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SJ-Chris's avatar
SJ-Chris
Explorer II
Jul 22, 2021

Onan 4000 generator cranks but won't start

Hi all,

I have a 2015 Cummins Onan RV QG 4000 generator. It has somewhere between 300-1000hrs (not sure, I've only owned it for about 2 years and it was a previous rental...might not be the original generator on this RV and I don't trust the hour meter coming from the rental company). About 1 year ago, I replaced the oil, air filter, and spark plug. Since then there has been 50-100 hours. Up until recently it has been working fine.

Recently, it won't start. It cranks and cranks very strong, but doesn't start.

To troubleshoot so far here is what I have done to no avail...
- I have a full tank of gas in the motorhome.
- The motorhome is level.
- Altitude adjustment set to 0 (I am near sea level).
- I checked the oil to make sure there wasn't too much (it is to the low end on the dipstick as most seem to recommend).
- I swapped in a good spark plug to make sure that wasn't the problem, and it didn't fix it.
- I checked the air filter and it seems fine (...even tried starting it without the air filter and it didn't start).
- I changed the fuel filter with a new one, primed it and tried starting it several times and that didn't fix the problem.
- I disconnected all the batteries (and my solar) per someone's suggestion to "reset" the generator. Hooked everything back up and it still didn't fix the problem.

It still cranks very strong...just doesn't start.

The only error code I could get from the lights was '4' (which is over-cranking). I don't think in all the testing that I did I ever let it crank for more than 10-20 seconds at a time.

I have reached the current extent of my generator knowledge! lol.... I'm hoping some of you can help me expand that knowledge with some more suggestions/recommendations.

One thing I've learned about owning an RV (...I actually have 3 now) is that it makes sense to try to learn to fix as much yourself as possible because RV mechanics are a)busy, b)expensive, and c)a hassle to drop off/pick up/etc. Plus, it's fun/satisfying when we can fix our own rigs and not be as dependent on others.

Thanks in advance!
Chris
  • Update:

    I checked the spark plug. Took it out, then plugged it back into the wire connector and put it against the metal of the engine and when the engine cranked it produced rapid sparks. Yellow/white/orange in color (not blue). Is that significant?

    Then I put the spark plug back in.

    Then I took off the air filter and I sprayed some starter fluid into the carb area. At least that's what I tried to do. The spray can had a ~4" straw that helped me aim towards the carb opening but wasn't long enough for me to get it 100% into the carb, and because of the angle it was hard to see exactly what I was doing. I gave it 3-4 blast while manually holding the carb flap open. Then I tried starting it up. Didn't seem to make much of an impact and the engine just still cranked and cranked but didn't really seem to get any further. I tried spraying starter fluid 2-3 times more and still nothing. Because of some residual starter fluid spraying into the carb area (the housing that holds the air filter) at one point there was a tiny fire that started burning the excess fuel. I put it out within 5-10 seconds and it didn't look like it had any damage whatsoever. (I had a fire extinguisher next to me during all of this just in case!) Does this imply it is receiving the spark from the spark plug??

    I'm not sure where to go from here. Any thoughts??

    Thanks!
    Chris
  • Did you check to see if spark is present at a plug? Possible bad coil.
    Remove plug, connect plug wire, lay on metal surface and crank engine. Spark should be visible.
  • gbopp wrote:
    Did you try spraying starter fluid into the intake while it's cranking? If it starts and runs a few seconds you probably have a fuel delivery problem.


    Thanks for the suggestion. Please help me understand how to implement your suggestion...

    I assume the "intake" (carb?) is basically where the air filter is sitting, right? So would I remove the air filter and then spray starter fluid in there while cranking? The way the air filter housing is situated, I cannot see inside there so that will make it a bit challenging.

    I guess something like this would work?
    https://www.walmart.com/ip/STA-BIL-Starting-Fluid-22004/764691516?wmlspartner=wlpa&selectedSellerId=0&wl13=5766&adid=22222222420449455996&wmlspartner=wmtlabs&wl0=&wl1=g&wl2=c&wl3=501107745824&wl4=pla-293946777986&wl5=9032145&wl6=&wl7=&wl8=&wl9=pla&wl10=8175035&wl11=local&wl12=764691516&wl13=5766&veh=sem_LIA&gclid=CjwKCAjwruSHBhAtEiwA_qCppnLIDPa5g5DilwKFOS9sPvo0Jw7f8NKKMvDtZkLdTiH-NhoFiSPzRhoCEYsQAvD_BwE&gclsrc=aw.ds
    Does it usually come with some sort of straw so that I could get it in closer to where the carb is (...the air filter housing is probably 4-5 inches deep).

    I'll give it a shot. Thanks!

    Any other suggestions?

    -Chris
  • Did you try spraying starter fluid into the intake while it's cranking? If it starts and runs a few seconds you probably have a fuel delivery problem.