I have been having problems with the generator and in looking through my manual in an attempt to solve the problem (which is I believe related to the starter) I came across some terminology which I really do not know what it means. In the Standard features section of the manual it refers to but does not explain what is meant by "Starter overcrank protection". Can you explain what this is and what it actually means to me. Many thanks.

Is this a Model "4KY" genset? Please confirm that and provide the Spec Code (single letter at the end of Model.And also please describe the problem.I tried to look Overcrank up in the Service Manual for 4KY and didn't find it. My belief is it keeps the starter from being engaged too long and burning out. Many engines have a cranking time limitation.If your problem is that it won't start, try priming the fuel system. (Again, if it's 4KY) Hold the Start/Stop rocker switch to STOP till it lights up then hold another several seconds. This causes the fuel pump to run, and you should hear a rattling sound which is the pump running. When it stops, the fuel bowl should be full. Then try to start the genset.How long has it been since it last ran, and how did it run then?

Hello jd and thanks for your quick reply. I hope I get all of this correct: First of all the generator is installed in a Jayco 2730W Designer Series on a 99Ford E40 SD 6.8L.The generator is Cummins Onan Microlite 4000 series Model # 4K4FA26100HI am a very low mileage RV user even tho I love the lifestyle. I have 48,000 miles on the RV and only 121 hours on the generator. About 4 years ago, I found that I could not start the generator as I had a trip planned so I took it to a local repair shop where I have had good experiences with in the past. They repaired the gen with a new starter for prox. $500.00 and I went on my trip. Since then I had some medical problems which kept me home for some time and when I was well enough to RV again I tried to start the generator prior to a trip and could not get it to start. I was aware of the cranking time limitation so I was careful to pay attention to that limitation. However, after trying to start it, the generator finally gave up with no turn over whatsoever which I assume is another starter problem. That was the reason for my question about the "Starter overcrank protection" section in the manual. I realize that my unit is old by todays standards but by the same token I had only put about 30 minutes or so on the generator after the first repair until I tried to start in for a second trip. The last time I ran the generator for that 30 minutes or so it was running just fine. I really appreciate your time and advice on this situation and my questions really come about as I am getting ready to go on another trip and wonder just where I stand with regards to an older gen set and the repair job done by my local repair shop. Could they have repaired it the first time and not done whatever was necessary to put the overcrank system into place? I realize that you can not possibly answer that question but if you have any ideas and feel free to express them then I would appreciate that. Many thanks from Bob Windom in Issaquah, WA

Starter Overcrank Protection is a built in timer to prevent burning up the Starter by engaging longer than 30 seconds. Once you engage the starter and the unit does NOT start, after 15 to 25 seconds the starter will disengage. You then have to wait a few seconds and retry. IF you have overheated the starter, you may have to wait longer for it to cool down before a restart. This is IN the Onan operators manual, not NOT listed under a Overcrank feature. Doug

really need to start at the beginning....when you push the start button. what happens?Nothing?anything?cranks, but won't start?any "pop" at all?How much gas is in your tank?

Are the first three characters in your Model Number actually 4K4? I would have expected 4KY. The rest of the characters, beginning FA, make sense, and your Spec is H. ONAN gensets, with proper maintenance, are very long-lived machines. If it wasn't run much in actual "duty" as a power source, wasn't run monthly or so as "exercise" if not otherwise run, and the fuel wasn't stabilized, then problems crop up. Their carburetors have tiny passages and that makes them very vulnerable to Gum and Varnish. Then they won't start or won't keep running. Then we work the starter too hard...

Onan MicroLite 4000 series generator question

12 Replies

isswindy
Explorer
Aug 25, 2013
Hello jd and thanks for your quick reply.
I hope I get all of this correct: First of all the generator is installed in a Jayco 2730W Designer Series on a 99Ford E40 SD 6.8L.
The generator is Cummins Onan Microlite 4000 series Model # 4K4FA26100H

I am a very low mileage RV user even tho I love the lifestyle. I have 48,000 miles on the RV and only 121 hours on the generator. About 4 years ago, I found that I could not start the generator as I had a trip planned so I took it to a local repair shop where I have had good experiences with in the past. They repaired the gen with a new starter for prox. $500.00 and I went on my trip. Since then I had some medical problems which kept me home for some time and when I was well enough to RV again I tried to start the generator prior to a trip and could not get it to start. I was aware of the cranking time limitation so I was careful to pay attention to that limitation. However, after trying to start it, the generator finally gave up with no turn over whatsoever which I assume is another starter problem. That was the reason for my question about the "Starter overcrank protection" section in the manual. I realize that my unit is old by todays standards but by the same token I had only put about 30 minutes or so on the generator after the first repair until I tried to start in for a second trip. The last time I ran the generator for that 30 minutes or so it was running just fine.
I really appreciate your time and advice on this situation and my questions really come about as I am getting ready to go on another trip and wonder just where I stand with regards to an older gen set and the repair job done by my local repair shop. Could they have repaired it the first time and not done whatever was necessary to put the overcrank system into place? I realize that you can not possibly answer that question but if you have any ideas and feel free to express them then I would appreciate that.

Many thanks from Bob Windom in Issaquah, WA
j-d
Explorer II
Aug 24, 2013
Is this a Model "4KY" genset? Please confirm that and provide the Spec Code (single letter at the end of Model.
And also please describe the problem.
I tried to look Overcrank up in the Service Manual for 4KY and didn't find it. My belief is it keeps the starter from being engaged too long and burning out. Many engines have a cranking time limitation.
If your problem is that it won't start, try priming the fuel system. (Again, if it's 4KY) Hold the Start/Stop rocker switch to STOP till it lights up then hold another several seconds. This causes the fuel pump to run, and you should hear a rattling sound which is the pump running. When it stops, the fuel bowl should be full. Then try to start the genset.
How long has it been since it last ran, and how did it run then?

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Onan MicroLite 4000 series generator question

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