Failure To Properly Follow The Instructions . - Polaris Inc.

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Failure to properly follow the instructions and precautions inthis manual can result in property damage, serious injury orDEATH!For your nearest Polaris dealer, call 1-800-POLARIS or visit www.polaris.comPolaris Sales Inc., 2100 Hwy 55, Medina, MN 55340Phone 1-888-704-5290Part No. 9924213 Rev 02

INTRODUCTION . . . . . . . . . . . . . . . . . . . . 1SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . 3CONTROLS AND FEATURES . . . . . . . . . 9FIRST USE INSTRUCTIONS . . . . . . . . . 13PRE-OPERATION INSPECTION . . . . . . 15OPERATION . . . . . . . . . . . . . . . . . . . . . . 17MAINTENANCE . . . . . . . . . . . . . . . . . . . 25TRANSPORTATION AND STORAGE . . 35SPECIFICATIONS . . . . . . . . . . . . . . . . . . 39WIRING DIAGRAM . . . . . . . . . . . . . . . . . 41TROUBLESHOOTING . . . . . . . . . . . . . . . 43WARRANTY . . . . . . . . . . . . . . . . . . . . . . 47MAINTENANCE LOG . . . . . . . . . . . . . . . 51

INTRODUCTIONINTRODUCTIONWelcomeThank you for purchasing a Polaris PowerTM Generator,and welcome to our world-wide family of Polaris owners.Be sure to visit us on-line at www.Polaris.com for thelatest news, new product introductions, upcoming events,career opportunities, and more.Here at Polaris we proudly produce an exciting line ofutility and recreational products.Intended UseThe Polaris PowerTM Generator is intended to supplypower for appliances.Appliances that use more than 2800 Watts of combinedpower consumption should not be connected to thisgenerator. Snowmobiles All-terrain vehicles (ATVs) RANGER utility vehicles RANGER RZR utility vehicles Low emission vehicles (LEVs) Victory Motorcycles Digital Inverter GeneratorsWe believe Polaris sets a standard of excellence for allutility vehicles, recreational vehicles, and powerequipment manufactured in the world today. Many yearsof experience have gone into the engineering, design,and development of your Polaris machine.For safe and enjoyable operation of your generator, besure to follow the instructions and recommendations inthis owner’s manual. Your manual contains instructionsfor minor maintenance, but information about majorrepairs is outlined in the Polaris Service Manual andshould be performed only by a factory certified MasterService Dealer (MSD) Technician.Your Polaris dealer knows your generator best and isinterested in your total satisfaction. Be sure to return toyour dealership for all of your service needs during andafter the warranty period.We also take great pride in our complete line of apparel,parts, and accessories, available through our on-linestore at www.purepolaris.com. Have your accessoriesand clothing delivered right to your door!The engine exhaust from this product contains chemicals known to the State of California to cause cancer,birth defects, or other reproductive harm.1

INTRODUCTIONSafety PrecautionsFailure to follow recommended precautions and procedures could result in severe injury or death. Always heed all safety warnings on the product, andfollow all operation, inspection, and maintenanceprocedures outlined in this manual.Please read the entire Owner’s Manual. This manual contains information essential to safe operation and propermaintenance of the generator. Anyone who operates thegenerator must read the owner’s manual before operatingthe generator.Read and understand the information found in the safetysection starting on page 3 of this manual, and have themanual on hand when operating the generator. Followingthe safety precautions and procedures will ensure a safeoperating experience.Understand and follow all inspection and maintenanceprocedures outlined in this manual starting on page 15.Following these procedures will ensure that the generatorremains in safe operating conditions at all times.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 USEOperating the generator after consuming alcohol ordrugs could adversely affect operator judgment. Never consume alcohol or drugs before or while operating the generator.Identification Numbers and LocationsRecord your generator’s identification numbers in thespace provided. The model and serial number decal islocated on the bottom of the side panel.Warnings, Cautions, and NoticesSignal Words and Safety TermsThe following signal words and symbols appear throughout this manual. Your safety, and the safety of others, isinvolved 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.MODEL NUMBER:SERIAL NUMBER:PURCHASE DATE:A safety alert caution indicates a hazardous situationwhich, if not avoided, may result in minor or moderate injury.2PURCHASE LOCATION:

SAFETYSAFETYSafety Warnings and PrecautionsIMPORTANT SAFEY INSTRUCTIONS. SAVE THESEINSTRUCTIONS.Failure to follow recommended precautions and procedures could result in severe injury or death. Always read all safety precautions and follow alloperation, inspection, and maintenance proceduresoutlined in this manual.General Read and understand all of the safety andoperating information in this manual and on theproduct before using the machine. Use thegenerator only as described in this manual. Understand and follow all inspection andmaintenance procedures outlined in this manual.Following these procedures will ensure that thegenerator remains in safe operating condition. Turn the Engine switch to the OFF position. Turnoff the gasoline valve and close the fuel cap ventwhen the generator is not in use for a long time.Before and During Operation Perform all Pre-Operation Inspection activities asshown on page 15 of this manual. Inspect andtighten all parts before each use. Ensure thegenerator does not have any damaged, loose, ormissing parts before use. All defects should becorrected before use. Do not operate thegenerator if it has been dropped or damaged untilall defective parts have been repaired. Do not place any flammable materials near thegenerator. Never start the generator or let it run in anenclosed area. Exhaust vapors are poisonous andcan cause loss of consciousness or death in ashort time. Keep the generator away frombuildings and other equipment during operation. Do not operate the generator in exposed locationswhere it will be subjected to wet conditions. Do not touch the generator with wet hands, as thismay cause severe electric shocks. Do not pour water directly over the generator orwash it. Do not use or store the generator in the rain orsnow.It is the responsibility of the owner to ensure that allusers of this generator are fully informed of the safety and operating information prior to use. Do not cover the generator when in use. Always operate the generator on a firm, flat, andlevel surface, as the generator will vibrate on anirregular surface. If the generator is tilted, fuel mayspill or the generator may tip over, causing ahazardous situation. Lock the wheels before using. Do not connect the generator to another powersupply source. The engine becomes extremely hot during andimmediately after it has been in use. Be careful notto touch any parts of the hot engine, especially themuffler or muffler cover, or serious burns mayresult. Do not connect external equipment to thegenerator before starting the engine. Do not use for life support, or life sustainingsystems.3

SAFETYOperator SafetyFuel SafetyOperating the generator with worn, damaged, or malfunctioning components could result in serious injury or death. Never start the engine without checkingall of the generator components to be sure of properoperation.Gasoline is highly flammable and explosive undercertain conditions. Always use caution when handling gasoline. Read and understand all of the safety andoperating information in this manual and on allwarning labels before using the generator. Use thegenerator only as described in this manual. Know how to stop the generator quickly in case ofemergency, see page 19 for information onstopping the unit quickly. Keep children, pets, and bystanders at a safedistance from the generator. Review and understand the use of all generatorcontrols. Be sure that anyone who operates the generatorreceives proper instruction and reads this manualcompletely. Do not let children operate thegenerator. Gasoline is extremely flammable, and gasolinevapor can explode. Before refueling allow theengine to cool completely if the generator hasbeen in operation. Always store gasoline in an approved container. Always refuel outdoors or in a well-ventilated areaaway from any combustible materials. Do not smoke or allow open flames or sparks in ornear the area where refueling is performed orwhere gasoline is stored. Never permit children to handle gasoline. Never refuel around bystanders, pets, andflammable objects. Loosen the fuel cap slowly to relieve pressure inthe tank. Use the generator only for intended purposes. Take care not to overfull or spill any fuel on thegenerator or muffler when refueling. Turn off the generator immediately if the unitbegins to operate abnormally. After the generatorhas cooled, disconnect the generator and take toyour authorized Polaris dealer. If gasoline spills on skin or clothing, immediatelywash it off with soap and water and changeclothing. While operating the generator, if you experienceheadache, fatigue, nausea / vomiting, confusion,or seizures, immediately get to fresh air. Do notdelay and do not attempt to shut down the unit. Do not use the generator if you observe y and before using it again. When operating or transporting the generator, besure it is kept upright. If it tilts, fuel may leak. Besure the fuel tank cap is tightened whentransporting the generator. Do not refuel using gas station pumps. Remove fuel from the generator beforetransporting in a vehicle.Do not swallow gasoline, inhale gasoline vapors, orspill gasoline. If you swallow gasoline, inhale morethan a few breaths of gasoline vapor, or splash gasoline in your eyes, see a physician immediately. If gasoline spills on skin or clothing, immediately wash itoff with soap and water and change clothing.4

SAFETYCarbon Monoxide SafetyElectrical SafetyGenerator exhaust contains Carbon Monoxide (CO)vapors. Exposure to Carbon Monoxide by people orpets can result in SEVERE INURY or DEATH. ALWAYS operate generator according to guidelines inlabels and this manual.This generator produces high voltage electricity. This portable generator runs on gasoline. Thegenerator exhaust vapor contains carbonmonoxide (CO). Carbon monoxide is odorless. You cannot smell it. The generator produces enough electric power tocause serious shock or electrocution if misused. Always connect the generator to a suitable groundcircuit. When servicing the generator, disconnect thespark plug wire and place it where it cannotcontact the plug. Turn the engine switch to theOFF position. Carbon monoxide is colorless. You cannot see it. Never run an engine in an enclosed area. Exhaustcontains poisonous carbon monoxide vapor thatcan cause loss of consciousness or death.Operate the engine in an open, and well ventilatedarea. The generator is for outdoor use only. Do not use the generator indoors in garages,basements, crawl spaces, sheds, portablebuildings, or similar areas even if doors and / orwindows are open or if ventilating fans are used tocirculate air. Do not use the generator near windows, doors,vents or any other building openings even if theyare closed. Poor seals on a door, as just oneexample, could still permit high levels of carbonmonoxide to infiltrate the living area of a home. Be sure to install approved carbon monoxidedetectors in your home that have battery back-upsystems that will continue to detect the presenceof carbon monoxide during electric-power outages.Test these devices and replace batteries asrecommended by their respective manufacturers. If you experience headache, fatigue, nausea /vomiting, confusion, or seizures, immediately getto fresh air and away from the unit. Do not delayfor any reason. Do not check for a spark with the plug removed.Use only approved spark plug testers. Using a generator or electrical appliance in wetconditions, such as rain or snow, or near a pool orsprinkler system, or when your hands are wet,could result in electrocution. Keep the generatordry and away from all sources of moisture. If the generator is stored outdoors, unprotectedfrom the weather, check all of the electricalcomponents on the control panel before each use.Moisture or ice can cause a malfunction or shortcircuit in electrical components that could result inelectrocution. Do not connect the generator to a building’selectrical system unless an isolation switch hasbeen installed that meets applicable electricalcodes and regulations. To avoid overloading the generator, ensure thatthe load is kept within the rated power rangestated on the generator. Overloading will damagethe unit and / or shorten its operating lifespan. Do not attempt to connect generators in parallel.5

SAFETYFire SafetyGenerator exhaust system gets hot enough to ignitesome materials and burn skin if touched. Keep the generator away from buildings, otherequipment, and combustible materials duringoperation. Do not enclose the generator in any structure. Keep children and pets away from generator. Exhaust system components are very hot duringand after use. Hot components can cause burnsand fire. Do not touch the hot exhaust systemcomponents. Always keep combustible materialsaway from the exhaust system. Ensure that any spilled fuel is properly wiped upprior to using the generator as fuel vapors areflammable.Extension Cord Information Read the manufacturer starting and runningwattage details and operating instructions for thedevice(s) and appliance(s) that will be used. Oftenthis information can be found in the owner'smanual or on specification decals on the device orappliance. Polaris recommends using only U.L. (UnderwritersLaboratories, Inc.) approved extension cordslabeled with the use, size, and wattage rating.Only use heavy-duty extension cords with a threeprong (grounded) plug for your safety. Decide onwhat length extension cord is required as cordlength determines the extension cord gauge.Remember, as the cord gets longer, the currentcapacity 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 overtime. Never keep an extension cord plugged in when notin use. The cord will still conduct electricity until itis unplugged from the outlet. Before plugging an extension cord or power cordinto the generator, check the cord for any signs ofdamage.Equipment ModificationsModifying the generator by adding or removing any parts,components, or any modifications not approved by Polaris may void the warranty. Such modifications may makethe generator unsafe to operate and could result in severe injury to operators and / or bystanders, as well asdamage to the generator. Some modifications may not belegal in your area. If in doubt, contact your authorized Polaris dealer.6

SAFETYSafety Labels and LocationsHot Exhaust CautionSafety and warning decals have been placed on thegenerator for your protection. Read and follow theinstructions of the decals and warnings on the generatorcarefully. If any of the decals depicted in this manual differfrom the decals on your generator, always read andfollow the instructions of the decals on the generator.The hot exhaust caution is located on the mufflercover.Contacting a hot exhaust system can cause seriousburns.Carbon Monoxide WarningDo not touch if generator is or has been running.Using a generator indoors CAN KILL YOU INMINUTES.The carbon monoxide warning is located on top of thegenerator.CAUTIONContacting a hot exhaust systemcan cause serious burns.Do not touch if generator is or hasbeen running.WARNINGImproper Generator use can result in SEVERE INJURY or DEATH. Read the Owner’s Manual. Follow all instructions and Warnings.Gasoline is flammable and explosive. Severeburns can result. ALWAYS stop engine and letcool before refueling. ALWAYS check for fuelleaks and wipe up any spills. ALWAYS turn fuel toOFF when not in use. NEVER handle gasolineindoors. NEVER overfill fuel tank.Generator exhaust contains poisonousCarbon Monoxide (CO) vapors. ALWAYSoperate in a well-ventilated area.NEVER operate in a home, garage, enclosedarea 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 improperconnections. ALWAYS keep generator and surroundingarea dry. NEVER connect generator to any buildingwithout electrical-isolation protection that meetsapplicable codes and regulations.Outdoor Use ONLY Danger LabelGenerator Exhaust contains carbon monoxide. Thisis a poison you cannot see or smell.NEVER use inside a home or garage, EVEN IF doorsand windows are open.Only use OUTSIDE and far away from windows,doors, and vents.DANGERUsing 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 homeor garage. EVEN IF doorsand windows are open.Only use OUTSIDE andfar away from windows,doors, and vents.Improper Generator use can result in SEVEREINJURY or DEATH. Read the OWNER’S MANUAL.Follow all Instructions and Warnings.Gasoline is flammable and explosive. Severe burnscan result. ALWAYS stop the engine and let cooldown before refueling. ALWAYS check for fuel leaksand wipe up any spills. ALWAYS turn the fuel to OFFwhen not in use. NEVER handle gasoline indoors.NEVER overfill the fuel tank.Generator exhaust contains poisonous CarbonMonoxide (CO) vapors. ALWAYS operate in a wellventilated 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 improperconnections. ALWAYS keep generator andsurrounding area dry. NEVER connect generator toany building without electrical-isolation protectionthat meets applicable codes and regulations.7

SAFETYNOTES8

CONTROLS AND FEATURESCONTROLS AND FEATURESGenerator DESCRIPTIONAChoke KnobProvides proper starting mixture when engine is cold.BIndicator PanelLow Oil, Overload, and Output LEDsCFuel Valve LeverTurns fuel supply to carburetor on and off.DSMART Throttle SwitchAutomatically reduces engine speed when loads are shut off or disconnected.EIgnition SwitchControls the ignition system functions On, Off and operates electric startFDC ReceptacleDC Circuit BreakerCharges 12 Vdc automotive-type batteries.G120V AC Twist Lock Receptacle Provides connection for properly rated, 120V AC appliances.HGround TerminalProvides ground for non-conductive metal parts and receptacle ground terminals.I120V AC ReceptacleProvide two connections for properly rated, AC appliances.JFuel Level IndicatorProvides indication of fuel level.KStarter GripCauses the recoil starter to crank the engine when pulled.LOverload ProtectionResets the circuit protector by pushing in the buttonMBatteryProvides electricity for the starting systemNAir FilterCleans the air going into the engine to reduce ware on internal componentsOFuel Filler CapProvides access to the fuel tankPAir Quality IndexLabel attached to every certified engine showing the engine emissionsQAir ExhaustDispels exhaust air from cooling the engineRMufflerReduces noise and emissions from engine combustionSService DoorProvides access

RANGER utility vehicles . repairs is outlined in the Polaris Service Manual and should be performed only by a factory certified Master . manual on hand when operating the generator. Following the safety precautions and procedures will ensure a safe operating experience.

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