Kohler 18RCAL troubleshooting: 25 fault codes and 32 symptom-cause-remedy entries from the manufacturer's own service documentation.
Kohler 18RCAL — full specs, parts & maintenance.
| Code | Meaning | Cause | Remedy |
|---|---|---|---|
| Current A High Warning | Over Current | ||
| Frequency High Warning | Over Frequency | ||
| Frequency Low Warning | Under Frequency | ||
| Reactive Power Low Warning | Loss of Field | ||
| Real Power High Warning | Over Power | ||
| Real Power Low Warning | Reverse Power | ||
| Voltage L1-L2 High Warning | Over Voltage | ||
| Voltage L1-L2 Low Warning | Under Voltage | ||
| BusDeadLive | The bus is measured to be dead when one of the generators is supposed to be supplying voltage to the bus (closed contactor) | Bus metering V9A and V9B connections to V9 of paralleling protection harness are connected incorrectly | |
| BusLiveDead | The bus is measured to be live when no generators are connected to it (both contactors open) | Bus metering V9A and V9B connections to V9 of paralleling protection harness connected incorrectly | |
| CfgModelNum | The two generators that are intended to be paralleled have incompatible model numbers | Incorrect configuration of one of the generators. Different generator types | The paralleled generator sets must be the same kW model. (i.e. two 14 kW or two 20 kW models) |
| CfgSysVolt | The system voltage of the two generators intended to be paralleled is not the same. Because the system does not know which voltage is correct, the generators will not be allowed to start | One of the two generators is incorrectly configured; Intermittent connections on RBUS network wiring | |
| ChkngMeter | This generator has paralleled to the other generator and is verifying that the metering is connected and establishing the connection direction | Status message appears the first time the two generators are paralleled | |
| ConCheckFail | Failure to Auto-Discover APM connections | Wires 9A and 9B crossed between the generators; Wires 9A or 9B not connected | |
| ConChecking | Performing APM connection auto-discovery | This generator has started in RUN, the other generator is in OFF | |
| ConNotDeterm | APM connection auto-discovery is not complete. This means that the generator does not know which contactor is connected to it | Generators not yet started in RUN with other generator in OFF | See the APM instruction sheet for instructions to perform the auto-discovery procedure |
| ContactorOk | Successful auto-discovery of APM connections | Auto-discovery was activated by placing other generator in OFF and this generator in RUN | |
| ErraticSig | The power metering on this controller gives a signal that is not consistent with the system configuration. Reversing the power direction does not resolve the problem | Bad wiring to the CT; Too much tension on wires from the CT to the controller | |
| LossOfComAPM | The Automatic Paralleling Module has stopped communicating on RBUS. (An APM was detected on the RBUS network but is no longer communicating) | APM is unplugged; Primary controller is powered down. Check the battery connections; Intermittent connections on RBUS network wiring | Check RBUS communication connections |
| LossOfComm2 | The primary controller has lost communication with the secondary controller. (A secondary controller was detected, then communication was lost.) | RBUS disconnected, secondary controller battery disconnected, updating firmware in secondary controller, or intermittent RBUS connections | |
| LossOfField | This generator has absorbed more than 25% reactive power (magnetic excitation current) for 20 seconds | Generator voltage on this generator is not calibrated correctly; Generator voltage on other generator is not calibrated correctly; Bus voltage on this generator is not calibrated correctly; Bus voltage on the other generator is not calibrated correctly | |
| MeteringOk | The generator has verified that the metering is connected correctly and that the direction is consistent with expected power direction | Status message indicates that the CT is connected to the generator correctly | |
| MeterUnknown | This generator does not know if the metering is connected or the orientation of the connection. This means that the generators can’t share load accurately until this information is known | System commissioning and startup not yet complete | See the APM instructions |
| NoCurrent | The generator has applied load (using the other generator) and has observed no current on the power sensing inputs | The CT is not connected to the controller; The output leads from the generator do not go through the CT in the correct direction | See the APM instructions |
| SyncFailure | The generator has been attempting to synchronize for over 2 minutes without success | Generator is hunting; Advanced speed control settings need adjustment; Load is changing frequently to disturb the online generator |
| Symptom | Cause | Remedy |
|---|---|---|
| Controller display backlight is off | Backlight turns off after about 1 minute with no activity | Backlight will turn on when a button is pressed or the generator set starts |
| Controller display is off | Low or no battery voltage | Check connections; Check generator set battery. See the Service Views section |
| The generator set does not crank | Battery weak or dead | Recharge or replace the battery. Make sure that the AC power to the generator set controller is backed up by the generator set |
| The generator set does not crank | Battery connections reversed or poor | Check the connections |
| The generator set does not crank | Emergency stop switch activated | Verify that it is safe to start the engine and apply load. Then reset the stop switch or engine shutdown switch |
| The generator set does not crank | Fault shutdown | Check the controller display for fault messages. Correct the fault condition and reset the controller |
| The generator set does not crank | Generator set in the OFF mode | Press the RUN button to start the engine or press AUTO to allow remote starting |
| The generator set does not crank | Generator thermostat tripped | Check for obstructed air inlets and outlets. Reset the thermostat |
| The generator set cranks but does not start, starts hard, lacks power, or operates erratically | Air cleaner clogged | Clean and/or replace the air cleaner |
| The generator set cranks but does not start, starts hard, lacks power, or operates erratically | Battery weak or dead | Recharge or replace the battery |
| The generator set cranks but does not start, starts hard, lacks power, or operates erratically | Battery connection poor | Clean and tighten the battery connections |
| The generator set cranks but does not start, starts hard, lacks power, or operates erratically | Spark plug wire connection loose | Check the spark plug wires |
| The generator set cranks but does not start, starts hard, lacks power, or operates erratically | Low oil pressure shutdown | Check for oil leaks. Check the oil level and add oil if necessary |
| The generator set cranks but does not start, starts hard, lacks power, or operates erratically | Fuel pressure insufficient | Check the fuel supply and valves |
| The generator set cranks but does not start, starts hard, lacks power, or operates erratically | Engine malfunction | Contact an authorized Kohler dealer |
| No AC output | Line circuit breaker in the OFF position | Place the circuit breaker in the ON position |
| No AC output | Line circuit breaker tripping because of overload | Reduce the load on the generator set by unplugging non-essential appliances |
| No AC output | Line circuit breaker tripping because of short circuit | Contact an authorized Kohler dealer for service |
| No AC output | Auxiliary winding circuit breaker tripped | Reset the circuit breaker (located in controller’s service access area). Contact an authorized dealer for service if breaker trips repeatedly |
| Low output or excessive drop in voltage | Generator set overloaded | Reduce the load by unplugging non-essential appliances |
| Generator set stops suddenly | Low oil pressure shutdown | Check for oil leaks. Check the oil level and add oil if necessary |
| Generator set stops suddenly | No fuel | Check fuel valves and fuel supply; Check enclosure thermostat and reset if tripped. Check and clear air inlets and exhaust outlets |
| Generator set stops suddenly | Overcrank shutdown | Reset the controller. If the overcrank fault occurs again, contact an authorized Kohler dealer |
| Generator set stops suddenly | Auxiliary winding circuit breaker tripped | Reset the auxiliary winding circuit breaker. Contact an authorized dealer for service if breaker trips repeatedly |
| Generator set stops suddenly | Emergency stop switch activated | Verify that it is safe to start the engine and apply load. Then reset the stop switch or engine shutdown switch |
| Generator set stops suddenly | Fault shutdown | Check the controller display for fault messages. Correct the fault condition and reset the controller |
| Generator set stops suddenly | Generator set in the OFF mode | Press the RUN button to start the engine or press AUTO to allow remote starting |
| Generator set stops suddenly | Remote stop command received from a remote switch, ATS, or OnCue® Plus | Check the remote switch position. Check OnCue® Plus |
| Generator set stops suddenly | Generator thermostat tripped | Check for obstructed air inlets and outlets. Reset the thermostat |
| Generator set stops suddenly | Engine malfunction | Contact an authorized Kohler dealer |
| Emerg Stop Shutdwn | Emergency stop button activated or shutdown switch moved to the off (open, O) position | Remove the locking device and pull the button out. Reset the controller by pressing the OFF/RESET button |
| Overcrank fault | The generator set does not start in three crank cycles (15 seconds crank and 15 seconds off) | Reset the controller. If the overcrank fault occurs again, contact an authorized Kohler dealer |
Fault codes and symptom→remedy steps extracted from this model’s service/owner documentation; verify against the official manual before servicing.
Documented causes: Low oil pressure shutdown; No fuel; Overcrank shutdown; Auxiliary winding circuit breaker tripped. See the table for the matching fixes.
Documented causes: Air cleaner clogged; Battery weak or dead; Battery connection poor; Spark plug wire connection loose. See the table for the matching fixes.
Documented causes: Battery weak or dead; Battery connections reversed or poor; Emergency stop switch activated; Fault shutdown. See the table for the matching fixes.