Question about Watts Onan Portable Generator - 4000 , Model# 5500

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I have a 5gf-lde generator(china origin, silent type) and recently replaced the fuel tank guage in it which involved removing the casing,Whilst doing this I wragged off a few wires of its electric control circuit board (IT IS NOT A DIGITAL READOUT TYPE, IT IS ANALOG AND THIS CIRCUIT BOARD IS FASTENED ON TO THE REAR OF THE VOLTMETER) namely a red positive wire coming from the 12volt side from the alternator,a yellow wire going to the oil preasure switch which stops the machine from running if the oil level goes to low and a brown wire which is connected to an led which lights up when the oil switch is active giving a visual indication of low oil.Can you help in resolving just where the wires should be reconnected to

Posted by pkiff on


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wiring problem on a 5GF-LDE SILENT TYPE GENERATOR - image-2fwsrbehqcya13uxwt41l5dc-5-0.jpg

Posted on Aug 19, 2019



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4 Related Answers

Sheldon Dedek

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SOURCE: Onan Marquis Gold 5500 on

A1 controller could be suspect, can get you going with board cheaper than OEM, last longer too.

Does the generator shut down immediately after you let go of the start switch? If so, you are looking at oil pressure / level fault. Check oil level and sending unit. If generator continues to run for a few seconds and then shuts down, that is due to no or low AC voltage being produced and shutdown occurs. Shutdown for AC usually indicates an open winding or damaged voltage regulator.

Posted on Aug 25, 2009


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SOURCE: where do the four wires coming out of the right


Is it a 220 volt generator? If so then the green is ground, the white is neutral and the other two are hot wires. Do you have more information?


Posted on Jan 07, 2010



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SOURCE: I have a 1988 honey motorhome with a 5.0 cck onan

It is a wire to let the charging system know what voltage/amps, is being devoloped. It has a diode to check the voltage one way.
Take a volt meter. Put it on OHMS. You should read only one way, if not replace it.

Posted on Mar 02, 2010



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SOURCE: My Onan Emerald Advantage 5500

Hi and welcome to FixYa, I am Kelly

I can probably help you figure out where the wire goes if I had an idea of where this wire originates.

There are 2 wires connected to the side of the fuel pump I think either one of those 2 wires is the one your missing or the

Here is the start sequence for just the starter:

Sequence of Events:

Battery + pos) at PI-6, Battery - (neg) at P1-8.

Operator pushes start button at AI.

B+ from PI-2 to start solenoid

(S terminal).

Solenoid contacts close send B+ to

This is the ignition:

Sequence of Events:

Operator pushes start button on AI.

Safeties are bypassed.

B+ from P3-3 to ignition coil.

Breaker points open/close path to


High voltage jumps spark plug gap.
B+ supplied to fuel pump from PI-2.

This is the ignition / running:

Sequence of Events:

I. Engine starts, oil pressure causes

LOPKO to close sending ground

signal to P3-4.

AC from generator B1 -B2 winding

enter board at P1-1 and P1-7.

These two inputs cause the control

to switch from start mode to run

Starter automatically disengages.

Field flash automatically removed.

Start switch released.

Safeties enabled.

Bl-B2 powers choke heater (Hl).

Fuel Pump power now from P3-6
through R7.

The fuel pump power for run is from P3 pin 6 though resistor R7 to the fuel pump. THIS may be the wire that was damaged. However... a broken wire from the low oil pressure switch (located under the oil filter covered by metal cover) or... no AC output sensed on the control board due to a broken wire to P1-1 or P1-7 it will never switch to the run mode.

Your going to have to do pin to termination point readings one wire at a time. More in next post... (30 minutes or less)


Posted on Aug 01, 2011

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3 Answers

Missing wire of generator falcon 5GF-LDE from regulator to wich place ,so battery not charging

cant answer that one
5 kva diesel generator ....
needs a volt meter and or electrician to
ask why wire is disconnected
check regulator isnt faulty
and identify the right wire from its regulator to the right connection


Sep 20, 2016 | Cars & Trucks

2 Answers


Did this get replaced recently?
Fuel level senders typically work by changing the resistance (and therefore current) depending on the fuel level determined by the position of the float mechanism in the tank. Since the guage you are describing is working exactly opposit to as intended, is it possible that an incorrect sender was installed, or, if there are 2 terminals on the guage, have the wires been switched so that the current is going through the wrong way?

Apr 03, 2015 | 2000 GMC Yukon

1 Answer

How do you fix the gas guage on a 1988 Ford F-150. It stays on empty all the time.

you have two remove fuel tank fuel sending unite is in tank float is bad make sure to empty gas with a suction pump when all out take tank off of truck dont unhook all the way just far enough to get unite out and not bend fuel lines be carefull not to kink fuel lines and remember working with gas have a fire extinggisher close buy i mean right next to you next pull out sending unite by monipulating it out of the hole unhook it install new one reinstall in reverse make sure you jack up truck to do this

Aug 31, 2014 | Powermate Parts s: 61904 - 64902 - Part:...

1 Answer

Where is fuel pump locate

It's in the gas tank. If you've never pulled a tank off to replace a pump, I advise you to buy a Haynes or Chilton repair manual for your Olds to follow the procedure-not immensely difficult, but pretty involved. All lines to the tank removed, electrical plugs disconnected, filler hose removed, then lower and drop the tank-2 straps usually hold it up-(helps to have as little gas as possible in the tank, or it will be quite heavy-in that case, use a floor jack with some wood padding to avoid denting the tank), remove tank away from car. To get to the pump, remove the locking ring (on top of tank) with a brass punch or wooden dowel (so no sparks, see?) or be very careful if you use a steel punch or big screwdriver-NOT RECOMMENDED-but I have done it without sparks, so just be careful. pull the locking ring off and pull out the pump and fuel sender unit. Take off old pump, and replace with new-hopefully it is a OEM-original equipment manufacture-Aftermarket brand pumps just do not perform as well as original (olds) equipment. If the pump has failed, it is good practice to also replace the fuel pump relay-a failing pump can sometimes damage or shorten the life of the fuel pump relay, or so I've heard. Common tools and ratchets are needed for the job-possibly also a release tool for the fuel line fittings-if you have those types of fittings, I think you do, called quick connect fittings.
There's lots of other procedures to get the tank off-like lowering tank, then remove lines and electricals from top of tank, probably the exhaust will have to be lowered, you can siphon gas out the filler neck after lowering the tank a bit. You need to know how to relieve fuel pressure before disconnecting lines, but if little or no gas is in the lines, there won't be pressure. You just need a repair manual to do it step by step-...and label all lines removed, so you know where they go back on the tank.
If I haven't discouraged you yet, buy the manual, and get set for a dirty Saturday afternoon. Essentials like beer and pot are a given. lol.

May 06, 2013 | 1998 Oldsmobile Eighty Eight

1 Answer


To confirm if the fault is with the Rheostat float within the fuel tank or the fuel guage in the dashbboard, you can remove the wiring to the fuel tank float. If the guage reading changes- to full- then the guage is good and the fault can be a jammed rheostat which can be removed from the tank and replaced after draining the tank. The guage can be tested on the outside with a ground wiring to the plate of the fittings and as the float is moved the guage must show a change in reading. if not the voltage must be measured to confirm the working of the guage.

Oct 19, 2011 | 2001 Buick Century

1 Answer

Replaced fuel pump replaced replaced fuel filter everything works fine except fuel guage will not register. put 25 dollars fuel in tank still will not register help!!!

Possible that the fuel tank level sensor is not working or conneccting to the dashboard meter. You need to check if the float of the rheostat is damaged as then it will not act if the float is damaged.
Also if the rheostat is damaged it will not indicate as the resistance is open.
Make use of a multimeter to test the voltage and after removing the float-- the tank must be emptied in this case to remove the float sensor. Before this is removed to confirm , the line to the sensor when disconnected must indicate a Full level. If not the fuel guage must be checked before the float is removed.

Oct 07, 2011 | 2003 Pontiac Sunfire

1 Answer

Yes i have a 1999 ford expedition eddie bauer 4x4 from brand new or at lease 1200 miles . Recently i had a fuel pump problems and i have had a new fuel pump and ascending unit install professionally but...

The fault maybe with the fuel tank sender unit or wiring. Some manufactures do not send new fuel level sensors fitted to the new pump unit. Meaning that the old one needs to be removed from the faulty pump and fitted to the new one. If this is the case here, it might not of been swapped over, or plugged in properly. Also if the tank was removed to do this job they may over damaged the wiring during removal or installation

Oct 10, 2010 | 1999 Ford Expedition

1 Answer

Fuel guage shows 3/4 full right after fillup

It is most likely your fuel level sending unit has gone bad. It sits inside your fuel tank and uses a float similar to that uded in your toilet to tell the fuel guage how much gas you have in the tank.

In many cases, the unit can be accessed for replacment by removing the rear seat and opening the access port (3-4 screws) and removing the sending unit from the top of the fuel tank. It looks like this...


Feb 17, 2010 | 2005 Chrysler PT Cruiser

1 Answer

Fuel gauges bounces - 1996 Chrysler T&C 3.8

hi the sending unit is located at the very top of the tank to replace this part the tank will need removing to get to the top of the tank. Once the tank is removed its easy to remove the sender unit make sure your tank is empty first as it will be really heavy and hard to manage with fuel in the tank.

I you havnt got the use of a garage ramp or pit then it can be a big job removing the tank as it would involve removing all the fuel hoses and the filler hose from the tank to allow you enough freedom to get the tank off.

Let me know how you get on or if you need further assistance ok

Aug 25, 2009 | 2000 Chrysler 300M

2 Answers

Fuel gauge / range meter

this is an old post so not sure if problem has been resolved ?? but if not ? from your symptoms it sounds like the fuel tank sender unit is faulty and unfortunately not servicable but not too expensive to diy a new unit for a quick confirmation it is sender ? remove the wire from sender unit then scratch /hold to good earth whilst ignition is turned on and fuel guage is read by assistant ? if guage goes to full ? sender is faulty hope this helps?

Jul 25, 2008 | 2006 Hyundai Sonata

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