Real Power RP050 User manual

OWNER’S MANUAL RP050 | RP075 | RP100
464 Southpoint Circle, Suite C
Brownsburg, Indiana 46278
[phone]
Fax [phone]
www.realacpower.com
For customer assistance, please call [phone]

2 of 25 Rev. 22-05
TABLE OF CONTENTS PATENTED DEVICE ........................................................................................................................... 3
LIMITED WARRANTY ....................................................................................................................... 3
OWNER’S RESPONSIBILITIES ........................................................................................................... 4
LIMITATIONS ................................................................................................................................... 4
SAVE THIS MANUAL ........................................................................................................................ 5
SAFETY WARNINGS AND PRECAUTIONS ......................................................................................... 6
ELECTRIC GENERATOR SAFETY PRECAUTIONS AND WARNINGS .................................................... 7
COMMON SENSE AND CAUTION PREVAIL ...................................................................................... 7
REAL POWER SYSTEM OVERVIEW .................................................................................................. 8
RP050, RP075, & RP100 - MECHANICAL REFERENCE DIAGRAM .................................................... 9
RP100 STANDARD ELECTRICAL PANEL - REFERENCE DIAGRAM ................................................... 10
RP100 STANDARD ELECTRICAL PANEL - REFERENCE DIAGRAM (INTERNAL) ............................... 11
RP050, RP075, & RP100 ELECTRICAL LIMITATIONS AND CAPABILITIES ....................................... 12
DSR REGULATOR DIAGRAM .......................................................................................................... 13
OPERATION ................................................................................................................................... 14
MAINTENANCE .............................................................................................................................. 16
TROUBLE SHOOTING ..................................................................................................................... 24
ENVIRONMENTAL IMPACT ON ELECTRICAL PERFORMANCE ....................................................... 25
UNAUTHORIZED AND UNTESTED USE - MISUSE ........................................................................... 25
COPYRIGHT © 2022 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. is a trademark of Contour Hardening, Inc.

Rev. 22-05 3 of 25
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 Application 2021/0316617 A1 filed 10/14/21
LIMITED WARRANTY
Contour Hardening Inc. (CHI) hereby warrants to the Purchaser of the Real Power™ chassis integrated
AC generator system (SYSTEM) that the System will be free of defects in material and workmanship from
the date of installation marked on the warranty registration card or other written documents that
independently collaborate the installation date. If the installation date cannot be verified the warranty
will begin 30 days after the date of shipment from CHI as follows:
All rotating parts and components: 1 year
Electrical Distribution-Outlet box and components therein: 1 year
Repair or replacements parts: 90 days*
Paint or coating on all components: NOT WARRANTED
PROVIDED that the System is operated in accordance with the operating instructions included with all
shipments. CHI may require reasonable proof of date of purchase. THEREFORE PURCHASER SHOULD
RETAIN THE SALES RECEIPT OR INVOICE.
Defective parts must be returned to CHI for inspection before they can be covered under this warranty.
Parts or a System returned to CHI without prior authorization will not be accepted. After CHI confirms
the defect and approves the warranty claim, CHI will authorize the replacement of the defective part(s).
For confirmed and approved warranted repairs, CHI will pay for the parts to repair or replace the
defective parts or System. CHI will not pay for labor to disassemble or reassemble the System unless
the system was installed by CHI and it is still under warranty. Systems installed by CHI must be repaired
by CHI in Indianapolis, Indiana for disassembly and reassembly to be covered under warranty.
CHI retains the right to make ALL subjective decisions regarding warranty claims.
Labor to repair or replace parts will occur only during normal business hours, overtime to expedite
repair or replacement will not be covered under warranty.
Any and all labor provided by the purchaser, an agent of the purchaser or any other party other than
CHI, either during the original installation or repair, is not covered under CHI’s warranty.
* Repair or replacement parts are also warranted for ninety (90) days from the date of shipment from
CHI. Any part repaired or replaced during the warranty period assumes the remainder of the original
System warranty or ninety (90) days, whichever is greater.

4 of 25 Rev. 22-05
OWNER’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 CHI’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. Shipping or delivery to Real Power for vehicles or parts covered under this warranty;
2. 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;
3. telephone and other communication expenses;
4. living and travel expenses;
5. the premium costs for overtime labor requested by the Purchaser to expedite the repair;
6. the cost of airfreight or other extraordinary expenses for shipment of parts over and above
premium surface transportation;
7. 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 CHI, improper storage, vandalism, and
improper installation or improper maintenance or service;
8. transportation of vehicle to designated repair facility; and
9. failures due to electrical overload 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 upon examination shall indicate to CHI’s satisfaction they are
defective. This Limited Warranty will not cover repair where normal use has exhausted the life of a part
of the System 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.
Use of this System on a vehicle used for snow removal causes excessive wear and is not covered under
this warranty.
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 CHI, vandalism, improper
installation or improper maintenance or service, or failure to perform normal and routine maintenance.
Deterioration or damage due to severe weather conditions such and hurricanes, earthquakes or
tornadoes and exposure to corrosive chemicals either direct or in the atmosphere, is not covered by this
Limited Warranty. Damage associated with ground clearance under the vehicle is not covered by this
Limited Warranty.

Rev. 22-05 5 of 25
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 IMPLIIED WARRANTIES
ARE EXCLUDED. Some regions do not allow limitation on how long an implied warranty lasts, so this
limitation may not apply to Purchaser.
CHI 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.
CHI 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 CHI.
CHI 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. 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.
THIS LIMITED WARRANTY ONLY APPLIES TO SYSTEMS SOLD AT RETAIL.
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.

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SAFETY WARNINGS AND PRECAUTIONS
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 system!
1. 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.
2. Keep unauthorized personnel and children away from the vehicle. The Real Power system contains
rotating components and lethal voltages. Only trained personnel should be allowed near the vehicle
while the system is operating.
3. Lethal voltage is present whenever the system is operating. Real Power generators can produce
voltages in excess of 480V.
4. 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.
5. 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.
6. Do not overreach. Keep proper footing and balance at all times. Do not reach over or across running
machines.
7. Do not start or stop the generator with a load connected. Unplug connected tools, appliances and
cords when not in use and prior to starting or stopping the System.
8. Check for damaged parts. Before using the Real Power system inspect it thoroughly. Make sure all
bolts are tight. The generator should be dry and free of debris.
9. 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 Real Power.
You contact us by calling [phone]. Parts and accessories should be installed by qualified
technicians.
10. Do not operate a Real Power system 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 system.
11. Use proper size and type cable. Follow Local and National Electric Code guidelines when connecting
loads to the generator.

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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 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 in accordance with NEC or
the locally applicable Electrical Code .
4. Do not exceed the generator's rated capacity. The total electrical loads 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 is designed to operate at a set
speed. Changing this speed will change the output voltage and frequency. 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 equipment 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 equipment or 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 your 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.

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REAL POWER SYSTEM OVERVIEW
Real Power generator systems are manufactured exclusively for use with the power take off (PTO) of a
Class 4 or larger work tuck with diesel engine and automatic transmission. While in a parked, stationary
mode, the engine of the truck provides rotational power to the generator via the PTO attachment,
turning it at a constant 1800 RPM to produce 60Hz. The truck engine RPM, power output, and torque
are controlled automatically by the truck ECM and TCM with no input required from the user.
Power from the generator is typically routed to a remote electrical panel box, located in the body of the
truck, which contains both the low voltage DC control signals and the high voltage AC power distribution
with main breaker, sub breakers, and either plug-in receptacles or hard wire lines for other equipment.
With the exception of specially ordered, dedicated 240/120V-only systems, the generators provided by
Real Power have an industry-standard 12 wire reconnectable configuration, capable of 480V 3Φ, 208V
3Φ, or 240/120V 1Φ depending on how they are tapped. All Real Power generators are equipped with a
proprietary set of enhancements to make them robust against difficult road environments.
A diagram showing the connection options is provided with each system. All connections to the
generator should be done in accordance with NEC guidelines and any other applicable electrical code for
your area.

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RP050, RP075, & RP100 - MECHANICAL REFERENCE DIAGRAM
Notes:
1. This diagram is intended to help the reader familiarize themselves with the generator mechanicals. There is some variability between trucks depending on model year,
wheelbase, and body style.
2. 4x4 Vehicles have an added Live Drive transfer case adapter (not pictured here) allowing the drive shaft to pass through.

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RP100 STANDARD ELECTRICAL PANEL - REFERENCE DIAGRAM
Notes:
1. This diagram is intended to help the reader familiarize themselves with the standard Real Power electrical panel. Exact design will vary by generator size and specification.
Always take care to use proper electrical safety procedures when using any connection panel.
2. To reset E-Stop, pull red knob out.

Rev. 22-05 11 of 25
RP100 STANDARD ELECTRICAL PANEL - REFERENCE DIAGRAM (INTERNAL)
Notes:
This diagram is intended to help the reader familiarize themselves with the standard Real Power electrical panel. Neither the power panels for the RP075 and RP050, nor
any custom build match this layout exactly. Always take care to use proper electrical safety procedures when using any connection panel.

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RP050, RP075, & RP100 ELECTRICAL LIMITATIONS AND CAPABILITIES
Notes:
The capacities listed in this table pertain to maximum continuous generator capacity at 60Hz, at sea level with up to 125C temperature rise. Power factor (PF) is assumed to
be 0.8 when converting kVA to kW.

Rev. 22-05 13 of 25
DSR REGULATOR DIAGRAM
Notes:
All Real Power generators are 4-pole, brushless, 1800 rpm AC generators with digital voltage regulation. The regulators are located inside the main connection panel and
include 4 potentiometer adjustments. The only adjustment that should ever be made to the regulator once it has been installed is the VOLT setting. All others are set by the
factory.

OPERATION
Custom applications may have slightly different instructions. If you have any questions contact
your installer or Real Power.
Warm Up and Cool Down
The generator should be allowed to warm up before use when the weather is cold. This allows the
system to reach operating temperature before the components are stressed with a load. For
temperatures at or below 32°F the system should be allowed to warm up for approximately 10 minutes.
When the weather is hot or the generator is used under heavy load the system needs time to cool
down. This can be done by leaving the truck idling for 10 minutes with the PTO engaged allowing the
integrated generator fan to cool down the generator. Approximately a 10 minute cool down period is
recommended if the air temperature is greater than 80°F or if the generator is used at greater than 80%
load.
Starting the Generator
1. Verify that there is no load on the generator. All equipment should be unplugged or off.
2. Confirm that the E-Stop switch on the panel is reset (pulled out).
3. Ensure truck is in Park
4. Set Parking Brake
5. Turn the Ignition Key if vehicle is not running. (Truck does not need to be turned off and on.)
6. Set upfitter switch labeled “PTO”
PTO Clutch will automatically engage. Engine RPM will automatically ramp to the correct speed
and hold there.
7. Allow the generator to warm up if necessary. (see above Warm Up and Cool Down section)
8. The generator is ready to supply power.
Stopping the Generator
The normal procedure for shutting down the generator is as follows:
1. Remove all loads from the generator. All equipment should be unplugged or in off position.
2. Return PTO switch to off.
3. Reset Parking Brake.
4. Allow the generator a few seconds to spin down and come to a rest before moving the vehicle.

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Resettable PTO Interrupts [Does Not Require System to be Turned Off and On Again]
The command signal for the vehicle to run PTO mode and engage the generator passes through all
three of these checks in series. Removing any one of them in will shut of the generator system. If
the truck is running, it will immediately restart the generator once the interrupt is restored.
1. PTO Upfitter Switch
2. Real Power Emergency Stop Button
3. Generator Over-Temperature Switch
Note: The order in which these signals are engaged or disengaged does not affect operation. For example, if the
Over Temperature Switch shuts the PTO off but the PTO dash switch remains engaged with the engine on,
the generator system will automatically come back on (whether intentional or not) once the temperature
switch resets. The same is true for the Emergency Stop, but it should be noted: Real Power recommends
always using the PTO upfitter switch to operate the generator rather than the emergency stop.
Stationary Elevated Idle Control (SEIC) program interrupts
[Requires System to be Turned Off and On Again]
In addition to the PTO enable command signal, there are a number of fault conditions that will cause the
truck shut down the PTO and high idle internally. Once they occur, the command signal must be cycled
by switching the PTO switch off and on again. Fault conditions include:
1. Pressing the foot brake pedal
2. Shifting out of Park
3. Releasing the Parking Brake
4. Pressing the accelerator pedal
5. Vehicle rolling / motion
6. Over temperature of the engine or transmission coolant
REAL POWER Secure Truck Feature
All Real Power generators installed on Ford and Dodge trucks come equipped with the Real Power
Secure Truck feature, which allows the PTO, once engaged, to continue to run even after the ignition
key is turned off and removed. At any time that the generator is running, the operator may remove
the key from the truck and lock the doors behind him, allowing him to work on power equipment
hundreds of feet away without concern for the security of the vehicle.
PTO operation will continue unless and until any one of the above interrupts is engaged or a fault
condition occurs. At that time, the vehicle will shut down completely, including the engine and be
inoperable until the key is put into the ignition and turned back to start up. Alternatively, an
operator can put the key back in the ignition while the generator is still running and return it to the
RUN position. Then the truck will not shut down when the PTO is turned off.
Periodic Cycling
The Real Power generator system should be started and ran for 10 minutes once every 30 days if not
used regularly. This will cycle the shaft and bearings and keep them lubricated.

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MAINTENANCE
In order to ensure proper functioning of your Real Power Generator and prevent possible damage to
your vehicle, it is paramount to conduct regular checks and perform preventative maintenance actions
on your generator, the driveline, and PTO. Make sure to keep records of maintenance activities that are
conducted. Failure to properly maintain your generator system could void the warranty.
Before performing any maintenance on any portion of the Real Power generation system, the vehicle
must be off with the keys removed from the ignition and the generator and all parts of the vehicle
must be allowed to cool down after use.
Item
Component
(s)
Maintenance Item
Frequency
1 Drive Shaft Lubricate 4x4 Ball Joint 60hrs / 1 Month
2 Drive Shaft Lubricate Slip Joint Zerk Fitting 100hrs / 1 Month
3 Drive Shaft Inspect U-Joints and Carrier Bearing 100hrs / 1 Month
4 Drive Shaft & PTO Check paint indicators on fasteners 100hrs / 1 Month
5 PTO & Generator Free Rotation Check 100hrs / 1 Month
6 Generator Remove and Wash Air Filter 300 hrs
7 Generator Full visual inspection 1 year
8 Drive Shaft Full visual inspection 1 year
9 Drive Shaft & PTO Check fasteners 1 year
10 Panel Internal Inspection 1 year
11 Truck Engine Oil Change 5000-7500 miles*
12 Truck Fuel Filter 15,000 – 25,000miles**
13 Truck Transmission Fluid Replacement 150,000 miles**
*As indicated by vehicle oil life monitoring system
**Include generator hours x 50 miles/hr calculation
1. Real Power drivelines connecting the PTO to the Generator are generally equipped with Sealed,
Non-Serviceable U-joints which do not have grease fittings. However, 4x4 vehicles have a
driveline with a CV joint attached to the back of the transfer case which does have a greaseable
ball joint in the center.
This joint must be lubricated monthly or every 50-60 hrs, whichever is more frequent. To do so,
use a needle-nose grease point to inject directly into the fitting at the center of the CV joint.
From the manufacturer:
Dana recommends lubrication with Spicer ultra-premium synthetic grease, Chevron Ultra-Duty EP-2, or a compatible
lithium-based grease meeting NLGI Grade 2 and ASTM D4950 LB specifications. Spicer ultra-premium synthetic grease
is available in 10-packs of 14-oz. tubes (SPL1051) and 1-gal. pails (SPL1052)

Rev. 22-05 17 of 25
Note: In some applications, 4x4 drivelines use greasable U-joints along with the greasable ball
joint. If you have a 4x4 truck, familiarize yourself with all U-joints and lubricate them on the same
schedule if they are not sealed.
2. All Real Power systems have a slip joint in the center with its own zerk fitting. This must be
lubricated every 100hrs or 1 month.
3. To ensure the safe and reliable operation of the drive shafts, the U-joints must be inspected
monthly or every 100 hours. Visually inspect the 4 cups of each U-joint for signs of heat
damage, slop, or water penetration. Snap rings should all be snug in place without any visible
cracks. The drive joint should have no play in it and be able to rotate smoothly by hand.
Above: 1. A new U-joint. 2. Good U-joint – clean and sealed with smooth rotation. 3. Bad U-joint – Rusted out with
gritty motion and/or slop in the joints.
Check for a characteristic pattern of grease spatter which could indicate that the seals are failing
and grease is leaking out. NOTE: if your vehicle has greasable U-joints and a CV joint, it is normal
to have some amount of spatter from those fittings.
Slip Joint
Zerk Fitting

18 of 25 Rev. 22-05
Similarly, the carrier bearing mount should be firmly holding the driveline collar in place without
slop or free motion. Check seals for separation or degradation.
Above: 1. New Carrier Bearing. 2. Bad carrier bearing with torn rubber and displaced front seal.
If any issues are found, the U-joints or drive line may need to be replaced. Contact Real Power
for help determining a course of action.
4. All fasteners have been marked with tamper evident paint. Every 100 hrs or 1 month, check all
marks for signs of movement or loosening. If found, immediately retighten and make a note to
track possible future issues.
NOTE: Take special notice of the PTO mounting bolts. If PTO comes partially loose during operation,
catastrophic failure to transmission could occur.
5. When the truck is off, the driveshaft should rotate freely and smoothly. Every 100hrs or 1
month, rotate the drive shaft by hand and check the PTO and generator for smooth, even
rotation. Take note of bearing friction, noise, or roughness and contact Real Power in the event
of a substantial or worsening noise and/or roughness on either end of the drive line.

Rev. 22-05 19 of 25
6. The air filter on the generator should be periodically cleaned. Inspect the air filter every 300
hours and make sure it is not clogged.
i. Remove the rear dust cover on the generator with 10mm socket.
ii. Wash the filter with warm water and mild soap.
iii. Allow the filter to dry.
iv. Re-install the filter and dust cover.
7. Once per year, conduct a thorough inspection of the generator. Look for signs of loosening
hardware, signs of wear or abrasion on the conduit leaving the generator, or rubbing between
the generator fan shroud or output box and the truck’s driveline.

20 of 25 Rev. 22-05
8. Carefully inspect the drive shaft for signs of deterioration, including missing balance weights,
compromised welds or tubing, or cracks.
9. While every measure possible has been taken to secure the bolts and hardware on your
generator system, vibration may cause them to loosen over time. Once per year, check and if
necessary, retighten the fasteners per the following
i. If PTO is a Muncie FR3C, follow this guide for torque requirements.
Reference:
https://www.munciepower.com/cms/files/Products/Literature/
Documents/Service_Parts/SP16-03_FR3C_Service_Parts.pdf