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Aurora Portable Generator
Operation Manual
Models AGI6500DE & AGI6500SDE
Summary of Contents for Aurora AGI6500DE
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Page 1: Operation Manual
Aurora Portable Generator Operation Manual Models AGI6500DE & AGI6500SDE…
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Page 2
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4.1 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… -
Page 3: Safety Information
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4.1 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 •…
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Page 4: Electrical Shock Warning
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4.1 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.
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Page 5
It is not a smart charger and can over charge batteries. Caution should be used when charging any battery. Aurora Generators use a charge controller / voltage regulator to maintain its down 12 volt battery for electric starting. Page 5… -
Page 6: Generator Overview
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4.1 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.
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Page 7
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4.1 Page 7… -
Page 8
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4.1 Page 8… -
Page 9
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4.1 Technical Specifications Technical Specifications Generator Model AGI6500DE & AGI6500SDE 2011 / 2012 EPA Certifications ETL Approved to CSA 22.2 No.100 Engine Model Aurora 186F Engine Type Air cooled single cylinder, 4 stroke, direct injection diesel. -
Page 10: Principles Of Operation
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4.1 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.
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Page 11: Engine Speed Control
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4.1 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.
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Page 12: Engine Pre-Heating
The diesel engine electrical starting system can be used to start the diesel engine whenever there is a 12 VDC power source connected. Aurora generators have a battery included with the generator that may already be connected. When the generator is running, it recharges the battery.
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Page 13: De Compression Lever
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4.1 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.
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Page 14
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4.1 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… -
Page 15: Starting The Generator
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4.1 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.
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Page 16: Electric Starting
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4.1 Electric Starting 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.
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Page 17: Stopping The Generator
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4.1 STOPPING THE GENERATOR 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.
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Page 18: Initial Setup
The battery must be fully charged then connected before using it and you must have read and understand the complete instructions. If you are not sure of anything, call Aurora Generators at 1-877-510-6807 or email technical support at Support@AuroraGenerators.com…
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Page 19
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4.1 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. -
Page 20
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4.1 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. -
Page 21
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4.1 • 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. -
Page 22
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4.1 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. -
Page 23
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4.1 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). -
Page 24: Preventive Maintenance Checks And Services
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4.1 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 Interval Interval Interval Interval Interval Item To Be…
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Page 25
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4.1 (1st Intake and Adjust valve head clearance after Time) Exhaust the first 20 hours of operation Valves and then every 500 hours. Primary and Prefilter, Air Replace air filter elements Filter… -
Page 26
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4.1 Damaged ground Generator Set Check ground strap for damage. strap. Low Oil Damaged or Pressure Check for damaged push-pull misadjusted (LOP) Engine cable and tube. Check cable LOP engine Shutdown adjustment. -
Page 27: Installation
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4.1 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.
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Page 28
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4.1 Air Filter Element Replacement. Removal 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… -
Page 29: Oil Filter Replacement
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4.1 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& Remove oil filter retainer screw Twist or pull of oil filter Rinse off in soap and water and let dry.
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Page 30
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4.1 Fuel Pump Service & Replacement http://www.youtube.com/watch?v=a1ZrAAYGt40& Page 30… -
Page 31: Fuel Injector Replacement
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4.1 Fuel Injector Replacement. Removal Shut down generator set. Disconnect pressure and return fuel lines from fuel injector. Remove nuts and retainer from cylinder head. CAUTION To prevent damage to nozzle tip, wrap fuel injector in a clean cloth after removal.
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Page 32
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4.1 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. -
Page 33
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4.1 Aurora 186F Diesel Engine Specifications Valve timing, initial angle of fuel delivery and valve clearances in Valve timing, initial angle of fuel delivery and valve clearances in degrees. degrees. Intake Valve Open BTDC 13°… -
Page 34
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4.1 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… -
Page 35: Cold Weather Usage
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4.1 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.
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Page 36
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4.1 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. -
Page 37
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4.1 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. -
Page 38
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4.1 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. -
Page 39
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4.1 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. -
Page 40
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4.1 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. -
Page 41
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4.1 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. -
Page 42: Parts And Service
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4.1 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.
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Page 43
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4.1 AGI6500SDE Schematics Page 43… -
Page 44
AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4.1 AGI6500SE Schematics Page 44…
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