52-00159-A Installation Manual - Real Power · Manufactured by Contour Hardening, Inc. 8227...

Manufactured by Contour Hardening, Inc. 8227 Northwest Blvd., Suite 130 • Indianapolis, IN 46278 • 877-670-7325 • Fax (317) 275-9370 •

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INSTALLATION

MANUAL

52-00159-A COPYRIGHT 2005 by Contour Hardening, Inc. All rights reserved.

Revised: 4/6/2010


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Caution: This product is not the

typical after-market

bolt-on unit. Please read

and understand all

directions before

proceeding with

installation!


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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


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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


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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,


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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.


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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.


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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


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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.


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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 [email protected]

This symbol warns of entanglement.


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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


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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


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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


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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


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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


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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


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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


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19

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


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20

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


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21

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: 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.

Date post:	01-Apr-2018
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