Kodiak SGA2300GC Service manual

SGA2300GC
Gasoline-Powered
2300 Watt Portable Generator
Operating Instructions and
Parts Manual
Printed in Canada Man-SGA2300GC-00
John Brooks Company Limited
Mississauga, Ontario L5N 7K5
1

2
Warranty
This product is warranted to be free of defects in materials and workmanship
under normal use and service, for a period of one year 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. Warranty 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:
[phone] in Ontario
or
1-888-881-6667
Fax: [phone]

3
Product Specifications
Model SGA2300GC
Engine Honda GC160VXC
5.0hp
Oil Alert Yes
Fuel Tank Capacity 2 Litres
Run-Time (under
half load) 2.3 Hours
Maximum Output 2300W
Rated Continuous
Output 2000W
AC Output 120V
Maximum Amps 17A
Circuit Breaker
Protection Yes
Receptacles 2 Duplex 115V
Dimensions 22”x16”x16”
Weight 32kg (70lbs.)
The SGA2300GC has been designed with ease of portability, quiet operation,
dependability and versatility in mind. This generator is powered by Honda’s
proven and reliable GC160 series engine, which features Oil Alert for enhanced
operational reliability. The alternator features a brushless design eliminating
the need for costly carbon brush replacement and increases the service life of
the generator.
Ideally suited for camping, boating, farm, household, workshop and
construction usage, the SGA2300GC is perfect when remote, or back-up power
is required.
In order to determine the power requirements of the equipment you wish to
operate, please consult the chart below. The ratings indicated are
approximations only. You should always check the start-up and running
wattage requirements of the equipment you intend to use.
Application Start Watts Running Watts SGA2300GC
Refrigerator, Freezer 2500 700 C
Toaster - 1050 Y
Microwave - 950 Y
Coffee Maker 1500 850 Y
Washing Machine 2000 750 C
Furnace Fan 1400 700 C
Sump Pump 2500 600 C
TV - 350 Y
Circular Saw 1500 750 Y
Drill 1000 250 Y
Sander 1000 375 Y
Y= Will operate C = Check equipment wattages
Please note that this chart represents a sample of applications only.

4
Safety Precautions
Careful operation is your best insurance to prevent accidents and mishaps.
Read this section carefully before operating your generator. All operators, no
matter how much experience they have acquired, should familiarize themselves
with the capabilities of this generator and the precautions outlined in this
manual.
1. To prevent electrical shocks, do not operate this generator in the rain or
with wet hands.
2. Do not refuel the engine while it is in operation or is still hot.
3. Do not refuel the engine near open flames, pilot lights, or sparking
electrical devices (e.g. power tools, welders, or grinders)
4. The engine should be refueled in a well-lit area.
5. Avoid fuel spillage.
6. Do not use any other fuel except gasoline (or as specified by the engine
manufacturer).
7. Do not operate the generator near flammable products.
8. Do not operate the generator in areas with poor ventilation. The exhaust
fumes contain carbon monoxide, a poisonous, odorless, invisible gas.
Prolonged exposure can lead to unconsciousness and death.
9. Do not connect the generator to a commercial power line.
10. Do not operate any generator with missing or broken parts. Contact your
dealer for replacement parts.
11. The generator should be grounded in damp or highly conductive
conditions.
12. Do not operate with damaged or defective extension cords, or power
cords. Never operate any electrical equipment with damaged or defective
cords.
13. Always check the engine oil level before starting. Fill as necessary
referring to the Honda Engine Owners Manual for the specified engine
oil.
14. Do not cover the generator while it is in operation. Overheating can
result in damaged equipment.
15. For storage, do not cover the generator until it has completely cooled
down.
16. The ambient temperature should not exceed 100ºF/40ºC.

5
Before starting, read and understand all safety instructions
included in this manual
Starting Operation
1. Locate the generator on flat terrain, away from water hazards and/or
flammable liquids. Check all electrical cords for cracked or exposed
wires. Replace if necessary.
2. Follow the engine starting procedures contained in the Honda Engine
Owners Manual. Once started, allow the engine to reach operational
temperature for a few minutes without applying load on the alternator.
3. Make sure that the appliance is switched off before connecting it to the
generator. Do not move the generator while it is running.
4. Be sure to ground the generator if the connected appliance is grounded.
Failure to ground the generator may lead to electrical shock.
5. If the generator is overloaded, or short-circuited, a breaker switch is
automatically tripped, preventing electrical current from being supplied
to the appliance. Check the appliance to ensure that the start-up wattage
requirements does not exceed the capacity of the generator. Press the
reset button.
Shutdown Procedure
1. Turn off the power switch of the electrical appliance and disconnect from
the generator.
2. Allow the engine to cool down for approximately 3 minutes at no-load.
3. Refer to the Honda Engine Owner’s Manual for engine shutdown
procedures.
4. Remove any mud, dirt or condensation from the generator. Store in a dry
place.
Maintenance and Storage
(Please refer to the Honda Engine Owner’s Manual)
Periodic inspection and maintenance of the Honda engine are essential if a high
level 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 and outlined in the Honda Engine Owner’s Manual.

6
Transportation and Storage
(Please refer to the Honda Engine Owner’s Manual)
When transporting the generator, turn the fuel valve OFF and keep the engine
level to prevent fuel spillage.
When the generator will be stored over long periods, carry out the following
maintenance. (Please refer to the Honda Engine Owner’s Manual)
a) Store the generator in a well-ventilated, low humidity area.
b) Clean each part with an oil-soaked rag.
c) Change the engine oil.
d) Clean the air cleaner.
e) Empty the gasoline from the fuel tank and carburetor.
f) Pull the recoil starter until resistance is felt, leaving the handle in that
position.
Caution: Never use water to clean the generator.
Troubleshooting
The majority of problems with generator units are with the engine. Please refer
to the Honda Engine Owner’s Manual if engine problems arise. If the problem
persists, contact your local Honda Equipment Dealer.
Trouble Cause Remedy
Engine fails to start. Low fuel level
Fuel strainer cock
closed.
Spark plug loose or
dirty.
Refill the fuel take making sure
not to overfill.
Open fuel strainer cock.
1. If loose, push spark plug
cap back into place.
2. Remove the spark plug and
clean the electrode.
Generator fails to
generate power. No-fuse breaker is in the “off” position.
Terminal has loose
connections.
Ensure that the total wattage of
the electrical appliance is within
permissible limits and that there
are no defects with the
appliance. Turn the no-fuse
breaker to the “on” position.
Inspect and secure connections.
Voltage is too low. Engine speed is too
low. Increase engine speed to rating- refer to the Honda Engine
Manual..

SGA2300GC Breakdown
Position Description Part Number
Honda Engine GC160VXC
Frame SG900000
Alternator AP-85/2
2 Terminal Box Lid ***
7 End Housing 0390302217
8 Stator ***
9 Drive-end Housing 0391700138
14 Rotor ***
15 Fan 0392000030
19 Bearing (6202-2RS1) 0390302530
25 Rectifier Bridge 0391400601
26 Diode 0390400012
27 Varistor 0392000256
28 Cover Bolt ***
29 Stud ***
65 Capacitor ***
67 Enclosing Band ***
68 Flange ***
107 Rubber Cap 0391802005
103 Socket ***
109 Breaker ***
124 Rubber Cap 0390200749
7