Operation and Maintenance Manual for PowerKit M26 Series

a. The oil shall conform to the specified requirements, or it may lead to inadequate oil pressure

as well as abnormal wear and startup difficulty of the engine; the oil must be very clean.

b. Tighten the drain plug.

c. Open the cap to fill oil. The oil should be filtered with filter screen in filling.

d. Install the engine horizontally; pull out the dipstick and check the oil level height. For the

first time, oil should be filled to the upper limit mark of dipstick.

e. Tighten the oil cap.

Note: Check the oil level height each time before starting the engine.

3.1.3 Fuel filling

1. The fuel used shall conform to provisions.

2. The fuel must be clean; before filling, make a static storage more than 72 hours. The fuel

should be filled into the tank after passing through the filter screen.

Note: Check the fuel level each time before starting the engine.

3.1.4 Air bleeding of fuel system

a. Loosen half a turn of fuel outlet screw on the fuel delivery pump. Operate the hand pump of

the fuel delivery pump till there is fuel coming out of the outlet; then tighten the fuel screw.

b. Loosen the air bleeding screw of the fuel filter. Operate hand pump of the fuel delivery

pump till there is diesel fuel coming out. Then tighten the air bleeding screw.

c. Loosen fuel screw of return hole on fuel pump; operate hand pump of the fuel delivery

pump till there is diesel fuel coming out; then tighten the air bleeding screw.

d. Continue to operate hand pump and check the fuel pipe for leaks and then tighten the hand

pump if there is no leakage.

3.1.5 Coolant adding

The coolant is prepared with softened clean water, anticorrosive or antifreeze; the preparation

must strictly abide by the provisions of the additive manufacturer.

Add coolant from the water inlet of radiator or heat exchanger and release the air in cooling

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 Operation and Maintenance Manual for PowerKit M26 Series

circulation system.

Note: Check coolant level each time before starting the engine.

3.2 Operation precautions

3.2.1 Engine startup

Warning !

Don't operate the engine in the locations with presence or possible generation of
inflammable gas. If not, the inflammable gas will be sucked in by the intake system and
lead to engine acceleration or over speed and thus cause fire, explosion and significant
property loss. The engine owner and operator are responsible for its safety operation
under the harsh environment.
Before starting, rotate the engine flywheel several revolutions to confirm that the crankshaft
can be turned freely. Put the speed regulation lever of the injection pump in the middle
position and switch on the power supply.
Do not start the engine before making sure that the equipment and the environment are
safe. When the engine fails to start in 10s, release the start button immediately and make
secondary start 1 min later. If it fails to start in three consecutive times, stop starting, and start
again after troubleshooting.
3.2.2 Engine operation

Attention

After the engine is started, operate it under idle speed for 2-3 min. and check the oil
pressure (it should no less than 200kPa, if it's inadequate stop the engine immediately);
when the cooling water temperature is lower than 60 , don't operate the engine at high
speed with high load suddenly, otherwise, the wear resistance and reliability of the engine
will be adversely affected.
If the engine coolant temperature is lower than 60 , the unburned fuel will wash away the
lubricating oil on the cylinder wall and dilute that in the crankcase. The thinner in the fuel will
affect the quality of lubricating oil and shorten engine lifetime, so try to shorten idle speed
running time to prevent such a situation.
Do not operate the engine at idle speed or with no-load for a long time.
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 Operation and Maintenance Manual for PowerKit M26 Series

The operation at idle speed or with no-load for more than 10 min. will damage the engine,

since the temperature in the combustion chamber is too low to make the fuel burning

completely. And thus will lead to carbon deposit surrounding the fuel injector nozzle and

piston ring and valve sticking.

During engine operation, frequently check coolant temperature, oil temperature and oil

pressure to ensure that the engine speed, oil pressure and oil temperature etc conform to

technical specifications. For M26 series land diesel engine, it is required that: coolant

outlet temperature should be , main oil passage temperature should be , and

oil pressure should be 400-650kPa (giving alarm if the oil pressure is lower than 200kPa).

An early alarm will be given for the majority of faults. Detect the variations of the engine

in terms of performance, sound and appearance through watching and listening; and such

variations will indicate that the engine requires service or maintenance. Some anomalies are

as follows: engine misfire (i.e. abnormal shutdown), abnormal vibration, abnormal noise,

sudden variation on engine temperature or operation pressure, too heavy smoke exhaust,

power loss, increased oil consumption, increased fuel consumption and three leakages

(water, oil and gas leakage).

Check three leakages of the engine each time after operation.

Check the lubricating oil level: subject to the tested height 5 min. after the engine is stopped.

Description

The structure and function of M26 series diesel engine hand pre-supply oil pump:

Function: it may realize pre-lubrication Pre-lubrication

before startup. Switch

Pump oil by pulling the handle back and forth:

Emptying
There are three switch positions for controlling Neutral

oil outlet direction.

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 Operation and Maintenance Manual for PowerKit M26 Series

1) Neutral position: the oil outlet is closed. When the hand oil pump is not used, the Handle
switch

should be at the neutral position.

2) Pre-lubrication position: before starting the engine, switch to pre-lubrication

Oilposition
suction and

pull the handle back and forth to supply oil to the engine bearing, bearing bush and several

other friction pairs and discharge the air inside the oil pump to realize rapid lubrication after

engine startup. This operation may reduce friction, extend service life of the engine and

achieve smooth startup of diesel engine.

3) Emptying position: suck out the oil in the oil pan and discharge it out of the engine. It's

used when replacing oil in the oil pan.

3.2.3 Engine stop

A sudden stop under the full load should be prevented. Before stopping, reduce the load

and the speed first and operate the engine at idle speed or low speed and small load for 3-5

min. for cooling of the piston, cylinder head, cylinder liner, bushing and turbocharger to avoid

cylinder scuffing, bearing burnt and several other issues. It's particularly important for the

turbocharged engine. The high temperature exhaust has strong influence on the bearing and

the oil seal of turbocharger. The heat arising out of the engine operation is taken away by the

circulating oil; if the engine suddenly stops, the turbocharger temperature will rise greatly and

the overheating will cause the bearing be seized up or the oil seal become failure.

Turn the key switch to "off" position or press down the stop button to stop operation of the

diesel engine till the flywheel stops or the dashboard speed shows zero.

For the engine used in winter, if there is no antifreeze in the circulation water, discharge the

cooling water inside the engine after shutdown to prevent engine damage. The drain valve is

located at the bottom of the oil cooler. The cooling water inside the radiator should be

discharged through the drain plug on the radiator.

3.3 Operation environment

The diesel engine can be normally started when the ambient temperature is above -15 ; if
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 Operation and Maintenance Manual for PowerKit M26 Series

the ambient temperature is between -15 and -35 , auxiliary start device should be used for

normal starting of diesel engine. If it's used in the area where the altitude and temperature is

relatively high, the engine power may reduce. The engine should stay far away from the

combustible and explosive environment.

4. Maintenance Specifications for Baudouin Industrial Diesel Engine

The correct operation will extend the engine lifetime, and obtain better performance as well as

more economic benefits. The maintenance cycle in table below is used for the general

industrial engines; however, you should make your own maintenance cycle table according to

the operation environment and working conditions. If the engine is operated under severe

environment, the maintenance cycle should be shortened.

4.1 Diesel engine maintenance cycle

First maintenance (P) New engine operated 30-50h

Level 1 maintenance (WD1) operating every 250h

Level 2 maintenance (WD2) operating every 500h

Level 3 maintenance (WD3) operating every 1000h

Level 4 maintenance (WD4) operating every 3000h

4.2 Daily maintenance of diesel engine

4.2.1 Pay close attention to oil temperature, oil pressure and water outlet temperature so that

the engine may operate with specified water/oil temperature and oil pressure.

4.2.2 Check the appearance of the engine. Operate the engine for 8-10 min. and check whether

there is any oil, water or gas leakage or abnormal noise of the engine. The anomalies detected

should be timely removed.

4.2.3 Check fuel, fresh water coolant and oil capacities after engine stops; Refill if necessary.

4.2.4 Remove the water in 1st stage fuel filter.

4.2.5 Check the appearance of the transmission belt. Replace the worn belt or belt with cracks;

if the belt surface is polished or shining, it means the belt may skid. Correct mounting and
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 Operation and Maintenance Manual for PowerKit M26 Series

tensioning may make pulley and belt wear evenly. Check the tension of belt and adjust if

necessary.

4.2.6 Check cooling fan blades. The fan blade fault may lead to personal injury. Never pull or

lever the fan; or else, it may damage the fan blade and lead to fan faults. Before starting, check

the cooling fan to see whether there is crack, rivet loosening and blade bending and loosening;

check the fan and ensure solid installation; if necessary, tighten the bolts.

4.2.7 If the ambient temperature may be possibly lower than 0 and there is no antifreeze in

the diesel engine cooling water, fully drain the cooling water from the engine to prevent

freezing rupture of the engine component.

4.3 Main works should be carried out during check and maintenance
First Routine
Working items WD1 WD2 WD3 WD4
maintenance Inspection
Replace engine oil and oil filter
element
Replace fuel filter

Check and regulate valve

clearance

Check coolant volume and

refilling
Check the water pump for leaks
Clean fuel pump coarse strainer
Tighten intake pipeline and hose
Wash and clear oil cooler core
Wash and clear intercooler core
Wash and clear fan and water
tank
Wash or replace air filter element
Check and tighten belt
Check fuel injection pump in the
maintenance station

denotes necessity of maintenance

Description: The above maintenance cycle is calculated based on a yearly operation time of 1,500 hours; if

the yearly operation time of the engine doesn't exceed 500 hours, the maintenance cycle should be 0.5 times of

the above maintenance cycle.

4.4 Spare parts and oil products

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 Operation and Maintenance Manual for PowerKit M26 Series
The users shall purchase special Baudouin spare parts and oils (grade CF-4 15W-40) to ensure
good equipment operation and extended service life.
4.5 Maintenance specifications
In case of faults appearing during the warranty period of the engine, timely call Baudouin
service hotline 400-618-3066 for repair; the calling center shall timely assign Authorized
Service Center for Baudouin Engine for service. If the spare parts used are not Baudouin
special parts or maintenance is not conducted in the authorized service center, Baudouin shall
not responsible for the losses caused.

5. Analysis of Common Faults and Troubleshooting

5.1 The engine can't be started
SN Reason Troubleshooting
1 Improper use
(1)Electric starter engine, the battery Conduct maintenance according to the
electricity is insufficient. manual for free -maintenance battery
(2) Starting handle not in starting position Tighten the starting handle in place
(3) Engine is loaded Unloading
(4) Engine oil with high viscosity and poor According to ambient temperature, choose
fluidity the corresponding oil or heating it
(5) Air enters into the fuel system Fully bleed the air in the fuel system
Check fuel tank and open plug at the bottom
(6) The fuel containing water
of diesel filter to drain water
(7) Improper selected diesel fuel Make selection according to local season
2 Fuel system
(1) Fuel pipe connector leakage Check and tighten the connector
(2) Fuel pipe blocked Check, clean or blow the clogging.
(3) Diesel filter blocked Replace or clean filter element
Adjust and repair the injector; if necessary,
(4) Bad injector spraying
replace the needle valve coupling
(5) Incorrect fuel supply advance angle Adjust
(6) Fuel pump or injector damaged Repair or replace
3 Others
(1) Inlet and outlet valve are leaked Repair and adjust valve clearance
Check all cylinder gaskets and tighten
(2) Cylinder leaked
cylinder head nuts
(3) Valve spring is fractured Replace
(4) Piston ring leaked Replace with new piston rings
(5) Piston is stuck in cylinder Disassemble and repair
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 Operation and Maintenance Manual for PowerKit M26 Series
(6) There is water accumulated in the Disassemble the cylinder head, remove water
cylinder and find out the reasons

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 Operation and Maintenance Manual for PowerKit M26 Series

5.2 The engine fails to give specified power

SN Reason Troubleshooting
1 Improper use
(1) Speed is lower Adjust to rated speed
Make correction according to the
(2) The local altitude or ambient temperature
environment conditions referring the power
is too high
correction table (table 1)
2 Fuel system
(1) Injector failure (nozzle blocked, bad
spraying, inadequate injection pressure and Adjust or repair the injector according to
incorrect nozzle extension length out of the specification
cylinder head)
(2) Uneven fuel supply or pump does not Adjust fuel injection or repair the injection
work pump
Properly move out the limit screw of fuel
(3) Injection pump wear; inadequate fuel
pump control rack, increase fuel injection or
supply
replace with a new plunger coupling
(4) Diesel filter blocked, insufficient fuel
supply pump pressure, the check valve of fuel Check, clean or make regulation or
supply pump is fractured or worn; the spring replacement
is fractured.
Select fuel with specified grade according to
(5) Improper selected diesel fuel
local season (ambient temperature)
(6) Incorrect fuel supply advance angle Check and adjust
3 Valve train
(1) Air filter, compressor of turbocharger and
Disassemble and clean them
intercooler are not clean
(2) External exhaust pipe does not meet the
Design and install external exhaust pipe
requirements, exhaust back pressure is too
according to the specifications
high
(3) Inlet and outlet valves are leaking Check and repair them
(4) Wrong intake or exhaust timing Check and adjust
4 Others
(1) Compression pressure is insufficient
(incorrect compression ratio or piston rings Check, adjust or replace the piston
are severely worn)
Disassemble the cylinder head, check the
(2) Piston and cylinder head galling or other
inner surface of cylinder liner or other wear
wear part failure
parts and make timely repair or replacement
Check belt tensioning and various cooling
(3) Insufficient engine cooling
system components or remove water scale
(4) Bad bearing lubrication and overheating Repair or clean the lubrication system

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 Operation and Maintenance Manual for PowerKit M26 Series

5.3 Smoke emission

SN Reason Troubleshooting
1 Greyish white smoke
(1) The engine is too cold Increase water inlet temperature
Disassemble the exhaust pipe or cylinder
(2) Water leaks inside cylinder
head to check
Check the injector or compression pressure
(3) Incomplete combustion
inside cylinder
2 Taupe smoke
(1) The engine load is too high Reduce the load
(2) Too much fuel supply of individual
Adjust according to the method in 5.4
cylinder of injection pump
(3) Injector failure (such as nozzle drips fuel Check the injector or repair (replace) the
which leads to intermittent smoke emission) nozzle
(4) Insufficient advance angle of fuel supply Adjust the fuel supply advance angle
(exhaust with black smoke or flame) according to specification
3 Azure smoke
(1) The oil enters into the combustion
Increase the water inlet temperature
chamber when the engine is cool
(2) The new engine operated for a short time Increase the run-in time
(3) Piston ring worn Check and repair

5.4 Abnormal noise or vibration during diesel engine operation

SN Reason Troubleshooting
Too early injection or uneven cylinder fuel
supply leads to clear and rhythmic metallic Adjust fuel supply advance angle or fuel
1
knocking sound, which is particularly strong injection evenness
during starting or at low speed
Generate rhythmic slight knocking sound due
2 to over big clearance of the inlet or outlet Adjust valve clearance
valve
Increase load without engine warm-up;
3 generate knocking sound due to relatively big Remove load and idling warm-up run
clearance between piston and cylinder liner
Knocking noise arising from over wear
4 Replace the corresponding component
among piston, piston ring and cylinder liner
Over wear of the crankshaft journal and
bearing shell so that knocking sound may be
5 Check and repair or replace
heard along the whole length of the cylinder
block
Over high compression ratio, rough running, Adjust compression ratio according to the
6
big vibration specification
Over small inlet and outlet valve clearances
7 Adjust valve clearance or valve timing
or incorrect intake and exhaust valve timings

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 Operation and Maintenance Manual for PowerKit M26 Series
lead to impacting of the valve and the piston
5.4 Abnormal noise or vibration during diesel engine operation continued
Individual cylinder does not work and thus
8 Check fuel system and eliminate fault
diesel engine vibration increased
Valve broke (generating sudden and violent
Immediately stop the engine and make
9 knock due to valve cotter damaged, valve
checking
falling or piston ruptured)
Check cylinder head nut tightness or replace
10 Air leakage hiss at cylinder head gasket
the cylinder gasket
11 Knocking noise from over worn gears Check and replace
The engine fastening bolts loosened or
12 Fastening or replace the bolts
damaged, thus the vibration increased
Diesel engine crankshaft is not coaxial to the
13 connected work device, thus the vibration Check and adjust
increased
The uneven foundation deforms the common
14 Check and adjust
chassis

5.5 Unstable engine running

SN Reason Troubleshooting
1 Frequent load variation of the engine Check load output
Intermittent firing of individual cylinder;
cylinder knock arising from rapid
2 Check the fuel system
combustion of accumulated oil in the
cylinder
Inconsistent fuel amount and injection time
3 Check and adjust
of the diesel pump cylinders
4 There is air in the fuel system Check and bleed the air
5 Containing water in the fuel system Check fuel and drain the water
6 The Timing gear moves back and forth Check tightness of the gear

5.6 Water pump doesn't suck water or water supply is inadequate

SN Reason Troubleshooting
1 Air enters water pump or suction pipe Add water to remove air
Clear or add hot water or pre-add
2 Water pipe blocked or froze (cold season)
antifreeze
Gas leakage arising from water pump
3 Repair or replace
sealing device or gasket damage
4 Water pump belt too loose Check and adjust
Serious scaling in water pump of diesel
5 Remove the incrustation
engine
Install water pump according to
6 Water pump suction head too big
specifications

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 Operation and Maintenance Manual for PowerKit M26 Series

5.7 The oil pressure is too low

SN Reason Troubleshooting
Inferior oil (which shows gradual decrease
1 Select oil according to specifications
of oil pressure with engine operation)
2 The engine over heat, oil is diluted Troubleshoot according to section 5.8
3 Oil filter blocked Clean
Oil pipe joint loosened or air enters oil
4 Check and fasten
pipeline
5 Diesel fuel is mixed into the oil Replace and find out the reason
The oil pump pressure regulation valve
6 Replace
spring fractured
Too little oil in the tank or the suction head Refill oil, or reinstall the oil pump or oil
7
of oil pump is excessive big tank
Too big clearance between connecting rod
8 Check and replace
bearing and main bearing

5.8 Diesel engine overheating

SN Reason Troubleshooting
1 Cooling water is insufficient Troubleshoot according to section 5.6
2 Water inlet temperature is too high Reduce the water inlet temperature
3 The oil pressure is too low Troubleshoot according to section 5.7
4 Engine is overloaded Reduce load and find out reasons
5 Fuel injection is too late Check and adjust
6 Piston ring leaking Check and replace
7 Too tight bearing matching Check and properly repair
8 Ambient temperature is too high Correct the power and reduce load

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 Operation and Maintenance Manual for PowerKit M26 Series

Attached table 1 Correction Coefficient of Engine Power

When the engine is operated below an altitude of 1000m, no correction is required since the
engine power drop relatively small; when operating above an altitude of 2000m, due to
reduced air intake and turbocharger speed limit, the power of engine has obvious variation, the
power of engine or engine set should be corrected; the correction coefficient should be as per
the table below:

Atmospheric Atmospheric temperature

Altitude
pressure
(m) 0 5 10 15 20 25 30 35 40 45
(kPa)
0 101.35 1.02 1.02 1.01 1.00 1.00 1.00 1.00 0.99 0.98 0.97
200 98.66 1.02 1.01 1.01 1.00 1.00 1.00 1.00 0.99 0.98 0.97
400 96.66 1.01 1.01 1.00 1.00 1.00 1.00 1.00 0.99 0.98 0.96
600 94.39 1.01 1.00 1.00 1.00 1.00 1.00 0.99 0.98 0.97 0.95
800 92.13 1.00 0.99 0.99 0.99 0.99 0.98 0.97 0.97 0.96 0.94
1000 89.86 0.99 0.99 0.98 0.98 0.98 0.97 0.96 0.96 0.95 0.93
1500 84.53 0.98 0.97 0.96 0.96 0.95 0.94 0.93 0.92 0.91 0.89
2000 79.46 0.96 0.94 0.93 0.92 0.92 0.91 0.90 0.87 0.86 0.82
2500 74.66 0.91 0.89 0.89 0.88 0.88 0.86 0.84 0.82 0.81 0.78
3000 70.13 0.86 0.85 0.84 0.84 0.83 0.82 0.79 0.78 0.76 0.73
3500 65.73 0.83 0.82 0.81 0.79 0.77 0.76 0.74 0.73 0.72 0.68
4000 61.59 0.79 0.78 0.76 0.74 0.72 0.71 0.69 0.68 0.67 0.65

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

Website: Baudouin.com

Aftersales Service Center: [email protected]

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