Kohler 22.5ROZ troubleshooting: 13 fault codes and symptom-cause-remedy entries from the manufacturer's own service documentation.
Kohler 22.5ROZ — full specs, parts & maintenance.
| Symptom | Cause | Remedy |
|---|---|---|
| Battery voltage switched to starter (engine not necessarily turning). | Lights only during ‘‘on-crank’' cycles. | |
| CR relay coil energized. | Deenergizes C relay | |
| 1TS contacts in series with CR relay open to stop cranking (or stop unit if started and producing no AC output). | The overcrank reset switch must be activated to reset 1TS contacts. | |
| CR relay energized. | Initiates cranking, Energizes ignition circuit, Energizes 1TS circuit, Energizes primary field, Energizes hourmeter, Energizes anti-diesel solenoid (Gasoline only), Energizes water valve (city-water cooled only), Energizes choke (Gasoline only), Energizes gas valve (Gasoline only) | |
| SDR relay energized. | Locks in SDR relay, Energizes reset lamp, Deenergizes CR coil | |
| Fuse blown. | Generator set will stop. Unit will not crank with a blown fuse. If set has stopped due to causes other than lack of fuel, or fault shut-down — check fuse. If blown, replace the fuse and attempt to restart generator set. If the set will not start, or if the fuse blows again, locate and correct the cause. | |
| LAMP TEST button on controller does not flash. | If not, push LAMP TEST button on controller. If other lamps do not light, check/replace 3 amp fuse at rear of controller, and/or replace bulbs as needed. | |
| CRK. lamp does not light (voltage not conducted to starter circuit). | Replace uni-board. Fix 1CR relay wiring or replace relay. Repeat test. | |
| IGN., CRK., and REG. lamps of Fast Check do not light. | Check wiring to 1CR. Replace uni-board. Repeat test. | |
| No or low AC output | Blown fuse on sensing leads V7, V8 and V9; regulator board or SCR module overcurrent condition; exciter field issue; controller issue; stator winding problem; rotor resistance or ground issue. | Check for blown fuses. Check controller and exciter field. Inspect stator windings, rotor resistance, and grounding. |
| Generator Set will stop. | 3-Amp fuse 'blows'. | Check fuse. If blown, replace the fuse and attempt to restart generator set. |
| Unit will not crank with a blown 15-Amp fuse. | If this fuse blows while the generator set is running, the unit will shut down. If set has stopped due to causes other than lack of fuel, or fault shut-down — check fuse. If blown, replace the fuse and attempt to restart generator set. | |
| No or low AC output. | Unbalanced stator windings. | Check for continuity between 'quick disconnect' point on each brush lead and its adjacent slip ring. Repair or replace assembly if fault is detected. |
Fault codes and symptom→remedy steps extracted from this model’s service/owner documentation; verify against the official manual before servicing.
Documented causes: Blown fuse on sensing leads V7, V8 and V9; regulator board or SCR module overcurrent condition; exciter field issue; controller issue; stator winding problem; rotor resistance or ground issue.; Unbalanced stator windings.. See the table for the matching fixes.
Documented causes: 3-Amp fuse 'blows'.. See the table for the matching fixes.