Polaris Power P1000i Operator's Manual
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Polaris Power P1000i Operator's Manual

Polaris power p1000i/ p2000i generator
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POLARIS POWER™
Operator's Manual
(Australian models)
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
P1000i
P2000i
Failure to properly follow the instructions and precautions in
this manual can result in property damage, serious injury or
DEATH!
PMS 419
Part No. 9925471 Rev 02

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  • Page 1 (Australian models) Failure to properly follow the instructions and precautions in this manual can result in property damage, serious injury or DEATH! For your nearest Polaris supplier, call 0393945610 or visit www.polarispower.com.au Polaris Sales Australia Pty Ltd., (ABN 62088081949) of Locked Bag 2006,...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS Introduction ......2 Safety ....... . . 7 Controls and features .

  • Page 3: Introduction

    INTRODUCTION Welcome Thank you for purchasing a POLARIS POWER 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) ®...

  • Page 4: Intended Use

    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 •...

  • Page 5: Safety Precautions

    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.

  • Page 6: Signal Words And Safety Terms

    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.
  • Page 7 INTRODUCTION 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. Serial Number P2000i P1000i MODEL NUMBER: ______________________________________________________ SERIAL NUMBER: ______________________________________________________ PURCHASE DATE: ______________________________________________________ PURCAHSE LOCATION: __________________________________________________...

  • Page 8: Safety

    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.

  • Page 9: Fire Safety

    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.

  • Page 10: Operator Safety

    • 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.

  • Page 11: Fuel Safety

    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.
  • Page 12 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. •...

  • Page 13: Electrical Safety

    / 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...

  • Page 14: Extension Cord Information

    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.

  • Page 15: Safety Labels And Locations

    SAFETY 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.
  • Page 16 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.

  • Page 17: Controls And Features

    CONTROLS AND FEATURES Generator Components: ITEM NOMENCLATURE DESCRIPTION Spark Plug Cap Remove the top to access the spark plug Control Panel Generator controls Protects the air flow to the carburetor from Air Filter becoming obstructed with debris Oil Dipstick Measures oil level in the engine Carburetor Vent Hose Atmospheric vent Carburetor Drain Hose...

  • Page 18: Control Panel Components

    Illuminates RED for appliance short circuits Overload Indicator or overloads Illuminates RED prior to the oil level falling Low Oil Indicator below a safe limit Overload Reset Switch Resets the circuit after an AC overload Parallel Receptacles For use with proper POLARIS Parallel kits...

  • Page 19: Choke Lever

    CONTROLS AND FEATURES 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.

  • Page 20: Smart Throttle Switch

    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...

  • Page 21: Ground Terminal

    CONTROLS AND FEATURES 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.

  • Page 22: Overload Protector Reset Switch

    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.

  • Page 23: First Use Instructions

    FIRST USE INSTRUCTIONS 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.

  • Page 24: Fuel Recommendation

    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.

  • Page 25: Adding Fuel

    FIRST USE INSTRUCTIONS Adding Fuel 1. Remove the fuel tank cap (A). Loosen Tighten 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.

  • Page 26: Pre-Operation Inspection

    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.

  • Page 27: Operation

    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.

  • Page 28: Safe Operating Precautions

    OPERATION Safe Operating Precautions Refueling 1. Remove the fuel tank cap (A). Loosen Tighten 2. Fill carefully to avoid spilling fuel or exceeding the bottom of the fuel tank strainer (B). 3. Securely tighten the fuel tank cap (A) until it clicks. 4.

  • Page 29: Before Starting The Engine

    OPERATION Safe Operating Precautions Before Starting the Engine Read, understand, and follow the Safety Section of this manual. DANGER 1. Ensure the generator is away Using a generator indoors CAN KILL YOU IN MINUTES. Generator exhaust contains carbon monoxide. from the fueling source. This is a poison you cannot see or smell.
  • Page 30 OPERATION 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.

  • Page 31: Stopping The Engine

    OPERATION 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.

  • Page 32: Ac Operation

    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.
  • Page 33 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:...
  • Page 34 Space / Wall Heater 1800 Table Saw / Radial Arm Saw - 2000 2000 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...

  • Page 35: Power Management

    OPERATION Safe Operating Precautions Power Management ADDITIONAL RUNNING DEVICE STARTING (SURGE) (RATED) WATTS WATTS Paint Sprayer 1080 Radio 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.
  • Page 36 (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.

  • Page 37: Disconnecting The Battery Charging Cable

    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.

  • Page 38: Standby Power

    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.

  • Page 39: Parallel Generator 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.

  • Page 40: Shutting Off The Generators

    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.

  • Page 41: Carburetor Modification

    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.

  • Page 42: Emission Control System Information

    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.

  • Page 43: 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.

  • Page 44: Maintenance

    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.

  • Page 45: Maintenance Safety

    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.

  • Page 46: Periodic Maintenance

    (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.

  • Page 47: Opening The Service Door

    MAINTENANCE 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.

  • Page 48: Fuel System

    MAINTENANCE 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.
  • Page 49 MAINTENANCE 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.

  • Page 50: Oil Recommendation

    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.

  • Page 51: Oil Change Procedure

    MAINTENANCE 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.

  • Page 52: Engine Oil

    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.
  • Page 53 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.

  • Page 54: Air Filter Cleaning

    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;...

  • Page 55: Spark Plug

    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 56 MAINTENANCE 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 Inspect electrode carbon buildup.

  • Page 57: Transportation And Storage

    TRANSPORTATION AND STORAGE 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.

  • Page 58: Storage Preparation

    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.

  • Page 59: Accessing The Fuel Tank

    TRANSPORTATION AND STORAGE 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). Loosen Tighten 2. Remove the fuel tank strainer (C) from the fuel tank. Remove debris as needed.
  • Page 60 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.
  • Page 61 TRANSPORTATION AND STORAGE 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.

  • Page 62: Storage Precautions

    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.

  • Page 63: Specifications

    KG144 KG158 Type Single cylinder, 4 stroke, vertical shaft, air-cooled, OHV Displacement (cc) Engine Oil POLARIS 5W-30 Generator 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.)

  • Page 64: Specifications

    SPECIFICATIONS POLARIS Lubricants and Maintenance Products ENGINE OIL PART NUMBER DESCRIPTION 2879383 POLARIS 5W-30 Generator Oil (1 Quart) (32 oz.) GREASE / SPECIALIZED LUBRICANTS 2871329 Dielectric Grease (Nyogel™) ADDITIVES 2871326 Premium Carbon Clean / Fuel Stabilizer (12 oz.) (12 count)

  • Page 65: Wiring Diagrams

    WIRING DIAGRAMS P1000i Wiring Diagram Stepping motor Stop switch Ignition winding Trigger winding Low oil pressure switch Spark plug Ignition coil Single-phase receptacle...
  • Page 66 WIRING DIAGRAMS P2000i Wiring Diagram Stepping motor Stop switch Ignition winding Trigger winding Low oil pressure switch Spark plug Ignition coil Single-phase receptacle...

  • Page 67: Troubleshooting

    Engine Will Not Turn Over POSSIBLE CAUSE SOLUTION Starter recoil damage Take the generator to an authorized POLARIS servicing supplier or refer to the service manual Internal engine damage Take the generator to an authorized POLARIS servicing supplier or refer to the service manual...

  • Page 68: Engine Lacks Power

    Drain the fuel system and refuel without treating or draining petrol, or refueled with bad petrol Mechanical failure Take the generator to an authorized POLARIS servicing supplier or refer to the service manual Engine Backfires POSSIBLE CAUSE SOLUTION Weak spark from spark plug Inspect, clean, and / or replace spark plug...
  • Page 69 Poor quality or low octane Replace with recommended fuel fuel Incorrect ignition timing Take the generator to an authorized POLARIS servicing supplier or refer to the service manual Incorrect spark plug gap or Set gap to specification or replace spark plug...
  • Page 70 Inspect and replace vent Low octane fuel Drain the fuel system and refuel Carburetor jetting incorrect Take the generator to an authorized POLARIS servicing supplier or refer to the service manual POSSIBLE RICH SOLUTION FUEL CAUSE Incorrect fuel / fuel is very...
  • Page 71 Faulty power tool or appli- Replace or repair the power tool or appliance; stop and ance restart the engine Faulty generator Take the generator to an authorized POLARIS servicing supplier or refer to the service manual Engine Stops or Loses Power POSSIBLE CAUSE SOLUTION...

  • Page 72: Warranty

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

  • Page 73: Warranty Period

    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.

  • Page 74: Warranty Exclusions

    Your will not be entitled to make a claim under this POLARIS POWER™ Generator Warranty: a. in respect of any fault or damage which, in Polaris' reasonable opinion, has been caused by or arises from: 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;...
  • Page 75 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™...
  • Page 76 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™...

  • Page 77: Maintenance Log

    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. SERVICE SUPPLIER / DATE/HOURS COMMENTS PERMORMED TECHNICIAN Initial/20 hrs 3 months/50 hr 6 months/100 hr...

  • Page 78: Index

    INDEX AC Capacity ....32-33 Engine Lubricants ....63 AC Operation ....31 Engine Specifications .
  • Page 79 INDEX Maintenance Safety ... . . 44 Transporting the Generator ..56 Modified coefficient table ..63 Troubleshooting.
  • Page 80 PMS 419...

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Power p2000i

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