Aurora Portable Generator Operation Manual Models AGI6500DE & AGI6500SDE
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4 INTRODUCTION Customer satisfaction is very important to us. If at anytime you have any questions about this manual or require further help we encourage you to contact us by visiting our website at www.AuroraGenerators.com and using our LIVE CHAT, sending an e-mail to Support@AuroraGenerators.com or call us Toll Free at 1-877-510-6807 This manual is updated on a regular basis.
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4 SAFETY INFORMATION (For safe operation please follow the instructions strictly) Risk of fire and explosion • • • • • • • • • • Never use gasoline in a diesel engine or fire and explosion may result. Always handle fuel outdoors Identify the correct fuel type and model before refueling. Always wipe off any spilled fuel and oil before using your generator. Keep generator away from any flammable products and at least 3 feet clearance on every side.
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4 Electrical Shock Warning • Electricity can kill you. • Installation should be preformed by a certified electrician. Improper installation can result in electrical shock and death. • Follow all electrical safety code for your area. Consult an electrical safety inspector or electrician. • Do NOT hook up any generator to a buildings electrical system without the proper use and installation of a transfer switch installed by a qualified electrician.
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4 components to the ground terminals in the AC output receptacles. The system ground may or may not be connected to the AC neutral wire. This is called "neutral bonding" Local regulations, codes or laws may require that the ground system be connected to the AC neutral wire depending on its use. Most of our products have a "neutral bonded" grounds.
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4 GENERATOR OVERVIEW The main difference between the Aurora open frame generator and enclosed silenced type is the noise it produces. Both models use the same engine and alternator with some minor differences. The enclosed silent diesel generator uses two much larger mufflers and a separate diesel oxidation catalyst ( also known as a catalytic converter) The enclosed diesel generator does not use a manual recoil starter.
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4 Technical Specifications Generator Model AGI6500DE & AGI6500SDE Certifications 2010 / 2011 EPA ETL Approved to CSA 22.2 No.100 Engine Model Aurora 186F Engine Type Air cooled single cylinder, 4 stroke, direct injection diesel.
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4 PRINCIPLES OF OPERATION Fuel System The Generator Fuel System provides filtered and pressurized diesel fuel to the diesel engine. It consists of a fuel tank with removable fuel fill strainer, fuel lines, fuel filter, fuel injection pump, and a fuel injector. The diesel fuel is stored in a fuel tank. The tank features a plastic mesh strainer in the fill neck opening and a fuel tank drain valve.
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4 required for automatic engine starting and stopping. Removing the plunger inside will defeat it and let you continue using your engine in the event of this component failure. If this component fails immediate replacement is recommended in order for low oil pressure auto safety shut down the engine and prevent further damage.
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4 The governor control mechanism features two operator controlled levers. The diesel engine RUN lever places tension on a spring attached to the governor lever. The tension places the governor lever in a position to allow fuel flow to the fuel injector for diesel engine start up and to allow the diesel engine to continue running after start up.
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4 heater warms the air intake piping and manifold in order to warm up the intake air during attempted cold weather starts. To use it, toggle the momentary switch located on the front panel. Press down on it and hold it for up to 20 seconds. It will power the glow plug to heat it up. Release it and start your generator normally.
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4 from the power input circuit. This current is rectified to DC and reapplied via A1 pins F+ and F- to the AC alternator rotor brushes at G2 pins + and -. The application of direct current to the rotor increases the field magnetism between the AC alternator stator and rotor which in turn, increases the current measured across the alternator power windings.
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4 STARTING THE GENERATOR Before you begin Observe WARNINGS, CAUTIONS and INSTRUCTIONS contained in this manual and on plates or decals located on the generator. Do not operate if there is any deficiencies or irregularities or you do not fully understand the operation of this equipment and any hazards. Operator Preventive Maintenance Checks and Services • Check load terminals, sockets and outlets for any irregularities or deficiencies.
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4 Electric Starting 1. Ground generator. Never attempt to start the generator set if it is not properly grounded. Failure to observe this warning could result in serious injury or death by electrocution. Drive an eight-foot (or longer) ground rod into ground until clamp on top of ground rod is just above surface. Connect a 6 AWG minimum to the ground terminal on your generator. 2.
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4 STOPPING THE GENERATOR 1. 2. 3. Remove the load from the generator by turning OFF the mains circuit breaker Turn the starter key to the OFF position If generator fails to shut off, press the red stop lever to release the throttle and refer to the troubleshooting section of this manual. A decompression lever on the engine helps the operator start the engine when it is extremely cold, when the battery is low, or when bleeding the fuel system.
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4 INITIAL SETUP Your generator has been run and load tested at the factory to insure it meets specifications. A external fuel tank has been used and all the fuel that remains is in the fuel filter and fuel lines. Most of the lube oil has also been removed. If you find any oil in a new product, it must be flushed and replaced. Oil and fuel is considered hazardous material. For shipping, most if not all fluids are removed.
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4 Generally, the higher TBN value more the alkalinity reserve or acid neutralizing capacity the oil contains. Your generator requires 15W40 diesel lube oil only. For the first 25 hours a non synthetic lube oil is required. After the initial 25 hour break in process, synthetic diesel engine lube oil 5w40 to 15w40 is required.
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4 Regardless of how little you may use your generator the oil on its own will break down losing some of its properties in 3 months. The same applies to your vehicle. You must replace it every 3 months. If you use your generator within that time, the oil should be changed every 100 hours or earlier. There is nothing you can do that will add more life to your engine then regular oil changes.
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4 • • • • • • • • Insure when filling that no fuel is spilling or leaking for any hoses or filters. When filling from oil drums, ensure that no dirt or water enters the fuel tank. Contamination can cause serious fuel system problems. Never over fill the fuel tank. Filling should only be done in a well-ventilated area with the generator turned off. Never refill while the generator is running. Spilled fuel can ignite on a hot surface.
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4 Priming and Bleeding the Fuel System. http://www.youtube.com/watch?v=uQLkLtUdgh4& Under normal conditions, the fuel system does not require priming. Certain conditions may allow air into the fuel system such as running out of fuel. Once this occurs, the air must be bled before the engine will start or run smoothly again. The engine fuel pump can only pump fuel, it can't pump air.
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4 the engine and generator circuitry are possible sources of ignition. Failure to observe this warning could result in severe personal injury or death. 1. Check that fuel tank has fuel and that fuel shutoff valve located on the filter is positioned to ↓O (open). 2. Open two bleed screws at top of filter in the order listed below. (a) Open left bleed screw to bleed air from tank-to-filter fuel line.
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4 PREVENTIVE MAINTENANCE CHECKS AND SERVICES Within designated intervals, these checks are to be performed in the order listed. M-Monthly Q-Quarterly S-Semi-annually A-Annually B-Bi-annually H-Hourly Interval Item Item To Be Inspected Procedure Generator should not be used if x Diesel Engine Check for loose, damaged, or missing parts. Tighten loose parts. Repair or replace damaged or missing parts. Inspect decompression lever for debris.
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4 20 (1st Time) 500 500 20 (1st Time) 200 1000 2000 Intake and Exhaust Valves Adjust valve head clearance after the first 20 hours of operation and then every 500 hours. Primary and Prefilter, Air Filter Elements Replace air filter elements Cylinder Head Nuts Fuel Injector Fuel Injection Pump Check after first 20 hours of operation and then every 500 hours. Check for loose head nuts. Torque cylinder head nuts. Head nuts are loose.
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4 x Generator Set Check ground strap for damage. Damaged ground strap. x Low Oil Pressure (LOP) Engine Shutdown Cable Check for damaged push-pull cable and tube. Check cable adjustment. Damaged or misadjusted LOP engine shutdown cable Check for damaged or missing tubing and protective boot; damaged or burned wires and insulation.
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4 DETAILED PREVENTIVE MAINTENANCE PROCEDURES Fuel Filter Replacement Removal 1. Shut down the generator set 2. Close the fuel shut off valve 3. Unscrew the retaining ring and separate the bowl and head using care not to spill diesel fuel trapped in the bowl. Then pour diesel fuel into suitable container 4. Remove and discard fuel filter element and gasket Installation 1. 2. 3. 4. 5.
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4 Air Filter Element Replacement. Removal 1. 2. 3. 4. 5. 6. Shut down the generator set Remove 4 nuts securing metal cover on the silent diesel generator to expose the air filter assembly inside the enclosure. Remove the wing nut Remove the pre filter element Remove the paper element If necessary, remove gaskets from mounting plate and cover. Clean adhesive residue from surfaces Inspecting and Cleaning 1. 2. 3. 4. 5.
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4 Oil Filter Replacement This video shows the oil filter service on a disassembled engine for reference only. There is no need to disassemble the engine. http://www.youtube.com/watch?v=YZ0p8hVF7D4& 1. Remove oil filter retainer screw 2. Twist or pull of oil filter 3. Rinse off in soap and water and let dry. 4. Inspect rubber o-ring and replace if necessary. 5. Lubricate o-ring before replacing. 6.
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4 Fuel Pump Service & Replacement http://www.youtube.
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4 Fuel Injector Replacement. Removal 1. 2. 3. Shut down generator set. Disconnect pressure and return fuel lines from fuel injector. Remove nuts and retainer from cylinder head. 4. CAUTION To prevent damage to nozzle tip, wrap fuel injector in a clean cloth after removal. Do not place unprotected nozzle tip directly on dirty surface. Pull fuel injector straight out of cylinder head, wrap in clean cloth, and remove spacer and gasket.
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4 Engine & Alternator Resilient Mounts Replacement. Cylinder Head Nuts Tightening. 1. Clean fuel injector sleeve surface in cylinder head. 2. Install new gasket, spacer, and fuel injector in cylinder head. Ensure fuel injector is positioned to connect pressure fuel line prior to securing in cylinder head. 3. Secure fuel injector in cylinder head with retainer and nuts. Torque nuts evenly to 7-9 lbs-ft (9-12 Nm). 4.
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4 Aurora 186F Diesel Engine Specifications Valve timing, initial angle of fuel delivery and valve clearances in degrees. Intake Valve Open BTDC 13° Intake Valve Close ATDC 52° Exhaust Valve Open BBDC 57° Exhaust Valve Close ABDC 8.5° Initial angle of fuel delivery 22° ± 1° Intake valve clearances 0.10-0.15 mm cold Exhaust valve clearances 0.10-0.15 mm cold Injection Pump Pressure 19.6 ± 0.
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4 The Break In Period The diesel engine must be broken-in, avoiding heavy loads (no greater than 75%), for a period of twenty (25) hours to ensure proper operation of the generator set. After the initial break-in period, engine lubricating oil must be changed, cylinder head nuts torque must be checked, and intake and exhaust valve clearances must be checked and adjusted.
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4 engine operates for a long period of time below 40% it begins to over fuel. This happens because the injection tips begins to carbonize and disrupt the fuel spray pattern. The only way to correct a diesel engine if it has begun to wet stack is to load the engine for a couple of hours to burn off the excess fuel and clean up the engine.
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4 Number 2 fuel and ignites more readily under cold conditions. Keep the fuel tank full to prevent condensation inside the tank. Water from condensation can freeze and plug fuel lines from the tank to the engine. Add winter diesel fuel additive to the fuel to lower the possibility of gelling and improve starting. Store generators inside tool sheds, barns, garages or other suitable locations that are heated or warmer than outside temperatures.
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4 To recharge a lead-acid battery, it is necessary to convert the lead sulfate material which attaches to the discharged areas of the plates back to active plate material. If the battery has not remained discharged for long or has only been discharged slightly, this is a relatively easy process.
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4 is to help identify some important things necessary to truly befit from diesel and insure your generator continues to run long after its equivalent gasoline generator has died. Diesel engines operate at twice the compression ratio of gasoline engines; create greater internal pressures and heat. Components are made to closer tolerances, therefore are more easily damaged by dirt, corrosion improper fuel and lubricants.
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4 should be replaced as well. We suggest you change your oil after the first 25 hours and then every 100 hours or sooner. The cost of the oil is far cheaper then the cost of a new engine. This is an area where you have great control over how long our generator will last. The advantage of synthetic oil is that it can withstand higher temperature and can work longer without losing its lubricating qualities.
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4 troubles. A small amount of exhaust smoke is normal during initial start-up or rapid acceleration. Excessive black smoke is caused by a rich air-fuel mixture. This may result form problems with the injection pump or infection timing, which may in turn be clue to a choked air cleaner, worn fuel injectors, adulterated diesel fuel or the engine itself.
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4 Some engines use an electric fuel switch mounted on the fuel pump. You see it on the right side of this photo. It has one wire connected to it. The fuel valve is opened by applying 12 volts the top terminal. When powered it causes a spring loaded plunger and stopper to open. When open, fuel flows normally to the fuel pump.
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4 Larger wattage units can be selected for simultaneous starting and operation of multiple appliances. We carry a huge selection of transfer switches, electrical cables, plugs and outlet boxes. See what we have to offer that will help make your installation one that will get the job done right. Parts & Service Aurora carries a huge selection of parts. Shop online at www.AuroraGenerators.
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.
