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Related Manuals for Baudouin M26 Series
Summary of Contents for Baudouin M26 Series
- Page 1 1003195965...
- Page 2 Operation and Maintenance Manual for PowerKit M26 Series Diesel Engine GDMB26V1901...
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Page 3: Foreword
O&M Manual for PowerKit M26 Series Diesel Engine Foreword Please be advised, do not operate or per- Safety form any operation, maintenance, or repair The Safety section of this manual covers on this PowerKit engine until you have read basic safety precautions and shows warn- and understood the information in this ings and potentially hazardous situations. -
Page 4: Table Of Contents
O&M Manual for PowerKit M26 Series Diesel Engine Foreword ..........................3 1. Safety ..........................6 1.1 Safety Information ......................6 1.2 Symbols Used ......................7 1.3 Personal Safety ......................10 1.4 Environmental Safety ....................10 1.5 Fluid Safety ......................... 11 1.6 Batteries ........................ - Page 5 O&M Manual for PowerKit M26 Series Diesel Engine 6.2 Lubricant Recommendation ..................64 6.3 Fuel Recommendation ....................66 6.4 Special Tools Recommendation ................. 67 6.5 Common Faults and Troubleshooting ................ 71 6.6 Engine Maintenance Log.................... 78 Index ..........................82...
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Page 6: Safety
Baudouin cannot anticipate or identify every possible hazard in your operating environment. Persons operating or maintaining the engine must be able to recognize haz- ardous situations, and they must have the necessary skills, training and tools to perform op- eration and maintenance activities properly. -
Page 7: Symbols Used
O&M Manual for PowerKit M26 Series Diesel Engine 1.2 Symbols Used Please take note of the warnings and precautions indicated throughout this Manual in order to avoid unsafe practices and conditions. In this Manual, the following symbols are used to high- light specific information. - Page 8 O&M Manual for PowerKit M26 Series Diesel Engine Safety symbols Symbol Definition Wear hand protection Wear ear protection Wear eye protection Wear head protection Wear foot protection Wear a protective mask Wear overalls Avoid naked flames Do not smoke Do not use a mobile phone...
- Page 9 O&M Manual for PowerKit M26 Series Diesel Engine Universal Warning The location of the Universal Warning label is illustrated below. 12M26 Series Figure 1.2-12M26 Illustration Do not operate or perform maintenance on this engine unless you have read and understand the instructions and warnings in this Operation and Maintenance Manual.
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Page 10: Personal Safety
To ensure compliance with environmental protection laws, consult your local authorities who will advise you. Obey all local regulations for the handling and disposal of liquids. The products and spare parts supplied by Baudouin do not contain asbestos. -
Page 11: Fluid Safety
O&M Manual for PowerKit M26 Series Diesel Engine 1.5 Fluid Safety All oil, fuel, and some coolant liquids are flammable. If these liquids are leaking onto hot surfaces they can cause a fire which can cause injury and/or damage. -
Page 12: Welding
O&M Manual for PowerKit M26 Series Diesel Engine The battery cables must be fitted with a battery switch and fuse or circuit breaker to isolate the circuit. Sulphuric acid contained in batteries is toxic and corrosive; it can burn clothes and skin or even cause blindness in case of contact with the eyes. -
Page 13: Electrical Risks
O&M Manual for PowerKit M26 Series Diesel Engine before welding (control cabinets, elec- trical cabinets etc.). Comply with all legal provisions in force before conducting welding work. Do not use open fires. Make sure that the work will not affect the on-board electrical and electronic equipment. -
Page 14: Lines, Tubes And Hoses
O&M Manual for PowerKit M26 Series Diesel Engine Flexible connections for cooling Flexible circuit connections fuel Electrical control systems and electronic fuel injection Earth faults can cause corrosion in the pipes and engine or genset unit compo- nents. -
Page 15: Cleaning The Engine
O&M Manual for PowerKit M26 Series Diesel Engine Slowly unscrew the coolant filler plug to release pressure. 1.11 Cleaning the Engine Use personal protective equipment when cleaning an engine. Regularly clean the engine surface to remove any greasy deposits that may be flammable. -
Page 16: General Precautions For Operation
Before removing the last two bolts, pry open the plate and gradually release the pressure. Do not remove any hydraulic components or parts until the pressure in the system has been relieved. Contact Baudouin for procedures required to remove hydraulic compo- nents. - Page 17 O&M Manual for PowerKit M26 Series Diesel Engine 1.12.2 Starting the Engine For initial start-up of a new engine, or the first start after a service, make provisions to be able to stop the engine if a fault occurs. This can be done by shutting off the fuel or air supply to the engine.
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Page 18: Product
O&M Manual for PowerKit M26 Series Diesel Engine 2. Product 2.1 Rating Definitions Rating definitions Running conditions Engines of this rating provide unlimited hours of usage in a constant 100% load. Continuous power No overload capability is allowed. -
Page 19: Engine Model
O&M Manual for PowerKit M26 Series Diesel Engine 2.2 Engine Model 2.2.1 Abbreviations M26MP: M26 with Mechanical Injection Pump 2.2.2 Engine Plate 6M26 Series Diesel engine ** ** ** **** Figure 2.2.2A-6M26 12M26 Series Diesel engine Figure 2.2.2B-12M26... -
Page 20: Engine Overview
O&M Manual for PowerKit M26 Series Diesel Engine 2.3 Engine Overview 2.3.1 Schematic Diagrams of 6M26 1-Radiator 2-Fan 3-Turbocharger 4-Flywheel Cover 5-Starter 6-Oil Sump 7-Fuel Filter 8-Fuel Pump Figure 2.3.1A-Left Side 9-Air Filter 10- Valve Cover 11-Thermostat 12-Water Pump 13-Oil Cooler... - Page 21 O&M Manual for PowerKit M26 Series Diesel Engine 2.3.2 Schematic Diagrams of 12M26 1-Radiator 2-Pre-lub Pump 3-Valve Cover 4-Turbocharger 5-Air Filter 6-Flywheel Cover 7-Starter 8-Centrifuge Filter 9-Oil Cooler 10-Oil Filter Figure 2.3.2A-Left Side 11-Water Pump 12-Oil Inlet 13-Fuel Inlet 14-Fuel Filter 15-Pre-fuel Filter Figure 2.3.2B-Right Side...
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Page 22: Cooling Circuits
O&M Manual for PowerKit M26 Series Diesel Engine 2.4 Cooling Circuits 2.4.1 Cooling Circuits for 6M26 Series Diesel Engine Overall Layout 1 -Radiator 2-Fan 3-WaterPump 4-Drain Valve 5-Oil Cooler 6-Cylinder Block Cooling 7-Cylinder Head Cooling 8-Water Outlet Pipe -Thermostat Assembly 10-Low Temp. - Page 23 O&M Manual for PowerKit M26 Series Diesel Engine 2.4.2 Cooling Circuits for 12M26 Series Diesel Engine Overall Layout 1 -Radiator 2-Fan 3-WaterPump 4-Drain Valve 5-Oil Cooler 6-Cylinder Block Cooling 7-Cylinder Head Cooling 8-Water Outlet Pipe -Thermostat Assembly 10-Low Temp. Circuits 11-High Temp.
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Page 24: Lubrication System
O&M Manual for PowerKit M26 Series Diesel Engine 2.5 Lubrication System 6M26 Series engines are equipped with a lubrication system including an oil cooler. 12M26 Series engines are equipped with a lubrication system including two oil coolers. The gear driving oil pump is located at the low front of the engine. -
Page 25: Fuel System
O&M Manual for PowerKit M26 Series Diesel Engine 2.6 Fuel System 2.6.1 Fuel circuit diagrams of 6M26 The fuel pump draws the fuel from the genset fuel tank through pre-filter/water-separator and through full flow filter to the injection pump. Injection pump delivers fuel under high pressure to the injectors. - Page 26 O&M Manual for PowerKit M26 Series Diesel Engine 2.6.2 Fuel circuit diagrams of 12M26 The fuel pump draws the fuel from the genset fuel tank through pre-filter/water-separator and through full flow filter to the injection pump. Injection pump delivers fuel under high pressure to the injectors.
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Page 27: Installation
It is essential when installing and operating diesel engines also to comply with the necessary guidelines of the local authority. S. I. Moteurs Baudouin is only liable for qualitaty defects when these installation instructions have been fully observed. Failure to comply with the installation and operating instructions defined by S. -
Page 28: Engine Lifting
O&M Manual for PowerKit M26 Series Diesel Engine 3.1 Engine Lifting 3.1.1 Lifting device Use lifting devices to lift and move heavy parts over 20kg (44 lb.). Check the condition of lifting hooks and chains. Verify the expiration date of appropriate protective equipment (goggles, gloves, shoes, masks, overalls, helmet etc.) before beginning work. - Page 29 O&M Manual for PowerKit M26 Series Diesel Engine The lifting points of M26 series engine are illustrated as followings: 6M26MP Figure 3.1.3A-6M26 Lifting 12M26MP Figure 3.1.3B-12M26 Lifting...
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Page 30: Engine Mounting
The number of engine supports must not be reduced. Flexible support between the engine and the chassis should be arranged to reduce en- gine vibration. The mounting points of M26 series engine are illustrated as followings: 6M26MP Figure 3.2A-6M26 Mounting... - Page 31 O&M Manual for PowerKit M26 Series Diesel Engine 12M26MP Figure 3.2B-12M26 Mounting...
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Page 32: Accessories
O&M Manual for PowerKit M26 Series Diesel Engine 3.3 Accessories In order to ensure satisfactory engine life and performance, the installation of pipes must meet the following criteria: The intercooler pipe and the engine are connected by a V-clamp. When in-... -
Page 33: Air Intake System
O&M Manual for PowerKit M26 Series Diesel Engine 3.4 Air Intake System The air intake system must avoid the followings entrance: Water Dust Exhaust gas. 3.5 Exhaust System The exhaust system must meet at least the following requirements: ... -
Page 34: Lubrication System
O&M Manual for PowerKit M26 Series Diesel Engine If the PowerKit is installed in a soundproof box, seal rubber is installed around the radiator to prevent the hot air in the engine compartment from flowing back into the air intake channel. - Page 35 O&M Manual for PowerKit M26 Series Diesel Engine or collapse. Both suction and return lines must be installed at the bottom of the tank and must be kept at a distance (≥300 mm) Filler port from each other, and the line must be...
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Page 36: Genset Installation Recommendations
O&M Manual for PowerKit M26 Series Diesel Engine 3.9 Genset Installation Recommendations Users must choose the genset installation location very carefully in order to not disturb anyone and not to cause noise pollution. If the location is not appropriate, enclosure has to be insu- lated for noise reduction. -
Page 37: Operation
O&M Manual for PowerKit M26 Series Diesel Engine 4. Operation The first engine commissioning process should be handled by S. I. Moteurs Baudouin ap- proved personnel. The successful completion of this process, along with the checks and ad- justments required by S. I. Moteurs Baudouin, will ensure that the engine runs efficiently, reliably, and safely. -
Page 38: Preparations Before Start
O&M Manual for PowerKit M26 Series Diesel Engine 4.1 Preparations before Start Adding of engine oil Open the oil filler cap and add the engine oil. Using the dipstick to check the oil level. Figure 4.1A-Adding of engine oil Fuel ... -
Page 39: Starting Up
O&M Manual for PowerKit M26 Series Diesel Engine 4.2 Starting Up The following starting/stopping procedure is a simple example and it’s based on a simple starting control panel equipped with starting key. Please refer to the genset and/or genset control panel use & maintenance manual for the starting operation mode. -
Page 40: Operation Of The Powerkit Engine
O&M Manual for PowerKit M26 Series Diesel Engine 4.3 Operation of the PowerKit Engine After the start of diesel engine, idle the engine for 3min, and then increase the speed to 1000r/min to 1200r/min with some load. Only when the coolant temperature is above 60º... -
Page 41: Precautions For Running In Cold Environments
O&M Manual for PowerKit M26 Series Diesel Engine 4.4 Precautions for running in cold environments Fuel: Choose a grade of diesel fuel depending on the environmental temperature. Lubricating oil: Choose lubricating oil of different viscosities depending on the seasons. -
Page 42: Stopping The Powerkit Engine
O&M Manual for PowerKit M26 Series Diesel Engine 4.5 Stopping the PowerKit Engine Avoid shutting down the engine at full load. Before the shut-down, engine load and should be reduced, and the engine should operate at ow-load condition for 3 to 5 minutes. This allows the piston, cylinder head, liner, bushing and turbocharger to cool down, avoiding cylinder and bearing damage. -
Page 43: Maintenance
O&M Manual for PowerKit M26 Series Diesel Engine 5. Maintenance 5.1 General Safety Conditions for Maintenance SAFETY WARNING Users should carefully read the safety instructions before installation and operation of the en- gine. Electrical insulation controls must NOT be done with a voltage higher than 50VDC Safety conditions for preventive and corrective maintenance operations are intended to check. -
Page 44: Maintenance Table
O&M Manual for PowerKit M26 Series Diesel Engine 5.2 Maintenance Table NOTE Hours and Months: A first-come-prevail... - Page 45 O&M Manual for PowerKit M26 Series Diesel Engine NOTE Hours and Months: A first-come-prevail...
- Page 46 O&M Manual for PowerKit M26 Series Diesel Engine NOTE Hours and Months: A first-come-prevail...
- Page 47 O&M Manual for PowerKit M26 Series Diesel Engine NOTE Hours and Months: A first-come-prevail...
- Page 48 O&M Manual for PowerKit M26 Series Diesel Engine NOTE Hours and Months: A first-come-prevail...
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Page 49: Maintenance Operations
O&M Manual for PowerKit M26 Series Diesel Engine 5.3 Maintenance Operations 5.3.1 MD Maintenance Operations Check the coolant level Inspection window Check the level by eyes. Coolant level sensor Check the level on control panel. Level gauge. - Page 50 O&M Manual for PowerKit M26 Series Diesel Engine Check the fuel level Check the fuel level with fuel meter or fuel gauge, which is installed in the side of the fuel tank. If the fuel is not enough, add fuel through fuel filler to fill the tank.
- Page 51 O&M Manual for PowerKit M26 Series Diesel Engine Check the belt The belt is automatically tensioned with a tensioner. Inspect the alternator belt and the fan drive belts for wear and for cracking. Replace the belts if the belts are not in good condition as shown A and B.
- Page 52 O&M Manual for PowerKit M26 Series Diesel Engine Check if the operating sound of diesel engine is in normal condition. Note any abnormal sounds and troubleshoot as necessary. Check if the vibration of diesel engine is in normal condition, and if the speed is stable.
- Page 53 O&M Manual for PowerKit M26 Series Diesel Engine 5.3.2 M1 Maintenance Operations Replace the fuel water separator Drain the water from water col- lecting vessel. Remove the Screw 1 from the wa- ter collecting vessel. Remove the fuel filter element.
- Page 54 O&M Manual for PowerKit M26 Series Diesel Engine Simple overall check Check the hose clamps Check the hoses and lines Replace engine oil Run engine to warm oil slightly. Stop engine. Loosen drain nut 2. Drain oil into the container.
- Page 55 O&M Manual for PowerKit M26 Series Diesel Engine Replace oil cartridges Remove oil filters by hand. Clean filter seat. to be done with EVERY oil change Lubricate seal ring on new filter with a small amount of clean en- gine oil.
- Page 56 O&M Manual for PowerKit M26 Series Diesel Engine Clean the condensing draining pipes Check whether the drain valve is normal or not, clean it up if there is a blockage. Check leaks, oil, coolant and fuel levels with engine running ...
- Page 57 O&M Manual for PowerKit M26 Series Diesel Engine Replace fuel cartridges Remove oil filters by hand. Clean filter seat. Lubricate seal ring on new filter with a small amount of clean en- gine oil. Tighten the filter by hand, till the seal surface meets the interface.
- Page 58 O&M Manual for PowerKit M26 Series Diesel Engine 5.3.3 M2 Maintenance Operations M2 maintenance operations include ALL M1 MAINTENANCE OPERATIONS and the follow- ings: Clean the intercooler, air and water side (if equipped) Air Side. To clean the fins, immerse the stack in a tank containing a de- greasant solution.
- Page 59 O&M Manual for PowerKit M26 Series Diesel Engine Clean the radiator and cooling system Clean the oil cooler(s) Use steam to clean the oil cooler core. This removes any remaining residue from the cleaner. Flush the fins of the oil cooler core. Remove any other trapped debris ...
- Page 60 O&M Manual for PowerKit M26 Series Diesel Engine 5.3.4 M3 Maintenance Operations M3 maintenance operations include ALL M1 MAINTENANCE OPERATIONS, ALL M2 MAINTENANCE OPERATIONS and the followings: Check tightness of hoses and hose clamps Check conditions and tightness of elec- trical connections(if equipped) ...
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Page 61: Engine Maintenance For Long-Term Storage
O&M Manual for PowerKit M26 Series Diesel Engine 5.4 Engine Maintenance for Long-term Storage 5.4.1 Preparing the Engine for Long-term Storage In the case of a long-term storage that lasts longer than two months, to prevent the interior parts of the engine and some components of the injection system from oxidizing, prepare the engine as follows: ... - Page 62 O&M Manual for PowerKit M26 Series Diesel Engine 5.4.2 Engine Start-up after Long-term Storage Drain the residual 30/M protective oil from the sump. Add the type and quantity of lubricant oil to the engine as specified in the REFILLING table.
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Page 63: Appendix
45% glycol content is the minimum required values to maintain the best boiling temperature. Additives of Cooling Circuits These products are designed to prevent or clean coolant circuits from contaminants by greasy and oily materials. Please ask your S. I. Moteurs Baudouin Distributor. -
Page 64: Lubricant Recommendation
Lubricant grade for the engine Present lubricant certification process according to API and ACEA standards is adequate to guarantee adequate quality and performances. Therefore S. I. Moteurs Baudouin requires use of following lubricants: API CI-4 or ACEA E7 15W40 ... - Page 65 O&M Manual for PowerKit M26 Series Diesel Engine Viscosity and temperature properties specification High-temperature and Low-temperature Viscosity （100℃） high-shear viscosity Pour point/℃ ≤ Project kinematic viscosity （150℃, 10 ） /mm² /s /mPa· s(℃）≤ /mPa· s ≥ Test method SH/T 0618...
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Page 66: Fuel Recommendation
O&M Manual for PowerKit M26 Series Diesel Engine 6.3 Fuel Recommendation IMPORTANT: Improper fuel additive usage may cause damage to fuel injection equipment of diesel engines. Quality Grade Use commercially available diesel fuel with less than 0.35% Sulphur content. If the sulfur content is higher than 0.5%, oil change intervals should be halved. -
Page 67: Special Tools Recommendation
O&M Manual for PowerKit M26 Series Diesel Engine 6.4 Special Tools Recommendation Name 3D Model Piston Cylinder Guide Barring Tool 6M26 Rear Oil Seal Installer 12M26 Rear Oil Seal Installer M26 Front Oil Seal Installer... - Page 68 O&M Manual for PowerKit M26 Series Diesel Engine Name 3D Model Flywheel brake Cylinder liner installer Flywheel hanger tool Camshaft mounting tool (material aluminum) Valve Collet Assembling Tool...
- Page 69 O&M Manual for PowerKit M26 Series Diesel Engine Name 3D Model Rolling out tool Shock absorber guide bar Piston extraction tool Injector removal tool Injector Bush tool...
- Page 70 O&M Manual for PowerKit M26 Series Diesel Engine Name 3D Model 21# The party tools Camshaft Bush Installer...
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Page 71: Common Faults And Troubleshooting
O&M Manual for PowerKit M26 Series Diesel Engine 6.5 Common Faults and Troubleshooting Diesel engine cannot be started. Causes Troubleshooting Check and eliminate electrical wiring The starter motor does not work. fault. Ambient temperature is too low. Use starting aid. - Page 72 O&M Manual for PowerKit M26 Series Diesel Engine Insufficient engine power. Causes Troubleshooting Check the air filter and intake pipe. Intake system (air filter) is clogged. Clean or replace the filter element. Check and adjust the valve timing. Exhaust back pressure is too high.
- Page 73 O&M Manual for PowerKit M26 Series Diesel Engine Excessive fuel consumption. Causes Troubleshooting Check the air filter and intake pipe for Intake system clogged. clogging. Remove clogging if any. Exhaust back pressure is too high. Check and clean the exhaust pipe.
- Page 74 O&M Manual for PowerKit M26 Series Diesel Engine Engine exhaust gas is white or blue. Causes Troubleshooting Poor fuel quality with excessive moisture. Replace fuel. Check the working temperature of the Coolant temperature is too low. thermostat. Replace it if necessary.
- Page 75 O&M Manual for PowerKit M26 Series Diesel Engine Oil pressure is too low. Causes Troubleshooting There is no oil in oil pan or oil is insufficient. Add oil as required. Engine oil grade is not compliant. Replace with compliant engine oil.
- Page 76 O&M Manual for PowerKit M26 Series Diesel Engine Parts wear too fast. Causes Troubleshooting Check and replace the air filter ele- Air filter element is unqualified or damaged. ment. Check the intake pipe, gasket and Short circuit of air intake system.
- Page 77 O&M Manual for PowerKit M26 Series Diesel Engine Starter motor does not work. Causes Troubleshooting Fuse burnt. Replace the fuse. Check the circuit and tighten the Poor contact of circuit. terminals. Insufficient charge of battery. Check, recharge or replace battery.
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Page 78: Engine Maintenance Log
O&M Manual for PowerKit M26 Series Diesel Engine 6.6 Engine Maintenance Log... - Page 79 O&M Manual for PowerKit M26 Series Diesel Engine...
- Page 80 O&M Manual for PowerKit M26 Series Diesel Engine Current Frequency Preventive Overhaul Note Maintenance Operating Hours Hours Visa or Date / Period / Period stamp...
- Page 81 O&M Manual for PowerKit M26 Series Diesel Engine Current Frequency Preventive Overhaul Note Maintenance Operating Hours Hours Visa or Date / Period / Period stamp...
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Page 82: Index
O&M Manual for PowerKit M26 Series Diesel Engine Index Abbreviations ........................19 Before any operation or maintenance on any Baudouin product ........16 Cooling Circuits for 6M26 Series Diesel Engine Overall Layout ........22 Cooling Circuits for 12M26 Series Diesel Engine Overall Layout ........23 Engine Plate ........................ - Page 83 O&M Manual for PowerKit M26 Series Diesel Engine Contact Us Address: Moteurs Baudouin, Technoparc du Bregadan, 13260 Cassis, France Website: Baudouin.com Aftersales Service Center: sav@baudouin.com ©2018 Société International des Moteurs Baudouin All Rights Reserved...