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Baudouin PowerKit 6M12 Series Operation And Maintenance Manual

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Operation and Maintenance Manual
PowerKit 6M12 Series Diesel Engine

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Summary of Contents for Baudouin PowerKit 6M12 Series

  • Page 1 Operation and Maintenance Manual PowerKit 6M12 Series Diesel Engine...
  • Page 3 (for example guards and covers may be removed), and some equipment shown in The use of Baudouin Genuine Spare Parts is this manual may be different to your engine. imperative to the optimal operation, perfor- For the latest information, please contact mance and longevity of your PowerKit en- your local Baudouin representative.

  • Page 4: Table Of Contents

    Content Foreword ..........................2 1. Safety ..........................1 1.1 Safety Information ......................1 1.2 Symbols Used ......................2 1.3 Personal Safety ......................5 1.4 Environmental Safety ....................5 1.5 Fluid Safety ........................6 1.6 Batteries ........................6 1.7 Welding ......................... 7 1.8 Electrical Risks ......................
  • Page 5 Content 5.3 Maintenance Operation ....................50 5.4 Storage Protection Instruction ..................81 6. Appendix ........................88 6.1 Coolant Recommendation ..................88 6.2 Lubricant Recommendation ..................89 6.3 Fuel Recommendation ....................91 6.4 Common Faults and Troubleshooting ................ 93 6.5 Engine Maintenance Log................... 115 6.6 Recommended Torques for Bolts ................

  • 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: Foreword

    Safety 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. HAZARD WARNING This warning symbol is recognized across the world.
  • Page 8 Safety 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 Keep an extinguisher close by Danger: battery acid Danger: live cables, electrical risks Highly flammable products...
  • Page 9 Safety Universal Warning The location of the Universal Warning label is illustrated below. 6M12 Series ◼ Figure 1.2 - 6M12 Series Engine Do not operate or perform maintenance on this engine unless you have read and understood the instructions and warnings in this Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in serious injury or death.

  • 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

    Safety 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. ◼ Do not check for leaks using any body part.

  • Page 12: Welding

    Safety ◼ 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

    Safety 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

    Safety ◆ 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. 1.9 Lines, Tubes and Hoses ◼...

  • Page 15: Cleaning The Engine

    Safety engine has stopped. ◼ 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 Safety 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.

  • Page 18: Recommendations For Engines Equipped With Common Rail System

    Safety 1.13 Recommendations for Engines Equipped with Common Rail System ◼ Wear personal protective equipment (PPE) where required. ◼ High-pressure fuel spray can cause irreversible body damage. Wear required protection when conducting operations on the entire circuit. Make sure that the lines are depressurized before any dismantling operations. ◼...

  • Page 19: Product

    Product 2. Product 2.1 Rating Definitions Rating definitions Running conditions ◼ Annual running time is unlimited. ◼ Continuous rated power is allowed. Continuous power ◼ No overload ability. ◼ Annual running time is unlimited. ◼ The average load rate is no more than 70% during a range of 24 hours.

  • Page 20: Engine Model

    Product 2.2 Engine Model 2.2.1 Model Definition Product Model of Baudouin Industrial Engine 2.2.2 Product Series Code Product series Code is comprised by Cylinder Number, Product Code for Baudouin (M) and Displacement per Cylinder. 2.2.3 Application Code Code Application Land Power Generation Land Power Generation for Tele com Variable speed models (Pump, Air pressure…)
  • Page 21 Product 2.2.5 Speed Code 3000 1500 1800 1500 & 1800 Code Engine speed is only used for gen-set application using, and is shown as table, the speed code for other application will not be used. 2.2.6 Emission Stage Codes Emission Stage Code Non-road No emission certification U.S.
  • Page 22 Product 2.2.8 Engine Plate Figure 2.2.8 - Engine Name Plate...

  • Page 23: Engine Overview

    Product 2.3 Engine Overview Below figures are schematic diagrams of 6M12. 1-PCV 2-Air intake manifold 3-Common rail 4-ECU 5-Air exhaust pipe 6- Alternator 7-Engine lifting eye 8-Belt 9-Cooling fan 10-Vibration absorber 11-Engine mount 12-Oil filter 13-Fuel pre-filter 14-Fuel filter 15-HP fuel pump Figure 2.3.1 - Right Side 16-Flywheel house 17-Fuel outlet...

  • Page 24: Cooling Circuits

    Product 2.4 Cooling Circuits Figure 2.4 is overall layout of cooling circuit for 6M12 series diesel engine. Figure 2.4 – Cooling Circuit Diagram Part name Part name Coolant pump inlet Coolant through oil cooler Coolant before cooling cylinder liner Coolant for cooling cylinder liner Coolant flowing to cylinder head from liner Coolant for cooling cylinder head Coolant after cooling cylinder head...

  • Page 25: Lubrication System

    Product 2.5 Lubrication System Following is overall layout of lubrication circuit for 6M12 series diesel engine. Figure 2.5 – Lubrication Circuit Diagram Part name Part name Oil sump Oil suction port filter Oil pump Safety valve Oil cooler Bypass valve Oil filter Bypass valve Oil passage...

  • Page 26: Fuel System

    Product 2.6 Fuel System Overall Layout of Fuel Circuit for 6M12 Series Diesel Engine is in below figure. Figure 2.6 – Fuel Circuit Diagram Part name Part name Fuel inlet High pressure fuel pump Fuel feed pump Fuel filter Fuel pre filter Fuel injector Pressure release valve of common rail Common rail...

  • Page 27: Electronic Control Unit (Ecu)

    Each slot has 76 pins. The engine wire harness includes harness of sensors, fuel injectors and fuel metering unit, which have been installed by Baudouin. The genset side wire harness includes the functional pins, and OEM connects the wire har- ness according to the functions they need.
  • Page 28 Product Operating conditions ◼ Rated voltage: ECU power supply voltage: 28V ECU grounding voltage: 0V ◼ Power supply voltage: Normal operating voltage range: 9-32V Low working voltage range: 6.5-9V, the ECU function is degraded, only the starting condition can be satisfied. Waterproof and dustproof The PCB is firmly glued to the housing using a silicone sealant.
  • Page 29 Product to it. The ECU must not be used in the genset and has to be scrapped after a mechanical in- cidence. Water or other liquids are prohibited to enter the ECU pin and connector. Welding of ECU is prohibited. In case of welding operation of the genset, it is required to dis- connect the battery positive and negative electrode, and to meet the welding point and welding gun in the case of the ECU on the side of the rail, not to remove the ECU genset connector.
  • Page 30 Product Electrical connection to the ECU ◼ ECU power line Pin No.: X1-01, X1-03, X1-05 (positive), X1-02, X1-04, X1-06 (negative) ◆ Functional description: ECU main power (24V DC) ◆ ◆ Operating voltage range: 9-32V A 25 Ampere fuse is to be included in the positive line to the ECU Wire diameter: 10mm Wire length (recommended): <6m...
  • Page 31 Product ⚫ Second start protection: if the engine is already started but ECU receives a start signal, the starter relay will not respond. Prevent blind meshing and starting time control: When the starter fails to drive ⚫ the crankshaft to a certain speed within a certain period of time, ECU will think that the starter and the flywheel are not engaged, and the relay will be discon- nected.
  • Page 32 Product ◼ Dual frequency switch (Optional function) ◆ Pin No.: X1-55, X2-24 (24V from engine side 2P connector) Functional description: It is a changeover switch between 50 Hz power generation ◆ mode and 60 Hz power generation mode. ◼ Idle to rated switch (Optional function) ◆...
  • Page 33 Product ◆ Functional description: ECU senses the ambient temperature based on the temper- ature sensor on the engine and automatically controls the operation of the intake grid heater via the intake air heating relay to facilitate cold start. When the intake air heating is working, the light will stay on.

  • Page 34: 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 quality defects when these installation instructions have been fully observed. Failure to comply with the installation and operating instructions defined by S.

  • Page 35: Engine Lifting

    Installation 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 36: Engine Mounting

    Installation The lifting eyes of 6M12 series engine are illustrated as followings: Figure 3.1.3 - 6M12 Lifting Eyes 3.2 Engine Mounting In order to ensure the durability of the engine installation, the installation of the engine must meet the following criteria: ◼...

  • Page 37: Accessories

    Installation Figure 3.2 - 6M12 Mount 3.3 Accessories In order to ensure satisfactory engine life and perfor- mance, the installation of pipes must meet the following criteria: ◼ The intercooler and radiator are connected with en- gine by heat and pressure resistant rubber hoses. These rubber pipes are fixed by T-bolt type clamps.

  • Page 38: Exhaust System

    Installation 3.5 Exhaust System The exhaust system must meet at least the following requirements: ◼ Exhaust back pressure must not exceed the limits in the engine data sheet. ◼ Exhaust system components should not exert excessive stress on the exhaust manifold or turbocharger due to their own weight, inertia, relative movement between components, or dimensional changes due to thermal expansion.

  • Page 39: Cooling System

    Installation 3.6 Cooling System In order to ensure satisfactory engine life and performance, the installation of the radiator must meet the following criteria: ◼ When installing the radiator, install the elastic support. Figure 3.6 - Elastic Support ◼ 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 40 Installation ◼ The device should be set up to periodically drain the condensed water in the fuel tank and the filter, and signs should be placed to remind the user of such. The fuel tank has ventilation function to prevent the pressure inside the tank from being ◼...

  • Page 41: Electrical Components

    Installation 3.9 Electrical Components 3.9.1 Start-up Circuit ◼ Wire size of starting main cable: ≥ 70mm ◼ Wire size of battery negative terminal ground wire: ≥70mm ◼ Wire size of starting system control end cable: ≥1.5mm ◼ The wiring terminals of starter shall be equipped with protective caps.
  • Page 42 Installation 3.9.2 Charging Circuit ◼ The charging cable shall be a complete cable without intermediate connector. ◼ Terminals of B+/D+/W shall be provided with protective caps. ◼ Working environment temperature: -40°C~105°C. ◼ The maximum leakage current: 2mA. Rated alternator speed 6000rpm, maximum operating speed 12000rpm. ◼...

  • Page 43: Genset Installation Recommendations

    Installation 3.10 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 have to be insu- lated for noise reduction. Also, the correct type of exhaust silencer must be used if necessary. The genset room should be well ventilated.

  • Page 44: Operation

    Operation 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 45: Preparations Before Start

    Operation 4.1 Preparations before Start Engine oil ◼ Adding of engine oil ◆ Open the oil filler cap and add proper engine oil which was de- scribed in appendix. ◆ Using the dipstick to check the oil level. Figure 4.1.1 - Adding of Engine Oil Fuel ◼...

  • Page 46: Starting Up

    Operation Note! After the genset is installed in site, please make sure must remove all long adjust- ment bolts of bellows before starting the genset. 4.2 Starting Up The following starting/stopping procedure is a simple example (not binding) and it’s based on a simple starting control panel equipped with starting key.

  • Page 47: Operation Of The Powerkit Engine

    Operation 4.3 Operation of the PowerKit Engine ◼ After the start of diesel engine, idle the engine for 3min. Only when the coolant tempera- ture is above 60ºC, can the engine run with full load. Increasing the load and speed gradually is important.

  • Page 48: Precautions For Running In Cold Environments

    Operation 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. ◼ Coolant: Add antifreeze additive into the cooling system and choose the coolant of differ- ent grades depending on the ambient temperature.

  • Page 49: Stopping The Engine

    Operation 4.5 Stopping the Engine Avoid stopping the engine with a full load. Before stopping, reduce load and run engine in idle for 3 to 5 minutes. This allows the piston, cylinder head, cylinder liner, bearing and turbo- charger to cool down, avoiding damage. This is particularly important for turbocharged engines. When engine stops suddenly, the turbocharger temperature will increase suddenly, which damages the bearing and the oil seal.

  • Page 50: Electronic Control System

    Press the diagnostic switch, and then turn on the T15. Keep pressing the diagnostic switch for 30s before releasing. ◼ Current faults cannot be cleared unless you have resolved it. Ask your local Baudouin representative for help as soon as possible if you need.

  • Page 51: Maintenance

    Maintenance 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 52: Maintenance Table

    Maintenance 5.2 Maintenance Table MOTEURS BAUDOUIN • Check = Mandatory maintenance, in working hours (H) or period о Adjust = (months - M), every, which occurs first Δ Clean = □ Replace = Hours 1,000 2,000 4,000 8,000 12,000 OPERATION Months •...
  • Page 53 Maintenance MOTEURS BAUDOUIN • Check = Mandatory maintenance, in operation working hours о Adjust = (H) or period (months - M), every, which occurs first Δ Clean = □ Replace = Hours 1,000 2,000 4,000 8,000 12,000 OPERATION Months □...
  • Page 54 Maintenance MOTEURS BAUDOUIN • Check = Mandatory maintenance, in operation working hours о Adjust = (H) or period (months - M), every, which occurs first Δ Clean = □ Replace = Hours 1,000 2,000 4,000 8,000 12,000 OPERATION Months Δ...

  • Page 55: Maintenance Operation

    Maintenance 5.3 Maintenance Operation NOTE! Before performing any maintenance work, the engine must be turned off and have cooled off, the battery main switch must be switched off and the ignition key removed, put ‘Do not start the engine’ sign aside the gen-set. 5.3.1 MD Maintenance Operations ◼...
  • Page 56 Maintenance ◼ Filling Coolant NOTE! Do not let coolant drip or leak out onto the ground or into the bodies of water while filling. Otherwise, the environment will be damaged. The engine's cooling system is to be filled with a mixture of coolant, glycol, and special additives .Never add the normal plain water only.
  • Page 57 Maintenance ◆ Close cap. ◆ Run engine for apporx.15 minutes at rated speed. Check the coolant level gauge. If it is ◆ need to fill, shut off engine and care- fully unscrew cap with safety valve to the first stop to release pressure. Let the engine cool down, and then fill the coolant.
  • Page 58 Maintenance ◼ Check the fuel NOTE! Do not allow dirt to enter the fuel system. Before disconnecting any part of the fuel system, thoroughly clean around the connection. When a component has been disconnected, for example a fuel pipe, always fit protective covers and plugs to prevent dirt ingress.
  • Page 59 Maintenance ◼ Check the oil level NOTE! Check the oil level when the engine is stopped. Check the oil level when engine has been stopped for at least 20 minutes. ◆ Pull out oil dipstick. ◆ Wipe off oil dipstick with a lint-free cloth.
  • Page 60 Maintenance ◼ Check the fuel water separator Note! Before handling fuel, make sure there is no flame or heat source in the area. Wipe spilled fuel thoroughly. Spilled fuel can cause a fire. Check the water collecting vessel, draining water as follows: ◆...
  • Page 61 Maintenance ◼ Check the belt tension NOTE! Slippage of loose belts can reduce the efficiency of the driven components. Vibration of loose belts can cause unnecessary wear on the belts, pulleys, and the relevant bear- ings. ◆ If the belt is equipped with an auto tensioner, pull on the belt and check the tensioner is moving.
  • Page 62 Maintenance ◼ Check the fan NOTE! Do not rotate the engine by pulling or moving the fan. Otherwise, it will damage the fan blades, cause fan failure and cause personal injury or property loss. The crankshaft should be rotated using an accessory drive shaft or crankshaft turning tool.
  • Page 63 Part ANNEX. ◆ If the problem cannot be solved, consult your Baudouin dealer in time. ◼ Inspect the exterior of the engine to make sure there is no fuel, oil and coolant leakage, if a fuel or oil leak is found, please stop the engine.to check and repair.
  • Page 64 Maintenance ◼ Check the air cleaner service indicator (if equipped). If equipped with a dust indicator, ◆ con-duct maintenance only when the clog warning sign appears. Figure 5.3.1.14 ◆ A red signal appears as a warning when the air cleaner element be- comes clogged and causes an ab- normally large pressure difference between be-fore and after the air...
  • Page 65 Maintenance ◼ Check the air inlet pipe Check the air inlet pipe daily for wear and damage, loose clamp and small holes, which may cause engine damage. If necessary, replace the damaged pipe and tighten the loose clamp to prevent leakage of the air system.
  • Page 66 Maintenance ◼ Check the battery, battery electrolyte level, battery charger, battery cables Note ！ Clean the top surface of the battery after performing maintenance work. Dust on the battery may cause short-circuit. Before inspecting or servicing any electrical component, disconnect the ground cable from the negative (-) battery to prevent short-circuits and fire.
  • Page 67 Maintenance 5.3.2 M1 Maintenance Operations ◼ Replace the fuel water separator NOTE ！ Fuel is flammable. If these liquids are leaking onto hot surfaces they can cause a fire which can cause injury and/or damage. ◆ Clean the area around the fuel water separator;...
  • Page 68 Maintenance Apply oil (instead of lubricating ◆ grease) onto the sealing gasket and fill the filter with clean fuel. Figure 5.3.2.4 ◆ Screw the filter by hand until the seal combines with the port; Con- tinue to screw the filter by hand until the filter is securely installed (by about 3/4 round).
  • Page 69 Maintenance ◼ Check the hose clamps ◆ Inspect all clamps, tighten any loose clamps. Make sure there is no crack on clamps. ◼ Check the hoses and lines ◆ Inspect any loose or damaged of lines; tighten all connections to the recommended torque.
  • Page 70 Maintenance ◼ Replace engine oil Note! Be careful when draining hot engine oil. Hot engine oil can cause burns to un-protected skin. Comply with applicable rules and regulations for the work place. Obey environ- mental regulations for the disposal of used oil. To perform this operation with warm engine, to get a better fluidity of the oil and get a full discharge of oil and impurities contained it.
  • Page 71 Maintenance ◆ Check the oil level after finished; refer to “Engine oil check”. And re- tighten the lubricant oil cap. ◆ Start engine and let it run at slow idle for 1 minute. Check for oil leaks at engine oil filter. Tighten only enough to stop leaks.
  • Page 72 Maintenance ◼ Clean the air filter(s), replace if needed Note! Never start the engine without the air filter as this could cause injury and severe engine damage. A dirty and blocked air filter will reduce the amount of air entering the engine which can cause black smoke and weak power.
  • Page 73 Maintenance ◼ Check defaults recorded in ECU(if equipped) Reading the fault code via the di- ◆ agnostic smart. Contact Baudouin dealer for the diagnostic smart purchasing and using. Figure 5.3.2.17 ◆ Refer to "List of fault codes" to find the text explanation corresponding to each fault code and you can determine the current fault.
  • Page 74 Maintenance ◼ Replace fuel cartridges Note! When handling fuel, make sure there are no flames or heat source in the area. Spilled fuel can ignite and cause fire. Wipe any spilled fuel completely. Do not allow dirt to en- ter the fuel system. Clean thoroughly the area around fuel system component that is disconnected.
  • Page 75 ◆ When cleaning the engine, keep water away from electrical parts. ◆ If malfunctioning of electrical parts is suspected, consult a Baudouin dealer. Figure 5.3.2.21 ◆ Also, do not use disassembled or reassembled electrical parts. ◼...
  • Page 76 Maintenance 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) ◆ Check that the intercooler is not clogged on the air side and that the cooling fins are not damaged.
  • Page 77 Refer to the Repair manual or your Baudouin distributor for the complete clearance checking and adjustment procedure. Operation with incorrect valve system clearance can reduce engine efficiency, and also reduce engine component life.
  • Page 78 Maintenance 5.3.4 R1/R2 Repair Operations ◼ Change Belt Note! The fan belt idler is under tension. Do not allow your hands to get between the idler and the belt or the fan hub. Personal injury can result. Remove the grid of radiator, and then ◆...
  • Page 79 Figure 5.3.4.4 ◆ Inspect the turbocharger compressor impeller blades for damage. Contact a Baudouin authorized service center if damage is found. ◆ Care must be taken to the air filters. For if the impellor was polluted, the...
  • Page 80 Maintenance ◆ Measure radial clearance (side-to-side) at the compressor impeller nose using a dial indicator. In case that the clearance to radial directions exceeds values above, replace or repair the turbo- charger. Figure 5.3.4.7...
  • Page 81 Replace the Coolant Note! For information regarding the disposal and the recycling of used coolant, consult your Baudouin dealer. Stop the engine and allow the engine to cool. Ensure that the engine will not start when the cooling system is drained.
  • Page 82 Maintenance ◆ Shut the engine OFF, allow it to cool to 50°C, and drain the cooling system. If the water drained is still dirty, the system must be flushed again until the water is clean. ◆ Open low temperature circuit and assemble the thermostat.
  • Page 83 Maintenance 5.3.5 Overhaul Operations 5.3.5.1 Overhaul Information An overhaul is replacing the major worn components of the engine. An overhaul is a mainte- nance interval that is planned. The engine is rebuilt with certain rebuilt parts or new parts that replace the worn parts.
  • Page 84 Maintenance ◼ In-Structure overhaul Some components that wear are replaced. The condition of components is inspected. Those components are replaced, if necessary. The recommendations of parts for in-structure overhaul is as followed: Clean/ Inspect /Test ➢ ➢ Condition of the cylinder head seating Perform sealing pressure test of cylin- in the plane of the cylinder head gasket der heads...
  • Page 85 Maintenance Other factors must also be considered for determining a major overhaul: ◆ Power output ◆ The service hours of the engine ◆ Reduced oil pressure ◆ The wear metal analysis of the lube oil ◆ An increase in the levels of noise and vibration An increase of wear metals in the lube oil indicates that the bearings and the surfaces that wear may need to be serviced.

  • Page 86: Storage Protection Instruction

    Maintenance 5.4 Storage Protection Instruction 5.4.1 Necessity of Anti-rust Protection If your engine is out of operation and using, and is not expected in short term, precautions should be taken to protect your engine from damage and ensure proper operation when you return to full production.
  • Page 87 Maintenance ◼ Up to three months Each week operate the engine until the normal temperature of operation is reached. If the engine cannot be operated, turn the crankshaft by hand, in the normal direction of rotation (anti-clockwise as seen on the flywheel), a minimum of three revolutions. 5.4.5 Necessary Materials Calibration oil ◼...
  • Page 88 Maintenance ◼ Sprayer Load the VCI oil dilution into the sprayer, then can be used to prepare the engine for storage. Change the nozzle adjustment in order to provide either a spray or a fog pattern. VCI oil dilution: mixture of 50 percent VCI oil and 50 percent engine oil. ◼...
  • Page 89 Maintenance be diluted according the instruction of suppliers. Note! If the stored engine will be subjected to below freezing temperatures, completely ◆ drain the fresh water system. The system can be drained by removing the drain plugs from the engine block, oil cooler, heat exchanger body, and radiator. ◆...
  • Page 90 Maintenance Fuel tank Open the fuel tank drain valve and allow any water or dirt to drain from inside the fuel tank. Apply a VCI oil of 30 ml per 30 L (1 oz per 7.50 gal) of fuel tank capacity to prevent rust in the fuel tank.
  • Page 91 Maintenance Alternator Cover the alternator in mouldable waxed paper, and seal with adhesive tape. Engine wiring harness Clean engine wiring harness, and keep dry. ◼ The others V-belt Loosen all the belts (tension, fan, alternator, etc.). Flywheel Spray a thin amount of VCI oil mixture on the flywheel, ring gear teeth, and starter pinion. In- stall the covers to keep in the VCI vapors.
  • Page 92 Maintenance ◆ Please assemble all the others parts back in engine. 5.4.8 Initial Running after Storage The purpose of this operational check is to ensure that the correct pressures and temperatures are kept in the lubrication, cooling, and fuel systems. Also, the operation ensures that any leaks are corrected.

  • Page 93: Appendix

    (chemical and galvanic). It improves also boiling temperature, resistance to rust and avoids scale deposit formation. The coolant used in Baudouin engines should meet the ASTM D6210 standard, and the ◼ coolant used in Baudouin engines should not contain 2-ethylhexanoate, which has compatibility problems with silicone rubber.

  • Page 94: 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 95 Appendix Viscosity and temperature properties specification High-temperature and Low-temperature high-shear viscosity Viscosity （100℃） Project kinematic viscosity Pour point/℃ ≤ /mm²/s （150℃, 10 ） /mPa·s(℃）≤ /mPa·s ≥ Test method SH/T 0618 SH/T 0703 GB/T 265 SH/T 0751 GB/T 6538 GB/T 3535 ASTM D-445 CECL-36-T-84 ASTM D5293...

  • Page 96: Fuel Recommendation

    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. The following fuels can be used on Baudouin engine: --- European standard EN 590. --- ASTM D-975 --- BS 2869 Part 1 Class A 1 standard ◼...
  • Page 97 The proper pour point is essential for engine start-up and running performance. If diesel fuel with proper pour point is unavailable, Baudouin recommends using fuel heater to resolve the wax problem. Fuel heater is a low cost solution in most application.

  • Page 98: Common Faults And Troubleshooting

    Appendix 6.4 Common Faults and Troubleshooting 6.4.1 Troubleshooting ◼ Engine Turns, But It Does Not Start Table 6-1 Engine turns, but it does not start Problem Cause Remedy (1) No fuel supplied to fuel injection pump Bleed air from fuel filter and fuel feed pipes, and inspect a) Air trapped in fuel supply each part for damage and air...
  • Page 99 Appendix Check relation of movement a) Fuel lever does not open with fuel lever, and disas- fully semble and repair if defec- tive. b) Seized tappet in fuel injec- Check for uneven movement, tion pump and disassemble and repair, or replace. c) Worn tappet roller or cam- shaft in fuel injection pump Replace, if worn.
  • Page 100 Appendix a）Sticking of needle valve in Check with nozzle tester, and fuel injection nozzle, or im- disassemble and repair, or proper valve seat sealing replace. Using nozzle tester, adjust b）Low fuel injection nozzle adjustment screw so that fuel valve opening pressure is injected at specified valve opening pressure.
  • Page 101 Appendix ◼ Engine Does Not Turn Table 6-2 Engine does not turn Problem Cause Remedy a）Malfunction of starting Inspect starting valve, and valve repair or replace A： Malfunction of starting air b）Starting air pressure lower Check air tank pressure, and system than specified increase pressure if low...
  • Page 102 Appendix Check for valve, valve guide a）Valve remaining open. sticking and valve clearanc- es, and repair. b）Inlet/exhaust valve not Disassemble and correct by contacting valve seat proper- lapping valve in valve seat, or replace if necessary. Disassemble and repair, or c）Broken inlet/exhaust valve replace if necessary.
  • Page 103 Appendix ◼ Engine Knocks Table 6-4 Engine knocks Problem Cause Remedy A：Engine knocks slightly Refer to C-(1) Table 6-1 Fuel injection timing too re- and emits black exhaust tarded smoke B：Knocking is severe, and Fuel injection timing is too exhaust smoke is white advanced Refer to C-(1)
  • Page 104 Appendix d)Piston hitting foreign item Disassemble and inspect. fallen inside cylinder H：Low compression tem- perature and retarded igni- Operate engine until it tion cause severe knocking, Engine too cold warms up before increasing especially after engine engine speed starts in cold weather ◼...
  • Page 105 Appendix Inspect, and repair or replace c）Improper spray of fuel by as described in C-(2) Table fuel injection nozzles Inspect, and repair or replace d）Low engine compression as described in C-(2) Table e）Large amount engine oil Inspect and repair or replace rising above pistons as described in Table...
  • Page 106 Appendix Disconnect oil pressure gage f) Defective oil pressure gage pipe. If oil pours out, replace oil pressure gage a) Clogged oil filter element Disassemble, clean, replace B：Oil pressure drops Oil temperature rises and gradually during operation causes oil pressure to drop. b) Engine oil viscosity too low Change oil to one with higher viscosity...
  • Page 107 Appendix 6.4.2 Diagnostic Fault Codes List for 6M12 Description Code P- code P2519 Fault path of air condition power stage 3-1-3 P2519 P060B P060B Error status of ADC monitoring 1-1-1 520192 P060B P060B P0123 Fault path of Accelerator Pedal 1 2-2-1 P0122 P2135...
  • Page 108 Appendix Description Code P- code Fault path for short circuit to battery for BPA power 3-4-4 1192 P0048 stage Fault path for short circuit to ground for BPA power 3-4-4 1192 P0047 stage P0045 Fault path for no load and excess temperature for 3-4-4 1192 BPA power stage...
  • Page 109 Appendix Description Code P- code Coolant temperature sensor absolute test 2-4-5 520198 P0116 Coolant temperature sensor dynamic test 2-4-5 520198 P0116 Error path for Misfire cylinder 1 5-1-1 1323 P0301 Error path for Misfire cylinder 2 5-1-2 1324 P0302 Error path for Misfire cylinder 3 5-1-3 1325 P0303...
  • Page 110 Appendix Description Code P- code Fault path for short circuit to battery for EGR power 3-5-1 2791 P0490 stage Fault path for short circuit to ground for EGR power 3-5-1 2791 P0489 stage P0404 Fault path for no load and excess temperature for 3-5-1 2791 EGR power stage...
  • Page 111 Appendix Description Code P- code Fuel filter fouling switch 2-1-3 P1017 P1008 Fault path for fuel filter heating output 2-1-6 520207 P1009 Water in fuel sensor 2-1-4 P2267 Water in fuel sensor 2-1-4 P2266 Fuel filter fouling detection 2-1-2 P1018 Dfp for Water Detection Sensor 2-1-1 P2269...
  • Page 112 Appendix Description Code P- code U110A Dfp for message TSC1-DR 4-2-2 523608 U110B U110C Dfp for message TSC1-PE 4-2-3 520218 U110D U110E Dfp for messages TSC1-TE 4-2-4 U110F U113A Dfp for message TSC1-TR 4-2-4 U113B U1110 Dfp for messages TSC1-VE 4-2-5 520219 U1111...
  • Page 113 Appendix Description Code P- code Error path for Recovery which is locked 520222 P0607 Error path for Recovery which is suppressed 520222 P0607 2-6-1 Error path for Recovery which is visible 520222 P0607 Error state supply voltage CJ940 upper limit 2-6-3 523612 P1607...
  • Page 114 Appendix Description Code P- code P062B P062B Fault path Chip-specific errors -> stop engine 1-5-3 523354 P062B P062B P062B P062B Fault path Chip-specific errors -> stop engine 1-5-3 523355 P062B P062B P0262 P0263 Fault path cylinder1-specific errors -> stop engine 1-4-1 P0261 P0263...
  • Page 115 Appendix Description Code P- code P0271 P0272 Fault path cylinder4-specific errors -> stop engine 1-4-4 P0270 P0272 P121C P121D Fault path cylinder4-specific warnings 1-4-4 P0204 P121E P0274 P0275 Fault path cylinder5-specific errors -> stop engine 1-4-5 P0273 P0275 P121F P1220 Fault path cylinder5-specific warnings 1-4-5 P0205...
  • Page 116 Appendix Description Code P- code P154A Error path of multiple state switch 3-2-7 520227 P154B P154C Error path for main relay 1 1-3-2 2634 P160E Error path for main relay 1 1-3-2 2634 P160F The fault path contains the supervision of the communication between Watchdog of CY310 and the controller.
  • Page 117 Appendix Description Code P- code P0629 P0628 Error path of power stage pre-supply pump 3-2-6 520231 P0627 P062A Fault path for run up test 5-2-3 520232 P1615 P1616 Fault path for test of redundant shut off paths during P1617 1-1-6 initialization P1618 P0643...
  • Page 118 Appendix Description Code P- code Error path for dataset variant coding, Npl = Re- P161D quested variant could not be set, Sig = variant da- 5-2-4 520239 P161E taset defect P162F P1630 Power Stage fault status for Warning Lamp 3-3-2 P1631 P1632 P0647...
  • Page 119 Appendix Description Code P- code Faults for checks in MeUn controlled mode 2-5-6 523613 P1018 Faults for checks in MeUn controlled mode 2-5-4 523613 P1019 P1636 12V sensor supply voltage 1-3-1 520235 P1637 P0617 Fault path for short circuit to battery or ground for 1-2-1 high power stage P0616...

  • Page 120: Engine Maintenance Log

    Appendix 6.5 Engine Maintenance Log Current Frequency Preventive Overhaul Note Maintenance Operating Hours Hours Visa or Date / Period / Period stamp...
  • Page 121 Appendix Current Frequency Preventive Overhaul Note Maintenance Operating Hours Hours Visa or Date / Period / Period stamp...

  • Page 122: Recommended Torques For Bolts

    Appendix 6.6 Recommended Torques for Bolts 6.6.1 Recommended Torques for Hollow Bolts Specification Head type Recommended tightening torque (N·m) M8×1 Hexagon head 7±1 17±2 Hexagon head M10×1 13±2 (Copper bolt and small combination washer) Flange bolt 20±3 Hexagon head 22±3 M12×1.5 Flange bolt 28±3...
  • Page 123 Appendix 6.6.2 Recommended Torques for Standard Bolts Friction coeffi- 0.125 (zinc plated) 0.14 (polished) cient Strength grade 10.9 12.9 10.9 12.9 Bolt size Recommended torque (N·m) 13.0 16.0 14.0 1100 1000 1200 1400 1650 1050 1500 1800 1100 1350 1850 2250 1200 1450...

  • Page 124: Index

    Index Index Ａ Accessories ............................. 32 Air Intake System ............................ 32 Ｃ Common Faults and Troubleshooting ..................... 92 Coolant Recommendation ........................88 Cooling Circuits ............................19 Cooling System ............................34 Ｅ Electronic Control Unit ........................... 22 Engine Control System ..........................36 Engine Lifting ............................
  • Page 125 Index Ｒ Rating Definitions ........................... 14 Recommended Torques for Bolts ......................117 Ｓ Safety Information ............................ 1 Starting Up .............................. 41 Stopping the PowerKit Engine ........................ 44 Storage Protection Instruction ....................... 81 Symbols Used ............................2...
  • Page 126 Contact Us SHANDONG HEAVY INDUSTRY INDIA PVT. LTD. S. NO 280/281, Phase II, Hinjewadi, Village Mann Tal - Mulshi, Dist - Pune. 411 057 Maharashtra, India. \\www.shigindia.com Toll free number: 1800 266 2388...

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