Contour Hardening realpower User manual

Rev. 6: 4/18/2007
CHASSIS INTEGRATED AC GENERATOR
OWNER’S MANUAL
Designed & Manufactured By
8401 Northwest Boulevard
Indianapolis, Indiana 46278
[phone]
Fax [phone]
www.realacpower.com
For customer assistance, please call [phone]

2 of 15 Rev. 6: 4/18/2007
TABLE OF CONTENTS
PATENTED DEVICE ....................................................................................................................3
LIMITED WARRANTY ..................................................................................................................3
OWNER’S RESPONSIBILITIES ...................................................................................................3
LIMITATIONS ...............................................................................................................................4
SPECIFICATIONS ........................................................................................................................5
SAVE THIS MANUAL ...................................................................................................................5
SAFETY WARNINGS AND PRECAUTIONS................................................................................6
ELECTRIC GENERATOR SAFETY PRECAUTIONS AND WARNINGS .....................................8
COMMON SENSE AND CAUTION PREVAIL ..............................................................................8
ENVIRONMENTAL IMPACT ON ELECTRICAL PERFORMANCE ..............................................9
UNAUTHORIZED AND UNTESTED USE - MISUSE ...................................................................9
INSTALLATION ............................................................................................................................9
OPERATION...............................................................................................................................10
MAINTENANCE..........................................................................................................................13
TROUBLE SHOOTING...............................................................................................................14
COPYRIGHT © 2006 by Contour Hardening, Inc. All rights reserved. No portion of this manual or any
artwork contained herein may be reproduced in any shape or form without the express written consent of
Contour Hardening, Inc. Real Power is a trademark of Contour Hardening, Inc.
Ford is a registered trademark and/or service mark of Ford Motor Company.
GM is a registered trademark and/or service mark of General Motors Corporation.
8401 Northwest Boulevard
Indianapolis, Indiana 46278
[phone]
Fax [phone]
www.realacpower.com

Rev. 6: 4/18/2007 3 of 15
PATENTED DEVICE
The following patents issued by the United States Patent and Trademark Office cover the Real Power ™
chassis integrated AC generation system and/or the methods for using it:
US Patent # 6,979,913
US Patent # 7,057,303
Patent applications and patents issued in various other countries also cover the Real Power system
and/or the methods for using it.
LIMITED WARRANTY
Contour Hardening, Inc. (MANUFACTURER) hereby warrants to the Original Purchaser (PURCHASER)
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 date of purchase, THEREFORE PURCHASER SHOULD
RETAIN THE SALES RECEIPT OR INVOICE.
After Manufacturer confirms the defect and approves the warranty claim, Manufacturer will authorize the
replacement of the defective part(s) and repair the System PROVIDED the work is coordinated and
completed by MANUFACTURER’S DESIGNATED TECHNICIANS. For confirmed and approved
warranted repairs, Manufacturer will pay for the parts and labor, including diagnostic labor as outlined in
the “Flat-Rate Warranty Schedule” unless pre-authorized by Manufacturer in writing.
* 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.
PURCHASER’S RESPONSIBILITIES
Purchaser is obligated to operate and maintain the System in accordance with the recommendations and
instructions contained herein. Purchaser is responsible for the costs associated with such use,
maintenance, and adjustments that may be required.
All warranty claims must be brought to Manufacturer’s attention within a reasonable time, preferably
within thirty (30) days, after discovery that the System fails to meet this warranty.
Purchaser is 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 of 15 Rev. 6: 4/18/2007
4. the premium costs for overtime labor requested by Purchaser 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,
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;
7. transportation of vehicle to designated repair facility; and
8. failures due to electrical overloads or short circuits.
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
DESIGNATED TECHNICIANS. INSTALLATION AND/OR REPAIR BY ANY OTHER MEANS WILL VOID
ALL WARRANTIES FROM THE MANUFACTURER. To take advantage of this Limited Warranty, contact
us by calling [phone].
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
designated 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 Purchaser.
Manufacturer is 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 Purchaser.
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.

Rev. 6: 4/18/2007 5 of 15
THE ABOVE WARRANTY SHALL ONLY BE IN EFFECT WHEN THE SYSTEM IS INSTALLED AND/OR
REPAIRED BY MANUFACTURER’S DESIGNATED TECHNICIANS. INSTALLATION AND/OR REPAIR
BY ANY OTHER MEANS VOIDS ALL WARRANTIES. MANUFACTURER MAKES NO
REPRESENTATION OR WARRANTY OF ANY KIND TO THE PURCHASER 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, MANUFACTURER EXPRESSLY STATES THAT
ALL REPAIRS AND PARTS REPLACEMENTS SHOULD BE UNDERTAKEN BY MANUFACTURER’S
DESIGNATED TECHNICIANS AND NOT BY THE PURCHASER. THE PURCHASER 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.
SPECIFICATIONS
ITEM DESCRIPTION
12kW Unit 15kW Unit
12,000 watts (continuous) rated
at 60 Hz
15,000 watts (continuous) rated
at 60 Hz
Power Output
13,200 watts (maximum-peak for
up to 2 hours in a 24 hour period)
16,500 watts (maximum-peak for
up to 2 hours in a 24 hour period)
Voltage Output 2 – 120 VAC (20 amp), single phase duplex GFCI receptacles;
1 – 240 VAC (30 amp), single phase twist-lock receptacle
Installed Weight 183 pounds
Environmental Operating
Temperature
maximum 180° Fahrenheit – thermal switch protection
Intake Air Filtration 200 micron filter
Generator operation 2-pole, revolving field, brushless excitation
SAVE THIS MANUAL
You will need the manual for the safety warnings and precautions, assembly instructions, operating and
maintenance procedures, parts list, and diagram. Keep your invoice with this manual. Write the invoice
number on the inside of the front cover. Keep the manual and invoice in a safe and dry place for future
reference.

6 of 15 Rev. 6: 4/18/2007
SAFETY WARNINGS AND PRECAUTIONS
READ AND FOLLOW ALL SAFETY LABELS AND WARNINGS
This symbol warns of injury.
This symbol warns of entanglement.
When using Real Power, basic safety precautions should always be followed
to reduce the risk of personal injury and damage to equipment.
Read all instructions before using this tool!
1. Keep work area and area under vehicle clean. Cluttered areas invite injuries.
2. Observe work area conditions. Do not use electricity or power tools in damp or wet locations. Keep
work area well lighted. Do not use electrically powered tools in the presence of flammable gases or
liquids.
3. Secure the vehicle and keep children away. Children must never be allowed in the work area or
near a running vehicle. Lock the vehicle at all times and set the parking brake whenever the System
is operating. Maintain separate keys or key-fabs on your person to unlock the vehicle after generator
use. Never leave a running vehicle unattended. Do not let children handle machines, tools, or
extension cords.
4. Lethal voltage is present whenever the System is operating.
5. Dress properly. Do not wear loose clothing or jewelry as they can be caught in
moving parts. Protective, electrically non-conductive clothes and non-skid footwear are recommended
when working. Wear restrictive hair covering to contain long hair.
6. Do not go under vehicle when System or engine is running. Do not work on or near
an exposed shaft while the engine is running.
7. Do not overreach. Keep proper footing and balance at all times. Do not reach over or across running
machines.
9. Maintain tools with care. Keep tools clean for better and safer performance. Inspect tool cords and
extension cords periodically and, if damaged, have them repaired by an authorized technician.
10. Disconnect power cords and appliances. Unplug connected tools, appliances and cords when not
in use and prior to starting or stopping the System.
11. Avoid unintentional starting. Be sure that all connected appliances and tools are off before starting
the generator.
12. Stay alert. Watch what you are doing and use common sense. Do not operate any tool when you are
tired.

Rev. 6: 4/18/2007 7 of 15
13. Check for damaged parts. Before using any tool, any part that appears damaged should be
carefully checked to determine that it will operate properly and perform its intended function. Check
for alignment and binding of moving parts; any broken parts or mounting fixtures; and any other
condition that may affect proper operation. Any part that is damaged should be properly repaired or
replaced by a qualified technician. Do not use the tool if any switch does not turn on and off properly.
14. Guard against electric shock. Prevent body contact with grounded surfaces such as pipes,
radiators, ranges, and refrigerator enclosures. The 120 volt duplex outlets are ground fault protected.
However, the 240 volt twist-lock socket is NOT ground fault protected. Use extreme caution
whenever connecting or disconnecting 240 volt plugs and equipment.
15. Replacement parts and accessories. When servicing, use only identical replacement parts. Use of
any other parts will void the warranty. Replacement parts and service are available from your Real
Power licensed retailer-installer. To locate a retailer-installer nearest you contact us by calling (888)
867-2184.
16. Do not operate tool if under the influence of alcohol or drugs. Read warning labels on
prescriptions to determine if your judgment or reflexes are impaired while taking drugs. If there is any
doubt, do not operate the tool.
17. Use proper size and type extension cord. All extension cords must be of the proper size and type
to supply the correct current to the tool without heating up. Otherwise, the extension cord could melt
and catch fire, or cause electrical damage to the tool. Depending on the appliance connected to the
generator, the use of an extension cord should have a 0 to 20 amp capability (up to 50 feet), with
wire size rated at 14 AWG or larger gauge (i.e. smaller numbers such as 12 or 10 AWG). Longer
extension cords require larger size wire. If you are using the tool outdoors, use an extension cord
rated for outdoor use (signified by "WA" on the jacket).
18. Maintenance. For your safety, service and maintenance should be performed regularly by a qualified
Real Power technician.
An extension cord that is hot to the touch is overloaded. Repair or replace
damaged extension cords immediately.

8 of 15 Rev. 6: 4/18/2007
ELECTRIC GENERATOR SAFETY PRECAUTIONS AND WARNINGS
When System is operating, lethal voltage is present!
1. The generator produces electrical current. Improper use can result in electrocution, injury or death.
Only a qualified technician should service or repair this generator.
2. The generator was designed to be used in a dry area. Use extreme caution when operating the
System in rain, snow, sleet, or damp conditions. Operating the System in such conditions is NEVER
recommended or encouraged. Moisture can carry electrical current and could cause electrocution.
3. If the generator is connected to a building, home, business, or any other electrical circuit normally fed
by utility power, steps must be taken to ensure that the generator output and the utility power are
positively isolated. Failure to isolate the systems could result in personal injury or death to those
working around these circuits. Any connection in this regard must only be done by a licensed
electrician.
4. Do not exceed the generator's rated capacity. The total electrical loads at each outlet must be added
to determine the total electrical load. If the electrical appliance does not list the wattage rating, you
can calculate it by multiplying amps times voltage (amps x voltage = watts).
5. Do not tamper with the drive engine-governed speed. The generator operates at a nominal speed of
3600 RPM. Increases in speed will damage rotating parts of the generator. Slower speeds may
damage the generator or appliances connected to the generator due to low voltage.
6. Always follow national and local safety codes.
7. Do not start or stop the System with tools or appliances connected and turned on.
8. Do not operate your Real Power equipped vehicle in an enclosed area due to the carbon monoxide
fumes produced. The fumes are colorless and odorless and are deadly.
9. Never handle electrical charged extension cords while standing in water.
10. Only use 3-prong, grounded extension cords.
11. Keep fingers, hands, cords and other loose items away from the spinning shafts and pulleys that are
rotating under your Real Power equipped vehicle.
12. Never refuel or add fuel to you vehicle or remove the fuel cap whenever the System is operating.
13. Read, understand, and follow all safety precautions in your vehicle owner’s manual prior to running
the System.
COMMON SENSE AND CAUTION PREVAIL
The warnings, cautions, and instructions discussed in this manual cannot cover all possible
conditions and situations that may occur. It must be understood by the operator that common
sense and caution are factors that cannot be built into this product, but must be supplied by the
operator.

Rev. 6: 4/18/2007 9 of 15
ENVIRONMENTAL IMPACT ON ELECTRICAL PERFORMANCE
Performance of the System will vary depending on the ambient temperature and elevation of the area in
which it is operated.
POWER VARIATIONS ACCORDING TO THE WORK ENVIRONMENT AND ALTITUDE
AMBIENT TEMPERATURE
ALTITUDE 25° C
77° F
40° C
104° F
45° C
113° F
50° C
122° F
55° C
131° F
< 1000 m
< 3281 feet 1.09 1 0.96 .093 .091
1000 – 1500 m
3281 – 4921 feet 1.01 0.96 0.92 0.89 .087
1500 – 2000 m
4921 – 6562 feet 0.96 0.91 0.87 0.84 0.83
2000 – 3000 m
6562 – 9843 feet 0.90 0.85 0.81 0.78 0.76
Multiply the above-listed power variation factor by the System’s rated output to determine the
environmentally adjusted output. For example, the environmentally adjusted output of the 12,000 watt
rated system when used in Denver, Colorado on a warm sunny day (45°C/113°F) is calculated as
follows: 12,000 rated output multiplied by the environmental factor of .87 (based on altitude in Denver
(approximately 1600 m and ambient temperature of 45°C/113°F) = 10,440 watts.
UNAUTHORIZED AND UNTESTED USE - MISUSE
The Real Power chassis integrated AC generation system was not designed
or intended for use in on-line control of devices or aircraft, air traffic, aircraft
navigation or aircraft communications, or in the design, construction,
operation or maintenance of any nuclear facility, or in the operation or
maintenance of any life support system. Manufacturer and all Licensed
Retailers-Installers disclaim any express or implied warranty of fitness for
such uses. Users who elect to utilize the Real Power system for such
purpose(s) assume all risks and liability associated therewith.
INSTALLATION
Installation of your Real Power AC generation system must be performed by a licensed and properly
trained installation technician that is certified by the Manufacturer. Installation by any other means
VOIDS ALL WARRANTIES from the Manufacturer.
To locate the licensed retailer-installer nearest you contact us by calling [phone].

10 of 15 Rev. 6: 4/18/2007
OPERATION
The System is not designed or intended for use in on-line control of devices or
aircraft, air traffic, aircraft navigation or aircraft communications, or in the design, construction, operation
or maintenance of any nuclear facility, or in the operation or maintenance of any direct life support
system. Manufacturer disclaims any express or implied warranty of fitness for such uses.
Do not overload the generator. Calculate the total wattage of all connected appliances and tools. If the
electrical appliance does not list the wattage rating, you can calculate it by multiplying amps times voltage
(amps x voltage = watts).
APPLICATION TYPICAL
WATTS
Finishing Sander 190
5” Bench Grinder 220
1/4” Drill 300
Soldering Gun 300
6” Bench Grinder 400
790° F Heat Gun 400
3/8” Reversible Drill 450
Jigsaw 450
Standard Sawsall 480
4 1/2” Disk Grinder 600
1/2” Reversible Drill 700
10 Gallon Wet/Dry Vacuum 900
6” Circular Saw 950
Router 1000
1200° F Heat Gun 1000
Disk Sander/Grinder 1200
POWER TOOLS
14” Chain Saw 1200
1/6 hp Submersible Sump Pump 880
1/4 hp Submersible Sump Pump 925
1/3 hp Submersible Sump Pump 1050
PUMPS
1/2 hp Submersible Sump Pump 1400
Can’t find your equipment on the chart? Multiply the amps of your device by its voltage to
determine required wattage. AMPS X VOLTS = WATTS
(Example: A 1/4” drill requires 2 1/2 Amps. 2 1/2 Amps x 120 Volts = 300 Watts)

Rev. 6: 4/18/2007 11 of 15
GM VEHICLES
To Activate
1. Unplug all electrical devices from the Electrical Distribution-Outlet box.
2. Place the STOP switch (located on the Electrical Distribution-Outlet box) in the ON position.
3. Set the vehicle parking brake.
4. Turn the key to the RUN position (key is on but engine is off).
5. Wait until the dash warning lights go out.
6. Turn the PTO switch (if installed) to the ON position.
OR
Turn the lighted rocker switch to the ON (illuminated) position.
7. Turn the key to the START position to start the vehicle’s engine.
8. Turn the PTO switch (if installed) to the SET position momentarily.
OR
Push the SET button or RESUME/ACCELERATE button on the cruise control.
To Deactivate
1. Unplug all electrical devices from the Electrical Distribution-Outlet box.
2. Press the brake pedal.
3. Turn the PTO switch (if installed) to the OFF position.
OR
Turn the lighted rocker switch to the OFF (non-illuminated) position.
4. Release the parking brake.
5. Your vehicle is now ready to drive as normal.
NOTE: If the generator does not engage or if it makes a grinding noise after the startup procedure,
shut the truck off and wait five (5) minutes before attempting the procedure again. Excessive
start attempts will cause the PTO solenoid to over heat. Once the solenoid has over heated,
the generator will not engage until the solenoid has cooled sufficiently.

12 of 15 Rev. 6: 4/18/2007
FORD VEHICLES
To Activate
1. Unplug all electrical devices from the Electrical Distribution-Outlet box.
2. Place the STOP switch (located on the Electrical Distribution-Outlet box) in the ON position.
3. Turn the key to the RUN position (key is on but engine is off).
4. Wait until the dash warning lights go out.
5. Place the upfitter switch #4 (if installed) in the ON position.
OR
Turn the lighted rocker switch to the ON (illuminated) position.
6. Turn the key to the START position to start the vehicle’s engine.
7. Set the vehicle parking brake.
To Deactivate
1. Unplug all electrical devices from the Electrical Distribution-Outlet box.
2. Release the parking brake.
3. Place the upfitter switch #4 (if installed) in the OFF position.
OR
Turn the lighted rocker switch to the OFF (non-illuminated) position.
4. Your vehicle is now ready to drive as normal.
NOTE: If the generator does not engage or if it makes a grinding noise after the startup procedure,
shut the truck off and wait five (5) minutes before attempting the procedure again. Excessive
start attempts will cause the PTO solenoid to over heat. Once the solenoid has over heated,
the generator will not engage until the solenoid has cooled sufficiently.

Rev. 6: 4/18/2007 13 of 15
MAINTENANCE
Before performing any maintenance on any portion of the Real Power
generation system, the vehicle must be off and the generator and all parts of
the vehicle must be allowed to cool down after use.
•The air filter on the generator should be cleaned periodically. If the Over-Temperature Light is
illuminated, the air filter needs to be cleaned. To clean the generator’s air filter:
1. Disconnect the vehicle battery and auxiliary battery cable if equipped.
2. Remove the rear dust cover on the generator.
3. Wash the filter with warm water and mild soap.
4. Re-install the filter.
5. Re-install the dust cover.
6. Re-connect the vehicle battery and auxiliary battery cable if equipped.
7. Never insert rags, tools, or any device into the generator openings.
•Periodically operate the System.
•Lubricate all drive shaft and pillow bearing grease points every 150 hours of operation with a high-
temperature EP2 type grease. Clean grease fitting before lubricating and DO NOT overfill. Failure to
follow these procedures will void the warranty.
•Follow the vehicle manufacturer’s recommended service and maintenance protocol for all engine,
transmission, and vehicle maintenance.

14 of 15 Rev. 6: 4/18/2007
TROUBLE SHOOTING
If electricity to one of the outlets stops, the circuit could have been overloaded. Check your appliance
wattage, press the RESET button on the applicable GFCI outlet and/or breaker to resume power.
If the generator will not engage when initiating the start protocol, shut the vehicle off and check the
Emergency Reset Switch to be sure it is in the “ON” or operating position. Then reinitiate the start up
procedure.
If the generator is running, but no voltage is present, follow the steps shown in the flowchart below.
Emergency
Reset Switch

Rev. 6: 4/18/2007 15 of 15
Is PTO
switch on?
Turn PTO
switch on.
Is emergency
reset switch on?
Is overtemp
light on?
Turn
emergency
reset switch
on.
Clean
generator filter.
Vehicle Running, Generator
Not Producing Voltage
Restart
vehicle.
Restart
vehicle.
Contact your Real Power
dealer or call [phone]
for assistance.
NO
YES
NO
YES
YES
NO