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Onan 4k start/stop light doesnt work and stops running when release start switch


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  #1  
Old 09-02-2014, 08:12:16 PM
JoshD JoshD is offline
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Default Onan 4k start/stop light doesnt work and stops running when release start switch

Ok guys i'm new here and have searched for same problem but no luck.

I have an Onan Micro 4k in a toyhauler I recently purchased.

Model # 4KYFA26100K SPEC K
S/N # I060972250

Here is the problem, The start stop switch does not light up inside or outside, the hour meter does not light up. The motor only starts if I spray starting fluid in air intake. I have tested spark, it is strong. I have cleaned float bowl and sprayed carb cleaner everywhere I could. But no luck.

I'm thinking its an electrical issue, maybe the control board but I don't wanna just throw money at it. We have a local cummins shop but shop rate is 115$ an hour. Ouch!

Any help is greatly appreciated!!!
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  #2  
Old 09-03-2014, 08:27:08 AM
okcnewbie okcnewbie is offline
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Default Re: Onan 4k start/stop light doesnt work and stops running when release start switch

Have you downloaded the service manual yet? The shop would surely just change your carb for starters. Your 4KY needs to produce AC voltage before it will stay running. If you're lucky you just have to clean the slip rings. If there are no threads in the three holes on the flywheel than the slip rings have probably never been cleaned. On my first KY the rotor was open. You have to ohm from P4-9 to P4-10 to check that. The service manual will take your through all of that. Pretty sure the manual number is 981-0503.
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Old 09-03-2014, 09:58:02 AM
Kevin K Kevin K is offline
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Default Re: Onan 4k start/stop light doesnt work and stops running when release start switch

You need the following manuals:

Service 981-0530C
Parts 981-0246B
Install 981-0621
Operator 981-0159D

Your problem sounds like lack of fuel. Press and hold the STOP/PRIME switch. You should hear the fuel pump running. Disconnect the fuel line where it goes into the carburetor and direct it into a bottle. Press the STOP/PRIME switch. You should see a stream of fuel flowing into the bottle.

Check for voltage to the fuel cutoff solenoid when you are cranking.
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Old 09-03-2014, 10:58:52 AM
Doug Reed Doug Reed is offline
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Default Re: Onan 4k start/stop light doesnt work and stops running when release start switch

As the other say, the first step is to download the manuals:

Manuals for the KY spec K generators are posted in several links:
981-0159 & 981-0530 are posted in the stickie manual links:
http://www.smokstak.com/forum/showthread.php?t=85628

981-0246 Parts manual is here or here:
http://yakimagenerator.com/generators/pdf/0981-0246.pdf
http://leipper.org/manuals/rv/microl...rts-manual.pdf

981-0621 Install manual is here:
http://www.cumminsonan.com/www/pdf/manuals/981-0621.pdf

Another thread says it uses wiring diagram 611-1267 but I don't have that one. It sounds like it is included in one of the other manuals but I didn't look.

I also agree it sounds like lack of fuel. Your first task it to get it so the engine starts (without starter fluid) when you push the Start switch. Once it runs, if it shuts off when you release the Start switch you have electrical checks to run. There are many message threads dealing with KY problems but yours will probably end up with the carb like most other starting problems. The trouble shooting procedures in the manuals are excellent and you can certainly ask here when you don't understand the test.....
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Old 09-03-2014, 11:49:58 AM
len k len k is offline
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Default Re: Onan 4k start/stop light doesnt work and stops running when release start switch

Probably carb needs cleaning, especially if it sat around for several months....ethanol in gas.

If have fuel to carb, use a voltmeter and check that you have voltage to solinoid on carb during cranking. If do likely need to clean carb or filter at carb if it has one. If you can easily blow thru filter it's fine.

Last edited by len k; 09-03-2014 at 01:21:13 PM. Reason: easily blow
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Old 09-03-2014, 05:40:16 PM
Gunny Gunny is offline
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Default Re: Onan 4k start/stop light doesnt work and stops running when release start switch

Fuel pump working? If it tries to start on ether, you have ignition and compression, no fuel. Fuel lines intact, no leaks?

If you have a failed electric fuel pump, an aftermarket would be an option, just be sure its a low pressure one, under 4 psi.
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Old 09-03-2014, 06:29:02 PM
len k len k is offline
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Default Re: Onan 4k start/stop light doesnt work and stops running when release start switch

If pump has power but outputs no fuel, give a wack with a small hammer. IF it's dried up inside it can glue the diaphram inplace or stick a valve. Did that to mine and gave it a shot of compressed air, it started right up.
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Old 09-05-2014, 02:52:58 PM
JoshD JoshD is offline
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Default Re: Onan 4k start/stop light doesnt work and stops running when release start switch

I replied before but guess I didnt hit send Lol. So the fuel pump works. Spits fuel out of the line where connects to carburetor. I have the manuals already but the schematic for my model is nothing like what it actually is. So I dont know how to troubleshoot the wiring. Any ideas on why the start/stop switchs and hr meter are not lighting up? Thanks for the help guys!
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  #9  
Old 09-05-2014, 04:08:49 PM
Kpack
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Default Re: Onan 4k start/stop light doesnt work and stops running when release start switch

Hello josh check this service manual 981-0530c
https://www.dropbox.com/s/5odhzt9r60...kyser.pdf?dl=0
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Old 09-05-2014, 04:46:15 PM
len k len k is offline
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Default Re: Onan 4k start/stop light doesnt work and stops running when release start switch

Schematics/Wiring diagrams are in the back of the manual. Compare and see if your wiring is as per the schematics. Before you start changing everything look at it and see the big picture. Maybe previous owner modified it because of some trouble with controlboard, or maybe he just had no idea what he was doing.

There are wire numbers faintly printed on the wire near the ends near the connectors. Things like P1-3 which means pin # 5 in plug/jack connector #1. There are corresponding designations ( P1-3 type) on the schematic.
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Old 09-05-2014, 05:02:08 PM
MBB MBB is offline
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Default Re: Onan 4k start/stop light doesnt work and stops running when release start switch

Ok I believe this is you wiring diagram. 0611-1265.I will send it to you. Oops you have no Email posted.
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Old 09-05-2014, 06:01:50 PM
JoshD JoshD is offline
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Default Re: Onan 4k start/stop light doesnt work and stops running when release start switch

Josh97501@yahoo.com

Sweet, thank you
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Old 09-06-2014, 07:51:40 AM
MBB MBB is offline
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Default Re: Onan 4k start/stop light doesnt work and stops running when release start switch

Wiring Diagram Sent. 0611-1265
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