Kodiak KD3000VR User manual

R
Models: KD3000VR
KD5500VR, KD5500VRS
KD7000VR, KD7000VRS
Gasoline Powered Generators
Owner’s Manual
Introduction ...................................................................................................................................... 1
Features & Specifications ................................................................................................................ 1
Safety Precaution ............................................................................................................................ 2
Before Starting Engine ................................................................................................................... 3
Operation ......................................................................................................................................... 4
Stopping Operation .......................................................................................................................... 7
Maintenance & Storage ................................................................................................................... 7
attage information ......................................................................................................................... 8
Troubleshooting ............................................................................................................................... 9
iring Diagram .............................................................................................................................. 10
IMPORT NT: Do not operate this equipment until you have read and understand all of the enclosed Owner’s
Manuals. Carefully read all Warnings, Safety Precautions, ssembly and Operating Instructions,
Maintenance and Storage information.

Warranty
This product is warranted to be free of defects in materials and workmanship under normal use and
service, for a period of three years from the date of purchase, when operated and maintained in
accordance with the Operating and Maintenance Instructions supplied with this unit. This warranty
does not cover misuse or negligence.
This warranty is extended only to the original purchaser. arranty is void if repairs are attempted
by anyone other than an Authorized Service Centre.
If a difficulty develops with the product, you should contact your nearest Authorized Repair Centre,
or JOHN BROOKS COMPANY Ltd. Only these locations are authorized to make repairs to the
product or affect replacement of defective parts, which will be done at no charge within a reasonable
time after receipt of the product. Units or parts should be returned at the customer’s expense to
the nearest JOHN BROOKS location or Authorized Service Centre. Pack unit in a strong carton
and pad tightly to avoid damage. Damage in-transit is not covered by warranty. Include original
purchase receipt with any claim (keeping a copy for your files).
JOHN BROOKS COMPANY LIMITED’s liability under warranty is limited to repair of the
product and/or replacement of parts and is given to the purchaser in lieu of all other
remedies including incidental and consequential charges. There are no express
warranties other than those specified herein.
For the nearest Authorized Service Centre call:
East 1-888-881-6667
est 1-800-527-8592
www.dynablast.ca

- 1 -
Dear Customer:
You are now the proud owner of a Kodiak generator. Kodiak generators are carefully designed and
manufactured to give you safe, dependable service. To obtain the best use of your generator, please read and
understand this manual as well as the onda Engine Owner’s Manual. Failure to do so could result in personal
injury or equipment damage.
Similar to all mechanical products, your machine will occasionally require routine maintenance. This manual
and the onda Engine Owner’s manual should be read carefully before operating or performing any
adjustments or maintenance on your machine.
This manual as well as the onda Engine Owner’s manual should be considered a permanent part of the
generator and should always remain with the unit.
All information contained in this manual reflects the latest product data at the time of publication. Specifications
are subject to change without prior notification or obligation.
A. Feature of the full range of Kodiak generators
KD3000VR KD5500VR(S) KD7000VR(S)
onda O V Engine ● ● ●
Full Frame Protection ● ● ●
Oil Alert ● ● ●
Automatic Idle Control ● ●
Voltage Regulator ● ● ●
Circuit Breaker ● ● ●
Optional Electric Start ● ●
B. Specifications
Model KD3000VR KD5500VR/ KD5500VRS KD7000VR/ KD7000VRS
Generator Type AVR
Engine Model GX160 GX340 GX390
Engine Type Air-Cooled, 4-cycle, O V gasoline engine
Oil Capacity 0.6ℓ(4.22USG) 1.1ℓ(1.16USG)
Tank Capacity US gal (ℓ) 4.2(16) 6.6(25) 6.6(25)
Operating ours 12.1 8.5 7.6
AC Output 120V 120/240V 120/240V
Rated Output 2400W 4800W 6000W
Rated Amps 20.0A 40.0/20.0A 50.0/25.0A
Noise level(dB(A)/7m) 75 78 79
Starting System Recoil Recoil / Electric Start
Dimensions (mm) 600 x 469 x500 690 x 580 x 535
Dimensions (inches) 23.6 x 18.5 x 19.7 27.2 x 22.8 x 21.1
Dry Weight lbs. (kg) 101.4 (46.0) 170.7(78.2) /
176.3 (81.2)
178.1 (82.0) /
184.6 (85.0)
Introduction
Features & Specifications

- 2 -
ARNING
NOTICE
CAUTION:
ARNING
C REFUL OPER TION IS YOUR BEST INSUR NCE G INST CCIDENTS!
Read carefully and understand this section before operating your generator. All operators, no matter how
much experience they have had, should read this and other manuals included with your machine. It is the
owner’s obligation to instruct all operation in safe operation.
Indicates possibility of personal injury or equipment
damage if instructions are not followed.
Indicates that equipment or property damage
can result if instructions are not followed.
Indicates that equipment or property damage
can result if instructions are not followed.
1. Read this manual and the Honda Engine Owner’s manual carefully
before using your new generator - KNO YOUR EQUIPMENT!!!
2. DO NOT operate generator in the rain or with wet hands.
If you ignore this condition, you may suffer severe electric shock.
3. REFUELING
a. DO NOT refuel the generator while it is in operation or still hot.
b. DO NOT refuel while smoking or near flames, pilot lights, sparking
electrical devices, etc. (e. g. power tools, welders, or grinders)
Unit should be refueled in a well lighted and well ventilated area.
c. Avoid spillage.
d. DO NOT operate this generator with any other fuel except gasoline.
4. DO NOT operate generator near inflammable products.
5. DO NOT operate in areas with poor ventilation where vapors may
be trapped. ( i .e .inside a room or tunnel)
Engine exhaust gases are dangerous – the exhaust fumes contain
carbon monoxide, a poisonous, tasteless, odorless, and invisible gas.
Engine exhaust gases will endanger lives.
6. DO NOT connect the unit to a commercial power line.
7. DO NOT connect any generators with missing or broken parts.
Contact your dealer for replacement parts.
8. A ground should be used in damp or highly conductive locations.
9. DO NOT operate with extensions, power cords or any other electrical
equipment, which is damaged or defective. Never operate any electrical
equipment with damaged or defective cords.
Safety Precaution

- 3 -
NOTICE
CAUTION:
1. Fill Engine with oil. Refer to the Honda Engine Owner’s Manual
for oil recommendations.
2. This Honda engine has an OIL ALERT system to protect the engine
against low oil level. If the engine oil level is low the engine will not start.
3. Do not cover the unit while in operation. It could cause overheating and
result in equipment damage.
4. For storage, do not cover unit until the engine has cooled completely.
5. Ambient temperature should not exceed 100°F/40℃.
1. Operate your unit only on a firm supporting, level surface.
2. Sophisticated electronics (i.e. computers, phone systemetc)
Should not be connected to this type of generator.
 Read and understand the Honda Engine Owner’s Manual.
 Check and fill engine with the recommended engine oil to the proper level.
 Change oil if it becomes dirty or discolored. (Diagram 1) Oil capacity at upper level mark on the
Oil dipstick : see Honda engine owner’s manual for more information.
 Remove the tank cap and check the fuel level. If fuel level is low, refill with unleaded automotive gasoline.
Diagram 1: Inspecting oil capacity
Safety Precaution
Before Starting Engine
OIL GAUGE
(OIL FILLER)
OIL FILLER NECK LO ER LEVEL
PROPER LEVEL

- 4 -
NOTICE
TESTRESET
TESTRESET
 Starting the engine:
1. Read Honda Engine Owner’s Manual.
2. Open fuel valve.
3. Set chock lever towards the “Close” position when engine is cold.
If engine is warm, chock lever should be moved to the “Open” position.
4. Set the engine switch to the “Run” position.
5. Pull on starter rope with a fast steady pull to start the engine. (Diagram 2)
6. After engine has started, move the chock
lever back gradually to the “Open” position.
7. Once the engine is running at normal
speed, useable AC power is available.
Diagram 2: Starting the engine.
 pplying C load (single voltage type) (Refer to Diagram 3):
1. Place generator’s “circuit breaker” switch in the “ON” position.
2. Start engine (Please refer to the Honda Engine Owner’s Manual.)
3. Allow the engine to warm up for 2-3 minutes before connecting tools or appliances.
4. Insert the plug of the electrical appliance into the “AC receptacle”.
5. Place generator’s “circuit breaker switch” in the “ON” position.
6. Reset the GFCI receptacle.
How to use GFCI receptacle
1. hen the indicator LED is “on”, there will be no Power
at the GFCI receptacle.
2. Press the reset button to turn “off” the indicator LED , then
power will return.
Operation
Recoil Starter Handle
Indicator LED
is “off”
Indicator LED
is “on”
No power Power is supplied.

- 5 -
ARNING
CAUTION:
Diagram 3: KD3000VR AC Panel
Be sure to ground the generator if the connected
electrical equipment is grounded.
hen the generator is overloaded or a short circuit is made, the “circuit breaker”
switch will stop the engine to protect the circuit automatically. If the “circuit breaker”
switch trips during operation, the generator is either over loaded or the appliance is
defective.
Check the appliance and/or generator for overloading or defect, make necessary
corrections or repairs before use.
 Dual voltage type (KD5500VR,KD5500VRS,KD7000VR,KD7000VRS) only (Diagram 4 , 5)
1. Select the voltage using the “select” switch in accordance with the electrical appliance.
Refer to table below
S ITCH LO ER VOLTAGE RECEPTACLE HIGHER VOLTAGE RECEPTCLE
120V RATED OUTPUT IS AVAILABLE UNAVAILABLE
120V/240V HALF OF RATED OUTPUT IS
AVAILABLE
RATED OUTPUT IS AVAILABLE
2. Place generator’s “Circuit breaker” switch in the “ON” position.
3. Start engine (Please refer to the Honda Engine Owner’s Manual.)
4. Allow the engine to warm up for 2-3 minutes before connecting tools or appliances.
5. Insert the plug of the electrical appliance into the “AC receptacle”.
6. Place generator’s “Circuit breaker switch” in the “ON” position.
7. Reset the GFCI receptacle.
Tee Slot GFCI Receptacle
NEMA 5-20R
“Power On” Indicator Light
Circuit Breaker
Ground Terminal
AC 120V 60Hz
ENGINE SW.
O N
OFF
PILOT
O N
OFF
CIRCUIT BREAKER
TOTAL
20A
R
LR 100643
NEUTRAL BOND TO FRAME
NEUTRE MIS A LA MASSE
A LA CARCASSE DU MOTEUR
ON
OFF

- 6 -
O N
OFF
120V / 240V 120V ONLY
TOTAL
20A
TOTAL
20A
30A
ENGINE SW.
PILOT IDLE CONTROL
CIRCUIT BREAKER
VOLTAGE SELECTOR
AC 120V/240V AC 120V
20A AT 120 / 240V
DO NOT OUTPUT
AT 120V ONLY
CIRCUIT BREAKER
PRESS TO RESET
PRESS A REENCLENCHER
R
LR 100643
NEUTRAL BOND TO FRAME
NEUTRE MIS A LA MASSE
A LA CARCASSE DU MOTEUR
Diagram 4: KD5500VR, KD7000VR AC Panel
Diagram 5: KD5500VRS, KD7000VRS AC Panel
Engine
“ON/OFF”
Switch
Idle Control Switch
“Power On” Indicator Light
Tee Slot GFCI Receptacle
NEMA 5-20R
Circuit Breaker
Output voltage selector switch
4 wire
Twist lock receptacle
NEMA L14-30R
Ground Terminal
“Power On” Indicator Light Circuit Breaker
Output voltage selector switch
4 wire
Twist lock receptacle
NEMA L14-30R
Idle Control Switch
Engine
“ON/OFF”
Switch
Tee Slot GFCI Receptacle
NEMA 5-20R
Ground Terminal 120 Volt
Twist lock receptacle
NEMA L5-30R
120 Volt
Twist
lock receptacle
NEMA L5-30R
30A

- 7 -
NOTICE
ARNING
 In an emergency
(Please refer to the Honda Owner’s manual)
To stop the engine in an emergency, move the engine switch to the “OFF” position.
 In normal use:
1. Turn the “circuit breaker” to the “OFF” position.
2. Unplug all appliances.
3. Move the engine switch to the “OFF” position.
4. Turn the fuel valve to the “OFF” position.
Never leave an appliance plugged into the generator when you stop the
generator, as damage could result to the generator and/ or appliance.
 Maintenance (Please refer to the Honda Engine Owner’s Manual):
Periodic inspection and adjustment of the Honda engine are essential if a high level of performance is to
be maintained. Regular maintenance will also ensure a long service life. The required service intervals
and kind of maintenance to be performed are described in the Honda Engine Owner’s Manual. Please
refer to the Honda Engine Owner’s Manual for more details.
 Transportation / Storage (Please refer to the Honda Engine Owner’s Manual)
hen transporting the generator, turn the fuel valve OFF and keep the unit level to prevent fuel spillage.
hen the generator is in storage for a long period, carry out the following maintenance.
Please refer to the Honda Owner’s Manual.
1. Store generator in a well-ventilated, low humidity area.
2. Clean each part with an oil permeated rag.
3. Change the engine oil.
4. Clean the air cleaner.
5. Empty the gasoline from fuel tank.
6. Start and run engine until it runs out of fuel.
Never use water to clean the generator
Stopping Operation
Maintenance & Storage

- 8 -
Some appliance need a ”surge” or “in rush” of power at start up. This means that the amount of electrical
power needed to start the appliance may exceed the amount needed to maintain its use. Refer to the
appliance for its maximum starting power.
Electrical appliances and tools normally come with a label indicating voltage, cycle (Hz), amperage and
electrical power needed to run the appliance or tool. If the appliance does not have this information in watts
– but does have it in voltage & amperage – simply multiply them together to get the power in watts. (Power
in watts= voltage x amperage)
Wattage information

- 9 -
The majority of troubles with generator units are with the engine. Please refer to the Honda Engine manual
if engine troubles arise.
If a problem persists please contact your local Honda dealer.
 Engine:
SYMPTOM CAUSE REMEDY
Engine fails to start Fuel level is low Refill fuel tank making sure not to
overfill
Oil level is low Fill oil to proper level
Fuel strainer valve is closed Open fuel strainer valve
Choke lever is not in the proper
position
Please move the lever to “close”
Spark plug loose or dirty 1.If loose, push spark plug cap back
into place
2.Remove spark plug and
clean electrodes
Others See Honda Owner’s manual
or contact your local Honda Dealer
for assistance
 Generators:
SYMPTOMS CAUSE REMEDY
No Power Circuit breaker is “0” position After making sure that the total
wattage of the electrical appliance is
within permissible limits and there are
no defects in the appliance, turn the
circuit breaker to the “ON” position
The GFCI receptacle has tripped or
has not been set
Press the reset button in the
GFCI receptacle
Voltage is too low Engine speed is too low Contact your local Kodiak dealer for
assistance
If problems persist, please call the Kodiak toll free hot-line below for the service center
nearest you.
Troubeshooting

- 10 -
ENGINE
GENERATOR
CONTROL BOX
E/G SW
GREEN
RED BLUE
PILOTLAMP
CIRCUIT
BREAKER
ＸＷ
GROUND
２０Ａ
ＧＲＥＥＮ/YELLOW
PLUG
IGNITION COIL
OIL LEVEL SW
MAIN COIL １MAIN COIL ２
GREEN
REDBLUE
ROTOR
YELLOW
SLIP RING
BLUE
SUB COIL
BLUE
BROWN
YELLOWYELLOW
A V R
 KD3000VR 120V 60Hz
Wiring Diagram

- 11 -
GENER ATOR
CONTRO
L
BOX
ENGINE
FUSE
IDOL S
OIL LEVEL S
IDOL CONTROL SOLENOID
IGNITION COIL
SPARK PLUG
FUEL CUT SOLENOID
HITE
GREEN
ORENGE
HITE
BLACK
BLACK
HITE
IDOL CONTROL
UNIT
30A
ＷＸＹ
VOLTAGE SELECT S
120/240V
120V ONLY
FS G
ENGINE KILL S
IG E
ＷＸＸＷ
12５V 20A
ＷＸＸＷ
12５V 20A
30A
ＸＷ
125V 30A
GROUND
BREAKER
20A
CIRCUIT
BREAKER
20A
CIRCUIT BREAKER
30A
CIRCUIT
BRIDGE DIODE
HITE
BLACK
CIRCUIT
BREAKER
PILOT LAMP
※Ａ
KD5500VR・・・20A
KD7000VR・・・25A
GREEN
RED
BLUE
GRAY
ORANGE
GRAY
BREAKER
CIRCUIT
RED
ORANGE BLUE
ROTOR
STATOR
SLIP RING
MAIN COIL
SUB COIL
RED
HITE
MAIN COIL
BRO N
A V R
BLUE
BLUE
GREEN
HITE
DC COIL
BRO N
125/240V 30A
BRO N
BRO N
 KD5500VR / KD7000VR 120V/240V 60Hz
Wiring Diagram

- 12 -
ROTOR
STATOR
GENERATOR
CONTROL BOX
ENGINE
IGNITION COIL
CHARGEING COIL
BATTERY
STARTER MOTOROIL LEVEL SWFUEL CUT SOLENOID
SPARK PLUG
IDOL CONTROL SOLENOID
FUSE
IDOL SW
FUSE
WHITE REDBLUE BLACK
WHITEWHITE
BLACK ORANGE WHITE
RED
IDOL CONTROL
UNIT
BREAKER
CIRCUIT
VOLTAGE SELECT SW
120/240V
120V ONLY
RED
RESET SW
DIODE
GREEN
FS GBAT ST E IG
ENGINE KILL SW
WHITE RED
WHITE GRAY
WHITE RED
125/240V30A
30A
ＷＸＹ
30A
ＸＷ
12５V30A
BREAKER
30A
CIRCUIT
GROUND
ＷＸＷＸ
BREAKER
CIRCUIT
BREAKER
CIRCUIT
ＸＷ
12５V20A
ＸＷ
12５V20A
CIRCUIT
BREAKER
20A20A
※Ａ
KD5500VRS・・・20AKD7000VRS・・・25A
SLIP RING
MAIN COIL
A V R
SUB COIL
RED
WHITE
BLUEBLUE
GREEN
WHITE
MAIN COIL
DC COIL
BROWNBROWNGRAY
GRAY
BLUEORANGE
BROWNBROWN GREEN ORANGE BLUE
PILOT LAMP
BRIDGE DIODE
WHITE
BLACK
 KD5500VRS / KD7000VRS 120V/240V 60Hz
Wiring Diagram