Polaris P2000i, P1000i User Manual

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PMS 419

Failure to properly follow the instructions and precautions in

POLARIS POWER™

P1000i P2000i

Operator’s Manual

(Australian models)

this manual can result in property damage, serious injury or

For your nearest Polaris supplier, call 0393945610 or visit www.polarispower.com.au Polaris Sales Australia Pty Ltd., (ABN 62088081949) of Locked Bag 2006, Sunshine Post Shop, Sunshine, Victoria, 3020 Australia

Part No. 9925471 Rev 02

TABLE OF CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Controls and features . . . . . . . . . . . . . . . . . . . 16

First Use Instructions . . . . . . . . . . . . . . . . . . . 22

Pre-Operation Inspection . . . . . . . . . . . . . . . . 25

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Transportation and Storage . . . . . . . . . . . . . . 56

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . 62

Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . . . 64

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 66

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . 76

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

INTRODUCTION

Welcome

Thank you for purchasing a POLARIS POWERTM Generator, and welcome to our world-wide family of POLARIS owners.

Here at POLARIS we proudly produce an exciting line of utility and recreational products.

• Snowmobiles

• All-terrain vehicles (ATVs)

• RANGER

•RZR

•VICTORY

• INDIAN

•GEM

• POLARIS POWER We believe POLARIS sets a standard of excellence for all utility

vehicles, recreational vehicles, and power equipment manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your POLARIS machine.

For safe and enjoyable operation of your generator, be sure to follow the instructions and recommendations in this owner’s manual. Your manual contains instructions for minor maintenance, but information about major repairs is outlined in the POLARIS Service Manual and should be performed only by a factory certified technician.

For all technical questions visit www.polarispower.com.au.

utility vehicles

sport vehicles

Motorcycles

Motorcycle

electric vehicles

Generator

INTRODUCTION

Intended Use

The POLARIS Power Generator is intended to supply power for appliances. Such items include, but are not limited to:

• Furnace fans

• Sump pumps

• Dishwashers

• Hotplates / Stoves

•Lamps

•Fans

• Washing machines

• Garage door openers

• Water heaters

• Televisions

• Refrigerators

• Computers Appliances that use more than recommended amount (see page 62) of

combined power consumption should not be connected to this generator.

INTRODUCTION

Safety Precautions

Failure to follow recommended precautions and procedures could result in severe injury or death. Always heed all safety precautions and follow all operation, inspection, and maintenance procedures outlined in this manual.

Please read the POLARIS P1000i/P2000i Generator Owner’s Manual. This manual contains information essential to safe operation and proper maintenance of the generator. Anyone who operates the generator must read the owner’s manual before operating the generator.

Read and understand the information found in the safety section, and have manual on hand when operating the generator. Following the safety precautions and procedures will ensure a safe operating experience.

Understand and follow all inspection and maintenance procedures outlined in this manual. Following these procedures will ensure that the generator remains in safe operating conditions at all times.

INTRODUCTION

Warnings, Cautions and Notices

Signal Words and Safety Terms

The following signal words and symbols appear throughout this manual. Your safety, and the safety of others, is involved when these words and symbols are used. Become familiar with their meaning before reading the manual.

A safety alert warning indicates a hazardous situation which, if not avoided, may result in death or serious injury.

A safety alert caution indicates a hazardous situation which, if not avoided, may result in minor or moderate injury.

A notice is used to address practices not related to physical injury.

IMPORTANT: Key reminders during assembly, disassembly, and inspection of components.

Note: Key information to clarify instructions.

ALCOHOL OR DRUG USE

Operating the generator after consuming alcohol or drugs could adversely affect operator judgement. Never consume alcohol or drugs before or while operating the generator.

INTRODUCTION

Serial Number

P1000i

P2000i

Identification Numbers and Locations

Record your generator’s identification numbers in the space provided. The model and serial number decal is located inside the service door.

MODEL NUMBER: ______________________________________________________

SERIAL NUMBER: ______________________________________________________

PURCHASE DATE: ______________________________________________________

PURCAHSE LOCATION:__________________________________________________

SAFETY

Safety Warnings and Precautions

IMPORTANT SAFEY INSTRUCTIONS. SAVE THESE INSTRUCTIONS.

Failure to follow recommended precautions and procedures could result in severe injury or death. Always read all safety precautions and follow all operation, inspection, and maintenance procedures outlined in this manual.

General

• Read and understand all of the safety and operating information in this manual and on the product before using the machine. Use the generator only as described in this manual.

• Understand and follow all inspection and maintenance procedures outlined in this manual. Following these procedures will ensure that the generator remains in safe operating condition.

• Turn off the petrol valve and close the fuel cap vent when the generator is not in use.

It is the responsibility of the owner to ensure that all users of this generator are fully informed of the safety and operating information prior to use.

Before and During Operation

• Preform all Pre-Inspection activities as shown on page 25 of this manual. Inspect and tighten all parts regularly. Ensure the generator does not have any damaged, loose, or missing parts before use. All defects should be corrected before use. Do not operate the generator if it has been dropped or damaged until all defective parts have been repaired.

• Do not place any flammable materials near the generator.

• Never start the generator or let it run in an enclosed area. Exhaust vapors are poisonous and can cause loss of consciousness or death in a short time. Keep the generator away from buildings and other equipment during operation.

SAFETY

Safety Warnings and Precautions

Before and During Operation

• Do not operate the generator in exposed locations where it will be subjected to wet conditions.

• Do not touch the generator with wet hands, as this may cause severe electric shocks.

• Do not pour water directly over the generator or wash it.

• Do not use or store the generator in the rain or snow.

• Do not cover the generator when in use.

• Always operate the generator on a firm, flat, and level surface, as the generator will vibrate on an irregular surface. If the generator is tilted, fuel may spill or the generator may tip over, causing a hazardous situation.

• Do not connect the generator to another power supply source.

• The engine becomes extremely hot during and immediately after it has been in use. Be careful not to touch any parts of the hot engine, especially the muffler or muffler cover, or serious burns may result.

• Do not connect external equipment to the generator before starting the engine.

• Do not use for life support, or life sustaining systems.

• The output of this generating set is potentially lethal. The set should not be connected to a fixed electrical installation except by an appropriately licensed person.

• Do not operate in a hazardous location, e.g. where there may be a risk of explosion of petrol fumes, leaking gas or explosive dusts.

• Do not operate in a confined area where exhaust gases, smoke or fumes could reach dangerous concentrations.

• Do not refuel while engine is running.

Fire Safety

Generator exhaust system gets hot enough to ignite some materials and burn skin if touched.

• Keep the generator away from buildings, other equipment, and combustible materials during operation.

• Do not enclose the generator in any structure.

SAFETY

Safety Warnings and Precautions

Fire Safety

• Keep the generator away from buildings, other equipment, and

combustible materials during operation.

• Do not enclose the generator in any structure.

• Keep children and pets away from generator.

• Exhaust system components are very hot during and after use. Hot

components can cause burns and fire. Do not touch the hot exhaust system components. Always keep combustible materials away from the exhaust system.

• Ensure that any spilled fuel is properly wiped up prior to using the

generator as fuel vapors are flammable.

Operator Safety

Operating the generator with worn, damaged, or malfunctioning components could result in serious injury or death. Never start the engine without checking all of the generator components to be sure of proper operation.

• Read and understand all of the safety and operating information in

this manual and on all warning labels before using the generator. Use the generator only as described in this manual.

• Know how to stop the generator quickly in case of emergency, see

page 30 for information on stopping the unit quickly.

• Keep children, pets, and bystanders at a safe distance from the

generator.

• Review and understand the use of all generator controls.

• Be sure that anyone who operates the generator receives proper

instruction. Do not let children operate the generator.

• Use the generator only for intended purposes.

• Turn off the generator immediately if the unit begins to operate

abnormally. After the generator has cooled, disconnect the generator and call your authorized POLARIS supplier.

• While operating the generator, if you experience headache, fatigue,

nausea / vomiting, confusion, or seizures, immediately get to fresh air. Do not delay and do not attempt to shut down the unit.

• Run the generator on flat, dry surfaces only. The generator can only

be run while stationary. Do not run the generator on any moving vehicle or objects.

SAFETY

Safety Warnings and Precautions

Fuel Safety

Petrol is highly flammable and explosive under certain conditions. Always use caution when handling petrol.

• Petrol is extremely flammable, and petrol vapor can explode. Before refueling allow the engine to cool completely if the generator has been in operation.

• Always store petrol in an approved container.

• Always refuel outdoors or in a well-ventilated area away from any combustible materials.

• Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where petrol is stored.

• Never permit children to handle petrol.

• Never refuel around bystanders, pets, and flammable objects.

• Loosen the fuel cap slowly to relieve pressure in the tank.

• Take care not to overfull or spill any fuel on the generator or muffler when refueling.

• If petrol spills on skin or clothing, immediately wash it off with soap and water and change clothing.

• Do not use the generator if you observe leaking petrol. Have the generator serviced immediately and before using it again.

• When operating or transporting the generator, be sure it is kept upright. If it tilts, fuel may leak. Be sure the fuel tank cap is tightened when transporting the generator.

• Do not refuel using petrol station pumps.

• Remove fuel from the generator before transporting in a vehicle.

Do not swallow petrol, inhale petrol vapors, or spill petrol. If you swallow petrol, inhale more than a few breaths of petrol vapor, or splash petrol in your eyes, see a physician immediately. If petrol spills on skin or clothing, immediately wash it off with soap and water and change clothing.

SAFETY

Safety Warnings and Precautions

Carbon Monoxide Safety

Generator exhaust contains Carbon Monoxide (CO) vapors. Exposure to Carbon Monoxide by people or pets can result in SEVERE INURY or DEATH. ALWAYS operate generate according to guidelines in labels and this manual.

• This portable generator runs on petrol. The generator exhaust vapor

contains carbon monoxide (CO).

• Carbon monoxide is odorless. You cannot smell it.

• Carbon monoxide is colorless. You cannot see it.

• Never run an engine in an enclosed area. Exhaust contains poisonous

carbon monoxide vapor that can cause loss of consciousness or death. Operate the engine in an open area, and well ventilated. The generator is for outdoor use only.

• Do not use the generator indoors in garages, basements, crawl spaces,

sheds, portable buildings, or similar areas even if doors and / or windows are open or if ventilating fans are used to circulate air.

• Do not use the generator near windows, doors, vents or any other

building openings even if they are closed. Poor seals on a door, as just one example, could still permit high levels of carbon monoxide to infiltrate the living area of a home.

• Be sure to install approved carbon monoxide detectors in your home

that have battery back-up systems that will continue to detect the presence of carbon monoxide during electric-power outages. Test these devices and replace batteries as recommended by their respective manufacturers.

• If you experience headache, fatigue, nausea / vomiting, confusion, or

seizures, immediately get to fresh air and away from the unit. Do not delay for any reason.

• Do not run the generator directly on grass or with the exhaust pipe

close to plants or grass. Exhaust gas temperature will be high.

SAFETY

Safety Warnings and Precautions

Electrical Safety

This generator produces high voltage electricity.

• The generator produces enough electric power to cause serious shock or electrocution if misused.

• Always connect the generator to a suitable ground circuit.

• When servicing the generator, disconnect the spark plug wire and place it where it cannot contact the plug. Turn the engine switch to the OFF position.

• Do not check for a spark with the plug removed. Use only approved spark plug testers.

• Using a generator or electrical appliance in wet conditions, such as rain or snow, or near a pool or sprinkler system, or when your hands are wet, could result in electrocution. Keep the generator dry and away from all sources of moisture.

• Do not store the generator outdoors unprotected from the weather.

• If the Generator has been subjected to water, moisture, or ice check all of the electrical components on the control panel before each use. Moisture or ice can cause a malfunction or short circuit in electrical components that could result in electrocution.

• Do not connect the generator to a building’s electrical system unless an isolation switch has been installed that meets applicable electrical codes and regulations.

• To avoid overloading the generator, ensure that the load is kept within the rating stated on the generator. Overloading will damage the unit and / or shorten its operating lifespan.

• Both the P1000i and P2000i can be paralleled with another P1000i or P2000i using the POLARIS parallel kit.

• Do not over charge a battery with the DC receptacle, over charging the battery may result in battery damage and potential ignite if a spark is introduced.

SAFETY

Safety Warnings and Precautions

Extension Cord Information

• Read the manufacturer starting and running wattage details and

operating instructions for the device(s) and appliance(s) that will be used. Often this information can be found in the owner's manual or on specification decals on the device or appliance.

• POLARIS recommends using only U.L. (Underwriters Laboratories,

Inc.) approved extension cords labeled with the use, size, and wattage rating. Only use heavy-duty extension cords with a three-prong (grounded) plug for your safety. Decide on what length extension cord is required as cord length determines the extension cord gauge. Remember, as the cord gets longer, the current capacity of the cord decreases.

• Never use an extension cord designated as “indoor use only”

outdoors.

• Store all extension cords indoors when not in use. Outdoor conditions

can deteriorate a cord over time.

• Never keep an extension cord plugged in when not in use. The cord

will still conduct electricity until it is unplugged from the outlet.

• Before plugging an extension cord or power cord into the generator,

check the cord for any signs of damage.

Equipment Modifications

Modifying the generator by adding or removing any equipment not approved by POLARIS may void the warranty. Such modifications may make the generator unsafe to operate and could result in severe injury to operators and / or bystanders, as well as damage to the generator. Some modifications may not be legal in your area. If in doubt, contact your authorized POLARIS supplier.

SAFETY

WARNING

Improper Generator use can result in SEVER E INJURY or DEATH. Read the Owner’s Manual. Follow all instructions and Warnings.

Generatorexhaust contains poisonous Carbon Monoxide (CO) vapors. ALWAYS operate in a well-v entilated area.

NEVER operate in a home, garage, enclosed

area or near windows, doors, or people.

NEVER operate near ammable objects.

Petrol is ammable and explosive. Severe burns can result. ALWAYS stop engine and let cool bef

ore refueling. ALWAYS checkfor fuel leaks and wipe up any spills. ALWAYS turn fuelto OFF when not in use. NEV ER handle petrol indoors. NEVER overll fuel tank.

Electrocution can result from using generator inrain, snow, nearwater, withwet hands, or with improper connections. ALWAYS keep generator and surrounding area dry. NEVERconnect generator to any building without electrical-isolation protection that meets applicable

codes and regulat ions.

DANGER

Using a generator indoors CAN KILL YOU IN MINUTES. Generator exhaust contains carbon monoxide.

This is a poison you cannot see or smell.

NEVER use inside a home or garage. EVEN IF doors and windows are open.

Only use OUTSIDE and far away from windows, doors, and vents.

CAUTION

Contacting a hot exhau st system can cause serious burns. Do not touch if generator is or has been running.

Safety Labels and Locations

Safety and warning decals have been placed on the generator for your protection. Read and follow the instructions of the decals and warnings on the generator carefully. If any of the decals depicted in this manual differ from the decals on your generator, always read and follow the instructions of the decals on the generator.

Carbon Monoxide Warning

Using a generator indoors CAN KILL YOU IN MINUTES.

The carbon monoxide warning is located on top of the generator.

Outdoor Use ONLY Danger Label

Generator Exhaust contains carbon monoxide. This is a poison you

cannot see or smell. NEVER use inside a home or

garage, EVEN IF doors and windows are open.

Only use OUTSIDE and far away from windows, doors, and vents.

Hot Exhaust Caution

The hot exhaust caution is located on the muffler cover.

Contacting a hot exhaust system can cause serious burns.

Do not touch if generator is or has been running.

SAFETY

Safety Labels and Locations

Improper Generator use can result in SEVERE INJURY or DEATH. Read the OWNER’S MANUAL. Follow all Instructions and Warnings.

Petrol is flammable and explosive. Severe burns can result. ALWAYS stop the engine and let cool down before refueling. ALWAYS check for fuel leaks and wipe up any spills. ALWAYS turn the fuel to OFF when not in use. NEVER handle petrol indoors. NEVER overfill the fuel tank.

Generator exhaust contains poisonous Carbon Monoxide (CO) vapors. ALWAYS operate in a well-ventilated area. NEVER operate in a home, garage, enclosed area or near windows, doors, or people. NEVER operate near flammable objects.

Electrocution can result from using generator in rain, snow, near water, with wet hands, or with improper connections. ALWAYS keep generator and surrounding area dry. NEVER connect generator to any building without electrical-isolation protection that meets applicable codes and regulations.

CONTROLS AND FEATURES

Generator Components:

ITEM NOMENCLATURE DESCRIPTION

A Spark Plug Cap Remove the top to access the spark plug

B Control Panel Generator controls

C Air Filter

D Oil Dipstick Measures oil level in the engine

E Carburetor Vent Hose Atmospheric vent

F Carburetor Drain Hose Drains fuel from the carburetor

G Starter Recoil Grip

H Choke Lever

I Fuel Tank Cap Accesses fuel tank

J Engine / Fuel Switch

Protects the air flow to the carburetor from becoming obstructed with debris

Causes the recoil starter to crank the engine when pulled

Provides proper starting mixture when engine is cold

Controls the ignition system and the fuel valve

CONTROLS AND FEATURES

P1000i

P2000i

Control Panel Components:

ITEM NOMENCLATURE DESCRIPTION

K SMART Throttle Switch

M DC Fuse Protector Protects DC charging circuit from overloads

N 12V DC Receptacle Charges 12V DC batteries

O Ground Terminal

P 240V AC Receptacles

Q Output Indicator

R Overload Indicator

S Low Oil Indicator

T Overload Reset Switch Resets the circuit after an AC overload

U Parallel Receptacles For use with proper POLARIS Parallel kits

Automatically reduces engine speed when loads are shut off or disconnected

Provides ground for non-conductive metal parts and receptacle ground terminals

Provides two connections for properly rated AC appliances

Illuminates GREEN when the generator is operating normally

Illuminates RED for appliance short circuits or overloads

Illuminates RED prior to the oil level falling below a safe limit

CONTROLS AND FEATURES

OFF

Choke Lever

Move the choke lever (H) to the START position when starting a cold engine. Slowly move the choke lever to the RUN position as the engine RPM stabilizes.

Fuel Tank Cap Vent Lever

When the engine is well-cooled and not in use, the fuel tank cap vent lever (I) must be placed in the OFF position to reduce the possibility of fuel leakage. The vent lever must be in the ON position to allow the engine to operate.

Engine Fuel Switch

The engine switch (J) controls the ignition system and the fuel valve. ON: opens the fuel valve and allows the engine to be started. OFF: closes the fuel valve and shuts off the engine.

Starter Recoil Grip

Do not allow starter grip to snap back against the generator. Return it gently to prevent damage to the starter.

The starter recoil grip (G) causes the recoil starter to crank the engine when pulled.

CONTROLS AND FEATURES

SMART Throttle Switch

The SMART throttle switch (K) automatically reduces engine speed when loads are shut off or disconnected. The engine returns to the proper speed to power the electrical load when appliances are turned ON or reconnected. Press the SMART throttle switch to the OFF position to reduce voltage changes when high electrical loads are simultaneously connected or when using the DC output.

DC Receptacle and Fuse

The DC receptacle (N) is protected from an overload with a fuse. If the DC circuit is overloaded, the 5 amp fuse (M) will blow and power to the DC receptacle will cease. The red light on the DC panel will illuminate. The fuse is located to the left of the receptacle and is accessed by snapping open the access door. See details on page 35. Replace the fuse with one of the same capacity. Using a higher rated fuse may cause damage to the generator alternator.

The DC receptacle charges 12V DC automotive-type batteries. The DC charging output is not regulated. The 12V DC receptacle has no battery overcharge protection function. Do not overcharge the battery.

CONTROLS AND FEATURES

P1000i P2000i

Ground Terminal

The ground terminal (O) connects to the frame of the generator, metal parts that do not conduct current, and ground terminals of each receptacle. Consult a qualified electrician, electrical inspector, or local agency having jurisdiction for local codes or ordinances for the intended use of the generator before using the ground terminal.

AC Receptacles

The AC receptacles (P) provide connections for properly rated AC appliances, see page 62 for specifications.

Indicator Panel

Output Indicator

The output indicator (Q) illuminates GREEN when the generator is in normal operation and producing electrical power at the receptacles.

Overload Indicator

The overload indicator (R) illuminates RED if there is a short circuit in the connected appliance(s), or if the generator is overloaded. The light remains illuminated for 5 seconds, then the current to the connected appliance is shut off and the output indicator light (GREEN) extinguishes.

Low Oil Indicator

The low oil indicator (S) illuminates RED before the oil level falls below a safe limit and the detection system automatically stops the engine. When there is a low engine oil level at startup, the engine will be prevented from starting.

CONTROLS AND FEATURES

Overload Protector Reset Switch

Should the generator overload, AC power will be cut off but the engine will stay running. Correct the overload condition and then press the overload reset switch (T) on the front panel. AC power will be restored immediately.

Parallel Receptacles

Two POLARIS parallel ready generators can be connected together to increase the total power available to a load, using the parallel receptacles (U). The system seamlessly matches frequency and automatically evenly distributes the load to each generator so one is not overloaded. Contact your supplier for the proper kit for your particular application. Only POLARIS parallel kit (PN 3410252) can be used for POLARIS generator parallel power output.

FIRST USE INSTRUCTIONS

Upper Level

Adding Engine Oil

Failure to use the recommended 4-stroke engine oil may result in engine damage, see page 62 for recommended oil and capacity.

1. Place generator on flat, level surface. Open the service door. See page 46.

2. Remove the oil filler cap / dipstick (A).

3. Fill the engine crankcase with the specified amount of engine oil. See page 62.

4. Insert the dipstick into the filler neck, without screwing it in.

5. Remove the dipstick and verify that the oil level is at the upper limit (B). Add additional oil and inspect the level as needed until the upper limit has been reached.

6. Re-install the dipstick (A). Use a clean shop rag to clean any spilled oil.

7. Re-install the service door.

FIRST USE INSTRUCTIONS

Fuel Recommendation

POLARIS recommends the use of 91 octane fuel or higher. Do not use fuel containing more than 10% ethanol. Do not use petrol containing methanol.

IMPORTANT: Operating the generator with an obstructed fuel system will result in serious engine damage. Perform maintenance as recommended.

IMPORTANT: Thoroughly read “Safety” section and all safety information when handling fuel.

IMPORTANT: In order to insure the optimum output and the maximum service life of the generator, the generator should run at a 50% load for the

first 20 hours.

Petrol is highly flammable and explosive and can cause serious injury. Stop the engine and keep heat, sparks, and flame away. Handle fuel only outdoors. Wipe up spills immediately.

Do not spill fuel when filling the fuel tank. Damage caused by spilled fuel is not covered under warranty. Spilled fuel is a fire hazard, causes environmental damage, and can damage paint and plastic. Wipe up spills immediately. Do not fill above bottom of strainer.

Refuel in a well ventilated area before starting the engine. If the engine has been running, allow it to cool.

Never refuel the engine inside a building where vapors may reach flames or sparks. Keep fuel vapors away from electrical appliances.

FIRST USE INSTRUCTIONS

Loosen

Tighten

Adding Fuel

1. Remove the fuel tank cap (A).

2. Fill carefully to avoid spilling fuel on the fuel tank strainer (B). Do not overfill the fuel tank (there should be no fuel above the upper limit mark).

3. Securely tighten the fuel tank cap (A).

4. Position the fuel tank vent lever (C) OFF for storage or transport, or ON to operate the generator.

5. Move generator away from the fueling source and site before starting the engine.

After refueling, securely reinstall the fuel tank cap (A).

PRE-OPERATION INSPECTION

Note: Always perform the recommended pre-operation inspections before each

use. Always perform the inspections at the beginning of a project and when removing the generator from storage.

Failure to perform the recommended pre-operation inspections could result in minor or moderate injury or property damage. When inspection reveals the need for adjustment, replacement, or repair, perform service promptly.

Pre-Operation Checklist

Open the service door to expose the generator inner components. See page 46.

Engine Oil

Perform “Oil Level Inspection” (see page 49). Add oil as needed.

Fuel Line

Petrol is highly flammable and explosive and can cause serious injury. Stop the engine and keep heat, sparks, and flame away. Handle fuel only outdoors. Wipe up spills immediately.

Inspect the fuel hose for cracks or damage. Replace as needed.

Fuel Level

Check the fuel level and refuel as needed. See page 26.

Exhaust System

If the engine has been running, the muffler will be very hot. Allow the muffler to cool before servicing.

Inspect the exhaust system for leakage. Tighten or replace the gasket as needed.

Carburetor

Inspect the choke lever operation.

Starting System

Inspect the recoil starter operation. Verify the starter recoil grip functions properly.

Air Filters

Inspect the air filters. Clean or replace as needed. See page 25.

OPERATION

Safe Operating Precautions

Fuel Recommendations

The generator engine is certified to operate on regular unleaded petrol with a pump octane rating of 91 or higher.

Never use stale or contaminated petrol or an oil /petrol mixture. Avoid getting dirt or water in the fuel tank.

The use of regular unleaded petrol containing no more than 10% ethanol (E10) by volume is permitted. Do not use petrol containing methanol. If the content of ethanol or methanol exceeds the specified limits, it may cause starting or performance problems. It may also damage metal, rubber, and plastic parts of the fuel system. Damage due to ethanol or methanol is not covered under warranty.

Refueling

IMPORTANT: Thoroughly read the “Safety” section and all warnings and cautions when handling fuel.

Petrol is highly flammable and explosive and can cause serious injury. Stop the engine and keep heat, sparks, and flame away. Handle fuel only

outdoors. Wipe up spills immediately.

Do not spill fuel when filling the fuel tank. Damage caused by spilled fuel is not covered under warranty. Spilled fuel is a fire hazard, caused environmental damage, and can damage paint and plastic. Wipe up spills immediately. Do not fill above bottom of strainer.

Refuel in a well ventilated area before starting the engine. If the engine has been running, allow it to cool.

Never refuel the engine inside a building where vapors may reach flames or sparks. Keep fuel vapors away from electrical appliances.

Safe Operating Precautions

Loosen

Tighten

OFF

Refueling

1. Remove the fuel tank cap (A).

2. Fill carefully to avoid spilling fuel or exceeding the bottom of the fuel tank strainer (B).

OPERATION

3. Securely tighten the fuel tank cap (A) until it clicks.

4. Position the fuel tank vent lever OFF for storage or transport, or ON to operate the generator, if equipped.

5. Move generator at least 10 feet (3 meters) away from the fueling source and site before starting the engine.

OPERATION

DANGER

Using a generator indoors CAN KILL YOU IN MINUTES. Generator exhaust contains carbon monoxide.

This is a poison you cannot see or smell.

NEVER use inside a home or garage. EVEN IF doors and windows are open.

Only use OUTSIDE and far away from windows, doors, and vents.

Safe Operating Precautions

Before Starting the Engine

Read, understand, and follow the Safety Section of this manual.

1. Ensure the generator is away from the fueling source.

2. The generator will vibrate during operation. Place the generator in a dry location and on a flat, level surface.

3. Unplug all power cords and extension cords from the generator.

Starting the Engine

1. Position the fuel tank cap vent lever to ON.

2. Position the SMART throttle switch to OFF.

3. For a cold engine start, position the choke lever to START. To restart a warm engine, leave the choke lever in the RUN position.

OPERATION

OFF

AC Switch

Safe Operating Precautions

Starting the Engine

4. Position the engine switch to ON.

5. Lightly pull the starter recoil grip until resistance is felt. Then, firmly pull straight out.

Do not allow starter grip to snap back against the generator. Return it gently to prevent damage to the starter.

6. If the choke lever was positioned to START the engine, gradually move it to RUN as the engine warms up.

7. After a 2 to 3-minute warm up, select ON or OFF on the SMART throttle switch as desired.

8. If connecting loads to generator, reference “AC Operation” or “DC Operation” as outlined later in this section.

9. Make sure to turn the AC switch to "ON" position. Otherwise, there will be no AC power output from AC receptacles.

OPERATION

OFF

Safe Operating Precautions

Stopping the Engine

In case of emergency, position the engine switch to OFF to stop the engine. Under normal conditions, perform the following procedure.

1. Shut off or disconnect all appliances connected to the generator.

2. Position the engine switch to OFF.

3. Allow the engine to cool and position the fuel tank cap vent lever to OFF.

OPERATION

Safe Operating Precautions

AC Operation

Before connecting a device or power cord to the generator, ensure it is in good condition. Faulty appliances or power cords can create a potential for electrical shock.

If an appliance begins to operate abnormally, becomes sluggish, or suddenly stops, immediately shut it off. Disconnect the appliance and determine whether the problem is the appliance or if the rated load capacity of the generator has been exceeded.

Ensure the combined electrical rating of the device or appliance does not exceed the maximum allowed by the generator. Never exceed the maximum power rating of the generator. Power levels between rated and maximum may be used for no more than 30 minutes.

Note: When the electric motor starts, the overload indicator (middle light) may

illuminate (RED) and extinguish within 4 seconds. If the overload indicator remains illuminated, consult the generator supplier.

Note: In order to insure the optimum output and the maximum service life of the

generator, the generator should run at a 50% load for the first 20 hours

1. Start the engine and ensure that the output indicator (A) illuminates (GREEN).

2. Plug the device or extension cord into one of the AC receptacles (B).

3. Turn on the device.

Note: If the generator is overloaded or if

there is a short circuit in a connected appliance, the overload indicator (RED) will illuminate. The overload indicator will remain illuminated and, after about 4 seconds, current to the connected appliance(s) will shut off but the engine will stay running. The output indicator (GREEN) will extinguish.

4. If overloaded or short circuit in a connected device occurs, stop the engine and refer to the “Troubleshooting” section. Determine if the cause is a short circuit in the connected device or an overload. Correct the problem and restart the generator.

5. After determining the cause of the overload and when it is safe to resume using the AC power in order to correct the overload condition and then press the overload reset switch on the front panel. AC power will be restored immediately.

OPERATION

Safe Operating Precautions

AC Capacity

In case of substantial overloading, the electronic circuit protector will activate. Slightly overloading the generator or running at maximum power operation (30 minutes) may not switch the circuit ON, but will shorten the service life of the generator.

Maximum power is: (see page 62) For continuous operation, do not exceed rated power: (see page 62) Consider the total power requirements of all connected devices.

Appliance and power-tool manufacturers usually list the rating information near the model or serial number. After plugging in a device, allow the generator to stabilize before plugging in additional items. Always consider the generator capacity before plugging in any device.

OPERATION

Safe Operating Precautions

AC Capacity

Note: Typical wattages are listed in the table below. Before plugging any device

into the generator, verify the manufacturer-listed wattage on the device.

Wattage Reference Table

DEVICE

Circular Saw - 7 1/4” 1400 2300

Coffee Maker 1000 0

Dehumidifier 650 800

Electric Drill - 3/8”, 4 Amps 440 600

Hair Dryer 300 - 1200 0

Light Bulb (75-Watt) 75 0

Microwave Oven1000-Watt 1000 1400

Paint Sprayer 360 1080

Heat Pump 4700 4500

Personal Computer with 17” Monitor

Radio 300 300

Refrigerator 400 - 800 2200

Space / Wall Heater 1800 0

Table Saw / Radial Arm Saw 10”

Do not use or only use with the POLARIS Parallel Kit, see page 38 for more information

High-Pressure Washer-1 HP 1200 3600

Garage Door Opener 1/2 HP 875 2350

Sump Pump - 1/2 HP 1050 2200

Central AC Unit48,000 BTU 6000 7800

Television (Color) - 27” 500 0

Air Compressor - 1 HP 1600 4500

RUNNING

(RATED) WATTS

800 0

2000 2000

ADDITIONAL

STARTING (SURGE)

WATTS

OPERATION

Safe Operating Precautions

Power Management

DEVICE

Paint Sprayer 360 1080

Radio 300 300

RUNNING

(RATED) WATTS

ADDITIONAL

STARTING (SURGE)

WATTS

Total Running (Rated) Watts = 660 Additional Starting Surge Watts = 1380 Total Generator Output Required = 2040

Ensure the combined electrical rating of the powered device(s) do not exceed the maximum allowed by the generator. Never exceed the maximum power rating of the generator. Power levels between rated and maximum may be used for no more than 30 minutes.

DC Operation

Connecting the Battery Charging Cable (included)

The battery emits explosive hydrogen gas during normal operation. A spark or flame can cause the battery to explode with enough force to kill or cause serious injury. Wear protective clothing and eye protection when charging a battery.

Battery posts, terminals, and related accessories contain lead and lead components. Wash hands after handling.

The DC charging output is not regulated. The DC receptacle should only be used for charging 12V DC batteries.The 12V DC receptacle has no

battery overcharge protection function. Do not overcharge the battery.

When using the DC output, position the SMART throttle switch to OFF. The DC receptacle may be used while the AC power is in use.

OPERATION

Safe Operating Precautions

DC Operation

Connecting the Battery Charging Cable (included)

1. Position the SMART throttle switch to OFF.

2. Disconnect the vehicle ground cable from the negative (-) battery terminal.

3. Plug the battery charging cable into the DC receptacle. See page 19.

4. Connect the red lead of the battery charging cable to the positive (+) battery terminal and then the black lead to negative (-) battery terminal.

Start the generator

Do not start the vehicle while the battery charging cable is connected and the generator is running. The vehicle’s charging system or the generator may be damaged.

An overloaded DC circuit, excessive current draw by the battery, or a wiring problem will trip the DC circuit fuse. If this happens, The fuse must be replaced before the DC receptacle is operative. Replace the fuse with one of the same size and rating (5 amp). Exceeding the current rating may lead to alternator damage. If the DC circuit protector fuse continues to trip, discontinue charging and see your authorized POLARIS generator supplier.

The circuit protector does not prevent overcharging the battery. Over charging the battery may result in battery damage and potential ignite if a spark is introduced.

OPERATION

Safe Operating Precautions

DC Operation

Disconnecting the Battery Charging Cable:

1. Stop the generator.

2. Disconnect the black lead of the battery charging cable from the negative (-) battery terminal and then the lead from the positive (+) battery terminal.

3. Unplug the battery charging cable from the DC receptacle. See page

19.

4. Connect the vehicle battery ground cable to the negative (-) battery terminal.

SMART Throttle System

With the SMART throttle switch in the ON position, engine speed is automatically lowered when loads are reduced, turned off, or disconnected. When devices are turned on or connected, the engine returns to the proper speed to power the electrical load. When the smart throttle is in the OFF position, the engine runs at rated load RPM

Appliances with large start-up power demands may not allow the engine to reach normal operating RPM when they are connected to the generator. Position the SMART throttle switch to OFF and connect the device to the generator. If the engine still will not reach normal operating speed, ensure the device does not exceed the rated load capacity of the generator.

If high electrical loads are simultaneously connected, position the SMART throttle switch to OFF to reduce voltage changes.

The SMART throttle system is not effective for use with devices or appliances requiring only momentary power. If the device or appliance will be quickly turned on and off, the SMART throttle switch should be in the OFF position. When using the DC output, position the SMART throttle switch to OFF.

OPERATION

Safe Operating Precautions

Standby Power

Improper connection to a building electrical system can allow current from the generator to back feed into the utility lines. Such back feed may electrocute utility company workers or others who contact the lines during a power outage. Additionally, the generator may explode, burn, or cause fires when utility power is restored. Consult the utility company or a qualified electrician prior to making any power connections.

Connections to a Building Electrical System

Connections for standby power to a building's electrical system must be made by a qualified electrician and must comply with all applicable laws and electrical codes. Improper connections can allow electrical current from the generator to back feed into the utility lines. Such back feed may electrocute utility company workers or others who contact the lines during a power outage; when utility power is restored, the generator may explode, burn, or cause fires in the building's electrical system. Do not connect this generator to an automatic transfer switch. Serious damage to the engine and inverter module may result.

In some areas, generators are lawfully required to be registered with local utility companies. Check local regulations for proper registration and usage procedures.

System Ground

To prevent electrical shock from faulty appliances, the generator should be grounded. Connect a length of heavy cable between the generator's ground terminal and an external ground source.

System Requirements

There may be federal or state regulations, local codes, or ordinances that apply to the intended use of the generator. Please consult a qualified electrician, electrical inspector, or the local agency having jurisdiction.

If the generator is used at a construction site, there may be additional regulatory requirements.

OPERATION

Parallel Generator Operation

Parallel operation features, kits sold separately.

Two POLARIS parallel ready generators can be connected together to increase the total power available to a load. The system seamlessly matches frequency and automatically evenly distributes the load to each generator so one is not overloaded.

Operating the generators in parallel has 0.9 power de-rate factor. For example, connecting a 1kw and 2kw together in parallel operation, the continuous rated combined output will equal 0.9x (900w + 1600w) = 2250W.

Any combination of two POLARIS parallel ready generators can be connected such as a P2000i and a P1000i, two P2000i models, etc. There are two different parallel connection kits. One kit has a 30A receptacle ideal for connecting two P2000i models or a P2000i and a P1000i.

Parallel operation procedure

1. Turn off both generators and disconnect all the electrical devices from the generators

2. Prepare two parallel ready generators for operation. Place them on a hard and level surface.

3. Connect the parallel kit to each generator by inserting one pair of leads from the parallel box to the parallel receptacles (A) on the panel

4. Ground the generators (B).

5. Start both generators and confirm that both green "RUN" lights are illuminated. The Smart throttle system may be used as long as the Smart throttle setting of both generators is the same.

6. Securely plug the electrical appliance plug into parallel cable receptacle and switch on the electrical appliance power supply.

OPERATION

Parallel Generator Operation

Parallel operation procedure

While operating in parallel, the only AC output is through the receptacle on the parallel cable box.

Do not use the receptacles on the control panel of the generator. The required output of the electrical appliance cannot exceed the rated

output of parallel generators.

Shutting off the generators

1. Turn off the power of electrical appliance then, pull out the receptacle plug.

2. Turn off the two generators.

3. Disconnect the parallel kits from the generators.

• The parallel cable connectors can only be used with POLARIS parallel ready

generators.

• While connecting the generator and electrical appliance with the parallel

output cable, do so carefully and safely insert the plug into the receptacle.

• While operating in parallel, the only AC output is through the receptacle on

the parallel cable box. Do not use the receptacles on the control panel of either generator.

• Do not disconnect the parallel cables during operation

OPERATION

High Altitude Use

Carburetor Modification

When carburetor has been modified for high altitude operation, the airfuel mixture will be too lean for low altitude use and may cause engine damage.

At high altitude, the standard carburetor air-fuel mixture will be excessively rich. Performance will decrease and fuel consumption will increase. A very rich mixture will also foul the spark plug and cause hard starting. Operation at an altitude different than that which this engine was certified, for extended periods of time, may increase emissions.

High altitude operation can be improved by specific modifications to the carburetor. If always operating the generator at altitudes above 5000 feet (1500 meters), have an authorized POLARIS servicing supplier perform the carburetor modification. The engine will meet each emission standard throughout its life when operated at high altitude with the carburetor modifications for high altitude operation.

With the carburetor modification, engine horsepower will decrease by about 3.5% for every 1000 feet (300 meters) increase in altitude. The effect of altitude on horsepower will be greater if no carburetor modification is made.

Operation of the generator at an altitude lower than the carburetor is jetted for may result in reduced performance, overheating, and serious engine damage caused by an excessively lean air/fuel mixture. Be sure to have any modification reversed at lower altitudes.

OPERATION

Emission Control System Information

Source of Emissions

Exhaust gas contains carbon monoxide, nitrous oxide (NOx), and hydrocarbons. It is very important to control the emissions of NOx and hydrocarbons as they are a major contributor to air pollution. Carbon monoxide is a poisonous gas. The generator engine utilizes a precise airfuel ratio and emission control system to reduce the emissions of carbon monoxide, NOx, hydrocarbons.

POLARIS utilizes appropriate air-fuel ratios and other emissions control systems to reduce the emissions of carbon monoxide, oxides of nitrogen, and hydrocarbons. In addition, POLARIS fuel systems utilize components and control technologies to reduce evaporative emissions.

To keep the engine emissions within the emission standards, the following procedures must be followed:

Alterations

Altering the emission control system may increase emissions beyond the legal limit. Some possible alterations are as follows:

• Removal or alteration of any part of the intake, fuel, or exhaust

systems

• Altering or defeating the governor linkage or speed-adjusting

mechanism to cause the engine to operate outside its design parameters

OPERATION

Emission Control System Information

Problems Affecting Emissions

If aware of any of the following, have the engine inspected and repaired by an authorized POLARIS supplier:

• Hard starting or stalling after starting

• Rough idle

• Shut down or backfire after applying an electrical load

• Afterburning (backfiring)

• Black exhaust smoke or high fuel consumption

Replacement Parts

The emission control system on the engine was designed, built, and certified to conform to applicable emission regulations. We recommend the use of POLARIS Genuine parts whenever maintenance is performed. These original design replacement parts are manufactured to the same standards as the original parts. The use of replacement parts that are not of the original design and quality may impair the effectiveness of the emission control system.

Aftermarket part manufacturers assume the responsibility that the part will not adversely affect emission performance. The manufacturer or rebuilder of the part must certify that use of the part will not result in a failure of the engine to comply with emission regulations.

MAINTENANCE

Importance of Maintenance

Good maintenance is essential for safe and economical operation. Proper maintenance will also help reduce air pollution.

To ensure the longevity of the generator, the following pages include a periodic maintenance schedule and inspection and maintenance procedures. Other, more difficult tasks, require special tools and expertise provided by a POLARIS technician or other qualified mechanic.

The maintenance schedule applies to normal operating conditions. If the generator is operated under unusual conditions, such as sustained high load or high temperature, or dusty conditions, consult the servicing supplier for applicable recommendations.

To ensure the best quality and reliability, use only new, POLARIS Genuine parts or their equivalents for repair and replacement.

All necessary replacement parts and labor incurred, with the exception of authorized warranty repairs, become the responsibility of the registered owner. If, during the course of the warranty period, part

failures occur as a result of owner neglect in performing recommended regular maintenance, the cost of repairs are the responsibility of the owner.

MAINTENANCE

Maintenance Safety

Personal safety is critical when attempting to service the generator. Improperly installed or adjusted components can make the generator unstable or dangerous. Improperly installed electrical components can cause engine or electrical systems failure. In either event, damage or serious injury could result. If you do not have the time, tools, and/or expertise necessary to complete a procedure properly, please see your POLARIS supplier for service.

Failure to correct a problem before operation and improper maintenance can cause a malfunction resulting in injury or death. Always follow the inspection and maintenance schedules and requirements in this manual.

The following important safety precautions cannot warn of every possible hazard from maintenance. The decision to perform a given task must be evaluated by the individual performing it.

Safety Precautions

Read the safety section of this manual. Ensure the engine is off before performing any maintenance or repairs.

This should minimize the potential for exposure to the following hazards:

• Fuel and fire - Avoid flames, sparks, and smoking during service.

• Carbon monoxide poisoning - Avoid indoor operation of engine and stay away from open windows and doors.

• Burns - Allow the engine and exhaust system to cool before touching. Exercise caution when working around hazardous materials.

• Injury from moving parts - Avoid running the engine unless specifically instructed.

Follow the instructions and ensure the required tools are used. Exercise caution when working around petrol to reduce the possibility

of fire or explosion. Use only non-flammable solvents to clean parts. Keep cigarettes, sparks, and flames away from all fuel-related components.

MAINTENANCE

Periodic Maintenance

• Always stop the engine before servicing. Disconnect all devices and

extension cords to avoid receiving an electrical shock.

• Periodic checks and maintenance are very important for keeping the

generator in good condition.

• Inspect, clean, lubricate, adjust, and replace parts as necessary. When

inspection reveals the need for replacement parts, use POLARIS Genuine parts available from your POLARIS supplier.

• Before beginning any maintenance procedure, read the instructions

for the entire procedure. During some procedures, potentially hazardous products may be used. Always follow the instructions and warnings on the product packaging.

Periodic Maintenance Chart

Pre-

Item Remarks

Check condition.

Spark plug

Spark arrester

Engine oil

Air filter

Combustion chamber

Fuel tank and filter

Val ve clearance

Fuel line

(1) Log hours of operation to determine proper maintenance. (2) Service more frequently when used in dusty conditions. (3) These items should be serviced by an authorized POLARIS supplier unless the owner has the proper tools and is mechanically proficient. Refer to the POLARIS Service manuals.

Adjust gap and clean.

Replace

Clean the carbon deposits.

Check the oil level. X

Replace X X

Check X

Clean. Replace as needed.

Clean

Check and adjust when engine is cold.

Check fuel line for twists, cracks, or damage. Replace as needed.

Operation Check (daily)

Initial 1 month or 20 hrs

Every 2 years (Replace as necessary)

Every 3 months or 50 hrs

Every 300 Hours

Every 6 months or 100 hrs

(2)

Every 12 months or 200 hrs

(3)

MAINTENANCE

OFF

Opening the Service Door

Use the following steps to open the generator service door and gain access to the inner components. Before performing any maintenance, the fuel tank cap vent lever and engine switch should be positioned to OFF. See page 18.

1. Position the fuel tank cap vent

lever (A) to OFF, if equipped. See page 18.

2. Position the engine switch (B)

to OFF. See page 18.

3. Loosen the service door screw

(C).

4. Open the service door (D).

5. Expose the generator inner

components.

6. Upon completion of

maintenance, return the fuel tank cap vent lever (A), and the engine switch (B) to the ON position to allow engine operation.

MAINTENANCE

Loosen

Tighten

Initial Maintenance

20-Hour Initial Break-In

In order to insure the optimum output and the maximum service life of the generator, the generator should run at a 50% load for the first 20 hours

1. Perform “Oil Change”.

2. Perform “Air Filter Inspection”. Replace as needed.

Fuel System

Petrol is highly flammable and explosive, and can cause serious injury or death. Stop the engine and keep heat, sparks, and flame away. Handle fuel only outdoors. Wipe up spills immediately.

Fuel Line Inspection

Inspect the fuel line to ensure absence of twists, cracks, and / or damage. Replace as needed.

Fuel Tank Strainer Inspection

1. Remove the fuel tank cap (A).

MAINTENANCE

OFF

Fuel System

2. Remove the fuel tank strainer (B)

from the fuel tank.

3. Remove any foreign objects or

debris from the fuel tank strainer (B).

4. Inspect the fuel tank strainer (B) for

damage. Replace as needed.

5. Install the fuel tank strainer (B) into

the fuel tank.

6. Securely tighten the fuel tank cap

(A) until it clicks.

7. Position the fuel tank cap vent lever

MAINTENANCE

Engine Oil

Oil Recommendation

Oil directly affects performance and service life. Use a 4-stroke automotive detergent oil. POLARIS 5W-30 Engine Oil is recommended for this generator.

The SAE oil viscosity and service category are in the API label on the oil container. POLARIS recommends the use of API service category “SJ” or later, equivalent oil.

Oil Level Inspection

Failure to use the proper 4-stroke engine oil may result in engine damage.

Using non-recommended oil may cause serious engine damage. Never substitute or mix oil brands.

Note: Inspect the oil level before each use with the engine stopped and the

generator on a level surface.

1. Open the service door.

2. Remove the oil filler cap /

dipstick (A) and wipe it clean.

3. Insert the dipstick (A) into

filler neck, without screwing it in, to inspect the oil level.

4. Remove the dipstick and

verify that the oil is at the upper limit (B). Add additional oil and inspect the level as needed until the upper limit has been reached.

5. Re-install the dipstick (A).

6. Re-install the service door.

MAINTENANCE

OFF

Engine Oil

Oil Change Procedure

Oil may be hot. Do not allow hot oil to come into contact with skin, as serious burns may result.

Note: Drain the oil while the engine is warm to assure rapid and complete

draining.

1. Start the engine and allow it to run for a few minutes. Stop the

engine.

2. Position engine switch and fuel cap

vent lever to OFF.

3. Open the service door. See page 46.

4. Place a drain pan beneath the generator for used oil.

5. Remove the oil filler cap /

dipstick (A), tip the generator toward the oil filler neck, and drain the oil into a drain pan.

Note: Improper disposal of engine oil

can be harmful to the environment and is unlawful. Properly dispose of used oil.

6. Drain the used oil into a

sealed container and take it to a recycling center. Do not

discard the oil into a rubbish bin, dump it on the ground, or pour it down the drain.

MAINTENANCE

Engine Oil

Oil Change Procedure

7. Fill the oil to the high limit mark (B)

on the dipstick (A).

8. Start the engine and let it run for 1 or

2 minutes. Stop the engine and look for leaks.

9. Re-check the oil level on the

dipstick (A) and add oil as needed to bring the level to the upper mark (B) on the dipstick.

10. Re-install the dipstick (A).

11. Re-install the service door.

12. Wash hands with soap and water after handling used oil.

MAINTENANCE

Air Filters

Operating the engine without air filters or with a damaged air filters will allow debris to enter the engine, causing rapid wear.

Air Filter Inspection

Note: An obstructed air filter restricts air flow to the carburetor. To prevent

carburetor malfunction, regularly service the air filter. Service more frequently when operating the generator in extremely dusty areas.

1. Open the service door. See page 46.

2. Loosen the cover screw (A)

and remove the air filter cover (B).

3. Remove the two air filters (C).

4. Inspect the air filters (C) to

ensure both are clean and in good condition. If obstructed, perform “Air Filter Cleaning”. If damaged, perform “Air Filter Replacement”.

5. Ensure the rubber seal is set in

to the groove of air filter cover (B).

6. When the maintenance complete, re-install the air filter cover and

service door.

MAINTENANCE

Air Filters

Air Filter Cleaning

Note: If operating the generator in a very dust area, clean the air filters more

frequently than specified in the Periodic Maintenance Chart.

1. Wash the air filters (C) in warm water and detergent, rinse, and

allow to completely dry; or clean with a high flash point solvent and allow to completely dry.

2. Soak the elements in clean engine oil and squeeze out the excess oil.

3. Wipe debris from the air filter housing and air filter cover (B) using

a moist towel.

4. Re-install the cleaned filter(s) (C).

Air Filter Replacement

1. Remove the air filters (C).

2. Install new air filters.

MAINTENANCE

Spark Plug

Spark Plug Inspection and Replacement

Using a non-recommended spark plug can result in serious engine damage. Always use recommended spark plugs.

Note: In order to service the spark plug, a commercially available spark plug

wrench is required.

Refer to the “Specification” (page 62) for the recommended spark plug type. Always torque the spark plug to specification.

Note: To ensure proper engine operation, the spark plug must be free of

deposits and properly gapped. If the engine has been running, allow it to cool before servicing.

Normal Spark Plug

The normal insulator tip is gray, tan, or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service.

Note: The tip should not be white. A white insulator tip indicates overheating,

caused by use of an improper spark plug, fuel, or incorrect carburetor adjustments.

Wet Fouled Spark Plug

The wet fouled insulator tip is black. A damp oil film covers the firing end. There may be a carbon layer over the entire nose. Generally, the electrodes are not worn. Fouling may be caused by excessive oil or by frequent short trips, especially in cold weather.

1. Remove the top of the generator by

removing the 4 bolts (A) in the top through the handles.

MAINTENANCE

Inspect electrode for wear and buildup

Spark plug gap

Spark Plug

Spark Plug Inspection and Replacement

2. Remove the spark plug cap (B).

3. Clean any dirt from around the

base of the spark plug.

4. Using a spark plug wrench,

remove the spark plug.

5. Inspect the electrode for wear and

carbon buildup. Look for a sharp outer edge with no rounding or erosion of the electrode.

6. Inspect spark plug. Replace if electrode is worn or if the insulator is

cracked, chipped, or fouled.

7. Using a wire-type feeler gauge,

measure the spark plug electrode gap. If necessary, correct the gap by carefully bending the side electrode. The gap should be 0.6 - 0.7 mm (0.024 - 0.028 in).

8. Ensure the spark plug sealing washer is in good condition and

thread the spark plug in by hand to prevent cross-threading.

A loose spark plug can overheat and damage the engine. Over tightening the spark plug can damage the plug threads.

9. After a new spark plug has been seated by hand, it should be

tightened 1/2 turn with a wrench to compress its washer. If a used plug is being reinstalled, it should only require 1/8 to 1/4 turn after being seated.

10. Re-install the spark plug cap (B).

11. Re-install the top of the generator by inserting and tightening the 4

bolts (A) through the handles.

TRANSPORTATION AND STORAGE

OFF

Transportation

Transporting the Generator

A hot engine or exhaust system can cause severe burns and ignite flammable material. Ensure adequate time for cooling before storage or transportation.

When operating or transporting the generator, be sure it is kept upright. If the generator tilts, fuel may leak. Be sure the fuel tank cap is tight during transportation.

Do not operate the generator while transporting or while it is in a vehicle. Do not transport the generator with fuel in the fuel tank.

IMPORTANT: Take care not to drop or strike the generator when transporting. Do not place heavy objects on the generator.

1. If the generator has been used, allow it to cool for at least 15

minutes before loading it on the transport vehicle.

2. Drain the fuel prior to transportation. See page 59.

3. Position the engine switch (A)

and the fuel tank vent lever (B) to OFF (see page 18), and keep generator level to reduce possibility of fuel leakage.

TRANSPORTATION AND STORAGE

Storage

Storage Preparation

Petrol is highly flammable and explosive and can cause serious injury. Stop the engine and keep heat, sparks, and flame away. Handle fuel only outdoors. Wipe up spills immediately.

Note: Long-term storage of the generator will require some additional

preventative measures to guard against deterioration. If fuel is kept in the generator, ensure that the engine is run for at least 30 minutes per month in order to ensure an easy start in emergencies.

1. If the generator will be stored with fuel, perform “Adding Fuel

Stabilizer”.

2. If the generator will be stored dry of fuel, perform the “Draining

Fuel” and “Fogging the Engine procedures.

3. Perform “Oil Change”. See page 50.

4. Clean the exterior of the generator with a clean cloth and apply a

rust inhibitor.

Do not pour water directly on to the generator or wash it with water.

TRANSPORTATION AND STORAGE

Loosen

Tighten

Storage

Accessing the Fuel Tank

1. Position the fuel tank vent

lever (A) to OFF (see page 18) to reduce leakage possibilities. Remove the fuel tank cap (B).

2. Remove the fuel tank strainer

3. When maintenance is complete, re-

install the fuel tank strainer (C) into the fuel tank.

4. Securely tighten the fuel tank cap (B)

until it clicks.

TRANSPORTATION AND STORAGE

Screw driver

Storage

Draining Fuel from the Fuel Tank and Carburetor

Petrol is highly flammable and explosive and can cause serious injury. Stop the engine and keep heat, sparks, and flame away. Handle fuel only outdoors. Wipe up spills immediately.

Do not spill fuel when draining the fuel tank. Spilled fuel is a fire hazard, causes environmental damage, and can cause damage to paint and plastic. Wipe up spills immediately.

Note: This procedure applies if fuel will NOT be kept in the fuel tank during

storage.

1. Access the fuel tank. See page 58.

2. Empty the fuel tank into an approved petrol container. POLARIS

recommends using a commercially available petrol hand pump to empty the tank. Do not use an electric pump.

3. Re-install the fuel tank strainer into the fuel tank.

4. Securely tighten fuel tank cap until it clicks.

5. Open the service door. See page 46.

6. Position engine switch to ON (see

18). Loosen the carburetor drain screw (A).

7. Drain the petrol from the carburetor

through the attached drain hose (B) and into a suitable container.

8. Remove the top of the unit to access

the spark plug. See page 54.

TRANSPORTATION AND STORAGE

OFF

Storage

9. Remove spark plug cap (C).

10. Pull starter grip (D) three to four

times to drain the petrol from the fuel pump and into a suitable container.

11. Position engine switch (E) to

OFF (see page 18) and tighten the carburetor drain screw.

12. Re-install spark plug cap on the

spark plug securely.

13. Re-install the top of the unit and

the service door.

Fogging the Engine

1. Remove the top of the unit to access the spark plug, see page 54.

2. Remove the spark plug cap (A).

3. Using a spark plug wrench, remove spark plug.

4. Pour about a tablespoon of clean engine oil into the cylinder. Crank

the engine several revolutions to distribute the oil and then reinstall the spark plug.

TRANSPORTATION AND STORAGE

Storage

Fogging the Engine

5. Ensure that the spark plug sealing washer is in good condition and

hand-tighten the spark plug to prevent cross-threading. Torque to specification on page 62.

6. Re-install the spark plug cap (A) and the top of the unit.

Storage Precautions

Do not store the generator outdoors in the cold weather when not in use.

• Select a well-ventilated storage area away from any flame-operated

appliance (i.e., furnace, water heater, or clothes dryer). Also avoid any area with a spark-producing electric motor, or where power tools are operated.

• If possible, avoid storage areas with high humidity to prevent rust and

corrosion.

• Place the generator on a level surface. Tilting can cause fuel or oil

leakage.

• With the engine and exhaust system cool, cover the generator to

prevent dust contamination. Do not use a sheet plastic as a dust cover. Nonporous covers trap moisture around the generator, promoting rust and corrosion.

• Unless fuel tank has been completely drained, position fuel tank cap

vent lever to OFF to reduce leakage possibilities.

Removing from Storage

Note: If the cylinder was coated with oil during storage preparation, the engine

may smoke briefly at startup. This is normal.

1. Perform “Pre-Operation Checklist”. See page 25.

2. If fuel was drained during storage preparation, fill tank with fresh

petrol (see page 26). If petrol is stored in a container, ensure the petrol is fresh. Petrol oxidizes and deteriorates over time, causing hard starting.

SPECIFICATIONS

General Specifications

ALTERNATOR

Model P1000i P2000i

Rated Frequency (Hz) 50

Rated Voltage (V) 240

Rated Current (A) 3.75 6.67

Max Current (A) 4.17 8.33

DC Output Voltage 12V (5A)

Rated Output 900 W 1600 W

Maximum Output 1000 W 2000 W

Phase Single

ENGINE

Model KG144 KG158

Type Single cylinder, 4 stroke, vertical shaft, air-cooled, OHV

Displacement (cc) 58 106

Engine Oil

Engine Oil Capacity qt (L) (0.25 or 0.26 L .42(.4)

Intake Valve Clearance 0.18-0.10 mm (0.0031-0.0039 in.)

Exhaust Valve Clearance 0.10-0.15 mm (0.0039-0.0059 in.)

Spark Plug-Gap UR5 - 0.6 - 0.7 mm (0.024 - 0.028 in.)

POLARIS 5W-30 Generator Oil

GENERAL

Fuel 91 Octane (Up to 10% Oxygenated)

Fuel Tank Capacity 2.6 L (0.7 gallons) 3.8 L (1 gallon)

Starting System Recoil

Dimensions (L x W x H)

Weight

Full Tank Run Time Hours at Rated Load

AC Circuit Breaker Electronic

DC Fuse 5 Amp

DC Charging Cord Standard

493 mm x 264 mm x 419 mm (19.4 in. x 10.4 in. x 16.5 in.)

16.5 kg (36.4 lbs.) 24.18 kg (53.3 lbs.)

4 Hours 3.5 Hours

545 mm × 330 mm × 448mm (21.4in. x 13 in. x 17.6 in.)

SPECIFICATIONS

POLARIS Lubricants and Maintenance Products

ENGINE OIL

PART NUMBER DESCRIPTION

2879383

2871329 Dielectric Grease (Nyogel™)

2871326 Premium Carbon Clean / Fuel Stabilizer (12 oz.) (12 count)

Modified coefficient table of ambient condition power

The conditions of generator rated output:

Altitude: 0 m Ambient temperature: 25°C Relative humidity: 30%

Ambient modified coefficient: C (Relative humidity 30%)

Altitude

(m)

0 1 .98 .96 .93 .90

500 .93 .91 .89 .87 .84

1000 .87 .85 .82 .80 .78

2000 .75 .73 .71 .69 .66

3000 .64 .62 .6 .58 .56

4000 .54 .52 .5 .48 .46

Note: When the relative humidity is 60%, the modified coefficient is C-0.01 When the relative humidity is 80%, the modified coefficient is C-0.02 When the relative humidity is 90%, the modified coefficient is C-0.03 When the relative humidity is 100%, the modified coefficient is C-0.04 Counting example: When the rated power of generator is P

temperature is 35°C relative humidity is 80%, the rated power of generator is: P=P

X (C-0.02) = 5 X (0.82-0.02) = 4KW

POLARIS 5W-30 Generator Oil (1 Quart) (32 oz.)

GREASE / SPECIALIZED LUBRICANTS

ADDITIVES

Ambient temperature (

25 30 35 40 45

=5KW, altitude is 1000m, ambient N

°C)

WIRING DIAGRAMS

White

Black

Yellow

Blue

Stepping motor

Charging winding

DC receptacle

Blue

Red

Black

Rectifier

Secondary winding

Primary winding

Blue

Pink(Black)

Orange(Red)

Inverter module

Red

Black

White

Brown

Gray

Red

Working indicator

Overload indicator

Low oil indicator

Smart Throttle Switch

Reset switch

Stop switch

Ignition winding

Trigger winding

Low oil pressure switch

Spark plug

Ignition coil

Black

White

Brown

Gray

Red

Green

Yellow

green

Purple

Orange

Blue

Yellow green

Single-phase receptacle

Parallel output

Red

Green

Yellow

green

Purple

Orange

Blue

Yellow

green

P1000i Wiring Diagram

P2000i Wiring Diagram

Inverter Module

Blue

Red

Brown

Pink(Black)

Orange(Red)

White

Black

Yellow

Blue

Secondary winding

Primary winding

Stepping motor

DC receptacle

Charging winding

Blue

Red

Black

Rectifier

Black

White

Gray

Reset switch

Smart Throttle Switch

Black

Red

Stop switch

Ignition winding

Trigger winding

Low oil pressure switch

Spark plug

Ignition coil

Red

Working indicator

Overload indicator

Low oil indicator

Black

White

Brown

Gray

Red

Green

Purple

Orange

Blue

Yellow

green

Parallel output

Single-phase receptacle

Red

Green

Yellow

green

Purple

Orange

Blue

Yellow

green

Yellow

green

WIRING DIAGRAMS

TROUBLESHOOTING

Troubleshooting Symptoms

Engine Will Not Turn Over

POSSIBLE CAUSE SOLUTION

Starter recoil damage Take the generator to an authorized POLARIS servicing

Internal engine damage Take the generator to an authorized POLARIS servicing

supplier or refer to the service manual

Engine Turns Over, but Will Not Start

POSSIBLE CAUSE SOLUTION

Out of fuel Refuel

Water is present in the fuel Drain the fuel system and refuel

Old or non-recommended fuel

Fouled or defective spark plug

No spark to spark plug Inspect spark plug, verify engine switch is ON

Water or fuel in crankcase Take the generator to an authorized POLARIS servicing

Mechanical failure Take the generator to an authorized POLARIS servicing

Low Oil Repeat Pre-operation inspection

Drain the fuel system and refuel

Inspect spark plug and replace as needed

supplier or refer to the service manual

TROUBLESHOOTING

Troubleshooting Symptoms

Engine Lacks Power

POSSIBLE CAUSE SOLUTION

Air filter restricted Clean or replace air filter(s)

Bad fuel; generator stored without treating or draining petrol, or refueled with bad petrol

Mechanical failure Take the generator to an authorized POLARIS servicing

Engine Backfires

POSSIBLE CAUSE SOLUTION

Weak spark from spark plug Inspect, clean, and / or replace spark plug

Incorrect spark plug gap or heat range

Drain the fuel system and refuel

supplier or refer to the service manual

Set gap to specification or replace plug

Old or non-recommended fuel

Incorrectly installed spark plug wires

Incorrect ignition timing Take the generator to an authorized POLARIS servicing

Mechanical failure Take the generator to an authorized POLARIS servicing

Loose ignition connections Check all connections and tighten

Water present in fuel Drain the fuel system and refuel

Drain the fuel system and refuel

Take the generator to an authorized POLARIS servicing supplier or refer to the service manual

supplier or refer to the service manual

TROUBLESHOOTING

Troubleshooting Symptoms

Engine Pings or Knocks

POSSIBLE CAUSE SOLUTION

Poor quality or low octane fuel

Incorrect ignition timing Take the generator to an authorized POLARIS servicing

Incorrect spark plug gap or heat range

Replace with recommended fuel

supplier or refer to the service manual

Set gap to specification or replace spark plug

Engine Runs Irregularly, Stalls, or Misfires

POSSIBLE CAUSE SOLUTION

Fouled or defective spark plug

Worn or defective spark plug

Incorrect spark plug gap or heat range

Loose ignition connections Check all connections and tighten

Water present in fuel Drain the fuel system and refuel

Kinked or plugged fuel tank vent line

Incorrect fuel Drain the fuel system and refuel

SMART throttle control malfunction

Inspect, clean, and / or replace spark plug

Take the generator to an authorized POLARIS servicing supplier or refer to the service manual

Set gap to specification or replace spark plug

Inspect and replace

Take the generator to an authorized POLARIS servicing supplier or refer to the service manual

Mechanical failure Take the generator to an authorized POLARIS servicing

supplier or refer to the service manual

TROUBLESHOOTING

Troubleshooting Symptoms

POSSIBLE LEAN

FUEL CAUSE

Low or contaminated fuel Add fuel or drain the fuel system and refuel

Kinked or plugged fuel tank vent

Low octane fuel Drain the fuel system and refuel

Carburetor jetting incorrect Take the generator to an authorized POLARIS servicing

Inspect and replace

supplier or refer to the service manual

POSSIBLE RICH

FUEL CAUSE

Incorrect fuel / fuel is very high octane

Stopping / starting without adequate warm-up

Incorrect spark plug Inspect and replace with correct spark plug

Clogged air cleaner filter Inspect and clean or replace

Drain the fuel system and refuel

Allow the engine to warm up before operating and / or stopping

SOLUTION

No Power at DC Receptacle

POSSIBLE CAUSE SOLUTION

DC circuit protector blown Replace the fuse

Faulty generator Take the generator to an authorized POLARIS servicing

supplier or refer to the service manual

TROUBLESHOOTING

Troubleshooting Symptoms

No Power at AC Receptacles

POSSIBLE CAUSE SOLUTION

Output indicator is OFF, and overload indicator is ON

AC circuit protector tripped Check the AC load and reset circuit protector

Faulty power tool or appliance

Faulty generator Take the generator to an authorized POLARIS servicing

Check the AC load; stop and restart the engine

Check the cooling air inlet; stop and restart the engine

Replace or repair the power tool or appliance; stop and restart the engine

supplier or refer to the service manual

Engine Stops or Loses Power

POSSIBLE CAUSE SOLUTION

Out of fuel Refuel

Fouled, worn, incorrect, or defective spark plug; incorrect spark plug gap or heat range

Loose ignition connections Check all connections and tighten

Water present in fuel / incorrect fuel

Kinked or plugged fuel tank vent line

SMART throttle control malfunction

Inspect, clean, and / or replace the spark plug, set the spark plug gap to specification

Drain the fuel system and refuel

Inspect and replace

Take the generator to an authorized POLARIS servicing supplier or refer to the service manual

No / low oil in the engine Check / replace oil

Clogged air filter Clean or replace the air filter(s)

Overheated engine Clean cover screens

Mechanical failure Take the generator to an authorized POLARIS servicing

supplier or refer to the service manual

WARRANTY

ABOUT THIS WARRANTY DOCUMENT

This warranty document sets out the details of the manufacturer's warranty given by Polaris Sales Australia Pty Ltd (ABN 62 088 081 949) for POLARIS POWER™ generators in respect of defects in these products which appear during the relevant warranty period (See POLARIS POWER™ Generator Warranty).

WARRANTY REGISTRATION FORM

At the time you purchase your POLARIS POWER™ Generator please complete and send the Warranty Registration Form. The Warranty Registration Form includes the date when the POLARIS POWER™ Generator Warranty starts for your POLARIS POWER™ generator.

POLARIS POWER™ GENERATOR WARRANTY

IMPORTANT NOTICE REGARDING YOUR CONSUMER RIGHTS

The benefits given to you in this POLARIS POWER™ generator Warranty are in addition to, and do not detract from, any rights and remedies that you may have under Australian consumer protection laws.

Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a replacement or refund for a major failure and compensation for any other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure.

This POLARIS POWER™ Generator Warranty is not intended to: a. change or exclude any statutory consumer rights that cannot be lawfully changed or

excluded; or

b. limit or exclude any right you have against the person who sold the POLARIS

POWER™ generator to you if that person has breached their sales contract with you.

PROVIDER OF THE POLARIS POWER™ GENERATOR WARRANTY

This POLARIS POWER™ Generator Warranty is provided by: Polaris Sales Australia Pty Ltd (ABN 62088081949) of Locked Bag 2006, Sunshine Post Shop, Sunshine, Victoria 3020 telephone number 03 9394 5610 and e-mail: onlineorders@polaris.com.

WARRANTY POLICY

Polaris warrants that if any genuine Polaris part or accessory in or fitted to your POLARIS POWER™ generator at the date of delivery is found to be defective in materials or workmanship during the relevant Warranty Period, the defect in materials or workmanship will, at Polaris' option, be rectified or the affected part(s) replaced free of charge by Polaris, subject to the conditions and exclusions set out in this POLARIS POWER™ Generator Warranty.

WARRANTY

POLARIS POWER™ GENERATOR WARRANTY

WARRANTY POLICY

Where any genuine Polaris parts or accessories are repaired or replaced under this POLARIS POWER™ Generator Warranty, this does not activate a new Warranty Period from the date of repair or replacement of that part or accessory. Any repaired or replacement Polaris parts or accessories will continue to be covered by this POLARIS POWER™ Generator Warranty for the remainder of the original Warranty Period, as defined below.

All defective parts removed from your POLARIS POWER™ generator remain the property of Polaris.

Polaris reserves the right to conduct all reasonably necessary tests on your POLARIS POWER™ generator to determine the cause of any defect or damage.

WARRANTY PERIOD

This POLARIS POWER™ Generator Warranty shall start from the date referred to in the Warranty Registration Form completed by you (Warranty Start Date) and shall continue as follows:

Warranty Period for consumer use: 3 years Warranty Period for commercial use: 1 year

TRANSFER OF WARRANTY

If you sell your POLARIS POWER™ generator during the applicable Warranty Period to another person, you can transfer the balance of the POLARIS POWER™ Generator Warranty to the purchaser. Please register the change of ownership within 30 days of the sale by filling out the form entitled "Owner Transfer", then scan and send to onlineorders@polaris.com.

HOW TO MAKE A CLAIM UNDER THIS POLARIS POWER™ GENERATOR WARRANTY / OBTAIN SERVICE FOR YOUR POLARIS POWER™ GENERATOR

To make a claim under this POLARIS POWER™ generator Warranty call Polaris on 03 9394 5610 or e-mail onlineorders@polaris.com.

Warranty repairs

Repairs and replacements covered under this POLARIS POWER™ Generator Warranty will be carried out free of charge by Polaris. However you will be responsible for any costs associated with making the warranty claim including but not limited to:

a. the transport of your POLARIS POWER™ generator to and from POLARIS or its

representative and all associated costs and expenses; b. shipping/handling fees; c. any loss of time or loss of profit; d. any costs of arranging a replacement generator during the time your POLARIS

POWER™ generator is being repaired under this POLARIS POWER™ Generator

Warr an ty.

WARRANTY

POLARIS POWER™ GENERATOR WARRANTY

WARRANTY EXCLUSIONS

Your will not be entitled to make a claim under this POLARIS POWER™ Generator Warr an ty :

a. in respect of any fault or damage which, in Polaris' reasonable opinion, has been

caused by or arises from: i. your failure to operate or maintain your POLARIS POWER™ generator in

accordance with the manufacturer's specifications and the instructions in the relevant Operator's Manual;

ii. your misuse, negligence, accident damage or improper or inadequate

maintenance of your POLARIS POWER™ generator, or as a result of negligence or accident;

iii. the POLARIS POWER™ generator having been serviced, or any part having

been repaired or replaced by any third party who is not authorised by POLARIS or a qualified technician and the service, or any part repaired or replaced, was not performed in accordance with the manufacturer's specifications set out in the Operator's Manual or relevant service manual;

iv. the use of parts or products other than genuine Polaris' parts or products (being

parts or products manufactured by Polaris or its related companies or purchased

from Polaris); v. improper use, operator error or abuse; vi. snow, water, dirt, chemicals or other foreign substance; vii. failure to adhere to the cleaning requirements for your POLARIS POWER™

generator as set out in the relevant Operator's Manual;

b. in respect of any surface imperfections caused by external stress, heat, cold,

contamination, operator error or abuse;

c. in respect of parts or accessories exposed to friction surfaces, stresses,

environmental conditions and/or contamination for which they are not designed or not intended, including but not limited to, bulbs, finished and unfinished surfaces, circuit breakers/fuses and electrical components (which are so exposed);

d. in respect of normal maintenance items; e. for normal replacement of service items unless due to a defect in materials or

workmanship;

f. in respect of damage (to the POLARIS POWER™ generator or part) caused by

weather conditions (including but not limited to oxidation, corrosion, hail, colour alteration, lost stickers and badges);

g. in respect of damage (to the POLARIS POWER™ generator or part) caused by the

failure to adhere to the storage requirements set out in the relevant Operator's Manual;

WARRANTY

POLARIS POWER™ GENERATOR WARRANTY

WARRANTY EXCLUSIONS

h. in respect of deterioration of any item due to normal use and exposure, unless due to

a defect in materials or workmanship;

i. in respect of any altered or modified POLARIS POWER™ generator where the

alteration or modification affects the electrical or structural functionality or design of the POLARIS POWER™ generator or of any of its components:

i. at least in so far as the alteration is concerned; and ii. to the extent that any failure on the part of the POLARIS POWER™ generator

is attributable to the alteration or modification; in respect of any POLARIS POWER™ generator which is sold outside of Australia or imported into Australia;

Note: Although this POLARIS POWER™ Generator Warranty does not apply in the circumstances set out above, you may still have rights under Australian laws, including the Australian Consumer Law (see page 71).

To the extent that the law permits and allows Polaris to exclude or limit its liability, Polaris under this POLARIS POWER™ generator Warranty accept no responsibility for the loss of use of the POLARIS POWER™ generator, loss of time or other damage consequential or otherwise including but not limited to transportation charges, rental generator charges during periods of repair, loss of earnings or income. This exclusion does not affect any rights you have under the Australian Consumer Laws.

POLARIS POWER™ GENERATOR OWNER RESPONSIBILITY

Not all faults, repairs, adjustments and replacements are the result of defects in material or workmanship. There are other circumstances beyond Polaris' control that may cause a fault. These circumstances might include weather and atmospheric conditions, normal wear and usage and individual operating habits. Some owners may misuse their POLARIS POWER™ generators by subjecting them to abnormal stress. In these circumstances, you will not have any right to make a claim under this POLARIS POWER™ Generator Warranty.

Now that you have read this document you should understand:

• What is and what is not covered under the POLARIS POWER™ Generator Warranty.

• The need for scheduled maintenance as specified in the Operator's Manual. If you have any queries please contact POLARIS on 03 9394 5610 or e-mail

onlineorders@polaris.com.

WARRANTY

IMPORTANT NOTICE

To aid in prompt support of any in-service or POLARIS POWER ™ Generator Warranty queries that may arise, it is highly important that current ownership details are on file with Polaris.

Therefore it is vital that should you change the details of your POLARIS POWER™ generator ownership (i.e. change of address, change of ownership) that you advise Polaris as soon as possible to ensure that records are amended accordingly.

Manufacturers are required by Federal Government to maintain current owner information should the purpose of a recall arise. Furthermore, current owner information will allow Polaris to readily contact you with relevant product and marketing information.

Your personal information is protected and you can see our Privacy Policy at http://www.polarispower.com.au.

MAINTENANCE LOG

Present this section of your manual to your supplier each time your generator is serviced. This will provide you and future owners with an accurate log of maintenance and services performed.

DATE/HOURS

Initial/20 hrs

3 months/50 hr

6 months/100 hr

9 months/150 hr

SERVICE

PERMORMED

COMMENTS

SUPPLIER /

TECHNICIAN

INDEX

AC Capacity . . . . . . . . . . . . . . . . 32-33

AC Operation . . . . . . . . . . . . . . . . . . 31

AC Receptacle . . . . . . . . . . . . . . . . . 20

AC Receptacles, Photo . . . . . . . . . . . 17

Accessing the Fuel Tank. . . . . . . . . . 58

Adding Engine Oil . . . . . . . . . . . . . . 22

Adding Fuel . . . . . . . . . . . . . . . . . . . 24

Additives . . . . . . . . . . . . . . . . . . . . . . 63

Air Filter Cleaning Procedure. . . . . . 53

Air Filter Inspection Procedure. . . . . 52

Air Filter Replacement Procedure . . 53

Air Filters . . . . . . . . . . . . . . . . . . . . . 52

Alternator Specifications . . . . . . . . . 62

Break-In Procedure. . . . . . . . . . . . . . 47

Carburetor Modification . . . . . . . . . . 40

Choke Lever . . . . . . . . . . . . . . . . . . . 18

Connecting Battery Charging . . . . . . 34

Connecting Charging Cable . . . . . . . 35

Connections to Buildings . . . . . . . . . 37

Control Panel Components . . . . . . . . 17

DC Circuit Protector . . . . . . . . . . . . . 19

DC Fuse Cover, Photo . . . . . . . . . . . 17

DC Operation . . . . . . . . . . . . . . . 34-36

DC Receptacle, Photo . . . . . . . . . . . . 17

Dipstick, Photo . . . . . . . . . . . . . . . . . 22

Disconnecting Charging Cable . . . . . 36

Draining Fuel from the Carburetor . . 59 Draining Fuel from the Fuel Tank . . 59

Economy Throttle System . . . . . . . . 36

Electrical Safety . . . . . . . . . . . . . . . . 12

Emission Control Alterations . . . . . . 41

Emission Control Information . . . . . 41

Emission Control Replacement Parts 42

Emissions Source . . . . . . . . . . . . 38, 41

Engine Fuel Switch. . . . . . . . . . . . . . 18

Engine Lubricants. . . . . . . . . . . . . . . 63

Engine Specifications . . . . . . . . . . . . 62

Equipment Modifications . . . . . . . . . 13

Exhaust and CO Safety . . . . . . . . . . . 11

Extension Cord Information . . . . . . . 13

Fire Safety. . . . . . . . . . . . . . . . . . . . 8-9

Fogging the Engine. . . . . . . . . . . 60-61

Fuel Line . . . . . . . . . . . . . . . . . . . . . . 47

Fuel Recommendations . . . . . . . 23, 26

Fuel Safety . . . . . . . . . . . . . . . . . . . . 10

Fuel System . . . . . . . . . . . . . . . . . . . 47

Fuel Tank Cap Vent Lever . . . . . . . . 18

Fuel Tank Capacity. . . . . . . . . . . . . . 62

Fuel Tank Strainer . . . . . . . . . . . . . . 47

Generator Components . . . . . . . . . . . 16

Generator Specifications. . . . . . . . . . 62

Grease / Specialized Lubricants . . . . 63

Ground Terminal . . . . . . . . . . . . . . . 20

Ground Terminal, Photo . . . . . . . . . . 17

High Altitude Operation . . . . . . . . . . 40

Identification Numbers and Locations 6

Indicator Panel . . . . . . . . . . . . . . . . . 20

Initial Maintenance . . . . . . . . . . . . . . 47

Inspection,Spark Plug . . . . . . . . . 54-55

Intended Use . . . . . . . . . . . . . . . . . . . . 3

Label Location

Carbon Monoxide Warning . . . 14

Hot Exhaust Caution. . . . . . . . . 14

Outdoor Use Only. . . . . . . . . . . 14

Low Oil Indicator . . . . . . . . . . . . . . . 20

Low Oil Indicator, Photo . . . . . . . . . 17

Lubricants/Maintenance Products . . 63

INDEX

Maintenance Safety . . . . . . . . . . . . . 44

Modified coefficient table . . . . . . . . 63

Oil Change Procedure . . . . . . . . . 50-51

Oil Level Inspection . . . . . . . . . . . . 49

Oil Recommendation. . . . . . . . . . . . 49

Opening the Service Door . . . . . . . . 46

Operator Safety . . . . . . . . . . . . . . . . . 9

Output Indicator. . . . . . . . . . . . . . . . 20

Output Indicator, Photo . . . . . . . . . . 17

Overload Indicator. . . . . . . . . . . . . . 20

Overload Indicator, Photo . . . . . . . . 17

Overload Protector Reset Switch. . . 21

Parallel Operation . . . . . . . . . . . . . . 38

Parallel Receptacles. . . . . . . . . . . . . 21

Periodic Maintenance Chart . . . . . . 45

Pre-Operation Checklist. . . . . . . . . . 25

Problems Affecting Emissions . . . . 42

Refueling . . . . . . . . . . . . . . . . . . . 26-27

Registration, Warranty. . . . . . . . . . . 71

Removing Generator from Storage . 61

Replacement,Spark Plug . . . . . . . 54-55

Safe Operating Precautions . . . . . 26-29

Safety Labels and Locations . . . . 14-15

Safety Precautions . . . . . . . . . . 4, 7, 44

Signal Words and Safety Terms . . . . 5

SMART Throttle Switch . . . . . . . . . 19

SMART Throttle Switch, Photo . . . 17

Spark Plug . . . . . . . . . . . . . . . . . . 54-55

Standby Power. . . . . . . . . . . . . . . . . 37

Starter Recoil Grip. . . . . . . . . . . . . . 18

Starting the Engine . . . . . . . . . . . 28-29

Stopping the Engine. . . . . . . . . . . . . 30

Storage . . . . . . . . . . . . . . . . . . . . . 57-61

Storage Precautions . . . . . . . . . . . . . 61

Storage Preparation . . . . . . . . . . . . . 57

System Ground . . . . . . . . . . . . . . . . 37

System Requirements . . . . . . . . . . . 37

Transporting the Generator . . . . . . . . 56

Troubleshooting. . . . . . . . . . . . . . . . . 66

PMS 419

Polaris P2000i, P1000i User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual