Moteurs Baudouin PowerKit 6M16 Series User manual

Operation and Maintenance Manual for PowerKit 6M16 Series
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Operation and Maintenance Manual
for PowerKit 6M16 Series

Operation and Maintenance Manual for PowerKit 6M16 Series
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Dear Customer,
Thank you for choosing a Baudouin PowerKit engine!
This series has a compact structure, reliable operation, excellent performance, low fuel
consumption and meets the requirements of international emission standards. The engine is quick to
start, simple to operate and easy to maintain.
We are committed to launching new products and continuously improving our range. Therefore
notification of changes will be made via our website; please visit Baudouin.com for the latest
product information.
This manual covers the basic information for the use and maintenance of the engine. To gain
optimal performance and to maintain the engine properly, please carefully read this operation and
maintenance manual, and operate in strict accordance with the relevant provisions.

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Notice
1. Before delivery, this series of diesel engines have already been tested, strictly following the test
specification. Therefore, never dismantle the lead sealing on the throttle to raise its openness.
Never dismantle or impact the rotor of turbocharger which belongs to the sophisticated parts;
never loosen or remove the main bearings of diesel engine and bolts attached to connecting rod
which have strict requirements for torque and angles.
2. As the bolts attached to connecting rod are disposable, never reuse them.
3. The operator of diesel engine should carefully read this Operation and Maintenance Manual, be
familiar with the structure of the diesel engines and closely abide by the technical operation and
maintenance procedures specified in this manual.
4. At any time of starting the diesel engine, please check whether the coolant and engine oil is
filled up.
5. For the new diesel engine, 50h running-in is needed, with maximum load not more than 80% of
the rated load and average load not more than 60%.
6. The starting time of the engine should not last for more than 30s. If the engine can’t be started
within 30s, wait for 1-2min for startup again.
7. After the diesel engine is cold started, please slowly increase the rotating speed, do not make
high-speed operation suddenly and never idle running for long time.
8. After engine running with heavy load, do not immediately stop it. It is necessary to idle
running for 5-10 min at low speed.
9. After engine is stopped, if the ambient temperature is less than 0℃, moreover additive is not
applied; please completely drain the water in radiator and diesel engine.
10. The diesel engine is prohibited to work without air filter which could prevent particulates from
entering the cylinder Please select the specified fuel and oil grades which will be filled into the
diesel engine (it is suggested to use the Baudouin special oil sold at all service stations of
Baudouin when change the lubricating oil). Use the special clean container.
11. The fuel and oil should be filtrated through the strainer before added. Let the fuel precipitate for
72h or more.
12. Do not simultaneously use the diethyl-ether-assisted starting equipment and pre-heater or glow
plug.
13. The inspection of electrical system should be done by the personnel mastering electrical
knowledge.
14. The invalid duration of oil sealing of diesel engine is one year. If they expire, please take
necessary supplement measures.
15. Our company perform the quality-trace filing for industrial power 6M16.

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Safety

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Before maintenance and repair, please notice that:
◆Avoid repeated exposure to used oil for a long time.
◆If possible, wear protective clothing and waterproof gloves.
◆Do not keep oil-soaked rags in the pocket.
◆Prevent oil from soaking the clothes, especially underwear.
◆Wash the uniform frequently. Throw away the oil-soaked clothes and shoes that cannot be
cleaned.
◆Use first aid immediately if there are any cuts or other injuries.
◆Apply protective cream before working so that the mineral oil is easier to get cleaned after
getting on the skin.
◆Clean your hands with soap and hot water, or use the hand sanitizer and nail brush to remove
all oil. If there’s skin natural sebum loss during the wash, products containing lanolin can be used to
help moisturize the skin.
◆Do not use gasoline, kerosene, fuel oil, thinner or other solvents to clean the skin.
◆If you have a skin irritation, consult a doctor immediately.
◆If possible, remove the oil/grease on the parts before handling them.
◆If there is possible danger to your eyes, use goggles or face shield. Eye wash solution must be
available around the operating location.
◆When maintaining the engine, do not splash oil or other liquids onto the floor. If there’s an
accidental release of hydrocarbons or other liquids, take all necessary measures to isolate the
leaking area to keep the environment clean and to protect personnel from injury.
◆The handling, storage and recycling of hydrocarbons, ethylene, glycol and petroleum must
comply with safety and environmental standards of the country where the operation is done.

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Contents
1.Structure and parameters of the diesel engine ....................................................................................... 7
1.1Model Meaning of the diesel engine........................................................................................... 7
1.2 External dimensions and structure of the diesel engine............................................................. 7
2. Brief introduction of main systems of the diesel engine....................................................................... 7
2.1 Gear train and valve mechanism............................................................................................ 7
2.2 Lubrication system ................................................................................................................ 8
2.3 Fuel system.......................................................................................................................... 10
2.4 Cooling system.................................................................................................................... 12
2.5 Electrical units..................................................................................................................... 13
3. Installation and use of the diesel engine............................................................................................. 15
3.1 Unsealing of the diesel engine ................................................................................................. 15
3.2 Hoisting of the diesel engine.................................................................................................... 16
3.3Installation of the diesel engine................................................................................................. 16
3.4 Preparations before starting the diesel engine.......................................................................... 17
3.5 Starting of the diesel engine..................................................................................................... 18
3.6 Stopping of the diesel engine................................................................................................... 18
3.7Running of the diesel engine..................................................................................................... 18
3.8Operation of diesel engine in winter......................................................................................... 19
3.9Power definition and usage conditions of diesel engine for land power generation................. 20
4. Maintenance of the diesel engine........................................................................................................ 21
4.1 Fuel, lubricating oil, coolant and auxiliary materials for the diesel engine ............................. 21
4.2Routine maintenance of the diesel engine................................................................................. 24
4.3 Regular maintenance of the diesel engine................................................................................ 28
4.4 Regular maintenance cycle of the diesel engine ...................................................................... 28
4.5Maintenance of the diesel engine for long-term storage........................................................... 29
5.Common faults and troubleshooting.................................................................................................... 29
5.1Diagnosis and adjustment methods........................................................................................... 29
5.2Common faults and troubleshooting......................................................................................... 30
6 .List of diesel engine wear parts .......................................................................................................... 40
7. Contact Us .......................................................................................................................................... 40

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1.Structure and parameters of the diesel engine
1.1Model Meaning of the diesel engine
1.2 Main technical parameters of the engine
Items
Unit
Parameters
Engine type
—
In line, watercooled, 4-stroke, DI, turbocharged and
intercooled
Number of cylinders
—
6
Bore/stroke
mm×mm
126×130
Displacement
L
9.726
Power
kW
320~360 (emergency standby power)
Oil/fuel consumption ratio
%
≤0.2
Emission level
--
China non-road Stage II
Crankshaft rotation direction
--
Clockwise (view from the free end)
Starting method
--
Electric started
Allowed longitudinal
inclination (front side/rear
side)
Long time
°
10/10
Short time
°
30/30
Allowed transverse inclination
(intake manifold side/exhaust
manifold side)
Long time
°
45/15
Short time
°
45/30
2. Brief introduction of main systems of the diesel engine
2.1 Gear train and valve mechanism
2.1.1 Sketch drawing of the gear train
6M16 series diesel engine adopts the front designed gear drive system (as shown in figure 2-1).

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1-crankshaft timing gear; 2-intermediate gear; camshaft timing gear; 4-air compressor gear;
5-injection pump gear; 6-oil pump intermediate gear; 7-oil pump gear
Figure 2-1 Gear train transmission diagram
2.1.2 Adjustment of valve clearance
Figure 2-2 Inlet valve clearance Figure 2-3 Exhaust valve clearance
(cold state) (cold state)
2.2 Lubrication system
The functions system include wear reduction, flushing, cooling and rust prevention, and the engine
oil to be used should be selected according to the company’s standards. And multi-grade oil is
preferred because it is benefit for cold starting performance. Multi-grade oils for use all year around,

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including 15W40, can be used within the specified temperature range. At occasional low
temperature, the engine oil can be preheated by taking appropriate measures, or replace the engine
oil suitable for the ambient temperature.
Time interval for replacement of engine oil is based on the requirements of maintenance and
service.
a)The engine is generally not filled with lubricating oil in delivery, and lubricating oil must be filled
prior to starting of diesel engine.
b) Please select the lubricating oil with appropriate viscosity grade based on the ambient
temperature (see table 1), and only multi-grade oil can be used.
c) It is recommended to use Baudouin Power special lubricating oil.
d)When the engine is stopped and remains stationary, the oil level in the oil pan must be located in
between the maximum and the minimum markings of the oil dipstick.
e)So far, the engine oil additives has not been found to bring any positive effect on operation of
6M16 series diesel engine, so the use of any engine oil additive is strictly forbidden.
Table 2-1 Selection of lubricating oil grade based on ambient temperature
Notice: The lubricating oil with grade CF-4 or above is used to 6M16 diesel engine forpower
generation. Each time when replacing the lubricating oil, the oil filter element must be replaced!
Ambient
temperature
Ambient
temperature
Multi-grade
oil

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Forced lubrication:
The engine oil from the oil pan passes through the oil strainer and then is pumped into the oil filter
and oil cooler by the oil pump, and finally arrives at the positions need to be lubricated through the
oil line system. Most of the oil will come to the main bearings and then to the connecting rod
bearings via the oil hole of crankshaft. The lubrication of cylinder liner surface and piston pin is
achieved through the lubricating oil injected by the piston cooling nozzle. The valve control system,
turbocharger, oil pump and intermediate gear bearing are also provided with forced lubrication via
the oil pipe and oil groove. The piston head is cooled through injecting lubricating oil to the inner
chamber of piston by the piston cooling nozzle; and the lubricating oil is cooled by the cooling
water in oil cooler. The pressure of lubricating oil in the circulation system is regulated by the
pressure limiting valve in the oil pump body.
When starting the diesel engine, with low oil temperature and high viscosity, the oil pressure will be
higher, but as water temperature of the diesel engine increases, the oil temperature will increase and
the oil pressure will gradually drop to the normal range of 350kPa~580kPa.
2.3 Fuel system
Since the fuel system is of critical part of the diesel engine, the manufacturing and installation of
fuel tank and fuel pipe and quality of the fuel used can influence the performance and reliability of
the diesel engine. The fuel tank prepared by the user must be clean and free of rust and corrosion,
and it must be made of materials which do not react with diesel fuel to avoid production of foreign
matters. The fuel tank must be provided with fuel drain device to drain the water and foreign
matters in the fuel. It is recommended that a valve should be designed on the outlet pipe of the fuel
tank to facilitate maintenance of the pipeline.
2.3.1 Fuel returning
When installing, the fuel return pipe shall not contact with hot parts (e.g. exhaust manifold,
turbocharger, and exhaust gas recirculation pipe) of the diesel engine. There should be no throttling
area in the fuel return pipe. The fuel return pipe cannot touch any sharp edge, be folded to form
sharp corners or even be twisted. Incorrect installation of fuel return pipe will cause fuel leakage.