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Old 08-23-2020, 09:23 PM   #1
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Generator wonít start

I have an Onan QG 4000 gas gen with 200 hrs. Has run flawlessly this season, but now will not turn over. Start solenoid clicks, but does not crank at all.
I have:
Cleaned battery connections (2-6v deep cycle 4 months old) and grounds
Tried starting with truck engine running, boosting voltage to 13.5v
Jumpered a ground from chassis to solenoid base just to be sure of good ground
Checked voltage at solenoid (12.8v)
Checked voltage on engine side of solenoid (.1v)
Replaced solenoid ( same results as the old one)
Turned the engine over by hand (Spins easily)

Where do I go from here? We’re on the road so access to assistance is limited to phone and internet.

Any suggestions welcomed, thanks in advance!
Brad
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Old 08-23-2020, 09:26 PM   #2
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didja clean and tighten the battery connections at the genny side, too?
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Old 08-23-2020, 11:23 PM   #3
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If the solenoid clicks, but doesn't chatter, it's making contact. Sounds like it could be a bad starter. Try smacking it with a hammer if you can reach it.
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Old 08-23-2020, 11:36 PM   #4
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Quote:
Originally Posted by HarryStone View Post
If the solenoid clicks, but doesn't chatter, it's making contact. Sounds like it could be a bad starter. Try smacking it with a hammer if you can reach it.
This, +1.

If banging on it makes no difference, you should be able to pull it out with two bolts (if your genny is on a slide - it's on top on the inside side.) Pull it out and jump it directly to test it.

If you can't remove it, try jumping it from the batt + to the starter side of the solenoid.
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Old 08-24-2020, 07:01 AM   #5
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Thanks for your responses. All connections are clean. Can’t reach the starter, not in a slide, so looks to be inaccessible inside the sound case.
Is it the case that you’d have to drop the genset out to get to the starter? Definitely above my pay grade !
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Old 08-24-2020, 07:24 AM   #6
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If you still getting 1 volt in the generator side of the start solenoid, you have a bad connection.

Test the battery side of that solenoid while pushing the start switch. If it drops to less then 10 volts, follow back towards the battery for a bad connection.
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Old 08-25-2020, 11:15 AM   #7
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I discovered I did not get the correct solenoid as replacement. It looked the same but was not an Onan part. Also discovered that with a better method to bypass the solenoid, then the engine fired up immediately. Backwoods engineering to the rescue!
So Iíve escaped pulling the gen out to replace the starter motor. A beautiful thing.
Thanks again for your responses.
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Old 08-31-2020, 06:53 PM   #8
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Bad battery.
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