4 Most Common Onan p4500i Generator Problems And Easiest Fixes!

Onan p4500i generator problems

Last updated on August 9th, 2023 at 10:22 am

The Cummins Onan P4500i is a conveniently quiet and compact invert generator. It is best suited for RV travelers who want to enhance their freedom and outdoor life or any camping and tailgating hobbyists looking for a portable power source. However, just like any other generator, there are some common problems related to the Onan P4500i generator. 

These problems include generator overloading, overheating, tripping, or generator overloads with nothing plugged in. Many of these issues are best solved by having a professional check them out. This will help you avoid electrical shocks or fire hazards. 

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This article focuses on these issues and gives solutions to some of them so you know how to handle any situation. 

Onan p4500i Generator Problems and Easiest Fixing

Onan p4500i generator problems

The Onan P4500i generator is a great companion to carry outdoors. You can count on this great generator for compact size and quiet operation. However, there are some common problems that tend to be associated with this generator with frequent use or misuse. These common problems tend to occur when the generator is overloaded. 

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Generator Overheats and Won’t Start

Typically, a generator is installed with a sensor that detects overheating and shuts it off to prevent further damage. Even if you attempt to start it shortly afterward, once you release the starter, it shuts down. 

This is more of a safety feature. It is advisable to take it to a mechanic to check it out. It is possible to rebuild a generator. However, in worse-case scenarios, you may have to get a new one. 

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Generator Overload With Nothing Plugged In

A generator overloading with nothing plugging on is a rare situation that often takes place if you have been trying to run the generator without a load for too long. You may notice the overload light popping up or the generator just shuts down even with nothing plugged in.

All you are required to do is to reset it. This can be done by simply hitting the generator reset button and holding it for a few seconds or flipping the breaker. 

Restarting the generator will cause it to work as it should. If you are dealing with the GFCI outlets instead, you can reset the outlets. 

Generator Keeps Tripping

Usually, a short within the wiring or an appliance itself is to blame for a breaker that keeps tripping. When it comes to GFCI receptacles, tripping is a sign of loss of electric current, caused by torn or worn-out wiring. 

When too many appliances are connected to the generator and all are turned on simultaneously, the demand for electricity is greater than what the generator can supply, hence an overload occurs. Also, using long extension cords causes under-voltage which leads to tripping of the breaker as well. 

If you are unable to figure out what causes the tripping, it is advisable to consult a specialist and check the wiring. 

Generator Keeps Overloading

There are several reasons that would cause a generator to overload. These include having too many appliances plugged in, a shortage in the wiring, a change in the polarity of magnets, a generator malfunction, or a shortage in the appliances or equipment. 

If you notice that your generator is inclined to go on overload and you have tried every possible solution, it would be best to seek professional help. This is mainly because overloads are often a result of short circuits. If a short circuit is not given immediate attention, it could cause further damage to the generator, making it a fire hazard. 


All portable generators are to be covered for protection against the elements. This helps to lengthen their useful life. 

Overloading the generator generally means that too many appliances are plugged in and the generator does not have the capacity to keep up with them. The result is that the generator exceeds the rated wattage and possibly starts overheating. Some generators are fitted with circuit breakers to prevent the situation. If not, the generator overheats and causes damage to other electrical devices connected to it.

This unit is designed to be remotely started and stopped for added convenience. 0


Besides being affordable, portable generators are much more efficient and intelligent compared to the ones used before. One such generator is the Onan P4500i generator which does a great job outdoors.

However, there are some common problems related to this generator that you need to know about. They are as outlined above and some solutions that will help so you can be in the know in case of anything. 

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