Real Power RP015 Owner's Manual
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Real Power RP015 Owner's Manual

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OWNER'S MANUAL
RP015 | RP036
464 Southpoint Circle, Suite C
Brownsburg, Indiana 46278
(877) 670-7325
Fax (317) 275-9370
www.realacpower.com
For customer assistance, please call (877) 670-7325

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  • Page 1 OWNER’S MANUAL RP015 | RP036 464 Southpoint Circle, Suite C Brownsburg, Indiana 46278 (877) 670-7325 Fax (317) 275-9370 www.realacpower.com For customer assistance, please call (877) 670-7325...

  • Page 2: Table Of Contents

    RP015 & RP036 - MECHANICAL REFERENCE DIAGRAM ..............9 RP015 STANDARD ELECTRICAL PANEL - REFERENCE DIAGRAM ........... 10 RP015 STANDARD ELECTRICAL PANEL - REFERENCE DIAGRAM (INTERNAL) ....... 11 RP036 STANDARD ELECTRICAL PANEL - REFERENCE DIAGRAM ........... 12 RP015 & RP036 ELECTRICAL LIMITATIONS AND CAPABILITIES............. 13 DSR REGULATOR DIAGRAM ......................

  • Page 3: Patented Device

    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.

  • Page 4: Owner's Responsibilities

    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;...

  • Page 5: Save This Manual

    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.

  • Page 6: Safety Warnings And Precautions

    You contact us by calling (877) 670-7325. 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.

  • Page 7: Electric Generator Safety Precautions And Warnings

    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.

  • Page 8: Real Power System Overview

    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.

  • Page 9: Rp015 & Rp036 - Mechanical Reference Diagram

    RP015 & RP036 - MECHANICAL REFERENCE DIAGRAM Notes: 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. 4x4 Vehicles have an added Live Drive transfer case adapter (not pictured here) allowing the drive shaft to pass through.

  • Page 10: Rp015 Standard Electrical Panel - Reference Diagram

    Notes: 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.

  • Page 11: Rp015 Standard Electrical Panel - Reference Diagram (Internal)

    Notes: 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.

  • Page 12: Rp036 Standard Electrical Panel - Reference Diagram

    Notes: 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.

  • Page 13: Rp015 & Rp036 Electrical Limitations And Capabilities

    RP015 & RP036 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.

  • Page 14: 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.

  • Page 15: Operation

    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.
  • Page 16 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.

  • Page 17: Maintenance

    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.
  • Page 18 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.
  • Page 19 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.
  • Page 20 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. Remove the rear dust cover on the generator with 10mm socket. Wash the filter with warm water and mild soap. iii.
  • Page 21 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 If PTO is a Muncie FR3C, follow this guide for torque requirements.
  • Page 22 If PTO is a Muncie F20, follow this guide for torque requirements. Reference: https://munciepower.com/cms/files/Products/Literature/Documents/ Service_Parts/SP19-09.pdf iii. If PTO is a different 6 or 8 bolt Muncie, follow this description: Reference: https://www.munciepower.com/cms/files/Products/Literature/Documents/Install/IN 84-03_PTO_Operators_Manual-ENG.pdf 22 of 26 Rev. 22-05...
  • Page 23 If PTO is a Chelsea 210, torque requirements are given as 24-28ft-lbs. Reference: https://www.parker.com/Literature/Chelsea%20Products%20Division/Owners %20Manual%20PDFs%20-%20Chelsea%20SA/HY25-1400-M1_US.pdf (page 10) Check tightness of the set screws on the PTO and generator side flanges of the driveline with 3/16” and ¼” Allen driver (yellow arrows). Use a 5/8” wrench (RP100) or a 1/2” wrench (RP020) to snug up hex bolts on the generator input flange (orange arrows).
  • Page 24 15,000 – 25,000 miles. However, with a Real Power generator onboard, the hours on the generator count towards usage as well. Multiply the hour meter reading on the panel by a standard 50 miles/hr and add to the odometer miles to calculated the total.

  • Page 25: Trouble Shooting

    TROUBLE SHOOTING In the event of an issue with your Real Power generator system, this guide will help identify and diagnose a root cause and potential solution. Phone assistance is available at (877) 670-7325 When System is operating, lethal voltage is present. Working near rotating components is dangerous and carries risk of severe bodily harm or death.

  • Page 26: Environmental Impact On Electrical Performance

    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.

This manual is also suitable for:

Rp036

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