12KWG022004KOD PRINTED IN CANADA SGB12000HX PORTABLE GENERATOR OPERATING INSTRUCTIONS AND PARTS MANUAL John Brooks Company Limited Mississauga, Ontario L5N 7K5 12 1
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 Alternator excitation Low speed. Check rpm and set at nominal value failure Faulty condenser Check and replace Faulty windings Check windings resistance High no-load voltage Speed too high Check and adjust rpm Condenser with Check and replace high capacity Low no-load voltage Speed too low Check and adjust rpm Faulty rotary diodes Check and replace Breakdown in windings Condenser with low capacity Check winding resistance, as per tables Check and replace Proper no-load but Low loaded speed Check and regulate rpm low loaded voltage Load too big Check and change Rotary diodes Check and replace short-circuited Proper no-load but High speed in Check and regulate rpm high loaded voltage load condition Unstable voltage Loose contacts Check connections Uneven rotation Check for uniform rotation speed Noisy generator Broken bearings Replace Poor coupling Check and repair 2 11
SGB12000HX 10 3
PRODUCT SPECIFICATIONS ALTERNATOR PARTS LIST Model Engine AC Output (watts) SGB12000HX 20 HP HONDA OHV - maximum 12,000 - rated continuous 10,000 Rated Amperage (A) [120V] 92/120V [240V] 42/240V Frequency (Hz) 60 Voltage (volts) 120/240 Fuel Tank Capacity (l) 40 Run time (hours)- 1/2 load 10 - full load 7 1/2 Weight (lbs) 348 Dimensions (inches) - length 32 - width 22 - height 29 Oil Alert System Overload protection System Starting The SGB12000HX generator has been designed with ease of portability, quiet operation, dependability and versatility in mind. This generator is powered by Honda's proven and reliable 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, this generator is ideal 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 on the next page. The ratings indicated are approximations only. You should always check the startup and running wattage requirements of the equipment you intend to use. YES YES ELECTRIC Position Description Quantity Part # 1 GRID 1 G20042 2 TERMINAL BOX LID 1 G20043 5 TERMINAL BOARD 1 G20044 8 FRAME AND STATOR N/A 14 ROTATING INDUCTOR 1 N/A 15 FAN 1 G20045 19 NON-DRIVE END BEARING (6306-2RS) 1 G20046 26 DIODE 1 G20047 27 VANSTOR 1 G20048 29 SECURING STUD *** 39 PROTECTION SCREEN 1 G20049 40 FIXING RING 1 G20050 65 CAPACITOR 1 G20051 75 RUBBER CUP 1 G20052 107 RUBBER CAP 1 G20053 COMPLETE ALTERNATOR 1 G20054 4 9
Generator Usage Start Watts Running Watts SGB12000HX Refrigerator, Freezer 2500 700 Y Toaster 1050 Y Microwave 950 Y Coffee Maker 1500 850 Y Washing Machine 2000 750 Y Furnace Fan 1400 700 Y Sump Pump 2500 600 Y 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. Safety Precautions Position Description Quantity Part # 1 Battery Hold Down Kit 1 G20010 2 50 amp, 250 volt Straight Blade Receptacle 1 G20011 3 30 amp, 125/250 volt Twist Lock Rec. 1 G20012 4 50 amp, 125/250 volt Twist Lock Rec. 1 G20013 5 50 amp Main Switch Breaker 1 G20014 6 30 amp Breaker 1 G20015 7 30 amp, 125 volt Twist Lock Rec. 1 G20016 8 125 volt Duplex Rec. 2 G20017 9 15 amp Pop-out Breaker 2 G20018 10 Charging Coil 1 G20019 11 Gas Cap 1 G20020 12 Ignition Switch 1 G20021 13 Choke Cable 1 G20022 14 Gas Tank Screen 1 G20023 15 Frame 1 G20024 16 Muffler 1 G20025 17 Gas Tank 1 G20026 18 Muffler Cover 1 G20027 19 Electrical Box 1 G20028 20 Receptacle Face Plate 1 G20029 21 Battery Cables 2 G20039 22 Rubber Mounts 4 G20041 23 Voltage Gauge 1 G20040 Complete Engine 1 12V battery (lawn & garden type) 1 G20084 Engine Oil filter 1 G20055 8 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 5
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 100 F/40 C. 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. 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 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 and outlined in the Honda Engine Owner's Manual. 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. 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. 6 7