CUMMINS Onan P4500i Operator's Manual

1-2019

01-2019

Operator Manual

Onan P4500i Inverter

Digital Inverter Generator

Onan P4500i

3700 Running Watts

4500 Peak Watts

REMOTE
START

STOP

120V AC 30A TT-30R

GROUND

RUN

Push-button electric start

30A

START

EASY START

ECO MODE

120V AC 20A 5-20R

Have Questions?

1-800-CUMMINS

PARALLEL

OPERATION OUTLETS

REQUIRES SPECIAL CABLES
CONSULT OWNERS MANUAL

!

FUEL

START

INDICATOR

20A

LOW
OIL

OVERLOAD

OUTPUT
READY

DC 5V

1.0A 2.1A

DATA CENTER

RESET

F: Remaining Run Time

kW
P: Power Output in
L: Fuel Level in Liters

V: Voltage

Lifetime Run Hours

English
Original Instructions

1-2019

A062R852 (Issue 1)

1-2019

WARNING

Operating, servicing and maintaining this equipment can expose you to chemicals including engine exhaust,
carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth
defects or other reproductive harm. To minimize exposure, avoid breathing exhaust, do not idle the engine
except as necessary, service your equipment in a well-ventilated area and wear gloves or wash your hands
frequently when servicing your equipment. For more information go to www.P65Warnings.ca.gov.

DISCLAIMERS:

All information, illustrations and specications in this manual are based on the latest information available at the time of publishing.
The illustrations used in this manual are intended as representative reference views only. Moreover, because of our continuous product
improvement policy, we may modify information, illustrations and/or specications to explain and/or exemplify a product, service or
maintenance improvement. We reserve the right to make any change at any time without notice. Some images may vary depending
upon which model is shown.

ALL RIGHTS RESERVED:

No part of this publication may be reproduced or used in any form by any means – graphic, electronic or mechanical, including photocopying,
recording, taping or information storage and retrieval systems – without the written permission of Cummins Inc.

DANGER

This manual contains important instructions for operating this inverter. For your safety and the safety of others, be sure to read this
manual thoroughly before operating the inverter. Failure to properly follow all instructions and precautions can cause you and others to be
seriously hurt or killed.

TABLE OF CONTENTS

TECHNICAL SPECIFICATIONS ..................3

PRODUCT REGISTRATION .....................3

For Your Records: .........................3

Product Registration .......................3

Product Registration Form ...................3

SAFETY .....................................4

Safety Denitions ..........................4

Safety Symbol Denitions ....................4

General Safety Rules ........................5

UNPACKING .................................6

ASSEMBLY ..................................7

Hooking Up the Battery ......................7

FEATURES ..................................8

Basic Inverter Features .....................8

Control Panel Features ......................9

OPERATION .................................10

Before Starting the Inverter ...................10

Location Selection .......................10

Weather ...............................10

Grounding the Inverter ....................10

High Altitude Operation ...................10

Power Cord ...............................11

Transporting the Inverter .....................12

Initial Oil Fill ...............................13

Adding/Checking Engine Fluids and Fuel ........13

Checking and/or Adding Engine Oil ............13

Adding Gasoline to the Fuel Tank ..............14

Starting the Inverter .........................14

Electric Start ...........................15

Manual Start ............................15

Wireless Remote Start ....................15

How to manually set the choke ................16

Stopping the Inverter ........................17

Using Eciency Mode ......................17

Resetting the Reset Breaker ..................17

Programming Remote Start Fob ...............17

MAINTENANCE ..............................18

Maintenance Schedule ......................18

Engine Oil Maintenance .....................19

Checking Engine Oil ........................19

Adding Engine Oil ..........................19

Changing Engine Oil ........................19

Air Filter Maintenance .......................20

Cleaning the Air Filter .....................20

Draining the Float Bowl ......................21

Spark Plug Maintenance .....................21

Cleaning the Spark Arrestor ..................22

Checking and Adjusting Valve Lash ............22

Cleaning the Inverter ........................23

Battery Service ............................23

Storage ..................................24

TROUBLESHOOTING .........................25

EXPLODED AND ENGINE VIEWS ................26

P4500i Schematic ..........................26

P4500i Exploded View ......................27

P4500i Engine View .........................29

Copyright © 2019 Cummins Inc.

2

A062R852 (Issue 1)

1-2019

TECHNICAL SPECIFICATIONS

Model

P4500i 3700 4500 3.4/13 3600 TCI F7RTC 224 70X58 0.60 10W30 <3%

Running
Watts

Peak
Watts

Fuel Tank
Size (G/L)

Rated
Speed
(RPM)

Ignition
Type Spark plug

Engine
Disp
(cc)

Stroke
X Bore

Oil Cap.
(L) Oil Type THD

FOR YOUR RECORDS:

Date of Purchase:

Inverter Model Number:

Purchased from Store/Dealer:

Inverter Serial Number:

IMPORTANT: KEEP YOUR PURCHASE RECEIPT TO ENSURE TROUBLE-FREE WARRANTY
COVERAGE.

PRODUCT REGISTRATION

To ensure trouble-free warranty coverage, it is important you
register your Cummins inverter.
You can register your inverter by either:

1. Filling in the product registration form below and mailing to:

Product Registration

Cummins Inc
301 E. Market St.

Indianapolis, IN 46204

2. Registering your product Online at www.cummins.com/support/product-registration

To register your inverter you will need to locate the following information:

• Model Info Decal located on side panel.

• Serial Number on back.

SERIAL NUMBER
LOCATION

PRODUCT REGISTRATION FORM

PERSONAL INFORMATION INVERTER INFORMATION

First Name: _______________________________________ Model Number: _____________________________________

Last Name: _______________________________________ Serial Number: ______________________________________

Street Address: ___________________________________ Date Purchased: ____________________________________

Street Address: ___________________________________ Purchased From: ____________________________________

City, State, ZIP: ____________________________________ Phone Number: _____________________________________

Country: __________________________________________ E-Mail: _____________________________________________

Copyright © 2019 Cummins Inc.

3

A062R852 (Issue 1)

SAFETY

1-2019

SAFETY DEFINITIONS

The words DANGER, WARNING, CAUTION and
NOTICE are used throughout this manual to highlight
important information. Be certain that the meanings of
these alerts are known to all who work on or near the
equipment.

This safety alert symbol appears
with most safety statements. It
means attention, become alert, your
safety is involved! Please read and
abide by the message that follows
the safety alerts symbol.

DANGER

Indicates a hazardous situation which, if not
avoided, will result in death or serious injury.

WARNING

Indicates a hazardous situation which, if not
avoided, could result in death or serious injury.

SAFETY SYMBOL DEFINITIONS

Symbol Description

Safety Alert Symbol

Asphyxiation Hazard

Burn Hazard

Burst/Pressure Hazard

Don’t leave tools in the area

Electrical Shock Hazard

CAUTION

Indicates a hazardous situation which, if not
avoided, could result in minor or moderate injury.

NOTICE

Indicates a situation which can cause damage to
the inverter, personal property and/or the environ­ment, or cause the equipment to operate improp­erly.

NOTE: Indicates a procedure, practice or condition

that should be followed in order for the
inverter to function in the manner
intended.

Explosion Hazard

Fire Hazard

Lifting Hazard

Pinch-Point Hazard

Read Manufacturer’s Instructions

Read Safety Messages
Before Proceeding

Wear Personal Protective
Equipment (PPE)

Copyright © 2019 Cummins Inc.

4

A062R852 (Issue 1)

1-2019

GENERAL SAFETY RULES

Never use the inverter in a location that is wet or damp. Never expose the inverter to rain, snow,
water spray or standing water while in use. Protect the inverter from all hazardous weather conditions.
Moisture or ice can cause a short circuit or other malfunction in the electrical circuit.

Never operate the inverter in an enclosed area. Engine exhaust contains carbon monoxide. Only
operate the inverter outside and away from windows, doors and vents.

Voltage produced by the inverter could result in death or serious injury.

• Never operate the inverter in rain or a ood plain unless proper precautions are taken to avoid being
subject to rain or a ood.

• Never use worn or damaged extension cords.

• Always have a licensed electrician connect the inverter to the utility circuit.

• Never touch an operating inverter if the inverter is wet or if you have wet hands.

• Never operate the inverter in highly conductive areas such as around metal decking or steel works.

• Always use grounded extension cords. Always use three-wire or double-insulated power tools.

• Never touch live terminals or bare wires while the inverter is operating.

• Be sure the inverter is properly grounded before operating.

SAFETY

DANGER

WARNING

WARNING

Gasoline and gasoline vapors are extremely ammable and explosive under certain conditions.

• Always refuel the inverter outdoors, in a well-ventilated area.

• Never remove the fuel cap with the engine running.

• Never refuel the inverter while the engine is running. Always turn engine o and allow the inverter to

cool before refueling.

• Only ll fuel tank with gasoline.

• Keep sparks, open ames or other form of ignition (such as match, cigarette, static electric source)

away when refueling.

• Never overll the fuel tank. Leave room for fuel to expand. Overlling the fuel tank can result in a
sudden overow of gasoline and result in spilled gasoline coming in contact with HOT surfaces.
Spilled fuel can ignite. If fuel is spilled on the inverter, wipe up any spills immediately. Dispose of rag
properly. Allow area of spilled fuel to dry before operating the inverter.

• Wear eye protection while refueling.

• Never use gasoline as a cleaning agent.

• Store any containers containing gasoline in a well-ventilated area, away from any combustibles or

source of ignition.

• Check for fuel leaks after refueling. Never operate the engine if a fuel leak is discovered.

WARNING

Never operate the inverter if powered items overheat,
electrical output drops, there is sparking, ames or smoke
coming from the inverter, or if the receptacles are damaged.

Never use the inverter to power medical support equipment.

Never modify the inverter.

Never operate the inverter if it vibrates
at high levels, if engine speed changes

greatly or if the engine misres often.

NOTICE

Always remove any tools or other service equipment used
during maintenance from the inverter before operating.

Copyright © 2019 Cummins Inc.

Always disconnect tools or appliances
from the inverter before starting.

5

A062R852 (Issue 1)

SAFETY

SAFETY LABELS AND DECALS

Model Modelo Onan P4500i
Part No Numero de parte A058U955
AC Voltage Voltaje 120V
Power (Running) Potencia (nominal) 3700W
Power (Peak) Potencia (pico) 4500W
Current Corriente 30A
DC Voltage Voltaje 5V
Current Corriente 2A
Frequency Frecuencia 60Hz
Phase Fase Single Soltero
RPM TR 5200
Power Factor Factor de potencia 1.0
Insul Class Clase de aislamiento F
Max Amb Temp Temperatura máxima 40
Fuel Combustible Gasoline
Fuel Tank Size Tamaño del tanque de combustible 12.8L/3.4G

Oil: SAE10W-30

Oil Capacity Capacidad de aceite .6 QT/20.3 OZ/600 ML

Read and understand operating instructions before starting.

Lea y comprenda las instrucciones de operación antes de
comenzar.

Provide proper ventilation! Do not operate in a confined area.

Proporcione una ventilación adecuada! No opere en un área
confinada.

Do not operate in wet conditions. Electrical shock may result and
could be fatal! No opere en condiciones húmedas. ¡Puede

producirse una descarga eléctrica y podría ser fatal!

o

C (104

Cummins Inc.

Columbus Indiana 47201 USA

Designed in Columbus, Ohio USA Made in China
Diseñado en Columbus, Ohio, EE. UU. Hecho en China

WARNING:

• Use gasoline with a minimum octane rating of 87.

• Do not direct exhaust fumes toward people, buildings or equipment.

• Check and refill oil as required to ensure proper inverter performance.

• When refueling, always stop the engine.

• Immediately wipe up any spilled fuel.

• Keep any flammable items away from this equipment.

• Do not touch or contact outlets with wet hands.

• Do not expose inverter directly to rain or snow.

• Do not connect the AC output to any indoor wiring.

• Clean spark arrestor every 50 hours to prevent engine damage.

• When operating your inverter, do not erect any barriers or obstacles
around the equipment or inhibit air or exhaust flow.

o

F)

Using a generator indoors

CAN KILL YOU IN MINUTES.

Generator exhaust contains carbon monoxide.

This is a poison you cannot see or smell.

Usar un generador en el interior PUEDE MATARLE EN

MINUTOS. El escape del generador contiene monóxido de

carbono. Este es un veneno que no puedes ver ni oler.

NUNCA lo use dentro de una

casa o un garaje, INCLUSO

SI las puertas y ventanas

están abiertas

Spark Plug Bujía

Use OEM spark plug only. Please refer to Owner’s Manual.

Utilice únicamente bujías OEM. Por favor, consulte el manual del propietario

Spark plug: Torch F7RTC Spark plug gap: .8 mm/.03 in

Use solo FUERA y lejos

de ventanas, puertas

y ventilaciones.

FOR USE IN DRY WEATHER PROTECTED LOCATIONS ONLY.

PARA USO EN LUGARES PROTEGIDOS CON TIEMPO SECO
SOLAMENTE.

1-2019

.

UNPACKING

CAUTION

Always have assistance when lifting
the inverter. The inverter is heavy;
lifting it could cause bodily harm.

Avoid cutting on or near staples
to prevent personal injury.

Tools required – box cutter or similar device.

1. Carefully cut the packing tape on top of the carton.

2. Fold back top aps to reveal the upper packing tray.

3. Remove and save the instruction manual, oil bottle,
oil funnel, LPG hose, spark plug socket wrench &
battery charger.

4. Remove and discard the upper packing tray.

5. Unfold the top of the plastic bag enclosing the
inverter.

6. Carefully cut the vertical corners of the carton to
access the inverter.

7. Recycle or dispose of the packaging materials
properly.

WHAT COMES IN THE BOX

Inverter
Battery
Manual
Quick Start Guide/Maintenance Schedule
Wireless Remote Starter (1)
.6 Liter Bottle of SAE 10W30 Oil (1)
11W Battery Charger, (14V .8A output) (1)
Spark Plug Socket Wrench (1)
Oil Funnel (1)

Copyright © 2019 Cummins Inc.

6

A062R852 (Issue 1)

1-2019

Negative

HOOKING UP THE BATTERY

WARNING

To avoid electrics shock:

• ALWAYS connect the positive (+)
battery cable (red boot) rst when
connecting battery cables.

• ALWAYS disconnect the negative (-)
battery cable (black boot) rst when
disconnecting battery cables.

• NEVER connect the negative (-)
battery cable (black boot) to the
positive (+) post on the battery.

• NEVER connect the positive (+)
battery cable (red boot) to the
negative (-) post on the battery.

• NEVER touch both battery posts
simultaneously.

• NEVER place a metal tool across
both battery posts.

• ALWAYS use insulated or
nonconducting tools when installing
the battery.

ASSEMBLY

4. Clip the battery quick connect from the battery
leads to the main lead inside the inverter (see image
above).

5. Verify the positive (+) battery cable (red boot) is
securely tightened to the positive (+) battery post.
Make sure boot is over battery post.

(Black)

NOTE: THE INVERTER COMES EQUIPPED WITH THE
POSITIVE BATTERY CABLE (RED BOOT) ALREADY
ATTACHED.

1. Unclip the battery access panel on the back of the
unit next to the muer (see Figure 1).

Figure 1: Battery service panel

2. Pull down on the battery strap clip and unhook it
from the mounting base.

3. Lift the battery up, withdraw it bottom-rst through
the battery access port and then stand it up vertically
in its normal orientation.

Positive

(Red)

Figure 2

6. Insert the battery top-rst through the battery access
port and stand it up on its mounting base.

7. Check that the battery is positioned correctly and
that the battery cables are not kinked or pinched.

8. Pass the battery strap under the negative (-) battery
cable and centrally over the top of the battery. Then
pull down on the battery strap clip and hook it onto
the mounting base.

9. Replace the battery access cover.

NOTE: The electric start inverter is equipped with a
battery charging feature. Once the engine is running,
a small charge is supplied to the battery via the
battery cables and will slowly recharge the battery.

Copyright © 2019 Cummins Inc.

7

A062R852 (Issue 1)

FEATURES

BASIC INVERTER FEATURES

4

1-2019

5

11

1

Control Panel: Contains the reset breaker,

outlets and warning lights.

2

Oil Access Cover: Remove the cover to

access the oil plug/dipstick.

3

Recoil Handle: Pull to manually start the

engine.

4

Fuel Cap: Close until clicking sound is heard.

1

9

3

6

2

7

8

7

Roller Board Wheels: For easy portability.

Telescoping Handle: Extends and retracts for

8

easy access.

Carry Handles: Built in handles to allow for

9

easy pick up.

10

Battery Access Panel: Easy access to

battery.

10

5

Engine Service Panel: Remove the panel to

access the engine, choke, air lter, spark plug
and oat bowl for maintenance.

6

Muer and Spark Arrestor: Avoid contact
until the engine is cooled down. The spark
arrestor prevents sparks from exiting the
muer. It must be removed for servicing.

Copyright © 2019 Cummins Inc.

11

Automatic Choke: Unit will automatically set

choke for cold starting.

8

A062R852 (Issue 1)

1-2019

CONTROL PANEL FEATURES

FEATURES

120-Volt, 20-Amp Duplex Outlet (NEMA 5-20R): The

1

outlet is capable of carrying a maximum of 20 amps.

120-Volt 30 Amp TT-30 Outlet: Travel Trailer outlet

2

can supply a maximum of 30 amps and 120 volts.

20-Amp Circuit Breaker: Circuit breaker limits the

3

current that can be delivered through the 120-volt
duplex outlets to 20amps.

30-Amp Circuit Breaker: Circuit breaker limits the

4

current that can be delivered through the 120-volt
TT-30R to 30amps.

5

USB Duplex: 5V DC USB outlets that come with 1 and

2.1 amp rating.

Reset Breaker: If the inverter is overloaded, the reset

6

breaker will trip. The engine will continue to run, but
there will be no output from the inverter. Unplug the
devices and reduce the load. Push in the reset breaker
to reset it.

Eciency Mode Switch: When turned to the ON

7

position, the engine will sense the load needed and run
at a slower RPM to save fuel.

8

Ground Terminal: The ground terminal is used to

externally ground the inverter.

LED Data Center: Displays remaining run time (F),

9

power output in kW (P), fuel level in liters (L), voltage
(V) and lifetime hours.

Have Questions?

1-800-CUMMINS

20A

START

INDICATOR

15

OUTPUT

READY

1011

9

DATA CENTER

F: Remaining Run Time

P: Power Output in kW
L: Fuel Level in Liters

V: Voltage

Lifetime Run Hours

OVERLOAD

12

17

STOP

4

120V AC 30A TT-30R

RUN

EASY START

Push-button electric start

30A

START

16

120V AC 20A 5-20R

ECO MODE

7

13

3

PARALLEL

OPERATION OUTLETS

1

2

18

REQUIRES SPECIAL CABLES

!

CONSULT OWNERS MANUAL

8

GROUND

Output Ready LED: Indicates the inverter is ready to

10

be used.

Overload LED: Indicates that the inverter is overloaded.

11

12

Low Oil LED: Indicates low oil level.

Battery Charging Port: Used to charge battery when

13

unit is o.

Fuel Control Switch: Allows fuel to ow to the engine.

14

Start Indicator: Indicates that power is on, light will

15

remain lit the whole time the unit is on.

FUEL

14

LOW

OIL

5

DC 5V

1.0A 2.1A

6

RESET

% FUEL
REMAINING

% POWER
OUTPUT

AUTOMATIC ROTATING DATA NUMBER DISPLAY

Remaining Run Time:

Displays time remaining
with current fuel level and
power output. Does not

Power Output:

Displays electrical power
output to receptacles in
kilowatts.

display lifetime hours.

Copyright © 2019 Cummins Inc.

Push-Button Automated Start: Press and hold for 1-2

16

seconds to automatically start the engine. Press and
hold again for 1-2 seconds to stop the engine.

Engine Control Switch: Turns on battery and energizes

17

ignition system for electric and remote start. Shuts
engine o.

18

Parallel Ports: Used with Cummins 50A parallel kit

(sold separate). Combine with additional Cummins
P2500i inverter (sold separate) to achieve 50A output.
Ideal for RV applications.

Fuel level:

Displays current fuel
level in liters.

9

Voltage:

Displays current voltage
output of inverter.

A062R852 (Issue 1)

Lifetime Hours:

Displays the total run
time of the inverter.

OPERATION

1-2019

BEFORE STARTING THE INVERTER

BEFORE STARTING THE INVERTER,
REVIEW SAFETY SECTION STARTING
ON PAGE 4.

Location Selection – Before starting the inverter, avoid

exhaust and location hazards by verifying:

• You have selected a location to operate the inverter
that is outdoors and well ventilated.

• You have selected a location with a level and solid
surface on which to place the inverter.

• You have selected a location that is at least 15 feet
(4.5 m) away from any building, other equipment or
combustible material.

• If the inverter is located close to a building, make
sure it is not located near any windows, doors and/
or vents.

Weather – Never operate your inverter outdoors during rain,
snow or any combination of weather conditions that could
lead to moisture collecting on, in or around the inverter.

Dry Surface – Always operate the inverter on a dry surface
free of any moisture.

No Connected Loads – Make sure the inverter has no
connected loads before starting it. To ensure there are no
connected loads, unplug any electrical extension cords that
are plugged into the control panel receptacles.

NOTICE

Starting the inverter with loads already applied to it could
result in damage to any appliance being powered o the
inverter during the brief start-up period.

Grounding the Inverter

Consult with your local municipalities for your grounding
codes.

THE Inverter (STATOR WINDING) IS ISOLATED FROM THE
FRAME AND FROM THE AC RECEPTACLE GROUND PIN

WARNING

Always operate the inverter on a level
surface. Placing the inverter on non
level surfaces can cause the inverter
to tip over, causing fuel and oil to spill.
Spilled fuel can ignite if it comes in
contact with an ignition source such
as a very hot surface.

NOTICE

Only operate the inverter on a solid, level surface.
Operating the inverter on a surface with loose

material such as sand or grass clippings can cause

debris to be ingested by the inverter that could:

• Block cooling vents

• Block air intake system

ELECTRICAL DEVICES THAT REQUIRE A GROUNDED
RECEPTACLE PIN CONNECTION WILL NOT FUNCTION IF
THE RECEPTACLE GROUND PIN IS NOT FUNCTIONAL

WARNING

Be sure the inverter is properly connected
to earth ground before operating.

High Altitude Operation

Engine power is reduced the higher you operate above sea
level. Output will be reduced approximately 3.5% for every
1000ft of increased altitude from sea level. This is a natural
occurrence and cannot be adjusted by engine. Increased
exhaust emissions can also result due to increased fuel
mixture. Other issues include hard starting, increased fuel
consumption and spark plug fouling.

WARNING

Do not rest inverter on exhaust panel. Do
not move Inverter
while it is on. The
inverter will be damaged

if operated in this

manner.

Copyright © 2019 Cummins Inc.

10

A062R852 (Issue 1)