Operation and Maintenance Manual for PowerKit 4M11/6M11 Series

Operation and Maintenance Manual

for PowerKit 4M11/6M11 Series

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 Operation and Maintenance Manual for PowerKit 4M11/6M11 Series

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 4M11/6M11

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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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Table of Contents
I. Model meaning of the diesel engine ................................................................................... 7
1. Fuel, lubricating oil and coolant used for diesel engine .......................................................... 8
2. Installation and connection of diesel engine ......................................................................... 11
3. Precautions and operational requirements for diesel engine ............................................... 13
4. Maintenance specifications for industrial engines ................................................................ 17
5 Main maintenance specifications for accessories of diesel engine ..................................... 20
6. Common failure analysis and troubleshooting ...................................................................... 31
7. Contact Us .............................................................................................................................. 35

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I. Model meaning of the diesel engine

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1. Fuel, lubricating oil and coolant used for diesel engine

1.1 Oil

1.1.1 Quality grade

Refer to the quality and feature to divide the oil into API and GB standards. Engine oil
allowed to be used:
API grade: CF-4 and CH-4
GB grade: CF-4 and CH-4
It is allowed to use the oil with higher quality grade to instead of engine oil with lower
quality grade.

1.1.2 Oil viscosity

Refer to table 1-1 for selection of oil viscosity.
Table 1-1 The relation between oil viscosity and ambient temperature
Applicable environmental
SAE viscosity grade
temperature (ºC)
0W-20 -35-20
5W-30 -30-30
10W-30 -25-30
15W-40 -20-40
20W-50 -15-45

Notice: Before starting of diesel engine, thoroughly check the oil level in the oil
pin.
Do not check engine oil level with engine running.
It is not allowed to mix different grades of oil.
Suggestion:
It is recommended to use the Baudouin special oil, which is mixed by the
imported quality basic oil and selected additive. This oil is sold at all the service
stations of Baudouin at the unified national sale price.

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1.2. Fuel
1.2.1 The diesel engine uses the light diesel as the fuel;
1.2.2 Quality grade
Sulfur content in the fuel with specified grade should not be higher than 1%.
It is allowed to use the following diesel fuels:
-GB252 0 ，－10 ，－20 ，－35 ，－50
-DIN 51601
-NATO CODES F54，F57，F76
-BS 2869：A1，A2 ( for A2, pay attention to the sulfur content)
-ASTM D975-81：1-D，2-D
-W-F-800C：DF-A，DF-1，DF-2
• Apply the following grades of diesel fuel based on the ambient temperature.
If the ambient temperature is higher than 5℃, it is recommended to use the 0# diesel fuel
(GB 252-94)
At low temperature, the diesel fuel may precipitate the waxy material, leading
to poor mobility of diesel fuel. In such case, the fuel system will be clogged, causing failures
of diesel engine.
1.3 Coolant
1.3.1 Coolant must be filled in the cooling system of diesel engine
The industrial power engine requires the coolant, which is glycol type for
heavy-duty diesel engine, should have such features as antifreeze, anticorrosion and
scale proofing, as well as high boiling point.
Coolant classification
Coolant are classified into two grades according to the engine loads:
a. Coolant for light-duty engine
b. Coolant for heavy-duty engine
1.3.2 Select coolant correctly
User could select different kinds of coolant depending on the ambient temperature. Generally, the
antifreeze selection standard is to be lower than ambient temper ature by 10℃.Never use the
untreated water as the coolant.

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Relation between the freezing point of coolant and mass fraction of glycol

Freezing point of Mass fraction of glycol Mass fraction of water

Density/(kg.m-3)
coolant /℃ (％) (％)
10 26.4 73.6 1.0340
20 36.2 63.8 1.0506
30 45.6 54.4 1.0627
40 52.3 47.7 1.0713
50 58.0 42.0 1.0780
60 63.1 36.9 1.0833

1.3.3 Correct use of coolant

a. Do not fill the coolant too quick. Otherwise, the gas in the engine cannot be drained easily.
b. It is better to keep the filling speed at 13.5L/min.
c. Do not fill the radiator up for the first time. Start engine to let its temperature rise in idle
speed, then check the coolant level again. Refill it, if necessary.
d. The concentration of antifreeze should be inspected every 1000h. The antifreeze should be
changed every two years to avoid corrosion. Each time of maintenance or starting engine,
check coolant level and leakage. Avoid continuously running diesel engine with coolant
temperature lower than 60℃ or higher than 100℃. If above situations occur, find out the
cause and resolve it.
Suggestion: It is recommended to use the Baudouin Power heavy-duty engine
coolant which is sold at all service stations at the unified national sale price.
1.4 Disposal of used oil/fuel/coolant
Use the special container to collect the waste oil. As the oil, fuel and coolant is toxic, neither
drink nor connect with skin.

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2. Installation and connection of diesel engine

Hoisting of diesel engine
2.1 Hoist diesel engine incorrectly will lead to damage in the process of hoisting.

Figure A

Figure B
There are 2 special bolts on the cylinder head in each diesel engine for hoisting. On the head of
hexagon bolt there is a screw rod with M14 hole for mounting hoisting device or lugs (see
figure A). When using the special hoisting device, screw the rods with the 2 bolts respectively,
adjust the center of gravity, then the engine can be hoisted. In case of hoisting by lugs on the 2
bolts, it is recommended to use device as shown in figure B.
When the engine is hoisted, the crankshaft shall be horizontal and the two hoisting ropes are
parallel. It is better not to use one rope in a triangle shape as shown in the right one of figure B.
As the rope, bolts and lugs are out of a straight line, the bolts in cylinder head may be damaged
or even broken, causing damage to the diesel engine.

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2.2 Installation of diesel engine

The diesel engine shall be installed with flexible connections and ensure the central line of
crankshaft shares an axis with transmission devices (gear box, transmission box) and the
crankshaft bears no axial force caused by the installation.

2.3 Installation of exterior system of diesel engine

The exhaust pipes shall be as straight as possible. There shall be expansion joints in the middle
of the pipe; the pipeline shall be supported additionally; the inner diameter of the exhaust
pipeline shall be not less than 83mm with exhaust back pressure not greater than 6kPa.
The outdoor exhaust pipe shall be covered with rain shield. To facilitate the release of water in
the pipe, install a water drain plug at the lowest position of the exhaust pipe.The outdoor
intake port shall be installed with a waterproof cap to prevent rainwater entering the intake
system.The capacity of fuel tank shall support the diesel engine for 8-hour running in rated
conditions. The outlet of the fuel tank shall be not lower than the inlet of injection pumpof oil
supply pump. Inner diameter of fuel pipeline shall be not less than 12mm.

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3. Precautions and operational requirements for diesel engine

3.1 Preparation for operation
3.1.1 Unsealing
After the diesel engine is unpacked, user should firstly refer to the packing list to check the
diesel engine and accessories, to check whether there is damage on the surface of diesel engine
and whether the connector are loosened, then perform the following procedures:
a. Wipe the antirust coat and anticorrosive agent on the
exposed parts.

b. Drain the sealing oil in the fuel filter and parts of the fuel system (it is allowed to start
the engine with the sealing oil not drained. But it is prohibited to load the engine until the
sealing oil is completely consumed and diesel oil begins to be supplied.)
c. Check whether the coolant/oil plugs are in good state and whether the water/oil
temperature sensors are supplied. In addition, any part provided by the user should be
installed.
Note: Do not start the diesel engine until it is correctly installed and connected. If diesel
engine runs in enclosed room, ventilation must be conducted to ensure the exhaust is
drained to the outside.
3.1.2 Filling engine oil
a. Engine oil should meet the requirements. If not, oil pressure may be insufficient, which
can lead to the wear and difficult startup. It is essential to keep the engine oil clean.
b. Tighten the oil drain plug.
c. Open the oil filler cap to fill the engine oil which should be filtrated by a mesh.
d. Diesel engine should be placed horizontally; take out the dipstick to check the oil level.
Add oil to the upper limit of the dipstick if necessary. Recommend amount for P4 model is
10L while for P6 model is 14L.

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e. Tighten the oil filler cap.

Note: At each time of starting diesel engine, check the engine oil level.
3.1.3 Filling fuel
a. The used diesel oil should meet the specifications.
b. Keep the diesel oil clean, and the diesel oil should be sedimentated at least 72h and then
filled into the fuel tank through the built-in mesh.
Note: At each time of starting diesel engine, check the diesel oil level.
3.1.4 Air bleeding of fuel system
a. Loosen the screw at the outlet of fuel supply pump by half circle. Repeat pressing down
the hand pump until the diesel emerges, then tighten the screw.
b. Loosen the air bleeding screw on the fuel filter. Repeat pressing down he hand pump until
the diesel emerges, then tighten the air bleeding screw.
c. Loosen the air bleeding screw on the fuel injection pump. Repeat pressing down the hand
pump until the diesel emerges, then tighten the air bleeding screw.
d. Continue to pump the hand pump to check whether the fuel pipe leaks, then tighten the
hand pump.
3.1.5 Filling coolant
Coolant is formulated by the softened clean water and anticorrosive agent or anti-freezing
agent, which should strictly follow the regulations from additive manufacturer.
The coolant should be filled via the inlet of radiator and heat exchanger to drain the air
in the cooling system.
Note: At each time of starting diesel engine, check the coolant level.

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3.2 Operation precautions

Rotate the crankshaft for several rounds before startup and make sure it rotates well, then
place the speed adjuster of the injection pump in the middle and switch on power.
If the diesel engine is not started within
5s, immediately release the button, and
then wait 1min for the second startup. If
the engine could not be started for 3
consecutive times, please stop at once,
troubleshoot for starting again.
After the diesel engine is successfully
started, idle it for 2-3min and the oil
pressure should not be less than 100kPa. Otherwise, stop the engine and find out
the cause. If the cooling water is still less than 60℃, do not suddenly speed up and
increase load, which otherwise impair the abrasive resistance and reliability. Check the
“three-leakage” after each operating.
Before loaded diesel engine stopping, please reduce the load and rpm, and idle it
for 5～10min.Avoid stopping engine with full load. Engine oil level inspection: it is correct to
check the oil level 5min after engine is stopped.

Caution: To avoid from damage the diesel engine, the cable to the voltage adjuster of
diesel engine and the cable to the positive pole of battery shall not be removed during
the running. Different from DC generator, it is prohibited to check voltage of the
alternator via temporary grounding.

3.3 Engine Stopping

3.3.1 The engine shall not stop with full load. Before stopping, reduce the load and
speed and idle speed for 5-10min. In case of manual shut-down, press down the brake
lever till the flywheels stops or the speed indicated in the instrument is zero.
3.3.2 For diesel engine without anti-freeze liquid in the circulating water, the cooling water
shall be drained off in cold weather so as not to damage the engine. Screw off the drain valve
at the bottom of the fuel cooler to drain off the water; at the same time, screw off
the plug on the top of the radiator to drain off water in it.
3.4 Operational environment
If the ambient temperature is higher than －15℃, the diesel engine can be
normally started. If the ambient temperature is within －15℃-35℃, some assistant
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equipments should be used for normal startup. If the diesel engines are used in high-altitude
or hot regions, power of diesel engine will drop. As the diesel engine is not explosion-proof, its
operational environment should be free of inflammable and explosive.

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4. Maintenance specifications for industrial engines

Maintenance intervals and specifications of industrial engines are suitable for P4, P6, 10L, 12L,
13L and Baudouin series products.
4.1 Maintenance intervals and specifications of industrial engines
4.1.1 Maintenance intervals of industrial diesel engines
Initial maintenance ( P ) The new engine running 30-50h
Level 1 maintenance (WD1) Diesel engine working interval 250h
Level 2 maintenance (WD2) Diesel engine working interval 500h
Level 3 maintenance ( WD3) Diesel engine working interval 1000h
Level 4 maintenance (WD4) Diesel engine working interval 3000h
4.1.2 Daily maintenance for diesel engine
a. With diesel engine running, always notice that the oil temperature, oil pressure and
coolant temperature at outlet, and check for “three-leakage” (oil, gas and water). In case of any
abnormal, find out the cause and troubleshoot.
b. After the diesel engine is stopped, check the fuel, fresh-water coolant and
oil capacity, refill it if necessary.
c. Drain the moisture in the stage-one fuel filter.
d. Check the tension of belts, adjust it if necessary.
e. If the ambient temperature is less than 0 ℃, and the diesel engine is not filled with
antifreeze, drain the coolant to prevent the diesel engine parts from being froze.
f. Check oil level in the fuel injection pump and governor, refill it properly if
necessary.

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4.1.3 Inspection and maintenance for diesel engines.

Initial
Items Routine WD1 WD2 WD3 WD4
maintenance
Replace diesel oil and engine oil
▲ ▲ ▲ ▲ ▲
filter element

Replace fuel filter. ▲ ▲ ▲ ▲

Check and adjust valve

▲ ▲ ▲ ▲ ▲
clearance.
Check the coolant level and
▲ ▲ ▲ ▲ ▲ ▲
refill if necessary.
Check the coolant pump for
▲ ▲ ▲ ▲ ▲
leakage
Clean strainer of fuel pump ▲ ▲ ▲ ▲

Tighten the intake pipe and hose ▲ ▲ ▲ ▲ ▲

Clean the oil cooler elements ▲ ▲

Clean the intercooler elements ▲ ▲

Clean the fan and radiator ▲ ▲

Replace or clean air cleaner

▲ ▲ ▲
element.
Check and tighten the belt ▲ ▲ ▲ ▲ ▲ ▲

Check the fuel injection pump

▲
at the service stations
Replace zinc-stick plug ▲

Note: ▲ means items needed to be maintained.

Explanation: The maintenance intervals are based on the diesel engine running for
1500h each year. If the diesel engine works for 500h or less each year, its
maintenance intervals should be 1/2 of ones in above table.

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4.1.4 Spare parts and oil/fuel grade specifications

It is suggested for the users to purchase the special spare parts and oil (CF-4, 15W-40)
from Baudouin special service stations which can ensure engine works normally,
prolonging its service life.
4.1.5 Maintenance Instruction
In case of any failure within the period of “three- guaranty”, timely call 400-618-3066, and
then the call center will arrange Baudouin special service center for inspection and
repair at once. Baudouin will bear no responsibility in case of failures caused by using
special spare parts or oil not from the Baudouin or maintenance not done at
Baudouin special service station.

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5 Main maintenance specifications for accessories of diesel engine

5.1 Use and maintenance of fuel injection pump
5.1.1 Preparation for operation
a. Check whether the pump model is correct before installing the fuel injection pump,
replace it if not.
b. Wipe the antirust oil on the surface of fuel injection pump.
c. Clean the antirust oil inside of governor and fuel injection pump, and then refill the
lubricant with stipulated grade.
d. Antirust oil in fuel pipe should be removed before using, then fill the
pipe connected to the fuel injection pump with fuel, and continuously crank the
camshaft of fuel injection pump until the clean fuel is rejected from the fuel outlet valve.
5.1.2 Fuel
Using the inferior fuel not only could reduce the engine performance, but also
could greatly shorten the service life of fuel injection pump and engine.
a. Use the high-quality fuel. Generally, 0# light diesel is used in summer and -10# or higher
grade light diesel in winter.
b. The fuel should be clean, without any foreign material and moisture. Therefore,
fuel should be sedimentated for 72h or more. Periodically clean the filter element and fuel
supply pump mesh. In addition, timely change if there is any damage.
c. As the air mixed in fuel can hinder the fuel injection pump to work normally, drain the
air entering the pump and low-pressure fuel pipeline if the fuel injection pump is not used for
long time or fuel pipe joint is replaced. For draining air, loosen the overflow valve joint, repeat
pressing down the hand pump. After that, timely tighten the overflow valve joint.
5.1.3 Lubricant
a. Generally, fuel injection pump is forcefully lubricated by connecting with engine
lubricating system which can provide the lubricant. The new fuel injection pump
should be filled with proper lubricant before being put into use, because it cannot
be lubricated before engine provides the lubricant. Refer to the engine maintenance
interval to service the fuel injection pump by loosening the bolts at the
back housing to drain the used lubricant. After that, tighten the bolts and refill the new
lubricant.
b. For the fuel injection pump non-forcedly lubricated (for example: P9 series oil
pump), fill it with the stipulated-grade oil to the proper level measured by

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a dipstick. That can lubricate the fuel injection pump, with engine running. Refer to the
engine maintenance interval to service the fuel injection pump by loosening the bolts at
the back housing to drain the used lubricant. After that, tighten the bolts and refill
the new lubricant.
5.1.4 Adjust the fuel injection advance angle
Fuel injection advance angle. Namely, 1 piston of cylinder should be at optimal
pressure fuel pipe of 1 cylinder, and loosen fastening bolt in fuel injection flange and
pumps to check when oil flowing into the 1 cylinder, meanwhile, checks the flywheel scale.
Adjust fuel injection advance angle according to requirements, and then tighten the loosened
bolts and joints.
5.1.5 Sealing
When the fuel injection pump is not used for long time, antirust treatment should
be done. Change the fuel and lubricant in the pump with antirust oil, cover the
joint of fuel/oil return pipe and reseal it once very year.
5.1.6 Precautions
a. Without some experience and testing conditions, it is prohibited to dismantle the
fuel injection pump assembly, especially, the lead sealing parts which cannot be
unsealed.
b. The fuel injection pump should be stored in the vent and dry garage and kept away from the
chemical goods which can lead to corrosion and rust, such as battery and acid.
5.2 maintenance of supercharger
The engine oil of the supercharger flows out from the main oil gallery of engine to
lubricate and cool the supercharger, then return back to the lower portion of
crankcase.
a. Good lubrication is essential to the supercharger. The oil filter element should be
periodically cleaned or replaced.
b As the supercharger works at extreme-high rpm (about 70000～ 100000r/min), idle the
diesel engine after being started for about 5min and then load it. Do not
suddenly stop diesel engine at high load or speed, whereas, it is correct to gradually reduce the
load and rpm and then idle for 3-5min. otherwise, supercharger bearing may be damaged or
fail.
c. Periodically remove and check the air compressor housing and turbine case, and
clean the flow channel between impeller and housing. . Refill the clean oil at the oil inlet for
reassembly of supercharger.
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d. Precaution: As the rotor of supercharger is accurate high-speed rotating part, users are
not allowed to dismantle or impact it. Otherwise, the factory guarantee will be invalid.
5.3 Use and maintenance of air compressor.
The air compressor for 4M11/6M11 series diesel engine is of single-cylinder
reciprocating-type crank and connecting rod structure, which is driven by the belt or
gear.
a. The lubricant of air compressor flows from the main oil galley to the lubricating
bearing in the air compressor via the lubricant pipeline, and eventually to the oil
pan via the timing gear chamber.
b. Before entering the air compressor, the air has been filtrated. Then the filtrated air flows
out of the air cleaner and into the air compressor before getting in the
supercharger.
5.4 Use and maintenance of water pump
Water pump for 4M11/6M11 series diesel engine is installed in the front of engine and the
water pump volute is on the upper of the timing gear chamber. The water flow to the
right water chamber through a intermediate block and then flow into of cylinder from the
lower right of the engine body to cool the cylinder, then it comes to the water chamber cylinder
head to cool the cylinder head, finally the water comes out from the outlet of cylinder head
and comes into outlet pipe where there is a thermostat at the end. There are two outlets
on the thermostat: one is connected to the radiator and the other to the inlet of
water pump which is also called as minor circulation. When cooling water reaches 75
±2℃, the thermostat will start and be fully opened with cooling water at 90℃.The entire
cooling water after flowing though the radiator for cooling will be pumped into
engine. However, when the temperature of cooling water is less than 75 ±
2 ℃ , thermostat will cut off abovementioned passage, making the cooling water
directly though the inlet of water pump and accordingly heat the engine rapidly until the
required thermal state is reached. Therefore, that can prevent the wear at low temperature
and prolong the useful life of diesel engine. In case of any leakage in water pump replace the
seal.

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5.5. Use and maintenance of starter

a. Starter, as a short-time working part, should work for 15s at most. In addition, the
b. starting interval should be more than 30s.
c. In winter, if ambient temperature is less than 5℃, preheat the engine before startup.
d. Release the starting switch the moment the engine is started, separating the drive
e. gear of starter from the gear ring of flywheel.
f. Do not power the starter until the engine stands still, which can prevent
5.6 the flywheel from impacting the starter gear.
a. The installation of starter must follow its wring drawing. Before removal of starter;
b. ensure the battery is disconnected to the starting wire of starter.
Frequently check whether the fastener and wire insulation of starter are damaged,
and whether the wire is well connected. In addition, remove the dirt.
Use and maintenance of generator
Reasonable matching: with engine idling, the generator should meet the electricity
consumed by the all electrical equipments. The generator mismatching the
electrical equipments could lead to lack of electricity in battery and generator
overheating that could resulting in damage to governor and stator burning.
Generator should have proper min. running rpm, because too-low working rpm.
(Determined by the engine idling) also can lead to abovementioned failures.
Reliable fixing: generator should be correctly and reliably fixed on the engine. The bolts
should be matched with the mounting hole of generator, and the pulley
groove should share the same plane with the driving roller groove. The generator
bracket should have sufficient rigid and strength, which otherwise may lead to
damage to the generator.
Check the belt tension (shouldn’t be neither tight nor too loose) by pressing down the
middle part of it with force of 150N. It is optimal that the deflection is 10-20mm.
Belt tension should be checked every two months. Belt slackening may lead to generator
“idling”, insufficient electricity production (that can result in lack of electricity in
battery), stator burning and damage to bearing etc.

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5.7 Use and maintenance of oil pump

Oi l pump mounted on the W P4/ 6M11 diesel engi ne is of external gear pump. The two
gears wi th same quantity of teeth could mesh with each ot her. The two-gear
contrarotation and gear space should push the oil from the l ow-pressure chamber t o t he
high-pressure chamber. The consecutive rotation of gear could continuously provide the
each lubricating system wit h oil.
a. The oil pump performance is mainly dependent on the clearance between the gear in
the oil pump and its housing (end clearance and radial clearance).
b. When the oil pressure drops, repair the oil pump if other failures are ruled out. To check
the oil pump, firstly check whether there is leakage or burn happened to the oil pump. If not,
firstly check the pressure-limiting valve, and then remove the oil pump. Check whether the
pressure-limiting valve spring is softened, or whether the pump and end cover wear. If needed,
replace the oil pump.
c. If the oil pressure is over high, dismantle and check the pressure-limiting valve,
specially, whether the pressure-limiting valve can be open.
d. During removal and installation of oil pump, pay specially attention to the end
cover, interface of pump body and each positioning pin.
5.8 Use and maintenance of air cleaner
Warning! Wrong maintenance method may greatly shorten the service
life of engine.
a. The use of air cleaner should correctly follow the performance index of diesel
engine, which otherwise may impair the diesel engine dynamic property and
economy.
b. For the air cleaner with alarm, firstly check the alarm before diesel engine. When
the intake resistance indicator becomes red, maintain the air cleaner filter.
c. For the filter with multi-stage filtration, the strainer must be installed.
d. During installation, avoid sharp corners and check for leakage.
e. Water is prohibited to enter the air cleaner.
f. For the air cleaner with safety element, it is prohibited to remove the safety element
during maintenance of air cleaner.
g. Generally, the paper main element of the air cleaner should be maintained every
100-200h. The paper main element should be removed, and then slightly tapped or
shaken to get the dust off. Check the sealings in each element and replace any
damaged one. It is allowed to use the clean and dry compressed air with pressure
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less than 500kpa to blow the element from the outside to the inside. Place a lamp
into the element to check whether the filter element is pervious to the light, whether there
is crack, piercing or other damage. Never flush the main element with oil and water.
h. The main element should be replaced every 1000-2000h, together with the safety
element.
i. In case of the following items, replace the filter element assembly:
-- The filter element is damaged.
-- After the filter element is cleaned, the alarm still sounds.
-- To replace the element after being cleaned for 3 -6 times,
Select high-quality products to ensure the reliability of the diesel engine.
Therefore, it is suggested to purchase original parts.
5.9 Use and maintena nce of diesel filter
Diesel filter consists of strainer and fine filter. As the time goes by, the dirt or foreign
material becomes increasingly accumulated on the filter element surface and bottom of
housing, which can clog the element if it is not removed timely. As a result,
diesel engine can not be provided with sufficient oil, reducing the power. Therefore,
it is important to periodically maintain or clean the diesel filter.
a. Periodically open the drain plug at the bottom of housing to drain the dirty oil or
accumulated water.
b. Generally, filter element should be maintained once every 200-300h, and shortened if the
fuel quality is poor. During maintenance, timely replace any damaged filter element.
c. Before maintenance, chock the two holes on the main element to prevent any dirt
from getting in. The filter element should be cleaned in clean kerosene and diesel using a
soft brush. After that, use clean kerosene and diesel to clean it again. If conditions
permit, use clean compressed air to blow it from the inside to the outside.
d. Use clean kerosene or diesel to clean the inside surface of housing and each hole of end
cover.
e. Check if the sealing is damaged, if so, timely replace it.

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f. After maintenance and before use, check if there is oil leakage around each sealing
5.10 Use and maintenance of fresh-water cooler
The fresh-water cooler mounted on 4M11/6M11 series diesel engine is of shell-and-tube
heat exchanger of which principle is that the seawater flowing in the coolant pipe cools the
fresh water circuitously going in the inside of shell. Thus that can optimize the
cooling conditions of diesel engine and then improve the useful life of diesel engine.
a. If the diesel engine is not in use, do drain the water in the fresh-water cooler, which
otherwise is harmful to parts in fresh-water cooler, especially in winter. The fresh-water
cooler should be checked each quarter by cleaning the pipeline, removing the dirt and
replacing the zinc slab. Before reinstalling the fresh-water cooler already cleaned,
hydrostatic test should be conducted. The installation can only be done if there is no leakage
after the test lasts 30min under 0.4MPa of pressure.
5.11. Use and maintenance of air cooler
Air cooler mounted on 4M11/6M11 series diesel engine is a tube-and-fin heat
exchanger of which principle is that coolant flowing in tube could dissipate
the thermal of air in supercharger via the tube wall. Therefore, it can reduce
the intake temperature of diesel engine, increase the intake density
and increase the power of diesel engine.
a. If the diesel engine is not in use, do drain the water in the air cooler. Otherwise it
would be harmful to parts in air cooler, especially in winter.
b. The air cooler should be checked each quarter by smoothing the pipeline, removing the
dirt and replacing the zinc slab.
c. Before re-installing the air cooler already cleaned, hydrostatic test should be
conduct. As a result, there should be no leakage, after it is pressed with 0.4Mpa for
30min.
5.12 Use and Maintenance of electronic governor
The electronic governor mounted on 4M11/6M11 series diesel engine consists of
rpm controller, electromagnetic executor, rpm sensor, idling/rating switch,
trimmer potentiometer; control power supply and power switch assembly. The principle will
be explained as shown: idea rpm of engine is determined by the rpm setting potentiometer
and rpm trimmer potentiometer. Whereas, the actual rpm of engine is determined by the rpm
sensor mounted on the root of flywheel teeth. The signal outputted by the rpm
sensor is of AC voltage signal with frequency in direct proportion to the rpm.
This signal can be converted into the DC voltage via the F/V circuit, and then compared
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to the set value of RPM, as a result, the deviation value of rpm can be obtained.
This deviation value is operationally amplified by the PIDⅠ governor, which creates
the fuel-supply position value, namely steady-state output position index of executor. After
this index of executor is compared with the actual position of executor, the actual
position deflection can be obtained. Then the actual position defection is operationally
amplified by PIDⅡ governor, and then converted into the current control manner
which can output the drive current to the executor and accordingly change the motion
displacement of executor.
a. It is suggested to install the rpm sensor onto the gear ring of engine. In addition, the
b. Between the sensor and teeth crest should be 0.4mm-0.8mm. Firstly rotate the
sensor to the teeth crest and then return it back by 1/3 (pitch 1.5mm) or 1/2 circle (pitch
1mm), then tighten the nut. If there is no flywheel gear ring, use other sensing gear of
which material must be permeability magnetic material. Moreover, within engine
running rpm, the frequency output by the sensor should be not less than 1000Hz.
c. The electromagnetic executor is mounted on the engine and suggested to be
installed together with fuel pump. But in special cases, external mounting type can be used.
d. The rpm controller should be installed in the protection case without any intense
impact or electromagnetic interference. In addition, sufficient space should be
reserved for installation, maintenance and thermal dissipation. The housing of rpm controller
should be properly grounded. In addition, rpm sensor and rpm trimmer potentiometer
should be connected to the controller by shield cable of which shielding layer
should be grounded at one point of controller.
The governor has the working voltage of DC 24V (12V optional) and can be
powered by the control battery of engine, starting battery or other
regulated/non-regulated power supply, but the peak power consumption and voltage
fluctuation of system should meet the related requirements. If the governor is powered
by a starting battery, provide a charger and ensure the battery electricity is sufficient.
With engine running, battery-output-voltage dropping for short time will not impair the normal
working of governor.
Precautions for governor power supply wire:
The positive pole (pin2) of rpm controller on electronic governor should be
connected to the positive pole of 24V battery via the switch of power supply
(stopping switch) and fuse (if needed). Namely, the controlled is directly powered by the
positive pole of battery.

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The negative pole (pin1) of rpm controller on electronic governor should be

directly connected to the negative pole of battery. If the negative pole of power
supply is grounded, the negative pole of battery should be grounded at the negative
pole of battery rather than at the negative pole (pin1) of controller. more than 0.75 mm (include)
and if the power supply wire has length of more than 10mm, thicken it.
f. Daily maintenance of electronic governor
Timely replace or repair any damaged cable. Cable should be clamped to prevent against
rubbing engine. In addition, the layout of cable should be kept away from the high-temperature
parts (such as supercharger and exhaust pipe).
Check whether the executor is reliably installed.
Check whether the executor connector, sensor connector and cable screws are
contaminated with oil or loosened, if so, timely clean or tighten them.
Check whether the battery electricity is sufficient, or whether the charger is
normal.
For the non-forced oil pump, frequently check the oil level in high/low-pressure
chamber, and replace the lubricant on schedule.
If the engine is started at low temperature, finger to push the rocker arm of
executor for a few times for feeling whether the motion is smooth.
Maintenance every 2000h: remove and clean the rpm sensor probe on which the dirt
may be accumulated. Open the sightglass cover on the mid of governor to check
whether the fasteners or pins attached coupling to the rack of oil pump are loosened, if so,
timely tighten it.
Maintenance every 6000h: remove the executor from the high-pressure oil pump to check
whether the rack of oil pump can move smoothly.

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5.12.7 Precautions
a The matched rpm sensor is only used for electronic governor rather than other
rpm-metering devices.
b. To ensure the safety of engine system, the governing function of electronic
governor can not be replaced by the over speed protection function which should be
independently installed.
c. The emergency-stopping executor of over speed protection device should be
independent and can not be replaced by the electromagnetic executor.
d. Each time of starting engine, please ensure the “idling/rating” rpm switch is at
“idling” position.
e. The each potentiometer of controller has already well set at delivery and should not be
adjusted by the non-professional.
f. With engine not running, it is not allowed to adjust (specially increase) the rated rpm
of rpm controller, or to set the potentiometer or trimmer potentiometer. The set rpm should
not be too high, which could lead to over peed at the beginning of engine startup.
g. If the engine after being sealed for long time is to be reused or is started at low
temperature, finger to push the rocker arm of executor for a few times for feeling whether the
motion is smooth. If there is stuck phenomenon, do not start engine.
h. If the engine after being sealed for long time is to be reused, before startup, shortly
connect the two probes of controller and then executor should output max. amount of fuel.
The executor pointer should return back to zero the moment the two probes are
disconnected. Otherwise, timely find out the cause, do not start enginerashly.
5.13 Expansion pipe installed should be noted:
Expansion pipe shall not bear the weight and pull， connector from the mulfler, pipes, etc need
to be fixed.
Expansion pipe installation, the medium flows and flows to symbol of expansion joints should
be made consistent, it shall not be reversed.
The installation should ensure that the corrugated expansion pipe installed at both ends of the
pipe coaxiality deviations is not more than 2.5mm, no wave deformation force of expandable
tube adjust the pipe installation error, so as not to affect the normal function of expansion tube,
reducing its service life. It is not allowed to force it to reverse the expansion pipe in order to
align bolt holes on the other end of the spectrum, expansion tube cannot withstand reverse.
Non welded during installation in expansion pipe surface arc and prevent damage from
welding spatter bellow the surface.

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5.14 Use and maintenance of seawater pump

The inlet and outlet pipes must be supported by other thing not the pump set self. While
the pump set is operating，some unexpected noise within the set happens，the pump set
must be hurriedly stopped for inspections and remedies.
Keep the strainer at a certain distance form water bed not less than 300mm，water
surface and the bank.
The strainer should be installed in the inlet pipes of pump set. The density of strainer
should be determined by quality of the water.
The quality of water is better, density of strainer is less；the quality of water is
worse , density of strainer is more.
When the pump set has been used for a long time，it must be inspected.

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6. Common failure analysis and troubleshooting

6.1 Unable to start the diesel engine

S/N Cause Troubleshooting

1 Operation:
The starting pressure in the air bottle should
(1) For the air starter, the air pressure in the
frequently stay at 2Mpa. Be fore starting,
air bottle is insufficient or is not at the best
crank the engine until any one piston
starting position.
reaches
(2) For the electronic starter, the battery Refer to the service for free-maintenance
15degree after the TDC.
electricity is insufficient. battery

(3) The driving handle is not at the driving Fix the driving handle to the driving
position. position.
(4) Diesel engine is loaded Unload the diesel engine
(5) Oil viscosity is high, thus, the Refer to the ambient temperature to select
flowability proper oil, or heat oil.
is
(6)poor.
There is air in the fuel system. Deaerate the system
Check the fuel tank, and then open the plug
(7) Water is mixed in the diesel.
at the bottom of diesel filter for draining

(8) The vent screw of fuel injector is not water.

Clockwise rotate it.
tightened, unable to inject fuel.
(9) Diesel is not properly selected. Refer the local season for selection
2 Fuel system
(1) Fuel pipe joint leaked Check and then tighten the joint
(2) The fuel pipe is clogged Check, clean or blow the clogging.
(3) Diesel filter is clogged. Replace or clean filter element
Adjust and repair the fuel injector, if
(4). Fuel injector can not be well.
needed,
replace the needle valve assembly.

(5) Advance angle of fuel supply is wrong. Adjust to specification

(6) Fuel injection pump or fuel injector is
Repair or replace it
damaged.

6.2 The diesel engine can not output stipulated power

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S/N Cause Troubleshooting

1 Operation
(1) Rotating speed is low. Adjust to rated rpm.
(2) The local altitude or ambient te mperature is Refer to GB “Power Correction Table” for
too high. correcting the output power.

2 Fuel system
(1) Fuel injector failed (nozzle is clogged;
Refer to the specifications to adjust or
atomization is poor; fuel injection pressure is
repair
not insufficient; the height of nozzle protruding
the fuel injector.
(2)
fromFuel
theinjection
cylinder pump
head isunevenly
not correpumps
ct) the Adjust the amount of fuel injection or
fuel or some pump does not work. repair
the fuel injection
Properly screw outpump.
the limiting screw on
(3) Fuel injection pump wears, unable to pump
adjusting ra ck in fuel injection pump;
enough fuel.
increase
(4) Diesel filter is clogged; the oil pressure in the mount of fuel injection or replace with
the fuel supply pump is insufficient, the c heck Check,
the clean, adjust or replace it.

va lve of fuel supply pump is fractured or worn; new piston assembly.

the spring is
is not
fractured. Refer to the local season (ambient
(5) Diesel properly selected.
temperature)

(6) Advance angle of fuel injection is wrong. for grade

Check andselection.
adjust it
3 Air distribution system

(1) Air cleaner, air compressor of supercharger

Dismantle and then clean them
and
intercooler is not clean.

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6.3 Abnormal noise or vibration during diesel engine running

S/N Cause Troubleshooting

Premature fuel injection or uneven fuel injection causes Adjust the fuel supply advance
1
the clear, rhythmic and metallic knocking noise, angle or adjust the uniformity of
especially
The at start
clearance or lowthe
between speed.
intake valve and exhaust oil amount.
2 Adjust valve clearance
valve is excessive, making rhythmic and slight
knocking
Increase the load on diesel engine before being Unload diesel engine for idling
3
noise.
preheated. The clearance between the piston and and accordingly warming of
cylinder
The wearliner is excessive,
of piston, piston making
ring andknocking noise.is
cylinder liner diesel engine.
4 Replace the related parts
excessive, making knocking noise.

Each journal severely rubs with bearing bush on

5 Repair or replace it
crankshaft, making knocking noise along the overall
length of diesel
Compression engine.
ratio is too high, causing rough operation The compression ratio should be
6
and large vibration. adjuste d to spec ification.

The clearance between the intake valve and exhaust

7 Adjust valve clearance or timing
valve is
undersize,
Individual or the exhaust
cylinder or intake
does not timing
work and is not
diesel correct, Check the fuel system and solve
engine
8
causing
vibrationthat the valve impacts the top of piston.
is aggravated. the failure.

The valve is fractured (the valve lock clip is damaged,

Immediately stop vehic le for
9
valve drops or the piston fractures, causing sudden or
inspection.
strong knocking noise) Check the cylinder head nuts for
10 Howling due to air leaks from the cylinder head liner
tightness or replace the cylinder

11 liner. or replace it
Knocking noise due to the excessive wear of each gear Check
The fixing bolts attaching to diesel engine is loose or
12 Tighte n or replace the bolts
damaged, causing vibration aggravating.
Diesel engine is not coaxial to the connected work
13 Check and adjust it
device, aggravating the vibration.

Uneven foundation causes the deformation of common

14 Check and adjust it
base plate.

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6.4Unstable operation of the engine

S/N Cause Troubleshooting

Check for stuck phenomenon.
The flying iron in governor can not move smoothly, or its
1
Refer to the actual practice for
clearance widens.
The buffer circ lip in governor is lack of e lasticity or repair or replacement
2 Check or replace it
fractured, making the adjusting rack shake or unste ady.
Die sel engine rpm is too low; with engine idling at mid
3 Increase to rated rpm.
speed, two-purpose governor c an not be automatically

4 activated.
The diesel engine load varies frequently. Check the load output state.
Some cylinder intermittently fires, making the fuel be
5 Check the fuel system.
accumulated in cylinder and according leading to
knocking
The of cylinder.
fuel injectors have different amount of fuel
6 Check and adjust it
distribution and injection time.
7 Air enters the fuel system Check or deaerate it.
Check the fuel system and
8 Air enters the fuel system
deaerate it.
9 Timing gear plays forward/backward. Check each gear for tightness.

6.5 Coolant pump can not absorb coolant or pump enough coolant

S/N Cause Troubleshooting

1 Air enters the coolant pump or suction pipe. Fill them with water to drain the air.
Clean or fill it with hot water or
2 Coolant pipe is clogged or freezed (cold season)
antifreeze.
3 Sealings of coolant pump are damaged or leaked. Repair or replace it
4 Coolant pump belt is loosened. Check and adjust it
5 Coolant pump has too much scale. Remove the scale.
Refer to the specifications to install the
6 Coolant pump has too long suction.
coolant pump.

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6.6 Too low oil pressure

S/N Cause Troubleshooting

Oil quality is poor (because as the diesel engine is Refer to the specifications to select the
1
running, the oil pressure gradually drops) oil.
2 Diesel engine overheats or the oil is thinned. Refer to the section VIII in this
3 Oil filter is clogged Clean it.
chapter.
4 Oil pipe joint is loosened or air enters oil pipeline. Check and tighten it.
5 Diesel is mixed in the oil. Find out the cause.
6 Pressure-regulating valve spring is fractured. Replace it
Oil in the oil tank drop or the suction of oil pump Refill the oil, or reinstall the oil pump
7
is heightened. or oil tank.

The clearance between the connecting rod bearing

8 Check or replace it
and main bearing is widened.

6.7 Diesel engine overheats

S/N Cause Troubleshooting
1 Coolant is insufficient. Refer to the section VI in this chapter.
2 Coolant at the inlet is ve ry hot. Decre ase the coolant inlet temperature.
3 Oil pressure is too low. Refer to the section VII in this chapter.
4 Diesel engine is over loa de Reduce load and find out the cause
5 Oil injection delays Chec k and adjust it
6 Piston rings leak Check or replace it
7 Each bearing match too tight. Inspection and grind them
8 Ambient temperature is too high Correc t the power and reduce the load.

7. Contact Us
Address: Moteurs Baudouin, Technoparc du Bregadan, 13260 Cassis, France
Website: Baudouin.com
Aftersales Service Center: [email protected]

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