Baudouin PowerKit 6M12 Series User manual

Operation and Maintenance Manual
PowerKit 6M12 Series Diesel Engine

Foreword
Foreword
Please be advised, do not operate or per-
form any operation, maintenance, or repair
on this PowerKit engine until you have read
and understood the information in this
Manual in its entirety. This Manual must be
read in full before operating your PowerKit in
order to gain the maximum operational per-
formance of the engine and to safely operate
and maintain the engine. The operation and
maintenance instructions are given as a
guide for engines operating at the rating as
sold.
Documentation
Baudouin uses English as the primary
business language for all publications. Other
languages may be available, please consult
with your local Baudouin representative.
The photos and illustrations in this manual
are for reference only. Some illustrations
may have been modified to ensure clarity
(for example guards and covers may be
removed), and some equipment shown in
this manual may be different to your engine.
For the latest information, please contact
your local Baudouin representative.
The 'DT' technical documents ('documenta-
tion technique') quoted in this Manual are
available from the Baudouin Network for
reference.
The information contained in this Manual is
correct at the time of publication. Baudouin
reserves the right to modify these specifica-
tions without notice.
Safety
The Safety section of this manual covers
basic safety precautions and shows warn-
ings and potentially hazardous situations.
This Manual must be read in full before op-
erating your PowerKit in order to operate
and maintain the engine safely.
Maintenance & Spare Parts
Maintenance should be carried out at the
appropriate intervals as shown in the
Maintenance Table. The inspection and
maintenance intervals are given as a guide,
for engines operating under normal condi-
tions. Consult with your Baudouin repre-
sentative for operation under severe condi-
tions.
We recommend that a copy of the Mainte-
nance Schedule be displayed near the en-
gine and that a service record be kept and
stored with the engine.
The use of Baudouin Genuine Spare Parts is
imperative to the optimal operation, perfor-
mance and longevity of your PowerKit en-
gine. The use of alternatives or counterfeit
parts can lead to voiding engine warranty，
damage, failures, and personal injury or
death.
Overhaul
This Manual does not include detailed in-
structions for overhaul of your engine. Con-
tact your local Baudouin representative who
can help you to proceed with an overhaul
program for your engine. All major repairs
should be carried out by an authorized
Baudouin partner.

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 ............................................................................................................. 8
1.9 Lines, Tubes and Hoses............................................................................................... 9
1.10 Coolant Safety............................................................................................................ 9
1.11 Cleaning the Engine ................................................................................................. 10
1.12 General Precautions for Operation ...........................................................................11
1.13 Recommendations for Engines Equipped with Common Rail System .................... 13
2. Product...........................................................................................................................14
2.1 Rating Definitions ....................................................................................................... 14
2.2 Engine Model ............................................................................................................. 15
2.3 Engine Overview ........................................................................................................ 18
2.4 Cooling Circuits .......................................................................................................... 19
2.5 Lubrication System..................................................................................................... 20
2.6 Fuel System ............................................................................................................... 21
2.7 Electronic Control Unit (ECU) .................................................................................... 22
3. Installation......................................................................................................................29
3.1 Engine Lifting.............................................................................................................. 30
3.2 Engine Mounting ........................................................................................................ 31
3.3 Accessories ................................................................................................................ 32
3.4 Air Intake System ....................................................................................................... 32
3.5 Exhaust System ......................................................................................................... 33
3.6 Cooling System .......................................................................................................... 34
3.7 Lubrication System..................................................................................................... 34
3.8 Fuel System ............................................................................................................... 34
3.9 Electrical Components ............................................................................................... 36
3.10 Genset Installation Recommendations .................................................................... 38
4. Operation .......................................................................................................................39
4.1 Preparations before Start ........................................................................................... 40
4.2 Starting Up ................................................................................................................. 41
4.3 Operation of the PowerKit Engine.............................................................................. 42
4.4 Precautions for running in cold environments ............................................................ 43
4.5 Stopping the Engine ................................................................................................... 44
4.6 Electronic control system ........................................................................................... 45
5. Maintenance ..................................................................................................................46
5.1 General Safety Conditions for Maintenance .............................................................. 46
5.2 Maintenance Table ..................................................................................................... 47

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..............................................................................117
Index ................................................................................................................................119

Safety
1
1. Safety
1.1 Safety Information
Failure to comply with the preventive measures and safety instructions included in this manual
and with warnings indicated on the engine may lead to injury or death. This Operation and
Maintenance Manual must be kept on or near the engine and must be easily accessible and
ready to be consulted at any time. Furthermore, this manual must stay with the engine at all
times.
Most accidents can be prevented by following basic safety precautions, recognizing hazardous
situations and acting accordingly, but these safety instructions alone are not sufficient to avoid
every hazard. 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.

Safety
2
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. In this Manual this symbol is used
to highlight the importance of the information
that follows. Make sure that you understand
the consequences of a dangerous situation
and the ways in which to avoid danger.
Failure to comply with warnings can result in
material damage, serious injury or even
death.
WARNING
This type of warning indicates a potentially
dangerous situation, which if not avoided,
may result in serious injury, death, or con-
siderable material damage.
CAUTION
This type of warning indicates a potentially
dangerous situation, which if not avoided,
may result in minor injury or material dam-
age. It can also warn against dangerous
practices.
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.

Safety
3
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
Keep away from hanging loads
Risk of thermal burns
Risk of mechanical drive / rotating parts
Lifting is forbidden
Risk of steam burns
Water drain valve

Safety
4
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.

Safety
5
1.3 Personal Safety
These personal safety precautions are designed to reduce the risk of contamination, serious
injury or death.
◼Wear personal protective equipment (PPE) as required.
◼Avoid prolonged and repeated contact with oil and diesel fuel.
◼Do not put oily rags in pockets.
◼Avoid contaminating clothing with oil.
◼Wash overalls regularly. Throw away unwashable clothing and shoes impregnated with
oil.
◼Emergency treatment must be immediately sought in the event of any injury.
◼Always wear protective mechanic's gloves before working in order to avoid prolonged and
repeated contact with oil and diesel fuel.
◼Wash with soap and hot water or, alternatively, use hand detergent and a nailbrush to
make sure that all oil is removed. Products containing lanolin can help replace the skin's
natural oils that may have been removed.
◼DO NOT use petrol, kerosene, fuel, thinners or solvents to clean the skin.
◼If skin problems occur, immediately consult a doctor.
◼If possible, degrease components before handling them.
◼When there are risks for the eyes, use safety glasses or a face shield. An eye-rinsing
solution must be kept close at hand.
◼Do not spill oil or other fluids on the ground when repairing the engine. In the event of an
accidental spillage of hydrocarbon or other fluid, take all the necessary measures to
section off the area, clean up and protect people and the environment.
◼The handling, storage and recycling of hydrocarbons, ethylene, glycol and oil must
comply with the safety and environmental standards applicable in the country where
these operations take place.
◼Ensure that all guards and covers are secured in place on the engine.
◼Make sure adequate, non-expired extinguishers are available and that personal are
adaquately trained in extinguisher operation.
1.4 Environmental Safety
◼There are laws regarding environmental protection and the disposal of waste of
hydrocarbons. 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.

Safety
6
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. Use a cardboard section or other
appropriate tool to check for a leak.
◼Store all fuels and lubricants in closed,
clearly labelled containers in a safe
place.
◼When draining liquids from the engine,
ensure that the correct tools are used
and that liquids are collected in a suita-
ble container and disposed of following
all local regulations.
◼Oily rags and other flammable materials
must not be stored in close proximity to
engine, genset, or system.
◼Do not smoke near the fuel tank or
while in the filling area. Ensure there
are no open flames or sparks. Always
stop the engine before refuelling.
◼Mobile phones (in particular their bat-
teries) may give off sparks that could
cause an explosion in certain high-risk
areas. Switch off all mobile phones
when filling the fuel tank or while in the
filling area.
1.6 Batteries
◼Wear personal protective equipment
(PPE) as required.
◼Do not smoke in areas where batteries
are charged or near fuel circuits.
◼The batteries release flammable fumes
that can explode. Ensure there are no
open flames or sparks near the battery.
◼If the batteries are in a closed area,
make sure there is sufficient ventilation.

Safety
7
◼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.
◼Disconnect the batteries before any
operation involving the electrical sys-
tem.
◼Never disconnect any battery cable
while the engine is operating.
◼Never check battery charge by short
circuiting it.
◼Do not charge a frozen battery; heat it
up 16°C (61°F) beforehand.
◼In the event of corrosive material con-
tact with a body part:
◆Rinse the affected part with plenty
of water.
◆Apply bicarbonate of soda or lime
to neutralise the acid.
◆Rinse your eyes for 10 to 15
minutes.
◆See a doctor immediately.
◼In the event of ingestion see a doctor
immediately.
◼Make sure the batteries are clean and
fitted with the recommended covers,
cables and connections.
◼Electric wiring must be kept in good
condition, properly positioned and at-
tached.
1.7 Welding
◼Do not weld or flame cut pipes, hoses
or tanks that contain flammable fluids.
Components containing flammable flu-
ids must be drained and cleaned ap-
propriately with a non-flammable sol-
vent before conducting any welding of
flame cutting.
◼Disconnect the engine wiring harness

Safety
8
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.
◼Make sure that the automatic fire sup-
pression system is deactivated before
any welding or grinding work.
◼Make sure that there is sufficient venti-
lation in the premises where welding is
to be carried out.
1.8 Electrical Risks
◼Electrical checks must be carried out
regularly.
◼Electric wiring must be kept in good
condition, properly positioned and
soundly attached.
◼All wires should be of the recommend-
ed size.
◼Wires and cables must be protected by
a fuse or calibrated circuit breaker.
◼Do not short-circuit fuses and/or circuit
breakers.
◼The electrical circuit of the engine must
be isolated from the engine and gener-
ator.
◼Ensure that the engine is grounded
correctly to prevent uncontrolled elec-
trical circuit paths which can cause
damage.
◼Insulation problems can cause short-
circuits or stray current. Stray current
can damage electrical and electronic
components, bushing or crankshaft
seating and may also cause ra-
dio-frequency disturbance.
◼The engine earth must be properly con-
nected to the chassis, as well as all the
flexible hoses.

Safety
9
◆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
◼Ensure that all high pressure lines are
not bent, worn or damaged. High pres-
sure lines must be positioned, sup-
ported and firmly fastened. Do not at-
tach any other components to the high
pressure lines. Tighten all connections
to the recommended torque.
◼Do not check for leaks using your hand.
Use a cardboard to check for a leak.
◼Tighten all connections and filter hous-
ings to the recommended torque.
◼Release the lubrication, fuel and pres-
sure cooling circuits before discon-
necting or removing hoses or associ-
ated parts.
1.10 Coolant Safety
◼At operating temperature, the coolant is
hot and pressurized. When pressure is
released sharply, this hot liquid may be
transformed into fumes. Any contact
with this hot liquid or these fumes may
cause serious burns.
◼The cooling system also contains alkali
which can cause injury. Do not allow
alkali to contact your skin, eyes or
mouth.
◼Let the components of the coolant cir-
cuit cool down before draining the cir-
cuit.
◼Only check the coolant level when the

Safety
10
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.
◼Do not wash an engine in operation or
which has just stopped.
◼Use the safety equipment required by
your local codes and standards.
◼Make sure high-pressure water cannot
damage the equipment being washed.
Do not get electrical equipment or seals
wet.
◼Take necessary precautions when us-
ing a high-pressure cleaner. Comply
with the safety instructions indicated for
the cleaning equipment used as well as
local codes and standards.
◼High pressure cleaning can blow out
high-speed debris from the engine
which can cause injury.

Safety
11
1.12 General Precautions for Operation
1.12.1 before any operation or maintenance on Baudouin product
◼Wear personal protective equipment (PPE) where required.
◼For maintenance, place a “Do Not Use” or similar sign on the starter switches.
◼Access to the equipment is only for authorized and qualified personnel.
◼Ensure that all guards and covers are secured in place on the engine.
◼Make sure that the repair premises and surrounding area are suitable for safe working.
◼Inspect the engine for potential hazards. Ensure there are no personnel on, under or
around the engine.
◼Ensure that the pipes and hoses are not worn or damaged. Pipes must be positioned,
supported and firmly fastened.
◼Ensure that the electrical wiring is not worn or damaged. Wiring must be positioned,
supported and firmly fastened
◼Remove all wiring that is obstructive to repair/maintenance or unattached.
◼Use the proper tools for the operation being performed.
◼Report all necessary repairs promptly.
◼Remove any rings, chains and watches before starting work. Wear suitable and proper-
ly-fitting work clothes.
◼Remove and isolate the control panel key.
◼Do not perform any operation or maintenance operations which are not fully understood.
◼Clear the engine of any flammable materials such as fuel, oil or debris.
◼Do not smoke near the engine or where flammable materials are stored.
◼Exhaust shields (if equipped) must be fitted correctly.
◼Do not expose the engine or components to flames.
◼Do not touch hot parts of an engine in operation or which has just been stopped.
◼Ensure the starter battery insulation switch is in open position.
◼Switch off the circuit breaker located in engine connection box (if equipped).
◼Switch off engine room lock switch or emergency stop (if equipped).
◼For maintenance, for engines fitted with a pneumatic starter system, isolate the tanks and
evacuate the pipe linking the tanks to the starter.
◼For engines installed on automatic start genset select the lock position on the selection
mode of the control panel, to avoid the engine start.
◼Use caution when cover plates or other components are removed. Gradually loosen and
remove bolts/nuts but do not remove the last two bolts which are located on opposite
ends of the plate. 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.

Safety
12
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.
◼Never use any engine starting agents (for example, ether) to facilitate start-up due to a
risk of explosion or injury.
◼Never start an engine without checking that this operation can be carried out without
danger to people or equipment. If there is a warning tag attached to the control panel or
start switch do not start the engine or touch the controls.
◼Start the engine from the control panel or operator’s booth.
◼Ensure that the jacket water heater and/or lube oil heater (if equipped) are working
properly by checking the temperature gauges during the heating operation.
◼Never short across the starting motor terminals or the batteries as this could damage the
electrical system.
◼Never bypass or disable the automatic shutoff circuit – these are provided to help prevent
injury and engine damage.
◼Engine exhaust could be harmful to your health, therefore always start and operate the
engine in a well-ventilated area. If in an enclosed area, ensure the engine exhaust is
vented properly to the outside.
1.12.3 Stopping the Engine
◼Stop the engine from the control panel or operator’s booth.
◼Use the Emergency Stop Button (if equipped) only in the event of an emergency. Do not
use the Emergency Stop Button for normal engine stopping. Do not start the engine after
using the Emergency Stop Button until the problem that caused the emergency stop has
been corrected.
◼Let the engine cool down before carrying out any maintenance operation.
◼Do not perform any operations on the engine for at least 15 minutes after an emergency
shutdown.

Safety
13
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.
◼Release the high pressure before handling the feed and injection circuit of a common rail
engine.
◼When checking the injectors, make sure that the high-pressure jet does not touch the
skin.
◼All investigations of leaking fuel, oil or other high pressure liquids must be conducted us-
ing a screen and never with bare hands.
◼Use a spray fumes extracting device.
◼If fuel comes into contact with the skin, it can cause injury. Consult a doctor immediately.
◼Fuel, oil and coolant contain harmful chemicals. Avoid any contact with skin and hands.

Product
14
2. Product
2.1 Rating Definitions
Rating definitions
Running conditions
COP
Continuous power
◼Annual running time is unlimited.
◼Continuous rated power is allowed.
◼No overload ability.
PRP
Unlimited Prime Rated Power
◼Annual running time is unlimited.
◼The average load rate is no more than 70% during a
range of 24 hours.
◼Maximum time range with overload 10% within 12h
is 1 hour.
ESP
Emergency Standby Power
◼The annual running time shall not exceed 200h.
◼The average load rate shall not exceed 70% in 24h
cycle.
◼No overload.
◼The acceleration requirement is in accordance with
Q/WCG136.13. Acceleration from starting to rated
power should be within 10s without engine warm
stage.
◼For natural aspirate diesel engine, when the envi-
ronment temperature is below 5 degrees Celsius, it
is need to use preheat facilities to warm coolant
temperature higher than 30 degrees Celsius. When
environment temperature is higher than 5degrees
Celsius, no preheating facilities are required.
◼For diesel engine with turbocharger, when the en-
vironment temperature is below 10 degrees Celsius,
it is need to use preheat facilities to warm engine
coolant temperature higher than 30 degree Celsius.
When environment temperature is higher than 10
degree Celsius, no preheating facilities are required.

Product
15
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
G
Land Power Generation
GT
Land Power Generation for Tele com
V
Variable speed models (Pump, Air pressure…)
2.2.4 Power Code
◼Common rules
Use number 2, 4, 6…..as the different power lever for the models, choose 2 as the lowest
power and increase the power with the order of the number, 1, 3, 5, 7…..as the alternate
power code and will be used according to market demands.
◼For the single speed engines that without emission (can only be used for PRP
or ESP)
Power code for 50Hz correspond Standby Power (kVA) of generating set.
Power code for 60Hz correspond Standby Power (kW) of generating set.
Contents of emission phase code and fuel code will not be used.