Novation Ex-Power DEFENDER Manual

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: [phone]
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.

Overview –Applications and Features
Ex-Power DEFENDER Generator Applications:
The Man-Portable Ex-Power DEFENDER from Novatio Engineering is the reliable choice for
mobile electric power requirements, specifically designed, built, and tested for military use.
Utilizing patented technology from Novatio that aerosolizes military grade JP-8,F24, JET-A, and
JP-5 fuel, this lightweight, portable generator will dependably start in even the most austere
climates without the need for any starting agents. Rigorously tested for harsh environments, this
durable and compact generator will automatically maintain optimum internal operating
temperatures for peak performance. With a dry weight of only 32.9 pounds, the Ex-Power
DEFENDER is the undeniable solution to provide the war-fighter with a true expeditionary
portable generator that provides continuous 900W (1000kW Peak) of clean AC power.
Ex-Power DEFENDER 1.0 Generator Features:
•2 AC Receptacles (GFCI Protected)
oAC Voltage Output: 120VAC, 60Hz
oAC Power Output: 0-900W continuous at sea level
oPeak AC Output Power: 1000W
•Parallel Operation:
o1.8 kVA Output Continuous Power
oPeak AC Output Power: 2.0 kVA (maximum load of up to 1000W for brief surge
capacity)
•DC Receptacle
oDC Output: 96W (8A at 12VDC)
oDC Circuit Protector
•Climatic Temperature Operating Parameters: 0°F to 120°F (derated to 750W above
104 degrees F)
•Auto-Temperature Control During Generator Operation
•Audio Noise: 59dB(A) at 900W, 53dB(A) at 300W
•Fuel Tank Capacity: 0.6 gallons
•Fuel: JP-8, F24, JET-A, and JP-5 (Diesel or Gasoline may be used on select models)
•Dry Weight: 32.9 LBS
•System Dimensions: 17.8” x 11.5” x 14.9”
•Ground Terminal
•Hour Meter
•Oil Level Alert Indicator Light: turns red when oil level is low
•Overload Indicator Light: turns red when generator is overloaded
•Output Indicator Light: turns green when generator is putting out power

Ex-Power DEFENDER –Operation and Maintenance Manual
Novatio Engineering Confidential Document
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Version History
Date
Revision #
Author
Revision Description
29-Sept-2015
(Original)
Jim Eiland
Original Release
15 Jan 2016
01
Jim Eiland
Added hour meter.
14-Feb-2018
02
D. Schiller
Added muli-fuel information; updated UIB configuration; added jump
start procedure; added JET-A and JP-5 to fuel list; removed Defender
1.0 reference
Keep this Operation and Maintenance Manual handy so that it can be referred to at any time.
This Operation and Maintenance Manual is considered a permanent part of the generator and
should remain with the generator.
Hazard Awareness Notice
Abide by all warnings within this manual. Improper operation can result in injury, damage the
generator, or other property. Most injuries or property damage can be prevented by following all
instructions in this manual. Report all hazards. If at 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, publicized, or corrected, as required.
The Ex-Power DEFENDER is designed for 1kW operation. Major generator
repairs are only done safely by Novatio Engineering trained personnel. Know
how to stop the generator in case of an emergency. Operators can be burned from
hot parts. Let the engine exhaust system cool, since the exhaust system gets hot
enough to burn flesh or ignite materials. Exhaust from the generator contains
poisonous carbon monoxide in unventilated spaces, which can cause loss of
consciousness and may lead to death. Therefore, do not run generator in a
confined area. To prevent electrical shock from generator, do not use generator in
wet conditions. Before refueling, turn engine off and allow generator to cool to
prevent fuel fires. Only refuel outdoors in a well-ventilated area and wipe up fuel
spills immediately. Keep flames and other sparks away from generator while
refueling.
GENERAL WARNING

Ex-Power DEFENDER –Operation and Maintenance Manual
Novatio Engineering Confidential Document
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Warnings, Cautions, and Notes within the Manual
Definition: An operating procedure, practice, or condition, etc., that may result in injury or
death, if not carefully observed or followed.
Definition: An operating procedure, practice, or condition, etc., that may result in damage to
equipment or property, if not carefully observed or followed.
NOTE
Definition: An operating procedure, practice, or condition, etc., that is essential to emphasize.
Foreword/Preface
This manual 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 (Army, Navy, Marines, and Air Force).
Operator Technical Level and Prerequisites
Operators: must read and understand safety concerns and user instructions presented in this
manual.
Intermediate Level Maintainers: must have completed safety training as an integral part of
standard mechanical, engine, and electrical training in order to service this equipment.
Depot Level Maintainers: are factory trained and handle repairs/replacements after the
generator is sent back to Novatio, as noted in the maintenance section of this technical manual.
CAUTION
WARNING

Ex-Power DEFENDER –Operation and Maintenance Manual
Novatio Engineering Confidential Document
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Table of Contents
1. INTRODUCTION AND GENERATOR SAFETY ................................................................................................1-1
1.1.1 Purpose............................................................................................................................................... 1-1
1.1.2 Safety Information and Warning Labels on Generator ...................................................................... 1-1
1.2 IMPORTANT SAFETY INFORMATION...................................................................................................................... 1-1
1.2.1 Operator Safety Responsibilities......................................................................................................... 1-1
1.2.2 Carbon Monoxide Hazards ................................................................................................................. 1-1
1.2.3 Electric Shock Hazards........................................................................................................................ 1-1
1.2.4 Fire and Burn Hazards ........................................................................................................................ 1-2
1.2.5 Refueling Hazards............................................................................................................................... 1-2
1.3 SAFETY LABEL LOCATIONS .................................................................................................................................. 1-2
2. DESCRIPTION OF GENERATOR CONTROLS AND COMPONENTS..................................................................2-1
2.1 ENGINE SWITCH AND STARTER GRIP .................................................................................................................... 2-2
2.2 FUEL TANK CAP,VENT LEVER,AND CHOKE............................................................................................................ 2-3
2.3 PARALLEL AC OPERATION CONNECTIONS.............................................................................................................. 2-4
2.4 DC RECEPTACLE AND DC CIRCUIT PROTECTOR....................................................................................................... 2-4
2.5 OUTPUT INDICATOR.......................................................................................................................................... 2-5
2.6 OVERLOAD INDICATOR ...................................................................................................................................... 2-5
2.7 OIL LEVEL ALERT INDICATOR............................................................................................................................... 2-6
2.8 GROUND TERMINAL.......................................................................................................................................... 2-6
3. OPERATION ...............................................................................................................................................3-1
3.1 OPERATION TIME AND POWER RATING ................................................................................................................ 3-1
3.2 PRE-OPERATION -WARNINGS,CAUTIONS,AND 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 Emergency Stop.................................................................................................................................. 3-7
3.4.2 Stopping Engine Under Normal Conditions ........................................................................................ 3-7
3.5 AC OPERATION................................................................................................................................................ 3-7
3.5.1 Connecting an Appliance or Power Cord to Generator....................................................................... 3-8
3.5.2 AC Parallel Operation - Cautions and Notes....................................................................................... 3-9
3.5.3 AC Parallel Operation - Connections and Operation Procedures........................................................ 3-9
3.6 DC OPERATION (USING OPTIONAL BATTERY CHARGING CABLE).............................................................................. 3-10
4. GENERAL ROUTINE MAINTENANCE AND SAFETY CONCERNS.....................................................................4-1
4.1 THE IMPORTANCE OF MAINTENANCE ................................................................................................................... 4-1
4.2 SAFETY PRECAUTIONS ....................................................................................................................................... 4-1
4.3 MAINTENANCE SCHEDULE.................................................................................................................................. 4-2
5. SERVICING, STORAGE, TRANSPORTING AND REMOVING FROM STORAGE ................................................5-1
5.1 REFUELING...................................................................................................................................................... 5-1
5.2 ENGINE OIL LEVEL CHECK .................................................................................................................................. 5-1
5.3 ENGINE OIL CHANGE......................................................................................................................................... 5-3
5.3.1 Draining Oil......................................................................................................................................... 5-3
5.3.2 Replenishing Engine Oil ...................................................................................................................... 5-3
5.3.3 Engine Oil Recommendations............................................................................................................. 5-4
5.4 AIR CLEANER SERVICE ....................................................................................................................................... 5-4
5.4.1 Remove and Replace Foam Air Filter.................................................................................................. 5-4
5.4.2 Foam Air Filter Cleaning ..................................................................................................................... 5-5
5.5 SPARK PLUG SERVICE ........................................................................................................................................ 5-6
5.6 SERVICING SPARK ARRESTOR (IN MUFFLER)........................................................................................................... 5-8
5.7 STORAGE ...................................................................................................................................................... 5-10

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5.7.1 Generator Storage Preparation ........................................................................................................ 5-10
5.7.2 Cleaning Generator before Storage.................................................................................................. 5-10
5.7.3 Engine Fuel System –Short-Term and Long-Term Storage Requirements ....................................... 5-10
5.7.4 Engine Oil Service before Long-Term Storage .................................................................................. 5-11
5.7.5 JP-8, F24, and other Fuel Storage Recommendations ...................................................................... 5-12
5.8 REMOVAL OF EX-POWER DEFENDER FROM STORAGE......................................................................................... 5-12
5.9 TRANSPORTING EX-POWER DEFENDER............................................................................................................ 5-13
6. TROUBLESHOOTING ..................................................................................................................................6-1
6.1 TROUBLESHOOTING -ENGINE WILL NOT START ..................................................................................................... 6-1
6.2 TROUBLESHOOTING -ENGINE LACKS POWER OR SHUTS DOWN................................................................................. 6-3
6.3 TROUBLESHOOTING -AC APPLIANCE NOT WORKING............................................................................................... 6-3
List of Figures
FIGURE 1-1:WARNING LABELS ...................................................................................................................................... 1-2
FIGURE 2-1: EXTERNAL COMPONENTS AND FEATURES ..................................................................................................... 2-1
FIGURE 2-2: SPARK PLUG,MUFFLER AND HOUR METER................................................................................................... 2-1
FIGURE 2-3: FRONT CONTROL PANEL............................................................................................................................. 2-2
FIGURE 2-4: ENGINE SWITCH AND STARTER GRIP............................................................................................................ 2-2
FIGURE 2-5: FUEL TANK CAP,VENT LEVER,AND CHOKE .................................................................................................. 2-3
FIGURE 2-6: PARALLEL AC OPERATION CONNECTIONS USING OPTIONAL CABLE ASSEMBLY ................................................ 2-4
FIGURE 2-7: DC RECEPTACLE (USED WITH OPTIONAL DC CABLE ..................................................................................... 2-4
FIGURE 2-8: OUTPUT INDICATOR LIGHT........................................................................................................................... 2-5
FIGURE 2-9: 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 CLOSED POSITION WHEN STARTING COLD ENGINE................................................. 3-5
FIGURE 3-3: ENGINE SWITCH AND EMERGENCY OFF ........................................................................................................ 3-7
FIGURE 3-4: CONNECTING AC APPLIANCE TO GENERATOR............................................................................................... 3-8
FIGURE 3-5: PARALLEL OPERATION (USING OPTIONAL AC PARALLEL CABLES)................................................................... 3-9
FIGURE 5-1: COVER SCREW &MAINTENANCE COVER ...................................................................................................... 5-2
FIGURE 5-2: DIPSTICK &UPPER OIL LEVEL LIMIT............................................................................................................. 5-2
FIGURE 5-3: REPLENISHING OIL -OIL FILLER NECK &UPPER LIMIT ................................................................................... 5-3
FIGURE 5-4: EX-POWER GENERATOR -OIL VISCOSITY CHART....................................................................................... 5-4
FIGURE 5-5: REMOVING &REPLACING FOAM AIR FILTER.................................................................................................. 5-5
FIGURE 5-6: CLEANING FOAM AIR FILTER ....................................................................................................................... 5-6
FIGURE 5-7: SPARK PLUG CAP &SPARK PLUG MAINTENANCE COVER............................................................................... 5-6
FIGURE 5-8: REMOVING SPARK PLUG FROM ENGINE ........................................................................................................ 5-7
FIGURE 5-9: SPARK PLUG GAP SETTING......................................................................................................................... 5-7
FIGURE 5-10: REMOVING MUFFLER PROTECTOR COVER .................................................................................................. 5-8
FIGURE 5-11: SPARK PLUG ARRESTER ACCESS .............................................................................................................. 5-9
FIGURE 5-12: CLEANING SPARK PLUG ARRESTER ........................................................................................................... 5-9
FIGURE 5-13: DRAINING FUEL TANK FOR LONG-TERM GENERATOR STORAGE (EXAMPLE METHOD).................................... 5-11
List of Tables
TABLE 4-1:PREVENTIVE/ROUTINE MAINTENANCE ............................................................................................................ 4-2
TABLE 6-1:TROUBLESHOOTING -ENGINE WILL NOT START.............................................................................................. 6-1
TABLE 6-2:TROUBLESHOOTING -ENGINE LACKS POWER OR SHUTS DOWN........................................................................ 6-3
TABLE 6-3:TROUBLESHOOTING -AC APPLIANCE NOT WORKING ....................................................................................... 6-3

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1. Introduction and Generator Safety
1.1.1 Purpose
The purpose of the Operation and Maintenance Manual is to provide instructions for the safe
operation and maintenance of Novatio’s Generator (Ex-Power DEFENDER).
NOTE
This entire manual contains important safety information, please read carefully.
This operation and maintenance manual does not warn about all possible hazards,
therefore use good judgement while operating generator.
1.1.2 Safety Information and Warning Labels on Generator
Safety information on printed labels alert operators to potential harmful hazards.
You CAN be KILLED or SERIOUSLY HURT if you do not
follow instructions.
1.2 Important Safety Information
Ex-Power DEFENDER generators are designed for use with electrical equipment that has
suitable power requirements. Other uses can result in injury to the operator or damage to the
generator and other property. Most injuries or property damage can be prevented by following
all instructions in this manual. The most common 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 to OFF).
Understand the use of all generator controls, output receptacles, and connections, as described in
this manual. Be sure that anyone who operates the generator receives proper instruction and
understands procedures and safety requirements contained in this manual.
1.2.2 Carbon Monoxide Hazards
Exhaust contains poisonous carbon monoxide, a colorless, odorless gas. Breathing carbon
monoxide can cause loss of consciousness and may lead to death. Do not run generator in an
area that is confined or even partly enclosed. Never run generator inside a garage, house, or near
open windows or doors.
1.2.3 Electric Shock Hazards
The generator has GFCI Protected AC outlets. Generator produces enough electric power to
cause a serious shock or electrocution if misused or not properly maintained. Using a generator
or electrical appliance in wet conditions, or when hands are wet, could result in electrocution if
the GFCI Protected AC outlets are not working properly. Keep generator dry. Do not connect to
a building’s electrical system. Never connect different generator models in parallel operation.

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1.2.4 Fire and Burn Hazards
The exhaust system gets hot enough to ignite materials. Keep generator at least 3 feet (1 meter)
away from buildings and other equipment during operation. Do not enclose generator in any
structure. Keep flammable materials away from generator. The muffler becomes very hot
during operation and remains hot for a while after stopping the engine. Be careful not to touch
muffler while it is hot. Let engine 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 in a well-ventilated area with the engine OFF. Do
not overfill the fuel tank. Never smoke near fuels, and keep other flames and sparks away.
Always store fuels in an approved container. Make sure that any spilled fuel has been wiped up
before starting engine.
1.3 Safety Label Locations
Refer to warning labels on generator to warn against potential hazards that can cause serious
injury. Read warning labels carefully. If a label comes off or becomes hard to read, contact
Novatio for a replacement.
Figure 1-1: Warning Labels

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2. Description of Generator Controls and Components
The following figures show external 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
MAINTENANCE
COVER
FUEL TANK CAP
VENT LEVER
STARTER GRIP
FUEL TANK CAP
FRONT CONTROL
PANEL
(Includes GFCI
Protected AC
Outlets)
USER INTERFACE
PANEL
ENGINE SWITCH
ON –OFF
&
(EMERGENCY STOP)

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Figure 2-3: Front Control Panel
2.1 Engine Switch and Starter Grip
The engine switch controls 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 allows
engine to be started.
OFF - Stops engine
and closes fuel
valve.
OIL LEVEL ALERT INDICATOR LIGHT
GFCI PROTECTED AC OUTLET
(When Small Green LED is Lit
while Running Engine, Status is
Normal.)