Lennox RGEN12, RGEN17, RGEN18 Operation Manual
E 2009 Lennox Industries Inc.
Dallas, Texas 75379-9900
This manual provides operation and maintenance
instructions for models RGEN12 and RGEN17/18
generator sets.
Generator sets are approved for use in stationary
standby applications in locations served by a reliable
utility power source. Have a Lennox dealer who is
approved to sell and install Lennox generator sets
(hereinafter referred to as a Lennox dealer) install the
generator set. Refer to XP-6514, Installation
Instructions, for installation instructions.
Information in this publication represents data available
at the time of print. The manufacturer reserves the right
to change this publication and the products represented
without notice and without any obligation or liability
whatsoever.
Read this manual and carefully follow all procedures
and safety precautions to ensure proper equipment
operation and to avoid bodily injury. Read and follow the
Safety Precautions and Instructions section. Keep this
manual with the equipment for future reference.
The equipment service requirements are very important
to safe and efficient operation. Inspect the parts often
and perform required service at the prescribed intervals.
Obtain service from a Lennox dealer to keep equipment
in top condition.
RETAIN THESE INSTRUCTIONS
FOR FUTURE REFERENCE
Shipping and Packing List
1 -- Generator Set
Check equipment for shipping damage. If you find any
damage, immediately contact the last carrier.
506088-01
OPERATION
MANUAL
RGEN12, RGEN17/18
RESIDENTIAL GENERATOR SET
XP-6515 4/09a
Table of Contents
Product Identification Information 2...............
Safety Precautions and Instructions 3.............
Introduction 7...................................
Section 1 Features 9.............................
1.1 Specifications 9.............................
1.2 Generator 9.................................
1.3 Engine 9...................................
1.4 Controller 9.................................
1.5 Generator Set Components 10.................
Section 2 Operation 12............................
2.1 Prestart Checklist 12..........................
2.2 Exercising Generator Set 12...................
2.3 Controls and Indicators 12.....................
2.4 Controller Power 13...........................
2.5 Generator Set Operation 14....................
2.6 Faults 14....................................
2.7 Battery Charger 17...........................
Section 3 Scheduled Maintenance, RGEN12 18......
3.1 Routine Maintenance 18.......................
3.2 Service Schedule, RGEN12 19.................
3.3 Lubrication System 20.........................
3.4 Spark Plugs 21...............................
3.5 Air Cleaner Element and Precleaner 21..........
3.6 Cooling System 22............................
3.7 Exhaust System 23...........................
3.8 Battery 23...................................
3.9 Battery Charger 24...........................
3.10 Circuit Protection 24..........................
3.11 Storage Procedure 25.........................
Section 4 Scheduled Maintenance, RGEN17/18 26...
4.1 Routine Maintenance 26.......................
4.2 Service Schedule, RGEN17/18 27..............
4.3 Lubrication System 28.........................
4.4 Spark Plugs 29...............................
4.5 Air Cleaner Service 30........................
4.6 Cooling System 30............................
4.7 Exhaust System 31...........................
4.8 Battery 31...................................
4.9 Battery Charger 32...........................
4.10 Circuit Protection 32..........................
4.11 Storage Procedure 33.........................
Section 5 Troubleshooting 34......................
5.1 Introduction 34...............................
5.2 Controller Troubleshooting 34..................
5.3 Generator Set Troubleshooting 35..............
5.4 Battery Charger Troubleshooting 36.............
California Proposition 65
WARNING
Engine exhaust from this product contains chemicals
known to the State of California to cause cancer, birth
defects, or other reproductive harm.
Product Identification Information
Product identification numbers determine service parts.
Record the product identification numbers in the spaces
below immediately after unpacking the products so that
the numbers are readily available for future reference.
Record field-installed kit numbers after installing the
kits.
Generator Set Identification Numbers
Record the product identification numbers from the
generator set nameplate(s).
Model Designation
Specification Number
Serial Number
Accessory Number Accessory Description
Controller Identification
Record the controller description from the generator set
operation manual, spec sheet, or sales invoice.
Controller Description
Engine Identification
Record the product identification information from the
engine nameplate.
Manufacturer
Model Designation
Serial Number
Safety Precautions and Instructions
IMPORTANT SAFETY INSTRUCTIONS.
Electromechanical equipment,
including generator sets, transfer
switches, switchgear, and accessories,
can cause bodily harm and pose
life-threatening danger when
improperly installed, operated, or
maintained. To prevent accidents be
aware of potential dangers and act
safely. Read and follow all safety
precautions and instructions. SAVE
THESE INSTRUCTIONS.
This manual has several types of safety
precautions and instructions: Danger,
Warning, Caution, and Notice.
DANGER
Danger indicates the presence of a
hazard that will cause severe
personal injury, death,orsubstantial
property damage.
WARNING
Warning indicates the presence of a
hazard that can cause severe
personal injury, death, or substantial
property damage.
CAUTION
Caution indicates the presence of a
hazard that will or can cause minor
personal injury or property damage.
NOTICE
Notice communicates installation,
operation, or maintenance information
that is safety related but not hazard
related.
Safety decals affixed to the equipment
in prominent places alert the operator
or service technician to potential
hazards and explain how to act safely.
The decals are shown throughout this
publication to improve operator
recognition. Replace missing or
damaged decals.
Accidental Starting
WARNING
Accidental starting.
Can cause severe injury or death.
Disconnect the battery cables before
working on the generator set.
Remove the negative (--) lead first
when disconnecting the battery.
Reconnect the negative (--) lead last
when reconnecting the battery.
Disabling the generator set.
Accidental starting can cause
severe injury or death. Before
working on the generator set or
connected equipment, disable the
generator set as follows: (1) Move the
generator set master switch to the OFF
position. (2) Disconnect the power to
the battery charger. (3) Remove the
battery cables, negative (--) lead first.
Reconnect the negative (--) lead last
when reconnecting the battery. Follow
these precautions to prevent starting of
the generator set by an automatic
transfer switch, remote start/stop
switch, or engine start command from a
remote computer.
Battery
WARNING
Sulfuric acid in batteries.
Can cause severe injury or death.
Wear protective goggles and
clothing. Battery acid may cause
blindness and burn skin.
WARNING
Explosion.
Can cause severe injury or death.
Relays in the battery charger
cause arcs or sparks.
Locate the battery in a well-ventilated
area. Isolate the battery charger from
explosive fumes.
Battery electrolyte is a diluted
sulfuric acid. Battery acid can cause
severe injury or death. Battery acid
can cause blindness and burn skin.
Always wear splashproof safety
goggles, rubber gloves, and boots
when servicing the battery. Do not
open a sealed battery or mutilate the
battery case. If battery acid splashes in
the eyes or on the skin, immediately
flush the affected area for 15 minutes
with large quantities of clean water.
Seek immediate medical aidin thecase
of eye contact. Never add acid to a
battery after placing the battery in
service, asthis may result in hazardous
spattering of battery acid.
Battery acid cleanup. Battery acid
can cause severe injury or death.
Battery acid is electrically conductive
and corrosive. Add 500 g (1 lb.) of
bicarbonate of soda (baking soda) to a
containerwith4L(1gal.)ofwaterand
mix the neutralizing solution. Pour the
neutralizing solution on the spilled
battery acid and continue to add the
neutralizing solution to the spilled
battery acid until all evidence of a
chemical reaction (foaming) has
ceased. Flush the resulting liquid with
water and dry the area.
XP-6515 4/09 3Safety Precautions and Instructions
Battery gases. Explosion can cause
severe injury or death. Battery gases
can cause an explosion. Do not smoke
or permit flames or sparksto occur near
a battery at any time, particularly when
it is charging. Do not dispose of a
battery in a fire. To prevent burns and
sparks that could cause an explosion,
avoid touching the battery terminals
with tools or other metal objects.
Remove all jewelry before servicing the
equipment. Discharge static electricity
from your body before touching
batteries by first touching a grounded
metal surface away from the battery. To
avoid sparks, do not disturb the battery
charger connections while the battery
is charging. Always turn the battery
charger off before disconnecting the
battery connections. Ventilate the
compartments containing batteries to
prevent accumulation of explosive
gases.
Battery short circuits. Explosion
can cause severe injury or death.
Short circuits can cause bodily injury
and/or equipment damage.
Disconnect the battery before
generator set installation or
maintenance. Remove all jewelry
before servicing the equipment. Use
tools with insulated handles. Remove
the negative (--) lead first when
disconnecting the battery. Reconnect
the negative (--) lead last when
reconnecting the battery. Never
connect the negative (--) battery cable
to the positive (+) connection terminal
of the starter solenoid. Do not test the
battery condition by shorting the
terminals together.
Engine Backfire/Flash
Fire
WARNING
Fire.
Can cause severe injury or death.
Do not smoke or permit flames or
sparks near fuels or the fuel system.
Servicing the fuel system. A flash
fire can cause severe injury or death.
Do not smoke or permit flames or
sparks near the carburetor, fuel line,
fuel filter, fuel pump, or other potential
sources of spilled fuels or fuel vapors.
Catch fuels in an approved container
when removing the fuel line or
carburetor.
Combustible materials. A fire can
cause severe injury or death.
Generator set engine fuels and fuel
vapors are flammable and explosive.
Handle these materials carefully to
minimize the risk of fire or explosion.
Equip the compartment or nearby area
with a fully charged fire extinguisher.
Select a fire extinguisher rated ABC or
BC for electrical fires or as
recommended by the local fire code or
an authorized agency. Train all
personnel on fire extinguisher
operation and fire prevention
procedures.
Exhaust System
WARNING
Carbon monoxide.
Can cause severe nausea,
fainting, or death.
The exhaust system must be
leakproof and routinely inspected.
Generator set operation. Carbon
monoxide can cause severe nausea,
fainting, or death. Carbon monoxide
is an odorless, colorless, tasteless,
nonirritating gas that can cause death if
inhaled for even a short time. Avoid
breathing exhaust fumes whenworking
on or near the generator set. Never
operate the generator set inside a
building. Never operate the generator
set where exhaust gas could seep
inside or be drawn into a potentially
occupied building through windows, air
intake vents, or other openings.
Carbon monoxide symptoms.
Carbon monoxide can cause severe
nausea, fainting, or death. Carbon
monoxide is a poisonous gas present in
exhaust gases. Carbon monoxide isan
odorless, colorless, tasteless,
nonirritating gas that can cause death if
inhaled for even a short time. Carbon
monoxide poisoning symptoms include
but are not limited to the following:
D Light-headedness, dizziness
D Physical fatigue, weakness in
joints and muscles
D Sleepiness, mental fatigue,
inability to concentrate
or speak clearly, blurred vision
D Stomachache, vomiting, nausea
If experiencing any of these symptoms
and carbon monoxide poisoning is
possible, seek fresh air immediately
and remain active. Do not sit, lie down,
or fall asleep. Alert others to the
possibility of carbon monoxide
poisoning. Seek medical attention if
the condition of affected persons does
not improve within minutes of breathing
fresh air.
Fuel System
WARNING
Explosive fuel vapors.
Can cause severe injury or death.
Use extreme care when handling,
storing, and using fuels.
Gas fuel leaks. Explosive fuel
vapors can cause severe injury or
death. Fuel leakage can cause an
explosion. Check the LP vapor gas or
natural gas fuel system for leakage by
using a soap and water solution with
the fuel system test pressurized to
6--8 ounces per square inch
(10--14 inches water column). Do not
use a soap solution containing either
ammonia or chlorine because both
prevent bubble formation. Asuccessful
test depends on the ability of the
solution to bubble.
Servicing the air cleaner. A sudden
backfire can cause severe injury or
death. Do not operate the generator
set with the air cleaner removed.
XP-6515 4/094 Safety Precautions and Instructions
Hazardous Noise
CAUTION
Hazardous noise.
Can cause hearing loss.
Never operate the generator set
without a muffler or with a faulty
exhaust system.
Engine noise. Hazardous noise can
cause hearing loss. Generator sets
not equipped with sound enclosures
can produce noise levels greater than
105 dBA. Prolonged exposure to noise
levels greater than 85 dBA can cause
permanent hearing loss. Wear hearing
protection when near an operating
generator set.
Hazardous Voltage/
Moving Parts
WARNING
Hazardous voltage.
Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
areinplace.
WARNING
Hazardous voltage.
Backfeed to the utility system can
cause property damage, severe
injury, or death.
If the generator set is used for
standby power, install an automatic
transfer switch to prevent inadvertent
interconnection of standby and
normal sources of supply.
Moving parts.
CAUTION
Welding the generator set.
Can cause severe electrical
equipment damage.
Never weld components of the
generator set without first
disconnecting the battery, controller
wiring harness, and engine electronic
control module (ECM).
Grounding electrical equipment.
Hazardous voltage can cause
severe injury or death. Electrocution
is possible whenever electricity is
present. Ensure you comply with all
applicable codes and standards.
Electrically ground the generator set,
transfer switch, and related equipment
and electrical circuits. Turn off the main
circuit breakers of all power sources
before servicing the equipment. Never
contact electrical leads or appliances
when standing in water or on wet
ground because these conditions
increase the risk of electrocution.
Welding on the generator set. Can
cause severe electrical equipment
damage. Before welding on the
generator set perform the following
steps: (1) Remove the battery cables,
negative (--) lead first. (2) Disconnect
all engine electronic control module
(ECM) connectors. (3) Disconnect all
generator set controller and voltage
regulator circuit board connectors.
(4) Disconnect the engine batterycharging alternator connections.
(5) Attach the weld ground connection
close to the weld location.
Connecting the battery and the
battery charger. Hazardous voltage
can cause severe injury or death.
Reconnect the battery correctly,
positive to positive and negative to
negative, to avoid electrical shock and
damage to the battery charger and
battery(ies). Have a qualified
electrician install the battery(ies).
Short circuits. Hazardous
voltage/current can cause severe
injury or death. Short circuits can
cause bodily injury and/or equipment
damage. Do not contact electrical
connections with tools or jewelry while
making adjustments or repairs.
Remove all jewelry before servicing the
equipment.
Electrical backfeed to the utility.
Hazardous backfeed voltage can
cause severe injury or death. Install
a transfer switch in standby power
installations to prevent the connection
of standby and other sources of power.
Electrical backfeed into a utility
electrical system can cause severe
injury or death to utility personnel
working on power lines.
WARNING
Airborne particles.
Can cause severe injury or
blindness.
Wear protective goggles and clothing
when using power tools, hand tools,
or compressed air.
Heavy Equipment
WARNING
Unbalanced weight.
Improper lifting can cause severe
injury or death and equipment
damage.
Do not use lifting eyes.
Lift the generator set using lifting bars
inserted through the lifting holes on
the skid.
XP-6515 4/09 5Safety Precautions and Instructions
Hot Parts
Notice
WARNING
Hot engine and exhaust system.
Can cause severe injury or death.
Do not work on the generator set until
it cools.
Servicing the exhaust system. Hot
parts can cause severe injury or
death. Do not touch hot engine parts.
The engine and exhaust system
components become extremely hot
during operation.
Servicing the engine heater. Hot
parts can cause minor personal
injury or property damage. Install the
heater before connecting it to power.
Operating theheater before installation
can cause burns and component
damage. Disconnect power to the
heater and allow it to cool before
servicing the heater or nearby parts.
NOTICE
Canadian installations only.For
standby service connect the output of
the generator set to a suitably rated
transfer switch in accordance with
Canadian Electrical Code, Part 1.
XP-6515 4/096 Safety Precautions and Instructions
Introduction
Nameplate
The following illustration shows a typical generator set
nameplate. Copy the model, serial, and specification
numbers from the nameplate into the spaces provided in
the product information section on the inside front cover
of this manual. See Figure 1-1 or Figure 1-2 for the
nameplate location.
Emission Compliance, RGEN12
All model RGEN12 generator sets with multi-fuel
systems are emission-certified.
An engine or generator set with the following
identification label is certified to meet Small Off-Road
Engine emission standards for EPA/CARB.
IMPORTANT ENGINE INFORMATION
THIS ENGINE MEETS U.S. EPA PH2 AND
CA 2008 AND LATER EXH EMISSION
REGS FOR SI SORE
FAMILY
DISPL (CC)
MODEL NO.
SPEC NO.
SERIAL NO.
BUILD DATE
EMISSION COMPLIANCE PERIOD:
EPA: CATEGORY A CARB: EXTENDED
CERTIFIED ON: LPG / NATURAL GAS
REFER TO OWNER’S MANUAL FOR HP RATING,
SAFETY, MAINTENANCE, AND ADJUSTMENTS
1-800-544-2444 KohlerEngines.com
KOHLER CO. KOHLER WISCONSIN USA
N11236
tp6515
Figure 1 Emissions Label, RGEN12 Engine
(CH740)
This engine/generator is certified to operate using
natural gas or propane fuel.
The Emission Compliance Period referred to on the
Emission Control or Air Index label indicates the number
of operating hours for which the engine has been shown
to meet CARB emission requirements. The following
table provides the engine compliance period (in hours)
associated with the category descriptor found on the
certification label.
Emission Compliance Period, Hour
CARB
Moderate,
125
Intermediate,
250
Extended,
500
Figure 2 RGEN12
Refer to the certification label for engine displacement.
The exhaust emission control system for the CH 740
engine is EM.
XP-6515 4/09 7Introduction
Emission Compliance, RGEN17/18
The RGEN17/18 generator set engine is certified to
meet emission regulations for U.S. EPA phase 2 small
off-road engines and CA 2006 and later LSI engines
(large spark-ignited engines at or below 1 liter).
The Emission Compliance Period referred to on the
engine identification label indicates the number of
operating hours for which the engine has been shown to
meet EPA emission requirements. The engine
compliance period (in hours), associated with the
Category A descriptor found on the certification label, is
1000 hours.
Refer to the certification label for engine displacement.
The exhaust emission control system for the CH980
engine is EM.
Figure 3 Engine Identification Label, RGEN17/18
XP-6515 4/098 Introduction
Section 1 Features
1.1 Specifications
The generator set specification sheets provide specific
generator and engine information. Refer to the spec
sheet for data not supplied in this manual. Consult the
generator set service manual, engine operation manual,
and engine service manual for additional specifications.
Obtain copies of the latest spec sheets, manuals,
diagrams, and drawings from a Lennox dealer.
1.2 Generator
The generator uses a unique voltage regulation system,
which provides instant response to load changes.
This unique voltage regulation system ensures reliable
motor starting and consistent voltage levels. It utilizes a
voltage excitation system that employs a winding
independent of the main output windings to provide
excitation voltage.
1.3 Engine
The generator set has a four-cycle, twin cylinder, aircooled Kohlerr engine. The engine operates on cleanburning natural gas or propane (LP) vapor. Engine
features include:
D Efficient overhead valve design and full pressure
lubrication for maximum power, torque, and reliability
under all operating conditions.
D Dependable, maintenance-free electronic ignition.
D Precision-formulated cast iron construction of parts
subjected to the most wear and tear.
D Field-convertible multi-fuel systems that allow fuel
changeover from natural gas to LP vapor (and viceversa) while maintaining CARB emission
certification.
1.4 Controller
Controller features include the following:
D Compact controller
D Integrally mounted to the generator set
D LED display:
D Engine runtime, hours
D AC voltage
D Frequency (Hz)
D Battery voltage
D Crank cycle status
D Setup information
D Application software version
D LED display communicates faults:
D High battery voltage
D High engine temperature
D Low battery voltage
D Low oil pressure
D Overcrank safety
D Overfrequency
D Overspeed
D Overvoltage
D Underfrequency
D Undervoltage
D Membrane keypad for configuration and adjustment
D Password-protected user access to menus
D Voltage, gain, and speed adjustment
D System configuration (system voltage/frequency
settings and generator set model)
D Remote two-wire start/stop capability
D Digital isochronous governor to maintain steady-
state speed at all loads
D Digital voltage regulation: ±1.5% RMS no-load to
full-load
D Digital spark advance optimizes ignition timing for the
selected fuel.
XP-6515 4/09 9Section 1 Features
D Automatic start for programmed cranking cycle
D Master control switch mounted on the junction box:
Run/Off-Reset/Auto
D Upgradeable application software
1.5 Generator Set Components
1234
5 6 7
19 19
17 20
15
23
1. Muffler
2. Oil check
3. Oil fill
4. Air cleaner
5. Fuses
6. RS-232 connector (for application program updates)
7. Controller user interface (see Figure 2-1)
8. Generator set master switch (RUN-OFF/RESET-AUTO)
9. Load circuit breaker
10. Field-connection terminal block location
11. Spark plug locations (both sides)
12. Oil drain hose
14 13
12
16
8
9
10
24
11
13. Oil drain valve
14. Oil filter
15. Exhaust
16. Equipment ground
17. Battery charger
18. DSAI lead location
19. Fuel block
20. Gas regulator assembly
21. Fuel solenoid valve
22. Fuel inlet
23. Air intake
24. Engine starting battery location (battery purchased separately)
21
22
23
ADV-7466-
Figure 1-1 Generator Set Components, RGEN12
XP-6515 4/0910 Section 1 Features
Control detail, top view
8
17
24
12
11
9
10
See control
12 5420
3
6
18
19
21
detail
7
22
28
23
27
26
24
24
ADV-7341A-B
16
13
1415
25
1. Muffler
2. Oil check
3. Oil fill
4. Air cleaner
5. Spark plug locations (both sides)
6. Oil filter
7. Oil cooler location
8. Controller user interface
9. Generator set master switch (RUN-OFF/RESET-AUTO)
10. Line circuit breaker
11. Fuses
12. RS-232 connector (for application program updates)
13. Engine starting battery location (battery purchased separately)
14. Oil drain hose
15. Nameplate location (on base)
Figure 1-2 Generator Set Components, RGEN17/18
16. Oil drain valve
17. Exhaust outlet
18. Carburetor heater access opening
19. LP fuel orifice location (inside hose fitting)
20. Gas regulator assembly
21. DSAI leads
22. Fuel solenoid valve
23. Fuel inlet
24. Air intake
25. Battery cables
26. Battery charger
27. Field-connection terminal block location
28. 120 VAC receptacles for battery charger and optional
carburetor heater
XP-6515 4/09 11Section 1 Features
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