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Baudouin PowerKit 6M21 Series Operation And Maintenance Manual

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Operation and Maintenance Manual
PowerKit 6M21 Series Diesel Engine
6M21(CR)
6M21(MP)
OMMBV2001

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Summary of Contents for Baudouin PowerKit 6M21 Series

  • Page 1 Operation and Maintenance Manual PowerKit 6M21 Series Diesel Engine 6M21(CR) 6M21(MP) OMMBV2001...
  • Page 2 (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 ........................... 1 1. Safety ..........................1 1.1 Safety Information ......................1 1.2 Symbols Used ......................2 1.3 Personal Safety ......................6 1.4 Environmental Safety ....................6 1.5 Fluid Safety ........................7 1.6 Batteries ........................7 1.7 Welding ......................... 8 1.8 Electrical Risks ......................
  • Page 5 Content 5. Maintenance ....................... 57 5.1 General Safety Conditions for Maintenance .............. 57 5.2 Maintenance Table ..................... 58 5.3 Maintenance Operation ....................61 5.4 Storage Protection Instruction ..................86 6. Appendix ........................93 6.1 Coolant Recommendation ..................93 6.2 Lubricant Recommendation ..................94 6.3 Fuel Recommendation ....................

  • Page 6: Foreword

    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

    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 The warnings in this guide cannot cover every situation imaginable. Please only use proce- dures, methods, tools, and parts specially recommended by the engine manufacturer.
  • Page 9 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 10 Safety Universal Warning The location of the Universal Warning label is illustrated below. Figure 1.2A-6M21 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. Failure to follow the instructions or heed the warnings could result in serious injury or death.

  • Page 11: 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 12: 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 13: 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 14: 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 15: 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 16: Cleaning The Engine

    Safety  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.  Do not wash an engine in operation or which has just stopped.

  • Page 17: 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 18 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 19: 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 20: 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 21: Engine Model

    Power Code Application Code Displacement per Cylinder Product Code for Baudouin Cylinder Number 2.2.3 Product Series Code Product series Code is comprised by Cylinder Number、Product Code for Baudouin (M) and Displacement per Cylinder. 2.2.4 Application Code Code Application Land Power Generation Land Power Generation for Tele com Variable speed models (Pump, Air pressure…)
  • Page 22 Product 2.2.6 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. 2.2.7 Emission Stage Codes Emission Stage Code Non-road No emission certification U.S.
  • Page 23 Product 2.2.9 Engine Nameplate ** ** Figure 2.2.9A-6M21 Series Diesel Engine **** ***...

  • Page 24: Engine Overview

    Product 2.3 Engine Overview 2.3.1 Schematic Diagrams of 6M21CR 1-Lifting Rings 2-Turbocharger 3-Thermostat 4-Fan 5-Water Pump 6-Oil Cooler 7-Oil Filters 8-Oil Sump 9-Flywheel Housing Figure 2.3.1A-Right Side 10-Radiator 11-Common Rail 12-Air Intake Manifold 13-Air Filter 14-Oil Filler 15-Fuel Pump 16-Starter 17-Fuel Filter 18-Fuel Coarse Filter 19-Dipstick...
  • Page 25 Product 2.3.2 Schematic Diagrams of 6M21MP 1-Lifting Rings 2-Turbocharger 3-Thermostat 4-Fan 5-Water Pump 6-Oil Cooler 7-Oil Filters 8-Oil Sump 9-Flywheel Housing Figure 2.3.2A-Right Side 10-Radiator 11-Air Intake Manifold 12-Air Filter 13-Oil Filler 14-Fuel Pump 15-Starter 16-Fuel Filter 17-Dipstick 18-Fuel Coarse Filter Figure 2.3.2B-Left Side...

  • Page 26: Cooling Circuits

    Product 2.4 Cooling Circuits 1-Thermostat assembly 2-Hot Coolant Outlet Pipe 3-Radiator 4-Cooled Coolant Inlet Pipe 5-Water Pump 6-Lube Oil Cooler 7-Water Gallery 8-Outlet Pipe from Engine 9-Cylinder Block Cooling 10-Cylinder Head Cooling Figure 2.4-Overall Layout of cooling circuits 6M21 series diesel engine cooling circuits: The water pump draws coolant from the radiator.

  • Page 27: Lubrication System

    Product 2.5 Lubrication System 6M21 Series engines are equipped with a lubrication system including an oil cooler. The gear driving oil pump is located at the low front of the engine. Many engine parts are lubricated by pressurized oil through piping and crankcase hoses. ...

  • Page 28: Fuel System

    Product 2.6 Fuel System 2.6.1 Fuel circuit diagram of 6M21CR The fuel pump draws the fuel from the fuel tank through fuel coarse filter and through full flow filter to the injection pump. Injection pump delivers fuel under high pressure through the common rail and high pressure line to the injectors.
  • Page 29 Product 2.6.2 Fuel circuit diagrams of 6M21MP The feed pump draws the fuel from the fuel tank through pre-filter and through full flow filter to the injection pump. Injection pump delivers fuel under high pressure to the injectors. Excess fuel not sprayed is returned to the fuel tank. Injector holder leakages return to fuel tank.

  • Page 30: Electronic Control Unit (Ecu)

    Product 2.7 Electronic Control Unit (ECU) 2.7.1 ECU for 6M21CR The WISE15 ECU has two wire harness slots, in which the gray stands for the engine side and the black stands for the genset control panel, each with 76 pins. The engine wire harness includes engine sensors, fuel injectors and electrically controlled fan pins, which have been installed before delivery.
  • Page 31 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 32 Product  Starter switch (T50)  Pin No.: X1-58  Functional description: The engine starter is controlled by ECU; the switch will be onto control the start relay output. Benefits of the ECU-controlled start are as fol- lowing:  With the help of the second start protection, the starter will not respond after the start switch is pressed again when...
  • Page 33 Product  Speed adjustment knob  Pin No.: X1-24, X1-09, X1-25  Functional description: It is used to adjust the engine speed, and cannot be used together with the speed fine-tuning switch.  Speed governing rate knob  Pin No.: X1-28, X1-10, X1-27 ...
  • Page 34 Product reset automatically, the diagnostic lamp may stay on due to the diagnostic switch off. Each flash code consists of 3 bits, for example: 3-2-1, the flashing diagram is as follows: Figure 2.7.1F-Flash Diagram  Engine speed output  Pin No.: X1-19 ...
  • Page 35 Product  CAN communication  Pin No.: X1-42, X1-43  Functional description: It is used for information exchange between engine ECU and other CAN nodes on the genset control card. Note: The twisted-pair wire is required, 25 units/m, and 120Ω terminal resistor is integrated in- side ECU;...

  • Page 36: Electronic Governor System For Mechanical Pump Engine

    Product 2.8 Electronic Governor System for Mechanical Pump Engine 2.8.1 The Principle of the Electronic Governor System Its system type is all-electronic single pulse speed and close loop position structure, provided with functions of non-corresponding or corresponding control, speed and rated speed during running maximum fuel supply control, emergency stop and etc.
  • Page 37 Product 2.8.4 Speed Pick-up The Speed Pick-up of the Electromagnetic Governor is Speed Pick-up of magnetoelectricity, inner structure of which are made of sensor, loop, alnico and plug. Its structure refers to Figure 2.8.4A. The gap between the magnetic speed sensor and the ring gear teeth should not be any smaller than 0.02 in.

  • Page 38: 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 39: 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 40 Installation The lifting points of 6M21 series engine are illustrated as followings: 6M21CR Figure 3.1.3A-6M21CR Lifting 6M21MP Figure 3.1.3B-6M21MP Lifting...

  • Page 41: Engine Mounting

    Installation 3.2 Engine Mounting In order to ensure the durability of the engine installation, the installation of the engine must meet the following criteria:  The engines’ own mounting bracket should be used, and four-point support should be adopted. The number of engine supports must not be reduced. ...
  • Page 42 Installation 6M21MP Figure 3.2B-6M21MP Mounting...

  • Page 43: Accessories

    Installation 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- stalling, ensure that the direction of the pipe in the expansion joint is consistent with the direction of the air flow.

  • Page 44: Air Intake System

    Installation 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:  Exhaust back pressure must not exceed the limits in the engine data sheet. ...

  • Page 45: Lubrication System

    Installation  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.  Radiator grounding measures must be taken to eliminate potential differences and pre- vent electrical corrosion (aluminum radiators do not require this).

  • Page 46: Engine Control System

    Installation 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 Fuel filter screen open.
  • Page 47 Installation 3.9.2 Charging Circuit  The alternator must be agile rotation and have not abnormal noise.  The charging cable shall be a complete cable without intermediate connector.  The alternator and battery in parallel may not operate without battery. ...

  • Page 48: Electrical Components

    Installation 3.10 Electrical Components 3.10.1 Sensors  Sensor wiring terminal (male tab type) shall be provided with protection after connection.  Sensor connector shall be inserted in place, well positioned and firmly fastened.  For resistance type sensors, for example, temperature and pressure sensors, their cable lengths connecting to the instrument shall be less than 10m.

  • Page 49: Installation And Debugging Of Electronic Governor System

    Installation 3.11 Installation and debugging of Electronic Governor System 3.11.1 Speed controller The speed Controller is installed on the control box or fixed other peripheral equipment in the engine. It should be installed in the place of air drying and temperature suitable. If it be in- stalled in the place of more water and humidity, the speed Controller should be mounted ver- tically.
  • Page 50 Installation Figure3.11.1B-Connection Diagram of the C2002 Speed Controller for Normal Generator Set Wire harness Terminal Less than 6 meters More than 6 meters 1,2 shall connect with the actuator winding end 1 mm² 2.5 mm² 3,4 shall connect with a speed sensor ( the mini- 0.5 mm²...
  • Page 51 Installation  The Electromagnetic Actuator connects to Terminals 1 and 2 and battery connects to Terminals 5 and 6. Terminals 1, 2, 5, and 6 should be #16 AWG (1 mm sq) or larger. Long cables require an increased wire size to minimize voltage drops. The battery posi- tive (+) input, Terminal 6, should be fused for 15 amps as illustrated.
  • Page 52 Installation Rated and idle speed of the speed Controller had been set by factory. Normally, this value is near from the user’s engine working rotate speed value. In practice, after some adjustments, controller can achieve rated and idle speed, and the stability would be very well. 3.11.3 Adjustment of the Controller after Starting ...
  • Page 53 Installation 3.11.4 Speed Droop Operation  Droop is typically used for the paralleling of engine driven generators.  Place the optional external selector switch in the DROOP position, which is connected Terminals 10 and 11. Droop is increased by clockwise rotation of the DROOP adjustment control.

  • Page 54: Genset Installation Recommendations

    Installation 3.12 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, enclosures have to be in- sulated for noise reduction. Also, the correct type of exhaust silencer must be used if neces- sary.

  • Page 55: 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 56: Preparations Before Start

    Operation 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  Adding of fuel ...

  • Page 57: Starting Up

    Operation 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. Please refer to the genset and/or genset control panel use & maintenance manual for the starting operation mode. ...

  • Page 58: Operation Of The Powerkit Engine

    Operation 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 C and the oil temperature is above 51º C, can the engine run with full load. The load and speed should be increased gradually.

  • Page 59: 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 60: Stopping The Powerkit Engine

    Operation 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 61: Electronic Control System

    If you fail to delete a fault code, it remains a current fault. You need to resolve the current fault before clearing the error memory in ECU. If you fail to clear the fault code, please notify your local Baudouin representative as soon as possible.

  • Page 62: 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 63: Maintenance Table

    Maintenance 5.2 Maintenance Table MOTEURS BAUDOUIN • Check = Mandatory maintenance, in operation working hours (H) о Adjust = or period (months - M), every, which occurs first Δ Clean = □ Replace = Hour 1,000 2,000 4,000 8,000 16,000...
  • Page 64 Maintenance MOTEURS BAUDOUIN • Check = Mandatory maintenance, in operation working hours о Adjust = (H) or period (months - M), every, which occurs first Δ Clean = □ Replace = Hour 1,000 2,000 4,000 8,000 16,000 OPERATION Month □...
  • Page 65 Maintenance MOTEURS BAUDOUIN • Check = Mandatory maintenance, in operation working hours о Adjust = (H) or period (months - M), every, which occurs first Δ Clean = □ Replace = Hour 1,000 2,000 4,000 8,000 16,000 OPERATION Month Δ...

  • Page 66: 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 67 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 68 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 69 Maintenance  Check the oil level NOTE! Check the oil level when the engine is horizontal at idle speed or engine stopped. If check the oil level when engine stopped only after at least 20 minutes have passed since the engine was switched off. ...
  • Page 70 Maintenance  Check the air cleaner service indicator and the air filter valve vacuator.  Conduct maintenance when the clog warning sign appears. Figure 5.3.1.G  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 cleaner.
  • Page 71 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 72  Inspect the engine with the help of trouble shooting information listed in the Part AN- NEX.  If the problem cannot be solved, consult your Baudouin dealer in time.  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.
  • Page 73 Maintenance  Check the hoses and hose clamps  Inspect all clamps, tighten any loose clamps. Make sure there is no crack on clamps.  Inspect any loose or damaged of lines; tighten all connections to the recommended torque.  Make sure there is no crack, swell, collapse, rubber peeling on the hoses and lines.
  • Page 74 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 75 Maintenance  Apply oil (instead of lubricating grease) onto the sealing gasket and fill the filter with clean fuel. Figure 5.3.2.D  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 76 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 77 Maintenance  Replace oil cartridges Note! Hot oil and components can cause personal injury. Wear gloves to prevent hot oil or components from contacting your skin. Do not install the cartridges over tighten.  Clean the area around the oil car- tridges and place a proper con- tainer under the oil cartridges, Remove the used cartridges and...
  • Page 78 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.N  Refer to "List of fault codes" to find the text explanation corresponding to each fault code and you can determine the current fault.
  • Page 79 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 80 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 81 Maintenance  Clean the breather filter cartridge  After opening the cover of oil-gas separator, can remove the filter cartridge. Figure 5.3.2.U  Clean the breather cartridge with fuel. Figure 5.3.2.V  Assemble the cartridge and cover.  Check the engine and generator connection ...
  • Page 82  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.X  Also, do not use disassembled or reassembled electrical parts. ...
  • Page 83 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 84 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 loose the fan.
  • Page 85 Figure 5.3.4.D  Inspect the turbocharger compressor impeller blades for damage. Contact a Baudouin authorized service cen- ter if damage is found.  Care must be taken to the air filters. For if the impellor was polluted, the...
  • Page 86 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 87 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.  Assemble the thermostats. ...
  • Page 88 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 89 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 90 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 91: 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 for a period of time, then precautions should be taken to protect your engine from damage and to ensure proper operation when you re-operate the engine.
  • Page 92 Maintenance  Up to three months Each week operate the engine until the normal temperature of operation is reached. If the engine is not going to be operated, turn the crankshaft by hand, in the normal direction of ro- tation (anti-clockwise as seen on the flywheel), a minimum of three revolutions. 5.4.5 Necessary Materials ...
  • Page 93 Maintenance  Sprayer Load the VCI oil dilution into the sprayer, then can be used to prepare the engine for storage. Change the nozzle adjustment to provide either a spray or a fog pattern. VCI oil dilution: mixture of 50 percent VCI oil and 50 percent engine oil. ...
  • Page 94 Maintenance the freshwater system. Drain the system by removing the drain plugs from the engine block, oil cooler, heat exchanger body, and radiator.  The mixture must NOT contain less than 50% inhibited ethylene glycol or propyl- ene glycol and may contain up to 70% by volume. Fresh Water Systems Drain the coolant from cooling system and thoroughly flush with the clean water.
  • Page 95 Maintenance 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. Add 0.15 ml per L (.02 oz per 1 gal) of commercial biocide such as Biobor JF or an equivalent to the fuel.
  • Page 96 Maintenance Clean the engine wiring harness, and keep it 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 97 Maintenance any leaks are corrected. To ensure a safe operation, use the following procedure:  Before starting the engine, use hand oil pump or electric pre-supply pump to establish the oil pressure of the engine.  Crank engine for 20 seconds with starter (do not allow the engine to start). Wait 2 minutes and crank the engine for additional 20 seconds to assure bearing surfaces are adequately lubricated.

  • Page 98: 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 99: 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 100 Appendix 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 SH/T 0703 GB/T 265 SH/T 0751 GB/T 6538 GB/T 3535 ASTM D-445 CECL-36-T-84...

  • Page 101: Fuel Recommendation

    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 102: 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 103 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 104 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 105 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 106 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 107 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 108 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 109 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 110 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 111 Appendix 6.4.2 Diagnostic Fault Codes List 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 P0223 Fault path of Accelerator Pedal 2...
  • Page 112 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 113 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 114 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 115 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 116 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 117 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 118 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 119 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 120 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 121 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 122 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 123 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 124: 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 125 Appendix Current Frequency Preventive Overhaul Note Maintenance Operating Hours Hours Visa or Date / Period / Period stamp...
  • Page 126 Appendix Current Frequency Preventive Overhaul Note Maintenance Operating Hours Hours Visa or Date / Period / Period stamp...

  • Page 127: 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...
  • Page 128 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...

  • Page 129: Index

    Accessory Input and Output ....................48 Adjustment of the Controller after Starting ................47 Adjustments before Starting Engine ..................46 Before any operation or maintenance on any Baudouin product ..........12 Charging Circuit ........................42 Diagnostic Fault Codes List ....................106 ECU for 6M21CR ........................
  • Page 130 Overhaul (In-Structure) ......................83 Overhaul (Major) ........................84 Overhaul Information ....................... 83 Overhaul Operations ....................... 83 Preparation before Storage ..................... 86 R1/R2 Repair Operations ......................79 Recommended Torques for Hollow Bolts ................122 Recommended Torques for Standard Bolts ................123 Removal from Storage ......................
  • Page 131 Appendix 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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