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Old 02-05-2017, 21:04   #1
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Kohler Generator starting problem

Ahoy all, I have a Kohler generator, model 8CCO23, that the fuel solenoid will not draw in when the start switch is activated. It will run all day when I manually actuate the fuel control lever or "rig" a 12VDC directly to the fuel solenoid but I fear that applying a jumper for 12VDC will be bypassing the safety switch logic of the oil pressure, water temperature, and manifold Temperature.
I get 12.53 VDC up to the "C" relay but when I activate the start switch the voltage drops to 8.3 volts. Not enough to draw in the fuel solenoid to complete the start sequence

Thanks in advance for any ideas of the fix

Jeff
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Old 03-05-2017, 04:56   #2
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Re: Kohler Generator starting problem

Do you have three wires going to the solenoid? An earth, a pull, and a hold?

It possible for the pull side if the solenoid to have shorted. It's also possible that you've got high resistance electrical connections or a dirty relay contact somewhere in the system.
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Old 03-05-2017, 05:55   #3
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Re: Kohler Generator starting problem

There are only two wires coming from the fuel solenoid, a power and a ground Both have 0.00 resistance when checked for continuity. There are two relays in the system, both are new, both bench tested several times.
I have 8.3 VDC, dropped from 12.5 VDC, at the starter solenoid. I've had the alternator and new voltage regulator bench tested yesterday, both fine. The regulator putting out 14.8 volts and altenator 32amps. And the starter is newly replaced.
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Old 07-06-2017, 22:31   #4
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Re: Kohler Generator starting problem

Discovered the problem. Turned out wrong relays were installed. The correct relays have an internal diode. Someone had installed the wrong relays and when I replaced them I used the same wrong part number. I looked at my buddy's Kohler generator and discovered the difference.
The correct relay is a Bosch 12-796-772
Same one that fits a 2003-2011 Saab 9-3 Fuel Pump Relay
NAPA Part number AR143
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