FOREWORD

Dear Customer,

Congratulations and thank you for purchasing a Baudouin Generating set diesel
engine. We believe we make the best Diesel engines and each time you purchase
Baudouin engine, you reaffirm your confidence on us.

This manual contains operating information of 6M16 series Baudouin diesel

engines for Generating set application (G-drive). Content of this manual is intended
to explain about safety, operation and maintenance instructions, specifications for
fuel, lube oil & coolant. Information provided in this manual is limited to regular
operation and maintenance. Hence cannot be considered for major overhaul or
repair.

Technician who is operating any Baudouin diesel engine must understand the safe
operating procedure, routine inspection and maintenance practices. Repairing and
maintenance of this diesel engine must be carried out by trained professionals and
this service can be available in all our authorized service centers.

As a policy of continuous improvement, Shandong Heavy Industry India Pvt. Ltd

reserves the right to change /modify/ upgrade content of this manual at any time
without prior notice to the customer.

This manual is only for reference purpose. All the 6M16 series G drive diesel
engines are meeting latest emission norms. These engines also have distinguishing
features like improved reliability, quick starting, and extended maintenance interval.
Baudouin engines are popular for their best in class fuel efficiency, low operating
cost, low noise, low vibrations and comparatively low engine room temperature
during operation. Construction of this engine is simple, thus the operation and
maintenance is easy.

6M16 series G-drive engines are the ideal for industrial and domestic generators
with a power range of 160 kVA to 250 kVA.
 CONTENTS

SECTION I
SAFETY REGULATIONS.......................................................................1
1.1 General Instructions.......................................................................1
1.2 Correct use....................................................................................1
1.3 Modifications or conversions.........................................................1
1.4 Spare parts....................................................................................1
1.5 Reworking of components.............................................................1
1.6 Safety regulations for startup and operation..................................2
1.6.9 Prevention of harms caused by engine emission....................2

SECTION II
ENGINE SPECIFICATION......................................................................3
2.1 Engine Description.........................................................................3
2.2 Main Technical Specification of 6M16 G-Drive Diesel Engine.......4
2.3 Specification of Main Components................................................5
2.4 Identifying the engines from name plate........................................6
2.5 Engine Model Identification............................................................6

SECTION III
OPERATING INSTRUCTION..................................................................7
3.1 Safety precautions for operation of diesel engine..........................7
3.2 General instructions.......................................................................7
3.3 Preparation for first start................................................................7
3.3.1 Cooling system........................................................................8
3.3.2 Lubrication system..................................................................9
3.3.3 Checking the oil level..............................................................9
3.3.4 After an extended storage.......................................................10
3.3.5 Pre-lubricating the engine.......................................................10
3.3.6 Fuel system.............................................................................11
3.3.7 Priming the fuel system...........................................................12
3.3.8 Fuel returning..........................................................................12
3.3.9 Air intake system.....................................................................12
3.3.10 Exhaust system.....................................................................12
3.3.11 Electrical system....................................................................13
 3.3.12 Engine starting and stopping:................................................16
3.3.13 Running in period & Operation precautions..........................19
3.4 Regular operation..........................................................................20
3.4.1 Engine starting and warm up..................................................20
3.4.2 Monitoring the engine oil.........................................................21
3.4.3 Monitoring the engine coolant.................................................21
3.4.4 Monitoring the exhaust gas.....................................................21
3.4.5 Engine shutdown.....................................................................22

SECTION IV
PERIODIC MAINTENANCE....................................................................24
4.1 Safety precautions.........................................................................24
4.2 Importance of periodic maintenance..............................................24
4.3 Replacement of parts and components.........................................24
4.4 Reliability of parts..........................................................................25
4.5 Safe use of oil and fuel in a diesel engine.....................................25
4.6 Disposal of used oil or fuel.............................................................25
4.7 Periodic Maintenance instructions.................................................28
4.7.1 Check air filter.........................................................................28
4.7.2 Cleaning air filter.....................................................................28
4.7.3 Replacement of engine oil and filters......................................28
4.7.4 Replacement of fuel filter........................................................30
4.7.5 Air bleeding from fuel system..................................................30
4.7.6 Adjustment of Poly V-belt Tension...........................................30
4.7.7 Adjustment of Valve Clearances..............................................31
4.8 Maintenance Recommendation.....................................................33
4.9 Tightening Table and Torque Value For Main Fasteners................36
4.10 Recommended Standard Torque Values For Bolts......................37
4.11 Trouble Shooting Guide For 6M16 Series G-Drive Engine..........39
4.11.1 Shutdown shortly after starting..............................................39
4.11.2 Inadequate power..................................................................39
4.11.3 Excessive fuel consumption..................................................40
4.11.4 Black smoke in exhaust.........................................................41
4.11.5 White smoke and blue smoke in exhaust..............................41
4.11.6 Oil gathering at turbocharger air inlet and air inlet pipe.........42
4.11.7 Unstable speed......................................................................42
4.11.8 Excessively low oil pressure..................................................42
 4.11.9 Excessively high coolant temperature...................................43
4.11.10 Parts wear too fast...............................................................43
4.11.11 Excessive noise...................................................................44
4.11.12 Insufficient output of starting motor.....................................45
4.11.13 No power generated by alternator.......................................45
4.11.14 The battery cannot be charged fully through alternator.......45

SECTION - V
LUBRICANT AND COOLANT SPECIFICATIONS.................................46
5.1 Lubricant........................................................................................46
5.1.1 The functioning of lubricating oil in a diesel engine.................46
5.1.2 Engine oil consist of................................................................46
5.1.3 Why oil should be drained.......................................................46
5.1.4 How engine oil performance is getting deteriorated................46
5.1.5 Oil performance classification system.....................................47
5.2 Engine oil recommendations for Baudouin engines..........................47
5.3 Grease Recommendations................................................................48
5.4 Coolant..............................................................................................48
5.5 A good coolant should have following properties..............................49
 SECTION I
SAFETY REGULATIONS

1.1 General Instructions

6M16 series Baudouin G-drive diesel engine has been designed and assembled
by company, meeting all applicable safety regulations of international standards. In
addition to the instructions in this manual, applicable industrial safety regulations
regarding accident prevention and environmental protection must be followed by
the operator of this engine.

The engine may nevertheless present a risk of injury or damage in the following
cases:
• Incorrect use
• Unauthorized modifications or conversions
• Non-compliance with the safety instructions
• Skipping of routine checks and inspection
• Operation, maintenance and repair by unqualified personnel
1.2 Correct use
Every engine is designed and built to suit a desired application. 6M16 G-drive
diesel engine is specifically designed solely for the use of Genset application only.
Any other use is being considered as improper use. The engine manufacturer
accepts no-liability whatsoever for resultant damage or injury. In such case the
responsibility will be borne by the user alone.
Correct use also includes periodically monitoring engine operating parameters,
carryout routine inspection and maintenance as per recommendation by the
company.

1.3 Modifications or conversions

Any modification on engine may impair its performance and shorten its life.
Unauthorized modifications on the engine are also a risk to human and machine
safety. The company will accept no liability or warranty claims for any damage
caused by unauthorized modifications or conversions.
1.4 Spare parts
Only Baudouin genuine spare parts must be used to replace components or
assemblies. The company accepts no liability whatsoever for damage or injury
resulting from the use of other spare parts and the warranty shall be void in such
case.
1.5 Reworking of components
Any repair or overhaul of the engine must be carried out by the company authorized
service centers. The company accepts no liability whatsoever for damage or injury
resulting from the repair by unauthorized person.

1
1.6 Safety regulations for startup and operation

1.6.1 Before installing or operating the engine, the operator should carefully read
and understand the content of this manual to get familiar with the engine
structure, correct operation and maintenance procedures.

1.6.2 This diesel engine is a high speed rotating machinery. When the engine is
in operation, do not touch any moving parts

1.6.3 Tampering with the fuel injection and electronic system could affect engine
power output and threat to engine safety. Any attempt, to tamper which
will void the warranty and the company will not be responsible for any injury
due to alteration.

1.6.4 If the engine is new or overhauled with major parts (in either case), In such
condition , Engine should run 1 hour by following / as per procedure.

1.6.5 Select the lubricating oil and coolant as recommended in section-V.

1.6.6 Always use recommended lubricant and coolant. The company recommends
to use premixed coolant for better protection of engine cooling system.

1.6.7 Never operate the engine without air filters. Inducting un-filtered air to
the combustion system will shorten engine life and adversely affect the
engine performance.

1.6.8 Any service or repair related to the electrical system must be carried out by
a trained electrical/electronic professional.
1.6.9 Prevention of harms caused by engine emission
It is absolutely prohibited to operate the engine in a closed room without
proper ventilation, because exhaust gas from engine emission is toxic,
which is harmful to human health.

2
 SECTION II
ENGINE SPECIFICATION

2.1 Engine Description

The 6M16 series diesel engines are direct injection engines. The engines are
controlled with a mechanically actuated fuel injection pump. The engine cylinders
are arranged in-line. The cylinder head assembly has two inlet valve and two
exhaust valve for each cylinder. Each cylinder valve has two valve springs.
Each piston is provided with two compression rings and an oil control ring. The
correct piston height also ensures efficient combustion of fuel that is necessary in
order to conform to requirements for emissions.
The crankshaft for a six cylinder engine has seven main bearing journals. End play
is controlled by the thrust washers that are located on the rear main bearing.
The timing gears are stamped with timing marks in order to ensure the correct
assembly of the gears. When the No. 1 piston is at top dead center position in the
compression stroke, the teeth stamped on crankshaft gear and camshaft gear will
be in alignment with the idler gear and the fuel injection pump.

The crankshaft gear turns idler gear which then turns camshaft gear and gear for
the engine oil pump.
The fuel injection pump is mounted on cylinder block. The fuel injection pump
conforms to requirements for latest emissions. If any adjustments to the fuel
injection pump timing and high idle are required you must refer to your Baudouin
authorized service centre. Fuel injection pumps have electronic governors that
control the engine speed
The engine oil pump sends lubricating oil to the main oil gallery through a pressure
relief valve and an engine oil filter. The rocker arms receive pressurized oil through
an externally located oil line that runs from the main oil gallery to the cylinder head.
Coolant from the bottom of the radiator passes through the belt driven centrifugal
water pump. The coolant is cooled by the radiator and the temperature is regulated
by thermostat valve.
Engine efficiency, emission controls, and engine operation life is directly dependent
on correct operation and maintenance as recommended by the company.
Engine performance and efficiency also depend on the use of recommended
lubrication oils, and coolants. Read the manual carefully to get familiarized with the
engine and its operation and maintenance procedure.

3
2.2 Main Technical Specification of 6M16 G-Drive Diesel Engine
SR. DESCRIPTION OF
MODEL WISE DETAILS
NO. SPECIFICATION
1 Engine Model 6M16 6M16 6M16 6M16
D155E31 D175E340 D204E340 D240E340
2 Power Rating (kW) 155 175 204 240
3 Rated Speed(RPM) 1500
4 Compression ratio 17 : 1
5 Aspiration NA/TCI TCI
Type, number of
6 6
cylinders
7 Swept Volume (Ltrs) 9.726
8 Bore x stroke (mm) 126X130
9 Injection Timing 11-12 deg
10 Firing Order 1-5-3-6-2-4
11 Fuel Type Diesel
Lube oil sump
12 24
capacity (Ltrs)
Lube oil temperature
13 at normal working 85 - 105 Degree C
condition (°C)
14 Cooling method Water Cooled
Coolant capacity
15 38 38 40 40
(Ltrs)
Max. Coolant
16 95 Degree C
Temperature
10.43 mm
17 Valve Clearance
11.97 mm
Intake valves open
22 deg. BTDC
(Before T.D.C.)
Intake valves close
34 deg. ABDC
(After B.D.C.)
18
Exhaust valves open
49 deg. BBDC
(Before B.D.C.)
Exhaust valves
21 deg. ATDC
close (After T.D.C.)
19 Starting Method Electrical
Length 2230
Overall dimension
20 Width 780
(mm)
Height 1539

4
2.3 Specification of Main Components
Model DHL10D0001
Type Mechanic
Injection pump Governor Electronic
Fuel feed Pump 612600081317
Type 612640080471*3011
Holder No. multi-hole
Injector type
Nozzle No. 7
Nozzle hole diameter(mm) 0.21
Nozzle opening pressure (Mpa) 30
Type Gear
Oil pump Speed (r/min) 1900
Flow rate (L/min) 167
Type centrifugal
Water Pump Speed (r/min) 2800
Flow rate (L/min) 660-720
Fuel filter Type closed type rotating filter
Type dry
Air filter
Model KLQ-65
Oil filter Type spin-on
Thermostat Type wax
Type wd61509qd
Starting motor Voltage (V) 24
Power (KW) 5.5
Voltage (V) 28
Power (KW) 1.5-2

5
2.4 Identifying the engines from name plate

MODEL NO. 6M16G250/5E3

SERIAL NO.

ORDER NO. DHL10D0001*01

POWER-SPEED kW 240 BHP 362 RPM 1500

DATE OF MFG 2016-06-15

[Link].

THIS ENGINE CONFORMS TO THE ENVIRONMENT(PROTECTION) RULES, 1986.

Shandong Heavy Industry India [Link].
Survey No.280, 281, Village Mann, Taluka Mulshi, Hinjawadi Phase II,

Pune - 411057, Maharashtra, India

2.5 Engine Model Identification

6 M 16 G 240 5E3

Emission Norms

Power Rating

Application Code

Displacement per cylinder

Product code for Baudouin

No. of cylinder

6
 SECTION III
OPERATING INSTRUCTION

3.1 Safety precautions for operation of diesel engine

Before the engine is started, the operator must understand the operating method;
master the working principle of diesel engine and understand its power limit.
During starting and running of engine, lack of experience and careless operation
may cause fatal accident. However, if the operator has mastered the operating
technique and understood the power limit in advance, and is carefully operating,
then the personal injury caused by accident can be completely avoided.

3.2 General instructions

Proper attention and care of engine will ensure optimum performance, long life and
more economical operations, best practice to maintain the engine in good condition
if,
• Follow daily maintenance as per the guidelines.
• Ensure all meter and gauges are in operational conditions.
• Running the engine on idle speed must be limited to 3~ 4 minutes. Idling the
engine for longer periods will cause carbon to clog injector spray holes and
piston rings.
• Do not operate the engine with low engine body temperature for longer period
3.3 Preparation for first start
When preparing to start a new or overhauled engine, perform all the operations
listed below. Failure to follow these instructions may result in serious engine
damage. The operator must be familiar with all the instruments, gauges, and
controls which are needed to operate the engine. Understand the locations and
function of the following: Oil pressure indicator, low oil pressure warning indicator,
coolant temperature indicator, high coolant temperature warning indicator etc.
Closely monitor the overall engine performance and if any abnormal sign like
excessive blow by, overheat, excessive consumption of fuel or lube oil, abnormal
vibration or noise, change in exhaust gas color etc. is noticed, turn off the engine
immediately and rectify the cause of trouble. Engine damage may be avoided by a
quick response to early indications of problems.

System-wise checks
Carry out a system wise check to avoid any mistakes or points left out before the
first start of engine.

7
3.3.1 Cooling system
System Capacity- 42 Liters
Make sure the main drain valve of the coolant cooling system is properly closed.
Refer the figure 3.1

Figure 3.1
The coolant can be filled in the Radiator by removing the pressure cap provided
on the top of the radiator tank (figure 3.2) and slowly fill the cooling system with
recommended coolant (figure 3.3 and 3.4).
Slowly filling the coolant will help the air to escape without trapping in the system.
For detailed coolant specification, refer section V.

Figure3.2 Figure3.3

Figure3.4

8
3.3.2 Lubrication system
Sump Capacity: 24 Liters
Check and drain out any residual oil from the sump. After draining, fix the drain
plug properly. Engine oil can be filled from the filling port provide don cylinder head
cover. Refer figure 3.5, 3.6 and 3.7

Figure3.5 Figure3.6

Figure3.7

Fill up the engine oil up to the correct level. Recap and firmly tight the oil filler cap.
For detailed lube oil specification, refer section V.

Use only recommended grade of lubricating oil

3.3.3 Checking the oil level

Check the oil level by using the oil dipstick provided in the crankcase near to the
ECU (figure3.8). Safe oil level range is marked on the dipstick bottom. If the oil level
is in between the high level and low level area, then the oil is at the proper level
for engine operation. (Figure 3.9) If necessary, top up the oil through the oil filling
port. Do not overfill

9
 Oil dipstick

H H
H
OK OK

L L L
OK

Figure3.8 Figure3.9

Immediately clean up any oil spillage to avoid personal injury

CAUTION

3.3.4 After an extended storage

If an engine is non operational for an extended period of time (6 months or above),
chances for water dilution in lube oil due to air humidity. Water mixed lube oil cannot
provide adequate lubrication and may cause severe damages to various internal
engine components. For this reason, Baudouin recommends replacing the engine
oil with filters after extended storage.
The lubricating oil film on the rotating parts and bearings of an engine (which has
been in storage for 6 months or more), may be insufficient when the engine is
started for the first time. Hence it is necessary to pre lubricate the engine before
start up.

3.3.5 Pre-lubricating the engine

To ensure instant lubrication of all bearing surface set initial engine start up, prepare
the engine as follows: (For long storage)
Manually lubricate the turbocharger bearings and spin the shaft by hand several
times. (Figure 3.10, 3.11 and 3.12)
Crank the engine with the help of starter motor for 3 to 4 times till the oil pressure
is displayed on the pressure gauge/panel display.
Each cranking duration should not last for more than 10 seconds.

10
 Figure3.10 Figure3.11

Figure3.12

3.3.6 Fuel system

Fuel tank capacity: Refer the Gen-set manual
Ensure that the fuel tank is clean and dry before filling the diesel to the fuel tank.
Fill the tank with the high speed diesel only.
Always keep the fuel tank in maximum level to reduce water condensation - which is
necessary to protect the injection system sub-assemblies like FIP &Injectors. Filling
the tank to the maximum level will protect the fuel tank inner wall from corrosion.
For detailed fuel specification, refer section V.

Properly check the fuel system for loose connections and leaky
joints. Loose connection or damaged sealing will cause air to enter
into the system

11
3.3.7 Priming the fuel system
Operate the hand priming pump (lift pump) provided on the Fuel Injection Pump
(FIP) for several times till the low pressure system get pressurized (figure 3.13).
Remove trapped air from the system stage by stage. The fuel filters, FIP and the
high pressure line is filled with fuel when assembled and tested in the factory. In
normal case, no air bleeding is required after the FIP.
Since the fuel system is a critical part of the diesel engine, manufacturing and
installation quality of fuel tank and fuel line connected to it and quality of the fuel
used will influence the performance and reliability of the diesel engine. Fuel tank
provided by the user must be clean and free of rust and corrosion, and it must be
made of materials which do not react with diesel fuel to avoid production of foreign
matters. The fuel tank must be provided with a drain device to drain water and
foreign matters in the fuel. It is recommended that a valve be added to the outlet
pipe of the fuel tank to facilitate maintenance of the piping.

3.3.8 Fuel returning

When installing, prevent the fuel return pipe from contacting with hot parts (e.g.
exhaust manifold, turbocharger, and exhaust gas recirculation pipe) of the diesel
engine. There should be no throttling area in the fuel return pipe. The fuel return
pipe should not touch any sharp edges, should not be folded to form sharp corners
or even twisted. Incorrect installation of fuel return pipe will cause fuel leakage to
the engine.
Fuel return of 6M16 electronic controlled power generating series diesel engine
is internal fuel return through the cylinder head (figure 3.14). In this manner, the
injector mounting hole is located in the cylinder head, so it should be ensured that
fuel return is completely free of leakage.

3.3.9 Air intake system

This system is assembled in the factory and taken necessary performance trial.
However make sure the tightness of all clamps in the system. Also make sure there
is no blockage in the air filter inlet mouth.

Air inlet of the diesel engine should be arranged outside the unit in order to ensure
fresh air supply to the diesel engine. Air inlet pipe of diesel engine should have
the fewest elbows, and large arc transition should be used. The air filter at the air
inlet should be provided with a protective cover to prevent water and pollutant from
entering the diesel engine.

3.3.10 Exhaust system

The external exhaust pipe must be steel pipe with the smallest number of bents,
and it should be firmly fixed on the unit. No vibration of such pipe is allowed, and it
shall not impose any force on expansion pipe of the diesel engine. After installation
of the exhaust system, the exhaust back pressure of the diesel engine shall not

12
exceed 6kPa in order to avoid impacts on performance of the diesel engine. Since
surface of the exhaust pipe will become hot during operation of the diesel engine,
the exhaust pipe must be installed away from flammable objects, and to prevent
workers from being burnt, the external exhaust pipe must be provided with thermal
insulating device on the surface

3.3.11 Electrical system

The engine control and safety is managed through electrical system. This includes,
start, stop, parameter monitoring and safety stop of the engine in case of parameter
goes beyond the limit. The electrical system is operated by 24VDC supply.
The main electrical sub-assemblies of this engine are:
1. Starter motor
2. Charging alternator
3. Pressure sensor
4. Temperature sensor
5. Speed sensor
6. Actuator
7. Speed controllers
8. Controller
Brief description about each sub assembly is mentioned below:
1. STARTER MOTOR: The starter motor is used to crank the engine at minimum
required speed to start up the engine. It drives the engine through a pinion
gear engaged with the flywheel ring gear. .The pinion disengages soon after
the engine gets started.

2. CHARGING ALTERNATOR: This alternator is designed to generate

continuous DC output voltage in 24-28 Voltage range with 25 Ampere current.
This sub assembly is mounted on the engine and driven by a B type V belt. It
is powerful enough to charge for two 12V lead acid battery with a maximum
capacity of 180 Ah.

13
3. PRESSURE SENSOR: A resistive type pressure sensor cum switch is used in
the lube oil system which is mounted on the main oil gallery. The controller will
monitor and display engine oil pressure according to the change in resistance
of the sensor. The measuring range of the sensor is 0-10 Kg/Cm2

4. TEMPERATURE SENSOR: The water temperature sensor operates at

temperature of -25~120°C, and is constructed in two types: ordinary sensor
and sensor with alarm. The sensor with alarm will give alarm at 96±3°C.
The allowable external force torque of water temperature sensor is 19.6Nm
(2kgfm), and its rated voltage is 6~24V.

.
5. SPEED SENSOR: A magnetic pickup is essentially a coil wound around a
permanently magnetized probe. When discrete ferromagnetic objects-such
as gear teeth, turbine rotor blades, slotted discs, or shafts with keyways-
are passed through the probe’s magnetic field, the fluxdensity is modulated.
ThisinducesAC voltages in the coil. One complete cycle of voltage is generated
for each object passed

14
6. ACTUATOR: The actuator is installed in the engine, its installation location
and method depend on specific circumstance, we recommend installing the
actuator produced by For trust with the pump in an integration installation way,
but under some special circumstances or some specific requirements, you can
also use the way of external installation.
The output shaft of the actuator and the injection pump rack of the engine
joint directly, with output in a straight line and the output displacement of 10-
[Link] installation, the initial position shall guarantee that the pump can
have fuel cut reliably and the pump rack stroke and the actuator stroke shall
cooperate well. Generally, it is required to ensure the stroke from fuel cut to
fuel full to be about 75% of the actuator’s working stroke.
There are several connecting ways between output connecting rod of the
actuator and the pump rack, which must ensure there is no jam or slippage
after installation. The installation shall realize the purpose of no clearance
transmission between the output connecting rod and pump rack

7. SPEED CONTROLLER: The speed controller C1003 is usually installed in the

control cabinet where there is no strong impact vibration and electromagnetic
interference, or fixed on the outer equipments in other similar places of the
engine; you shall choose the location with dry air and appropriate temperature
to install; the speed controller has the moisture proof processing, but still have
to prevent from water, fog or coagulation; when installation , it shall be far
away from the high temperature and thermal radiation to avoid the damage
of engine components. it shall be installed vertically under the moisture
condition; special shielding device shall be used under the condition with huge
electromagnetic field .

15
8. CONTROLLER: A controller is as a safety device that is use d for the complete
genset control and protection. For engine safety, the controller will monitor
the speed; lube oil pressure and coolant temperature. Based on the engine
technical requirement, an alarm and or safety stop value is set in the controller.
In case the measured value exceeds the set value, the controller will generate
an alarm or stop signal and protect the engine before it reaches the unsafe
condition.

DSE

L1N 239V
L2N 238V
L3N 240V

Auto

Stop Auto Start

For more information about the controller, please refer the operation manual of the
controller supplied by the OEA.

3.3.12 Engine starting and stopping:

The engine can be started and stopped by manual and auto mode. The customer
can choose the starting option according to the generator application. Please
consult your nearest Baudouin service center to set up the operation mode.

The starting and stopping sequence is a general guideline. Please

refer the respective generator controller manual for more specific
and customized operating procedures.

Manual Mode
Starting: Switch on the power supply to the controller. Ensure that the battery is
healthy and power supply voltage is [Link] the warning, fault and timer status
on the controller display. Clear the faults if any, before the starting attempt. (Refer
the controller manual for details)

16
Press the start button; the signal will pass to starter motor relay and crank the
engine If the engine cannot be started within 5~10s, ”Controller automatically gives
start command -3 times repeatedly with the time interval which programmed.” If
the engine cannot be started for 3 successive times, stop starting, and restart it
after the cause has been found and eliminated. Once the engine is started, release
the button, while taking notice of instrument readings. The oil pressure should be
immediately displayed on the oil pressure gauge. Please note that the cold engine
should not run at high speed, it should run at idle speed for some time but not too
long.
After starting the engine, pay attention to the operation parameters such as lube
oil pressure and engine speed. The parameters should be stable and achieved
the minimum required value as mentioned in the parameter table. Also check the
engine for any leakages or abnormal sound, vibration, smoke etc. then increase
the speed from idle to rated speed. Apply the load gradually.

Stopping: Prior to shutdown, unload the engine first, and then slow down the
engine to run it at 600~1,000r/min for several minutes, and operates the shutdown
lever to stop the engine. Switch off the power supply to instruments after shutdown.
If emergency shutdown is needed, in addition to rapidly placing the fuel cut-off lever
to the shutdown position, it can also be achieved by rapidly cutting off the fuel pipe
to the injection pump or blocking the air filter inlet.

Auto mode:
Starting: The auto mode starting is après-defined activity used in AMF application.
For automatic/ Self-switching Gen-set, the gen-set will stimulate mains power
failure after the gen-set is switch to auto mode.

Do not press the start button when the engine is running. It will
damage flywheel ring gear and starter motor pinion gear.

17
 ACT
ACT ELECTROMAGNETIC
ACT ACTUATOR
-- AUX.
SPEED [Link].
SPEED
SPEED
RATED
RATED / IDLE SW
IDLE
ACT+
ACT-

GLP
MPU-
SPEED SENSOR
MPU+

ENINE SPEED CARD CI1003

+VE 24V
FUSE 10A
- VE 24V

GLP
AIR INTAKE
HEATER/DC
CONVERTER
WIRING DIAGRAM FOR 6M16

Index Drawing No. Name Quan. Material Comments

Name Drawing No.

WIRING DIAGRAM FOR WIRING DIA.

G DRIVE (6M16/6M19) State Format Weight
Sign Amou. Document Signature Date
A3
Designed Tech. Sheet /Of Scale &scale

Drawn Stand. Material Projection Method

Corrected Approved Shandong Heavy Industry

NA
Examined Date India [Link].

18
3.3.13 Running in period & Operation precautions
The engine components are made of materials with different thermal expansion
and stability. It should gradually bring to the thermal stability during the initial stage
of operation. First 60 hours of operation is considered as running in period. During
this period, engine needs to be run with care at normal load (80to85%maximum).
Aggressive operation and overloading during running in will disturb thermal stability
and leads to shortened engine life.
1. After starting, run the engine at rated speed without load for 5 minute then
increase some load step by step and sudden loading or unloading should be
avoided.
2. The engine should not operate at idle speed for a long time to avoid oily smoke
and other faults.
3. During normal operation, the diesel engine is allowed to run continuously at
80% of rated power. Overload of 10% to meet peak power demands should
not be no more than 1 hr in every 12 hr.
4. After unloading, the diesel engine should be stopped only after running at idle
speed for (1~2) min or till the coolant temperature is below 70 degC.
5. During operation, pay attention to the following parameters and inspect the
following parts periodically or timely.
Pressure in main oil passage: 350~500 kPa.
Coolant outlet temperature: 80+5°C, but not exceeding 98°C. Exhaust
temperature after turbine: <550°C.
Check the exhaust color to identify the working performance of injector and
operating load of the diesel engine. If the exhaust gas color greatly deviates
from the specified, shut down the engine for inspection.
Pay attention to inspection on water, air or oil/fuel leakage of the diesel engine.
If any of the above is found, shut down the engine for remedy.

6. The operator is required to have knowledge about the following features of the
diesel engine:
a) The engine will reach the optimal fuel economy when its medium load range
is 60% ~ 90% of the rated load.
b) Provide the diesel engine with inspection and maintenance at the required
time intervals for routine inspection and technical maintenance.
Shutdown: During shutdown in cold weather, first remove the load, then run the
engine at no load for (1~2) min, and shut it down when the temperature of oil and
water has decreased.

19
3.4 Regular operation
Practice the daily inspection and maintenance for trouble free, safe and reliable
engine performance (refer below table 3.1)

DAILY INSPECTION AND MAINTENANCE

BEFORE START UP
• Ensure oil level is correct.
• Ensure coolant level is correct.
• Ensure sufficient fuel level in the fuel tank.
• Drain out water and impurities from fuel water separator and filter respectively
• Ensure the belt tightness is sufficient, and that there is no crack, peel off etc.
• Ensure no leakage from any of the fluid systems - coolant, oil, fuel, etc.
• Ensure all electrical control system is in order and ensures the battery is
healthy.
• Ensure all the hoses are free from leakage, not developed any cracks.
• Ensure sufficient greasing wherever required (water pump, belt tensioner
pulley etc.).

AFTER STARTING
Keep the engine on rated speed for 2 -3 minutes and let it warm up.
• Ensure no leakage in the fluid system – Coolant, oil etc.
• Observe the oil pressure, oil temperature, coolant temperature are normal.
• Observe the engine operation and ensure no abnormal noise, vibration, etc.
• Observe the exhaust smoke is normal.
• Ensure no variation in engine speed (hunting etc.)

Table 3.1

Record basic engine parameter during early life of the engine.

Monitor every parameter during routine inspection and maintenance.
Gradual drop in oil pressure is the indicator of progressive wear
in internal parts. If any abnormal change in parameter is noticed,
shutdown the engine immediately. Find out and rectify the cause of
trouble before restart.

3.4.1 Engine starting and warm up

After the engine is started, it takes a while for the lubricating oil to re- establish
the required oil filming between moving parts. The most appropriate clearance
conditions between moving parts are obtained only when the engine parts reach
the normal operating temperature.

20
In case of emergency Genset application, the customer should choose “AUTO”
mode on the controller. In this mode the engines get started automatically and go
for loading in case of main power supply failure. The auto operation parameter will
be set by the ASC/OEA representative during the installation and commissioning
of the Genset.

3.4.2 Monitoring the engine oil

Always maintain the correct oil level in the sump. Too high and very low level will
be a threat to engine safety. Required oil pressure will ensure enough oil flow to
various engine sub-assemblies and parts. Oil pressure will vary depending on
viscosity and oil viscosity depends on temperature.
Never operate the engine with very low or very high oil level (Refer
CAUTION dipstick mark)

3.4.3 Monitoring the engine coolant

Maintain the correct coolant level in the radiator. Coolant is the media to maintain
the engine body temperature within the specified range (75°Cto95°C).Maintaining
engine body temperature in the required range will ensure proper fit and clearance
between the moving parts.
If there is no coolant in emergencies, slowly add coolant with temperature not too
lower from the coolant filler. Finally cover the filler cap.

Do not check oil or coolant level while engine is running

OK OK

CAUTION

3.4.4 Monitoring the exhaust gas

Healthy engine operation and performance can be properly pointed out by the
engine exhaust gas. A chocked air cleaner, poor grade fuel or over-fueling, wrong
mechanical adjustments may cause a smoky exhaust. Action should be taken
immediately to find out the route cause and rectify the fault. If any serious color
change is noticed, stop the engine and carry out the inspection procedure. Refer
below table 3.2 for monitor and analyzing the exhaust gas.

21
 EXHAUST GAS QUALITY MONITORING
Sr. no Color Reason
1 Clear Healthy combustion system
Poor combustion quality (improper valve clearance,
2 Grey faulty injector or injection pump, weak compression,
etc.)
Poor combustion quality (one or more system failed
Dark grey/
3 - choked air filter, weak turbocharger, chocked
Black
intercooler, failed injector or fuel injection pump etc.)
Engine oil burning in combusting chamber piston rings
4 Blue
and liner worn-out, valve guide or stem seals damaged
Water ingresses in fuel/combustion system - water
5 White
containing in fuel, leakage cylinder head gasket etc.
Table 3.2

3.4.5 Engine shutdown

Caution for operation
In normal operation of the engine, it is allowed to operate continuously at described
rated power. However, the permissible over-load is 110% of the rated power.
Duration for permissible overload is strictly limited to 1 hour within every 12 hours.
Mixture of different grade or brands of engine oil is strictly prohibited. During
operation, always pay attention to the parameter values displayed on the panel
and observe the performance of various systems. Even though proper and regular
inspection and maintenance practices will eliminate the chances of breakdown,
carefully check the engine for water leakage, air leakage, oil or fuel leakage during
the operation. Stop the engine if any leakage is found, and rectify the trouble.

Engine economy balancing tips

• It is most economical to operate the engine at rated power

• Carry out the inspection and maintenance according to schedule (Refer
section IV of this manual).
• During operation, maintain engine parameter as per table 3.3

Any sudden rise in oil/coolant temperature which is not caused by

increase in load is a possible system failure warning and should be
CAUTION
investigated thoroughly at once.

22
 PARAMETERS TO MONITOR DURING REGULAR OPERATION
Sr No Parameters Unit Value Remark
Oil pressure in main oil pas-
1 Bar 3~7 Rated speed and power
sage
Coolant outlet temperature at
2 °C 70~95 It should not exceed 95°
normal operation
Exhaust gas
3 temperature after °C ≤550
gas turbine

Table 3.3

Before most of the failure, engine will develop early warning in the form
of abnormal sound, changes in parameter and performance or engine
appearance. Close monitoring of the engine will help to detect the fail-
ure in the preliminary stage.
Few signs, to look out for are as below:
‒ Leakage of oil, fuel, coolant, compressed air or exhaust gas
‒ Color change in exhaust gas
‒ Rise/drop of pressure and temperature of lubricating oil
‒ Excessive vibration
‒ Sudden unusual noise
‒ misfiring of engine
‒ Rise in oil/fuel consumption
‒ Power loss

Operation of diesel engine in winter

1. Fuel: Select and use the diesel of different brands according to the outdoor
temperature in winter.

2. Oil: Select the oil with different viscosities according to different seasons.

3. Coolant: Select and use different brands of anti-freeze additive and add additive
in different quantity into the cooling system according to the outdoor temperature.
4. Starting: In winter, use the auxiliary starter if required. It is allowed to run the
engine at higher speed and apply load after attaining the normal oil pressure and
water temperature.
Shutdown: When stopping the engine in cold weather, first remove the load,
then keep the engine at idle speed for 3~4 minutes, stop the engine only after all
temperatures drop down. Do not drain off coolant with anti-freeze additive after the
engine is stopped. If the coolant is not added with the anti-freeze additive, then it is
necessary to open water drain valve and completely drain off all coolant. This will
prevent damages caused to the engine due to freezing.
23
 SECTION IV
PERIODIC MAINTENANCE
Baudouin engines are designed for high reliability and long life. The engines are
built to withstand operational environment in various altitude and climatic conditions.
Preventive maintenance is the cost effective and economical way to reduce the
operational cost of a diesel engine. If the preventive maintenance is carried out
as per schedule by a trained technician, downtime and costly breakdowns can be
eliminated.
The maintenance schedule is defined by the actual operating environment of
the engine. The maintenance schedule given in table 4.1 is for ideal operating
condition. In case of heavy dust or adverse operating environment, the frequency
of the maintenance must be increased.

4.1 Safety precautions

Before performing maintenance operations, the engine operator must carefully
read and understand the instructions provided in this section. The operator must be
aware of and strictly follow the relevant operating instruction and safety precaution,
accident preventive measures, he also should practice the generally recognized
industrial safety measures.

4.2 Importance of periodic maintenance

Life of a diesel engine is depends on various factors such as regular inspection and
maintenance practices, quality of consumables used in the engines such as fuel,
lube oil and coolant, the skill of operator and method of using the engine etc
Routine inspection shall help the owners to monitor engine operating parameters
and prevent any serious break down to occur. Whereas the maintenance practice
are designed to eliminate the chances of failure and breakdown by performing
necessary adjustments and replacements on certain sub-assemblies as required
by the engine manufacturer. Skipping of routine inspection and maintenance will
lead to serious and or major breakdown which shall not be considered for warranty
at any point of time. Refer table 4.1 for recommended inspection and maintenance
interval for 6M16 Series Generating set diesel engines.

4.3 Replacement of parts and components

It is worth while to replace the parts as recommend by the manufacturer. The
genuine parts have undergone various quality checks before it moved out from the
factory. Only trust and buy the parts from our authorized sources only.

24
 It is allowed to use only genuine spare parts on the engine which
is procured from a reliable outlet of the engine manufacturer. If
the customer has installed non-genuine parts or sub-assemblies,
theCustomer should take the responsibility and bear all the cost
CAUTION
of damage to engine which may subsequently damage and cause
injury to persons. In such cases the engine is out of legal scope of
product warranty.

4.4 Reliability of parts

Prior to replacing any parts and components, customer must make sure that
the new parts and components to be installed are made by the original engine
manufacturer, and use necessary measuring instruments to check and make sure
they meet the relevant technical specifications if required.

Usages of non-genuine spare parts may cause to physical damage

of the engine components, threat to the functional safety of the
engine, human injury or severe equipment damage.

4.5 Safe use of oil and fuel in a diesel engine

Hazardous working media like lubricant and fuel are explosive, flammable, toxic
and corrosive. They are also harmful to human health if not properly handled

Following measures must be taken while handling the hazardous materials:

• Avoid direct contact with hazardous working media.
• If the clothes contaminated by hazardous working media, it must be changed
as soon as possible
•

• Only use neutral soap to wash the part of body where it is contaminated by
oil or fuel (trying to remove the deposits are removal of the by using fine sand
or solvent is not allowed).
Hot oil and hot components can cause personal injury. Do not allow
hot oil or hot components to contact the skin.

4.6 Disposal of used oil or fuel

Polluting the environment is a punishable offence by the government. It is the
responsibility of customer to make necessary arrangements to properly dispose
the used oil and other hazardous waste generated during engine operation and
maintenance. Collect used oil or contaminated fuel in special containers and
dispose it through approved disposing vendors.

25
1. In case of standby application of the Diesel Generating set, it
is recommended to run the engine on rated speed for 10-15
minutes every day.
2. Kindly ensure to contact our authorized service center to avail
the free services.
3. Consumables and material cost to be borne by the customer.
4. Always use recommended lubricant and coolant procured from
Authorized service center only.
5. Use 15W40 CI4+ Grade lubricating oil

26
4.7 Periodic Maintenance instructions
4.7.1 Check air filter
Cleaned air is playing a major role for the optimum engine performance and life of
internal components. Periodically check, clean and replace the air filter to ensure
optimum performance and maximum life.

It is not allowed to use the engine without air filter, otherwise the
dust and impurities will cause aggressive wear of the internal parts.

4.7.2 Cleaning air filter

Always use clean and dry air to clean the air filter element. To make cleaning
process more efficient, always direct the compressed air from inside to outside the
element. Don’t clean air filter with diesel or water. (Refer figure 4.1).
Check the condition of the sealing rings every time the air filter is removed for
cleaning. Replace it if the same is deformed or at least once in a year.

Figure 4.1

4.7.3 Replacement of engine oil and filters

Precautions
• Never run an engine without oil.
• Do not run an engine with oil filler port open or oil dipstick taken out.
Engine oil must be replaced when the additives are active. As per our standard, the
first time oil should be replaced at 50 hours. Later, it should be replaced every 1000
hours or 12 months from the date of last oil change.
The oil should be as per the recommendation of the company (grade and brand).
The oil and oil filter are required to be replaced at the same time. The oil should
be drained when the engine is warm. (About 45 to 55°C).Locate the engine oil
drain plug provided on the oil sump bottom. Position a suitable bin below the drain
plug. Remove the drain plug with the help of a suitable spanner. Drain out the oil
completely.

28
 After the engine oil is drained off completely, carefully inspect the
magnetic part of the drain plug for accumulation of metal particles.
Accumulation of various metal particles is the indication of abnormal
wear of internal components. If metal particle accumulation is
noticed, carry out necessary inspection before proceeding to the
next step.
Remove the oil filter with the help of special filter wrench. Let the oil drain out
completely from the filter housing. Take new oil filter and confirm the seal ring is
positioned on the filter mating face. Fill up sufficient quantity of fresh oil in the filter
and lubricate the sealing ring face. Position the filter and tight it on the housing by
hand. Use the filter wrench and gently tight the filter on its housing with the help of
filter wrench
Recap the drain plug and properly tighten it with the help of suitable spanner. Fill
up the recommended engine oil up to specified level through the filling port. Check
and confirm the sump oil level with the help of dipstick provided on the crank case.
Start the engine and run it for a short period (3-4 minutes).during running check
and ensure no leakage from the filter sealing and sump drain plug. Stop the engine
and check the oil level after 5 to 10 minutes; top up if required.

Figure 4.2 Figure 4.3

Figure 4.4 Figure 4.5

29
4.7.4 Replacement of fuel filter
Use the filter wrench to loosen and retighten the filter. Use a suitable tray under the
filter location to collect diesel spillage during removing the filter. Loosen and remove
the filter. Refer figure 4.5 Let the fuel drain completely from the filter housing. Wipe
the sealing surface with a clean cloth, then position new diesel filter on housing.
Firmly tight the filter on its body with the help of filter wrench

Figure 4.6 Figure 4.7

4.7.5 Air bleeding from fuel system

After every filter change and maintenance of engine fuel system, or air entered into
the system, check the whole fuel system and bleed out the air from the system.

4.7.6 Adjustment of Poly V-belt Tension

6M16 series diesel engine is provided with a cog Poly V belt, which drives the water
pump and charging alternator. To ensure efficient operation of the engine, wit is
important to maintain correct belt tension. Hence it is recommended to check and
adjust the belt tension periodically.
Check the belt tension only when the engine is stopped. Press on the middle of
a straight section of the belt with a force of 30~40 N (see fig 4.8). The bending of
Poly V-belt should be within the range of 10~15 mm. If not qualified, loosen the
adjusting bolt on the adjusting bracket to move the generator to adjust the belt to a
proper tension. Excessive tension will shorten the service life of the belt and lead
to premature failure of bearings in the alternator and water pump due to the heavy
load resulted from excessive belt tension. Insufficient belt tension, however will
lead to belt creep and fracture, resulting in engine overheating.

30
 Figure 4.8 Figure 4.9

4.7.7 Adjustment of Valve Clearances

Proper valve clearance is important for the engine efficiency and long life. Hence
it is necessary to check and adjust the clearance periodically. The checking and
adjustments are necessary due to wearing of related internal parts.

Preparation:
Adjust the clearance only when the engine is stopped and cold. (≤ 50°C).Required
Valve clearance Inlet valve: 0.30 mm Exhaust valve: 0.40 mm
Method:
Remove the cylinder head cover. Turn the crankshaft until the mark of the top dead
center of the first cylinder on the crankshaft pulley aligns with the pointer of the
timing indicator (see fig 4.11).

Figure 4.11 Figure 4.12

When the piston of the first cylinder is at its top dead center on the compression
stroke, both intake and exhaust valves of the first cylinder will be in the closed
position. In this position, check the valve clearances as per the sequence mentioned
in below table, step-1. After completing the first step rotate the crank shaft for 360°
and follow step -2 from the 6th cylinder.

31
If the valve clearance is found incorrect, follow the adjusting sequence as mentioned
here. Loosen the lock nut of the clearance adjusting screw with the help of spanner
and hold it. Loosen the adjusting screw with the help of a screw driver and insert
the correct feeler gauge. Screw in or out the adjusting screw until the feeler gauge
inserted between the rocker arm and the top surface of the valve stem feels neither
too loose nor too tight. Then tighten the lock nut and check the clearance again.
Readjust if necessary till it is properly set. Repeat the operation if required of other
cylinders. Once the checking and adjustment is completed, relocate the cylinder
head cover with a new gasket.

CYL. NO 1 2 3 4 5 6
STEP- 1 I E I - - E I - - E - -
0.4mm

0.6mm
Figure 4.13

Rotate the engine 360°-match the OT mark to the pointer. Adjust the clearance in
the following order.

Figure 4.14

CYL. NO 1 2 3 4 5 6
STEP- 1 - - - E I - - E I - I E

32
4.8 Maintenance Recommendation
The major maintenance is depends on main factor like routine inspection and
maintenance, quality of fuel, lubricant and coolant, atmosphere etc. Considering
the ideal situation, periodic maintenance chart is prepared (refer table 4.2)
ABBREVIATIONS: A- Adjust, C- Clean, I-Inspection, M- Monitor, R- Replace,
S- Service, CAL- Calibrate, MS- Major Service

Maintenance Interval (hours)

ABBREVIATIONS: A- Adjust, C- Clean, I-Inspection,

RELATED SYSTEM OR SUBASSEMBLY M- Monitor, R- Replace, S-Service, CAL- Calibrate, MS-
Major Service

Sr. Sr. 50 500 1000 1500 3000 6000 12000

Description Description
No. No. Hrs. Hrs. Hrs. Hrs. Hrs. Hrs. Hrs.

500 hours of operation from last oil change or 6

1 LUBE OIL R
months, whichever occurs earlier.

LUBE OIL
2 C
STRAINER

3 OIL PUMP M M M M M M M

4 OIL COOLER C&I C&I C&I

5 OIL FILTER REPLACE ON EVERY OIL CHANGE

6 OIL FILTER SEAT C&I

LUBE OIL PRESSURE
1 7 I I R
SYSTEM SENSOR

PRESSURE
8 I R
RELIEVE VALVE

9 OIL GALLERY C&I

TURBO CHARGER
10 I I I
OIL SUPPLY LINE

TURBO CHARGER
11 I I I
OIL RETURN LINE

12 GASKETS & SEALS REPLACE EVERY TIME WHEN REMOVED

Change500 hours or 6 months, whichever occurs

1 FUEL FILTER M
earlier.

ELECTRICAL
2 M M M M M M M
MOTORIZE PUMP

FUEL INJECTION CAL&

3 M C&I CAL
2 Fuel system PUMP MS

CAL&
4 INJECTOR NOZZLE M I CAL
MS

RETURN LINE
5 I R R
FLEXIBLE HOSE

6 GASKETS & SEALS REPLACE EVERY TIME WHEN REMOVED

33
 Maintenance Interval (hours)

ABBREVIATIONS: A- Adjust, C- Clean, I-Inspection,

RELATED SYSTEM OR SUBASSEMBLY M- Monitor, R- Replace, S-Service, CAL- Calibrate, MS-
Major Service

Sr. Sr. 50 500 1000 1500 3000 6000 12000

Description Description
No. No. Hrs. Hrs. Hrs. Hrs. Hrs. Hrs. Hrs.

AIR FILTER
1 I C&I REPLACE ON EVERY 1000 HOURS
ELEMENT

2 CAC M M M M C&I C&I C&I

Air Intake AIR INTAKE

3 3 I I I
System MANIFOLD

HOSES AND
4 I I I I I R R
CLAMPS

5 GASKETS & SEALS REPLACE EVERY TIME WHEN REMOVED

EXHAUST
1 I I I
MANIFOLD

EXHAUST 2 TURBO CHARGER I C&I

4 C&I
SYSTEM
3 FASTENERS R R

4 GASKETS & SEALS REPLACE EVERY TIME WHEN REMOVED

1 COOLANT M M M M M&I R R

COOLANT WATER
2 I R
PUMP

3 WATER JACKET I C&I

4 THERMOSTAT M I R R

5 RADIATOR M M M M C&I C&I C&I

COOLING HOSES AND
5 6 M M M M R R R
SYSTEM CLAMPS

7 FUEL TANK C&I C&I C&I

FLEXIBLE HOSES
8 R R R
AND CLAMP

FUEL WATER
9 M M R R R R R
SEPERATOR

10 GASKET & SEALS REPLACE EVERY TIME WHEN REMOVED

INTAKE & EXHAUST

1 I I R
VALVE

2 VALVE SEAT I I R

3 VALVE GUIDE I I R

4 COLLETS I I R
CYLINDER
6 5 SEALS I R R
HEAD
6 SPRING SET I I I

WATER JACKET
7 I I R
DUMMY

8 FASTNERS I I

9 GASKETS & SEALS

34
 Maintenance Interval (hours)

ABBREVIATIONS: A- Adjust, C- Clean, I-Inspection,

RELATED SYSTEM OR SUBASSEMBLY M- Monitor, R- Replace, S-Service, CAL- Calibrate, MS-
Major Service

Sr. Sr. 50 500 1000 1500 3000 6000 12000

Description Description
No. No. Hrs. Hrs. Hrs. Hrs. Hrs. Hrs. Hrs.

1 PUSH ROD I I

ROCKER ARM
2 I I
ASSEMBLY

CHECKING &
7 Valve Train 3 ADJUSTING VALVE C&A C&A C&A
CLEARANCE

CHECKING &
ADJUSTING
4 C&A C&A
VALVEBRIDGE
CLEARANCE

1 PISTON I R

2 PISTON PIN I R

3 PISTON RING SET R R

4 CYLINDER LINER R R

8 Moving Element 5 CONROD BOLT EVERY TIME WHEN IT IS LOOSENED

CONROD SMALL
6 I R
END BUSH

CONROD BIG END

7 R R
BEARING

8 CONROD I R

MAIN BEARINGS &

1 R
THRUST BEARINGS

CAM BUSH BEAR-

2 R
ING

BEARINGS RELAT-
3 R
ED TO GEAR TRAIN
CRANK CASE
- CAM SHAFT - 4 OIL SEALS R R
9
CRANK SHAFT
- GEAR TRAIN 5 TAPPET I I

6 CAM SHAFT I

7 CRANK SAHFT I

8 CAM & IDLE GEAR I

9 FASTNERS I

36
35
 Maintenance Interval (hours)

ABBREVIATIONS: A- Adjust, C- Clean, I-Inspection,

RELATED SYSTEM OR SUBASSEMBLY M- Monitor, R- Replace, S-Service, CAL- Calibrate, MS-
Major Service

Sr. Sr. 50 500 1000 1500 3000 6000 12000

Description Description
No. No. Hrs. Hrs. Hrs. Hrs. Hrs. Hrs. Hrs.

REPLACE ON EVERY 1500

1 FAN BELT M M
HOURS

2 BELT PULLEY I I I

FLEXIBLE HOSES
3 C C C C R R
AND CLAMP

SET OF O RINGS
4
AND GASKETS REPLACE ON WHEN REMOVE
OTHERS SUB
10
ASSEMBLIES
5 STARTER MOTOR M M M I I&S I&S

6 ALTERNATOR M M M I I&S I&S

ENGINE CON-
7 M M M M M M
TRILLER

8 WIRE HARNESS M M M I I I

FUEL SHUT OFF

9 M M M M I I
SOLINOID

Table No 4.8 maintenance Chart

Replacement period of engine oil varies according to the operating

Conditions below.

Normal operating condition (the above-listed is normal operation condition, when

the oil consumption is normal): the ambient temperature is normal, and fuel with
sulfur content lower than 0.5% (by weight) is used. Adverse operating condition (oil
consumption is high):

A: In tropical climate or cold zone (temperature exceeds +30° or lower than-10°);

the oil drain period shall be half of that under normal operation condition.

B: When sulfur content of fuel with is 0.5~1.5%, the oil drain period shall be half of
that under normal operation condition.

C: In adverse operating condition with A+B, the oil drain period shall be one fourth
of that under normal operating condition.
 Replacement period of engine oil varies according to the operating
Conditions below.

Normal operating condition (the above-listed is normal operation condition, when

the oil consumption is normal): the ambient temperature is normal, and fuel with
sulfur content lower than 0.5% (by weight) is used. Adverse operating condition (oil
consumption is high):
A: In tropical climate or cold zone (temperature exceeds +30° or lower than-10°);
the oil drain period shall be half of that under normal operation condition.
B: When sulfur content of fuel with is 0.5~1.5%, the oil drain period shall be half of
that under normal operation condition
C: In adverse operating condition with A+B, the oil drain period shall be one fourth
of that under normal operating condition

4.9 Tightening Table and Torque Value For Main Fasteners

Description Tightening torque(Nm)
Main Bearing Bolt 250N-m~280N-m
Connecting Rod Bolt Hand tightening:(170~250)N-m
Cylinder Head 1. Auxiliary bolt 100N-m;Main bolt of
cylinder 200N-m .
2. Auxliary bolt turn 90°~Main bolt of
cylinder turn 90°
3. Auxiliary bolt turn 90° or (120~160)
N•m~Main bolt of cylinder turn 90°or
(240~340)N-m
Flywheel Bolt 60N-m~80N-m~then turn
180°±10°(230~280)N-mº
Crankshaft pulley plate bolt 60 N-m
Exhaust Pipe Bolt 65~95N-mº
Injector plate bolt 8Nm+90°
High-pressure fuel pipe 30~40N-m
Fuel Injection Pump Drive gear nut 250~300N-m

36
4.10 Recommended Standard Torque Values For Bolts

Friction
0.125(Galvanization) 0.14(Bright)
Coefficient
Strength
6.9 8.8 10.9 12.9 6.9 8.8 10.9 12.9
Rating
Bolt
Recommended torque N-m
Specifications
M8×1 21 25 35 42 23 27 38 45
M10×1.25 41 49 66 82 44 52 73 88
M12×1.25 74 88 125 150 80 95 135 155
M12×1.5 70 83 115 140 76 90 125 150
M14×1.5 115 140 195 235 125 150 210 250
M16×1.5 175 210 295 350 190 225 315 380
M18×1.5 255 305 425 510 275 325 460 550
M20×1.5 360 425 600 720 385 460 640 770
M22×1.5 480 570 800 960 520 610 860 1050
M24×1.5 610 720 1000 1200 650 780 1100 1300
M27×1.5 890 1050 1500 1800 970 1150 1600 1950
M30×1.5 1250 1450 2050 2500 1350 1600 2250 2700

Main bearing bolts tightening sequence Cylinder Head main bolt tightening
sequence

Banjo Bolt Torque Recommendation

Bolt Torque
Types of Bolt Material
Specifications developed(Nm)
M10x1.0 Copper Bolts (13±2)N-m
M10x1.0 (21±3)N-m
Hollow hex head
M14x1.5 (27 ±3)N-m
bolt torque Steel bolts
M16x1.5 (40 ±5)N-m
M6x1 (6±1)N-m
M10 20±3
M12 28±3
Hollow bolt flange Steel bolts
M14 32±3
M16 36±3

TABLE 4.5

37
List Of Sealants And Thread Locking Compounds Used For Engine
Maintenance
SR NO DESCRIPTION COLOR USAGE AND APPLICATION
Apply it to smooth metal surface
to prevent seizing for example:
1 Molykotte Pulver Black
apply it on the outer surface of
cylinder sleeve.
Take the lubricating function
before the lubricating oil
2 Molykotte G. u. plus Dark Grey pressure is established, for
example, apply on inlet valve
rod.
Apply it on the thread surface
for fixing, avoid the looseness
caused by shake, with medium
3 Loctite242 Blue
strength, for example, apply on
the thread of main oil passage
pressure limiting valve.
Apply it on the thread outer
surface for locking, sealing and
prevention of looseness due to
4 Loctite262 Red
vibration, in high strength. For
example: Cylinder head bolt
threaded part
Apply on the surfaces on pipe
and junction for fixing; for
5 Loctite275 Green example, apply on the surface
of water outlet pipe and heating
water inlet pipe.
Apply it on the bright metal
surface to play a sealing role For
Red
6 Loctite510 example, apply it to the faying
(orange)
surface between cylinder block
and crankcase
Apply on cavity or passage for
sealing between element and
7 Loctite277 Red hole. For example, Bowl shaped
plug matching cylindrical
surface.
Apply it on the bright metal
surface to play fixing role For
8 Loctite648 Green
example: Tension pulley bearing
bore and shaft outer surface.

38
4.11 Trouble Shooting Guide For 6M16 Series G-Drive Engine
Check the air inlet temperature and pressure sensors, water temperature sensor
and rail pressure sensor, and ensure that the connectors are connected firmly.
Troubleshooting for other faults

4.11.1 Shutdown shortly after starting

Failure Symptoms Check Points

Check the fuel pipe and its joint for leakage.
Check Whether the bleeder screw is
Air trapped in fuel system
securely tightened. Expel the air out of the
fuel system
Take down the filter body. Remove dirt and
Fuel filter clogged Moisture. If necessary, replace the filter
element
Poor fuel quality with excessive moisture Clean the filter, and replace fuel
Check, clean and repair the piston and valve
Fuel supply pump does not work
of the fuel supply pump
Idle speed too low Re-adjust
Check the fuel pipe and its joint for leakage.
Check.
Air trapped in fuel system Whether the bleeder screw is securely
tightened.
Expel the air out of the fuel system

4.11.2 Inadequate power

Failure Symptoms Check Points

Check air filter and intake pipe, clean or
1. Intake system (air filter) clogged
replace The filter.
Check valve timing, check the exhaust pipe
2. Excessively high exhaust back pressure
for Blockage, adjust and repair.
3. Insufficient pressure in turbocharger Check and eliminate leakage at pipe
system connections
4. Turbocharger works abnormal Replace the assembly.
4.1 Compressor, turbine flow passage
Clean or replace
clogged
4.2 Floating bearing failure Replace
4.3 Carbon or sludge deposit in the back of
Clean
turbine and compressor
5. Damage, blockage or air leakage of
Replace or repair
intercooler

39
 Check fuel pipe and joint for tightness,
check filter and fuel pipe for contamination,
6. Leakage or blockage of fuel line
repair or clean Blockage and replace filter
element.
Clean fuel tank, filter element and fuel pipe,
7. Poor fuel quality
and Change the fuel.
Check the oil dipstick, and drain excessive
8. Engine oil level in oil pan too high.
oil.
9. Gas leaks from cylinder gasket, poor While the diesel engine is hot. Replace the
valve Sealing Damaged cylinder gasket.
10. Worn or broken piston ring, excessive Replace the damaged part or overhaul the
bearing bush clearance diesel Engine.
11. Worn cylinder liner or piston ring or
Overhaul the diesel engine.
cylinder Scuffing

4.11.3 Excessive fuel consumption

Failure Symptoms Check Points

Check air filter and intake pipe, clean or
1. Intake system clogged (air filter blocked)
replace The filter.
2. Excessively high exhaust back pressure
Check valve timing, check the exhaust pipe
for Blockage, adjust and repair.

Clean fuel tank, filter element and fuel pipe,

3. Fuel of poor quality
and Change the fuel.
4. Leakage in fuel pipe Check and repair
5. Improper valve timing or fuel supplying
Check and adjust.
timing
6. Cylinder gasket leaks air, poor valve While the diesel engine is hot. Replace the
sealing Damaged cylinder gasket.

7. Excessive bearing bush clearance Check and overhaul.

8. Expanded piston stuck in cylinder Replace cylinder liner, piston and piston ring

9. Insufficient pressure in turbocharger Check and eliminate leakage on pipe and

system Connections.
10. Turbocharger works abnormal Check or replace the assembly.
11. Intercooler damaged, blocked or
with air Leakage Replace or repair.

40
4.11.4 Black smoke in exhaust

Failure Symptoms Check Points

[Link] pipe clogged or high exhaust
Clean
back Pressure
Clean fuel tank, filter element and fuel pipe,
2. Fuel of poor quality
and Change the fuel.

3. Improper valve timing or fuel supplying

Check and adjust.
timing
4. Injector nozzle with poor atomization Adjust and repair.
5. Insufficient pressure in turbocharger Check and eliminate leakage on pipe and
system Connections.
6. Turbocharger works abnormal Check or replace the assembly.
7. Intercooler damaged, blocked or with
Replace or repair
air Leakage

4.11.5 White smoke and blue smoke in exhaust

Failure Symptoms Check Points

1. Fuel of poor quality and with excessive
Change the fuel .
water Content
Check operating temperature of thermostat,
2. Low coolant temperature
and Replace if necessary.
3. Injector nozzle with poor atomization Adjust and repair.
4. Low compression pressure,
Check piston ring, cylinder liner and cylinder
incomplete combustion and expanded
Gasket, and repair them if necessary.
piston stuck in cylinder
5. Piston ring and cylinder liner lack of
Continue running-in.
running in
6. Piston ring openings failing in staggering Adjust and re-assemble.
7. Failed piston ring Replace
8. Excessive engagement clearance
Repair or replace.
between piston and cylinder liner
9. Worn turbocharger seal ring Check and replace.
10. Worn turbocharger thrust bearing Check and replace
11. Blocked turbocharger oil return pipeline Clean or repair.

41
4.11.6 Oil gathering at turbocharger air inlet and air inlet pipe

Failure Symptoms Check Points

1. Failed turbocharger seal Repair or replace.
2. Failed oil-gas separator Replace.
3. Too high oil level in oil pan, excessive
Check and drain appropriate amount of oil.
oil filled

4.11.7 Unstable speed

Failure Symptoms Check Points
1. Fuel of poor quality and containing water
Clean fuel pipeline and change the fuel.
and Wax
Check fuel pipe and joint for tightness, and
2. Fuel suction pipe is sucking air in
remove the air if any.
3. Uneven fuel supply Check and repair (by dedicated workshop)
4. Injector with uneven atomization Check and repair.
Check and clean air compressor passage
5. Turbocharger with surge duct, remove the fouling and soot deposition
in Exhaust passage.
6. Damaged turbocharger bearing Replace.

4.11.8 Excessively low oil pressure

Failure Symptoms Check Points
Check the oil level, check for oil leakage,
1. Oil level too lower in oil pan If oil level low, fill recommended oil by
following the procedure.
2. Main oil passage pressure regulating
Check the valve, clean and repair.
valve is Failure
3. Blocked or broken oil collector, oil Check oil collector, oil line joint and oil gallery
pipeline and joint gasket, etc. for Cast shrinkage, and repair if necessary.
4. Engine oil grade is not compliant Change oil as required.
5. Oil inlet pipe of oil pump leaks Check oil pipe and joint, repair or replace.
6. Too high water temperature in cooling Check operation of the cooling system, and
system, too high oil inlet temperature correct it.
7. Excessive resistance in oil filter Replace filter element.
8. Blocked oil cooler Check and clean.
9. Blocked main oil passage Check and clean.
10. Excessive bearing bush clearance or
Check and replace.
damaged bearing bush
11. Excessively worn components Check for service hours of diesel engine,
requiring Overhaul and carry Out overhaul.

42
4.11.9 Excessively high coolant temperature

Failure Symptoms Check Points

1. Too low water level in the water tank Check for leakage, and fill water.
2. Radiator of water tank (intercooler) is
Clean or repair.
blocked
3. Slack water pump belt Adjust tension force of the belt as required.
4. Damaged pump seal gasket and worn
Check and repair or replace.
pump Impeller
5. Thermostat fault Replace.
Check water pipe, joint and gasket, and
6. Damaged water pipe is sucking air in
replace Any damaged part.
Check the oil level, check for oil leakage,
7. Insufficient oil in oil pan
repair And add oil.

4.11.10 Parts wear too fast

Failure Symptoms Check Points

1. Air filter element damaged Check and replace air filter element.

Check air intake pipe and gasket, repair or

2. Short circuit of air intake system
replace Damaged part.
Check the oil level, check for oil leakage,
3. Insufficient oil in oil pan
and add Oil.
4. Engine oil grade is not compliant Change oil as required.

5. Oil passage clogged Clean oil passage.

6. Piston ring broken or worn Replace damaged part.

7. Oil filter element is not replaced timely Replace filter element as required.
8. Worn cylinder liner or piston or cylinder Disassemble piston and cylinder liner,
scuffing check, and Repair or replace.
9. Crankshaft axis is not in line with the axis
Check the mounting bracket, and repair.
of driven shaft
Check for service hours of diesel engine,
10. Part/component is worn excessively
and carry Out overhaul.

43
4.11.11 Excessive noise

Failure Symptoms Check Points

1. Poor fuel quality Change the fuel.

Check the thermostat, and replace if

2. Too low coolant temperature
necessary.
3. Improper valve timing or fuel supplying
Check and repair or adjust.
timing
4. Instable atomization of fuel injector Check and repair or adjust.

5. Excessive fuel injection Check and adjust (by dedicated workshop).

6. Vibration damper damaged Check for damage, and replace if necessary.

7. Valve with leakage or improper adjust-
Check the valve and make adjustment.
ment
8. Excessive gear clearance or broken
Check and replace damaged part
tooth
9. Worn cylinder liner or piston or cylinder
Check and repair or replace.
scuffing
10. Bent or broken push rod Replace
11. Broken or worn piston ring Check or replace damaged part
12. Excessively worn bearing Check or replace bearing
13. Excessive crankshaft thrust bearing
Replace thrust bearing
clearance
14. Main bearings are not concentric Check and repair
15. Crankshaft axis is not in line with the
Check bolt of mounting bracket, and repair.
axis of driven shaft
16. Excessively worn components Check parts and determine whether
Overhaul overhaul is Needed.
17. Turbocharger with surge Clean air compressor air duct, and repair.
18. Damaged turbocharger seal ring Replace the assembly.
19. Damaged turbocharger bearing,
collision between rotating part and fixed Replace the assembly.
part
20. Foreign matters come into
Repair or replace.
turbocharger turbine or air compressor

44
4.11.12 Insufficient output of starting motor

Failure Symptoms Check Points

1. Battery insufficiently charged Check, charge or replace battery.
2. Worn bearing bushing Replace the assembly.
Remove the oil stain and grind with abrasive
3. Commutator is dirty or burnt
paper Or replace the assembly.
4. Terminal unsoldered Re solder.
5. Poor switch contact Inspection and repair the switch.

4.11.13 No power generated by alternator

Failure Symptoms Check Points

1. Short or open circuit, connector loosened Repair.
2. Short or open circuit of rotor or stator
coil, or Grounded Repair or replace the assembly.

3. The rectifier valve is damaged Replace the assembly.

4. Damaged paper insulation of terminal,

causing broken wire Repair.

5. Regulator voltage regulated to be too low Repair.

6. Burnt regulator contact Repair or replace the assembly.

4.11.14 The battery cannot be charged fully through alternator

Failure Symptoms Check Points

1. Open circuit, short circuit or loose
Repair.
connector
2. Short/open circuit of rotor or stator coil,
Repair or replace the assembly.
or Grounded

3. The alternator belt is slack Repair and adjust tension force of the belt.

4. Damaged rectifier valve of alternator,

Repair.
poor contact of battery terminal

5. Regulator voltage regulated to be too low Make adjustment.

6. Magnetic field coil or resistance wiring

Repair or replace.
of regulator disconnected
7. Insufficient electrolyte in battery, or
Add electrolyte or replace battery.
battery is too Old

45
 SECTION - V
LUBRICANT AND COOLANT SPECIFICATIONS

5.1 Lubricant
5.1.1 The functioning of lubricating oil in a diesel engine

The lubricating oil used in the engine must be multifunctional. It must perform the
primary functions of:
1. Lubrication: Basic function is to reduce friction and minimize the wear and tear.
The engine oil forms a film between the moving parts (such as bearings, pistons,
piston rings, cylinder liners and the valve train) and ensures sufficient lubrication
between the moving parts.
2. Cooling: Acts as a media for high heat transfer (from combustion chamber) and
protecting the moving parts from overheating.
3. Detergency: Cleaning pistons and preventing sludge build-up on internal surfaces
4. Prevention from corrosion: Corrosion prevention by neutralizing the acid and
protecting the components from atmospheric humidity by creating a layer.

5. Sealing: By filling in the uneven surfaces in the cylinder wall, valve stems and
Turbocharger oil seals.
5.1.2 Engine oil consist of
Engine oil consists of base oil and additives. Base oil is the most basic raw materials
of engine oil and additives are added for enhancing the oil properties which is
suited for diesel engine applications. Basic additives are viscosity modifiers, anti-
wear additives, detergents, dispersant and antioxidant etc.
5.1.3 Why oil should be drained
Engine lubricating oil must be drained when it can no longer perform its functions in
an engine. Oil doesn’t wear out, but it becomes contaminated/ degraded to the point
that it can no longer satisfactorily protect the engine. The engine oil degradation is
a normal result of engine operation, where oil properties changed mainly because
of reaction to the combustion by products.

5.1.4 How engine oil performance is getting deteriorated

1. By-products of Engine Combustion: Soot from partially burned fuel will

contaminate the fresh oil and over a period of time, viscosity of the oil will increase
2. Base (BN) additives become neutral due to reaction with acid, produced during
combustion process.
3. Varnish and sludge which are formed as a result of the oxidation of the oil as it
breaks down or decomposes which leads to oil thickening.
4. Contamination due to dirt entering the engine through the atmospheric air and
bad fuel.
46
5. Other additive depletion due to reaction which will affect the performance of oil.
5.1.5 Oil performance classification system

Following are the organizations designing and approving oil classification and
specification standards.
API (American Petroleum Institute)
ACEA (Association des Constructers Europeans automobiles - European) ASTM
(American Society for Testing Materials)
JASO (Japanese Automobile Standards Organization)

5.2 Engine oil recommendations for Baudouin engines

Quality of lubricating oil is one of the key drive factors to decide the performance,
durability and total cost of operating of diesel engine. Hence, we have always been
recommending the best available/suitable engine oil to be used in our engine.
Lubricating oil has also undergone various improvements to meet the requirements
of these changes in diesel engine technology. With this, SAE 15W40grade
lubricating oil with API CI4+ classification is now available in India from most of oil
companies. This is the best engine oil currently available in India.
This provides several advantages such as,
1. Reduced wear and tear of internal moving parts like piston rings, liner, bearing,
shaft etc.
2. Better oxidation stability at high temperature
3. Stabilized engine temperature on higher loads
4. Optimum lube oil consumption
5. Better emission control
6. Improved detergency for better cleanliness of internal passages and
components
7. Less sludge formation due to improved dispersancy
8. Improved capability on acidneutralization formed during combustion process,
resulting in less corrosion damage in internal engine components.

Hence, we strongly recommend the use of SAE 15W40 lube oil with API CI4+
classification For all engines to get the various advantages and optimum
performance from the engine.
This oil should have a minimum TBN (Total Base Number) of 10.5 to counteract the
higher Sulphur content of high speed diesel available in India.

47
 Beware of spurious oils in the market. Bad oil quality is detrimental
to engine performance. Hence oil should always be procured from
CAUTION
the original manufacturer or the authorized distributor.

Lubricating oil to be used in the engine must meet all qualities as per manufacturer’s
specifications. We recommend audit checks of fresh engine oil to ensure the
quality of oil. Facility to check suitability of oil for using it in the engine is available
with the service centers. If in doubt about the quality of lube oil, contact lube oil
manufacturing company and get oil analyzed in their laboratories.
Do not intermix different brands of oil as two different brands of oils may not be
compatible with each other. It is therefore recommended that the brand which is
used for initial fill/oil change should only be used for top-up. Different brand of oil
may be used after draining all the existing oil i.e., at the oil drain interval and after
flushing the lube oil system with new brand of oil.

The responsibility of meeting oil quality lies with the oil manufacturer
and Baudouin will not be responsible for problems occurring on
CAUTION
engines due to poor quality of oil.

5.3 Grease Recommendations

We recommend the use of grease meeting the specifications of ML-G-3545,
excluding those of sodium or soda soap thickeners. Contact lubricant supplier for
grease meeting these specifications.

Do not mix brands of grease can cause damage to bearings

Excessive lubrication is as harmful as Inadequate lubrication.
CAUTION After replacing fan hub replace both the pipe plugs. Use of fittings
will allow lubricant to be thrown out, due to relative speed.

The responsibility of meeting oil quality lies with the oil

manufacturer and Baudouin will not be responsible for problems
occurring on engines due to poor quality of oil.

5.4 Coolant
An engine coolant is a heat transfer fluid which flows through or around an engine
to prevent it’s overheating, transferring the heat produced by the engine to radiator
that dissipates it. An operating engine typically converts only one third of the energy
derived through the combustion of fuel into work. The other two thirds is converted
into heat, of which one third goes out with the exhaust and remaining one third
is removed by engine coolant. The coolant absorbs this heat, transport it to the
radiator/heat exchanger and dissipate it into the environment/ atmosphere.
Research has shown that 40% of all engine problems in high speed diesel engines
are related, directly or indirectly, to improper cooling system maintenance.

48
We recommend use of ES Complete EG Premix 50/50.
ES Complete EG Antifreeze/Coolants are Extended Life formulations that contain
Ethylene Glycol (EG) base fluids and are designed specifically for Extended Service
use in heavy duty diesel engines. ES Complete is specifically designed for use with
ES Slow Release coolant filters or liquid ES Extender to provide simplified coolant
maintenance while extending coolant service intervals to 150,000 miles (260,000
km) or 4000 hours of operation. ES Complete can also be used in standard service
maintenance intervals with the use of Supplemental Coolant Additives (SCA) and
standard coolant filters.
Composition ES Complete EG Concentrate mixes readily with clean tap water
or dematerialized water, while ES Complete EG Premix is formulated with
dematerialized water and is ready to use. Both EG antifreeze products are low
silicate, contain a full charge of heavy duty chemical inhibitors and are compatible
with SCA chemical filters. ES Complete EG Antifreezes are formulated with Borate/
Nitrite chemistry recommended for use in heavy duty diesel engines.

5.5 A good coolant should have following properties

• Overheating and antifreeze protection

• Excellent scale, rust and corrosion protection
• Harmless to water pump seal, hoses and gaskets.

Premixed READY TO USE antifreeze engine coolant is recommended to use as is

condition, as a FIRST FILL as well as for TOP UP of the cooling system.
Refer table 5.3 to select the best suitable coolant solution

49
 Engine Log Book
ENGINE STARTED AT ________ HRS RUN TILL YESTERDAY _______________

ENGINE STOPPED AT HRS. RUN TODAY

TOTAL HRS TOTAL HOURS

ENGINE ALTERNATOR
TIME (HRS.) W. T. L.O.P. L.O.T. RPM VOLTAGE CURRENT HZ PF KW KWh

DIESEL FILLED __________LTS. __________HRS.__________LTS.__________HRS.

LUB OIL TOP UP __________LTS. __________HRS.__________LTS.__________HRS.

OBSERVATION REGARDING SMOKE CONDITION, LEAKAGES IF ANY, ENGINE SOUND ETC.

Maintenance due after________ HRS. __________Carried out detail.

SAMPLE FOR REFERENCE ONLY

50
 BAUDOUIN SALES AND SERVICE NETWORK

Head office

Parts Franchise

Service center
Head Office

Customer
Training Centre

New Delhi
Greater Noida
Jaipur

Indore
Dhar Contai
Raipur
Mangrol
Nagpur Balasore

Navi Mumbai
Pune
Kakkinada

Goa Rajahmundry
Bangalore

Mangalore
Chennai

Salem
Palakkad Madurai
Tuticorin
Cochin

51