Kohler 38RCLB troubleshooting: 41 fault codes and 31 symptom-cause-remedy entries from the manufacturer's own service documentation.
Kohler 38RCLB — full specs, parts & maintenance.
| Code | Meaning | Remedy |
|---|---|---|
| Auxiliary Input | Auxiliary Input — An optional customer-connected input is closed. (Digital input from optional PIM.) | Check customer-supplied equipment. |
| Battery CrLo | Critically Low Battery Voltage — Engine starting battery voltage falls below 11 V for more than 10 seconds. Inhibited during the engine crank cycle. Clears when the battery voltage returns to an acceptable level. | Check the battery rating and condition.; Check the battery charger operation.; Charge or replace the battery. |
| Battery High | High Battery Voltage — Engine starting battery voltage rises above 133% (16 V) of the battery voltage setting for more than 10 seconds. Inhibited during the engine crank cycle. Clears when the battery voltage returns to an acceptable level. | Check the battery rating and condition.; Check the battery charger operation. |
| Battery Low | Low Battery Voltage — Engine starting battery voltage falls below the battery voltage setting (typically 12.5 volts) for more than 90 seconds when the engine is not running. Inhibited during the engine crank cycle. Clears when the battery voltage returns to an acceptable level. | Check the battery rating and condition.; Check the battery charger operation.; Charge or replace the battery. |
| Chk DateTime | Verify Date Time Setting — The time and date have not been set on the generator controller. | Enter the date and time using the RDC2 controller. See Figure 3-8 and Figure 3-16. |
| Coolant Lvl Low | Low Coolant Level Shutdown — The coolant level switch input has been activated. | Check coolant level.; Check radiator hoses for leaks.; Contact an authorized distributor/dealer for service. |
| CoolTempHigh | Ect Higher Than Expected 1 — Coolant temperature is too high. | Check coolant level.; Check radiator and fans for obstruction.; Contact an authorized distributor/dealer for service and provide the fault code. |
| CoolTemp Vhi | Ect Higher Than Expected 2 — Coolant temperature is extremely high. | Check coolant level.; Check radiator and fans for obstruction.; Contact an authorized distributor/dealer for service and provide the fault code. |
| CoolntTemp 0 | Coolant Temp 0 Shutdown — The ECM reported a problem with the coolant temperature sensor reading: 0 = high temperature. | Check coolant level.; Check radiator and fans for obstruction.; Contact an authorized distributor/dealer for service and provide the fault code. |
| CoolntTemp 3 | Coolant Temp 3 Shutdown — The ECM reported a problem with the coolant temperature sensor reading: 3 = high voltage. | Contact an authorized distributor/dealer for service and provide the fault code. |
| CoolntTemp 4 | Coolant Temp 4 Shutdown — The ECM reported a problem with the coolant temperature sensor reading: 4 = low voltage. | Contact an authorized distributor/dealer for service and provide the fault code. |
| CoolntTemp 5 | Coolant Temp 5 Shutdown — The ECM reported a problem with the coolant temperature sensor reading: 5 = open circuit. | Contact an authorized distributor/dealer for service and provide the fault code. |
| Crank Lost | Crank Signal Lost — Crankshaft Position Sensor (CPS) timeout error occurred. | Contact an authorized distributor/dealer for service and provide the fault code. |
| ECM warnings | ECM warnings (any warnings with ECM in the fault name) — This group of faults includes a wide variety of faults that originate from the engine ECM and also contain ECM in the fault name. | Contact an authorized distributor/dealer for service and provide the fault code. |
| Emerg Stop | Emergency Stop Shutdown — The emergency stop switch has been activated, or there has been an open circuit in the wiring. | Contact an authorized distributor/dealer for service. |
| Eng Speed High | High Engine Speed — Engine speed exceeds 115% of the normal running speed for more than 0.3 seconds. | Contact an authorized distributor/dealer for service. |
| Eng Speed Low | Low Engine Speed — Engine speed drops below 85% of the normal running speed for more than 3 seconds. | Reduce the load by turning off appliances.; Contact an authorized distributor/dealer for service. |
| Exer Not Sch | ATS Exercise Not Scheduled — Exercise Not Scheduled. No exercise has been scheduled on the RDC2 controller. | See Section 2.5 for instructions to set the exerciser. |
| Frequency High | High Frequency — Governed frequency exceeds 110% of the system’s frequency setpoint for more than 10 seconds. Function becomes active 10 seconds after engine start (10 second inhibit). | Contact an authorized distributor/dealer for service. |
| Frequency Low | Low Frequency — Governed frequency falls below 90% of the system frequency setting for more than 10 seconds, or 1 Hz below the system frequency setting for more than 60 seconds. Function becomes active 10 seconds after engine start (10 second inhibit). | Reduce the load by turning off appliances and restart the generator set.; Contact an authorized distributor/dealer for service. |
| Genset S/N Unaval | Unavailable Genset Serial Number — Generator set serial number is unavailable. | Contact an authorized distributor/dealer for service. See section 3.11. |
| Ground Fault | Ground Fault Warning — The digital input for Ground Fault Warning is active (low). (PIM required.) | Check customer equipment connected to the PIM. |
| IAT High 1 | Iat Higher Than Expected 1 — Engine manifold air temperature is too high. | Contact an authorized distributor/dealer for service and provide the fault code. |
| IAT Volt Lo | Iat Low Voltage — The ECM reported an Engine Air Temperature/Manifold Absolute Pressure Sensor (TMAP) error. | Contact an authorized distributor/dealer for service and provide the fault code. |
| Lo Crank Vlt | Low Cranking Voltage — Low cranking voltage. Battery voltage falls below 60% of system battery voltage for more than 6 seconds while the starter is engaged. | Charge or replace the battery. |
| Locked Rotor | Locked Rotor — No engine rotation is sensed during cranking. Shuts down 3 seconds after the fault is detected. | Check the battery.; Check for loose connections.; Check for obstruction of alternator or engine.; Contact an authorized distributor/dealer for service. |
| MainPwrOverL | Main Power Overload — Main power overload. An over current fault on the 70 controller power output (short circuit). | Check for shorted run relay. Check wiring for short circuits.; Contact an authorized distributor/dealer for service. |
| Maint Req’d | Maintenance Required Warning — Engine maintenance is due. | Check the maintenance schedule in the operation manual for tasks such as changing the oil, spark plugs or the air filter. |
| Not in Auto | Not In Auto — The generator set is not in Automatic (standby) mode. Remote start and stop commands from a transfer switch or remote switch will be ignored. | Press AUTO to place the generator set in Automatic mode, when appropriate. |
| Oil Pres Low | Low Oil Pressure — The engine ECM indicates low oil pressure. Note: The low oil pressure shutdown does not protect against low oil level. Check the engine oil level regularly as recommended in Section 4. | Check for leaks in the lubrication system.; Check the oil level and add oil if the level is low.; Check the oil pressure switch and wiring. |
| Over Crank | Over Crank — Three unsuccessful starting attempts. | Check the fuel supply, spark plug, and battery.; Check for loose connections.; Contact an authorized distributor/dealer for service. |
| PrimLoopOpn | Primary Loop Open — Ignition coil 1 voltage is below normal or there is an open circuit. | Check the battery voltage.; Contact an authorized distributor/dealer for service and provide the fault code. |
| PrimLoopSht | Primary Loop Shorted — Ignition coil 1 voltage is abnormal. | Check the battery voltage.; Contact an authorized distributor/dealer for service and provide the fault code. |
| Spd Sens Flt | Speed Sensor Fault — Engine speed sensor has failed or engine stalled. ECM is no longer reporting valid speed. | Contact an authorized distributor/dealer for service. |
| Volts L1-L2 High | High Generator Voltage L1-L2 — Generator Voltage High. Output voltage exceeds 120% of the system nominal voltage for more than 2 seconds. | Contact an authorized distributor/dealer for service. |
| Volts L1-L2 Low | Low Generator Voltage L1-L2 — Generator Voltage Low. Output voltage falls below 80% of the nominal system voltage for more than 10 seconds. | Reduce the load by turning off appliances and restart the generator set.; Contact an authorized distributor/dealer for service. |
| Volts L2-L3 High | High Generator Voltage L2-L3 — Generator Voltage High. Output voltage exceeds 120% of the system nominal voltage for more than 2 seconds. | Contact an authorized distributor/dealer for service. |
| Volts L2-L3 Low | Low Generator Voltage L2-L3 — Generator Voltage Low. Output voltage falls below 80% of the nominal system voltage for more than 10 seconds. | Reduce the load by turning off appliances and restart the generator set.; Contact an authorized distributor/dealer for service. |
| Volts L3-L1 High | High Generator Voltage L3-L1 — Generator Voltage High. Output voltage exceeds 120% of the system nominal voltage for more than 2 seconds. | Contact an authorized distributor/dealer for service. |
| Volts L3-L1 Low | Low Generator Voltage L3-L1 — Generator Voltage Low. Output voltage falls below 80% of the nominal system voltage for more than 10 seconds. | Reduce the load by turning off appliances and restart the generator set.; Contact an authorized distributor/dealer for service. |
| TP-6905 4/16 | Generator set serial number is unavailable. | Contact an authorized distributor/dealer for service. See section 3.11. |
| Symptom | Cause | Remedy |
|---|---|---|
| The generator set does not crank. | Battery weak or dead. | Recharge or replace the battery. |
| The generator set does not crank. | Battery connections reversed or poor. | Check the connections. |
| The generator set does not crank. | Blown fuse(s). | Replace the fuse. Contact an authorized Kohler distributor/dealer for service if fuse blows repeatedly. |
| The generator set does not crank. | Generator set is OFF. | Press the RUN button to start the engine or press AUTO to allow remote starting. |
| 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 distributor/dealer. |
| No AC output. | AC circuit breaker in the OFF position. | Place the circuit breaker in the ON position. |
| No AC output. | AC circuit breaker tripping because of overload. | Reduce the load on the generator set. |
| No AC output. | AC circuit breaker tripping because of short circuit. | Contact an authorized Kohler distributor/dealer for service. |
| Low output or excessive drop in voltage. | Generator set overloaded. | Reduce the load. |
| 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. | Out of fuel. | Check fuel supply. |
| Generator set stops suddenly. | Overcrank shutdown. | Reset the controller. If the overcrank fault occurs again, contact an authorized Kohler distributor/dealer. |
| Generator set stops suddenly. | Blown fuse(s). | Replace the fuse. If the fuse blows again, contact an authorized Kohler distributor/dealer. |
| Generator set stops suddenly. | Overspeed shutdown. | Reset the controller. If the overspeed fault occurs again, contact an authorized Kohler distributor/dealer. |
| Generator set stops suddenly. | Generator set is OFF. | 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 OnCuer Plus. | Check the remote switch position. |
| Generator set stops suddenly. | Engine malfunction. | Contact an authorized Kohler distributor/dealer. |
| Fans run after engine shuts down. | The fans continue to run for 2 minutes after the engine shuts down to evacuate the engine compartment. | |
| Controller LCD display is off. | Low or no battery voltage. | Check connections.; Check generator set battery. See Figure 5-1. |
| 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. |
| Loss of communication to accessory modules. | Bad connections. | Check wiring and connections. Verify that cable size and length of run comply with the instructions in the Installation manual. |
| Loss of communication to accessory modules. | Low or no battery voltage. | Check battery connections.; Check generator set battery. See Figure 5-1. |
| Load management relays do not operate. | Bad connections. | Check wiring and connections. Verify that cable size and length of run comply with the instructions in the Installation manual. |
| Load management relays do not operate. | Low or no battery voltage. | Check battery connections.; Check generator set battery. See Figure 5-1. |
| Date is flashing. | Controller power was disconnected and then reconnected. | Check battery connections. See Figure 5-1.; Check utility power connection for the built-in battery charger.; Reset the time, date, and exercise schedule. See Section 2.5.7, Setting the Exerciser at Power-Up. |
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.; Out of fuel.; Overcrank shutdown.; Blown fuse(s).. 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.; Blown fuse(s).; Generator set is OFF.. See the table for the matching fixes.