Polaris Power P3000iE Operator'S Manual Download Page 79

Page: 79 / 81

INDEX

AC Capacity. . . . . . . . . . . . . . . . . 33-34

AC Operation. . . . . . . . . . . . . . . . 32-33

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

Accessing the Battery . . . . . . . . . . . 55

Accessing the Fuel Tank . . . . . . . . . 60

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

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

Additives . . . . . . . . . . . . . . . . . . . . . 65

Air Filter Inspection Procedure . . . . 52

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

Alternator Specifications . . . . . . . . . 64

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

Choke Knob . . . . . . . . . . . . . . . . . . . 18

Connecting the Charging Cable. . 35-37

Connections to Buildings. . . . . . . . . 39

DC Fuse . . . . . . . . . . . . . . . . . . . . . . 20

DC Operation. . . . . . . . . . . . . . . . 35-37

Disconnecting the Charging Cable . 37

Draining Fuel from Carburetor . . . . 61

Draining Fuel from Fuel Tank. . . . . 61

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

Emission Control Alterations . . . . . 41

Emission Control Information . . . . . 41

Emission Control Replacement Parts 42

Emissions Source. . . . . . . . . . . . . . . 41

Engine Lubricants . . . . . . . . . . . . . . 65

Engine Specifications . . . . . . . . . . . 64

Equipment Modifications . . . . . . . . 13

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

Extension Cord Information . . . . . . 13

Fire Safety . . . . . . . . . . . . . . . . . . 12-13

Fogging the Engine . . . . . . . . . . . . . 62

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

Fuel Recommendations . . . . . . . 23, 27

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

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

Fuel Tank Cap . . . . . . . . . . . . . . . . . . 24

Fuel Tank Capacity . . . . . . . . . . . . . . 65

Fuel Tank Strainer . . . . . . . . . . . . . . . 48

Fuel Valve Lever . . . . . . . . . . . . . . . . 19

Fuel Volume Indicator. . . . . . . . . . . . 21

Generator Components . . . . . . . . 16-17

Generator Exercise . . . . . . . . . . . . . . 63

Generator Specifications . . . . . . . . . . 65

Grease / Specialized Lubricants . . . . 65

Ground Terminal . . . . . . . . . . . . . . . . 21

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

Identification Numbers and Locations 5

Ignition Switch . . . . . . . . . . . . . . . . . 19

Inspection,Spark Plug . . . . . . . . . 53-54

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

Label Location

Carbon Monoxide Warning . . . . 14

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

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

Low Oil Indicator . . . . . . . . . . . . . . . 18

Lubricants/Maintenance Products . . . 65

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

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

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

Opening the Service Door . . . . . . 46-47

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

Output Indicator. . . . . . . . . . . . . . . . . 18

Overload Indicator. . . . . . . . . . . . . . . 18

Overload Protection Device. . . . . . . . 33

Summary of Contents for Power P3000iE

Page 1: ...ns 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 Sunshine Post Shop Sunshine Victoria 3020 Australia Part No 9925472 Rev 02 POLARIS POWER ...

Page 2: ...fety 6 Controls and features 16 First Use Instructions 22 Pre Operation Inspection 26 Operation 27 Maintenance 43 Transportation and Storage 58 Specifications 64 Wiring Diagram 66 Troubleshooting 67 Warranty 72 Maintenance Log 77 Index 78 ...

Page 3: ... 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...

Page 4: ...e entire 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 starting on page 6 of this manual and have the manual on hand when operating the generator Following the safety preca...

Page 5: ... 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 ge...

Page 6: ...l number decal is located inside the service door MODEL NUMBER _______________________________________________________ SERIAL NUMBER _______________________________________________________ PURCHASE DATE _______________________________________________________ PURCAHSE LOCATION __________________________________________________ Serial Number ...

Page 7: ... 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 the Engine swit...

Page 8: ...s 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 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 caus...

Page 9: ...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 ga...

Page 10: ...ders 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 and reads this manual completely 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...

Page 11: ...ieve 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 u...

Page 12: ...ts 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 ...

Page 13: ...ator is stored outdoors unprotected from the weather 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 re...

Page 14: ...g 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...

Page 15: ...ad the Owner s Manual Follow all instructions and Warnings 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 Petrol is flammable and explosive Severe burns can result ALWAYS stop engine and let cool before refueling ALWAYS check for...

Page 16: ...n 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 ALWAY...

Page 17: ...utput LEDs C Fuel Valve Lever Turns fuel supply to carburetor on and off D SMART Throttle Switch Automatically reduces engine speed when loads are shut off or disconnected E Ignition Switch Controls the ignition system functions On Off and operates electric start F DC Receptacle DC Circuit Breaker Charges 12V DC automotive type batteries A C D F B E H I R P O J K Q W U S M N L X T ...

Page 18: ...turn the AC switch to ON position Otherwise there will be no AC power output from AC receptacles M Battery Provides electricity for the starting system N Air Filter Cleans the air going into the engine to reduce ware on internal components O Fuel Filler Cap Provides access to the fuel tank P Fuel Tank Fuel tank Q Air Exhaust Dispels exhaust air from cooling the engine R Muffler Reduces noise and e...

Page 19: ...ll come on when you operate the starter and the engine will not run If this occurs search for any oil leaks Add engine oil to resume normal operation Overload Indicator If the generator is overloaded to the point that the max power rating of 25 amps is exceeded or if there is a short in the connected appliance the output indicator will go out and the overload indicator will go on and current to th...

Page 20: ...cording to the amount of load applied to the generator Placing the smart throttle in the on position is recommended to minimize fuel consumption and engine noise while in operation When high electrical load appliances are connected simultaneously turn the SMART throttle switch to the OFF position to reduce voltage fluctuation The SMART throttle system does not operate efficiently if the electrical...

Page 21: ...ed by snapping open the access door Replace the fuse with one of the same capacity Using a higher rated fuse may cause damage to the generator alternator The DC receptacle F2 may be used for charging 12 volt automotive type batteries only It is not designed to operate DC motors Output voltage is 15 30V DC output will vary according to the position of the Smart throttle switch AC Receptacles Two AC...

Page 22: ...ocal agency having jurisdiction for local codes or ordinances for the intended use of the generator before using the ground terminal Fuel Volume Indicator Fuel Volume Indicator J provides an indication of fuel quantity Starter Recoil Grip Do not allow starter grip to snap back against the generator Return it gently to prevent damage to the starter Starter grip K causes the recoil starter to crank ...

Page 23: ...e the oil filler cap dipstick A 3 Fill the engine crankcase with the specified amount 20 3 ounces 0 6 liters of engine oil 4 Insert the dipstick in the filler hole and tighten the dipstick 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 ...

Page 24: ...e 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...

Page 25: ...e fuel tank strainer B Do not overfill the fuel tank there should be no fuel above the upper limit mark 3 Tighten fuel tank cap A securely until it clicks 4 Position fuel valve lever OFF for storage or ON to operate the generator 5 Move generator away from fueling source and site before starting engine A B ON OFF ...

Page 26: ...eel 2 5 Bolt M6X16 8 Wheel assembly First remove all four rubber mounting feet Put a washer on each side of the wheel then slide them on the axle securing with a lock pin 1 Wheel 2 2 Axle 1 3 Lock pin 2 4 Washer 4 Locking swivel wheel Secure each locking swivel wheel with 4 M6X16 bolts 1 Locking swivel wheel 2 Bolt M6X16 Note Make sure to push two universal wheels to lock position when the generat...

Page 27: ...e the generator inner components See page 46 Engine Oil Perform Oil Level Inspection Add oil as needed See page 49 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 ref...

Page 28: ...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 c...

Page 29: ...ove the fuel tank cap A 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 Move generator away from the fueling source and site before starting the engine A B ...

Page 30: ...nerator is away from the fueling source 2 Unplug all power cords and extension cords from the generator 3 Position the fuel valve lever to ON 4 Position the SMART throttle switch to OFF 5 For a cold engine start position the choke knob to CLOSE To restart a warm engine leave the choke knob in OPEN DANGER Using a generator indoors CAN KILL YOU IN MINUTES Generator exhaust contains carbon monoxide T...

Page 31: ...ion for 5 seconds before repeating until it starts 7 To start the generator using the recoil 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 8 If the choke knob was positioned to CLOSE to start the engine move it to OPEN as the engine warms up 9...

Page 32: ... will be no AC power output from AC receptacles Stopping the Engine Continually stopping the generator with a load applied can lead to damage of the control module 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 ignition switch to OFF 3...

Page 33: ...ximum power rating of the generator Do not exceed the current limit specified for any one receptacle Power levels between rated and maximum may be used for no more than 30 minutes IMPORTANT Before connecting a device or power cord to the generator ensure the device is in good condition and its electrical rating does not exceed the maximum allowed by the generator Note When the electric motor start...

Page 34: ... load to the receptacle and reset the circuit protector by pushing in the button AC power will be restored immediately 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 3 0 k...

Page 35: ...NAL STARTING SURGE WATTS Circular Saw 7 1 4 1400 2300 Coffee Maker 1000 0 Dehumidifier 650 800 Electric Drill 3 8 4 Amps 440 600 Garage Door Opener 1 2 HP 875 2350 Hair Dryer 300 1200 0 Light Bulb 75 Watt 75 0 Microwave Oven 1000 Watt 1000 1400 Paint Sprayer 360 1080 Personal Computer with 17 Monitor 800 0 Radio 300 300 Refrigerator 400 800 2200 Space Wall Heater 1800 0 Sump Pump 1 2 HP 1050 2200 ...

Page 36: ...ion when charging a battery Battery posts terminals and related accessories contain lead and lead components Wash hands after handling To prevent the possibility of creating sparks near the battery connect the charging cable first to the generator then to the battery Disconnect the cable first at the battery The battery contains sulfuric acid electrolyte Contact with skin or eyes may cause severe ...

Page 37: ...C motor or transformer This generator is not designed to operate DC motors Output voltage is 15 30V DC output will vary according to the position of the Smart throttle switch 1 Disconnect the vehicle ground cable from the negative battery terminal 2 Plug the battery charging cable into the DC receptacle 3 Connect the red lead of the battery charging cable to the positive battery terminal and then ...

Page 38: ...scontinue charging and see your authorized POLARIS generator supplier The overload fuse does not prevent overcharging the battery The fuse is located to the left of the receptacle and is accessed by snapping open the access door Replace the fuse with one of the same capacity Using a higher rated fuse may cause damage to the generator alternator Disconnecting the Battery Charging Cable 1 Stop the g...

Page 39: ... not generally recommended for air conditioners exceeding 13 500 BTUs 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...

Page 40: ...ocute 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 utilit...

Page 41: ...s to the carburetor If always operating the generator at altitudes above 1500 meters 5000 feet 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 b...

Page 42: ...el 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 emi...

Page 43: ...ertified 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 manufactur...

Page 44: ...erating 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 o...

Page 45: ...ible 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 poison...

Page 46: ...ic Maintenance Chart Item Remarks Pre Operation Check daily Initial 1 month or 20 hrs Every 3 monthsor 50 hrs Every 6 monthsor 100 hrs Every12 months or 300 hrs Spark plug Check condition Adjust gap and clean X Replace X Spark arrester Clean the carbon deposits X Engine oil Check the oil level X Replace X X Air filter Check X Clean Replace as needed X 2 Fuel sediment cup Clean X Fuel tank and stra...

Page 47: ...ntenance the ignition switch should be positioned to OFF See page 19 Note Use this procedure to open the service door on either side of the generator 1 Position the ignition switch A and fuel valve lever to OFF 2 Unlock the access panel latch B slide the lock down to have the latch handle C pop out 3 Turn the latch handle C clockwise to disengage the latch A C B C ...

Page 48: ...ock wise and pushing in securing with the lock slider B and position the ignition switch A to the ON position to allow generator operation 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 t...

Page 49: ... 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 7 Position the fuel valve lever OFF for storage or transport or ON to run the generator A B ...

Page 50: ...roper 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 screwing it in to inspect t...

Page 51: ...lete draining 1 Start the engine and allow it to run for a few minutes Stop the engine 2 Position the fuel valve lever to OFF 3 Open the service door 4 Remove the oil filler cap dipstick A 5 Remove the drain bolt B and drain the oil The generator will have to be raised off the ground and supported while the oil drains Make sure the wheels are in LOCK position before the oil drain process A B Oil P...

Page 52: ...ubbish bin dump it on the ground or pour it down the drain 7 Re install the oil drain bolt B Fill oil to the high limit mark D on the dipstick 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 D on the dipstick 10 Re install the dipstick A 11 Close the service...

Page 53: ...etor 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 2 Unsnap the clips and remove the air cleaner cover A 3 Remove the air filter B 4 If the paper element B is dirty or torn replace it with a new one Do not attempt to clean the element 5 Reinstall the air cleaner cover 6 Close ...

Page 54: ...fore 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 We...

Page 55: ... by carefully bending the side electrode The gap should be 0 028 0 031in 0 7 0 8mm Correct as necessary by carefully bending the side electrode 9 Ensure the spark plug sealing washer is in good condition and thread the spark plug in by hand to prevent cross threading 10 After a new spark plug has been seated by hand it should be tightened 1 2 turn with a wrench to compress the sealing washer If a ...

Page 56: ... Follow with milk of magnesia beaten egg or vegetable oil Seek immediate attention Overheating of battery may cause an explosion and severe injury or death Stop charging if the battery becomes very warm to the touch Allow battery to completely cool before resuming charging Avoid spilling of electrolyte Damage to equipment may result Immediately wash off any electrolyte spills with a solution of on...

Page 57: ...age is 12 8V DC or greater STATEOF CHARGE VOLTAGE ACTION CHARGE TIME Using constant current charger standard amps specified on top of battery 100 12 8 13 0 Volts None Check at 3 months from manufacture date None required 75 99 12 5 12 7 Volts May need slight charge if no charge given check in 3 months 3 6 hours 50 74 12 0 12 4 Volts Needs charge 5 11 hours 25 49 11 5 11 9 Volts Needs charge At lea...

Page 58: ...r handle and exhaust cover to gain access to the spark arrestor Before performing any inspection or maintenance on the battery ignition switch should be positioned to OFF 1 Remove the generator rear cover A to access the spark arrestor B by removing the 4 screws C 2 Remove the spark arrestor from the muffler by unscrewing the clamp 3 Clean the spark arrestor with a stiff wire brush 4 Replace if th...

Page 59: ...during transportation IMPORTANT Take care not to drop or strike the generator when transporting Do not place heavy objects on the generator IMPORTANT When transporting firmly secure the generator to the transport vehicle 1 If the generator has been used allow it to cool for at least 15 minutes before loading it on the transport vehicle 2 Position the ignition switch A and the fuel valve lever B to...

Page 60: ...0 minutes per month in order to ensure an easy start in emergencies Note Be sure the storage area is free of excessive humidity and dust 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 Remove the battery and store in cool dry locati...

Page 61: ...el Tank 1 Remove the fuel tank cap A 2 Remove the fuel tank strainer B from the fuel tank Remove debris as needed 3 When maintenance is complete re install the fuel tank strainer B into the fuel tank 4 Securely tighten the fuel tank cap until it clicks A B ...

Page 62: ...lls immediately Note This procedure applies if fuel will NOT be kept in the fuel tank during storage or before transportation 1 Access the fuel tank See page 60 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 tigh...

Page 63: ...g sealing washer is in good condition and hand tighten the spark plug to prevent cross threading 7 Using a spark plug wrench carefully tighten the spark plug Torque the spark plug to specification See page 53 8 Slowly pull the starter grip until resistance is felt At this point the piston is coming up on its compression stroke and both the intake and exhaust valves are closed Storing the engine in...

Page 64: ...cise Note Exercise the generator by running it at a 50 load for two hours every month This insures fresh fuel is run through the fuel system and prevents varnishing In addition seals and engine components are lubricated and the chance of carbon buildup in the upper cylinder head is lessened Any moisture that has accumulated in the generator windings is baked out as well as keeping the battery char...

Page 65: ...NGINE Model KG205 Type 4 stroke OHV Air cooled Single Cylinder Displacement 196cc 12 0 cu in Compression Ratio 8 5 1 Engine Speed 3600 RPM with smart throttle off Cooling System Forced Air Ignition System Transistorized Engine Oil POLARIS 5W 30 Generator Oil Engine Oil Capacity 0 6 L 0 63 qt Intake Valve Clearance Cold 0 10 mm 004 in Exhaust Valve Clearance Cold 0 15 mm 006 in Spark Plug Gap WR7DC...

Page 66: ...m Electric with recoil backup Dimensions L x W x H 686 mm 27 0 in 425 mm 16 7 in 505 mm 19 9 in Weight 57 kg 125 6 lbs Full Tank Run Time Hours Rated Load 6 25 hours AC DC Simultaneously Usage Yes 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 ...

Page 67: ... Yellow Orange Blue Pink Red Black Working indicator Overload indicator Oil pressure indicator Single phase receptacle Yellow green Black White Brown Gray Red Green Yellow green Purple Orange Blue Red Green Blue Yellow green Purple Orange Red Yellow green Rectifier Stop Orange Gray Red Black Starting motor Starting relay Ignition winding Yellow green Trigger winding Low oil pressure switch Spark p...

Page 68: ...or refer to the service manual POSSIBLE CAUSE SOLUTION Out of fuel Refuel Low Oil Repeat Pre operation Inspection Water is present in fuel Drain the fuel system and refuel Old or non recommended fuel Drain the fuel system and refuel Fouled or defective spark plug Inspect spark plug and replace if needed No spark to spark plug Inspect spark plug verify engine switch is ON Water or fuel in crankcase...

Page 69: ... and or replace spark plug Incorrect spark plug gap or heat range Set gap to specification or replace spark plug Old or non recommended fuel Drain the fuel system and refuel Incorrectly installed spark plug wires Take the generator to an authorized POLARIS servicing supplier or refer to the service manual Incorrect ignition timing Take the generator to an authorized POLARIS servicing supplier or r...

Page 70: ...tive spark plug Take the generator to an authorized POLARIS servicing supplier or refer to the service manual Incorrect spark plug gap or heat range Set gap to specification or replace spark plug Loose ignition connections Check all connections and tighten Water present in fuel Drain the fuel system and refuel Low battery voltage Recharge battery to 12 8V DC Kinked or plugged fuel tank vent line I...

Page 71: ...authorized POLARIS servicing supplier or refer to the service manual POSSIBLE RICH FUEL CAUSE SOLUTION Incorrect fuel Drain the fuel system and refuel Stopping starting without adequate warm up Allow the engine to warm up before operating and or stopping Incorrect spark plug Inspect and replace with correct plug Clogged air filter Inspect and clean or replace POSSIBLE CAUSE SOLUTION Is the fuse bl...

Page 72: ...rvice manual POSSIBLE CAUSE SOLUTION Out of fuel Refuel Fouled worn incorrect or defective spark plug incor rect spark plug gap or heat range Inspect clean and or replace the spark plug set the spark plug gap to specification Loose ignition connections Check all connections and tighten Water present in fuel incorrect fuel Drain the fuel system and refuel Kinked or plugged fuel tank vent line Inspe...

Page 73: ... 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 again...

Page 74: ...NSFER 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 POLARI...

Page 75: ...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 conta...

Page 76: ...enerator 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 RESPO...

Page 77: ...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 ...

Page 78: ... 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 hr 3 months 50 hr 6 months 100 hr 9 months 150 hr ...

Page 79: ...odifications 13 Exhaust and CO Safety 11 Extension Cord Information 13 F Fire Safety 12 13 Fogging the Engine 62 Fuel Line 47 Fuel Recommendations 23 27 Fuel Safety 10 F Fuel System 47 Fuel Tank Cap 24 Fuel Tank Capacity 65 Fuel Tank Strainer 48 Fuel Valve Lever 19 Fuel Volume Indicator 21 G Generator Components 16 17 Generator Exercise 63 Generator Specifications 65 Grease Specialized Lubricants ...

Page 80: ...7 30 Safety Labels and Locations 14 15 Safety Precautions 3 6 44 Signal Words and Safety Terms 4 SMART Throttle Switch 19 SMART Throttle System 38 Spark Arrestor Maintenance 57 Spark Plug 53 54 Standby Power 39 Starter Recoil Grip 21 Starting the Engine 29 31 Stopping the Engine 31 Storage 59 63 Storage Precautions 63 Storage Preparation 59 System Ground 39 System Requirements 39 T Transporting th...

Page 81: ...PMS 419 ...

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