Baudouin PowerKit 6M21 Series Manuale utente
Operation and Maintenance Manual
PowerKit 6M21 Series Diesel Engine
6M21(CR)
6M21(MP)
OMMBV2001
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...........................................................................................................................1
1. Safety............................................................................................................................1
1.1 Safety Information........................................................................................................ 1
1.2 Symbols Used.............................................................................................................. 2
1.3 Personal Safety............................................................................................................ 6
1.4 Environmental Safety................................................................................................... 6
1.5 Fluid Safety .................................................................................................................. 7
1.6 Batteries ....................................................................................................................... 7
1.7 Welding......................................................................................................................... 8
1.8 Electrical Risks............................................................................................................. 9
1.9 Lines, Tubes and Hoses............................................................................................. 10
1.10 Coolant Safety.......................................................................................................... 10
1.11 Cleaning the Engine..................................................................................................11
1.12 General Precautions for Operation .......................................................................... 12
1.13 Recommendations for Engines Equipped with Common Rail System.................... 14
2. Product........................................................................................................................15
2.1 Rating Definitions....................................................................................................... 15
2.2 Engine Model ............................................................................................................. 16
2.3 Engine Overview........................................................................................................ 19
2.4 Cooling Circuits.......................................................................................................... 21
2.5 Lubrication System..................................................................................................... 22
2.6 Fuel System ............................................................................................................... 23
2.7 Electronic Control Unit (ECU) .................................................................................... 25
2.8 Electronic Governor System for Mechanical Pump Engine....................................... 31
3. Installation................................................................................................................... 33
3.1 Engine Lifting.............................................................................................................. 34
3.2 Engine Mounting ........................................................................................................ 36
3.3 Accessories ................................................................................................................ 38
3.4 Air Intake System ....................................................................................................... 39
3.5 Exhaust System ......................................................................................................... 39
3.6 Cooling System.......................................................................................................... 39
3.7 Lubrication System..................................................................................................... 40
3.8 Fuel System ............................................................................................................... 40
3.9 Engine Control System............................................................................................... 41
3.10 Electrical Components ............................................................................................. 43
3.11 Installation and debugging of Electronic Governor System ..................................... 44
3.12 Genset Installation Recommendations .................................................................... 49
4. Operation.................................................................................................................... 50
4.1 Preparations before Start........................................................................................... 51
4.2 Starting Up ................................................................................................................. 52
4.3 Operation of the PowerKit Engine.............................................................................. 53
4.4 Precautions for running in cold environments............................................................ 54
4.5 Stopping the PowerKit Engine ................................................................................... 55
4.6 Electronic control system ........................................................................................... 56
Content
5. Maintenance ............................................................................................................... 57
5.1 General Safety Conditions for Maintenance .............................................................. 57
5.2 Maintenance Table..................................................................................................... 58
5.3 Maintenance Operation.............................................................................................. 61
5.4 Storage Protection Instruction.................................................................................... 86
6. Appendix .....................................................................................................................93
6.1 Coolant Recommendation.......................................................................................... 93
6.2 Lubricant Recommendation ....................................................................................... 94
6.3 Fuel Recommendation............................................................................................... 96
6.4 Common Faults and Troubleshooting........................................................................ 97
6.5 Engine Maintenance Log...........................................................................................119
6.6 Recommended Torques for Bolts............................................................................. 122
Index............................................................................................................................. 124
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.
Safety
3
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
4
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
5
Universal Warning
The location of the Universal Warning label is illustrated below.
Figure 1.2A-6M21 Illustration
Do not operate or perform maintenance on this engine
unless you have read and understand 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.
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