Cummins/Onan P4500iDF Generator Set

⚠ Checking and adjusting valve clearance must be done when the engine is cold.

Tools: feeler gauge

1. Remove the rocker arm cover and carefully remove the gasket.
2. Remove the spark plug so the engine can be rotated more easily.
3. Rotate the engine to top dead center (TDC) by pulling the recoil handle slowly.
4. Both rocker arms should be loose at TDC on the compression stroke.
5. Insert a feeler gauge between the rocker arm and valve stem to measure clearance.
6. If adjustment is necessary, hold the rocker arm pivot and loosen the pivot adjusting nut.
7. Turn the rocker arm pivot to obtain the specified clearance.
8. Hold the pivot and re-tighten the pivot adjusting nut to the specified torque.
9. Perform this procedure for the other valve.
10. Install the gasket, rocker arm cover, and spark plug.

⚠ DO NOT use thread seal tape or any other sealant on the LPG/propane hose connection.

Tools: 19 mm or adjustable wrench

1. Turn the generator OFF and place on a flat surface in a well ventilated area.
2. Verify the propane tank valve is fully closed.
3. Remove the cover on the generator propane inlet valve.
4. Hand thread the LPG/propane hose to the propane inlet on the generator.
5. Tighten the hose connector with a 19 mm or adjustable wrench. Do not over-tighten.
6. Remove the safety plug or cap from the propane tank valve.
7. Attach the other end of the hose to the tank and hand tighten.
8. Open the propane tank valve fully and check all connections for leaks with soapy water.

1. Push down the battery access cover tab and pull the cover forward to remove it.
2. Verify the rubber battery strap firmly secures the battery in place.
3. Remove the cable tie securing the quick-connect plugs.
4. Push firmly to connect the quick-connect plugs.
5. Align the tabs on the cover and push to reinstall the cover.

⚠ NEVER use gasoline or other flammable solvents to clean the air filter.

1. Place generator on a level surface and allow engine to cool several minutes.
2. Remove the engine service cover.
3. Turn the air cleaner cover knobs to unlocked and tip the cover down to remove.
4. Wash the foam air filter in household detergent soap and warm water.
5. Rinse by submerging in fresh water; allow to dry thoroughly.
6. Dip the foam filter in clean engine oil and squeeze out excess.
7. Install the foam air filter and lock the air cleaner cover.
8. Install the engine service cover.

⚠ The supplied battery charger is not a trickle charger; DO NOT use for more than 8 hours.

1. Plug the charger into the battery charging port on the control panel.
2. Plug the wall receptacle end into a 120 Volt AC wall outlet.
3. Unplug the battery charger from wall outlet and control panel jack after 8 hours of charging.

⚠ Burn hazard. The battery contains sulfuric acid (electrolyte) which is highly corrosive and poisonous.

1. Remove the battery access cover.
2. Remove the quick-connect plug and the battery strap; remove the battery.
3. Disconnect the quick-disconnect cable leads from the battery.
4. Connect the white (-) quick-connect cable to the negative terminal; slide boot over connection.
5. Connect the red (+) quick-connect cable to the positive terminal; slide boot over connection.
6. Install the battery into the generator and secure the battery strap.
7. Connect the quick-connect plug and install the battery access cover.

1. Remove the engine service cover.
2. Locate the drain hose extending from the bottom of the carburetor float bowl.
3. Place the loose end of the hose into an approved gasoline container.
4. Loosen the float bowl drain screw and allow the fuel to drain; then tighten.
5. Route the drain hose between the air cleaner housing and engine service cover; install the cover.

⚠ DO NOT use an electric pump.

Tools: gasoline hand pump

1. Unscrew the fuel tank cap and remove the fuel screen filter.
2. Siphon gasoline from the fuel tank into an approved gasoline container.
3. Reinstall the fuel screen filter and the fuel tank cap.
4. Start the generator and allow it to run until the engine stops.
5. Push the battery switch to the OFF position.
6. Disconnect the battery quick-connect plug.
7. Remove the spark plug.
8. Put a teaspoon of engine oil into the cylinder and pull the recoil handle until resistance is felt.
9. Reinstall the spark plug; leave the spark plug boot disconnected.
10. Install the engine service cover.

⚠ Accidental start-up. Remove the spark plug boot and battery quick-connect plug when working on the generator.

Tools: 10mm wrench

1. Place generator on a level surface and allow engine to cool several minutes.
2. Remove engine service cover; disconnect the spark plug wire.
3. Remove the oil access cover.
4. Clean around and remove the oil dipstick; wipe clean.
5. Remove the rubber plug under the oil drain bolt; place an oil pan under the drain hole.
6. Using a 10mm wrench, remove the oil drain bolt and allow oil to drain.
7. Install the oil drain plug and tighten securely; install the rubber plug.
8. Slowly pour oil into the oil fill until level is between L and H marks.
9. Replace the dipstick and hand-tighten.
10. Connect the spark plug wire and install the engine service cover.

1. Place generator on a level surface and allow engine to cool several minutes.
2. Remove the oil access cover.
3. Clean around the oil dipstick with a damp rag.
4. Remove the oil dipstick and wipe it clean.
5. Insert dipstick into filler neck without screwing; verify oil level is in safe range.
6. If low, add recommended oil incrementally until level is between L and H marks.
7. Replace the oil dipstick and hand-tighten.
8. Install the oil access cover.

⚠ Generator has been shipped without oil. DO NOT start before adding recommended oil.

Tools: oil funnel

1. On a level surface, remove the oil access cover and oil dipstick.
2. Add supplied oil into the engine using the funnel.
3. Add oil incrementally near end of bottle to prevent overfilling.
4. Replace the oil dipstick and hand-tighten.
5. Replace the oil access cover.

Tools: screwdriver, wire brush

1. Place generator on a level surface and allow the muffler to cool.
2. Remove the cover screws and the muffler cover.
3. Remove the spark arrestor with a screwdriver.
4. Remove carbon deposits from the spark arrestor screen with a wire brush.
5. Reinstall the spark arrestor and muffler cover.