Polaris P2000i, P1000i User Manual

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.

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