Kohler 5ECD won't crank, starter solenoid question

[Bluto310]

My 2008 5ECD won't crank when I place the master switch (on the ADC2100) to run and I'm out of troubleshooting ideas. The battery is supplying good voltage to the starter solenoid and the generator cranks fine when the solenoid is jumped. The ADC2100 seems to be functioning properly, it sends the start command to the Relay Interface Board, the run, crank and flash LEDs illuminate and the power arrives at the solenoid start terminal but the solenoid does not function. I replaced the solenoid yesterday with a new Kohler replacement part, no change. If I jump the start terminal directly to the battery terminal the solenoid functions and cranks the generator just as briskly as jumping directly from batt to the starter terminal. I realize this is providing a little more voltage to the start terminal than it normally receives from it's circuit so...I suppose it's possible that the new solenoid is bad also. What am I missing? Solenoids aren't that complicated. Any suggestions before I take it back off? If you're unfamiliar the 5ECD uses a remote, insulated base 89-850187 solenoid, Kohler PN GM45936. Thanks in advance for your help!

 

[JimFromMD]

Not trying to convince you that the new part is bad, but just confirming that it's not out of the question. I had generator issues for quite a while... ended up with a new carbeurator (from kohler branded box) last fall replaced by a kohler authorized rep. More gen problems this spring. Same tech ended up replacing the new carb which had a malfunctioning float with another new carb and sent the other one back. Seems to be working smoothly so far after about 10 hours of running. So... not out of the question, but perhaps not the first thing to try if there are other suggestions.

 

[Bluto310]

thanks, I'll admit to being in some denial about the new solenoid being bad. Glad to hear you got your problem solved and your gen running good...there is hope

 

[Bluto310]

Solenoid is not bad!?! I'm out of ideas other than a new controller ($900) so... I'm setting up an appointment with Marine Maintenance in Panama City Beach, Service Manager Jody seems pretty knowledgeable on Kohler issues. Anyone have experience with these folks?

 

[larrytbull]

Solenoid is not bad!?! I'm out of ideas other than a new controller ($900) so... I'm setting up an appointment with Marine Maintenance in Panama City Beach, Service Manager Jody seems pretty knowledgeable on Kohler issues. Anyone have experience with these folks?

check your ground wire.

had issue where ground wire from battery was bad.
take an auto jumper cable and clamp from battery ground to any grounding point on gen
then try again

 

[Bluto310]

Just to follow up the problem turned out to be a bad ADC2100 controller, $1,304 later it's running again...for now.

 

[BigBoysToys]

Wish I had replied sooner. I have an ADC2100 controller new in the box. Bought it thinking I needed to replace it but repaired the Genny before it arrived. Never even opened the box.

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