Aurora Generators Inc.

Quick Startup Guide | Reference Manual

AGI4000DE
AGI6800DE
AGI6800SDE

The quick start reference covers most important information on your generator. Please read it carefully before you operate your generator. For more detailed information please refer to our website

Starting your generator for the first time.

1. Use your generator outdoors only. Insure proper ventilation and keep it dry.
2. Check your battery acid level and fill it if required. Maintenance free batteries require no filling.
3. Fully charge the battery before using it. (do not charge or boot battery while connected to generator)
4. Fill engine with oil to level shown on oil dip stick. Use Synthetic Diesel Motor Oil only. 15w40 for diesel engines. ( Do not use engine oil for gasoline engines )
5. Fill fuel tank with diesel automotive fuel only. Do not overfill tank and make sure all fuel valves are open.
6. Remove the rubber fuel line from the fuel pump and let fuel bleed out into a container until all air is removed from the lines and fuel filter.
7. Connect fully charged battery to your generator.
8. Make sure there is no load connected to your generator or turn main breaker off before starting or turning off your generator.
9. Insure the throttle lever is locked into the run position.
10. In cold weather turn the ignition key to the to the “heat” position for about 20 seconds then clockwise to crank the engine. Release the key when the engine starts. If you are having difficulty starting below freezing consider cranking the engine after the decompression leaver on top of the engine has been held open for a moment to help the engine crank faster. Release decompression leaver and engine should have built up enough momentum to assist in starting.
11. If engine does not start, wait until start cools down before trying again.
12. The remote control should only be used after the engine has successfully started using the key switch method above.

Manual Starting

1. Open the fuel cock
2. Pull the engine speed lever to the “run” position
3. Hold the starting handle loosely…
   Pull the starting handle slowly….until you feel resistance.. then return it slowly
4. Push the decompression leaver down and release
5. Hold the starting handle firmly.. Pull hard and fast all the way out.

Generator Break In Period

All engines require some kind of break-in period. Current technology provides the means of manufacturing engine parts with unimaginable precision but they still fall short of achieving the near perfect fit that a proper break-in will provide. “Break-in,” for the most part, is the allowance of the machined cylinder and ring surfaces to conform to each other’s shape during engine operation. This conforming or “mating” of ring and cylinder surfaces is the ultimate goal of a proper break-in. “Mating” these two specific parts will produce a very tight seal in each cylinder. A tight seal is very important because it prevents the escape of unburned fuel and pressurized gasses into the crankcase, while further preventing crankcase oil from entering the cylinder above the top compression ring.

Break-in can occur in the first 100 hours of use. The first 20 are critical and will determine how long your engine will last and run in the future. Avoid heavy loading as it introduces more fuel into the combustion chamber, increases the amount of heat generated and will promote any existing blow by oil to flash burn and glaze to the cylinder walls. This glaze will build up and result in a poor seal. Under loading on the other hand is also bad for the engine. Decreased combustion chamber pressures cause piston rings to not seal as well and to hydroplane or skip over the oil film leaving behind trace amounts that will also burn and glaze to the cylinder walls.

Remember that during the break-in period there is more friction from surfaces mating to each other. Watch for overheating and dirty oil filters.

Synthetic motor oil intended for diesel engines ONLY should be used. The more often you can change your oil the longer your engine will last.

After your break in period remember Diesels are designed to work, and in many cases, they operate best under a load.

Maintenance Schedule

Items / Intervals	Every Day	20 Hours	50 Hours	100 Hours	200 Hours	500 Hours	1000 Hours
Check all nuts and bolts	•
Check & Refill Engine Oil	•
Replace Engine Oil		• (first time)	• (second time)
Replace Oil Filter		• (clean)	• (clean)				• (replace)
Check For Oil Leakage	•
Replace Air Filter						•
Clean / Replace Fuel Filter				•		•	• (replace)
Check Fuel Injector				•
Check Fuel Injection Pump				•
Adjust clearance of intake / exhaust valves		•		•
Replace Piston Rings							•

*These are minimum guidelines that must be followed. If you are using your generator in harsh conditions or for per-longed periods of them additional maintenance may be required.

Generator Overview

Generator Specifications

Item	Model	4000DE	6800DE	6800SDE
Generator	Generator Type	Brushless, 2-Pole, single Phase
	Excitation	Self-Excitation voltage
	Voltage Regulator	Capacitor ( Brushless Alternator ) AVR ( Brush Alternator
	Frequency	60 Hz ( Available in 50 Hz)
	Maximum Output	4000 Watts	6500 Watts	6500 Watts
	Rated Output	3500 Watts	5500 Watts	5500 Watts
	Rated Amps	29 @ 120 Volts 14.5 @ 240 Volts 8.3 @ 12 Volts	46 @ 120 Volts 23 @ 240 Volts 8.3 @ 12 Volts	46 @ 120 Volts 23 @ 240 Volts 8.3 @ 12 Volts
	Power Factor	1.0
	Noise Level	80 db	87 db	70 db
	Insulation Class	B	B	B
Engine	Engine Type	4 Stroke, Air Cooled, Single Cylinder OHF
	Engine Model	Aurora 178	Aurora 186	Aurora 186
	Bore x Stroke	3.07″ x 2.44″	3.39″ x 2.83″	3.39″ x 2.83″
	Displacement (in3)	18.1	25.5	25.5
	Max Output (HP)	5.9	9.3	9.3
	Rated Output (HP)	6.6	10.3	10.3
	Fuel Type	Diesel	Diesel	Diesel
	Lube Oil Capacity	27.1 oz	39.9 oz	39.9 oz
	Fuel Tank Capacity	3.3 gallons	3.3 gallons	3.9 gallons
	Continuous Operation @ Half Load	12 Hours
	Ignition System	T.C.I.	T.C.I.	T.C.I.
	Starting System	Recoil Starter + Electric	Recoil Starter + Electric	Electric
	Compression Ratio	19:1	19:1	19:1
	Lube Oil Type	SAE15W40 Synthetic Diesel Engine Oil Only
	Dry Weight (lb)	84	117	117
	Dimensions L x W x H	15.1 x 16.6 x 17.7	16.4 x 17.4 x 19.5	16.4 x 17.4 x 19.5
Electrical Outlets	NEMA Rating	2 x NEMA 5-20R 120 Volt @ 20 amps 1 x NEMA L5-30R 120 Volt @ 30 amp 1 x NEMA L14-30R 120 / 240 Volt @ 30 amp 1 x DC12V @ 8.3 amp
Weight	Net Weight (lbs)	212	263	352
Dimensions	Product L x W x H	27.2 x 18.5 x 21.9	29.1 x 19.7 x 23.2	36.2 x 20.9 x 27.8
	Carton L x W x H	28.2 x 19.1 x 23.4	30 x 20.5 x 23.8	37.2 x 21.5 x 29.0
Operating Parameters	Maximum Elevation	3000 Feet	3000 Feet	3000 Feet
	Maximum Relative Humidity	60% @ 68 F 90% @ 104 F

Applying a load to your generator

1. Safety First, insure proper grounding and isolation from any other power source.
2. Never connect your generator directly to your home. A properly installed generator transfer switch must be used or plug in your devices directly to your generator.
3. Never start of shut off the engine with a load connected to the generator. Switch the generator main breaker to OFF or disconnect all connections first.
4. Keep your generator clean and dry.

You have a two pole alternator / generator. This means it has two windings or outputs that each supply 120 volts.

The voltage switch on the panel changes how the two outputs are connected to your electrical outlets so you can get different voltages. 120 or 240 volts. In series you can get 240 volts and in parallel you can get 120 volts but TWICE the power because you are using two supplies tied together.

The two windings are called “R” and “L” Lets just call it Left and Right. Left has two connections 1 and 2 same with Right, 1 and 2

What is important to remember is that you can either use the generator set to 120 volts and get the maximum power out of the 120 volt outlets or if you need 240 volts switch it to 240 v0lts but you can only get now half the power on each 120 volt output on the larger L14-30 Outlet .

You can download the complete generator wiring diagram –>here<–

Using The Remote Control

Most Aurora Portable Diesel Generators include an installed remote control. This remote lets you start and stop your generator without using a key. The purpose is not so you can operate your generator unattended, indoors or be left outside in the rain.

Do not use the key switch when using the remote control. Do not start with one and turn off with the other. If you forget your key in the on position and turn off with the remote for example then there are things left on that will drain the battery or even burn out.

When using the remote you should remove the key and do not use both at the same time.

The receiver is always on and using generator battery power so it can listen for signal and turn on your generator. It will slowly drain your battery. Either exercise your generator on a regular basis to recharge the battery or disconnect the receiver by unplugging it during storage. It is installed and held in place by a magnet so it can easily be removed. Also check your key chain battery on a regular basis and replace as necessary.

You can purchase an optional second channel remote. The second channel and second set of buttons let you control the glow plug and engine pre heating feature without using a key. Pressing the on button will energize the glow plug for 25 seconds then attempt to start your engine. This makes starting easier in cold weather.

Without this option you should use the key switch to preheat and start your generator.

Starting in cold weather

Diesel fuel can gel in cold weather. It will not vaporize as easily and when injected into a cold engine it can also gel as it hits the cold cylinder walls making starting difficult. Here are a few ways to start under difficult conditions.

• Try and keep your generator battery charged and warm. Try keeping it indoors and or warm and charged so it is ready to use when needed.
• Keep your engine warm with a block heater.
• Take advantage of the glow plug. Let it preheat the air before trying to start.
• Use the decompression leaver. Keep it open and let engine crank at full speed before releasing it.

Aurora portable diesel engines are fitted with a decompression lever. The decompression leaver enables the user to start the engine easier when it is extremely cold, when the battery is low or when bleeding the fuel system.

USE CAUTION

THE DECOMPRESSION LEVER MUST NOT BE USED TO STOP THE ENGINE EXCEPT IN EMERGENCY SITUATIONS SUCH AS RUN AWAY ENGINE OR THROTTLE DAMAGE, AS SERIOUS DAMAGE CAN BE DONE TO THE EXHAUST VALVES.

When the battery is weak or starting in extremely cold weather:

1. Pull decompression lever to release position and hold
2. Turn ignition switch to the heat postion for 20 seconds
3. Crank engine
4. After 3 to 5 seconds, when the engine has gained momentum, return decompression lever to its original position. Engine should now start.

If you require further assistance

If you require further assistance please see our other articles posted on our website.

If you require further assistance please email us first SUPPORT@EmergencyPower.com
We can often respond to your e-mail within a few minutes and will call if necessary. ( Don’t forget to include your phone number )