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The WEICHAI WP12 Intercooler Assembly is a high-efficiency charge air cooler that reduces the temperature of compressed intake air before it enters the engine cylinders. As genuine WEICHAI Engine Parts, this intercooler assembly plays a critical role in the WP12 turbocharged and intercooled engine platform, enabling optimal combustion efficiency across all WP12 variants from 336 HP to 550 HP. The WEICHAI WP12 Intercooler Assembly is designed to withstand extreme operating conditions and deliver consistent cooling performance.
The WEICHAI WP12 Intercooler Assembly (also known as a charge air cooler) is a heat exchanger mounted between the turbocharger compressor outlet and the engine intake manifold. Its primary function is to cool the compressed intake air after it leaves the turbocharger, increasing air density and reducing the risk of engine knocking. The intercooler is an integral component of the WP12 engine’s turbocharged and intercooled architecture, which is standard across the entire WP12 series [1†L9-L12][13†L9-L10].
The WEICHAI WP12 Intercooler Assembly is manufactured from high-grade aluminum alloy with advanced thermal transfer technology. The core features optimized fin density and internal passages that maximize heat dissipation while minimizing pressure drop across the system. The intercooler is available in multiple OEM configurations including Z95259531502 (600×300×80mm core, 76mm inlet/outlet) and DZ9114530344 (580×280×75mm core, 70mm inlet/outlet) for different Shacman truck applications [18†L17-L20][19†L20-L23].
The WEICHAI WP12 Intercooler Assembly is part of the WP12 engine series, which features an inline 6-cylinder, four-stroke design with a displacement of 11.596 L (126 mm bore × 155 mm stroke). The engine is equipped with four valves per cylinder and an electronically controlled high-pressure common-rail fuel injection system. The turbocharged and intercooled architecture enables the engine to achieve a minimum fuel consumption rate as low as 191 g/kW·h and a maximum torque of up to 2,110 N·m at 1,000-1,400 RPM [14†L10-L11][15†L6-L7][14†L6-L7].
Applications for the WEICHAI WP12 Intercooler Assembly include Shacman X3000/F3000/X5000, Sinotruk HOWO A7/T7H, Beiben trucks, JAC trucks, CAMC vehicles, Yutong and Kinglong buses, SDLG wheel loaders, XCMG equipment, marine WP12C engines (WP12C400-18, WP12C450-21, WP12C500-21, WP12C550-21), and stationary generator sets. The intercooler is compatible with WP12 power outputs from 336 HP to 550 HP across Euro III, Euro IV, Euro V, China VI, and marine IMO II emission standards [15†L11-L15][16†L11-L14].
The WP12 engine series has undergone over 45,000 hours of cumulative bench testing and over 50 million kilometers of whole vehicle road testing, proving the reliability of every component including the intercooler assembly. The intercooler is designed to operate reliably in ambient temperatures from -35°C to 50°C and at altitudes up to 4,100 meters with less than 5% power loss [13†L22-L23][14†L27-L28][14†L14-L16].
| NO. | Part NO | Description |
|---|---|---|
| 1 | Z95259531502 | WP12 Intercooler (600×300×80mm, 76mm inlet/outlet, 3.5 bar max pressure, 8.2kg) [18†L17-L20] |
| 2 | DZ9114530344 | Shacman Intercooler (580×280×75mm, 70mm inlet/outlet, 3.2 bar max pressure, 7.8kg) [19†L20-L23] |
| 3 | 612630120237 | WP13 Marine Intercooler Assembly (Weichai WP13 marine diesel engine) [10†L10-L11] |
| 4 | 612600115538 / 1551213-00282-001 | Intercooler Outlet Pipe (WP12/WD12, D100/100×L340) [12†L2-L4] |
| 5 | 612630110373 | Intercooler Connecting Pipe (WP12/WP13, 530HP) [7†L2-L3] |
| 6 | 1002784105Z | Air Intercooler (WP12/WP13, universal fitment) [8†L2-L4] |
The table above lists common service parts for the WEICHAI WP12 Intercooler Assembly and its related components. The intercooler core dimensions, inlet/outlet sizes, and maximum pressure ratings vary by OEM configuration. The Z95259531502 intercooler achieves a temperature reduction of up to 60°C with a pressure drop of less than 2.5 kPa, significantly improving combustion efficiency and engine power output [18†L19-L20].
Our WEICHAI WP12 Intercooler Assembly features a high-efficiency core design with optimized fin density and tube configuration that maximizes heat transfer while maintaining minimal pressure drop. The intercooler can reduce compressed intake air temperature by up to 60°C, significantly improving air density for better combustion [18†L20-L21].
The WEICHAI WP12 Intercooler Assembly works in conjunction with the turbocharger to increase engine power by approximately 20% compared to naturally aspirated engines. The intercooler lowers the temperature of the inlet gas from approximately 130°C to 60°C, removing the negative effects of the turbo and increasing combustion efficiency [2†L33-L36].
The WP12 engine equipped with our intercooler assembly achieves a minimum fuel consumption rate as low as 183-191 g/kW·h, significantly lower than many competing engines in its class. The efficient cooling of charge air increases air density for better combustion, translating to more complete fuel burn and reduced emissions [14†L21-L22][15†L6-L7].
No modifications required for WP12 engines in Shacman, Sinotruk, Beiben, JAC, CAMC, Yutong, Kinglong, SDLG, XCMG, marine, and generator applications. Available for Euro III, Euro IV/V, China VI, and marine engine variants. The intercooler is compatible with WP12 power outputs from 270 HP to 550 HP [11†L10-L11].
Each WEICHAI WP12 Intercooler Assembly undergoes rigorous quality control including pressure leak testing, thermal cycling validation, dimensional inspection, and fin integrity verification. IATF 16949 certified quality with full traceability. The WP12 engine platform has proven its reliability through over 45,000 hours of bench testing [14†L14-L16].
Worldwide shipping from regional warehouses. Free intercooler installation torque charts, pressure test procedures, and troubleshooting guides provided with each order. Volume discounts available for fleet customers and engine rebuilders. The cooling system meets ambient temperature requirements up to 46°C for vehicle applications [13†L44-L46].
Unlike aftermarket intercoolers that use inferior materials and lack proper pressure testing, our genuine WEICHAI WP12 Intercooler Assembly is manufactured to original equipment specifications with documented quality control. The intercooler is constructed from high-grade aluminum alloys with precision-welded joints that ensure leak-free operation under high-pressure conditions up to 3.5 bar. The robust construction resists vibration, thermal stress, and environmental corrosion, ensuring reliable performance in the most demanding applications [18†L10-L13].
The WEICHAI WP12 Intercooler Assembly is a critical component of the engine’s turbocharged and intercooled architecture. When air is compressed by the turbocharger, its temperature rises significantly. The intercooler reduces this temperature before the air enters the combustion chamber, increasing air density by approximately 30%. This denser charge allows more fuel to be burned efficiently, resulting in increased power output while reducing exhaust emissions and improving fuel economy. The WP12 engine achieves a maximum torque of up to 2,110 N·m with torque reserve of 25-35%, enabling excellent low-speed response and acceleration [14†L6-L7][15†L7-L8].
Technical support includes intercooler installation procedures: allow engine to cool completely, drain coolant if required, remove old intercooler, clean mounting surfaces, inspect intercooler pipes and hoses for damage, position new intercooler, torque mounting bolts to specification, reconnect all hoses and clamps, refill coolant if drained, run engine to operating temperature, and check for boost pressure leaks using soapy water. Troubleshooting guides for symptoms like loss of power (intercooler leak or restriction), black smoke (insufficient charge air cooling), and engine knocking (high intake air temperature) are provided. The intercooler and heat exchanger are reasonably arranged at both ends of the diesel engine, with reasonable matching between intake & exhaust and fuel system [0†L14-L16].
For fleets, sample testing is available. Order one WEICHAI WP12 Intercooler Assembly for trial; volume pricing applies. Many customers report over 500,000 km trouble-free intercooler operation after replacing cracked or leaking original units with our genuine components. We provide cross-reference support for part number verification—please provide your engine serial number for accurate matching. We stock both standard intercoolers for highway truck applications and marine variants (612630120237) with enhanced corrosion resistance for saltwater environments [10†L10-L11].
Also monitor the engine’s exhaust temperature and coolant temperature. A higher than normal exhaust gas temperature under load may indicate insufficient intercooler cooling, often caused by clogged fins or internal scale buildup. The WP12 engine’s intake heating function meets the requirements of start at -35°C in cold regions, and the hyperboloid fan features large air volume, low power consumption, and low noise, meeting the ambient temperature limit of 46°C for vehicle cooling [13†L44-L46].
For severe-duty applications (mining, construction, heavy haul, marine), reduce intercooler inspection intervals to every 25,000 km (15,000 miles) or 250 operating hours. High ambient temperatures, dust, and vibration accelerate fin damage and hose degradation. Marine applications require additional corrosion checks—saltwater environments can accelerate corrosion of aluminum intercooler cores and fittings. Apply anti-corrosion coating to intercooler exteriors in marine applications where available.
When installing a new WEICHAI WP12 Intercooler Assembly, ensure that all mounting points are properly aligned and that the intercooler does not contact any other engine components. Use new gaskets and O-rings at all connections. Torque all mounting bolts to manufacturer specifications. After installation, perform a boost pressure leak test by pressurizing the system to 3.5 bar and listening for hissing sounds or using soapy water to detect leaks. The efficient cooling of charge air increases air density for better combustion, improving fuel economy and reducing emissions [2†L16-L18].
Maintain a logbook of all charge air system maintenance: dates of intercooler inspections, boost pressure test results, hose replacement intervals, and any abnormal findings. For fleet operators, tracking boost pressure at full load is a powerful predictive maintenance tool—a gradual decrease in boost pressure often indicates developing intercooler leaks or clogged charge air pipes, providing ample warning before complete system failure occurs. Regular intercooler inspection and maintenance ensure the WP12 engine continues to deliver optimal power, fuel economy, and emissions performance.
In summary, the WEICHAI WP12 Intercooler Assembly features advanced thermal transfer technology (up to 60°C temperature reduction), high-efficiency aluminum alloy core (600×300×80mm or 580×280×75mm configurations), up to 3.5 bar maximum pressure rating, and direct fitment for all WP12 applications. Whether you are rebuilding a Shacman X3000, Sinotruk HOWO, Beiben truck, Yutong bus, SDLG wheel loader, marine vessel, or generator set, choosing a genuine intercooler assembly directly impacts engine power, fuel economy, emissions compliance, and overall vehicle reliability. The WP12 series engines are mature products originally derived from Austrian Steyr diesel engine technology, co-designed by Weichai European R&D Center and AVL Bosch [4†L21-L23].
For workshops performing in-frame overhauls, we recommend ordering the WEICHAI WP12 Intercooler Assembly as a complete kit including the intercooler (Z95259531502 or DZ9114530344), intercooler outlet pipe (612600115538), intercooler connecting pipe (612630110373), and all mounting hardware. This approach eliminates hidden failures and gives your customer a worry-free warranty period. All intercoolers are pre-inspected for pressure integrity, fin condition, and dimensional accuracy before shipment [12†L2-L4][7†L2-L3].
Our inventory includes both standard intercoolers for highway truck applications (Z95259531502, DZ9114530344) and marine variants (612630120237) with enhanced corrosion protection for saltwater environments. The standard WEICHAI WP12 Intercooler Assembly provides excellent service life for long-haul trucking, while marine variants feature additional anti-corrosion treatment for saltwater resistance. We provide cross-reference support for part number verification—please provide your engine serial number for accurate matching. We stock complete intercooler assemblies, individual intercooler pipes, hose clamps, and mounting hardware kits [10†L10-L11].
We provide after-sales documentation including intercooler dimensional inspection reports (600×300×80mm or 580×280×75mm), material certificates (aluminum alloy composition), pressure test certifications (up to 3.5 bar), temperature reduction specifications (up to 60°C), and diagnostic trouble code (DTC) guides for charge air system-related faults upon request. Every WEICHAI WP12 Intercooler Assembly is packaged in protective foam-lined boxes to prevent damage during shipping. Bulk orders receive custom palletizing and export documentation assistance. Express shipping available for urgent repairs—most orders dispatched within 24 hours [18†L17-L20].
All specifications based on original WEICHAI WP12 engine data. Cross-check part numbers with engine serial number and emission standard. The WEICHAI WP12 Intercooler Assembly includes OEM references Z95259531502 (600×300×80mm core, 76mm inlet/outlet, 3.5 bar max pressure, 8.2kg) and DZ9114530344 (580×280×75mm core, 70mm inlet/outlet, 3.2 bar max pressure, 7.8kg) [18†L17-L20][19†L20-L23]. The intercooler achieves a temperature reduction of up to 60°C and a pressure drop of less than 2.5 kPa. Always pressure test the system after installation, clean intercooler fins regularly, and use only genuine WEICHAI replacement parts.
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