Polaris P2000i - Manuals

4 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 Genera...

5 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 ...

6 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. MODEL NUMBER: ______________________________________________________ SERIAL NUMBER: ________________________...

7 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 outline...

9 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...

10 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 b...

11 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 gener...

12 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,...

13 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 t...

14 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...

16 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 Protects the air flow to the carburetor from becoming obstructed with debris D Oil Dipstick Measures oil level in the ...

17 CONTROLS AND FEATURES Control Panel Components: ITEM NOMENCLATURE DESCRIPTION K SMART Throttle Switch Automatically reduces engine speed when loads are shut off or disconnected M DC Fuse Protector Protects DC charging circuit from overloads N 12V DC Receptacle Charges 12V DC batteries O Ground Te...

18 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...

19 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 t...

20 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 ord...

21 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 Receptacl...

22 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. Remove the oil filler cap / dipstick (A). 3. Fill...

23 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. Perfo...

24 FIRST USE INSTRUCTIONS 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 ...

25 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...

26 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 reg...

28 OPERATION 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 surfac...

29 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 s...

30 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. 3...

31 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 sto...

32 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 genera...

33 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 RUNNING (RATED) WATTS ADDITIONAL STARTING (SURGE) WATTS Circul...

34 OPERATION Safe Operating Precautions Power Management Total Running (Rated) Watts = 660Additional Starting Surge Watts = 1380Total 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 m...

35 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...

36 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 charg...

37 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. Additional...

38 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 ...

39 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 t...

40 OPERATION High Altitude Use Carburetor Modification When carburetor has been modified for high altitude operation, the air- fuel 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. Performan...

41 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...

42 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• Af...

43 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 proced...

44 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...

45 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...

46 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. Position the fuel tank cap vent le...

47 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 hours1. Perform “Oil Change”.2. Perform “Air Filter Inspection”. Replace as needed. Fuel System Pet...

48 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. 6. Securely tigh...

49 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 recommend...

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

51 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 uppe...

52 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...

53 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 hi...

54 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” (p...

56 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 ...

57 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 add...

58 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). 2. Remove the fuel tank strainer (C) from the fuel tank. Remove debris as needed. 3. When maintenance is complete...

59 TRANSPORTATION AND STORAGE 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 th...

60 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. 12. Re-install spark plu...

61 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...

62 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 Sin...

63 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) Mod...

64 WIRING DIAGRAMS P1000i Wiring Diagram White White Black Black Black Y ellow Blue Stepping motor Charging winding DC receptacle Blue Red Black Rectifier Secondary winding Primary winding Blue Pink(Black) Orange(Red) Inverter module Red Black Black White Brown Gray Red Red Red Red W orking indicato...

66 TROUBLESHOOTING Troubleshooting Symptoms Engine Will Not Turn Over Engine Turns Over, but Will Not Start 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 auth...

67 TROUBLESHOOTING Troubleshooting Symptoms Engine Lacks Power Engine Backfires 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 Drain the fuel system and refuel Mechanical failure...

68 TROUBLESHOOTING Troubleshooting Symptoms Engine Pings or Knocks Engine Runs Irregularly, Stalls, or Misfires POSSIBLE CAUSE SOLUTION Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing Take the generator to an authorized POLARIS servicing supplier or refer to t...

69 TROUBLESHOOTING Troubleshooting Symptoms No Power at DC Receptacle POSSIBLE LEAN FUEL CAUSE SOLUTION Low or contaminated fuel Add fuel or drain the fuel system and refuel Kinked or plugged fuel tank vent Inspect and replace Low octane fuel Drain the fuel system and refuel Carburetor jetting incor...

70 TROUBLESHOOTING Troubleshooting Symptoms No Power at AC Receptacles Engine Stops or Loses Power POSSIBLE CAUSE SOLUTION Output indicator is OFF, and overload indicator is ON Check the AC load; stop and restart the engine Check the cooling air inlet; stop and restart the engine AC circuit protecto...

71 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 (Se...

72 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 repai...

73 WARRANTY POLARIS POWER™ GENERATOR WARRANTY 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:i. your failure to operate or maintai...

74 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 affe...

75 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™ generat...

76 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 SERVICE PERMORMED COMMENTS SUPPLIER / TECHNICIAN Initial/20 hrs 3 months/50 hr ...

77 INDEX A AC Capacity . . . . . . . . . . . . . . . . 32-33 AC Operation . . . . . . . . . . . . . . . . . . 31 AC Receptacle . . . . . . . . . . . . . . . . . 20 AC Receptacles, Photo . . . . . . . . . . . 17 Accessing the Fuel Tank . . . . . . . . . . 58 Adding Engine Oil . . . . . . . . . . . . ...