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Operation & Maintenance Manual for 12M26 Series Gas Engine

Table 4-5 Auxiliary materials

No.

Name

Color

Function and application

Molykote Pulver

(fine molybdenum

powder)

Black

Applied on flat and smooth metal surfaces to prevent seizing

Molykote G-N plus

(Molybdenum disulfide,

oil solution)

Dark grey

Achieve lubrication function before lubricating oil pressure is built

For instance: Applied onto intake valve stem

4.2 Routine maintenance of the gas generator

◆

Check the coolant level, oil level and gas pressure; and refill if necessary;

◆

Check for oil, water and gas leakages;

◆

Check the connection reliability of external parts and accessories;

◆

Check the tension of belt;

◆

Check the oil pressure of engine;

◆

Check the connector and wire connection;

◆

Check the water temperature of engine;

◆

Check the temperature and color of exhaust gas, sound, vibration and speed of engine;

◆

Check the liquid level and coolant temperature.

Check the coolant level through the glass sight hole. And if it is insufficient, open the filler port
cap to add coolant, as shown in Figure 4-1.

Figure4-1 Coolant filler port cap

Notice

: Before opening the filler cap, push down the air bleeding button to avoid personal injuries

by the hot coolant while the engine is hot.

◆

Check the oil level

Oil level as shown in Figure 4-2.
It is not allowed to start the engine when the oil level is below the lower marking or above the
upper marking.
When checking the oil level, stop the engine and wait for at least 5 minutes, enabling the oil to

Summary of Contents for 12M26 Series

Page 1: ...12M26 Series Gas Engine Operation Maintenance Manual ...

Page 2: ...quipment and is frequently used as a main or standby power source in coal mine oil field farm gas station and other places In addition it can be fueled by natural gas methane and biomass gas etc This manual briefly introduces the technical parameters performance indicators structural features and usage maintenance precautions of 12M26 series natural gas generator The user shall comply with various...

Page 3: ...he filling amount of coolant and oil is proper Make sure that the engine uses the natural gas for automobiles as specified in the national standard Never run the engine without an air filter A new engine must be subject to running in for 50 h before being put into service Each time the spark plug is replaced tighten them to the specified torque and ensure the ceramic body is clean If the ambient t...

Page 4: ...Operation Maintenance Manual for 12M26 Series Gas Engine 3 make and model as original ones otherwise Weichai will not be responsible for any consequences ...

Page 5: ... more than 60 6 The operator must check whether the amounts of coolant and engine oil in an engine meet the requirements before starting the engine every time 7 Before starting the engine switch to pre lubrication position and pull the handle back and forth to supply oil to the engine bearing bearing bush and several other friction pairs and discharge the air inside the oil pump to realize rapid l...

Page 6: ...Operation Maintenance Manual for 12M26 Series Gas Engine 5 ...

Page 7: ...ere s skin natural sebum loss during the wash products containing lanolin can be used to help moisturize the skin Do not use gasoline kerosene fuel oil thinner or other solvents to clean the skin If you have a skin irritation consult a doctor immediately If possible remove the oil grease on the parts before handling them If there is possible danger to your eyes use goggles or face shield Eye wash ...

Page 8: ...3 Installation of the natural gas engine 27 3 4 Preparations before starting the engine 28 3 5 Engine starting 29 3 6 Engine operating 29 3 7 Engine shut down 30 3 8 Power Definition and Operation Conditions of natural gas Engine for Power Generation 30 3 9 Environmental conditions 31 CHAPTER 4 12M26 SERIES GAS GENERATORS MAINTENANCE 32 4 1 Fuel Lubricating Oil Coolant and Auxiliary materials 32 4...

Page 9: ...s Gas Engine I Scope 54 II Normative references 54 III Requirements and steps for removal and refitting of spark plug 54 APPENDIX 3 CORRECTION COEFFICIENT OF POWER OF ENGINE 60 APPENDIX 4 CORRECTION COEFFICIENT OF POWER OF ENGINE 60 CONTACT US 14 ...

Page 10: ...ngine 1 1Model Meaning of M26 series industrial engine Model Meaning of M26 engine 1 2 Size of M26 series industrial engine Size of M26 series industrial engine See Fig 1 1 1 2 1 3 1 4 for reference XM26 XXX EX XX X D Model varity Emission level Overload Power kW Electricity generation Product Series ...

Page 11: ...Operation Maintenance Manual for 12M26 Series Gas Engine 2 Fig1 1 Outside drawing of 12M26 natural gas engine ...

Page 12: ...Operation Maintenance Manual for 12M26 Series Gas Engine 3 Fig1 2 Outside drawing of 12M26 natural gas engine ...

Page 13: ...Operation Maintenance Manual for 12M26 Series Gas Engine 4 Fig1 3 Outside drawing of 12M26 natural gas engine ...

Page 14: ...Operation Maintenance Manual for 12M26 Series Gas Engine 5 Fig1 4 Outside drawing of 12M26 natural gas engine ...

Page 15: ...tercooling Cylinder diameter stroke mm 150 150 Displacement L 31 8 Compression ratio 11 5 Ignition sequence A1 B2 A5 B4 A3 B1 A6 B5 A2 B3 A4 B6 Cold state air valve gap mm Inlet valve 0 3 0 03 exhaust valve 0 4 0 03 Valve timing Air valve gap Inlet valve 0 3 Exhaust valve 0 4 Inlet valve is open 34 before TDC Inlet valve is closed 40 after BDC Exhaust valve is open 70 before BDC Exhaust valve is c...

Page 16: ... 660 Table 1 3 Tightening torque of main bolts and nuts Bolt name Bolt specification Tightening torque N m Re twist angle Allowable number of repetition Spark plug M14 1 25 25 28 N m Oxygen sensor M18 1 5 50 5 N m Water temperature sensor M12 1 5 25 5 N m The corresponding requirements are posed on the strength grade of bolts and nuts used on the different parts of the engine and bolts and nuts of...

Page 17: ... diagram of 12M26 series natural gas engine 1 Fan 2 Pre supplying oil pump 3 Ingnition coil 4 Oxygen sensor 5 Exhaust pipe 6 Turbocharger 7 EFR 8 Air filter 9 Starting motor 10 Oil filler and dipstick 11 Oil cooler 12 Oil filter 13 Cooling water inlet 14 Electronic throttle ...

Page 18: ...Operation Maintenance Manual for 12M26 Series Gas Engine 9 1 Belt pulley 2 Gas inlet ...

Page 19: ...Operation Maintenance Manual for 12M26 Series Gas Engine 10 1 Engine support bracket 2 Flywheel housing 3 Flywheel ...

Page 20: ...Operation Maintenance Manual for 12M26 Series Gas Engine 11 1 ECU 2 Oil pan 3 Engine support bracket ...

Page 21: ...ation Maintenance Manual for 12M26 Series Gas Engine 12 Chapter 2 Natural Gas Engine Control System 2 1 Schematic diagram of natural gas control system Figure 2 1 12M26 electronic control schematic diagram ...

Page 22: ...Operation Maintenance Manual for 12M26 Series Gas Engine 13 Figure 2 2 12M26 electronic control schematic diagram ...

Page 23: ...engine with distance not exceeding 2m It shall be installed behind the filter and installation position shall be convenient for regular adjustment inspection and maintenance of pressure reducer Pipeline connecting to pressure reducer shall be reasonably arranged and free from interferences Pressure reducer gas outlet and the bottom shall not be upward to prevent fuel gas greasy dirt from back flow...

Page 24: ...row pointed airflow direction during installatio 2 2 3 EFR valve Figure 2 5 EFR valve Technical parameters 1 Fuel type natural gas 2 Inlet pressure 2 kPa 3kPa 3 Working temperature 40 121 Installation requirements and operating instructions Regulate mixer s installation angle a in 60 60 to prevent the condensation of water back Pay attention to arrow pointed airflow direction during installation 2...

Page 25: ...d other signals and controls the action of electronic throttle ignition timing and ignition orders after calculation so as to accomplish electronic control of engine Engine control unit ECU shall be installed in control panel to realize real time monitoring of engine parameters Figure 2 7 Engine control unit 1 Technical parameters 2 Working voltage 24V 3 Working environment 40 105 2 2 6 Inlet temp...

Page 26: ...ated working voltage 5 0 25 V 3 All magnetic field allowable 2kA m 4 Maximum torque allowable shall be 8 2 N m during assemble when 8 8 M6 12 bolts are used installation gap shall be 0 5mm 1 5mm 2 2 8 Water temperature sensor Water temperature sensor is mainly used to measure cooling water temperature ECU may regulate idle speed and ignition advance angle in different water temperatures according ...

Page 27: ...t pipe and causing the difficulty in disassembly molybdenum disulfide should be applied evenly on the threads of the oxygen sensor If the vehicle is equipped with an exhaust brake the oxygen sensor should be installed at 15cm 25cm downstream of the exhaust brake and should be placed as close as possible to the turbocharger The wire harness and connector of the oxygen sensor should be far away from...

Page 28: ...m 3 Maximum torque allowable shall be 8 2N m during assemble when 8 8 M6X12 bolts are used installation gap shall be 0 5mm 1 5mm 2 2 11 Electronic throttle Electronic throttle is mainly used for controlling mixture flow engine idling and maximum revolving speed ECU controls the action of throttle and its working stroke is limited to 10 90 opening of butterfly valve by ECU Failure of electronic thr...

Page 29: ...t 6 5A under any conditions Figure 2 15 Ignition coil Installation requirements Ignition coil wiring harness shall be free from stresses Use multimeter to check the contact situation of wiring harness and connectors Ignition coil shall be kept away from engine metal rack to prevent breakdown of sparking 2 2 13 Ignition cable Ignition cable is used to transmit high pressure spot generated by igniti...

Page 30: ...tor When installing and connecting the generator attention should be paid to the followings The generator must be fully cooled The generator must be dust proof splash proof oil proof The tension of the motor belt must be checked The generator can only be connected with the voltage regulator and battery The generator s rated voltage is 28V and the schematic diagram is shown in Fig 2 18 Fig 2 18 Gen...

Page 31: ...nted a starter relay must be installed to protect the starter from tooth engagement The current capacity of the starter relay should be greater than 80A and the starter circuit should be shut off immediately after the engine starts to operate normally the starter relay axis should be parallel with the ground and be perpendicular to the vehicle running direction preventing the starter from accident...

Page 32: ... engine stopped IDLE RATED switch The switch is off the speed reduced to idle speed of 700rpm if the switch is on the speed increase to rated speed EXTERNAL SHUTDOWN If the switch is on the engine come to a sudden stop GENERATOR BREAKER SWITCH If the switch is on the generators can be operated in parallel and synchronously Contrarily the generators cannot working synchronously ...

Page 33: ...engine s speed raised to the maximum limited speed according to a certain rate The switch is off then the speed is kept in current speed If the engine is at the rated speed the LOWER SPEED switch is on then the engine s speed reduced to the minimum limited speed according to a certain rate The switch if off then the speed is kept in current speed ALARM RESET If the switch is on all alarm informati...

Page 34: ...Operation Maintenance Manual for 12M26 Series Gas Engine 25 ...

Page 35: ...eement between the customer and the manufacturer oil should be filled into the oil pan according to the requirements if there isn t any inside Drain the sealing oil in the fuel filter and fuel system components it is only allowed to run the engine with load when the sealing oil is used up and the normal natural gas fuel has been supplied Please take notice that the oil seal is only valid for one y...

Page 36: ... able to meet the requirements of8 hours of work under rated load The location of the fuel tank should not be lower than the fuel supply pump inlet of the injection pump The inner diameter of the fuel pipeline should not be less than 12 mm 3 3 3 Installation of the gas equipment Gas line Gas source Gas equipment Gas shut off valve Gas filter Pressure regulator Back fire relief valve Fuel valve Mix...

Page 37: ...e coolant level If the engine has been installed in the vehicle check the coolant level before each use When the coolant is not enough open the filler cap to add more coolant When opening the filler cap with the pressure relief valve and exhaust button press the exhaust button first if the engine is still hot It is prohibited to add a large amount of coolant when the engine is still hot for it wil...

Page 38: ...inutes instead of suddenly operating at high speed 3 6 Engine operating After starting the engine idle for 2 3 minutes before adding part of load Only when the water temperature is above 60 the oil temperature is above 50 and the oil pressure is higher than the oil pressure seen in sheet 1 1 it is allowed to operate the engine at full load Load and speed increases should be gradual to avoid sudden...

Page 39: ...piston cylinder head liner bushing and turbocharger have enough time to be cooled in order to avoid cylinder and bearing damage This is particularly important for turbocharging engines because the bearing and oil seal in the turbocharger are to be affected by the high temperature of the exhaust gas When the engine is running the heat will be transferred away by the cycling lubricating oil But when...

Page 40: ...llowed the yearly cumulative overload operation time shall not exceed 25h It s used for the specified power output If the utility power is reduced the generating set can be connected to the utility grid Emergency Standby Power ESP 1 The yearly operation time shall not exceed 200h including no more than 25h operation with 100 rated load yearly 2 The average load rate shall not exceed 80 within 24h ...

Page 41: ... can not improve the power of the engine but the lower heating value will lead to loss of the engines s power If the gas with the heating value is under 20 5MJ m and the content of CH4 is under 60 will cause the engine can not work 4 1 2 Gas Generator Lubricating oil Gas Generator Lubricating oil capacity 113L The actual filling volume should base on the markings of oil dipstick Different models o...

Page 42: ...ng in cold weather or boiling under high temperature and is applicable for vehicles under different temperature which gives a special protection for the water tank and the engine cooling chamber The properly selected coolant can effectively protect the engine components and extend the service life of the engine See Table 4 3 for more details Table 4 3 Natural gas engine coolant Coolant grade 25 35...

Page 43: ...er surface of the thread lock seal and prevent loosening Cylinder head vice bolt Weichai special sealant 271 Locking and tightening Bowl shape plug for oil hole Weichai special sealant 277 For sealing between core and hole Other bowl shape plugs Weichai special sealant 270 For sealing of cylinder head top surface Push rod tube and cylinder head Weichai special sealant 518 updated product based on ...

Page 44: ...Check the tension of belt Check the oil pressure of engine Check the connector and wire connection Check the water temperature of engine Check the temperature and color of exhaust gas sound vibration and speed of engine Check the liquid level and coolant temperature Check the coolant level through the glass sight hole And if it is insufficient open the filler port cap to add coolant as shown in Fi...

Page 45: ...ages Check the external surface of gas generators for water air gas and oil leakage Check the fan Visually check the fan blade for damage and check the connecting bolts As shown in Figure 4 3 Figure 4 3 Check the fan Check the belt tension The belt is automatically tensioned by the tensioner You can check the tension of belt by pushing the belt with hand As shown in Figure 4 4 ...

Page 46: ...perating the hand oil pump and then screw in the drain plug again 2 Open the oil filler cap add new oil through the filler port the oil should be filtered by a strainer when filling check the oil level through the scale mark of oil dipstick tighten the filler port cap finally As shown in Figure 4 5 Figure 4 5 Oil filler port Drain plug Replace the oil filter or filter element As shown in Figure 3 ...

Page 47: ...ten or replace the related parts to ensure the tightness of intake system Check the Air Filter Element When the intake resistance indicator alarm Reddish status as shown in Figure 4 7 should be shot down maintenance of air filter outside the filter Figure 4 7 Indicator Type I Radial seal air filter 1 Check whether the inner surface of the outer filter and the outer surface of the safety filter are...

Page 48: ...ngine shut down to inspect the dust can be removed by dust valve in time the dust valve damage and loss should be promptly replaced dust valve 2 Turn the yellow sealing cap counterclockwise and remove it at this time you can see the outer filter 3 Grasp the nose of the outer filter cover by hand and pull the outer filter cartridge out of the hollow space of the hollow filter housing 4 Follow the m...

Page 49: ... maintenance WD1 Every 250 hours of running Level 2 maintenance WD2 Every500 hours of running Level 3 maintenance WD3 Every 1 000 hours of running Level 4 maintenance WD4 Every 3 000 hours of running Note The maintenance cycle mentioned here is calculated based on the condition that the engine is running 1500 hours per year For engines running time less than 500 hours per year the maintenance cycl...

Page 50: ...00 hours per year For engines running time less than 500 hours per year the maintenance cycle is half Please perform daily maintenance according to the relevant provisions of the instructions Correct operation will extend engine life and get better performance and more economic benefits The above maintenance schedule for the general industrial use of power you should use the environment and workin...

Page 51: ...aged and become unusable 3 Disassemble and check the compressor casing and turbine casing regularly and clean up the impeller and the flow passage in casing When reassembling the turbocharger fill clean engine oil via the filler opening 4 Notice Turbocharger rotor shaft for precision high speed rotating parts dismantling collision or factory warranty failure 4 6 2 Operation and maintenance of wate...

Page 52: ...etween the generator and electric appliances in the complete machine may cause low battery energy or even regulator damage or stator burnt out due to overheating of generator The minimum working speed of generator must be guaranteed If the idle speed of generator is set too low the generator speed will be too low which will cause the above mentioned faults as well 2 Secure installation The generat...

Page 53: ... is negative grounded if not the generator and regulator will be burnt out 9 When the generator is in service do not check whether the generator is generating electric power by means of testing sparks while grounded otherwise the test lamp or diode may be burnt out 10 When connecting the rectifier to the stator winding do not check the insulation condition of generator using a mega ohm meter or 22...

Page 54: ...e most important is to inspect whether the pressure relief valve can be opened or not 5 Be careful not to damage the end cap pump body junction surface and each locating pin when disassembling and reassembling an oil pump 4 6 6 Operation and maintenance of air filter Warning The service life of your engine may be shortened greatly due to wrong maintenance methods 1 The air filter shall match the p...

Page 55: ...ommended to purchase the genuine parts 4 6 7 Hand press oil pump use Function It can realize pre lubrication before starting Reciprocating the handle to achieve oiling switch has 3 positions for controlling the oil direction to achieve the corresponding function 1 Neutral position the oil is shut down When not using a hand press pump the switch should be placed in neutral position 2 Pre lubricatio...

Page 56: ...de Observational method Determine the fault by observing the fault characteristics such as smoke exhaust from engine Listening method Determine the nature and degree of faulty parts by listening to the abnormal sound from the engine Cylinder disconnection method Stop one cylinder and determine whether this cylinder is in fault Usually the maintenance personnel stop supplying natural gas to the tar...

Page 57: ...t circuit Replace the oxygen sensor 8 The electronic throttle valve is broken Test the electronic throttle valve using software 9 The velocity sensor is in fault Check the clearance between fluted disc and sensor 10 MAP is broken Check the MAP by sofeware 11 Earth trap wire is loose Check the wiring harness is monted firmly 2 The idle speed is unstable 1 There is air leak in the air intake pipelin...

Page 58: ...he ignition advance angle and the clearance between phase sensors 7 The clearance between gas intake and exhaust valves is adjusted improperly Check the valve clearance according to the operation manual for engine 8 the temperature of intake gas is high Check the inter cooler and water tank 5 The vibration amplitude is large 1 The intercooler is cracked or the connecting pipe of intercooler is loo...

Page 59: ...he main bearing bolts alternatively and uniformly in sequence by two steps Manual tightening 200N m for first step and 550N m for second step Tighten sequence see Fig1 A N d Tighten the main bearing cover auxiliary bolts as follow sequence of Fig1 to 270N m Figure 1 sequence ofmain bearing bolt and main bearing cover auxiliary bolt 1 2 The main and auxiliary bolts of cylinder head a Tighten sequen...

Page 60: ... for third step Apply lubricating oil to the threads and carrying surfaces of connecting rod bolts d Flywheel bolts Install the flywheel bolts and tighten uniformly and alternatively by three steps 70N m for first step 400N m for second step and 640N m for third step Apply lubricating oil to the threads and carrying surfaces of flywheel bolts Figure 4 sequence of flywheel bolts e Flywheel shell bo...

Page 61: ... 1850 2250 1200 1450 2000 2400 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...

Page 62: ... clearance of A1 A3 A5 c Turn the engine for 90º clockwise face to flywheel the piston of B6 is at the top dead center Adjust the intake valve clearance of B3 B5 B6 and the exhaust valve clearance of B2 B4 B6 d Turn the engine for 270º clockwise face to flywheel the piston of A6 is at the top dead center Adjust the intake valve clearance of A3 A5 A6and the exhaust valve clearance of A2 A4 A6 Figur...

Page 63: ...ces only those dated references applies For undated references the latest edition including all amendments applies GB T20734 2006 Installation Requirements of Special Equipment of LNG Vehicle QC T755 2006 Technical Conditions of Special Equipment of LNG Vehicle QWCQTG4 22 2010 Technical Specifications of Accessories of LNG Engine III Requirements and steps for removal and refitting of spark plug 1...

Page 64: ...k plug otherwise it may cause damage to the spark plug nut and the fixed parts or spark plug thread remaining in the cylinder head Correct removal method After starting the engine heat the cylinder head fill the penetrating liquid into the threaded of the spark plug CRC penetrating oil etc five to ten minute later and then remove it It is strictly forbidden to remove the ignition coil bushing and ...

Page 65: ...le needs to check the ignition coil liner bolt tightening torque when replacing the spark plug All complex tight operation should be in accordance with the following requirements standardize operation Firstly checking the spark plug twist moment whether meet the requirements 25 to 28 N m and the spark plug should be tightened to the required torque range if not meet and try to ensure that the two ...

Page 66: ...ce adjustment Adjustment method If the clearance is wide insert the feeler gauge into the clearance and tap the corner of the side electrode gently with a small wrench if the clearance is narrow widen the clearance slowly with a vise insert the feeler gauge and then gently tap the side electrode with the wrench Spark plug clearance 0 35 0 05mm must be adjusted with a feeler gauge ATTENTION Make su...

Page 67: ...e spark plug wrench or high voltage coil and then install it with the spark plug wrench Do not throw the spark plug directly into the spark plug mounting hole When installing keep the instrument and other part of engine from touch with the outer electrode so as not to change the spark plug clearance Strictly forbidden Here to be parallel ...

Page 68: ...ch rotate the wrench for 90 degrees after the new spark plug thread is screwed to the end for the spark plug installed for the second time rotate the wrench for 15 degrees after the thread is screwed to the end 8 After tightening the spark plug insert the high voltage coil and tighten the high voltage coil anti fouling cap onto the sleeve mounting hole Tighten the anti fouling cap onto the sleeve ...

Page 69: ...01 1 01 1 01 1 015 1 025 1 025 1 025 1 05 1 05 1 05 1 075 15 0 995 0 995 0 995 1 005 1 005 1 005 1 01 1 015 1 025 1 025 1 025 1 05 1 05 1 075 10 0 99 0 99 0 99 1 1 005 1 005 1 005 1 01 1 025 1 025 1 025 1 05 1 05 1 075 0 250 500 800 1000 1200 1400 1600 1800 2000 2200 2500 2800 3000 Note the consumption of gas in above tables aimed to natural gas 12T gas according to GB 10847 if the fuel is methane...

Page 70: ...Weifang Shandong China Postcode 261000 Website http www weichai com Engine sales 0536 8232488 8233371 Accessories sales 0536 2297290 Service Hotline 400 Free Service Hotline 400 6183066 800 Free Service Hotline 800 8603066 Only use fixed phone Customer Service Center Tel 0536 8235369 Fax Customer Service Center Complaint Tel 0536 2297322 Publication date 2018 01 ...

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