Mercedes Mullins
The Onan 5500 generator has one or two fuel filters, depending on the model. Some gensets have two identical filters, while others have only one. The primary filter is located under the generator and can be accessed from underneath. There may be a second filter at the end of the fuel line attached to the carburetor, but newer designs have eliminated this. The little filter is one of the main reasons for generator issues, as it doesn't take much to restrict the fuel flow.
| Characteristics | Values |
|---|---|
| Number of fuel filters | 1 or 2 |
| Fuel filter location | Underneath the base of the generator, before the pump |
| Fuel filter type | Baldwin 836 inline filter |
| Fuel filter size | 3/8" inlet and outlet |
| Fuel line size | 1/4" |
| Fuel pump pressure range | 2.5 to 4 psi |
| Fuel pump location | Factory set up has pump located at the generator set |
| Fuel tank capacity | Not specified |
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What You'll Learn
- The Onan 5500 generator may have one or two fuel filters
- The primary filter is located under the generator and is accessible from underneath
- The secondary filter is at the end of the fuel line attached to the carburetor
- Newer carburetor designs have eliminated the need for the second filter
- The small size of the lower filter makes it hard to access
The Onan 5500 generator may have one or two fuel filters
The primary filter is located under the generator and is accessible from underneath. The lower filter is small and hard to access, so it is recommended to replace it with a 5/16" x 1/8" NPT barb fitting and install an inline filter in a more convenient location. This may require 12-18" of 5/16 fuel line to connect to the barb fitting.
Some Onan 5500 generators only have one filter, located underneath the base of the set, before the pump, screwing into the inlet of the pump. This filter can be replaced without cutting the gas line, as it has a screw clamp.
When replacing the fuel filter, it is important to be careful when removing the fuel line from the pump, as a small amount of gas may spill. It is also important to tighten the new filter snugly without over-tightening to avoid stripping the threads.
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The primary filter is located under the generator and is accessible from underneath
The Onan 5500 generator has two fuel filters. However, the primary filter is located under the generator and is accessible from underneath. This filter is small and hard to access. To replace the original filter, you can get a 5/16" x 1/8"npt barb fitting and install it in place of the filter. Then, install an inline filter in a location that is easy to access. You may need 12-18" of 5/16 fuel line to connect to the barb fitting so that the filter can be relocated.
The primary filter is one of the main reasons for generator issues as it doesn't take much to cause a restriction. It is recommended to use a Baldwin 836 inline filter as it also functions as a water trap. It is always good to have a spare.
The second filter is located at the end of the fuel line attached to the carburetor. However, some units are fuel-injected and do not have a carburetor. Newer carburetor designs have eliminated the second filter, so if your unit has one, it is most likely the older carburetor design.
Generator owners have reported that the Onan 5500 generator is very sensitive if there is any old fuel in the tank. It is important to ensure that the fuel pump and filter are working properly. One owner shared that they had to insulate the fuel lines all the way back to the tank and inside the cabinet up to the carburetor to fix an overheating issue.
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The secondary filter is at the end of the fuel line attached to the carburetor
The Onan 5500 generator has two fuel filters. One is located underneath the generator, below the mounting spring on the lower left of the unit, and the other is at the end of the fuel line attached to the carburetor.
The secondary filter, located at the end of the fuel line attached to the carburetor, can be difficult to access. It is important to ensure that the generator's fuel pump and filter are working correctly. This is because generators are sensitive to old fuel in the tank. Therefore, it is recommended to insulate the fuel lines all the way back to the tank, as well as inside the cabinet, right up to the carburetor.
The secondary filter is usually attached to the carburetor with a "permanent" clamp, which may require cutting the gas line to access. It is important to note that some newer carburetor designs have eliminated the need for a second filter. In such cases, the single filter is located before the pump, underneath the base of the generator set.
When replacing the fuel filter, it is important to be careful when removing the fuel line from the pump as a small amount of gas may spill. It is recommended to clamp the line or hang it above the level of the set to minimise spillage. Additionally, the filters should be tightened snugly, but not overtightened, to avoid stripping the threads.
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Newer carburetor designs have eliminated the need for the second filter
The Onan 5500 generator has one or two fuel filters. The primary filter is located under the generator and can be accessed from underneath. Some models also have a second filter at the end of the fuel line attached to the carburetor.
It is important to note that the presence or absence of the second filter does not impact the functionality of the generator. Both designs are effective in filtering fuel, and the newer design simply offers improved accessibility and ease of maintenance.
When replacing the fuel filter on an Onan 5500 generator, it is recommended to use a Baldwin 836 inline filter, as it also functions as a water trap. Additionally, when removing the fuel line from the pump during maintenance, exercise caution as a small amount of gas may spill.
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The small size of the lower filter makes it hard to access
The Onan 5500 generator has two fuel filters, although some models have only one. The primary filter is located underneath the generator, below the mounting spring on the lower left of the unit, and the second is at the end of the fuel line attached to the carburetor. However, some gensets do not have a carburetor, so they only have one filter.
One user reported that they changed the original filter for a 1/8" npt x 1/4" barb fitting and installed an inline filter near the tank. They noted that different builders install different sizes of fuel lines, which may be due to the distance from the tank to the generator.
Another user agreed that the small, hard-to-access lower filter was one of the main reasons for generator issues. They recommended a Baldwin 836 inline filter as it also acts as a water trap, and suggested carrying a spare.
It is important to note that when replacing fuel filters, it is necessary to be careful with the fuel line as a small amount of gas may spill. It is possible to clamp the line to prevent this. It is also important not to over-tighten the filters to avoid stripping the threads.
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Frequently asked questions
The Onan 5500 generator has either one or two fuel filters. Some gensets have two identical filters, while others have only one. Newer models may not have a secondary filter.
The primary filter is located underneath the generator, below the mounting spring on the lower left of the unit. The secondary filter is located at the end of the fuel line attached to the carburetor.
It is recommended to replace the fuel filters every three years to avoid fuel pump problems.
A Baldwin 836 inline filter is recommended as it also functions as a water trap.
You will need 12-18" of 5/16 fuel line to connect to the barb fitting and relocate the filter.
