1002532408 Weichai WP10.5 Generator Bosch F000BL072W

Pre-installation Preparation

• Equipment and Tool Inspection: Check that the generator housing is free of damage, the bearings operate smoothly without jamming, and the terminal blocks are free of oxidation. Ensure all accessories (flexible drive plate, connecting flange, bolts, etc.) are complete. Prepare tools such as 8.8-grade high-strength fixing bolts, wrenches, spirit levels, dial indicators, thin metal gaskets, and thread locker. For large units, prepare suitable lifting equipment.

• Installation Location Confirmation: Select a position away from heat sources. If avoidance is not possible, install a heat shield. For indoor installation, ensure good ventilation and reserve sufficient maintenance space. If exhaust is involved, plan the exhaust pipe route to minimize the number of bends.

• Cleaning of Mating Surfaces: Remove oil, grease, and rust from the engine flywheel housing, flywheel bolt holes, and generator connecting flange. Ensure the mating surfaces are flat to avoid vibration caused by gaps after installation.

Mechanical Alignment and Fixation

• Precise Alignment and Positioning: For single-bearing generators, use lifting equipment to hoist the generator horizontally and align it with the engine flywheel housing. Insert two cylindrical pins into the symmetric bolt holes of the flywheel first to allow the generator's flexible drive plate to slide smoothly into the flywheel spigot. Adjust the generator height and correct the perpendicularity and coaxiality of the mating surfaces using thin metal gaskets, controlling the error within 0.1mm. For belt-driven generators, align the planes of the engine pulley and generator pulley to ensure smooth transmission.

• Tightening of Connecting Components: Apply thread locker to the connecting bolts. First fix the flexible drive plate to the engine flywheel, then secure the connecting flange to the flywheel housing. Tighten the bolts evenly in a diagonal pattern. Remove the cylindrical pins afterward and install the remaining bolts, tightening them securely. For belt-driven models, install the belt. Apply a pressure of 15 kg to the middle 1/2 of the belt—an indentation of 10-15 mm indicates proper belt tension.

• Fixation of Generator Base: Use special bolts to fix the generator base to the equipment frame or foundation. Shock-absorbing pads can be installed between the unit and the foundation to prevent vibration-induced displacement during operation. After fixation, recheck with a spirit level to ensure the generator is not tilted.

Pipeline and Accessory Installation

• Exhaust Pipe Connection: If the generator is equipped with an exhaust port, connect the exhaust pipe. The pipe diameter should not be smaller than that of the muffler outlet pipe. Incline the pipe downward by 5-10 degrees to prevent rainwater ingress. Limit the number of bends to no more than 3 to ensure smooth exhaust. Seal the joints tightly to prevent exhaust gas leakage.

• Fluid Filling: Some Weichai-matched generators require independent engine oil filling. Add the appropriate type of engine oil as specified in the instruction manual. Check that the oil level is between the scale marks to ensure adequate lubrication of bearings and other components, avoiding damage from dry friction.

Electrical Wiring Connection

• Power Cable Wiring: Select wires matching the rated current for the 28V system. For a rated current of 100-150A, the wire specification should be no less than 25mm² to prevent overheating and burnout due to undersized wires. Connect the generator output terminal to the equipment power distribution system. Ensure the terminal blocks are tightly fastened. For large-specification output wires not vertical to the ground, provide additional fixation to prevent joint loosening caused by vibration.

• Control Wire Connection: Follow the generator wiring diagram to connect the excitation wires (F+, F-) to the corresponding terminals of the regulator. Distinguish between positive and negative poles to avoid reverse connection, which may burn out the generator regulator or winding coils. Simultaneously connect the generator's speed and voltage detection wires to the equipment instruments to ensure normal signal transmission.

• Grounding Treatment: The generator housing must be reliably grounded. If neutral point grounding is required, it should be performed by professional personnel. Never use the municipal power grounding device to avoid electric leakage and electric shock hazards. A lightning protection device can be installed to enhance safety.

Post-installation Inspection and Test Run

• Static Inspection: Rotate the generator rotor to confirm there is no jamming or abnormal noise. Check that all bolts are tight, pipelines are free of leakage, and wiring is free of incorrect or missing connections.

• Start-up Test: Start the engine to drive the generator. After the speed stabilizes, measure the output voltage—for the 28V system, the voltage should not be lower than 26V at idle speed. Simultaneously monitor vibration and noise during operation. If abnormalities occur, stop the machine immediately to check coaxiality or belt tension.

• Recheck and Optimization: After a period of test run, stop the machine to cool down. Recheck the tightness of bolts, the temperature of terminal blocks, and the oil level. Make timely adjustments if any issues are found.

1. Mechanical Installation Precision Requirements

• Coaxiality is critical. The alignment error between a single-bearing generator and the engine must be ≤ 0.1mm; otherwise, it will cause bearing wear and excessive vibration.

• Fixing bolts must be of 8.8-grade strength or higher. Apply thread locker and tighten them evenly in a diagonal pattern to prevent loosening and falling off during operation.

• For belt-driven models, strictly control belt tension. An overly loose belt is prone to slipping and overheating, while an overly tight one will increase bearing load. Adjust according to the standard of "10-15mm indentation when 15kg pressure is applied".

2. Electrical Wiring Safety Specifications

• Power cable specifications must match the rated current. For 100-150A current, the wire size should be no less than 25mm² to avoid overheating and burnout due to undersized wires.

• Reverse connection of excitation wires (F+, F-) and power cable positive/negative poles is strictly prohibited; otherwise, it will burn out the generator regulator or winding coils.

• The housing must be independently and reliably grounded. The grounding resistance should meet equipment requirements. Never mix with municipal power grounding to prevent electric leakage and electric shock.

References：

• Article on the official website of Shaanxi Times Intelligent Power Technology Co., Ltd.: The content mentioned in the article, such as no more than 3 bends in the exhaust pipe, a 5-10 degree downward incline of the pipe, reliable grounding of the unit housing, and strict prohibition of mixing with municipal power grounding devices, is consistent with the core points of pipeline installation and grounding specifications in the organized content.

• Articles on the relevant installation processes of Weichai Co., Ltd.'s diesel generators: The provisions in this article on ventilation requirements, exhaust pipe installation standards, foundation level calibration, and grounding operations serve as important references for organizing content in links such as pre-installation preparation and pipeline installation. Details such as air outlet area and exhaust pipe diameter requirements are fully corresponding.

• Documents related to installation precautions for Weichai generator sets: The content therein regarding the cleaning of the installation environment, rain protection treatment of exhaust pipes, and installation of foundation shock-absorbing pads provides a basis for organizing the installation environment requirements and shockproof measures in the mechanical fixation link.