WEICHAI Baudouin PowerKit 12M33 Series Operation And Maintenance Manual Download Page 91

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Address: Moteurs Baudouin, Technoparc du Bregadan, 13260 Cassis, France

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Summary of Contents for Baudouin PowerKit 12M33 Series

Page 1: ...1...

Page 2: ...2 Operation and Maintenance Manual for PowerKit 12M33 Series Gas Engine OMMBV1910...

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 26 3 Installation 31 3 1 Engine Lifting 32 3 2 Engine Mounting 35 3 3 Accessories 36 3 4 Air Intake System 37 3 5 Exhaust System 37 3 6 Cooling Syst...

Page 5: ...Maintenance for Long term Storage 68 6 Appendix 70 6 1 Coolant Recommendation 70 6 2 Lubricant Recommendation 71 6 3 Fuel Recommendation 73 6 4 Special Tools Recommendation 74 6 5 Common Faults and T...

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 12M33 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 Maintena...

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: ...s allowed PRP Unlimited Prime Rated Power Engines of this rating provide unlimited hours of usage in a variable load application The average load factor should not exceed 70 of the engine s prime powe...

Page 19: ...Product 19 2 2 Engine Model 2 2 1 Meaning of Engine Model 2 2 2 Engine Plate 12M33 Series Gas engine Figure 2 2 2A 12 M33 Gas Engine Plate Position...

Page 20: ...Thermostat 2 Ignition Coil 3 Turbocharger 4 Mixer of Gas and Air 5 Water Outlet 6 Intercooler 7 Electronic Throttle 8 Starter 9 Oil Cooler 10 Oil Filter High Temperature 11 Water Pump 12 Intake Manifo...

Page 21: ...is IMPERATIVE to use the recommended coolant as defined in the 6 1 Coolant Recommendation The high temperature coolant pump is located at the engine s front side See item 2 of the above picture b Low...

Page 22: ...rature Cooling Circuits for 12M33 Series Gas Engine Overall Layout Figure 2 4 2 Overall Layout of low temp cooling circuits 1 Radiator 2 Electrical Low temp Water pump 3 Cooled Water Line 4 Intercoole...

Page 23: ...s a Full flow filters fitted in series on the circuit These cartridges are equipped with a by pass valve allowing the continuity of the engine lubrication even in case of a sudden clogging b Centrifug...

Page 24: ...gas filter and pressure reducer in turn The mixer mixes natural gas and air in proportion controlled by ECU Engine Control Unit The mixture of gas and air is compressed by turbocharger and then coole...

Page 25: ...filter Function description Filter the impurities in the gas Technical parameters Inlet pressure 0 2 bar Working temperature 20 70 Filter radius 50 m Figure2 6 3 Gas Filter Gas and air mixer Function...

Page 26: ...t ECU shall be installed in control panel to realize real time monitoring of engine parameters Technical parameters Working voltage 24V Working environment 40 105 Figure2 7 1 ECU Engine Control Unit T...

Page 27: ...king temperature measuring terminal 40 150 Rated working voltage 5 0 25 V All magnetic field allowable 2kA m Maximum torque allowable shall be 8 2 N m during assemble when 8 8 M6 12 bolts are used ins...

Page 28: ...ne Figure2 7 5 Oxygen sensor Engine speed sensor optional Function description Engine speed sensor is mainly used to measure engine s revolving speed We can use it to compare with engine s revolving s...

Page 29: ...of connectors in case that connectors and wiring harness have no problems and its feedback signal bounces replacement of new parts shall be taken into consideration Figure2 7 7 Electronic throttle Ig...

Page 30: ...lug Function description Sparking plug is used to receive high voltage generated by ignition coil generate electric spark and ignite flammable gas This engine uses double platinum sparking plug Figure...

Page 31: ...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 32: ...e 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 tightl...

Page 33: ...nstallation 33 The four lifting eyes of 12M33 series gas engine are illustrated as following Figure 3 1 3 A Right lifting eyes face to the flywheel Figure 3 1 3 B Left lifting eyes face to the flywhee...

Page 34: ...Installation 34 Figure 3 1 3 C Distance between left lifting eyes and right lifting brackets Figure 3 1 3 D Dimensions of lifting bracket 1045mm...

Page 35: ...g brackets should be used Vibration absorber should be arranged to reduce vibration from the engine to its chassis For the engine s installation angle The front rear orientation limitation is 10 The l...

Page 36: ...iteria Add O ring seal during installation in the coolant system pipes As the figure 3 3 the O ring should be arranged in the flange before it was connected to the radiator outlet pipe When you connec...

Page 37: ...exhaust manifold or turbocharger The exhaust system parts weight inertia relative movement between components and dimensional change due to thermal load can exert excessive stress Avoid the exhaust p...

Page 38: ...coolant pipe between the pump and radiator is 45mm The minimum distance between rear of the fan and front side of the engine is 100mm The coolant capacity of the engine W O radiator is approx 76L 3 7...

Page 39: ...shall be provided 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 p...

Page 40: ...ling cable 1 5mm 2 The wiring terminals of starter shall be equipped with protective caps Summation of startup cables resistance terminals No 30 and 31 1m Permissible voltage decrease of main cable 0...

Page 41: ...positive 69 70 negative Functional description ECU main power supply 24V DC The red wire marked POWER is connected to the battery The black wire marked with POWER is connected to the battery The cros...

Page 42: ...gnal wire Functional description When parallel or grid connection is required the signal line is connected to the speed control signal wire The two wires are labeled SPEED BIAS REMOTE SPEED and the wi...

Page 43: ...nvariant The ECU wiring harness reserves the two wires for this switch the two wires labeled RAISE SPEED The wire s cross sectional area is 0 75 mm 2 lower speed Pin No 14 signal 32 signal ground Inst...

Page 44: ...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 45: ...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 circulation of gases in exhaust ducts Check the natural g...

Page 46: ...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 47: ...e touch button 10 on the control panel Turn the key to position START to start the engine and then release the key The key will automatically return to position 1 Figure 4 2 Switch NOTE At the start o...

Page 48: ...C Exhaust temperature after turbine 550 C Intake temperature after intercooler 50 60 C Check the exhaust color to estimate the performance of the combustion and the load of the engine In the case of...

Page 49: ...o check the electrolyte liquid level viscosity and battery voltage If the engine is not going to be operated for a long time and under very low temperatures the battery should be removed and stored in...

Page 50: ...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 51: ...iagnostic lamp flashes and reports the fault code Repeat step 1 st for several times the subsequent fault codes will be shown one by one When the first fault code is repeated it indicates that all the...

Page 52: ...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 53: ...ur 8 750 1 500 6 000 12 000 24 000 Month 12 12 48 96 Coolant Level Gas Oil Level Belt Fan Sound Speed and Vibration of Engine Exhaust Gas Color Presence of Water Gas and Oil Leakages Air Filter Servic...

Page 54: ...MD M1 M2 R1 R2 R3 OPERATION Hour 8 750 1 500 6 000 12 000 24 000 Month 12 12 48 96 Belt Tensioner Rubber Hoses Water Pump Cylinder Head Cover Gasket Turbocharger Thermostat Ignition Coil Mxier Throttl...

Page 55: ...OPERATION Hour 8 750 1 500 6 000 12 000 24 000 Month 12 12 48 96 Intake Valve Piston Sensor Rocker Arm Rocker Arm Shaft Connecting Rod Bearing Piston Rings Cylinder Liner Oil Seal Lubricating Oil Pum...

Page 56: ...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 the engine which...

Page 57: ...d 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 level is in L mark add oil thr...

Page 58: ...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 59: ...t 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 2 Drain oil into the container Check t...

Page 60: ...lts for wear and for cracking Replace the belts if the belts are not in good condition as shown A and B Slippage of loose belts can reduce the efficiency of the driven components Vibration of loose be...

Page 61: ...sweep 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...

Page 62: ...emove air filters by hand 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 engine oil Tighten the filter by hand...

Page 63: ...ion of the solution either by raising or lowering the stack or by means of a jet of steam or air may accelerate the washing process Coolant Side To clean the tubes internally if the scale is hard and...

Page 64: ...with compressed air Direct the air in the reverse direction of the normal flow Check the rocker arm and cross bar clearance Clearance of intake valve is 0 3 0 03 mm 0 012 0 001in and that of exhaust...

Page 65: ...Maintenance 65 You can determine the current fault Clearing the memory of historical errors Check state and tightness of starter Check state and tightness of alternator...

Page 66: ...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 gently tap the side electrode wit...

Page 67: ...f 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 mixer i...

Page 68: ...with positive voltage equal to that of the nominal system voltage using the specifically provided conductor Spray the protective oil 30 M in a quantity of about 10g per liter of displacement in the t...

Page 69: ...toring normal conditions of use Connect the turbocharger intake inlet to the air filter Join the gas circuits to the machine s tank bringing it close the operation as indicated in point 4 of the 5 4 1...

Page 70: ...56 15 C Protection 25 C Concentrated liquid with antifreeze Recommended dilution 45 Maximum admitted dilution 50 In arctic conditions 32 C 54 C recommended use of a 60 ethylene glycol antifreeze Never...

Page 71: ...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 a...

Page 72: ...STM D4741 87 ASTM D 4582 95 ASTM D4624 93 GB T 3535 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...

Page 73: ...e 1kPa min 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 fuel is not used as specified there will be some loss of en...

Page 74: ...Appendix 74 6 4 Special Tools Recommendation SN Name 3D Model 1 Piston Cylinder Guide 2 Barring Tool 3 12M33 Rear Oil Seal Installer 4 M33 Front Oil Seal Installer...

Page 75: ...Appendix 75 SN 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 76: ...Appendix 76 SN Name 3D Model 10 Expansion tool 11 Shock absorber guide bar 12 Piston extraction tool 13 The 21 socket tools 14 Camshaft Bush Installer...

Page 77: ...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 5 The intake and exhaust valve adjustment is wrong Chec...

Page 78: ...anged by mistake 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 improper...

Page 79: ...ntake pipeline 2 The manual valve on gas bottle is not fully opened Check the gas bottle 3 The ignition system is in fault Check the spark plug oxygen 4 The pressure reducer is out of order incomplete...

Page 80: ...ed 0 110 261 ECT Voltage High 3 110 262 ECT Voltage Low 4 110 264 ECT Insufficient activity 10 110 266 ECT Warmup Slower than Expected 1 110 Engine Exhaust Temp 491 Engine EGT Voltage High 3 173 492 E...

Page 81: ...5 725 Load Sensing 126 Load Sensor Voltage High 3 2452 125 Load Sensor Voltage Low 4 2452 Lock off 251 Natural Gas Fuel LockOff Short Open Fault 5 632 252 Propane Gas Fuel LockOff Short Open Fault 5 5...

Page 82: ...4 Oil Temperature Voltage High 3 175 193 Oil Temperature Voltage Low 4 175 222 Oil Temperature High 16 175 198 Oil Temperature IR Low 17 175 Synchronization Input 812 Synchronizer input high 3 3938 81...

Page 83: ...on Voltage High 3 1442 634 L Series Trim Position Voltage Low 4 1442 636 L Series Trim Valve Status 12 1442 635 L Series Trim Valve Drive fault 5 1442 631 Trim Position adapt low fault 18 1442 632 Tri...

Page 84: ...653 Starter Control Relay Fault 5 1675 Memory 621 CPU Load Higher than Expected 9 629 623 SRAM Memory Fault 11 629 622 Flash Memory Fault 31 629 Fan Control 434 Fan Speed Close Loop Control 7 1639 43...

Page 85: ...18 1391 479 Delta P Zero Offset Fault 20 1391 Fuel Pressure 885 Fuel Pressure Voltage High 3 2980 886 Fuel Pressure Voltage Low 4 2980 Misfire 751 Cylinder 1 Misfire 31 1323 752 Cylinder 2 Misfire 31...

Page 86: ...Appendix 86 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 87: ...Appendix 87 Frequency Current Maintenance Preventive Overhaul Note Operating Hours Period M1 M2 R1 R2 R3 Date Hours Period Visa or stamp...

Page 88: ...Appendix 88 Frequency Current Maintenance Preventive Overhaul Note Operating Hours Period M1 M2 R1 R2 R3 Date Hours Period Visa or stamp...

Page 89: ...stic Fault Codes List 83 Engine Electronic Controlling System 41 Engine Lifting 32 Engine Maintenance for Long term Storage 71 Engine Model 19 Engine Mounting 35 Engine Overview 20 Engine Start up aft...

Page 90: ...Log 89 Maintenance Operations 56 Maintenance Table 53 Operation 45 Operation of the PowerKit Engine 48 Personal Safety 10 Precautions for running in cold environments 49 Preparations before Start 46...

Page 91: ...tact 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 Rights Re...

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