This is the service manual for the generator set (genset) models listed on the front cover. Read and carefully observe all of the instructions and precautions contained in this manual. Failure to do so could result in serious injury or death.

Introduction

This service manual provides comprehensive information on the Onan Marquis Gold 5500 generator set, covering operation, maintenance, troubleshooting, and parts identification. It is designed to assist technicians and owners in understanding the generator’s functions, performing routine maintenance, and resolving potential issues. This manual is an essential resource for ensuring optimal performance, longevity, and safety of your Onan Marquis Gold 5500 generator set.

The Onan Marquis Gold 5500 generator set is a reliable and powerful source of electricity for a variety of applications, including recreational vehicles (RVs), marine vessels, and emergency backup power. This manual will guide you through the proper procedures for starting, stopping, and operating the generator, as well as performing regular maintenance tasks to keep it running smoothly.

Remember, following the instructions in this manual will help you avoid potential hazards and ensure the safe and efficient operation of your generator. If you encounter any difficulties or have questions, consult a qualified technician for assistance.

Generator Set Models

The Onan Marquis Gold 5500 generator set is available in various configurations to meet specific power requirements and application needs. These models are designed for both residential and commercial use, offering reliable and efficient power generation. The generator set models typically include a range of features, such as⁚

• Engine Type⁚ Onan Marquis Gold 5500 generator sets commonly utilize gasoline-powered engines, providing a reliable and readily available fuel source.
• Power Output⁚ The Onan Marquis Gold 5500 is known for its 5.5 kW power output, capable of powering essential appliances and devices.
• Voltage and Frequency⁚ The generator sets typically operate at 120/240 volt, 60 Hz, compatible with standard North American electrical systems.
• Noise Reduction⁚ Some models incorporate noise-reducing features, such as insulated enclosures or mufflers, to minimize sound levels during operation.
• Optional Features⁚ Additional features like automatic transfer switches, remote control capabilities, and fuel-saving modes may be available depending on the specific model and configuration.

To ensure compatibility and proper operation, consult the specific model specifications and user manual before selecting an Onan Marquis Gold 5500 generator set for your application.

Safety Precautions

Operating a generator set involves inherent risks and requires strict adherence to safety precautions. Failure to follow these safety guidelines could result in serious injury or death. It is essential to understand and follow these precautions before operating the Onan Marquis Gold 5500 generator set⁚

• Carbon Monoxide (CO) Poisoning⁚ Never operate the generator set indoors, in enclosed spaces, or near windows or vents. CO is a colorless, odorless gas that can be deadly. Ensure adequate ventilation and fresh air circulation when using the generator.
• Electrical Hazards⁚ Always handle electrical connections and components with extreme care. Avoid contact with live wires or components. Use proper grounding techniques and ensure all electrical connections are secure.
• Fire Hazards⁚ Keep the generator set area free from flammable materials, such as gasoline, oil, or combustible debris. Never refuel the generator while it is running. Allow the engine to cool completely before refueling.
• Mechanical Hazards⁚ Use caution when working around moving parts, such as the engine, drive belt, or fan. Never attempt to make repairs or adjustments while the generator is running. Ensure all guards and safety devices are in place and functioning properly.
• Personal Protective Equipment (PPE)⁚ Wear appropriate safety gear, such as gloves, safety glasses, and hearing protection, when operating or servicing the generator set.

Always refer to the specific safety instructions provided in the Onan Marquis Gold 5500 generator set manual for detailed safety guidelines and procedures.

Generator Operation

The Onan Marquis Gold 5500 generator set is designed to provide reliable power for a variety of applications. Before operating the generator, carefully review the instructions and safety precautions in this manual. Understanding the proper operating procedures will ensure safe and efficient operation of the generator set.

The generator set is equipped with a variety of features to enhance its performance and reliability. These features include⁚

• Automatic Starting System⁚ The generator can be configured to automatically start in the event of a power outage, providing uninterrupted power to your essential equipment.
• Engine Protection System⁚ The engine is equipped with a protection system to prevent damage from overheating, low oil pressure, or other potential problems.
• Fuel Management System⁚ The fuel tank is designed to provide a sufficient fuel supply for extended operation, and the fuel management system helps to ensure efficient fuel consumption.

Regular maintenance is crucial for ensuring the long-term performance and reliability of the generator set. Follow the maintenance schedule outlined in this manual to keep the generator in optimal operating condition.

Starting and Stopping Procedures

The Onan Marquis Gold 5500 generator set is designed for easy starting and stopping. To start the generator, first, ensure the fuel tank is filled with the appropriate type of fuel. Next, check the oil level and add oil if necessary. Connect the generator to the load you wish to power. The generator can be started manually using the start switch or automatically using the automatic start system.

To stop the generator, simply press the stop switch. The generator will shut down smoothly and safely. Always allow the generator to cool down completely before performing any maintenance or servicing.

It is important to follow the proper starting and stopping procedures to ensure the safe and efficient operation of the generator. Failure to follow these procedures could result in damage to the generator or injury to the operator.

Refer to the detailed instructions provided in the Onan Marquis Gold 5500 service manual for specific steps and precautions related to starting and stopping the generator.

Automatic Generator Starting Devices

The Onan Marquis Gold 5500 generator set can be equipped with an automatic start system, making it convenient for providing uninterrupted power in case of an outage. The automatic start system is designed to monitor the incoming power supply and automatically start the generator when it detects a power failure. This feature is particularly useful for applications that require continuous power, such as homes, businesses, and critical infrastructure.

The automatic start system typically includes a control panel with settings for configuring the start delay, the number of attempts to start, and other parameters. It may also include a remote control for starting and stopping the generator from a distance. The system is designed to be reliable and easy to use, providing a convenient and efficient way to ensure power availability during emergencies.

For specific details about the automatic start system available for your Onan Marquis Gold 5500 generator, consult the service manual or contact an authorized Onan dealer.

Breaking in Your New Generator

Breaking in your new Onan Marquis Gold 5500 generator is essential for maximizing its lifespan and performance. This process involves running the generator under controlled conditions for a specific period to allow the engine components to wear in properly and to ensure optimal lubrication.

During the break-in period, it’s important to avoid overloading the generator and to operate it within the recommended load range. Gradually increase the load over time, allowing the engine to warm up properly before applying full power. Avoid prolonged idling, as it can lead to excessive wear on engine components.

Check the oil level frequently during the break-in period and change the oil after the first few hours of operation. Consult the service manual for specific break-in guidelines and recommended oil change intervals. Following these recommendations will help ensure your Onan Marquis Gold 5500 generator operates efficiently and reliably for years to come.

Maintenance

Regular maintenance is crucial for keeping your Onan Marquis Gold 5500 generator running smoothly and reliably. It helps prevent premature wear and tear, ensures optimal performance, and extends the generator’s lifespan. The key maintenance tasks include⁚

Oil and Filter Change⁚ This should be done every 100-150 hours of running time, or at least annually. Use oil viscosity based on the outside air temperature. Consult the service manual for specific recommendations.

Air Filter Inspection and Replacement⁚ Check filters every 50 hours and replace as needed. A dirty air filter restricts airflow to the engine, reducing performance and increasing fuel consumption.

Cooling System Maintenance⁚ Check the coolant level regularly and ensure the cooling system is functioning properly. A clogged or malfunctioning cooling system can lead to engine overheating.

Spark Plug Inspection and Replacement⁚ Inspect spark plugs for wear and fouling. Replace them according to the manufacturer’s recommendations.

Battery Maintenance⁚ Keep the battery terminals clean and free of corrosion. Check the battery electrolyte level and charge the battery as needed.

Oil and Filter Change

Changing the oil and filter is a crucial maintenance task for your Onan Marquis Gold 5500 generator. It helps remove contaminants and ensures proper lubrication, extending the engine’s life. Here’s how to perform an oil and filter change⁚

1. Warm Up the Engine⁚ Start the generator and let it run for a few minutes to allow the oil to thin and circulate. This makes draining easier.
2. Locate the Drain Plug⁚ Identify the oil drain plug, usually located at the bottom of the engine oil pan. Place a suitable drain pan underneath to collect the used oil.
3. Remove the Drain Plug⁚ Carefully loosen and remove the drain plug. Be cautious as hot oil will be discharged. Allow the oil to drain completely.
4. Replace the Drain Plug⁚ Once the oil is drained, replace the drain plug and tighten it securely. Check for leaks.
5. Remove the Oil Filter⁚ Locate the oil filter, typically situated near the top of the engine. Use a filter wrench to loosen and remove the filter.
6. Install New Filter⁚ Apply a thin coat of fresh oil to the new filter’s sealing gasket. Thread the new filter onto the housing, tightening it by hand until the gasket makes contact. Then tighten it an additional one-half to three-quarters of a turn.
7. Add New Oil⁚ Fill the engine crankcase with the recommended type and quantity of oil, as specified in your generator’s service manual. Consult the dipstick to ensure the oil level is within the recommended range.
8. Start and Check⁚ Start the generator and check for any leaks. Run the generator for a few minutes to allow the oil to circulate and check the dipstick again to verify the oil level.

Dispose of the used oil and filter responsibly, following local environmental regulations.

Air Filter Inspection and Replacement

A clean air filter is essential for your Onan Marquis Gold 5500 generator’s optimal performance and longevity. A clogged filter restricts airflow, reducing power output and increasing fuel consumption. Here’s how to inspect and replace the air filter⁚

1. Locate the Air Filter⁚ The air filter housing is usually situated near the carburetor or intake manifold. It may be a cylindrical or rectangular box with a cover.
2. Remove the Cover⁚ Unlatch or unscrew the cover of the air filter housing. You’ll find the filter element inside.
3. Inspect the Filter⁚ Visually examine the filter element. If it’s visibly dirty or clogged with dust and debris, it needs replacement.
4. Remove the Old Filter⁚ Carefully remove the old filter element from the housing.
5. Install the New Filter⁚ Insert the new air filter element into the housing, ensuring it’s properly seated.
6. Replace the Cover⁚ Securely reattach the air filter housing cover, making sure it’s latched or screwed on tightly.

It’s recommended to inspect the air filter every 50 hours of operation or more frequently in dusty environments. Replace the filter as needed.

Troubleshooting

If your Onan Marquis Gold 5500 generator experiences problems, it’s important to troubleshoot the issue to identify the cause and implement the appropriate solution. Here’s a general approach to troubleshooting⁚

1. Review the Owner’s Manual⁚ Start by consulting your generator’s owner’s manual. It often includes a troubleshooting section with common problems and solutions.
2. Check the Basics⁚ Verify that the generator is properly connected to the power source, fuel is available, and the circuit breaker is not tripped.
3. Check for Warning Lights or Codes⁚ Observe the generator’s control panel for any warning lights or error codes. These can provide valuable clues about the problem.
4. Inspect for Loose Connections⁚ Carefully examine all electrical connections and ensure they are secure and free of corrosion.
5. Test the Fuel System⁚ If the generator is not starting or running properly, check the fuel lines for leaks or blockages, and verify that the fuel filter is clean.
6. Check the Spark Plugs⁚ Inspect the spark plugs for wear, fouling, or damage. Replace them if necessary.

If you’re unable to diagnose or resolve the problem yourself, it’s recommended to contact a qualified Onan service technician for assistance.

Fault Codes

Your Onan Marquis Gold 5500 generator uses fault codes to indicate specific problems. Understanding these codes can help you diagnose and resolve issues more efficiently. The codes are usually displayed on the generator’s control panel.

Here’s a general description of how fault codes work⁚

• Blinking Lights⁚ The control panel may have indicator lights that blink in a specific pattern to represent a fault code.
• Two-Digit Codes⁚ Some models display two-digit fault codes on a digital display.
• Service Manual⁚ Your generator’s service manual will contain a comprehensive list of fault codes and their corresponding meanings.

It’s important to note that the specific fault codes and their interpretations may vary depending on the model and year of your Onan Marquis Gold 5500 generator. Always refer to the service manual for the most accurate information.