Although Kohler generators are recognized for their dependability, even the best machinery can have problems. Your generator will communicate a specific problem to you when a fault code emerges. In this manual, we’ll explain the most typical Kohler generator fault codes, explain what they indicate, and offer step-by-step instructions for fixing them to keep your generator running smoothly.
Kohler Generator Fault Code List
Here is a list of common Kohler generator fault codes, their causes, and possible solutions:
| Code | Cause | Solution |
|---|---|---|
| AC Sens Loss | The generator is not sensing AC power. | Check the AC generator, the AC wiring, or the AC breaker. |
| Batt Chg Flt | There is a problem with the battery charger. | Check the battery charger itself, the battery, or the battery cables. |
| Low Crank Vlt | The battery voltage is too low to crank the generator. | Charge or replace the battery. Check the battery cables for loose connections. |
| Over Crank | The generator is cranking for too long. | Check the starter, the battery, or the ignition switch. |
| Over Voltage | The generator output voltage is too high. | Check the voltage regulator, the generator, or the load. |
| Under Voltage | The generator output voltage is too low. | Check the voltage regulator, the generator, or the load. |
| LOC | Loss of coolant. | Check the coolant level and condition. Replace the coolant if necessary. |
| OC | Overcrank. | Check the battery voltage and condition. Replace the battery if necessary. Check the starter and ignition switch for problems. |
| UF | Under frequency. | Check the generator load. Reduce the load if necessary. |
| UW | Under voltage. | Check the generator load. Reduce the load if necessary. |
Kohler Generator Error Code List
AC Sens Loss (W, SD): Cracking the Code
Meaning: AC sensing lost. Generator output AC sensing is lost, typically within 10 seconds after crank disconnect.
Solution: Reach out to an authorized distributor or dealer for professional service. Swift action ensures your generator continues to perform efficiently.
Accy PwrOver W Warning: Navigating Overload Woes
Meaning: Accessory Power Overload. An over current fault on the accessory controller power output.
Solution: Connect with an authorized distributor or dealer for expert assistance. Addressing an accessory power overload promptly preserves your generator’s functionality.
Alt Protect (SD): Protecting Your Alternator
Meaning: High generator current detected, leading to shutdown for alternator protection (10RESV and 12RESV only).
Solution: Lighten the load to prevent overheating the windings. Your generator’s safety measures are in place to safeguard its longevity.
ATS ComError (W): Handling Communication Hiccups
Meaning: ATS communication error. Warning appears when ATS interface connection is lost.
Solution: Check communication wiring between the transfer switch interface board and the generator set. Ensuring a secure connection prevents potential disruptions.
ATS PhaseRot (W): Aligning Phase Rotation
Meaning: ATS phase rotation mismatch, resulting in transfer switch refusal to transfer.
Solution: Correct ATS connection according to installation manuals and wiring diagrams. Ensure proper phase rotation alignment for seamless operation.
Aux Input (SD): Investigating Auxiliary Inputs
Meaning: Optional customer-connected input is closed (digital input from optional PIM).
Solution: Examine customer-supplied equipment for closure issues. Addressing auxiliary input concerns maintains overall system integrity.
Batt Chg Flt (W): Battery Charger Hurdles
Meaning: Battery charger fault. External battery charger input to PIM detected.
Solution: Check the external battery charger input to the PIM. Ensuring the battery charger functions correctly is essential for a healthy generator system.
Battery High (W): Battling High Battery Voltage
Meaning: Engine starting battery voltage exceeds 16 VDC for over 10 seconds.
Solution: Evaluate battery rating and condition. Verify proper battery charger operation to avoid voltage spikes that could harm your generator.
Battery Low (W): Tackling Low Battery Voltage
Meaning: Engine starting battery voltage falls below 12.5 VDC for more than 90 seconds (engine not running).
Solution: Maintain battery health by assessing its rating and condition. Confirm battery charger operation and consider recharging or replacing the battery if necessary.
Battery CrLo Warning (W): Monitoring Battery Voltage
Meaning: Engine starting battery voltage drops below 11 Volts for more than 10 seconds.
Solution: Uphold battery performance by attending to its rating and condition. Ensure the battery charger operates as expected to avert potential issues.
Eng Speed High (SD): Engine Speed Alert
Meaning: Engine speed surpasses 115% of normal running speed for more than 0.3 seconds.
Solution: Connect with an authorized distributor or dealer for professional assistance. Addressing engine speed irregularities maintains generator stability.
Eng Speed Low (SD): Ensuring Optimal Engine Speed
Meaning: Engine speed drops below 85% of normal running speed for over 3 seconds.
Solution: Ease the load on your generator. Seek support from an authorized distributor or dealer for expert guidance.
Exer Not Sch (W): Exercising Your Generator
Meaning: No scheduled exercise on the controller.
Solution: Refer to Section 3.6 or 4.5 for instructions on setting the exerciser. Regular exercise is key to a well-maintained generator.
Frequency High (SD): Managing Frequency Surge
Meaning: Governed frequency exceeds 110% of the system’s frequency setpoint for over 10 seconds.
Solution: Collaborate with an authorized distributor or dealer to address frequency irregularities. Maintaining proper frequency enhances your generator’s performance.
Frequency Low (SD): Balancing Frequency Fluctuations
Meaning: Governed frequency falls below 90% of system frequency setting for over 10 seconds or 1 Hz below the setting for over 60 seconds.
Solution: Reduce load and restart the generator. Seek assistance from an authorized distributor or dealer to ensure your generator operates optimally.
Lo Crank Vlt (W): Monitoring Cranking Voltage
Meaning: Battery voltage drops below 8 VDC for over 6 seconds during starter engagement.
Solution: Preserve battery life by addressing low cranking voltage. Charging or replacing the battery prevents potential startup issues.
MainPwrOverL (SD): Shielding from Power Overload
Meaning: Main power overload. Over current fault on the 70 controller power output.
Solution: Reach out to an authorized distributor or dealer for professional assistance. Detecting and resolving a main power overload safeguards your generator.
Not in Auto (W): Automatic Mode Alert
Meaning: Generator set not in Automatic (standby) mode, ignoring remote start/stop commands.
Solution: Switch to Automatic mode by pressing AUTO when appropriate. Embracing Automatic mode ensures your generator responds to remote commands.
Oil Pres Low (SD): Navigating Low Oil Pressure
Meaning: LOP switch detects low oil pressure for over 5 seconds.
Solution: Check engine oil level and address any leaks. Maintaining adequate oil pressure protects your generator’s health.
Over Crank (SD): Overcoming Starting Challenges
Meaning: Three unsuccessful starting attempts.
Solution: Evaluate fuel supply, spark plug, and battery. Reset the thermostat and inspect connections. Engage an authorized distributor or dealer for professional assistance.
Spd Sens Flt (SD): Speed Sensor Troubles
Meaning: Engine speed sensor failure or engine stall.
Solution: Connect with an authorized distributor or dealer to address speed sensor issues promptly. A well-functioning sensor is essential for proper generator operation.
Total Power High (SD): Managing Load Measurement
Meaning: Load surpasses 102% of generator set power rating for over 1 minute (10RESV and 12RESV only).
Solution: Lighten the load to ensure optimal performance. Balancing load measurement contributes to your generator’s longevity.
Volts L1-L2 High (SD): Handling Voltage Surges
Meaning: Generator voltage exceeds 120% of system nominal voltage for over 2 seconds.
Solution: Collaborate with an authorized distributor or dealer to address voltage surges. Ensuring voltage stability safeguards your generator’s components.
Volts L1-L2 Low (SD): Addressing Voltage Drops
Meaning: Generator voltage falls below 80% of nominal system voltage for over 10 seconds.
Solution: Reduce load and restart the generator. Seek professional assistance from an authorized distributor or dealer to optimize voltage levels.
Ensuring a Smooth Shutdown
Note: Some shutdown options trigger an engine cool-down cycle before shutdown.
Navigating Kohler generator fault codes is a journey to maintaining a well-functioning generator system. Remember, a well-informed response to these codes ensures the longevity and performance of your Kohler generator. For comprehensive support, don’t hesitate to engage with Kohler professionals who understand the intricate language of fault codes.