01-2019 1-2019 Operator Manual Onan P9500df Dual Fuel Portable Generator English Original Instructions 1-2019 A062R858 (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.
1-2019 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 generator. You can register your generator 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.
1-2019 TABLE OF CONTENTS TECHNICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . 2 PRODUCT REGISTRATION . . . . . . . . . . . . . . . . . . . . . 3 For Your Records: . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Product Registration . . . . . . . . . . . . . . . . . . . . . . . 3 Product Registration Form . . . . . . . . . . . . . . . . . . . 3 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Safety Definitions . . . . . . . . . . . . . . . . . . . . . . . . .
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. SAFETY SYMBOL DEFINITIONS Symbol Description Safety Alert Symbol 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.
SAFETY 1-2019 GENERAL SAFETY RULES DANGER Never use the generator in a location that is wet or damp. Never expose the generator to rain, snow, water spray or standing water while in use. Protect the generator from all hazardous weather conditions. Moisture or ice can cause a short circuit or other malfunction in the electrical circuit. Never operate the generator in an enclosed area. Engine exhaust contains carbon monoxide. Only operate the generator outside and away from windows, doors and vents.
1-2019 SAFETY SAFETY LABELS AND DECALS 2 1 4 5 1 2 3 4 Copyright © 2019 Cummins Inc.
SAFETY 1-2019 SAFETY LABELS AND DECALS 5 6 9 3 7 8 5 6 7 8 9 Copyright © 2019 Cummins Inc.
SAFETY 1-2019 FUEL SAFETY When transporting or servicing the generator: • Make certain the fuel shutoff valve is off and the fuel tank is empty. • Make sure the LPG tank and LPG hose is not attached to the generator. • Disconnect the spark plug wire. DANGER Gasoline and liquid petroleum gas (LPG) are highly explosive and flammable. Explosions and fire can cause severe burns or death. When storing the generator: • Store away from sparks, open flames, pilot lights, heat and other sources of ignition.
UNPACKING 1-2019 1 CAUTION 4 Always have assistance when lifting the generator. The generator is heavy; lifting it could cause bodily harm. 2 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 flaps to reveal the manual. 3. Remove the Wheel Kit Accessories cardboard box. 4. Carefully cut two sides of the carton to remove the generator. 5.
ASSEMBLY 1-2019 INSTALLING WHEELS TO FRAME INSTALLING WHEELS AND FEET BEFORE ASSEMBLING THE GENERATOR, REVIEW THE SAFETY SECTION STARTING ON PAGE 5. 1. Insert axle pin through washer and wheel. CAUTION Never lift the generator without assistance. The generator is heavy and lifting without assistance could result in personal injury. Never use the handles as a lifting point to support the entire weight of the generator.
ASSEMBLY 1-2019 CONNECTING THE BATTERY 3. Locate the black negative (-) cable attached to the alternator case, route it to the negative (-) battery post. See Figure 5 below for location (1) of negative (-) cable. WARNING To avoid electrics hock: • ALWAYS connect the positive (+) battery cable (red boot) first when connecting battery cables. • ALWAYS disconnect the negative (-) battery cable (black boot) first when disconnecting battery cables.
FEATURES 1-2019 3 4 2 1 5 11 7 9 6 8 10 1 Fuel Selector Switch: Used to select and turn on gasoline or propane fuel source. 2 Push Button Electric Start: Starts and stops the engine. 3 Engine Control Switch/Battery Disconnect: Allows fuel to flow to engine and energizes the ignition system. Also, disconnects battery power when in STOP position. 8 Oil Drain Plug: Must be removed to drain engine oil. 9 Propane Hook Up: Hook up your propane tank with the LPG hose provided to this inlet.
FEATURES 1-2019 14 13 15 19 18 16 17 12 Auto Choke: Battery must be hooked up for auto choke to work properly. You can manually adjust the choke if the battery is not connected. 13 Gas Fuel Shut Off Valve: Controls the flow of gas to the engine. 14 Fuel Gauge: Indicates fuel level. 15 Spark Plug Boot (Wire): Must be removed when servicing the engine or the spark plug. 16 CARB Canister: Required for models sold into and used in California.
FEATURES 1-2019 CONTROL PANEL FEATURES 1 2 3 11 5 6 7 1A 2.1A 9 8 1 Fuel Selector Switch: Select and turn on gas or propane. 2 Push Start Button: • Hold to automatically start or stop the engine. 3 Engine Control Switch/Battery Disconnect: Switch to STOP to stop the engine. When in STOP position it prevents the unit from drawing power from the battery. Switch to RUN before starting engine. 4 5V USB Ports: 5V DC that come in 1 amp and 2.1 amps.
OPERATION 1-2019 BEFORE STARTING THE GENERATOR Weather – Never operate your generator outdoors during rain, snow or any combination of weather conditions that could lead to moisture collecting on, in or around the generator. BEFORE STARTING THE GENERATOR, REVIEW SAFETY SECTION STARTING ON PAGE 5. Dry Surface – Always operate the generator on a dry surface free of any moisture.
OPERATION 1-2019 POWER CORD Using Extension Cords Cummins Inc. assumes no responsibility for the content within this table. The use of this table is the responsibility of the user only. This table is intended for reference only. The results produced by using this table are not guaranteed to be correct or applicable in all situations as the type and construction of cords are highly variable.
OPERATION 1-2019 CONNECTING THE GENERATOR TO A BUILDING ELECTRICAL SYSTEM ADDING / CHECKING ENGINE FLUIDS AND FUEL It is recommended to use a manual transfer switch when connecting directly to a buildings electrical system. Connecting a portable generator to a buildings electrical system must be made in strict compliance with all national and local electrical codes and laws, and be completed by a qualified electrician.
OPERATION 1-2019 ADDING GASOLINE TO THE FUEL TANK BEFORE ADDING GAS TO THE TANK PLEASE REVIEW FUEL SAFETY SECTION ON PAGE 9 WARNING Never refuel the generator while the engine is running. Always turn the engine off and allow the generator to cool before refueling.
OPERATION 1-2019 CONNECTING TO LARGE LPG/PROPANE TANK BEFORE CONNECTING PROPANE TANK TO THE GENERATOR PLEASE REVIEW FUEL SAFETY SECTION ON PAGE 9 You can hook up you Duel Fuel Generator to a large home LP tank. It is required that you consult a plumber to properly connect your generator to the tank. To properly connect with a large propane tank you must first check and confirm the LP fuel pressure at the outlet of the LP tank.
OPERATION 1-2019 PROGRAMMING THE GENERATOR FOR REMOTE START NOTICE The key fob included with the generator should come already paired with the unit. If it does not you can follow the directions below to reconnect. If your unit was shipped without a key fob please contact our customer support team. WARNING Always make sure the area around the generator is clear of bystanders before using the remote start to start the generator.
OPERATION 1-2019 ELECTRIC START 5. Push the engine control switch into the RUN position (see Figure 11). Be sure to check oil levels before starting. If it is the first time starting make sure to add oil (see Adding Engine Oil page 26). 1. Make sure nothing is plugged into power outlets 2. Verify the battery is properly installed and both battery cables are attached (see Connecting the Battery on page 12). Figure 11 - Engine Control Switch - RUN 3.
OPERATION 1-2019 MANUALLY STARTING THE GENERATOR STOPPING THE GENERATOR 1. Make sure nothing is plugged into power outlets 1. Remove any connected loads from the control panel receptacles. Be sure to check oil levels before starting. If it is the first time starting make sure to add oil (see Adding Engine Oil page 26). Normal Operation During normal operation, use the following steps to stop your generator: 2. Make sure the circuit breakers are properly set (see Figure 8). 2.
MAINTENANCE 1-2019 BEFORE PERFORMING MAINTENANCE ON THE GENERATOR, REVIEW THE SAFETY SECTION STARTING ON PAGE 5, AS WELL AS THE FOLLOWING SAFETY MESSAGES. WARNING Avoid accidentally starting the generator during maintenance by removing the spark plug boot from the spark plug. For electric start generators, also disconnect the battery cables from the battery (disconnect the black negative (-) cable first) and place the cables away from the battery posts to avoid arcing.
MAINTENANCE 1-2019 TABLE 2: MAINTENANCE SCHEDULE - AUTHORIZED CUMMINS SERVICE DEALER PERFORMED Before Every Use After First 20 Hours or First Month of Use Valve Clearance - - - - Check/Adjust Fuel Filter - - - Check/Clean - Idle Speed - - - - Check/Adjust Maintenance Item CLEANING THE SPARK ARRESTOR After 50 Hours After 100 Hour After 300 Hours of Use or Every of Use or Every of Use or Every 6 Months 6 Months Year 5.
MAINTENANCE 1-2019 ENGINE OIL MAINTENANCE 6. Check oil level: When checking the engine oil, remove the oil fill plug/dipstick and wipe it clean. Thread the oil fill plug/dipstick all the way back in and then remove and check the oil level on the oil fill plug/ dipstick. Engine Oil Specification 1. Only use the engine oil specified in Figure 17. 2. Only use 4-stroke/cycle engine oil. NEVER USE 2-STROKE/CYCLE OIL. Synthetic oil is an acceptable substitute for conventional oil.
MAINTENANCE 1-2019 AIR FILTER MAINTENANCE CHANGING ENGINE OIL WARNING 1. Always operate or maintain the generator on a flat surface. Never use gasoline or other flammable solvents to clean the air filter. Use only household detergent soap to clean the air filter. 2. Stop the engine. 3. Let engine sit and cool for several minutes (allow crankcase pressure to equalize).
MAINTENANCE 1-2019 Cleaning the Air Filter - Continued from Page 27 NOTICE Never dispose of soap cleaning solution used to clean the air filter by dumping the solution into a sewer, on the ground, or into ground water or waterways. Always be environmentally responsible. Follow the guidelines of the EPA or other governmental agencies for proper disposal of hazardous materials. Consult local authorities or reclamation facility. Figure 23 - Remove Spark Plug Boot 7.
MAINTENANCE 1-2019 CHECKING AND ADJUSTING VALVE LASH 6. If an adjustment is required, hold the adjusting nut and loosen the jam nut. CAUTION 7. Turn the adjusting nut to obtain the correct valve lash. When the valve lash is correct, hold the adjusting nut and tighten the jam nut to 106 in-lb (12 N•m). Checking and adjusting valve lash must be done when the engine is cold. 8. Recheck the valve lash after tightening the jam nut. 1. Remove the rocker arm cover and carefully remove the gasket.
MAINTENANCE 1-2019 1. Remove the spark plug wire from spark plug. General Cleaning of the Generator – Use a damp rag to clean all remaining surfaces. 2. Loosen and remove the bolt on the battery holddown plate and swing the plate out. STORING GENERATOR BATTERY REPLACEMENT WARNING 3. Tip the battery forward slightly to access battery cables.
TROUBLESHOOTING 1-2019 WARNING Before attempting to service or troubleshoot the generator, the owner or service technician must first read the owner’s manual and understand and follow all safety instructions. Failure to follow all instructions may result in conditions that can lead to voiding of the EPA certification or product warranty, serious personal injury, property damage or even death. PROBLEM Engine is running, but no electrical output POTENTIAL CAUSE SOLUTION 1. Circuit breakers are tripped.
TROUBLESHOOTING PROBLEM 1-2019 POTENTIAL CAUSE SOLUTION 1. Dirty air filter 1. Clean the air filter. Engine runs erratic; does not hold a steady RPM. 2. Applied loads maybe cycling on and off 2. As applied loads cycle, changes in engine speed may occur; this is a normal condition. 3. If trying 1-3 above does not solve the problem, the cause might be a fault in the generator 3. Take the generator to your nearest authorized service dealer.
SCHEMATIC 1-2019 Copyright © 2019 Cummins Inc.
EXPLODED VIEW Copyright © 2019 Cummins Inc.
EXPLODED PART NO. 1-2019 # PART NUMBER DESCRIPTION 1 A058V123 FRAME 6 A058V131 CARB CANISTER CONNECTING PIPE LONG 11 A058V137 PANEL COMP 11.7 A058V112 START STOP SWITCH 13 A058U976 BOLT M8X16 14.1 A058V107 CARBON BRUSH COMP 14.2 A058V126 GROUNDING POST COMP 15 A058V096 REAR BEARING CARRIER 16 A058V114 GASKET, ROTOR BOLT Φ10.5XΦ30X4 22 A058U979 AVR 23 A058U977 END COVER,GENERATOR 26 A058V116 MUFFLER COMP 27.
ENGINE VIEW Copyright © 2019 Cummins Inc.
ENGINE PART NO. 1-2019 # PART NUMBER DESCRIPTION 11 A058U986 BOLT M6X16 21 A058V134 CYLINDER HEAD 40 A058V128 FUEL LINE CLAMP 69 A058V044 BOLT M6X25 78.
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