check winding resistance, as per tables.

4. Check and replace.

1. Check and regulate RPM.

2. Check and change.

3. Check and replace.

1. Check connections.

2. Check for uniform rotation speed.

1. Replace.

2. Check and repair.

Fabco Power Instruction Manual

FIXED DISPLACEMENT

TYPE GEAR PUMP

4

2

3

1

5

8

7

6

TYPICAL HYDRAULIC SCHEMATIC

9

1.

HYDRAULIC PUMP

2.

PRESSURE RELIEF VALVE

3.

CONTROL VALVE

4.

PRIORITY FLOW CONTROL*

5.

GENERATOR HYRAULIC MOTOR

6.

CASE DRAIN LINE**

7. RETURN LINE FILTER

8. OIL COOLER

9.

HYDRAULIC FLUID RESERVOIR

* Some units may be equipped with integral priority flow control, refer to specific model number.

** External case drain line may be required on some units refer to specific model number.

When external case drain is required it should be unobstructed direct return to reservoir with a minimum I.D. no less than that of case drain port on generator motor.

FOR SPECIFIC INSTALLATION RECOMMENDATIONS CONSULT FACTORY

• Page 9 •

Fabco Power Instruction Manual

BRUSHLESS GENERATOR

WIRING

• Page 10 •

Fabco Power

HYDRAULIC MOTOR

HOSE HOOK-UP

Fabco Power

• Page 11 •

Instruction Manual

Fabco Power Instruction Manual

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Fabco Power Instruction Manual

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