WP12NG Series Gas Engine Operation and Maintenance Manual

WP12NG 系列天然气发动机使用保养说明书
WP12NG 系列天然气发动机
使用保养说明书
Operation & Maintenance Manual for
WP12NG Series Gas Engines
潍柴动力股份有限公司
WEICHAI POWER CO.,LTD.
潍柴动力追求卓越 1
WP12NG 系列天然气发动机
Content
Chapter1 Technical Situation of the Products............................................................................................................ 48

1.1 Power and rated rotating speed.............................................................................................................. 48
1.2 Structural character of natural gas engine.............................................................................................. 48

1.3 Signification of WP12NG series natural gas engine code................................................................... 49
Chapter2 Performance and Technical Parameters of Natural Gas Engine.................................................................50
2.1 Technical parameters of WP12NG series natural gas engine...................................................................... 50
2.2 Performance parameters of WP12NG series natural gas engine................................................................. 51

Chapter3 Natural Gas Engine System........................................................................................................................ 52
3.1 Gas supply system........................................................................................................................................ 52
3.1.1Gas supply system.............................................................................................................................. 52
3.2 Function and Technical Requirement of Gas Supply System’s Main Parts.................................................52
3.2.1 Regulator(Used in CNG)...................................................................................................................52
3.2.2Regulator(Used in LNG).................................................................................................................... 53
3.2.3 Solenoid Valve...................................................................................................................................54
3.2.5 Heat exchanger and thermostat......................................................................................................... 55
3.2.6 FMV -Fuel Metering Valve............................................................................................................ 55
3.2.7 Mixer..................................................................................................................................................56
3.3 Electrical system...........................................................................................................................................57
3.3.1 Principle diagram of electrical system.............................................................................................. 57
3.4 Principle and attentions of electrical system’s parts.................................................................................... 58
3.4.1 Harness.............................................................................................................................................. 58
3.4.2 Engine control module（ECM）and ignition control module（ICM）.........................................58
3.4.3 T/MAP and PTP................................................................................................................................ 59
3.4.4 Camshaft signal (speed, phase) sensor..............................................................................................60
3.4.5 Water temperature sensor.................................................................................................................. 60
3.4.6 Universal exhaust gas oxygen sensor（UEGO）............................................................................ 60
3.4.7 Foot pedal.......................................................................................................................................... 61
3.4.8 Throttle.............................................................................................................................................. 62
3.4.9 WGCV-Waste Gate Control Valve.................................................................................................... 62
3.4.10 Ignition and spark plug....................................................................................................................63
3.4.11 humidity sensor................................................................................................................................64
Chapter4Application and operation of NG engine.....................................................................................................65
4.1 Installation specifications of natural gas engine.......................................................................................... 65
4.2 Unpacking.....................................................................................................................................................66
4.3 hoisting of engine......................................................................................................................................... 67
4.4 installation of engine.................................................................................................................................... 67
4.5 prepare work before start..............................................................................................................................67
4.6 daily operation of the engine........................................................................................................................ 67

Chapter5 Maintenance of engine................................................................................................................................69
5.1 Routine maintenance.................................................................................................................................... 69
5.2 Maintenance of all levels..............................................................................................................................71
5.3 Maintenance of diesel engine when it is not used for long time..................................................................73
Chapter6 analysis and solution for common failures................................................................................................. 75
6.1 estimate method............................................................................................................................................75
Special Attention
 The engine operator must read the manual before attempting to operate the natural gas engine, adhere to
follow the operation and maintenance routine rules in this manual.
 The natural gas engine has been tested strictly in accordance with the test specification before leaving the
factory. It is forbidden to adjust the data of ECM to increase the power, otherwise all the warranties will be
invalid.
 Customers should not dismantle the precision components like ICM, ECM and FMV, otherwise all the
warranties will be invalid.
 It is strictly forbidden to dismantle and impact rotor shaft of turbocharger as precision high speed rotating part,
otherwise all the warranties will be invalid.
 There are strict demands on torque and turned angle for main bearing bolts and connecting rod bolt, loosing
and dismantling is forbidden. The connecting rod bolt can be used only one time, otherwise all the warranties
will be invalid.
 Designation of engine oil in the NG engine must comply with the regulation in the manual. They should be
filtered by specified filter cleaner. The fuel should be according with the national standards of vehicle natural
gas. You must confirm if the filled capital of the coolant and oil comply with requirements before driving.
 It is forbidden that the engine works without air filter to prevent unfiltered air from entering into the cylinder.
 Before using a new engine, 50 hours test run should be carried out.
 Please screw the spark plug under prescribed load and ensure that the ceramic part of spark plug is clean
when changing it.
 Please take apart the power supply and ground the electric system before welding. Otherwise it may break the
ECM.
 After the engine is stopped, if the ambient temperature is lower than 0 ℃ and no anti-freezer is used, the
water in water tank and in engine should be drained off.
 Inspection and maintenance for electric system must be done by workers mastering electric appliance
knowledge.
 The inspection and repair of the components in the electronic control system should be conducted by special
7
personnel in service station.
 To prevent rust, the engine is oil sealed when it leaves the factory, the oil seal period of the engine is one year.
Inspect the engine and adopt necessary measures if beyond one year.
 After the engine is cold started, the speed should be increased slowly. It is forbidden to run the engine in high
speed suddenly or in idling for a long time. After running in high load, running the engine at low speed
without load for about 5-10min before stopping the engine.
 Before operating a new engine should confirm that gas pipes, gas supply device isn’t gas leakage. Pay special
attention to electric system in case of trustless connection of electric system and false connection of ignition
wire.
 Check if the voltage of battery is enough before starting the engine. It will need enough voltage to start and
running the engine.
 Pay attention to check the capacity of gas tank and fill gas in time. Fill the tank should be done by special
workers of gas station. Check the sealing of natural gas system.
 Engine coolant is used to heat the pressure reducer for natural gas engine. It will lead to furring inside water
cavity of pressure reducer and frost when starting the engine.
8
Forward
The WP12NG series natural gas engines are designed by increasing gas supply system and related devices at
the same time canceling fuel oil supply system on the basis of Weichai Power WP12 series diesel engine. This
engine has good technical indexes of compact structure, good reliability and power, economy, advantages of rapid
starting, simple operation and easy maintenance ect. It is the ideal power of heavy duty vehicles.
This manual simply introduces the main technical data, performance index, construction features and
operation and maintenance notices of WP12NG series natural gas engine. If users operate the engine according to
the stipulations of this manual, the service life of the engine should be extended greatly.
The engine in this manual is the basic model of WP12NG series engines. With continuous development of the
products, the structure will be improved. The content of this manual is not very new. Please users (or distributor)
go to our net(http:www.weichai.com) for latest production information.
Welcome users, further suggestions for modification of products.
Let’s cooperate in good faith and contribute to the development of clean vehicle project hand in hand!
April 2011
9
Chapter1 Technical Situation of the Products
1.1Power and rated rotating speed

The power range of WP12 series engine is 243～280kW, rated rotating speed is 2200rpm.
1.2Structural character of natural gas engine

 One cylinder head per cylinder, reliable and easily dismantle
 High rigidity of whole body is favorable to the reliability and extending the life of engine.
 It uses the electric throttle to improve the driving performance of the engine.
 The whole series are six-cylinder in-line engines, versatile degree is high, and they are easy for matching the
vehicle.
 By adopting electronic control single point injection technology to ensure well power, economy and emission
performance of the engine at any working conditions.
 By adopting water cooled turbocharger suiting for gas engine, the lubricating oil can be cooled by the
circulating water to prevent carbon depositing on the pressurized bearings. The reliability of the turbocharger
is improved. By adopting boost pressure electronic control technical, the intake pipe’s absolute pressure can
be adjusted to the set value by changing the open pressure of the turbocharger. Thus the power can be
controlled at most conditions. Maximum torque at low speed and boost compensation at high temperature can
be achieved.
 Surge-Proof technology is adopted. When the pedal is released at large load, ECM switches according to the
speed-down triggering signal. Throttle can maintains a certain open degree when the supply of gas is cut
away. So the surge of the turbocharger caused by the closed throttle is eliminated. And the reliability and
economy of the turbocharger is improved.
 Electronic control high-energy ignition system is adopted. The optimum ignition time is provided according
to the engine's rotating speed, intake pressure, intake temperature. At any working conditions, the ECM can
adjust the ignition advance angle to ensure the integrated performance of the engine.
 Special fuel mixing system for gas engine is designed to achieve lean and stable combustion of the mixture
and increase thermal efficiency.
 With the speed-up fuel enriching function, the engine can get more fuel at speed-up condition. High power at
speeding-up and good economy at steady condition can be ensured.
 The materials of intake/exhaust valve and valve seats are special for gas engine. Good wearability and
self-lubrication are ensured at high temperature.
 With the maximum speed control function, it ensures the running safety of the engine.
 High efficiency oxidation catalytic converter is adopted to greatly decrease the emission of harmful gases.
The emission is better than China Ш and possesses the potential to meet China Ⅳ standard.
10
 With good matching ability and air-conditioning idle control functions. ECM can provide load signal
(meeting SAE standard) for automatic transmissions case.
1.3 Signification of WP12NG series natural gas engine code

W P 12 NG XXX E4 X
Use sign
Emission level(China Ⅳ)
power(horsepower)
Natural Gas
Total displacement 12L
Power
Wei chai
11
Chapter2 Performance and Technical Parameters

of Natural Gas Engine
2.1 Technical parameters of WP12NG series natural gas engine

Tab2-1
Water cooled，four stroke，thin combustion，turbocharged
Type
and inter-cooled，fired by spark plug
Bore /stroke (mm) 126/155
Displacement (L) 11.596
Ratio 11.6:1
Ignition sequence 1-5-3-6-2-4
Gas supply system Electronic control, single point injection
Exhaust gas process device 氧化型催化转化器
Valve clearance at cool state(mm) Intake valve:0.3;exhaust valve:0.4
Intake valve open：before TDC34°～39°：after BDC61°～
Port timing 67°
（valve clearance：intake0.3exhaust0.4） Exhaust valve open ： before BDC76° ～ 81° ： after TDC
26°～31°
Open temperature is 79±2℃，fully open temperature is 90
Thermostat open temperature(℃)
℃
Starting method Electrical starting
Lubricating method Pressure lubricating
Oil trademark Special oil for natural gas
Cooling method Water cooling
Pressure of oil（kPa） 350～550
Oil pressure at idle speed（kPa） ≥100
Permissible
longitudinal Front /back Long-term 10/10 Short-term 30/30
inclination(°)
Permissible
Exhaust pipe/signal
transverse Long-term 45/15 Short-term 45/30
generator
inclination(°)
Crankshaft rotating direction(view from
clockwise
the free end)
12
2.2 Performance parameters of WP12NG series natural gas engine

Tab 2-2
Unit WP12NG engine
Engine type WP12NG330E40 WP12NG350E40 WP12NG380E40
Rated power kW 243 257 280
Rated rotating speed r/min 2200
Maximum torque Nm 1350 1400 1500
Speed at maximum r/min 1400
torque
Emission level — China Ⅳ
Fuel consumption at g/(kW·h) ≤205
rated speed
Minimum fuel g/(kW·h) 190
consumption under full
load
Cold starting
(without auxiliary/with ℃ -10 / -30
auxiliary)
1m noise dB(A) ＜98
B10 life km 800,000
13
Chapter3 Natural Gas Engine System
3.1 Gas supply system

3.1.1Gas supply system
1、gas supply
NG tank →reducer →filter→ heat exchanger→ thermostat→ FMV→ mixer (CNG Vehicle)
NG tank→ filter→ electromagnetic valve→ manostat→ heat exchanger→ thermostat→ FMV→ mixer（LNG
Vehicle）
2、water circulation
2.1 LNG system
2.1.1 water outlet pipe of engine→ carburetor →inlet pipe of water pump
2.1.2 water outlet pipe of engine→ heat exchanger→ thermostat →inlet pipe of water pump
2.1.3water outlet pipe of turbocharger →inlet pipe of water pump
2.2 CNG system
2.2.1water outlet pipe of engine→ heat exchanger→ thermostat→ inlet pipe of water pump
2.2.2water outlet pipe of turbocharger→ reducer→ inlet pipe of water pump
3 special attention
Before connecting, all pipes should be cleaned with high pressure air.
There should be no fold and worn out on the connecting pipes.
3.2 Function and Technical Requirement of Gas Supply System’s Main

Parts
3.2.1 Regulator(Used in CNG) Water outlet
Balance pipe
connector
Water inlet
Gas outlet
High pressure
Pressure release
lock off valve
Gas inlet
Fig 3-1 regulator

14
The pressure range of compressed natural gas is 5MPa ～ 20Mpa. The pressure of natural gas is about
0.8Mpa after it through the reducer. Pressure difference between that supplied to FMV and that in air intake pipe
should be changeless. It will absorb heat when the pressure of natural gas is decreased. Cooling water is used to
heat the regulator.
◆Technical parameter:
Max. flow: 49.9kg/h
Gas inlet pressure: 1.72-24.8MPa
Ambient temperature: －40-105℃.
Gas inlet temperature: －40-40℃.
Cooing water temperature: －40-100℃.
◆ Regulator should be mounted at the position with less vibration near the engine. It should be flexibly
connected with the engine.
◆The mounting position should be convenient for regular adjustment, check and repair of the regulator.
◆ Regulator should be far away from the exhaust system. If the distance between the regulator and exhaust
system is less than 150mm, heat-insulating device should be set.
◆The regulator is heated with cooling water of the engine. It should be lower than the top of the radiator and
beneath the thermostat. Pipe connector leakage is not permitted.
◆Pipeline connected with regulator should be arranged reasonably without any interference.
◆Balance pipe length should be long enough to avoid backfire. Balance pipe connector should be fixed up.
◆ Gas release outlet pipe should be extended to the outside of the engine room to meet related national
regulations.
◆ Neither the exit of gas nor bottom of regulator should be upward to prevent smear from returning to the
regulator.
◆ Regulator outlet pipe should endure a temperature of － 80℃. Pipe between regulator outlet and heat
exchanger should have enough flexure to bear heat expansion.
◆connect the water pipes according to the inlet and outlet water pipes' marks of the regulator. The temperature
of inlet water pipe is higher than that of outlet.
3.2.2Regulator(Used in LNG)
Max. pressure of gas inlet：28bar

Pressure range of gas outlet：7～14bar
Working temperature： -40℃～75℃
Arrow means the direction of gas flow
NGP is 110psi at idle speed
Fig 3-2 regulator
15
3.2.3 Solenoid Valve
Fig 3-3 solenoid valve

◆The mark in the valve body means the direction of gas flow.
◆The solenoid parts should be upward and higher than valve body.
3.2.4 Filter
Maximum working pressure：35bar
Flow：85m3/h@100psig
Working temperature：-40℃～107℃
Pressure difference：6.9kPa
0.3μm～ 0.6μm filtrate efficiency≥95%。
Downward of water oulet
Arrow means direction of gas flow
Drain the water inside filter per 3000km
Fig 3-4 Filter

◆The location of filter should be easy to check, clean and change.
◆The pressure difference should be less than 20kPa to ensure the performance of filter. Otherwise the power of
engine will decline.
◆The filter should be 20cm farther than high temperature parts of air outlet pipe.
16
3.2.5 Heat exchanger and thermostat
Fig 3-5 Heat exchanger and thermostat

Gas outlet temperature will decrease to lower than －20℃ at higher gas flow because of insufficiently heat
exchange of the regulator. That would decrease the service life of FMV. By combining the heat exchanger and
thermostat to control the flow of hot water, NG temperature is controlled to 40℃.
◆Technical parameters
Gas flow：0～68kg/h
Gas inlet temperature：－115℃～120℃
Water inlet temperature：－20℃～120℃
Water outlet temperature：－40℃～120℃
Allowable maximum air intake pressure：22bar
Break out pressure：86bar
3.2.6 FMV -Fuel Metering Valve
Fig 3-6 FMV

The FMV has 12 injectors in WP12NG series engine, per 2 injectors as one group and works together
according to ECM signals.
◆ Technical parameters:
Working voltage: 16-32V.
Peak current of each injector: 4A.
Working current: 1A.
Ambient temperature: －40～125℃.
Gas temperature: －40～90℃.
◆The mounting of FMV is reasonable and reliable.
17
◆There should be no interference between the harness and pipes that connected with FMV.
◆ Unilateral valve mounted inside FMV is used to measure gas pressure. It is convenient to check gas pressure
when mounting FMV.
3.2.7 Mixer
NG enters into mixer through FMV and then mixes with the inter-cooled air in the throat and then enters into
cylinders. The throat of this engine can be dismantled and cleaned.
Gas Air
inlet inlet
Fig 3-7 mixer
18
3.3 Electrical system

3.3.1 Principle diagram of electrical system
Fig 3-8 Principle diagram of electrical system
19
3.4 Principle and attentions of electrical system’s parts

The electrical system include: wire, ECM, ICM, sensor of water temperature, sensor of oil pressure, sensor of
gas temperature, sensor of rotate speed, humidity sensor, oxygen sensor, foot pedal, throttle, waste gas control
valve, ignition and plug, etc.
3.4.1 Harness
Harnesses include ignition harness, engine harness and ECU harness. Ignition harness and engine harness
have been assembled on engine before leaving factory. ECU is provided by our company and assembled by
vehicle factory.
Fig 3-9 harness

◆It is forbidden that the harnesses are assembled in the side of exhaust manifold.
◆Every connector and wire should can endure at least 20N pull force without looseness even fall off.
◆Harness can endure at least 125℃ and with well resistance to oxygenation.
◆The arrangement of harness is reasonable and it is convenient to maintain.
3.4.2 Engine control module（ECM）and ignition control module（ICM）
Engine control module（ECM） Ignition control module（ICM）

Fig 3-10 ECM and ICM
ECM collects signals of manifold air pressure (MAP), manifold air temperature (MAT), pre-throttle pressure
(PTP), natural gas pressure (NGP), natural gas temperature (NGT), engine phase, rotated speed, water outlet
temperature, exhaust oxygen density, pedal opening and so on. And controls ICM, throttle, FMV, waste gas
20
control valve (WGCV) to achieve control the engine.
ECM can also be assembled on the engine. It surppot CAN.
Special commutating and regulating circuit is set in the ICM to ensure the required current at any voltage.
Energy reserving process of ignition coil is called charging. The beginning of charging current is called charging
start time. Charging time is the duration between charging start time and charging end time. Different from
injection time, the key of ignition control is to control the charging end time. This action must take place at a
certain angle to get correct ignition time.
ICM of ignition system is driven in single direction. ECM controls charging start time and charging end time.
Correct firing sequence is achieved by connecting the output wire of ICM to the correct cylinder. ICM ignites
according to the firing sequence. The firing sequence of 6-cylinder engine is 1-5-3-6-2-4. Charging end time
(dropping section of trigger signal) is determined by expected ignition timing. Charging start time (rising section
of trigger signal) is estimated on above basis.
Parameters and attention of ECM and ICM
◆working voltage：18～32V，maximum current：25A.
◆temperature of environment ：-40℃～105℃.
◆Housing grounded.
◆ECM and ICM should be mounted on good ventilating place.
◆If electric cabinet is used, it is recommended to mount the cabinet in the carriage.
3.4.3 T/MAP and PTP
Fig 3-11 T/MAP and PTP

T/MAP and PTP are the same in Woodward2.0 system. It is the integration of temperature and pressure.
ECM calculates the flow of air intake according to the signals from sensor and defines the delivered fuel's flow.
Technical parameters:
◆working pressure：20～250KPa.
◆working temperature：-40℃～125℃.
21
◆working voltage：4.5V～5.5V.
T/MAP and PTP are fixed on the straight pipe of air intake manifold. It is forbidden to fix sensor on the
elbow pipe.
3.4.4 Camshaft signal (speed, phase) sensor
Fig 3-12 CAM sensor

ECM controls most parameters such as air flow, gas flow, ignition advance angle etc by engine rotation speed.
To control above parameters, it is essential for ECM to get exactly the camshaft position (such as which cylinder
is firing) and engine speed.
◆working temperature：measurement side-40℃～150℃，plug side-40℃～120℃
◆permitted magnetic field≤2KA/m
◆torque≦8N·m（the degree of M6×12 bolt is 8.8）
3.4.5 Water temperature sensor

Main function of water temperature sensor is to rectify idle speed, ignition advance angle, maximum boost
pressure limit and mixture density at lower water temperature.
If wrongly connect of water temperature sensor's lines, abnormal water temperature will be displayed on the
computer. It doesn’t affect the engine.
3.4.6 Universal exhaust gas oxygen sensor（UEGO）
Fig 3-13 Universal exhaust gas oxygen sensor
22
The function of UEGO is to measure oxygen density of exhaust gas and change it to electrical signal then
supply to ECM. ECM regulates fuel gas flow by adjusting spray pulse width according to excessive air coefficient
specified in the map to make the engine realize closed-loop control.
◆Mounting position of UEGO is very important to the correct working of the system, so the assembly must
be done strictly according to the requirements.
◆ UEGO mounting position should be 3-5 times of exhaust pipe diameter away from the outlet of
turbocharger or below of exhaust pipe.
◆Prohibit from mounting the UEGO on the exhaust elbow.
◆In order to prevent UEGO from cementing on the exhaust pipe, coat anti-seize grease evenly on the thread
when fix the UEGO.
◆If exhaust valve brake device (EVB) is mounted on vehicle, UEGO must be set at the rear side of EVB.
◆UEGO lines and insert parts should be far away from the exhaust pipe to prevent from sintering.
◆Nut seat height for UEGO weld on the exhaust pipe should be less than 10mm.
◆ UEGO failure or bad contact of lines or insert parts would cause higher gas consumption and unstable
speed.
3.4.7 Foot pedal
Fig 3-14 Foot pedal

Foot pedal adopts non-contact sensor. The outlet voltage: 0-5V. ECM controls the throttle opening degree
according to the signal of pedal.
◆working temperature：-40℃～50℃。
◆storage temperature：-40℃～120℃。
◆connection：red-A3 brown-H3 yellow-H3 green-H1 brown-T3 white-H3
23
3.4.8 Throttle
Fig 3-15 throttle

Main function of throttle is to control air flow, engine idle speed and maximum speed. ECM controls the
action of throttle by pulse width modulated (PWM) signal with 1600Hz. The working degree of throttle is limited
to 10%-90% of throttle opening (butterfly opening) by ECM. In general, error logic judgment of the system is to
compare the position command signal, feedback signal and intermediate position voltage signal (about 2.5V). If
the difference between command signal and feedback signal is larger than 0.5V, the system will confirm and
produce a system fault code in English (refer to Appendix B - System Fault Code).
Throttle fault or bad contact of connectors will cause unstable speed, start failure, difficult speed up, speed up
failure and so on. First check the connection with multi-meter. If there is no problem for connectors and harness
but the feedback signal always jumping, change a new part to test again.
◆throttle should be fixed in low temperature environment.

◆fix the throttle according to the mark on the throttle body.
3.4.9 WGCV-Waste Gate Control Valve
Fig 3-16 waste gate control valve
24
WGCV is connected with the pressure regulator of turbocharger. ECM controls the duty ratio of the exhaust
gas magnetic valve switch through PWM to adjust the pressure on top of the film of pressure regulator. Thus the
exhaust gas release valve opening degree of the turbocharger is in a certain pressure range as so to control the
engine speed indirectly.
◆WGCV should be mounted within 10 degrees in vertical direction.

◆WGCV should be mounted on the lower temperature side of the engine, the ambient temperature should
not be more than 125℃.
◆Pipe connected with WGCV should be appropriate.
3.4.10 Ignition and spark plug
1. insulator 2.head of spark plug 3.seal washer 4.intermediate body 5.spark plug body 6.glass sealant 7.wahser
8.electrode9．seal washer 10.central electrode 11.ground electrode 12.side electrode
Fig 3-17 ignition and spark plug

This system adopts separate ignition coil. ECM controls charging time, charging duration and discharging
time of the ignition coil to keep the charging current (6.5A) of the engine at any conditions.
◆No force should be put on the harness of the ignition coil.

◆ Check the connection of harness and connectors with multi-meter.
◆The engine adopts double platinum spark plug. The spark plug clearance is 0.35±0.05mm.
25
3.4.11 humidity sensor
Fig 3-18 humidity sensor

The function of humidity sensor is to modify the ratio of air and gas by measure pressure, temperature,
humidity of air intake to make sure that the engine work in best condition. The range of working temperature is
-40℃～105℃。The range of measurement is 0～100%RH.
◆The sensor should be fixed in the pipe that is between air filter and turbocharger.
◆The sensor should be away ventilator and air intake of air compressor.
◆The sensor should be parallel with direction of gas flow.
26
Chapter4Application and operation of NG engine
4.1 Installation specifications of natural gas engine

◆The joints of high pressure pipes should be as little as possible. The pipes should be with good sealing and high
reliability and convenient for connecting and checking.
◆Over flow protection device should be provided at the upstream of the fuel system high-pressure pipe and near
the gas bottles. The function of this device is to cut off gas supply when ignition switch is not open or engine not
running or accidental fuel leakage at the low pressure pipeline.
◆The fuel system components and pipes (except manual cutoff valve handle) should not pass through or be
mounted on the passenger compartment.
◆The fixed place of gas system components and pipes should be far from high temperature materials and electric
appliance and batteries. They must not be at the same closed space. The places where static electricity will be
possibly produced on the high pressure pipeline and other parts should be grounded reliably.
◆ Consider the influence of load distribution and height of bary-center on vehicle. Consider possible damage of
environment to gas bottle. And add guard device to the bottles if necessary.
◆The natural gas fuel for NG bus should be in accordance with GB/T18047 standard.
◆Check the connecting points of gas system with detecting liquid at the rated working pressure of NG gas system.
There should be no bubbles produced within one minute. Or check with gas detecting device that precision is not
lower than 25×10-6, and the detector should not give out alarm.
◆The material of the parts at gas filling port should meet the requirements of gas medium, service life and
ambient temperature. The joints should be made of anti-corrosive metal material especially copper alloy with
copper content of lower than 70% and hardness higher than HRB60.
◆The fixed place of gas bottle should be far from heat source and the ambient temperature should not be higher
than 55 ℃ . The distance between the gas bottle and the exhaust pipe should not be less than 75mm at any
condition.
◆If the gas bottle were mounted under the bus frame, the bottle and its accessories should not be arranged in
front of the front axle. The distance of the lowest position of bottle from the ground should not be less than the
minimum ground clearance when the bus is full load.
◆The gas bottle should be firmly fixed on the seat. There should be a rubber cushion ( ≥ 2mm) or elastic
anhydrous between the bottle and seat.
◆After the bottle is fixed, a static force 8 times that of the bottle weight (full of gas at rated pressure) should be
withstood at any directions. The maximum displacement between the bottle and the fixing seat must not be larger
than 13mm.
◆The gas bottles should be arranged reasonably. When the distance between the gas bottle and the exhaust pipe is
27
75-200mm, reliable heat isolating fittings should be set.
◆The integrated valves and connectors of the gas bottle should be protected properly to avoid damage caused by
impact, capsize or other accident. The distance between the integrated valves and the edge of vehicle outline
should not be less than 200mm.
◆The gas bottle should be mounted at wind obstructing position to prevent the leakage gas from entering the cab
and the passenger compartment. If the gas bottle were mounted inside the bus, the gas bottle and the integrated
valves should be closed in an airtight cabin with a window for maintenance and check. Or the integrated valves
are closed in a subsidiary cabin. The airtight cabin and the subsidiary cabin should be sealed reliably to avoid gas
leakage.
◆ The high pressure pipes should be as short as possible. And the pipe’s connectors should be mounted at the
visible or accessible position. All the high pressure pipes and connectors should be protected reliably.
◆Rigid high pressure pipe should be arranged reasonably and fixed on the chassis and bus body with clamps to
avoid come into collision and friction with adjacent parts. The rigid high pressure pipe should be fixed on the
chassis or the bus with clips and the space between two adjacent clips should be less than 600mm. When the pipe
contacts with the parts nearby or passes through a hole-plate, protective rubber cushion should be used. The pipe
between two parts should be of coil pipe or “U” pipe to protect the pipe from being influenced by vibration and
expansion or contraction with the temperature. The curvature radius of pipe centerline should not be less than 5
times of pipe outer diameter.
◆For hinge type bus, the high pressure pipe at the hinge place should be flexible pipe. And flexible high pressure
hose assembly special for NG conformed with related standard should be used. Every flexible high pressure hose
assembly should be signed with manufacture, specifications, rated working pressure and the symbol “NG”. The
high pressure pipe joint and the hose should be provided as a whole part.
◆ The flexible high pressure hose should be fixed on the base parts of the bus with spring clamps. The space
between two adjacent clamps should not be less than 300mm. And clamp the hose at the right and left of any
sinuosity. The clearance between the hose and the exhaust pipe of the engine should not be less than 100mm.
When the clearance is in between 100-200mm, fixed and reliable heat shielding should be mounted between the
high pressure hose and engine exhaust pipe.
4.2 Unpacking
When unpacking the engine, the user should check the engine and accessories as packing list. And examine
whether it is damaged, or fittings are loose, etc. Then follow what are below:
◆Clean the anti-rust coat of exposed parts and corrosion inhibitor, etc.
◆ As the agreement of manufactures and users, fill oil if no oil in the bottom. If the oil with accelerating
agent for running is filled completely in the oil bottom, it is recommended to instead old oil with new oil after the
users drive for 2000km (or drive for 50 hours).
◆ As the agreement of manufactures and users, when leaving factory, fill coolant as users’ requirement,
28
check coolant performance when unpacking it. If the antifreeze ability meets the requirements when the
temperature is -30℃ or -35℃, PH value is 7-8(neutrality), the total rigidity is 5-15°d[9-15°f(rigidity)], such
coolant can be used. If it doesn’t meet requirements, drain it out and fill the coolant with antifreeze additive.
4.3 hoisting of engine

When hoisting, the crankshaft center line of the engine should be kept level. It is forbidden to hoist aslant or
hoist with one side. Lifting up and lowering of the engine should be slow(see the fig 4-1)
Fig 4-1 hoisting of engine

4.4 installation of engine
In installation, it is necessary to ensure that the engine crankshaft centerline and the axis of the input shaft of
driving device (such as crankcase, gear box and generator) are coaxial, and ensure that the crankshaft does not
bear additional axial force induced by setting up.
4.5 prepare work before start

◆check the coolant liquid level
If the engine has been installed on the vehicle or bracket, the coolant liquid level should be seen from the
glass sight hole on the expansion tank anytime. If the coolant is not enough, open the filling hole cover to fill
coolant. When open filling hole cover with relief valve and exhaust valve, press releasing button before open the
cover if the engine is hot. It is avoided to fill large amount of coolant when the engine is hot by all means, parts
will be damaged due to sudden temperature change. In the abnormal condition with coolant, it is allowed to fill
slowly water which is not very cold. It is filled from the filling hole until is spills over. Start the engine and fill the
coolant until the liquid level is stable when engine is running (1000r/min), and finally cover he filling hole.
◆check the oil liquid level
Engine oil liquid level is in the middle between up scale and down scale. If necessary, fill the oil from its
filling hole.
◆check accessories of the engine
Check if all accessories are reliable, and clear off something abnormal. Check whether circuit connection of
start system is normal and storage battery charges fully.
4.6 daily operation of the engine

◆ Check if the connection is firm between gas bottle and bracket, gas supply device and crossbeam. Whether
29
there is gal leakage of gas pipes. Whether it is loosen of sensors’ connectors before start the engine.
◆Open power switch for 5-10s to make sure there is gas in pipes before start engine.
◆After the engine is started, run the engine for 30s in idle speed and check whether the oil pressure and water
temperature is normal.
◆Step down the clutch and accelerator pedals, turn electric key to start the engine. If it is not started within 5-10s,
repeat the process above after one minute. If it is not started for 3 sequential times, stop starting it. Do it after
finding caused and removal trouble. Notice readings of all meters after starting the engine. At this time, engine oil
pressure meter displays pressure. It should be noticed that cold engine should not be run in high speed. After
running for a period (but not too long) in idle speed, it can run in high speed.
◆For NG engine, when the ambient temperature is lower, there might be some white smoke or water drip from
exhaust pipe for short time after engine started. The cause is that the “H” content is higher in NG, and much H2O
resulted after combustion. The water forms white smoke or water drip at lower temperature and can not be
vaporized. With the rising of temperature, there will be no white smoke or water drips.
◆The acceleration ability of NG engine is not as well as diesel engine for the fuel property.
◆When stopping the engine in cold climate, reduce load and run for 1-2minutes in idle speed. After water and oil
temperature is lower, stop the engine. It should be noticed that the coolant with antifreeze additive can not be
drained out. If the coolant is not filled with antifreeze additive, you must open the valves and water blocks on the
cylinder body, engine oil cooler cover, radiator, air inlet pipe, etc. and drain up coolant to prevent the engine from
being frozen with cracks.
30
Chapter5 Maintenance of engine
5.1 Routine maintenance

Check coolant liquid level, engine oil level. Check whether lubricating grease is enough in the required place,
whether oil, water and gas is leaked or not, whether connection and tighten outside connecting parts and
accessories is good, whether fan and belt are over tight or loose, whether oil pressure, water temperature of engine,
as well as exhausting temperature, color, sound, vibration are normal, and whether the rotary speed is stable.
◆check liquid level and water temperature
Observe the liquid level from glass sight hole. When the coolant is not enough, open filling hole cover to fill
coolant.
Note: You must press air releasing button before open filling hole cover to avoid hot coolant damaging
person when engine is hot.
Fig 5-1 Fig 5-2

◆check oil level
When oil level is lower than down scale or topper than up scale, it is forbidden to start engine.
Check the oil level after 5min the engine stopped to make the oil flow return to oil pump.
The difference between the up scale and down scale is 3L.
Fig 5-3
31
◆Check leakage
There should not be leakage of water, oil and gas.
Fig 5-4
 Check fun
check whether the blade of fan is broken, and connecting bolts are tight.
Fig 5-5
 Check belt
The belt are tightened by pulley, and users should check the tension of belt by hand.
Fig 5-6
 Check whether sound is normal.
 Check whether rotary speed and vibration is normal.
32
5.2 Maintenance of all levels

Add following content besides routine maintenance：
 Replace oil
 Turn out oil draining screw plug on the bottom of oil pan, and drain out engine oil and then tighten oil
draining screw plug. See fig 5-7. Open filling hole cover (see fig 5-8) fill oil from filling hole to observe
scale of dipstick until it meets the requirements, finally cover the filling hole.
Filling hole
for oil
Fig 5-7 Fig 5-8

Oil purge
plug
Note: The oil should be drained out to special container to reuse.

◆Replace oil filter and filter element. See fig 5-9.
Replace oil filter as following:
① remove old oil filter
② fill clean oil to new filter
③ lay oil on rubber plate before installing new oil filter
④ when the rubber plate touches the base, tighten 3/4～1 round to seal
⑤ start the engine and check whether it leaks oil.
Oil filter
Fig 5-9
33
 Check and adjust inlet/outlet valve clearance
① when engine is cold, right barring and make (as the running direction) 1st and 6th cylinders to TDC, at this
time,”0” graduation of the flywheel and indicator on the sight hole are put in order. See fig 5-10
Index
点火刻度
Fig 5-10
② dismantle rocker cover to judge compressing stroke of cylinder 1st or cylinder 6th(there is
clearance between inlet and outlet valves of cylinder with compressing stroke and cover). See fig 5-11
Fig 5-11
③ check the clearance between surface of valve bridge and valve rocker by filler gage. WP12NG engine
requires inlet valve clearance is 0.3mm, outlet valve clearance is 0.4mm. If the clearance is too big or small, you
can adjust the adjusting screw on the rocker to get above clearance requirements.
④ after checking cylinder 1st and cylinder 6th ,right barring about 360°. Make cylinder 1st or cylinder 6th on
the working stroke to check and adjust the other valves.
Tab 5-1
34
Cylinder 1st Cylinder 2nd Cylinder 3rd Cylinder 4th Cylinder 5th Cylinder 6th
Compression Inlet/outlet Inlet valve Outlet valve Inlet valve Outlet valve Nonadjustab
stroke of 1st valve le
Compression Nonadjustab Outlet valve Inlet valve Outlet valve Inlet valve Inlet/outlet
stroke of 6th le valve
For the outlet valve with WEVB, its adjusting steps are below：
Fig 5-12 Adjustment of outlet valve and EVB clearances

◆ piston is located at compression TDC.
◆ loose adjusting bolt 2.
◆in case that the seal plane of outlet valve rocker arm is not pressed, first by using No.10 adjusting screw to
adjust the total valve clearance to 0.4mm, and then tighten the lock nut.
Note: During adjustment, the valve clearance adjusting screw should be turned until the filler gauge is
clamped so that No.5 valve rocker arm piston is pressed to the bottom and forms no gap with the bottom
plane of piston installation hole in outlet valve rocker arm.
◆ loose nut No.2
◆adjust the adjusting screw 2, insert 0.25mm filler gage between adjusting screw 2 and valve bridge.
Tighten the nut.
Note: during adjustment, No.2 adjusting screw assembly should be turned until the filter gauge is clamped so
that No.5 valve rocker arm piston is pressed to the bottom and forms no gap with the bottom plane of piston
installation hole in outlet valve rocker arm.
◆ Check valve clearance again and adjust it if necessary.
 Check air inlet system
Check whether inlet rubber pipe is aging with cracks, and hoop is loose. If necessary, you must
fasten or replace parts to ensure the seal of inlet system.
5.3 Maintenance of diesel engine when it is not used for long time
 Clean engine
 Protection
35
① after warming up, drain out oil, clean oil filter and fill rust-prevented oil.
② drain out water and fill coolant with rust-prevented agent.
③ start the idling run for 15 to 25 min.
④drain out oil and coolant.
⑤protect other parts.
 Protection in the period of stocking
Pack all inlet/outlet for oil, gas and water by cover or plastic. Seal the complete engine by rust-prevented file.
 If require shipment, the additional package should be necessary.
5.4 periodic maintenance and record

Tab5-2 operation conditions of two types matching with vehicles
（WGⅠtype）（WGⅡtype）
Operating condition is abominable(climate is cold or hot, with high The yearly number of miles
dustiness. Shipping distance is short. It is used in construction site, travelled by the vehicle is less
and used in public buses, municipal engineering vehicles, snow than 2×10 km
4
removing vehicles and fire engines) or the yearly number of miles

4
traveled by the vehicle is less than 2 × 10 km or yearly working
time is less than 600h.
Tab 5-3 maintenance term

Working
condition The yearly number of
WGⅠ WGⅡ
Items miles traveled（time）
First inspection 3000km （50h） A A

10000km（200h） B C
Routine inspection 30000km（400h） B
For WGⅡtype, replace oil filter element every 10000km(200h) in the
specifically service center of Weichai Power
A-first inspection：replace oil and filtering element，
B-routine inspection：replace oil and filtering element
C-only replace oil filter element
Tab 5-4 maintenance criterion
Maintenance items First time routine
Replace oil filter or filtering element ● 每次更换机油时
Check and adjust the clearance of valves ● ●
Check the volume of coolant and fill them ● ●
Fasten clamp of coolant pipes ●
Fasten air inlet pipe, hose pipe and flange ● ●
connector
Check maintenance indicator light of ●
36
indicator of air filter
Clean dust collecting container of air filter ●
（not including automatic dusting type）
Clean main filtering element of air filter When the indicator light is light
Replace main filtering element of air filter Refer to manual and relative regulations
Replace safety filtering element of air filter When clean main filter element for 5 times
Check and fasten belt ● ●
Check clearance of bearing of turbocharger Every 160000km
Check and adjust clutch travel ● ●
Note ：signal ● represents to require maintenance.
Chapter6 analysis and solution for common

failures
WP12NG series natural gas engine are designed and fabricated with strict quality system, and the required
test are applied on each engine prior leaving the factory. On the other hand, as NG engine is a kind of precise
machine, the normal maintenance is critical for its long term service. Generally, the reason for the failure of
engine are as follow:
◆ Illegal operation, lack of management and abnormal application
◆ Didn’t carry out the maintenance as regulation, or just repair as it is broken
◆ Poor quality of fitting, the cheap fake product will shorten the service life much.
◆ Improper type fuel and lubricant are applied
6.1 estimate method
The common estimate methods for NG engine failure are as follow：
37
◆ Observation：estimate the failure by observe the failure phenomenon like exhaust smoke etc.
◆ Hearing：estimate the failure part and degree by hearing the abnormal sound
◆ Ceasing cylinder：cease the work of certain cylinder to estimate whether the failure is happened in this
certain cylinder. The method of “ceasing cylinder” is to cease the fuel supply for the cylinder which is
suspected, and compare the difference of engine after ceased the cylinder, which can reduce the range of
failure parts.
◆ Comparing method：replace some assembly parts or components to make sure whether there are failure
on them.
Note：
① Estimating the failure of engine is a fairly precise work, it is forbidden to disassemble the engine
before acknowledge the failure reason, or the failure may get worse for the improper disassembly.
② For the key components like ICM, ECM, FMV and turbocharger, etc. the maintenance and
inspection should be implemented by special equipments and operator with qualification.
6.2 Common failure and solution

These failures mainly are the accumulation and summary of service experience for user reference. During
estimate, connect the WOODWARD OH 2.0 control software and check the failure code.
38

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WP12NG 系列天然气发动机使用保养说明书

Chapter1 Technical Situation of the Products............................................................................................................ 48

1.2 Structural character of natural gas engine.............................................................................................. 48

2.2 Performance parameters of WP12NG series natural gas engine................................................................. 51

4.3 hoisting of engine......................................................................................................................................... 67

4.4 installation of engine.................................................................................................................................... 67

4.5 prepare work before start..............................................................................................................................67

4.6 daily operation of the engine........................................................................................................................ 67

5.2 Maintenance of all levels..............................................................................................................................71

follow the operation and maintenance routine rules in this manual.

warranties will be invalid.

otherwise all the warranties will be invalid.

when changing it.

water in water tank and in engine should be drained off.

personnel in service station.

without load for about 5-10min before stopping the engine.

running the engine.

workers of gas station. Check the sealing of natural gas system.

cavity of pressure reducer and frost when starting the engine.

go to our net(http:www.weichai.com) for latest production information.

Welcome users, further suggestions for modification of products.

Chapter1 Technical Situation of the Products

1.1Power and rated rotating speed

1.2Structural character of natural gas engine

1.3 Signification of WP12NG series natural gas engine code

Total displacement 12L

Chapter2 Performance and Technical Parameters

2.1 Technical parameters of WP12NG series natural gas engine

2.2 Performance parameters of WP12NG series natural gas engine

Chapter3 Natural Gas Engine System

3.1 Gas supply system

3.2 Function and Technical Requirement of Gas Supply System’s Main

Fig 3-1 regulator

Max. pressure of gas inlet：28bar

Fig 3-2 regulator

3.2.3 Solenoid Valve

Fig 3-3 solenoid valve

Fig 3-4 Filter

Fig 3-5 Heat exchanger and thermostat

3.2.6 FMV -Fuel Metering Valve

Fig 3-6 FMV

Fig 3-7 mixer

3.3 Electrical system

Fig 3-8 Principle diagram of electrical system

3.4 Principle and attentions of electrical system’s parts

Fig 3-9 harness

3.4.2 Engine control module（ECM）and ignition control module（ICM）

Engine control module（ECM） Ignition control module（ICM）

3.4.3 T/MAP and PTP

Fig 3-11 T/MAP and PTP

3.4.4 Camshaft signal (speed, phase) sensor

Fig 3-12 CAM sensor

3.4.5 Water temperature sensor

3.4.6 Universal exhaust gas oxygen sensor（UEGO）

Fig 3-13 Universal exhaust gas oxygen sensor

3.4.7 Foot pedal

Fig 3-14 Foot pedal

Fig 3-15 throttle

◆throttle should be fixed in low temperature environment.

3.4.9 WGCV-Waste Gate Control Valve

Fig 3-16 waste gate control valve

◆WGCV should be mounted within 10 degrees in vertical direction.

3.4.10 Ignition and spark plug