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Fuel Injector Replacement.

Removal

  1.  Shut down generator set.
  2.  Disconnect pressure and return fuel lines from fuel injector.
  3.  Remove nuts and retainer from cylinder head.

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.

4. Pull fuel injector straight out of cylinder head, wrap in clean cloth, and remove

spacer and gasket. If gasket (black plastic) remains in cylinder head, use a bolt
(5/16 in. diameter) that will thread into gasket to remove.

Inspection

1. Inspect injector for nicks, cracks, scoring, corrosion, and other damage.
2. Inspect nozzle tip for carbon deposits. Carefully clean deposits from nozzle body

and clean nozzle injection ports with 0.019 in. diameter wire

http://www.youtube.com/watch?v=jq6_bY5zfl8&

Installation

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. Connect pressure and return fuel lines. Bleed fuel system if necessary

AGI6500DE & AGI6500SDE Operator / Owners Manual Version 11.4.1

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Содержание AGI6500DE

Страница 1: ...Aurora Portable Generator Operation Manual Models AGI6500DE AGI6500SDE ...

Страница 2: ... instructions are not meant to cover every possible condition and situation that may occur We reserve the right to change this product and instructions at any time without prior notice The information contained within this document is updated regularly on our website If there are any safety concerns do not operate this product Do not return this product to the retailer Contact customer service for...

Страница 3: ...n the fuel valve to the OFF position Acid warning Be careful when using any battery Batteries will exhaust hydrogen while charging Only charge a battery in a well ventilated place Keep away from open flame heat or spark Avoid spilled battery acid If contact with skin is made wash immediately with water Carbon monoxide warning Carbon monoxide poisoning occurs after the inhalation of carbon monoxide...

Страница 4: ...ctrician The connection must isolate the generator power from utility power and must comply with all applicable laws and electrical codes A CSA or UL approved transfer switch is recommended Improper connections to a building s electrical system can allow electrical current from the generator to back feed into the utility lines Such back feed may electrocute utility company workers or others who co...

Страница 5: ...peration or slightly overloading the generator may not switch the circuit breaker OFF but will shorten the service life of the generator Do not exceed the current limit specified for any one receptacle If an overloaded circuit causes the AC circuit breaker to switch OFF reduce the electrical load on the circuit wait a few minutes and then reset the circuit breaker An overloaded DC circuit excessiv...

Страница 6: ...osure around the engine and exhaust system to keep it running at normal temperatures The enclosed silent type generator runs much quieter and comes with a remote control to start and stop it Common Features EPA Approved 11 HP Diesel 186F Type Single Cylinder Engine 3600 RPM FCC Approved Remote Control Transmitter Silent Diesel Only ETL Certified to CSA Standard 22 2 No 100 Self Excited 2 Pole Sing...

Страница 7: ...AGI6500DE AGI6500SDE Operator Owners Manual Version 11 4 1 Page 7 ...

Страница 8: ...AGI6500DE AGI6500SDE Operator Owners Manual Version 11 4 1 Page 8 ...

Страница 9: ...15W40 for diesel motors only Oil Lube Capacity 1 65 L Engine Lube Oil Pump Forced Engine Run Time 12 Hours 2 9 Gallons under 75 load Cold Start Heater Installed on air intake Decompression Valve Installed on engine Fuel Type Diesel Ultra Low Sulfur Automotive Fuel Only Max Height Above Sea Level 1000 Meters 3280 feet Generator Type Self Excited two poll single phase Voltage Regulator User adjustab...

Страница 10: ...or The returning fuel is used to lubricate the injector and keep it cool Any derbies in the fuel system may cause the fuel injector to stick open or not close completely This dripping of fuel will result in poor combustion and engine operation The diesel engine is shutdown by the operator depressing the engine STOP lever which places the fuel injection pump control rack in the no fuel position Sto...

Страница 11: ...get very hot and personnel may occur if users inadvertently touch the muffler while the diesel engine is running or before it has cooled down Engine Speed Control Diesel engine speed is maintained by the speed control system which includes the mechanical governor governor lever RUN lever and STOP lever The system is designed to maintain engine speed under load at a constant rate of between 3570 an...

Страница 12: ...cal panel Starting the engine with the starter motor is possible when the operator places the start switch in the START position power is applied through the switch to the starter solenoid This energizes the coil in solenoid which pulls in the solenoid s plunger and pushes the starter drive pinion attached to the plunger toward the engine flywheel This movement engages the starter pinion drive wit...

Страница 13: ...age variations by manipulating the alternator field current to maintain the output voltage The field current controlled by the voltage regulator is supplied by the alternator excitation windings The voltage regulator performs this function using three interactive sub circuits power input load sensing and DC output The power input circuit draws current from the AC generator exciter windings through...

Страница 14: ...n Hz from 45 to 65 The mains circuit breaker protects the VOLTS AC and HERTZ frequency meters from a potential over current condition Low Oil Pressure Protection The low oil pressure protection system shuts down the diesel engine in the event of low oil pressure in order to protect the engine from further damage The system consists of a low oil pressure switch located in the engine block above the...

Страница 15: ...ck fuel filter bowl for water or other contaminants Inspect fuel system for loose or missing fuel line clamps damaged fuel lines and leaking damaged fuel tank Check for evidence of fuels leaks Check fuel level and if necessary service fuel tank to red line on fuel strainer Ensure fuel tank fill neck strainer is not clogged or damaged If you find any oil in a new generator it is from factory testin...

Страница 16: ... the engine RUN lever to RUN position 7 Do not crank engine more that 10 seconds without allowing the starter to cool for at least 15 seconds between attempted starts Over cranking can damage the starter Turn the START switch clockwise to the START position and release when the engine has started 8 If the engine fails to start you can utilize the engine preheater and decompression leaver 9 If the ...

Страница 17: ...oubleshooting 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 Caution The decompression lever must never be used to shop the engine except in emergencies such as a run away engine or throttle damage as serious damage can be done to the exhaust valves AGI6500DE AGI6500SD...

Страница 18: ...h sludge soot and carbon interfere with proper engine operation The engine oil keeps all the deposit forming material in suspension and gets rid of them by oil filter or draining out at proper intervals Engine oil is stored in the oil pan or sump at the bottom of the engine A pump forces the oil through a filter and then through a series of passages and galleries to lubricate the engine s moving p...

Страница 19: ...synthetic lube oil is required After the initial 25 hour break in process synthetic diesel engine lube oil 5w40 to 15w40 is required The engine is designed in such a way that it is difficult to overfill it and as you can see in this illustration above oil should be filled until it reaches just below the oil filter neck AGI6500DE AGI6500SDE Operator Owners Manual Version 11 4 1 Page 19 ...

Страница 20: ... for your generator however there are many different types and we can t guarantee the quality or that it will not damage your engine While a diesel engine can run on many different types of fuel such as vegetable oils and other bio diesels some can clog the fuel filter fuel injector and fuel pump A grain of sand is all it takes to plug a fuel injector Do not use old fuel Fuel does go bad over time...

Страница 21: ...ills and ensure that area is dry before starting the generator Do not use old fuel Under some fuel tanks is a fuel shut off valve When filling or transporting your generator it must be off The valve should be in the open position when you are using your generator Some people forget to open it and either can t start the engine or cause air to be sucked into the fuel pump if it can t get the fuel su...

Страница 22: ...damage your fuel injector and will cause rough engine operation since the fuel being delivered is not a consistent flow If there is some air in the fuel delivery system it may take up to 15 minutes to naturally be purged through The engine may not run normally during this time Note Not all fuel filter assemblies have the bleed screws on the top You my have to remove the rubber fuel line from the f...

Страница 23: ...filter to pump fuel line It may be necessary to squeeze line by hand to force air out of bleed screw 3 When fuel flows freely and evenly out of bleed screws without air bubbles tighten both bleed screws 4 Loosen output fuel line fitting at fuel injection pump place engine RUN lever to RUN position depress and hold decompression lever and pull recoil starter rope until fuel flows from around fuel l...

Страница 24: ...required or replace element if damaged Replace pre filter foam element Air cleaner element is clogged or damaged x Ground Terminal Lug Check for damage or corrosion x Control Panel Check for any loose hardware or corrosion 20 1st Time 100 Engine Lube System Change diesel engine oil after the first 20 hours of operation and then after every 100 hours 1 Remove diesel engine oil drain plug and collec...

Страница 25: ...mage x Fuel Tank Check for damaged corroded or missing fuel fill strainer tank cap lug and retaining rope Damaged corroded or missing components x Alternator Check for damaged flexible sleeve coupling and flexible flange couplings Damaged alternator coupling components x Control Panel External Check for damaged corroded or missing convenience receptacle and cover MEP 531A LOP engine shutdown cable...

Страница 26: ... Resilent Mounts Replace resilient mounts after 2000 hours x Frame Check for damage and corrosion Damaged or corroded frame x Fuel System Check for damaged or corroded fuel tank brackets and guard Damaged or corroded components x Engine Alternator Check for damaged corroded alternator guard brackets engine mounting bracket and fuel filter stiffener Damaged or corroded components x Air Intake Syste...

Страница 27: ...l trapped in the bowl Then pour diesel fuel into suitable container 4 Remove and discard fuel filter element and gasket Installation 1 Clean bowl with clean cloth 2 Install new fuel filter element in bowl 3 Lubricate new gasket with clean diesel fuel and seat in land of bowl 4 Assemble bowl to head and hand tighten retaining ring 5 Prime and bleed the fuel system AGI6500DE AGI6500SDE Operator Owne...

Страница 28: ... for cleanliness cracks and other damage Clean cover with mild soap and water 2 Inspect filter element for cleanliness dents and crushed corrugations 3 Replace damaged parts 4 Replace filter element if dirty 5 Replace pre filter Installation 1 If removed install new gaskets on mounting plate and cover 2 Soak new pre filter in clean engine oil and squeeze out ALL 3 Install pre filter over filter el...

Страница 29: ...l 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 Insure oil filter in inserted all the way into engine block and o ring is not pinched This video shows oil filter replacement on a disassembled engine There is no need to disassemble your engine it is for educational purposes only AGI6500DE AGI6500SDE Ope...

Страница 30: ...Fuel Pump Service Replacement http www youtube com watch v a1ZrAAYGt40 AGI6500DE AGI6500SDE Operator Owners Manual Version 11 4 1 Page 30 ...

Страница 31: ...Inspection 1 Inspect injector for nicks cracks scoring corrosion and other damage 2 Inspect nozzle tip for carbon deposits Carefully clean deposits from nozzle body and clean nozzle injection ports with 0 019 in diameter wire http www youtube com watch v jq6_bY5zfl8 Installation 1 Clean fuel injector sleeve surface in cylinder head 2 Install new gasket spacer and fuel injector in cylinder head Ens...

Страница 32: ...ighten fuel line connecting nut and bleed fuel system if necessary Intake and Exhaust Valve Adjustment Perform valve adjustment when engine is cold Procedure is the same for intake and exhaust valve 1 Remove bolts securing valve cover Then remove valve cover with gasket 2 Remove cooling fan cover refer to paragraph 4 53 b 3 Align T mark on flywheel with V notch on cylinder body fin This video show...

Страница 33: ...clearances 0 10 0 15 mm cold Exhaust valve clearances 0 10 0 15 mm cold Injection Pump Pressure 19 6 0 49 200 5 MPa kgf cm Torque Specifications in SI units Newton Meters Torque Specifications in SI units Newton Meters Connecting Rod Nut 40 45 Cylinder Head Nut 55 60 Flywheel Nut 120 140 Fuel Injector Nozzle retainer nut 12 120 Rocker Support Bolt 25 30 All Standard M8 Bolts 20 30 All Standard M6 ...

Страница 34: ...ngine before using it Don t forget oil will become contaminated faster because of combustion blow by fumes and metal that is ground away during the mating process The oil should be changed at at the first 25 hours This is an important time for an engine You should not subject the engine to significant loading for the first 25 hours or more however some load IS desirable since the heat and friction...

Страница 35: ...glow plugs need to stay on to preheat the combustion chamber for a smooth start Batteries that are weak may not crank the starter motor fast enough or long enough to start a cold engine As the temperature goes down so does battery capacity A battery that has all of its power available at 80 degrees F will have only about 46 available power at 0 degrees F Plus the engine will be 2 5 times harder to...

Страница 36: ...dily at operating temperatures and allows proper lubrication of engine parts and areas Tips Tricks and Things You Should Know Batteries Generator batteries are often required to be float charged for long periods of time and must be able to deliver high current when called upon Generator batteries are often sealed and maintenance free Lead Acid batteries are often used however because the content i...

Страница 37: ...re is overcharging Many chargers on the market will damage your battery if left attached for extended periods by boiling the water out of the electrolyte solution Eventually water loss will destroy a battery Checking the electrolyte level in a battery and adding distilled water when necessary is extremely important especially when using fast chargers or many of the trickle chargers on the market M...

Страница 38: ... expensive engine damage Clogged air filters reduce power Diesel engines make more use of oil as coolant because of greater heat and pressure For example the oil cools piston undersides Improperly or inadequately filtered oil can cause scoring and damaging of engine parts Inadequate circulation of oil and coolant can cause engine overheating and thermal distortion Poor quality fuel can cause hard ...

Страница 39: ... ignited in a gasoline engine by the spark plugs Ultra low sulfur diesel ULSD will begin replacing conventional diesel fuel starting in 2006 The new fuel will contain 97 less sulfur than conventional diesel sulfur will be reduced from 500 parts per million ppm to 15 ppm Sulfur was the main lubricating property of the fuel Since the removal of Sulfur from Diesel Fuel diesel shops have been flooded ...

Страница 40: ... use Alcohols As temperatures drop paraffin crystals precipitate from the fuel forming the waxy substance on the filters which blocks fuel flow This freeze up condition can be avoided by using a Wax Dispersant which keeps wax crystals evenly distributed throughout the fuel thus assisting in the prevention of wax clogging the fuel system The Wax Modifier Pour Point Depressant they use will lower th...

Страница 41: ...erence Note that poor fuel quality can damage the rubber fuel lines and this switch causing components to stick Hooking Up To Your Home A manual transfer switch is the key to safe and convenient operation of portable generators for standby power By isolating those circuits using generator power a transfer switch eliminates the risk of back feeding the electrical utility which can cause injury to w...

Страница 42: ...witches 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 com or call us at 1 877 510 6807 AGI6500DE AGI6500SDE Operator Owners Manual Version 11 4 1 Page 42 ...

Страница 43: ...AGI6500SDE Schematics AGI6500DE AGI6500SDE Operator Owners Manual Version 11 4 1 Page 43 ...

Страница 44: ...AGI6500SE Schematics AGI6500DE AGI6500SDE Operator Owners Manual Version 11 4 1 Page 44 ...

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