Weichai Generator Set

The Weichai generator sets made in China by Kecheng is a set of power generation equipment centered on reliable power. The power of this series of units ranges from 20 to 1,500 kilowatts. The core power adopts the mature and market-tested Weichai series diesel engines, ensuring the basic reliability of the power unit. The unit pays attention to environmental adaptability in the integrated design, can operate stably under heavy load conditions, and maintain good fuel economy. The product strictly adheres to relevant national standards, and the core components are provided with a warranty service of up to two years. Whether it is continuous power supply in industrial production, temporary power supply for engineering construction, or emergency backup in commercial places, this product, which has been deeply cooperated with Weichai, can provide solid and efficient power support. It is the preferred solution for those who pursue stability and practicality.

It covers three power ranges: small (20-100KW), medium (100-500KW), and large (500-1500KW):

Application scenarios (Exclusive adaptation for Weichai Power)

1. Civil and community emergency scenarios (20-100KW)

• Applicable scenarios: Old communities (emergency power supply for elevators and water pumps), residential communities (public lighting/charging piles during power outages), small nursing homes (basic medical equipment/living facilities)

• Core value: The failure rate of Weichai WP4 engine is ≤0.3% per year. It starts within ≤15 seconds after power failure, avoiding elevator entrapment and interruption of medical equipment for the elderly. The noise of the unit is ≤70dB@10 meters (for small models), which complies with the noise standards for residential areas. With a full tank of fuel, it can last for 8 to 12 hours, meeting the short-term emergency needs of civilian use and requiring no frequent maintenance.

2. Commercial and service venue scenarios (50-300KW)

• Applicable scenarios: Chain supermarkets (cold chain refrigerators/backup cash register systems), star hotels (room air conditioning/international conference center equipment), community clinics (infusion pumps/basic testing instruments)

• Core value: The fuel consumption of Weichai WP6 engine is as low as 200g/(kW · h), and the annual operating cost is 15%-20% lower than that of similar units. Kecheng Intelligent ATS enables shock-free switching between "mains power" and "power unit" (≤0.5 seconds), preventing food from deteriorating due to power outages in the cold chain. Supports remote monitoring via mobile APP, and one person can manage multiple store units.

3. Industrial and manufacturing scenarios (300-1500KW)

• Applicable scenarios: Heavy machinery factories (main and backup power supply for machine tools and stamping equipment), automotive vehicle manufacturers (welding robots/painting production lines), chemical industrial parks (large reactors/circulating water pumps)

• Core Value: Weichai WP12/WP17 engines can withstand continuous full-load operation for 24 hours (annual operating time ≥ 8,000 hours), making them suitable for heavy-duty industrial production. The high-voltage model (6kV) is directly connected to the industrial power grid, reducing the investment in voltage reduction equipment. Weichai engine's after-sales network covers the whole country, and the fault response time is no more than 4 hours.

4. Engineering and infrastructure scenarios (100-1000KW)

• Applicable scenarios: Highway construction (mixing plants/box girder pouring equipment), urban subway construction (auxiliary power supply for shield machines/tunnel ventilation), water conservancy hub projects (gate hoists/monitoring equipment)

• Core Value: Weichai engines feature reinforced pistons and crankshafts, capable of withstanding three times the starting current (suitable for engineering motor loads), preventing stalling during startup. Kecheng anti-vibration structure (the body frame is thickened to 10mm), suitable for bumpy transportation at construction sites. IP54 dust and water resistance, resistant to engineering dust and rain environments.

5. Remote areas and outdoor scenarios (50-500KW)

• Applicable scenarios: Mountainous mining sites (charging of crushing equipment and mining trucks), border guard posts (auxiliary for domestic electricity and heating), island fishing villages (charging of seawater desalination equipment and fishing boats)

• Core Value: Weichai engines can start at -35 ℃ (optional "engine oil + coolant + fuel" triple preheating), suitable for remote low-temperature environments; The fuel consumption rate is as low as 195g/(kW · h) (for medium-sized models), and the long-term on-site operation cost is controllable. Weichai's service network covers remote areas, with convenient spare parts supply, so there is no need to worry about after-sales problems.

Product Advantages (Core Competitiveness of Weichai Power)

Technical parameters (Full power range: 20-1500KW)

Technical Features (Exclusive design for Weichai Power)

1. Core technologies of Weichai engines

• Small models (20-100KW, WP4/WP6) :

① Adopting the "high-pressure common rail (2000bar) + turbocharged intercooling" technology, the combustion efficiency is increased by 15%. When starting at low temperatures, it can be started through the intake preheating plug (-25℃ can be started).

② Lightweight design (the entire WP4 weighs only 350kg), with a small overall volume of the unit, making it suitable for community and convenience store scenarios with limited space.

③ Weichai's exclusive ECU control system monitors the engine's operating conditions in real time, with a fault early warning accuracy rate of ≥98%, preventing sudden shutdowns.

• Medium-sized models (100-500KW, WP6/WP10) :

① Weichai WP10 is equipped with a "High-efficiency turbocharging system", which increases low-speed torque by 35% (torque ≥1400N · m at 1500r/min), making it suitable for starting engineering motors.

② Dual overhead camshafts (DOHC) + four-valve design, with a 20% increase in intake efficiency and emissions meeting National IV standards, making it suitable for commercial scenarios with high environmental protection requirements.

③ Weichai's original factory cooling system (water pump + fan) features high heat dissipation efficiency and can operate at full load in a 50℃ high-temperature environment without the risk of overheating.

• Large models (500-1500KW, WP12/WP17) :

① Weichai WP17 is a V-type 12-cylinder heavy-duty engine. The cylinder block is made of vermicular graphite cast iron (with a strength 80% higher than that of ordinary cast iron), which can withstand industrial heavy-load impacts.

② Exhaust after-treatment system (SCR+DPF), meeting the National V/Euro V emission standards, is suitable for industrial parks with strict environmental protection requirements;

③Weichai's intelligent fuel-saving technology (automatically adjusting the fuel injection advance Angle according to the load) consumes 5% to 8% less fuel than similar engines, with a significant advantage in long-term operating costs.

2. Kecheng customized integration technology

• Intelligent controller (KCPLC series) :

① Small model (KCPLC-03) : Displays core parameters such as voltage, current, and water temperature, and supports basic fault alarm (high water temperature, low oil pressure);

② Medium-sized model (KCPLC-04) : New features include remote monitoring via mobile APP (4G network connection) and peak-valley power consumption management (automatic adjustment of output power), saving 10% to 15% on electricity bills annually.

③ Large-scale models (KCPLC-05) : Supports high-voltage parameter monitoring (6kV voltage/current), multi-machine parallel control (load balancing deviation ≤5%), and can be connected to industrial DCS systems to achieve unattended operation.

• Protective and adaptive structure:

①Dust-proof and water-proof: Small and medium-sized models offer IP54 protection (double-layer sealing of the body + 50-mesh dust filter), while large models can be optionally equipped with IP65 (the entire machine is sealed and can withstand short-term immersion in water up to 0.5m deep).

② Anti-vibration and anti-corrosion: The body frame of medium and large-sized models is welded with 16Mn manganese steel (8-12mm thick), and the surface is sprayed with zinc + anti-corrosion paint (salt spray test ≥1200 hours), suitable for engineering and coastal scenarios.

③ Convenient deployment: For small models, a trailer type (pickup truck towing, with a minimum turning radius of ≤5 meters) is available. For large models, a modular design (block transportation, on-site assembly) is adopted, and the installation period is ≤4 hours.

3. Exclusive adaptation and optimization for Weichai

• Fuel system: Compatible with the requirements of Weichai engines, it adopts the original fuel filter element of Weichai (filtration accuracy 5μm), and the fuel pipeline uses oil-resistant rubber hoses (designated brand of Weichai) to prevent fuel impurities from clogging the fuel injectors.

• Lubrication system: Weichai special engine oil (CH-4 15W-40, in compliance with API standards) is used. The oil change cycle is 25% longer than that of general engine oil, reducing engine wear.• After-sales linkage: The Kecheng controller can read the fault code of the Weichai engine ECU. When a fault occurs, it will be synchronously pushed to the Weichai after-sales system, achieving seamless connection of "fault diagnosis - spare parts allocation - on-site maintenance", and improving the maintenance efficiency by 30%.

Power selection (Weichai Power Precise Matching)

1.Core Selecting basis

2.Power recommendation for typical scenarios

Usage Method (Exclusive operation for Weichai units)

1.Pre-startup inspection (Key Points for Weichai engines)

2.Startup operation (power division process)

(1) Small models (20-100KW, WP4/WP6)

1. Preheating start: Open the fuel valve → Enter the "Manual" mode of the Kecheng controller → Press the "Preheating" button in a low-temperature environment (the Weichai preheating plug works and the light goes out to complete the process. Preheat for 60 seconds at -25℃) → Press the "Start" button.

2. Status Check: After the engine starts, observe the rotational speed (1500r/min±50r/min) and oil pressure (≥0.3MPa, original Weichai pressure gauge), and stabilize for 3 minutes.

3. Loading operation: Close the output switch and gradually load (first add 50% load, run for 5 minutes and then increase to 100%), avoiding impact on the Weichai engine (one-time full-load loading is prohibited).

(2) Large models (500-1500KW, WP12/WP17)

1. High-voltage preparation: Confirm that the "grounding switch" of the high-voltage switch cabinet is open → the "disconnector" is closed → Use a high-voltage tester approved by Weichai (with a withstand voltage of 10kV) to confirm that there is no electricity.

2. Startup process: Hydraulic start → Engine speed rises to 1500r/min→ Check Weichai ECU parameters (water temperature ≤85℃, oil pressure ≥0.3MPa) → Close the high-voltage circuit breaker;

3. Staged loading: Load in the order of "20%→50%→80%→100%" (with a 5-minute interval between each stage), and monitor the load rate of Weichai engines (≤100%) through the Kecheng controller to prevent overload.

3. Operation Monitoring and Shutdown (Weichai Engine Protection)

• Monitoring focus: Real-time viewing of Weichai engine ECU parameters (water temperature ≤95℃, oil pressure ≥0.2MPa, fuel pressure ≥1.0MPa), and the voltage/current displayed on the Kecheng controller (≤ rated value);

• Exception handling:

① High water temperature of the engine: Check the Weichai cooling system (coolant level, fan speed), and clean the radiator dust (blow from the inside out with compressed air at 0.2MPa).

② ECU fault code: Read the fault code through the Kecheng controller and contact Weichai after-sales service for troubleshooting (for example, "P0193" indicates a fuel pressure sensor fault).

• Shutdown process:

① Unloading: Disconnect all load switches and reduce to no-load.

② Cooling: Run the Weichai engine idle for 8 to 10 minutes (to cool the turbocharger and prevent coking due to high-temperature shutdown).

③ Shutdown: Press the "Stop" button → Close the fuel valve (for long-term shutdown) → For high-voltage models, close the "ground switch" to discharge.④ Finishing: Clean the air filter/fuel filter of the Weichai engine, check for any leakage in the engine body (engine oil, coolant), and record the operation log.

Safety and Protection (Weichai Unit Specifications)

1. Installation safety (compatible with Weichai Power)

• Venue and Fixation:

① Install in a well-ventilated area away from open flames (≥15 meters). The exhaust port of the Weichai engine should face an area without personnel (exhaust temperature ≥550℃) to avoid scalding.

② The ground load-bearing capacity should be no less than 1.5 times the weight of the unit (for example, for a 6000kg unit, it should be no less than 9000kg/㎡). The temporary site of the project should be paved with crushed stones and steel plates (to avoid subsidence), and steel plates should be placed under the support legs (with an area of no less than 0.5㎡/ leg).

③ High-voltage cable laying: Run through galvanized steel pipes (wall thickness ≥5mm), with a burial depth of ≥0.7 meters (to avoid being run over by engineering vehicles), and the cable markings should be clear (marked as "Special for Weichai High-voltage Units").

• Electrical safety:

① Grounding system: The grounding resistance for low-voltage models is ≤4Ω, and for high-voltage models, it is ≤10Ω. The grounding electrode uses galvanized Angle steel of ∠50×50×5 (length ≥2.5 meters), which is reliably connected to the Weichai engine block (to avoid static electricity accumulation).

② Load wiring: For temporary engineering lines, use YCW heavy-duty rubber-sheathed cables (oil-resistant/wear-resistant, in line with Weichai's recommended specifications). The terminal blocks should be pressed tightly with copper nose (torque in line with Weichai's standards). For motor loads, a protective neutral wire needs to be connected.

③ High-voltage operation: For 6kV models, high-voltage insulating tools approved by Weichai (insulating gloves/boots, voltage detector, with a withstand voltage of 10kV) must be provided. During operation, two people should cooperate (one person operating and one person supervising), and fill out the "High-voltage Operation Ticket".

• Fire protection configuration:

① The installation area is equipped with 2 8kg ABC dry powder fire extinguishers (no more than 5 meters away from the unit) and 1 fire sandpit (with a volume of no less than 2 cubic meters). It is strictly prohibited to stack flammable materials (such as diesel drums and wood) around the Weichai engine.

② Post warning signs such as "Weichai Power, Non-operating personnel Prohibited from approaching" and "High Voltage Danger", and hang red flashing warning lights at night.

③ Develop a fire emergency response plan and organize operators to conduct drills every quarter (including the special fire extinguishing process for Weichai engines).

2. Operating Safety (Weichai Engine Specifications)

• Personnel requirements:

①Operators must undergo joint training by Weichai and Kecheng (40 hours, including operation of Weichai engines and troubleshooting). After passing the assessment, they can take up their posts with the "Weichai Engine Unit Operation Certificate".

② Before starting the Weichai engine, it is necessary to check the oil level (both are indispensable to avoid cylinder pulling). During operation, do not touch high-temperature components (exhaust manifold, turbocharger, temperature ≥500℃).

③When operating in engineering scenarios, wear safety helmets, anti-slip shoes and work clothes. For high-voltage operations, additional insulating equipment should be worn.

• Operating contraindications:

① Do not use non-Weicha-specific engine oil/filter elements (otherwise, the Weichai warranty will be lost and it may cause engine failure).

② It is prohibited to start Weichai engines without engine oil or coolant (a single idle run can cause wear on the cylinder block).

③ It is strictly prohibited to disconnect the high-voltage switch under load (to avoid impacting the Weichai generator and causing damage to the excitation system).

④ It is strictly prohibited to operate high-voltage models during thunderstorms. The power supply must be disconnected and grounded for discharge to prevent lightning strikes.

• Emergency response:

① Engine fire: Stop the machine immediately → Close the fuel valve → Use a dry powder fire extinguisher to spray at the base of the flame (do not use water to extinguish the fuel fire) → Evacuate the surrounding people.

② Oil leakage: Shut down the machine → Check the Weichai oil pipeline (whether the joints are loose and whether the sealing rings are damaged) → Replace the original Weichai sealing rings, replenish the special oil and then start again.

③ High-voltage leakage: Disconnect the upper-level power supply → Wear insulating equipment → Isolate the fault point with an insulating rod → Check the high-voltage cable/terminal block (whether it is damaged or grounded).

3. Maintain safety (Weichai After-sales Standards)

• Preparations before maintenance:

① Disconnect the power supply of the unit (disconnect the main switch for low voltage and the circuit breaker and ground for high voltage), close the fuel valve, hang the warning sign "Under maintenance, do not start", and notify the relevant loads to cut off the power.

② Maintenance of Weichai engines requires the use of original Weichai tools (such as special wrenches and torque wrenches), and spare parts must be genuine Weichai products (Kecheng provides authorized procurement channels).

③Before maintaining large models, the pressure of the cooling system should be released (by opening the vent valve) to prevent hot water from spraying and injuring people.

• Core maintenance projects:

① Engine oil change: Change the Weicha-specific engine oil every 600 to 1000 hours (depending on the Weichai engine model). Pour the used oil into the dedicated waste oil bucket (hand it over to a qualified institution for treatment, and prohibit random discharge).

② Filter element replacement: The original Weichai air filter/fuel filter should be replaced every 500 hours, and the oil filter should be replaced simultaneously with the oil (do not mix filter elements of different brands).

③ Engine inspection: Check the valve clearance of the Weichai engine (using a Weicha-specific feeler gauge) and the atomization state of the fuel injectors (carried out by Weichai's after-sales engineers) every 2000 hours to ensure they meet the original factory standards.

• Post-maintenance testing:

After maintenance is completed, the unit needs to be started (run no-load for 30 minutes), check the parameters of Weichai ECU (no fault code) and the display of Kecheng controller (normal voltage/current), load to 50% of the rated power and run for 1 hour. Only after confirming there are no abnormalities can it be connected to the normal load

Maintenance Cycle Table (Exclusive for Weichai Units)