Baudouin 6M33NG Operation And Maintenance Manual Download Page 55

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Maintenance

5.2 Maintenance Table

MOTEURS BAUDOUIN

Check =

•

In operation hours or period, every.

Hours and Months: A first-come-prevail.

Adjust =

Clean =

Replace =

□

OPERATION

Hour

750 1500 2250 3000 6000

Month

The coolant level

•

The gas pressure in the pipeline

•

Oil level

•

Fan

•

Lube grease quantity for fan pulley

bearing and fan belt tensioner

bearing

Exhaust gas color

•

Sound

•

The speed and vibration of gas

engine

•

Presence of water, gas and oil

leakages

•

Air filter service indicator

(if equipped)

•

Gas filter

•

□

Belt

•

□

Simple overall check

•

Hose clamps

•

Hoses and pipes

•

Summary of Contents for 6M33NG

Page 1: ...1...

Page 2: ...2 Operation and Maintenance Manual for 6M33 Series PowerKit Gas Engine OMMBV2007...

Page 3: ...in this Manual is correct at the time of publication Baudouin reserves the right to modify these specifications without notice Safety The Safety section of this manual covers basic safety precautions...

Page 4: ...Control Unit ECU and Electronic Parts Introduction 29 3 Installation 33 3 1 Engine Lifting 34 3 2 Engine Mounting 36 3 3 Accessories 37 3 4 Air Intake System 38 3 5 Exhaust System 38 3 6 Cooling Syste...

Page 5: ...Storage Protection Instruction 76 6 Appendix 82 6 1 Coolant Recommendation 82 6 2 Lubricant Oil Recommendation 83 6 3 Gas Recommendation 85 6 4 Baudouin Special Tools 86 6 5 Common Faults and Troubles...

Page 6: ...ore 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 in...

Page 7: ...ous situation and the ways in which to avoid danger Fail ure to comply with warnings can result in material damage serious injury or even death WARNING This type of warning indicates a potentially dan...

Page 8: ...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: ...e Series Figure 1 2B 6M33 Gas Engine Illustration Do not operate or perform maintenance on this engine unless you have read and understand the instructions and warnings in this Operation and Maintenan...

Page 10: ...nts 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 re...

Page 11: ...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 spa...

Page 12: ...event of corrosive material contact 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 d...

Page 13: ...ust be kept in good condition properly positioned and soundly attached All wires should be of the recommended size Wires and cables must be protected by a fuse or calibrated circuit breaker Do not sho...

Page 14: ...our hand Use a cardboard to check for a leak Tighten all connections and filter housings to the recommended torque Release the lubrication fuel and pressure cooling circuits before disconnecting or re...

Page 15: ...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 sea...

Page 16: ...ny 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 a...

Page 17: ...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 ar...

Page 18: ...Product 18 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...

Page 19: ...nery 2 2 2 3 Power Code Common rules Use number 2 4 6 as the different power level 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 altern...

Page 20: ...S EPA Tier 2 India CPCB 3 U S EPA Tier 3 EU Stage A B China stage 4 U S EPA Tier 4 India CPCB EU Stage China stage 5 EU stage 6 EU stage Note1 New product model should be compiled on the basis of the...

Page 21: ...Product 21 2 2 3 Engine Plate Figure 2 2 2A 6 M33 Gas Engine Plate Position...

Page 22: ...Right Side View 1 Air intake filter 2 Ignition coil 3 Air intake manifold 4 Air intake throttle valve 5 Cooling fan 6 Alternator belt 7 Alternator 8 Coolant pump inlet 9 Lube oil filter 10 Lube oil ce...

Page 23: ...gure 2 3 1B Left Side View 14 Crankcase breather 15 Turbocharger 16 Gas fuel mixer 17 Coolant outlet pipe 18 Air intake filter indicator 19 Starter 20 Lube oil draining plug 21 Vibration damper 22 Coo...

Page 24: ...Coolant Recommendation The coolant pump is located at the front end Overall Layout of 6M33 Series Gas Engine Cooling Circuit Figure 2 4 A Overall layout of Cooling Circuit Right Side 1 High temp coola...

Page 25: ...ling Circuit Left Side 1 High temp coolant from thermostat to radiator 2 High temp coolant collection pipe 3 High temp coolant from turbocharger 4 Coolant from cylinder block to turbocharger 5 Coolant...

Page 26: ...and one centrifugal oil filters a Full flow filters These filters are equipped with a by pass valve allowing the continuity of the engine lubrication even in case of a sudden clogging b Centrifugal o...

Page 27: ...in certain proportion with air by the mixer that is controlled by ECU Engine Control Unit The mixture of gas and air is compressed by turbocharger and then cooled by intercooler The throttle controls...

Page 28: ...r 70mbar Working temperature 15 60 Figure2 6 2 A Pressure Reducer Gas filter Function Filter the impurities in the gas Technical parameters Inlet pressure 0 2 bar Working temperature 20 70 Filter prec...

Page 29: ...eters ECU power supply rated voltage 24V normal operating voltage 8 32V Figure2 7 1 Engine Control Unit To prevent any damage to ECU it is forbidden to carry out plugging operation when ECU is powered...

Page 30: ...t temperature sensor Function Measure coolant temperature Technical parameters Rated working voltage 5 0 15 V Temperature measuring range 40 140 Figure2 7 4 Coolant temperature sensor Oxygen sensor Fu...

Page 31: ...Magnetic field allowable 2KA m Figure2 7 6 Speed sensor Electronic throttle Function Electronic throttle is mainly used for controlling mixture flow engine idling and rated speed ECU controls the act...

Page 32: ...is used to transmit high pressure spot generated by ignition coil to sparking plug so as to generate electric spark for igniting gas air mixture Figure2 7 9 Ignition cable Spark plug Function Sparkin...

Page 33: ...nstruction has been fully observed Failure to comply with the installation and operation instructions defined by Baudouin will void the warranty Notice After the gas engine is unpacked firstly the use...

Page 34: ...ng eye falls below 90 Use a lifting device with the crossbars as illustrated Avoid any contact between the chains and the engine parts The lifting hook and the engine lifting eye should be connected t...

Page 35: ...Installation 35 The two lifting eyes of 6M33 series gas engine are illustrated as following Figure 3 1 3 Lifting eyes 1 Rear lifting eye 2 Front lifting eye...

Page 36: ...l the engine s mounting brackets should be used Vibration absorber should be arranged to reduce vibration from the engine to its chassis The mounting brackets of 6M33 series gas engine are illustrated...

Page 37: ...s During installation add proper O ring sealing in the cooling system pipes As figure 3 3 the O ring should be arranged in the flange before connecting pipe with coolant pump inlet When connecting pip...

Page 38: ...a Exhaust system components should not exert excessive stress on the exhaust manifold or turbocharger The exhaust system parts weight inertia relative movement between components and dimensional chang...

Page 39: ...nding measures must be taken to eliminate potential difference and pre vent electrical corrosion aluminum radiator do not require The surface of the radiator should not be covered by other components...

Page 40: ...ed with an upstream protection device to cut off the gas when the engine is stopped or gas is leaking Test connection points with leakage detecting liquid under the rated gas working pressure and no b...

Page 41: ...y resistance Permissible resistance of the starter control wiring is 500m Before installing remove the paint on the connecting points 3 9 2 Charging Circuit The charging cable shall be a complete cabl...

Page 42: ...connected to the battery The black wire marked with POWER is connected to the battery The wire diameter is 2 5mm key switch wire T15 ECU pin No 38 Connect the wire with the battery via a key switch F...

Page 43: ...is applied to the engine that needs to be connected with the grid When the grid starts running the signal switch needs to be on When the grid is opened the signal switch needs to be off The ECU wiring...

Page 44: ...in connection is disconnected the engine will remain the final speed The ECU wiring harness reserves two wires for this switch the two wires labeled LOWER SPEED The wire s diameter is 0 75 mm diagnose...

Page 45: ...d conform to local code After compacting hard soil the precast concrete foundation should be at least 200mm thick When installing the vibration absorbers are evenly placed under the unit chassis The u...

Page 46: ...g its environment conditions Take the necessary measures for the emergency shut off of the gas or air supply to prevent from over speed risks Check the cleanliness of circuits Check for free circulati...

Page 47: ...ring mixing Add coolant through the water filler port of radiator or heat exchanger and bleed the air from the cooling circulation system When opening the filler cap with the pressure relief valve and...

Page 48: ...Operation 48 Note After installing the genset make sure removing all adjustment bolts illustrated in fig 4 1D before starting the genset Figure 4 1D Removing adjustment bolts after installing...

Page 49: ...e indicator lamps bulbs and buttons once by pressing the touch button on the control panel Turn the key to position START to start the engine and then release the key The key will automatically return...

Page 50: ...mperature after turbocharger 650 C Intake temperature after intercooler 45 C 25 C ambient temp Check the exhaust color to estimate the performance of the combustion and the load of the engine In the c...

Page 51: ...ns be sure to check the electrolyte liquid level viscosity and battery voltage If the engine is not going to be operated for a long time under very low temperatures the battery should be removed and s...

Page 52: ...he heat will be transferred away by the cycling lubricating oil When the engine shuts down suddenly the turbocharger temperature will increase greatly and cause the bearing or the oil seal to fail Tur...

Page 53: ...he diagnostic lamp flashes and reports the fault code Repeat step 1 for several times the subsequent fault codes will be shown one by one When the first fault code is repeated it indicates that all th...

Page 54: ...aintenance operations are intended to check Engine and generator alignment The tightness of the entire engine unit on the frame The tightness of the couplings and all elements transmitting power The i...

Page 55: ...8 750 1500 2250 3000 6000 Month 12 12 12 12 24 The coolant level The gas pressure in the pipeline Oil level Fan Lube grease quantity for fan pulley bearing and fan belt tensioner bearing Exhaust gas...

Page 56: ...2 R3 R4 R5 OPERATION Hour 8 750 1500 2250 3000 6000 Month 12 12 12 12 24 Engine oil Oil filters Air filter Condensing draining pipes if equipped Defaults recorded in ECU Belt and tensioning Centrifuga...

Page 57: ...el battery charger battery cables Tightness of hoses and hose clamps Conditions and tightness of electrical connections State and tightness of alternator State and tightness of starter Tightness of co...

Page 58: ...M3 R1 R2 R3 R4 R5 OPERATION Hour 8 750 1500 2250 3000 6000 Month 12 12 12 12 24 Coolant pump Gas shutoff valve Gas pressure reducer Gas pipes Overhaul Top 1 Overhaul In Structure 2 Overhaul Major 3 1...

Page 59: ...l Level gauge Check the level by eyes CAUTION If coolant is not enough shut off engine and after engine has cooled add coolant through radiator filler cap Fill the coolant When filling coolant into th...

Page 60: ...mable and dangerous Open hood Remove dipstick and wipe clean with a lint free cloth Insert dipstick until fully seated Remove dipstick and check oil level at 3 mm below the H on the dipstick If oil le...

Page 61: ...e belts can cause unnecessary wear on the following components Belts pulleys and bearings CAUTION If the belts are too tight unnecessary stress is placed on the components This reduces the service lif...

Page 62: ...lement as per the manufacturer s instructions Press the button at the top to reset Replace the engine oil Run engine to warm oil slightly Stop engine Loosen drain nut Drain oil into the container Chec...

Page 63: ...weep the dust on external filter element from inside to the outside and DO NOT wash the filter element with oil or water Release clamp 2 Remove air filter 3 and clamp 2 from flange of intake housing 1...

Page 64: ...with EVERY oil replacing Remove oil filters by special tool Clean filter seat Replace oil cartridges to be done with EVERY oil change Lubricate seal ring on new filter with a small amount of clean en...

Page 65: ...oler core thoroughly with clean water Dry the oil cooler core with compressed air Direct the air in the reverse direction of the normal flow Check the rocker arm and cross bar clearance Check the clea...

Page 66: ...a feeler into the clearance and tap the corner of the side electrode gently with a small wrench if the clearance is narrow widen the clearance slowly with a vise insert the feeler gauge and then gent...

Page 67: ...n of safety devices and alarm Replace the ignition coil Use multi meter to check the contact situation of wiring harness and connectors Replace the mixer and gas pressure regulator valve Regulate mixe...

Page 68: ...e 2 72mm exhaust valve Do not allow the projection of the exhaust valve stems to exceed this limit The inner diameter of valve guide is also considered as one factor for planning top overhaul the limi...

Page 69: ...ver evaluating both the conditions is the most accurate method of determining when an in structure overhaul is necessary Periodically measure each condition The first measurement should occur during t...

Page 70: ...major overhaul is performed for every fourth top overhaul The need for a major overhaul is determined by several factors Some of those factors are the same factors that determine the in structure over...

Page 71: ...ooler Throttle Inspect Replace Flywheel ring gear Timing gears clearances Gear Gear shaft Inlet air piping Rebuild Replace Starter Cylinder head assemblies Crankshaft Turbocharger Coolant pump Camshaf...

Page 72: ...e turbine wheel Do not attempt to clean the turbine wheel For information regarding removal and installation see the repair manual or consult your Baudouin dealer For information about repair of the t...

Page 73: ...n Change a new strainer assembly if necessary Install the strainer assembly and the oil pan Inspect gear Inspect the condition of the gears Whether the tooth surface of each gear is peeling and broken...

Page 74: ...the following conditions Malfunction of the solenoid Malfunction of the electric starting system Inspect the electrical system for the following conditions Loose connections Corrosion Wires that are w...

Page 75: ...e oil duct in pressure of 1 0 1 2 Mpa water duct in pressure of 0 4 0 5 Mpa Intake and exhaust manifold Inspect any crack or leakage from the manifold If there is any problem replace it as instruction...

Page 76: ...ntilation openings conduit connections etc to prevent entry of rodents snakes birds insects etc Keep the equipment dry Store in a dry indoor area Temperature swings should be minimal to prevent conden...

Page 77: ...volatile that any opening left unsealed will allow the vapors to escape causing the engine to lose protection Note VCI oil should not be used full strength on non ferrous metals where the inhibitor w...

Page 78: ...e engine stored for less than three months However for extended storage periods of three months or longer it is recommended that the cooling system to be drained flushed and refilled Refill with appro...

Page 79: ...h cylinder Use a bar or turning tool to rotate the engine slowly to put the oil on the cylinder walls Install all the spark plugs and tighten to the correct torque Intake and exhaust system Air filter...

Page 80: ...o prevent damage from condensation and put some desiccants then seal with the adhesive tape Attach a tag to the engine with a notation of the date that the unit was preserved Remove the waterproof cov...

Page 81: ...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...

Page 82: ...D6210 standard and the coolant used in Baudouin engines should not contain 2 ethylhexanoate which has compatibility problems with silicone rubber Do not use a commercial coolant that only meets the AS...

Page 83: ...w installation or the use of new types of oils Baudouin recommends take oil samples frequently from the engines for analysis to make sure the engine can be protected completely and make records of the...

Page 84: ...4582 95 ASTM D4624 93 ASTM D 97 0W 20 6200 35 5 6 9 3 2 6 40 0W 30 6200 35 9 3 12 5 2 9 0W 40 6200 35 12 5 16 3 2 9 5W 20 6600 30 5 6 9 3 2 6 35 5W 30 6600 30 9 3 12 5 2 9 5W 40 6600 30 12 5 16 3 2 9...

Page 85: ...n H2S 20mg Nm Impurity particle size 5 m Impurity content 30mg Nm Ammonia 20mg m Tar content 50mg m Moisture content 20mg Nm If the gas is not used as specified there will be some loss of engine power...

Page 86: ...Appendix 86 6 4 Baudouin Special Tools No Name 3D Model 1 Piston installing guider 2 Crankshaft rotating tool 3 Rear oil seal installer 4 Front oil seal installer...

Page 87: ...Appendix 87 No Name 3D Model 5 Flywheel brake 6 Cylinder liner installer 7 Flywheel hanger tool 8 Camshaft mounting tool aluminum 9 Valve collet assembling tool...

Page 88: ...Appendix 88 No Name 3D Model 10 Cylinder block expansion tool 11 Shock absorber guider 12 Piston extraction tool 13 The 21 socket tools 14 Camshaft bush installer...

Page 89: ...ake system for blockage and air leak 4 The start up rotating speed is too low the minimum start up rotating speed is 100r m Check whether the battery voltage can reach 24V or not 5 The intake and exha...

Page 90: ...take the spark plug does not work properly etc Check the spark plug ignition coil and wiring harness 2 The natural gas supplied is too thick or too thin the pressure reducer works improperly Check the...

Page 91: ...pipe 2 The manual valve on gas bottle is not fully opened Check the gas bottle valve 3 The ignition system has failure Check the spark plug oxygen sensor 4 The pressure reducer is out of order incompl...

Page 92: ...63 17 DTC ECT Insufficient activity 110 10 264 18 DTC ECT Warmup Slower than Expected 110 1 266 19 DTC Engine EGT Voltage High 173 3 491 20 DTC Engine EGT Voltage Low 173 4 492 21 DTC EGT Higher Than...

Page 93: ...n Fault 632 5 251 57 DTC Propane Gas Fuel LockOff Short Open Fault 516132 5 252 58 DTC MAP Voltage High 106 3 342 59 DTC MAP Voltage Low 106 4 341 60 DTC MAP Data Drift High 106 20 343 61 DTC MAP Data...

Page 94: ...high 3938 3 812 96 DTC Synchronizer input low 3938 4 813 97 DTC Remote Speed reference input high 189 3 638 98 DTC Remote Speed reference input low 189 4 639 99 DTC Battery Voltage Higher Than Expect...

Page 95: ...3057 2 414 136 DTC UEGO Air Cal at Lower Limit 3057 17 415 137 DTC UEGO Air Cal at Upper Limit 3057 15 416 138 DTC UEGO SNS Open Fault 3057 5 453 139 DTC UEGO SNS Short to GND Fault 3057 4 454 140 DT...

Page 96: ...Pressure 632 7 476 165 DTC deltaP Higher Than Expected 1391 16 477 166 DTC deltaP Lower Than Expected 1391 18 478 167 DTC deltaP Zero Offset Fault 1391 20 479 168 DTC Cylinder 1 Misfire 1323 31 751 1...

Page 97: ...Appendix 97 6 6 Maintenance Log Frequency Current Maintenance Preventive Overhaul Note Operating Hours Period M1 M2 R1 R2 R3 Date Hours Period Visa or stamp...

Page 98: ...Appendix 98 Frequency Current Maintenance Preventive Overhaul Note Operating Hours Period M1 M2 R1 R2 R3 Date Hours Period Visa or stamp...

Page 99: ...Appendix 99 Frequency Current Maintenance Preventive Overhaul Note Operating Hours Period M1 M2 R1 R2 R3 Date Hours Period Visa or stamp...

Page 100: ...Fault Codes List 93 Engine Electronic Controlling System 43 Engine Lifting 35 Engine Model 19 Engine Mounting 37 Engine Overview 22 Exhaust System 39 Fluid Safety 11 Fuel Recommendation 86 Gas filter...

Page 101: ...7 Operation of the PowerKit Engine 51 Personal Safety 10 Precautions for running in cold environments 52 Preparations before Start 48 Rating Definitions 18 Removal from Storage 81 Special Tools 87 Sta...

Page 102: ...2 Contact Us Address Moteurs Baudouin Technoparc du Bregadan 13260 Cassis France Website Baudouin com Aftersales Service Center sav baudouin com 2018 Soci t International des Moteurs Baudouin All Righ...

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