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Страница 1: ...1...
Страница 2: ...2 Operation and Maintenance Manual for 6M33 Series PowerKit Gas Engine OMMBV2007...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 21: ...Product 21 2 2 3 Engine Plate Figure 2 2 2A 6 M33 Gas Engine Plate Position...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 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...
Страница 98: ...Appendix 98 Frequency Current Maintenance Preventive Overhaul Note Operating Hours Period M1 M2 R1 R2 R3 Date Hours Period Visa or stamp...
Страница 99: ...Appendix 99 Frequency Current Maintenance Preventive Overhaul Note Operating Hours Period M1 M2 R1 R2 R3 Date Hours Period Visa or stamp...
Страница 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...
Страница 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...
Страница 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...
