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Manufactured by Contour Hardening, Inc. 8227 Northwest Blvd., Suite 130 • Indianapolis, IN 46278 • 877-670-7325 • Fax (317) 275-9370 •
www.realacpower.com
Page 1
INSTALLATION
MANUAL
52-00159-A COPYRIGHT 2005 by Contour Hardening, Inc. All rights reserved.
Revised: 4/6/2010
Manufactured by Contour Hardening, Inc. 8227 Northwest Blvd., Suite 130 • Indianapolis, IN 46278 • 877-670-7325 • Fax (317) 275-9370 •
www.realacpower.com
Page 2
Caution: This product is not the
typical after-market
bolt-on unit. Please read
and understand all
directions before
proceeding with
installation!
Manufactured by Contour Hardening, Inc. 8227 Northwest Blvd., Suite 130 • Indianapolis, IN 46278 • 877-670-7325 • Fax (317) 275-9370 •
www.realacpower.com
Page 3
Table of Contents
Assumptions for Truck ................................................................................................................... 4
LIMITED WARRANTY ................................................................................................................ 5
OWNER’S RESPONSIBILITIES .................................................................................................. 5
LIMITATIONS ............................................................................................................................... 6
52-00159-A BOM ........................................................................................................................... 8
Safety Information .......................................................................................................................... 9
General Safety Information............................................................................................................. 9
Proper Selection of P.T.O. .............................................................................................................. 9
Safety Information ........................................................................................................................ 10
Use of Set Screws ......................................................................................................................... 10
Important Safety Information and Owner’s Manual ..................................................................... 10
Foreword ....................................................................................................................................... 11
Safety Label Instructions .............................................................................................................. 11
Muncie CS6B PTO Installation .................................................................................................... 12
Generator Mounting Bracket/ Generator Mounting ..................................................................... 14
Drive Shaft Installation ................................................................................................................. 14
Generator Mounting Bracket to Truck Chassis ............................................................................ 15
Generator Support Bracket to Truck Chassis ................................................................................ 15
Outlet Box Mounting .................................................................................................................... 16
12 Volt DC Electrical Controls Connections ................................................................................ 16
Connections at Customer Interface Circuits ................................................................................. 17
Connections at Connector 7205, Allison TCM............................................................................. 17
Connections at PTO ...................................................................................................................... 17
Connections at Generator Over Temperature Switch ................................................................... 18
Connections at Outlet Box (12VDC) ............................................................................................ 19
Connections at Generator 120VAC/240VAC ............................................................................... 20
Truck ECM Parameter Programming ........................................................................................... 21
Allison TCM Parameter Programming ......................................................................................... 21
Operating Instructions ................................................................................................................... 21
Manufactured by Contour Hardening, Inc. 8227 Northwest Blvd., Suite 130 • Indianapolis, IN 46278 • 877-670-7325 • Fax (317) 275-9370 •
www.realacpower.com
Page 4
Assumptions for Truck
Real Power®
Generator systems are designed to fit specific trucks; any deviation from the truck
it was designed for may require custom modifications. This same kit may fit several different
models from what is listed here. Please check with Real Power before making modifications as it
may void the warranty.
This kit was designed to fit:
• 2011 4300M7 LP 4x2 Chassis
• MH06500-152” W.B., 84.9” C.A., 63” Axle to Frame
• 12NTE-MaxxForce 7 Diesel Engine
• 13AKX-Allison 1000/2000 Series Transmission, 5-speed, with PTO Provision
• 8XBK-40 Amp auxiliary switch
• 12VZA-Remote mounted engine control
• 15SCD-Right side under cab fuel tank, 50 gallon
• 12VXT- Hand control throttle, engine speed control
• 16WLM- PTO hour meter
• 13WDH- Transmission body builder wiring
• 7BDM- Exhaust system, single horizontal after treatment device frame mounted right
side back of cab, includes vertical tail pipe and guard
• 0008VTJ-Battery box mounted under cab left side
Manufactured by Contour Hardening, Inc. 8227 Northwest Blvd., Suite 130 • Indianapolis, IN 46278 • 877-670-7325 • Fax (317) 275-9370 •
www.realacpower.com
Page 5
Exhibit B
LIMITED WARRANTY Contour Hardening, Inc. (MANUFACTURER) hereby warrants to the Original Purchaser (BUYER) of the Real Power chassis integrated AC generation system (SYSTEM) that the System will be free of defects in material and workmanship from the date of purchase as follows:
All rotating parts and components (excluding belts): 1 year All belts: 90 days Electrical Distribution-Outlet box and components therein: 1 year Repair or replacements parts: 90 days* Paint or coating on Electrical Distribution-Outlet Box: NOT WARRANTED
PROVIDED that the System is operated in accordance with the instructions contained herein. Manufacturer may require reasonable proof of your date of purchase, THEREFORE YOU SHOULD RETAIN YOUR SALES RECEIPT OR INVOICE. If Manufacturer confirms the defect and approves the warranty claim, Manufacturer will authorize the replacement of the defective part(s) and repair your System PROVIDED the work is coordinated and completed by MANUFACTURER’S LICENSED AND CERTIFIED INSTALLATION TECHNICIANS. For confirmed and approved warranted repairs, Manufacturer will pay for the parts and labor, including diagnostic labor.
* Repair or replacement parts are also warranted for ninety (90) days from the date of purchase. Any part repaired or replaced during the warranty period assumes the remainder of the original System warranty or ninety (90) days, whichever is greater.
OWNER’S RESPONSIBILITIES You are obligated to operate and maintain the System in accordance with the recommendations and instructions contained herein. You are responsible for the costs associated with such use, maintenance, and adjustments that may be required.
All warranty claims must be brought to the attention of Manufacturer or MANUFACTURER’S LICENSED RETAILERS/INSTALLERS within a reasonable time, preferably within thirty (30) days, after discovery that the System fails to meet this warranty.
You are responsible for payment of any of the following expenses that might be incurred as a result of a failure under the terms of this Limited Warranty:
1. Rental equipment used to replace the System or the vehicle on which the System is mounted during the time the System and vehicle are being repaired
2. Telephone and other communication expenses
3. Living and travel expenses
4. The premium costs for overtime labor requested by you to expedite the repair
5. The cost of airfreight or other extraordinary expenses for shipment of parts over and above premium surface transportation
6. Failures due to normal wear or excessive wear, lack of reasonable and necessary maintenance, accident, misuse, abuse, negligence in operation or maintenance,
Manufactured by Contour Hardening, Inc. 8227 Northwest Blvd., Suite 130 • Indianapolis, IN 46278 • 877-670-7325 • Fax (317) 275-9370 •
www.realacpower.com
Page 6
unauthorized modifications or repairs, use of add-on or modified parts not supplied by the Manufacturer, improper storage, vandalism, and improper installation or improper maintenance or service by anyone other than MANUFACTUER’S licensed and certified technicians.
LIMITATIONS
This Limited Warranty shall be limited to the repair or replacement of parts that prove defective under normal use and service and which on examination shall indicate to Manufacturer’s satisfaction they are defective. This Limited Warranty will not cover repair where normal use has exhausted the life of a part or the entire System. Like all other mechanical devices, this System needs periodic parts replaced and service to perform well. The service life of the System is dependent on the care that it receives and the conditions under which it operates. Extreme heat and/or dusty or dirty conditions can cause excessive wear. EXCESSIVE WEAR, when caused by improper maintenance or operation, is NOT COVERED by this Limited Warranty.
ALL REPAIRS, including warranted repairs, MUST BE PERFORMED BY MANUFACTURER’S LICENSED AND CERTIFIED INSTALLATION TECHNICIANS. INSTALLATION AND/OR REPAIR BY ANY OTHER MEANS WILL VOID ALL WARRANTIES FROM THE Manufacturer. To take advantage of this Limited Warranty, the vehicle that is equipped with your System must be returned to a licensed retailer-installer. To locate the licensed retailer-installer nearest you, contact us by calling (888) 867-2184. This Limited Warranty does not cover any failures or operating difficulties due directly or indirectly to normal or excessive wear, collision, negligence or accidents, abuse, misuse, unauthorized modifications –alterations – or the use of add-on or modified parts not supplied by the Manufacturer, vandalism, improper installation or improper maintenance or service by anyone other than MANUFACTUER’S licensed and certified technicians, or failure to perform normal and routine maintenance. Deterioration or damage due to severe weather conditions such as hurricanes, earthquakes or tornadoes, and exposure to corrosive chemicals either directly or in the atmosphere, is not coved by this Limited Warranty.
THERE ARE NO OTHER EXPRESS WARRANTS and any applicable implied warranties of merchantability and fitness for a particular purpose are limited in duration to the period of coverage of this express written Limited Warranty. TO THE EXTENT PERMITTED BY LAW, ANY AND ALL IMPLIED WARRANTIES ARE EXCLUDED. Some regions do not allow limitation on how long an implied warranty lasts, so this limitation may not apply to you. Manufacturer and its licensed retailer-installers are NOT LIABLE for any special, incidental, indirect, contingent, or consequential damages arising from the use of the System. Some regions do not allow limitation or exclusion of incidental or consequential damages, so this limitation may not apply to you. This Limited Warranty gives you specific legal rights. You may also have other rights that may vary from state to state or province. Manufacturer does NOT authorize any person or company to assume for it any other obligation or liability in connection with the sale, installation, use, removal, return, or replacement of its equipment; and no such representations are binding on Manufacturer. THIS LIMITED WARRANTY ONLY APPLIES TO SYSTEMS SOLD AT RETAIL.
Manufactured by Contour Hardening, Inc. 8227 Northwest Blvd., Suite 130 • Indianapolis, IN 46278 • 877-670-7325 • Fax (317) 275-9370 •
www.realacpower.com
Page 7
THE ABOVE WARRANTY SHALL ONLY BE IN EFFECT WHEN THE SYSTEM IS INSTALLED AND/OR REPAIRED BY MANUFACTURER’S LICENSED AND CERTIFIED INSTALLATION TECHNICIANS. INSTALLATION AND/OR REPAIR BY ANY OTHER MEANS VOIDS ALL WARRANTIES FROM THE MANUFACTURER. THE MANUFACTURER AND RETAILER-INSTALLER MAKE NO REPRESENTATION OR WARRANTY OF ANY KIND TO THE BUYER THAT HE OR SHE IS QUALIFIED TO MAKE ANY REPAIRS TO THE SYSTEM OR THAT HE OR SHE IS QUALIFIED TO REPLACE ANY PARTS OF THE SYSTEM. IN FACT, THE MANUFACTURER AND RETAILER-INSTALLER EXPRESSLY STATE THAT ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY CERTIFIED AND LICENSED TECHNICIANS AND NOT BY THE BUYER. THE BUYER ASSUMES ALL RISK AND LIABILITY ARISING OUT OF HIS OR HER REPAIRS TO THE SYSTEM OR REPLACEMENT PARTS THERETO, OR ARISING OUT OF HIS OR HER INSTALLATION OF REPLACEMENT PARTS THERETO.
REAL POWER DOES NOT
WARRANTY PROBLEMS
CREATED BY INSTALLATION
ERRORS OR PAY CLAIMS FOR
LABOR TO REMEDY THESE
PROBLEMS.
WARRANTY IS ON PARTS ONLY.
ANY LABOR CHARGES
ASSOCIATED WITH REPAIRING
DEFECTIVE PARTS WILL BE PAID
ACCORDING TO OUR FLAT RATE
LABOR TABLE.
Manufactured by Contour Hardening, Inc. 8227 Northwest Blvd., Suite 130 • Indianapolis, IN 46278 • 877-670-7325 • Fax (317) 275-9370 •
www.realacpower.com
Page 8
52-00159-A BOM
52-00159-A Complete Kit, International 12kW
Item ID Item Description Qty Needed
. 52-00201-0 PTO,Clutch Shift International 1.00
. . CS6B-A6907-H3BP PTO, Clutch Shift 1.00
. . 43M68014 Fitting, Lube Pressure Port 1.00
. . 43M78840 Fitting, Street Tee Lube Tap 1.00
. . 131-2-0001 Hose Kit, High Pressure 1.00
. . 51-00717-0 Bracket, Solenoid Mounting 1.00
. 52-00202-0 Generator, 12.5kw, 1800 RPM 1.00
. . ECO28-S/4 Generator, Model ECO28, 12.5KW 1.00
. . 51-00586-0 Key 1.00
. . STO-190 Thermostat, Snap Action Disc 1.00
. . NCG100-100 Cord Grip, 1" Non-Metallic 1.00
. . BL100 Locknut, 1" Tiger Grip, Steel 1.00
. . 51-00711-0 Air Filter, 12-30 KW 1.00
. 52-00203-0 Hardware Pack, Documentation 1.00
. . 91310A718 HHCS, M12-1.75 x 40mm Lg. 2.00
. . 91166A290 Washer, M12 Flat 14.00
. . 91202A246 Washer, M12 Lock 7.00
. . 90591A181 Nut, M12-1.75 Hex 7.00
. . 98126A837 Shim, 1/2" ID x 3/4" OD x 1/8" 5.00
. . 95904 Ground Strap, 24" 1.00
. . 91257A720 HHCS, 1/2"-13 x 2" Lg. 1.00
. . 91102A770 Washer, 1/2" Lock 1.00
. . 98026A033 Washer, 1/2" Flat x 1.375" GR8 1.00
. . 91310A715 HHCS, M12-1.75 x 35mm Lg. 5.00
. . D-350-14 Ring Terminal, 8 AWG, #1/4 5.00
. . 90190A294 Screw, Sheet Metal #12 x 3/4" 4.00
. . RW150-100 Reducing Washer, 1-1/2" - 1" 1.00
. . S-2839 Bag, 6" x 12", 4 mil 1.00
. . 042204-1 Decal, 5 x 7 White Reflective 2.00
. . 042204-2 Decal, 5 x 3-1/2 White Reflect 1.00
. . 042204-3 Decal, 7 x 3-1/2 White Vinyl 1.00
. . 042204-4 Decal, 2-1/2 x 3-1/2 Clear 1.00
. . 042204-5 Decal, 2-1/2 x 3-1/2 Clear 1.00
. . 042204-6 Card, 5 x 7 White Index 1.00
. . 042204-7 Card, 7 x 10 Canary 1.00
. . 050604-1 Decal, 3-3/8 x 6-1/4 White Vin 1.00
. . 072105-1 Triplicate Form, 8-1/2 x 11 1.00
. . 52-00159-MN Installation Manual, 12kw 1.00
. . 12-15_CS_OWNERS-MN Owners, Manual 12-15kw CS 1.00
. . 082509-1 Decal, 3 x 5 White Vinyl 1.00
. . ROG-0001 Decal, 3x5 White Vinyl 1.00
. . 90272A825 Screw, 10-32 x 1/4" Pan Head 1.00
. . 91114A011 Washer, #10 External-Tooth Loc 1.00
. 51-00590-0 Driveshaft 1.00
. 52-00049-A Outlet Box Assembly 1.00
. RP-202002-A Harness, Wiring 1.00
. 52-00211-0 Generator Frame Assembly 1.00
. . 51-00584-0 Channel, Generator Mounting 1.00
. . 51-00588-0 Isolation Pad 2.00
. . 51-00587-0 Bracket, Generator Support 1.00
. . 51-00585-0 Nut, Beveled 1.00
Manufactured by Contour Hardening, Inc. 8227 Northwest Blvd., Suite 130 • Indianapolis, IN 46278 • 877-670-7325 • Fax (317) 275-9370 •
www.realacpower.com
Page 9
Safety Information
These Instructions are for your safety and the safety of the end user. Read all instructions before
beginning installation. Read them carefully and understand them.
General Safety Information
To prevent injury to yourself and/or damage to the equipment: -Read carefully all owner’s manuals, service manuals, and/or other instructions.
-Never attempt to install without certified training from a Real Power technician.
-Never work alone while under a vehicle or while repairing or maintaining equipment.
-Always use proper components in applications for which they are approved.
-Be sure to assemble components properly.
-Never use worn-out or damaged components.
-Always block any raised or moving device that may injure a person while under vehicle.
-Never operate the controls of the P.T.O. or other driven equipment from any position that could
result in getting caught in the moving machinery.
Proper Selection of P.T.O.
A P.T.O. must be properly matched to the vehicle transmission and to the
auxiliary equipment being powered. An improperly matched P.T.O. could cause severe damage
to the vehicle transmission, the auxiliary drive shaft, and/or the auxiliary equipment being
powered. Damaged components or equipment could malfunction causing serious personal
injury to the vehicle operator or to others nearby.
To Avoid Personal Injury and/or Equipment Damage:
-Always refer to Real Power installation and owner’s manuals, follow Real Power
recommendations when selecting, installing, repairing, or operating a P.T.O.
-Never attempt to use a P.T.O. not specifically designed by Real Power for the vehicle.
Manufactured by Contour Hardening, Inc. 8227 Northwest Blvd., Suite 130 • Indianapolis, IN 46278 • 877-670-7325 • Fax (317) 275-9370 •
www.realacpower.com
Page
10
Safety Information
Rotating Auxiliary Drive Shafts
-Rotating auxiliary drive shafts are dangerous. You can snag clothes, skin, hair, hands, etc. This
can cause serious injury or death.
-Do not go under the vehicle when the engine is running.
-Do not work on or near an exposed shaft while the engine is running.
-Shut off engine before working on any component of the P.T.O. or generator.
-Exposed rotating drive shafts must be guarded.
-Disconnect vehicle battery cable before servicing.
Use of Set Screws
Auxiliary drive shafts may be installed with either recessed or protruding
setscrews. If a square head setscrew is used, you should be aware that it will protrude above the
hub of the yoke and may be a point where clothes, skin, hair, hands, etc. could be snagged. A
socket head setscrew, which may protrude above the hub of the yoke, does not permit the same
amount of torque, as does a square head setscrew. Also a square head setscrew, if used with
safety wire, will prevent loosening of the setscrew caused by vibration. Regardless of the type of
setscrew used, an exposed auxiliary drive shaft must always be guarded.
Important Safety Information and Owner’s Manual
Real Power generators are packed with safety information decals, instructions, and an owner’s
manual. Be sure to read the owner’s manual before installing or operating the P.T.O.
Always install the safety information decals according to the instructions provided. Personally
hand-deliver the owner’s manual to the end user after the install. If you require additional labels
or owner’s manual please contact Real Power at: 1-877-670-7325 or sales@realacpower.com
This symbol warns of entanglement.
Manufactured by Contour Hardening, Inc. 8227 Northwest Blvd., Suite 130 • Indianapolis, IN 46278 • 877-670-7325 • Fax (317) 275-9370 •
www.realacpower.com
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11
Foreword
This booklet will provide you with information on correct installation of Real Power chassis
integrated generators. Proper installation and set up procedures will help additional and more
profitable miles from your truck equipment and components. This manual is not written step
by step since the installation steps will be different if you are using an automotive lift versus
installing the generator on the ground. It is important that you determine before beginning any
installation that the transmission of the truck does in fact have a P.T.O. gear. If the transmission
does not have the P.T.O. drive gear, the unit is not compatible with a Real Power generator at
this time.
Safety Label Instructions
1. The two (2) black and orange on white 5” X 7” pressure sensitive vinyl labels must be placed
on the vehicle frame rails (one (1) on each side), in a position that would be highly visible to
anyone that would go under the vehicle near the P.T.O. rotating shaft.
2. Place the one (1) black and orange on white 3.5” X 5” pressure sensitive vinyl label on the
visor nearest the operator of the vehicle. Do not cover any other label that is already affixed to
the visor.
3. Place the one (1) red and white with black lettering 3.5” X 7” on pressure sensitive vinyl label
on the opposite side of the visor from the above label. Again, do not cover labels already
affixed to the visor.
4. Place the one (1) white and black 5” X 7” heavy duty card in the vehicle glove box. Again in
a position highly visible to the operator, for example: Try to place this card on top of whatever
may be in the glove box.
5. Place one (1) 2” X 3.5” black and orange pressure sensitive vinyl label on driver side lower
right (viewed from outside of vehicle) window. Place one (1) 2” X 3.5” black and orange
pressure sensitive vinyl label on passenger side lower right (viewed from outside of vehicle)
window. If you require additional labels, send request to:
Contour Hardening, Inc.
Attn. Real Power Labels
8401 Northwest Blvd.
Indianapolis, IN 46278
(877) 670-7325
Manufactured by Contour Hardening, Inc. 8227 Northwest Blvd., Suite 130 • Indianapolis, IN 46278 • 877-670-7325 • Fax (317) 275-9370 •
www.realacpower.com
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International 4300LP 12kW Installation Manual
Muncie CS6B PTO Installation
1. If the leaf spring mounting bolt directly across from PTO opening has threads facing
toward the PTO it will need to have excess threads ground or cut off so that bolt is flush
at nut (no threads protruding past end of nut), Fig.12-1.
2. Install PTO per Muncie Installation Manual (key points listed below).
a. Remove PTO cover.
b. Install mounting studs (20TK4360) into transmission as described on
supplemental sheet provided with PTO.
c. Remove inspection cover from PTO.
d. See CS6 Series note on page 1.5 of Muncie Installation Manual. Install .020”
thick gaskets on both sides of spacer (Muncie P.N. 23M60270) onto mounting
studs, apply thin layer of transmission fluid to both sides of gasket, and do not use
sealant.
e. Position PTO on mounting studs and start nuts provided with studs, make sure
gear teeth are properly meshed before tightening nuts.
f. See CS6 Series note on page 1.5 of Muncie Installation Manual. Check
backlash on PTO gear through inspection cover, backlash should be .010” to
.024”.
g. Once correct backlash has been achieved, torque all mounting nuts to 40-45 lb-ft
unless noted in a separate stud kit instruction.
h. Install inspection cover on PTO, torque to 14-18 lb-ft.
3. Install pressure port fitting (43M68014) and lube tap fitting (43M78840) per Muncie
Installation Manual page 2.15, Fig. 12-2.
4. Install hydraulic hose fittings into PTO and solenoid per Muncie Installation Manual page
2.21.
5. Mount solenoid to mounting bracket (51-00717-0) using supplied hardware (2-19T36623,
2-22T35140, 2-21T37991), Fig.13-1.
Fig. 12-2 Fig. 12-1
Lube Tap Pressure
Port
Manufactured by Contour Hardening, Inc. 8227 Northwest Blvd., Suite 130 • Indianapolis, IN 46278 • 877-670-7325 • Fax (317) 275-9370 •
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6. Mount solenoid and mounting bracket to transmission bell housing using bolt above
transmission filter, Fig.13-2.
7. Using high pressure hose kit (131-2-0001), make hydraulic lines and connect per Muncie
Installation Manual page 2.21.
a. Cut hydraulic line to length.
b. Screw lower end of fitting onto hydraulic line (reverse threads), tighten, Fig. 13-3.
c. Using a leather punch ream the inside of the hydraulic line with the fitting, Fig. 13-4.
d. Apply a small amount of grease to the upper fitting, Fig. 13-5.
e. Install upper fitting into lower fitting and hydraulic line, tighten, Fig. 13-6.
f. Repeat for opposite end.
Fig. 13-1 Fig. 13-2
Fig. 13-3 Fig. 13-4
Fig. 13-5 Fig. 13-6
Lower end of fitting
Upper end of fitting
Ream inside of fitting
Manufactured by Contour Hardening, Inc. 8227 Northwest Blvd., Suite 130 • Indianapolis, IN 46278 • 877-670-7325 • Fax (317) 275-9370 •
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8. Install pressure switch per Muncie Installation Manual page 2.21.
9. Once all hydraulic hose connections are made, start truck, check for leaks, check
transmission fluid level, listen for noise, and if noisy refer to Muncie Installation Manual
pages 1.4-1.6.
Generator Mounting Bracket/ Generator Mounting
1. Locate generator mounting bracket (51-00584-0), Fig. 14-1, just behind the first cross
member rear of the back of cab. Position mounting bracket over truck drive shaft inside
of frame rails so that it rests on the lower flange of both frame rails, Fig. 14-2.
2. Place rubber isolation pads (51-00588-0) between generator mounting frame and lower
flange of both frame rails to create a “cushion” for the generator mounting bracket.
3. Raise generator assembly (52-00202-0) with shaft of generator pointing towards the front
of truck and the electrical connection box facing outboard on the driver’s side, Fig.14-3.
4. Using supplied hardware (4-M12-1.75x35mm hex head bolts, 8- M12 flat washers, 4-
M12 lock washers, and 4-M12-1.75 nuts); bolt the generator to generator mounting
frame. Torque to 88 lb-ft, Fig. 14-4.
Drive Shaft Installation
1. Coat PTO output shaft and key with white lithium grease. Coat generator input shaft and
key with white lithium grease.
2. Remove set screws from both ends of drive shaft.
3. Slide 1.25” yolk of drive shaft onto PTO until setscrew hole lines up with recessed area
in PTO shaft. Apply a drop of Loc-Tite Red to both set screws and tighten, setscrews
must be torqued to 22 lb-ft, Fig. 15-1.
Fig. 14-1 Fig. 14-2
Fig. 14-3
� Front of truck
Fig. 14-4
Manufactured by Contour Hardening, Inc. 8227 Northwest Blvd., Suite 130 • Indianapolis, IN 46278 • 877-670-7325 • Fax (317) 275-9370 •
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4. Slide 42mm yolk of drive shaft onto generator input shaft and key, if necessary reposition
generator so that drive shaft can be easily installed, Fig. 15-2. Slide yolk on until end of
generator shaft is flush with inside of yolk. Apply a drop of Loc-Tite Red to both set
screws and tighten, setscrews must be torqued to 22 lb-ft.
5. Reposition generator and mounting bracket with rubber isolation pads so that
approximately .5”-.75” of the drive shaft slip joint is exposed.
Generator Mounting Bracket to Truck Chassis
1. Mark 2 holes to be drilled in truck frame using the mounting holes on the generator
mounting bracket as a template.
2. Drill 2 marked holes .5” in diameter through truck frame rail.
3. Using supplied hardware (2-M12-1.75x40mm hex head bolts, 4- M12 flat washers, 2-
M12 lock washers, and 2-M12-1.75 nuts); loosely bolt the generator mounting bracket to
truck chassis, Fig. 15-3. Install U-Shaped shims between generator mounting bracket and
truck chassis to fill in any gaps on each side. Torque mounting hardware to 88 lb-ft.
Generator Support Bracket to Truck Chassis
1. Position generator support bracket (51-00587-0) so that a hole lines up with the generator
lifting eye on side of generator behind electrical cover. Using supplied hardware (1-1/2”-
13x 2” hex head bolt, 1-1/2” lock washer, 1-1/2”x1.375” flat washer and beveled nut (51-
00585-0); loosely bolt generator support bracket to generator, Fig. 15-4.
2. Position generator support bracket so that it lays flat against the truck frame. Mark hole to
be drilled in truck frame using generator support bracket as a template.
3. Drill marked hole .5” in diameter through truck frame rail.
Fig. 15-1 Fig. 15-2
Recessed area
Generator mounting bracket to
truck chassis mounting bolt
Fig. 15-3 Fig. 15-4
Manufactured by Contour Hardening, Inc. 8227 Northwest Blvd., Suite 130 • Indianapolis, IN 46278 • 877-670-7325 • Fax (317) 275-9370 •
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4. Using supplied hardware (1-M12-1.75x35mm hex head bolt, 2-M12 flat washers, 1-M12
lock washer, and 1-M12-1.75 nut); bolt generator support bracket to truck frame, Fig. 16-
1. Torque to 88 lb-ft.
5. Torque lower generator support bracket bolt to 110 lb-ft.
Outlet Box Mounting
1. Remove panel from inside of outlet bed box by removing the 6 screws down the left &
right side of panel, Fig. 16-2.
2. Remove locking nut from cable fitting, remove cable fitting.
3. Mark hole in center of box mounting location and use a 1 3/8” hole saw to cut the hole.
4. File rough edges from hole cut with hole saw.
5. Install cable fitting through outlet box, install provided reducing washer (1.5” to 1”) on
outside of body around cable fitting, and connect with lock nut. Tighten lock nut.
6. Mount box using four (4) #12 X ¾” sheet metal screws. Do not over tighten.
7. Route cable through cable fitting.
8. Route cable through frame rail towards generator location. Keep away from moving parts
and or sources of heat. Use zip ties to securely mount cable to vehicle frame.
9. Do not install panel, leave some space to attach wires to back of panel in a later step.
12 Volt DC Electrical Controls Connections
1. Secure Real Power wiring harness (RP-202002-A) near 12 Volt relays to truck wiring
harness near firewall and driver side fender under the hood using zip ties, Fig. 16-3.
Fig. 16-1
Support
bracket from
generator to
truck frame
Fig. 16-2
Fig. 16-3 Fig. 16-4
Manufactured by Contour Hardening, Inc. 8227 Northwest Blvd., Suite 130 • Indianapolis, IN 46278 • 877-670-7325 • Fax (317) 275-9370 •
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2. Route first bundle of wires (blue, green, blue w/white stripe, blue w/white stripe) to
customer interface circuits near the dash harness and mega fuse near the firewall on
driver side, Fig. 16-4.
Connections at Customer Interface Circuits
1. Connect the blue wire from the Real Power harness to the light green wire for 40 amp
auxiliary switch. Connect using supplied butt connector, heat butt connector to shrink
after crimping.
2. Connect the green wire from the Real Power harness to the light green wire for PTO
Hour Meter (circuit K88B). Connect using supplied butt connector, heat butt connector to
shrink after crimping.
3. Connect one of the blue w/white stripe wires from the Real Power harness to the wire
labeled: Pin 16 (Preset PTO Enable). Connect using supplied butt connector, heat butt
connector to shrink after crimping.
4. Connect the other blue w/white stripe wire from the Real Power harness to the wire
labeled: Pin 68 (Set PTO Speed). Connect using supplied butt connector, heat butt
connector to shrink after crimping.
5. Secure harness away from moving and hot parts using zip ties.
Connections at Connector 7205, Allison TCM
1. Route second bundle of wires (red, blue, purple, Fig. 17-1) to the body builder wires
located by the customer interface circuits near the dash harness and mega fuse on the
firewall, driver side.
2. Plug the red wire from the Real Power harness in to connector 7205 Pin C, PTO Enable
Output.
3. Plug the blue wire from the Real Power harness in to connector 7205 Pin B, PTO Enable
Input.
4. Plug the purple wire from the Real Power harness in to connector 7205 Pin G, Range
Indicator Output.
5. Secure harness away from moving and hot parts using zip ties.
6. Route remaining cable along chassis to PTO area taking care to zip tie cable away from
moving and hot parts.
Connections at PTO
1. Route the third set of wires (black, red, black, black, black, Fig. 17-2) to PTO.
Fig. 17-1 Fig. 17-2
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2. Connect the ring terminal to a suitable chassis ground (one of the mounting bolts for the
solenoid to the solenoid bracket is a good location) Fig. 18-1.
3. Plug the 2 pin connector in to the mating 2 pin connector on the PTO pressure switch.
4. Connect the red wire from the Real Power harness to one of the black wires on the PTO
solenoid, Fig. 18-1. Connect using supplied butt connector, heat butt connector to shrink
after crimping.
5. Connect the black wire from the Real Power harness to the other black wire on the PTO
solenoid, Fig. 18-1. Connect using supplied butt connector, heat butt connector to shrink
after crimping.
6. Route remaining cable along chassis to generator area taking care to zip tie cable away
from moving and hot parts.
Connections at Generator Over Temperature Switch
1. Remove the black electrical cover from the side of the generator.
2. Route fourth set of wires (blue and blue w/white stripe, Fig. 19-1) through rubber
grommet on generator electrical cover (rubber grommet may be removed from electrical
cover to make connections easier, Fig. 20-2) and connect blue and blue w/white stripe
wires to over temperature switch on generator, Fig. 19-2. It does not matter which side of
the over temperature switch the wires are connected as long as one wire is on each
connector.
3. Route remaining cable along chassis to outlet box area taking care to zip tie cable away
from moving and hot parts.
Fig. 18-1
Ground
Butt
connectors
Pressure
switch
Manufactured by Contour Hardening, Inc. 8227 Northwest Blvd., Suite 130 • Indianapolis, IN 46278 • 877-670-7325 • Fax (317) 275-9370 •
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Connections at Outlet Box (12VDC)
*Note: Outlet box should be mounted and electrical panel removed before making these
connections.
1. Route the last set of wires (black, blue, blue, red) through electrical bushing in outlet box
with large 5 conductor cable.
2. Connect the black wire with ring terminal to inside of outlet box, Fig.19-3, using
supplied 10/32 x .25” pan head machine screw and external tooth washer.
3. Connect blue wire with .187” female quick connect to terminal 4B on the Emergency
Stop Switch located on the electrical panel, Fig. 19-4.
4. Connect red wire with .187” female quick connect to terminal 3B on the Emergency Stop
Switch located on the electrical panel, Fig. 19-4.
5. Connect blue wire with .25” female quick connect to either terminal on Over
Temperature Light on the electrical panel, Fig. 20-1.
6. Connect the blue w/white stripe wire with .25” female quick connect to either terminal on
Over Temperature Light on the electrical panel, Fig. 20-1.
7. Re-install outlet panel to bed box with the six screws removed earlier.
Fig. 19-1 Fig. 19-2
Over
Temp.
Switch
Fig. 19-3 Fig. 19-4
Manufactured by Contour Hardening, Inc. 8227 Northwest Blvd., Suite 130 • Indianapolis, IN 46278 • 877-670-7325 • Fax (317) 275-9370 •
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Connections at Generator 120VAC/240VAC
1. Route five conductor cable through cord grip cable fitting on side of generator electrical
cover, Fig. 20-2.
2. Cut five conductor cable to length.
3. Carefully strip back the outer insulation of the five conductor cable to expose the five
individual wires beneath.
4. Strip approximately ¼” of insulation from each wire and crimp a supplied ring terminal
to each wire.
a. Connect the white wire from the five conductor cable to the terminal marked L1,
Fig. 20-3. Tighten nut on stud to 6 NM, do not over tighten.
b. Connect the black wire from the five conductor cable to the terminal marked L2,
Fig. 20-3. Tighten nut on stud to 6 NM, do not over tighten.
c. Connect the red, orange, green wires from the five conductor cable to the terminal
marked with the ground symbol, Fig. 20-3. Tighten nut on stud 6 NM, do not over
tighten.
d. Coat all connections with Scotch Liquid Electrical tape to seal the connections from
corrosion.
e. Install electrical cover onto generator using four screws previously removed, torque
to 6 NM.
f. Attach ground strap to body of generator and connect to clean chassis ground on
truck frame rail.
Fig. 20-1 Fig. 20-2
Cord
Grip
Rubber
grommet for
over temp.
wires
White wire
Black wire
Red, orange, & green wires
Fig. 20-3
Manufactured by Contour Hardening, Inc. 8227 Northwest Blvd., Suite 130 • Indianapolis, IN 46278 • 877-670-7325 • Fax (317) 275-9370 •
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Truck ECM Parameter Programming
Truck must be programmed before attempting to operate Real Power generator system. System
damage may occur if truck is not correctly programmed before operation.
Programmable Parameter Name Value
PTO: Power Take Off Mode Preset Engine Speed Control
PTO: In-Cab Mode Stationary Preset
PTO: In-Cab Control On
PTO: Preset RPM 1 (Set) 1200 RPM's
PTO: Preset RPM 2 (Resume) 1200 RPM's
PTO: Preset RPM 3 Off
PTO: Preset RPM 4 Off
PTO: Preset RPM 5 Off
PTO: Preset RPM 6 Off
PTO: Max RPM 1300 RPM's
PTO: RPM Ramp Rate 300 RPM's/Second
PTO: Max VS 1 MPH
PTO: Remote Pedal Enable Off
Allison TCM Parameter Programming
• Wires 143, 145, & 150 must be enabled and should be enabled from the factory. They
can be enabled by changing the CMC’s using the Allison DOC software.
• Change CMC: Max engine speed for PTO operation to 1500 RPM’s using the Allison
DOC software. This will prevent the generator from over speeding.
Operating Instructions
Operation instructions can be found in the Owner’s Manual.
Operational Test
Test at a no load condition. Test with generator running at operating speed.
1. Measure frequency at one of the outlets on the outlet box using a frequency meter.
Frequency should read between 58 to 62 Hz.
2. Measure voltage at one of the outlets on the outlet box using a voltage meter. Voltage
should read between 105 VAC and 125 VAC when measured at one of the GFCI’s.
Voltage should read between 210 VAC and 250 VAC when measured at the twist lock
plug.
3. Test the GFCI’s by pushing the test and reset buttons. GFCI should trip when test button
is pushed and reset when the reset button is pushed.
4. Test the dash mounted PTO switch by turning it off with generator running, voltage
should drop within 5 seconds and driveshaft should quit spinning within 15 seconds.
5. Test the emergency stop switch on the outlet box by turning it off with generator running,
voltage should drop within 5 seconds and driveshaft should quit spinning within 15
seconds.
6. PTO drag brake may need to be adjusted if voltage does not drop within 5 seconds
of turning off the emergency stop switch or the dash mounted PTO switch. See CS6
Series note on page 2.22 of Muncie Installation Manual for drag brake adjustment
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location. Adjust drag brake only with engine off. Tighten all 4 setscrews evenly in ¼
turn increments, checking after each adjustment. Driveshaft should stop spinning
within 5 seconds of turning off emergency stop or PTO dash switch when properly
adjusted. If PTO emits a noise after adjustment, PTO is adjusted too tight. Loosen
setscrews in ¼ turn increments, checking after each adjustment.
If any of these tests result in ranges outside of specifications given, contact Real Power
Technical Support @ 877-670-7325.