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OPERATION & MAINTENANCE MANUAL

For

Ex-Power DEFENDER Generator

Document Original Release Date: 29 September 2015

Revision 02 Date: 14 February 2018

Prepared For

Department of Defense

Prepared By

Novatio Engineering. (Manufacturer)

266 Calvary Street.

Waltham, MA, USA 02453

Telephone: 617-440-4410

Information, data, and drawings embodied in this document are strictly confidential and are provided on the understanding that this document

is for customer internal use only and that further distribution of this document will require Novatio

’s

permission.

Содержание Ex-Power DEFENDER

Страница 1: ...Defense Prepared By Novatio Engineering Manufacturer 266 Calvary Street Waltham MA USA 02453 Telephone 617 440 4410 Information data and drawings embodied in this document are strictly confidential a...

Страница 2: ...t provides continuous 900W 1000kW Peak of clean AC power Ex Power DEFENDER 1 0 Generator Features 2 AC Receptacles GFCI Protected o AC Voltage Output 120VAC 60Hz o AC Power Output 0 900W continuous at...

Страница 3: ...t any time you detect a hazard it is your responsibility to report the hazard through your chain of command to ensure that it is corrected This action ensures that this hazard is investigated publiciz...

Страница 4: ...al provides safety aspects as well as operation and maintenance instructions for the Ex Power DEFENDER The Ex Power DEFENDER generator is light weight portable and compatible for use in all services A...

Страница 5: ...D CHECKING THE ENGINE 3 1 3 2 1 Pre operation Safety Warnings and Cautions 3 1 3 2 2 Check the Engine before Starting 3 2 3 3 STARTING ENGINE AND APPLYING LOAD 3 3 3 4 STOPPING ENGINE 3 7 3 4 1 Emerge...

Страница 6: ...OVERLOAD INDICATOR LIGHT 2 5 FIGURE 2 10 OIL LEVEL ALERT INDICATOR LIGHT 2 6 FIGURE 2 11 GROUND TERMINAL 2 6 FIGURE 3 1 FILL FUEL TANK WITH PROPER FUEL TYPE 3 3 FIGURE 3 2 SETTING CHOKE LEVER TO CLOSE...

Страница 7: ...hazards are discussed below along with the best way to protect yourself and others 1 2 1 Operator Safety Responsibilities Know how to stop the generator quickly in case of emergency turn Engine Switch...

Страница 8: ...ine cool before storing generator indoors 1 2 5 Refueling Hazards Fuels are extremely flammable and fuel vapors can explode Allow engine to cool if generator has been in operation Refuel only outdoors...

Страница 9: ...components and frequently used controls Figure 2 1 External Components and Features Figure 2 2 Spark Plug Muffler and Hour Meter SPARK PLUG MAINTENANCE COVER SPARK PLUG MUFFLER HOUR METER CHOKE LEVER...

Страница 10: ...ls ignition system and fuel valve Pulling starter grip operates the recoil starter to crank the engine shown below Figure 2 4 Engine Switch and Starter Grip ON Running position opens fuel valve and al...

Страница 11: ...nk as shown below The vent lever must be in the ON position for engine to run When starting a cold engine temporarily set the choke lever CLOSED to enrich the air fuel mixture Gradually OPEN the choke...

Страница 12: ...nections Using Optional Cable Assembly 2 4 DC Receptacle and DC Circuit Protector The DC receptacle shown below should ONLY be used for charging 12 volt automotive type batteries The DC charging outpu...

Страница 13: ...utlets should also be on when running engine Figure 2 8 Output Indicator Light 2 6 Overload Indicator If the generator is overloaded in excess of 1 0 kVA or if there is a short circuit in a connected...

Страница 14: ...engine oil level see section 5 2 before troubleshooting in other areas Figure 2 10 Oil Level Alert Indicator Light 2 8 Ground Terminal The generator ground terminal is connected to the frame of the g...

Страница 15: ...t rating information near the model number or serial number It is not recommended to operate at no load conditions for long periods of time 3 2 Pre operation Warnings Cautions and Checking the Engine...

Страница 16: ...om of the generator If the cooling holes are blocked the generator may overheat and damage the engine inverter or windings Do not lay the generator on its side when moving storing or operating it Oil...

Страница 17: ...igure 3 1 Fill Fuel Tank with Proper Fuel Type 3 3 Starting Engine and Applying Load If generator is equipped with a Throttle switch ensure it is in the OFF position at all times during operation Figu...

Страница 18: ...to ON position 3 Turn Engine Switch to ON Figure 3 3 Engine Switch 4 On User Interface Panel see placard below ensure FUEL SELECTOR SWITCH is set to the same fuel that is in the tank Figure 3 4 Fuel...

Страница 19: ...lever CLOSED when starting a cold engine to enrich the air fuel mixture Figure 3 5 Setting Choke Lever to Closed Position when Starting Cold Engine 7 Pull engine starting grip engine crank chord and...

Страница 20: ...he start sequence Turn the Engine Switch OFF and then ON again and re initiate the Start Sequence If there is a problem starting the engine refer to Troubleshooting in Section 6 1 After correcting any...

Страница 21: ...then turn the fuel tank cap vent lever to OFF position 4 If two generators were connected for parallel operation disconnect the parallel operation cables after stopping the engines unless parallel op...

Страница 22: ...d for no more than brief surge capacity Substantial overloading will open the circuit protector Exceeding the time limit for maximum power operation or slightly overloading the generator may not switc...

Страница 23: ...generator models Only use approved parallel operation cables optional equipment provided by Novatio when connecting two Ex Power DEFENDER generators for parallel operation Review the Pre operation Wa...

Страница 24: ...cator red will stay ON and after about four seconds current to the connected appliance s will shut off and the output indicator green will go OFF Stop both engines and investigate the problem Determin...

Страница 25: ...Ex Power DEFENDER Operation and Maintenance Manual Novatio Engineering Confidential Document 3 11 Page Intentionally Left Blank...

Страница 26: ...which you can be seriously hurt or killed Failure to properly follow maintenance instructions and precautions can cause you to be seriously hurt or killed Always follow the procedures and precautions...

Страница 27: ...s or 100 hrs Every year Every 2 years or 300 hrs Engine Oil Check oil and add if necessary Change oil Change oil 1 Air Cleaner Check and clean if necessary Clean 2 Spark Plug Check Adjust Replace Spar...

Страница 28: ...rom electrical appliances Refuel carefully to avoid spilling fuel Spilled fuel is not only a fire hazard it causes environmental damage Do not fill above the upper level mark Fuel can damage paint and...

Страница 29: ...heck the oil level by inserting the dipstick into the oil filler neck without screwing it in 4 If the level is low fill to the upper limit of the oil filler neck with the recommended oil SAE 10W 30 5...

Страница 30: ...y of fuel leakage 2 Loosen the cover screw and remove the maintenance cover 3 Place a suitable container next to the engine to catch the used oil 4 Remove the oil filler cap dipstick and drain the oil...

Страница 31: ...Cleaner Service Operating the engine without an air filter or with a damaged air filter will allow dirt to enter the engine causing rapid engine wear 5 4 1 Remove and Replace Foam Air Filter See belo...

Страница 32: ...r operating the generator in very dusty areas clean the foam air filter more frequently than specified in the Maintenance Schedule see Section 4 3 1 Wash foam air filter in a solution of household det...

Страница 33: ...h a damp rag and reinstall the rubber air guide 5 5 Spark Plug Service If engine is hot allow it to cool before servicing spark plug to prevent burns Remove Inspect and Clean or Replace Spark Plug 1 R...

Страница 34: ...n or if the insulator is cracked chipped or fouled Recommended Spark Plug Replacement Types CR5HSB NGK U16FSR UB DENSO An incorrect spark plug can cause engine damage To ensure proper engine operation...

Страница 35: ...engine Over tightening spark plug can damage threads in the cylinder head 11 Reinstall spark plug cap on spark plug securely 12 Reinstall spark plug maintenance cover 5 6 Servicing Spark Arrestor in...

Страница 36: ...park arrester screen as shown below Be careful to avoid damaging the screen The spark arrester must be free of breaks and tears Figure 5 12 Cleaning Spark Plug Arrester 5 Replace the spark arrester if...

Страница 37: ...d oxidize rapidly Fuel deterioration and oxidation can occur in as little as 30 days and may cause damage to the fuel system For long term storage it best to drain the fuel to prevent damage to the ge...

Страница 38: ...nd ensure vent is in OFF position 4 Store generator in an upright position Figure 5 13 Draining Fuel Tank for Long Term Generator Storage Example Method 5 7 4 Engine Oil Service before Long Term Stora...

Страница 39: ...If possible avoid storage areas with high humidity that can cause rust and corrosion With the engine and exhaust system cool cover generator with a porous material to keep out dust A nonporous cover w...

Страница 40: ...Cable Location 5 9 Transporting Ex Power DEFENDER Do not lay the generator on its side when moving storing or operating Oil may leak and damage engine or property Allow the generator to cool for at le...

Страница 41: ...gine switch to OFF and then restart the engine Out of fuel Refuel JP 8 fuel mixed with Diesel fuel Drain fuel tank Refuel with fresh fuel either JP 8 or F24 Diesel or Gasoline my be used on select mod...

Страница 42: ...oting Engine Will Not Start With main Engine Switch ON and FUEL SELECTOR SWITCH set to the correct fuel type position lights are not lit on User Interface Panel due to internal battery problem Perform...

Страница 43: ...rly Notify Novatio Generator is equipped with Eco Throttle switch and it is ON Ensure Eco Throttle switch is turned OFF 6 3 Troubleshooting AC Appliance not Working Table 6 3 Troubleshooting AC Applia...

Страница 44: ...NOTES...

Страница 45: ...Novatio Engineering Manufacturer 266 Calvary Street Waltham MA USA 02453 Telephone 617 440 4410...

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