Service Manual

Version:0210

2 Engine System
 Service Manual of RS8140 Road Roller

Contents
2 Engine system ......................................................................................................... 2-1
2.1 Overview .............................................................................................................. 2-1
2.1.1 Engine functions ......................................................................................... 2-1
2.1.2 Engine block assembly ............................................................................... 2-3
2.1.3 Engine performance parameters ................................................................. 2-4
2.2 Crank & connecting rod mechanism ................................................................... 2-5
2.2.1 Crankshaft & flywheel assembly ............................................................... 2-5
2.2.2 Piston & connecting rod assembly ............................................................. 2-5
2.3 Valve train ............................................................................................................ 2-7
2.4 Intake & exhaust system ...................................................................................... 2-8
2.4.1 Intake system .............................................................................................. 2-8
2.4.2 Exhaust system ........................................................................................... 2-8
2.4.3 Turbocharger ............................................................................................... 2-8
2.5 Fuel supply system ............................................................................................... 2-9
2.6 Cooling system................................................................................................... 2-10
2.6.1 Thermostat ................................................................................................ 2-10
2.6.2 Radiator .................................................................................................... 2-11
2.6.3 Fan ............................................................................................................ 2-11
2.7 Lubrication system ............................................................................................. 2-12
2.8 Removal & refitting of engine system ............................................................... 2-13
2.8.1 Removal of engine .................................................................................... 2-13
2.8.2 Refitting of engine .................................................................................... 2-23
2.8.3 Removal & refitting of radiator ................................................................ 2-33
2.8.4 Removal and refitting of fuel tank ........................................................... 2-40

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 Service Manual of RS8140 Road Roller

2.9 Diagnosis and troubleshooting of engine system common problems ............... 2-45
2.9.1 Engine start failure ................................................................................... 2-45
2.9.2 Difficult engine start ................................................................................. 2-46
2.9.3 Engine underpower ................................................................................... 2-47
2.9.4 Rough idling of engine ............................................................................. 2-47
2.9.5 Abnormal air emission (black/white/blue smoke) .................................... 2-48
2.9.6 High/low lubricating oil pressure ............................................................. 2-49
2.9.7 High lubricating oil consumption ............................................................. 2-50
2.9.8 High coolant temperature ......................................................................... 2-50

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 Service Manual of RS8140 Road Roller

2 Engine system
2.1 Overview
2.1.1 Engine functions
RS8140 road roller is applied with an in-line,
6-cylinder, water-cooled, direct injection,
4-stroke, turbocharged diesel engine, which
features high reliability, low fuel consumption
and low noise and meets the China II emission
standard.
Product code and designation
WEICHAI engine is designated as per the
following rules:

Output power (unit: hp)

Displacement (unit: L)
POWER
WEICHAI

Engine ignition order

The cylinders are numbered in order, starting
from the flywheel. The ignition is performed in
the order of 1-5-3-6-2-4. Viewed from the
flywheel, the engine rotates counterclockwise.

Fig.2-1 Cylinder No.

Engine characteristics curve Engine characteristics curve

Torque M (Nm)

The engine speed characteristics curve shows

Power P (KW)

how the effective power P and torque M vary

Power with engine speed n continuously.
Torque

Engine speed n (r/min)

Fig.2-2 Engine characteristics curve

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 Service Manual of RS8140 Road Roller

Working principle
The diesel engine is designed with four strokes,
i.e. intake, compression, power and exhaust, all
of which consist of one working circle.
Specifically speaking, during air intake, engine
inhales fresh air continuously until the piston
approaches the bottom dead center (BDC),
marking the end of intake. Then, the
compression stroke begins as the piston starts
moving upwards, during which the fresh air is
compressed by the piston and its temperature
Fig.2-3 Engine
rises. When the piston approaches TDC, the
diesel is atomized and then injected into
combustion chamber via injector, where it is
mixed with high temperature gas (i.e. gas
mixture is formed) and combusts automatically
and quickly. When the pressure generated from
self-combustion forces the piston to move
downwards, the power stroke begins, which
will be ended as the piston gets close to BDC.
Diesel engine Following this, the exhaust stoke starts as the
Fig.2-4 Schematic diagram of diesel piston moves upwards by the force of inertia,
engine structure and when it approaches TDC, all remaining
waste gas resulted from mixture combustion is
discharged, marking the end of exhaust stroke.
That’s the whole working circle of the diesel
engine.

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2.1.2 Engine block assembly

Engine block assembly, mainly consisting of
engine block, cylinder head, cylinder head
cover, cylinder liner, main bearing cap and oil
sump, is the mounting of engine, on which the
crank & connecting rod mechanism, valve
train, and main parts of each engine system are
installed.
Characteristics of this engine block assembly
1. High gantry type block: the crankcase
sealing surface is lower than the crankshaft
bisecting surface, which improves the
Fig.2-5 Engine block assembly rigidity of the bottom half of the engine
1. Cylinder head cover 2. Cylinder gasket block.
3. Engine block 4. Cylinder head 2. Wet cylinder liner: direct contact of
5. Oil sump external surface of cylinder liner to coolant
results in good cooling effect.
3. Six independent cylinder heads: enabling
high rigidity and easy maintenance.

Engine block
The block, a casting connecting cylinder block
and crankcase, is usually forged by high
strength grey cast iron or aluminum alloy, and
its construction structure is related to cylinder
Inline V type Boxer type arrangement, cylinder structure and crankcase
Fig.2-6 Arrangement of cylinder structure (the cylinder arrangement types
include inline (applied for this engine), V-type
and boxer type).

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Cylinder head
Cylinder head is used to seal up the top of the
cylinder and integrated with the piston crown
and the cylinder wall to form a combustion
chamber. Besides, cylinder head, along with the
water/fuel passages in block and sump, is an
integral part of the cooling system and the
lubrication system respectively.

Fig.2-7 Cylinder head

Cylinder gasket
Cylinder gasket acts as a seal between the top
of engine block and the bottom of cylinder
head, which can ensure air tightness of cylinder
and avoid leakage of coolant/oil from the
engine block to the cylinder head.
Cylinder gasket is subjected to the pressure
Fig.2-8 Cylinder gasket produced from tightening of cylinder head bolt,
high temperature/pressure of gas combustion in
the cylinder, and corrosion of oil/coolant.
2.1.3 Engine performance
parameters
See Table 1 for engine performance parameters.
Table 2-1 Engine performance parameters
Item Parameter Item Parameter
Model WP6G125E202 Cylinder quantity 6
Inline, direct injection,
Type Cylinder bore/stroke (mm) 105 / 130
water-cooled, 4-stroke
Rated fuel consumption
Rated power (kW) 92 ≤220
(g/kW.h)
Rated speed (r/min) 2000 Max. torque (N.m) 540

Displacement (ml) 6750 Emission standard China II

Compression ratio 18:1 Idle speed (r/min) 750±30

Net weight (Kg) 750 Intake mode Turbocharged

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2.2 Crank & connecting rod

mechanism
Crank & connecting rod mechanism consists of
components of piston assembly, connecting rod
assembly, and crankshaft & flywheel assembly.
Function: Transform the reciprocating
Fig.2-9 Crank & connecting rod mechanism movement of piston into rotating movement of
crankshaft, and convert the force upon piston
into the torque to be output by crankshaft.
2.2.1 Crankshaft & flywheel
assembly
Crankshaft assembly
Crankshaft is used to convert the forces from
piston and connecting rod into torques, so as to
drive transmission system of vehicle, engine
Fig.2-10 Crankshaft assembly valve train, and other auxiliary devices.
1. Timing gear 2.Elastic cylindrical pin This engine is integrally forged by C38 blanks
3. Crankshaft under full support condition.
Flywheel assembly
The flywheel is a large disc-shape part with
great rotational inertia and functions as an
energy accumulator. The energy received by
crankshaft from engine in power stroke, except
for the purpose of external output, will be
absorbed by the flywheel, preventing the
rotational speed from rising too much. In
intake, exhaust and compression strokes, the
flywheel will release the energy stored to
Fig.2-11 Flywheel assembly compensate the power consumed therein,
1.Gear ring 2.Flywheel preventing the crankshaft rotational speed from
decreasing too much.

2.2.2 Piston & connecting rod

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assembly
Piston assembly
Piston is mainly used to bear the pressure from
gas combustion and then transfer it to the
connecting rod to drive the crankshaft.
There are three rings on the piston, i.e.
ladder-type ring as the first, cone-shape ring as
the second (with the side with "TOP" mark
upwards), and the fuel ring with coil-spring as
the third. During installation, those three rings
should be staggered with 120ºapart, and the
opening of the first ring should be at 30ºor
more to the piston pin edge.
Fig.2-12 Piston assembly Structure and materials of piston:
1.Double ladder ring 2.Cone-shape ring 1) The piston should not only have sufficient
3.Ladder steel fuel ring 4.Piston rigidity/strength together with minimum
5.Piston pin 6.Flexible retaining ring weight and suitable wall thickness, but also
be shaped properly. The piston skirt should
be properly shaped to obtain the best fit
clearance.
2) The piston should features small heating
area and good heat dissipation effect. The
piston in high-duty engine shall be cooled.
3) Piston shall be made of materials with
small thermal coefficient of expansion,
good heat-conducting property, small
specific gravity, good antifriction, and high
thermal intensity.

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Connecting rod assembly

Connecting rod is used to transfer the pressure
upon piston to crankshaft, and transform the
reciprocating movement of the piston into the
rotating movement of the crankshaft.
Saw tooth is so positioned that 45°oblique cuts
are marked in pairs.

Fig.2-13 Connecting rod assembly

1.Connecting rod 2.Connecting rod bush
3.Flexible cylindrical pin 4.Connecting rod cap
5.Connecting rod bolt
2.3 Valve train
All the four-stroke engines are provided with a
Valve
valve train consisting of valve assembly and
assembly
valve drive assembly.
Valve drive
Function: Open/close the intake/exhaust valves
assembly of each cylinder regularly as per the working
order and working circle of engine, so as to
allow fresh air into the cylinder and exhaust
waste gas out of it.

Components of valve train

Fig.2-14 Valve train

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2.4 Intake & exhaust system

2.4.1 Intake system
Intake system, consisting of air filter and intake
manifold, is used to supply as much pure air as
possible to each cylinder uniformly. After being
filtered in the air filter, the fresh air flows into
the turbocharger for pressurization and then
enters each cylinder via the intake manifold.
2.4.2 Exhaust system
The exhaust air flows into the exhaust manifold
via the exhaust valve and then passes through
the turbocharger into the muffler, where it will
be buffered and silenced in the muffler, and
finally the exhaust air will be discharged to the
Fig.2-15 Intake & exhaust system atmosphere via tail pipe.
1.Intake system 2.Exhaust system
3.Turbocharger
2.4.3 Turbocharger
Air When the diesel engine exhaust pipe is
exhaust
connected to the turbine housing of
turbocharger, the exhaust air of high
Air intake temperature and certain pressure discharged
from engine will flow to the nozzle ring via the
turbine housing. Due to progressive decrease of
passage area of the nozzle ring, the pressure
and temperature of exhaust air will decrease
Fig.2-16 Turbocharger
progressively, but its flow rate will increase
1.Turbine housing 2.Compressor housing
continuously. The high-speed exhaust air
3. Exhaust valve
impacts the turbine at a certain angle to drive it
to rotate at a high speed. The higher the exhaust
air pressure/temperature/ flow rate, the higher
the turbine rotating speed. Afterwards, the
exhaust air will flow out of the turbine and then
be discharged into the atmosphere.

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Considering that the turbine and the

compressor impeller are fixed on the same
rotor axis, they will rotate at the same speed to
suck the air filtered by the air filter into the
compressor housing. The high-speed rotating
compressor impeller throws the air to the outer
edge of impeller to increase its speed and
pressure, and forces it to flow into the diffuser,
which is designed with small inlet and large
outlet so that the air is pressurized and
decelerated herein. Following this, the air will
be further pressurized while passing through
the annular compressor housing with
progressively increasing section area, which
will finally flows into the cylinder via the air
intake pipe and mixes with the diesel for
combustion. That's how the turbocharger
performs air pressurization.
2.5 Fuel supply system
The fuel system of this diesel engine consists of
such major parts as injection pump, fuel
injector and regulator together with such
auxiliary devices as fuel tank, fuel delivery
pump, fuel filter/water separator, fuel filter and
fuel injection advancer.
Functions of diesel engine fuel system:
1) Inject a certain amount of clean
Fig.2-17 Fuel delivery system
turbocharged diesel into the combustion
1.Fuel tank 2.Prefilter fuel suction hose
chamber on a regular basis.
3.Fuel filter/water separator
2) Inject the diesel into each cylinder once in
4.Fuel fine filter 5.Injection pump
an order similar to the cylinder working
6.Inlet pipe of fuel delivery pump
order within one working cycle.
7.Fuel return pipe
3) Adjust the circulating fuel supply
automatically as per change of diesel

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 Service Manual of RS8140 Road Roller

engine load, so as to ensure the steady

operation of the diesel engine, especially
stabilization of idle speed and avoidance of
overspeed.
4) Store a certain amount of diesel to ensure
the max. range.

Schematic diagram of fuel system of diesel

engine with plunger injection pump
Fig.2-18 Schematic diagram of fuel supply
system
Air
heater
Air
heater 2.6 Cooling system
Pressure limiting

Cooling system is used to maintain the diesel

valve cap

Expansion
water tank

engine runs continuously at a suitable

Thermos
tat
Outlet pipe temperature, and the forced circulation cooling
Fan
Radiator

Cylinder head
is the best way to guarantee that the required
Oil cooler
compr
essor

Air

Water
pump
Diesel engine block
operation temperature is set up in the shortest
time. The cooling system of this diesel engine
Fig.2-19 Schematic diagram of cooling system
mainly consists of water pump, fan, expansion
tank, water tank and thermostat as shown.
The internal pressure in the cooling system
should be maintained at 50kPa so that the
steam pressure therein is higher than the
atmospheric pressure, which will improve
cooling efficiency of the cooling system and
avoid overheating to a large extent. Therefore,
various water tank caps in the cooling system
should be kept intact and closed all the time.

2.6.1 Thermostat
The thermostat is of built-in type with an open
temperature of 75±2°C. In case that the outlet
temperature of cooling water is lower than the
thermostat open temperature, the cooling water

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will flow into the water pump via the small

circulating water outlet of the thermostat to get
its temperature raised up to the value required
for normal operation of diesel engine. If the
outlet temperature of cooling water is higher
than the thermostat activation temperature, the
thermostat opens to the full, and part of or all
cooling water flows into the cooler for cooling
Fig.2-20 Schematic diagram of
and then enters the water pump.
thermostat structure
2.6.2 Radiator
The coolant flows inside the radiator core, but
the air flows around it so that the hot coolant
dissipates heat to the air for cooling, and the
cold air absorbs heat from the coolant for
heating. Thus, the radiator functions as a heat
exchanger.
2.6.3 Fan
The fan rotates continuously to absorb air and

Fig.2-21 Structural drawing of cooling system force it to pass through the radiator, helping to

1.Water radiator inlet pipe 2.Expansion tank enhance the heat dissipation capability of the

3. Radiator 4.Fan radiator and accelerate cooling speed of the

5. Radiator outlet pipe coolant.

The fan combined with silicone oil clutch is
commonly named as silicon oil fan. Due to the
application of the bimetallic temperature
sensing element, it operates under the control
of temperature and thus ensures a good energy
saving effect and more importantly the thermal
state of diesel engine, which obviously
improves the diesel engine performance and
prolongs its service life.
Special attention must be paid during operation
of silicon oil fan, i.e. the fan should not be
placed horizontally after removal; otherwise,

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the silicon oil will leak out of the fit clearance

of the sensor shaft, resulting in failure of the
fan.
2.7 Lubrication system
Lubrication system consists of strainer, oil
pump, oil cooler, oil filter, pressure limiting
valve, etc. It is used for antifriction, washing,
cooling and rust prevention. The oil should be
selected according to the related company
standards. The multigrade oil is better for cold
startup and should be preferred consequently.
The circulating route of the lubrication system
is as shown on the left.
Fig.2-22 Lubricating system
The oil pump applied is classified as gear
pump. The oil is pumped out by the oil pump
and enters filter seat, and if the oil pressure is
above 540-750kpa, i.e. the opening pressure set
for the safety valve installed on the filter seat,
the valve will open, allowing the oil to flow
into the oil sump.
Oil cooler and filter are connected to the filter
seat in parallel. Oil from the filter seat flows to
the oil cooler and the oil filter in sequence,
back to the filter seat again, and to the main oil
passage finally. Oil cooler is of plate-pin type.
Oil filter is of spin-on type and can be used for
one time only. In the lubrication system,
pressure lubrication is provided for main
bearing, connecting rod bearing, cam bearing,
rocker arm bearing, intermediate gear bearing,
injection pump, turbocharger and air
compressor; however, splashing lubrication is
applied for connecting rod small end, gear
train, piston and cylinder liner.

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2.8 Removal & refitting of engine system

2.8.1 Removal of engine
In case of replacement or overhaul of the engine, the following steps may be followed to remove the
engine as a whole.

1. Preparation
2. Drain out coolant

3. Drain out oil

4. Engine hood
5. Multifunctional bracket

6. Cab

7. Vibration pump pipeline Water temperature sensor wire harness

8. Steering pump pipeline A/C compressor wire harness

9. Radiator Starting system wire harness

10. Engine wire harness Alternator wire harness

11. A/C compressor Enrichment electromagnet wire harness

12.Oil-water separator and pipeline Fuel cut-off electromagnet wire harness

Engine
13. Heater water outlet pipe Oil pressure sensor wire harness

14. Heater water inlet pipe

15. Fuel pipe

16. Accelerator cable

17. Drive shaft

18. Clutch booster pump pipeline

19. Shift flexible shaft

20. Reverse gear/neutral gear switch

21. Shock absorber bolt

22. Lift down engine & transmission

23. Switch off engine & transmission Mufller

24. Accessories Air filter

Fuel filter/water separator

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 Service Manual of RS8140 Road Roller

1. Drive the complete road roller to the

maintenance location, turn the electric lock
key counterclockwise to shut down the
engine, and then park it properly.
CAUTION: The following
operations should be done only after the
road roller is cooled down. During
Fig.2-23 removal, all pipe joints should be
1.Road roller wrapped properly to avoid intrusion of
foreign matters.

2. Open the radiator drain valve and then

drain out the coolant to a clean container.
Antifreeze

Fig.2-24
1.Drain valve
3. Open the drain plug of engine oil sump
and drain out the engine oil to a clean
container, and then disconnect the hose
from the engine.
Oil

Fig.2-25
1.Hose 2.Drain plug

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4. Remove engine hood.

See Fig.8-25 for removal of engine hood.

Fig.2-26
1. Engine hood
5. Remove the multifunctional bracket.
See Fig.8-28 for removal of the
multifunctional bracket.

Fig.2-27
1.Multifunctional bracket
6. Remove the cab.
See Fig.8-14 for removal of the cab.

Fig.2-28
1.Cab

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7. Disconnect the pipes from the vibration

pump.
See Fig.9-5 for removal of vibration pump.

Fig.2-29
1.Vibration pump inlet pipe
2.Vibration pump
3.Vibration pump outlet pipe
8. Disconnect the pipes from the steering
pump.
See Fig.6-23 for removal of steering
pump.

Fig.2-30
1.Steering pump outlet pipe
2.Steering pump
3.Steering pump inlet pipe
9. Remove the radiator.
See Fig.2-32 for removal of the radiator.

Fig.2-31
1.Radiator

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10. Disconnect the wire harness of engine and

rear framework.
1) Disconnect the wire harness of water
temperature sensor.
2) Disconnect the wire harness connector
of A/C compressor.
3) Disconnect the wire harness of
starting system.

Fig.2-32
Layout of engine electrical components

4) Disconnect the wire harness of engine.

5) Disconnect the enrichment
electromagnet wire harness connector.
6) Disconnect the wire harness of fuel
4. Alternator cut-off electromagnet.
7) Disconnect the wire harness connector
of oil pressure sensor.

7. Oil pressure sensor 5. Enrichment

wire harness 6. Fuel cut-off electromagnet electromagnet

Fig.2-33
Layout of engine electrical components
11. Detach the A/C compressor from the
engine.

Fig.2-34 1.A/C compressor

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12. Disconnect hoses from the oil-water

separator, screw off the nut, and then
remove the oil-water separator.

Fig.2-35
1.Hose 2.Nut
3 Oil-water separator
13. Disconnect the heater water outlet pipe
from the water valve.

Fig.2-36
1.Heater water valve
2.Heater water outlet pipe
14. Disconnect the heater water inlet pipe from
its water valve and remove the pipe clamps
used for fixing the water pipe.

Fig.2-37
1.Heater water valve
2.Heater water inlet pipe

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15. Disconnect the fuel suction hose of fuel

transfer delivery from the engine.
Remove the connection of the fuel return
pipe from the engine.

Fig.2-38
1.Fuel suction hose of fuel delivery pump
2. Fuel return pipe

16. Disconnect the accelerator cable from the

engine.

Fig.2-39
1.Accelerator cable
17. Disconnect the drive shaft from the
transmission.

Fig.2-40
1.Transmission 2.Drive shaft

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18. Disconnect the clutch master cylinder hose

from the clutch booster pump.
Disconnect the booster air tube from the
clutch booster pump.

Fig.2-41
1.Clutch master cylinder hose
2.Clutch booster pump
3.Booster air tube
19. Disconnect the gearshift flexible shaft (red
and black) from the transmission.

Fig.2-42
1. Flexible shaft (red)
2. Flexible shaft (black)
20. Disconnect the connectors of the reverse
gear switching wire and the neutral gear
switching wire.

Fig.2-43
1.Neutral gear switching wire connector
2.Reverse gear switching wire connector

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21. Remove the shock absorber fixing bolt.

Fig.2-44
1. Shock absorber fixing bolt

22. Lift down the engine and the transmission.

Fig.2-45
1.Engine 2.Transmission
23. Detach the transmission from the engine.
See Fig.4-14 for removal of the
transmission.

Fig.2-46
1.Engine 2.Transmission

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24. Remove other accessories of the engine.

1) Remove the muffler:
Remove the muffler fixing nut;
Remove the exhaust steel pipe fixing
nut;

Fig.2-47
1.Muffler fixing nut
2. Exhaust steel pipe fixing nut
2) Remove the air filter:
Loosen the clamp of the intake hose;
Screw off the air filter fixing bolt.

Fig.2-48
1.Air filter 2.Nut
3. Hose clamp
3) Screw off fuel filter/water separator
fixing bolt and disconnect the fuel
pipe, and then remove the fuel
filter/water separator.

Fig.2-49
1.Prefilter fuel suction hose
2.Fuel filter/water separator
3.Bolt
4.Fuel suction hose of fuel delivery pump

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2.8.2 Refitting of engine

See the following steps for refitting of the engine.

Muffler

Air filter 1. Accessories

Fuel filter/water separator 2. Connect engine and transmission

3. Hoist engine & transmission

4. Shock absorber bolt

5. Radiator
Water temperature sensor wire harness 6. Engine wire harness
A/C compressor wire harness 7. Fuel pipe
Starting system wire harness 8. Accelerator cable
Alternator wire harness 9. Heater water inlet pipe
Concentrated electromagnet wire harness 10. Heater water outlet pipe
Fuel cut-off electromagnet wire harness 11. A/C compressor Engine
Oil pressure sensor wire harness 12.Oil-water separator and pipeline

13. Gearshift flexible shaft

14. Clutch booster pump pipeline

15. Drive shaft

16. Reverse gear/neutral gear switch

17. Steering pump pipeline

18. Vibration pump pipeline

19. Multifunctional support

20. Engine hood

21. Cab

22. Add oil

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1. Install the engine accessories.

1) Install the muffler:
Tighten the muffler fixing nut;
Tighten the exhaust steel pipe fixing
nut;

Fig.2-50
1. Muffler fixing bolt
2. Exhaust steel pipe fixing nut

2) Install the air filter:

Tighten the intake hose clamp;
Tighten the air filter fixing nut.

Fig.2-51
1.Nut 2. Hose clamp
3) Install the fuel filter/water separator.

Fig.2-52
1.Prefilter fuel suction hose
2.Fuel filter/water separator
3.Bolt
4.Fuel suction hose of fuel delivery pump

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2. Connect the engine and the transmission.

AT262 thread-lock agent
45±5Nm

Fig.2-53
1.Engine 2.Transmission
3. Hoist the engine & transmission onto the
rear framework.

Fig.2-54
1.Transmission 2.Engine
4. Install and tighten the shock absorber
fixing bolt of engine and transmission.
140~220Nm

Fig.2-55
1.Shock absorber fixing bolt

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5. Install the radiator.

See Fig.2-35 for refitting of the radiator.

Fig.2-56
1.Radiator
6. Connect the wire harness of engine.
1) Connect the wire harness of the water
temperature sensor.

1. Water 2) Connect the wire harness connector of

temperature
sensor A/C compressor.

3) Connect the wire harness of starting

system.
2. A/C
compressor
3. Starting system
Fig.2-57 engine electrical components
4) Connect the wire harness of
alternator.

5) Connect the wire harness connector of

enrichment electromagnet.

4. Alternator

6) Connect the wire harness of the fuel

cut-off electromagnet.

7. Oil pressure sensor 5. Enrichment

wire harness 6. Fuel cut-off electromagnet electromagnet
7) Connect the wire harness connector of
Fig.2-58 engine electrical components oil pressure sensor.

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7. Connect the fuel suction hose of fuel

delivery pump to the engine.
45~65Nm

Connect the fuel return pipe to the engine.

45~65Nm

Fig.2-59
1.Fuel suction hose of fuel delivery pump
2.Fuel return pipe
8. Connect the accelerator cable to the
engine.

1.Accelerator cable
Fig.2-60
9. Connect the heater water inlet pipe to the
water valve.
CAUTION:
The heater hose should be cleared
before connected to the water valve.

Fig.2-61
1.Heater water valve
2.Heater water inlet pipe

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10. Connect heater water outlet pipe to the

water valve.

Fig.2-62
1.Heater water valve
2.Heater water outlet pipe
11. Attach the A/C compressor to the engine.

Fig.2-63
1. A/C compressor
12. Install the oil-water separator and connect
the hose.

Fig.2-64
1.Hose 2.Nut

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13. Connect the flexible shaft to the

transmission.

Fig.2-65
1. Flexible shaft (red)
2. Flexible shaft (black)
14. Connect the clutch master cylinder hose to
the clutch booster pump.
Connect the booster air tube to the clutch
booster pump.

Fig.2-66
1.Clutch master cylinder hose
2.Clutch booster pump
3.Booster air tube
15. Connect the drive shaft to the transmission.
180~210Nm

Fig.2-67
1.Transmission 2.Drive shaft

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16. Connect the connectors of the reverse gear

switching wire and the neutral gear
switching wire.

Fig.2-68
1.Neutral gear switching wire connector
2.Reverse gear switching wire connector
17. Connect the pipes of steering pump.
See Fig.6-24 for refitting of the steering
pump.

Fig.2-69
1.Steering pump outlet pipe
2.Water inlet pipe 3.Steering pump inlet pipe
18. Connect the oil pipes to the vibration
pump.
See Fig.9-6 for refitting of the vibration
pump.

Fig.2-70
1.Vibration pump
2.Vibration pump inlet pipe
3.Vibration pump outlet pipe

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19. Install the multifunctional bracket.

See Fig.8-31 for refitting of
multifunctional bracket.

Fig.2-71
1.Multifunctional bracket
20. Install the engine hood
See Fig.8-27 for refitting of the engine
hood.

Fig.2-72
1.Engine hood
21. Install the cab.
See Fig.8-18 for refitting of the cab.

Fig.2-73
1.Cab

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22. Connect the oil hose and then inject the oil.
16L
CAUTION: Always keep away
from open flame during oil injection!
CAUTION: Open the engine hood
and then inject the required oil into the
engine via the engine filler. Run the
engine at idle speed and check the oil
filter and drain plug for any leakage.
Fig.2-74 Shut down the engine and wait for about
1. Filler 2.Hose 15min to allow as much oil as possible
flow back to the oil sump, and then
check the engine oil level again.

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2.8.3 Removal & refitting of

radiator
CAUTION: The fuel pipe joins should
be properly protected.
Removal of the radiator
1. Start the complete road roller, drive it to a
flat broad road, pull out the parking brake
Fig.2-75 handle, and then park it properly.
1.Complete road roller CAUTION: Remove it after cooling of
the road roller.
2. Removal of the engine hood.
See Fig.8-25 for removal of engine hood.

Fig.2-76
1.Engine hood
3. Remove the rear bottom closure.

Fig.2-77
1.Rear bottom closure 2.Bolt

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4. Screw off the radiator drain valve and drain

out all coolants to a clean container.
Antifreeze

Fig.2-78
1.Drain valve
5. Disconnect the connection between the
steel pipe and the outlet pipe of radiator.

Fig.2-79
1. Radiator steel pipe
2. Radiator outlet pipe
6. Disconnect the radiator inlet pipe from the
radiator.

Fig.2-80
1. Radiator inlet pipe

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7. Disconnect the water outlet pipe from the

radiator.

Fig.2-81
1.Radiator water outlet pipe
8. Disconnect the water inlet pipe and the
engine breather pipe from the radiator.

Fig.2-82
1.Engine breather pipe
2.Radiator water inlet pipe
9. Screw off the condenser fixing bolt and
remove the condenser.

Fig.2-83
1.Bolt

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10. Screw off the bolts of the radiator wind

deflector and remove the radiator wind
deflector.

Fig.2-84
1.Wind deflector 2.Bolt
11. Screw off the radiator fixing bolt, remove
the support, and then lift down the radiator.
CAUTION: The radiator should
be lifted up slowly to avoid fracture
of the fan.

Fig.2-85
1.Support 2.Bolt
Refitting of radiator
1. Lift up the radiator onto the rear
framework, fasten the radiator, and then
pre-tighten the support (Bolt 2 as shown is
to be tightened after step 6).

Fig.2-86
1.Support 2.Bolt

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2. Install wind deflector.

Fig.2-87
1.Bolt 2.Wind deflector
3. Connect the water outlet pipe to the
radiator.

Fig.2-88
1.Radiator water outlet pipe
4. Connect the water inlet pipe and the engine
breather pipe to the radiator.

Fig.2-89
1.Radiator water inlet pipe
2.Engine breather pipe

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5. Connect the radiator steel pipe with the

radiator outlet pipe.
85±10Nm

Fig.2-90
1. Radiator steel pipe
2. Radiator outlet pipe
6. Connect the radiator inlet pipe to the
radiator.
85±10Nm

Fig.2-91
Radiator inlet pipe
7. Attach the condenser to the radiator.

Fig.2-92
1.Bolt

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8. Install the rear bottom closure.

Fig.2-93
1.Rear bottom closure 2.Bolt
9. Install the engine hood.
See Fig.8-27 for refitting of the engine
hood.

Fig.2-94
1.Engine hood
10. Fill the radiator with antifreeze.
28L
CAUTION: Fill the radiator with
antifreeze fluid into the radiator via the
expansion tank, and then start the road
roller. After a while, replenish the
radiator with glycol type antifreeze until
the specified level is reached.
Fig.2-95
1. Water filler

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2.8.4 Removal and refitting of fuel

tank
CAUTION: During removal, all
removed pipe joints should be protected
properly to avoid intrusion of foreign
matters.
Removal of fuel tank
Fig.2-96
1. Start the complete road roller, drive it to a
1.Complete road roller
flat broad ground, pull up the parking brake
handle, and then park it properly.
2. Loosen the screw plug at the bottom of the
fuel tank and then drain out the fuel to a
clean container, and then cover the
container properly to avoid intrusion of
foreign matters.
CAUTION: Considering that the fuel
is highly combustible, any open flame is

Fig.2-97 strictly prohibited, the maintenance

1.Drain plug should be done at a position far away

from fire source, and such flame as
spark produced by collision shall be
avoided.
3. Disconnect the fuel sensor connector.

Fig.2-98
1.Fuel sensor connector

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4. Disconnect the prefilter fuel suction hose

from the fuel tank.

Fig.2-99
1.Prefilter fuel suction hose
5. Disconnect the fuel return pipe from the
fuel tank.

Fig.2-100
1. Fuel return pipe
6. Remove the fuel tank fixing bolt as shown.

Fig.2-101
1.Bolt 2.Bolt

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7. Lift down the fuel tank.

Fig.2-102
1.Fuel tank
Refitting of fuel tank
1. Lift the fuel tank onto the framework in
place.

Fig.2-103
1.Fuel tank
2. Tighten the bolts as shown.

Fig.2-104
1.Bolt 2.Bolt

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3. Connect the prefilter fuel suction hose to

the fuel tank.
55±10Nm

Fig.2-105
1.Prefilter fuel suction hose
4. Connect the fuel return pipe to the fuel
tank.
55±10Nm

Fig.2-106
1. Fuel return pipe
5. Connect the fuel sensor connector.

Fig.2-107
1.Fuel sensor connector

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6. Inject the fuel.

270L
CAUTION: Always keep far away
and eliminate fire sources.

Fig.2-108
1.Fuel filler

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2.9 Diagnosis and troubleshooting of engine system common problems

WP6 series diesel engines are designed and manufactured as per the strict quality assurance system,
and have went through all tests required. As a kind of precision machine, proper repair and
maintenance is highly related to a durable performance of the diesel engine. The following
conditions usually result in earlier failure of the diesel engine:
◆ Breach of related instructions and improper management and application;
◆ Repair and maintenance not in line with related instructions, especially maintenance
substituted for repair;
◆ Unqualified parts, especially fake parts for minimum cost, which shorten the service life of the
diesel engine to a large extent;
◆ Fuel or lubricating oil of poor quality or improper grade.
Troubleshooting methods that are commonly applied for the diesel engine are as follows:
◆ Observation: Observe the emitted smoke or other phenomenon to determine the failure.
◆ Auscultation: Listen the unusual noises of the diesel engine to determine the location, nature
and severity of the failure.
◆ Cylinder deactivation: Disenable one cylinder to determine if it involves any fault, which is
always performed when one cylinder is suspected to be faulty by cutting off its fuel supply and
then checking the state change of the engine before and after the deactivation to narrow down
the faulty range and causes.
◆ Comparison: Replace some assemblies or parts to confirm whether any fault occurs to them.
2.9.1 Engine start failure
The starter does not work.
◆ Check if the neutral position is engaged.
Before startup, check if the gearshift lever is in neutral.
◆ Check if the battery voltage is too low to start the starter.
The battery voltage is usually 24V. If lower than this value, the battery cannot start the starter.
If so, the multimeter may be applied and set in voltage range to check the voltage, or a scan
tool may be used to read the actual "battery voltage".
◆ Check if the starter relay and wiring are intact.
Check if there is too much oxide on the surface of wiring terminal and if the bolt on the
surface of wiring terminal loosens or fractures.
◆ Check if the starter is burned out.
Use a multimeter to check if the starter relay works normally.
◆ Check if the ignition switch or starting switch is damaged.

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Turn the ignition key to ON and then check if the instrument panel indicator lights up.
Turn the ignition key to START and then check if the starter acts (provided that all other
reasons have been excluded).
Starter can work normally, but cannot be started.
◆ Check if the fuel level of the fuel tank is too low.
Please pay special attention because it's apt to be neglected.
◆ Check if the hand fuel pump works normally.
Actuate the hand fuel pump manually to check if it works normally.
◆ Check if there is air in the low pressure pipe; if so, discharge the air (a more careful check
should be made since the leakage of the low pressure pipe is not obvious enough sometimes)
Discharging method: The discharging focus on the coarse filter, and is done as follows: screw
off the bleed bolt on the coarse filter and actuate the hand pump on the coarse filter manually
until fuel flows out of the bleed bolt continuously.
◆ In case that the diesel engine still cannot be started even after the air in the low pressure fuel
pipeline has been discharged, it can be judged that there is air in the high pressure pipe, which
should be discharged as well.
Discharging method: Loosen the high pressure pipes of some cylinder and activate the starter
to drive the diesel engine until the fuel flows out of the high pressure pipe continuously. (It's
not recommended to remove the high pressure pipe joints frequently!)
◆ Check if any leakage occurs to the high pressure pipe.
The high pressure pipe always involves leakage. If this situation occurs, please check if any
nuts of the high pressure pipe joint become loose and tighten them when necessary.
◆ Check if the fuel pipe and the fuel filter are blocked. It's recommended to replace the fuel filter
element in time when necessary.
Inspection Methods: Loosen the fine filter outlet bolt and activate the starter to drive the diesel
engine. Then, check if any diesel spurts or flows out. If the diesel flow is small, it can be
judged that the filter element is blocked and should be replaced then.
Wire harness connectors of fuel injector, sensors, and others are connected improperly,
opened or shorted
◆ Check the installation of connectors and use a multimeter ("wire inspection instrument" is
preferred) to check connection of the line as per pointer definition of the wiring diagram.
2.9.2 Difficult engine start
◆ Diesel engine has been withdrawn out of service for quite a long time: Extend the fuel return
pipe below the fuel level.

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◆ There is air in the low pressure pipe: Discharge air.

◆ Ambient temperature is too low and the preheating device fails. Check if the heater flange is
properly connected or replace the preheating device.
◆ Diesel and oil are totally unqualified: Replace them with qualified ones.
◆ Starter or flywheel gear ring involves teeth collision: Replace the starter and the flywheel gear
ring.
◆ Piston ring & cylinder liner are worn or valve is not sealed up: Replace the piston ring and the
cylinder liner, or the valve seat and valve.
2.9.3 Engine underpower
Fuel injector fails.
Fuel injector failure is usually classified into mechanical failure and wiring failure.
◆ Mechanical failure: Needle valve gets stuck in the fuel injector because of excessive foreign
matters in the diesel or valve corrosion resulted from water intrusion, and cannot move any
longer.
◆ Wiring failure: Wire harnesses are disconnected or directly grounded to the cylinder head to
cause short to ground due to vibration, wear, etc.
Water/oil temperature is too high.
◆ Causes and troubleshooting of high water temperature
① Water level is too low in the water tank: Check if any leakage occurs, and add water when
necessary;
② Fan rotates too slowly or even remains still: Check driving components of the fan:
③ Water tank is blocked: Check the water tank and then clean or repair it.
④ Water pump belt loosens: Adjust the tension force as required;
⑤ Water pump gasket is damaged and its impeller is worn: Check, and repair or replace.
⑥ Thermostat fails: Replace;
⑦ Water pipe seals are damaged and air leaks in: Check water pipes, joints, gaskets, etc. and
replace the damaged ones.
◆ Causes and troubleshooting of high oil temperature
① Low oil level or oil shortage in the sump: Check the oil level and leaking locations, and then
do repair and add oil;
② High water temperature: Find out causes of high water temperature and resolve.
③ Oil cooler blocked: Check and clean it.
2.9.4 Rough idling of engine
◆ Causes and troubleshooting of rough idling of engine:

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① Fuel injector fails to work normally: Check the fuel injector and the wire harnesses of each
cylinder;
② There is speed signal input during parking for the complete road roller equipped with speed
sensor: Check the signal and wiring of the speedometer and the speed sensor;
③ Fuel contains much water or waxes: Clean the fuel system and replace the fuel filter;
④ Air leaks into the low pressure fuel pipe: Check the tightness of fuel pipe and joint, and
discharge all the air;
⑤ Fuel nozzle atomization is destabilized: Check and repair.
2.9.5 Abnormal air emission (black/white/blue smoke)
Diesel engine emits blue smoke
◆ Lubricating oil level in the engine sump is too high.
Discharge excessive lubricating oil to allow the level within the required scale range of the oil
dipstick.
◆ Fuel injector needle valve is not closed tightly or burned out at the opening position, resulting
in diesel entering the oil sump.
Clean and calibrate fuel injector or replace needle valve coupling.
◆ Valve oil seal is damaged or the clearance between the valve and the guide pipe exceeds the
limit, resulting in fuel suction into combustion chamber during air intake.
Replace the faulty valve, guide pipe and oil seal (oil seals must be replaced in case of
disassembly, and the guide pipe may not be replaced if the clearance meets requirements after
replacement of valves)
◆ Turbocharger sealing ring is damaged, so that the lubricating oil enters the combustion room
along the intake passage and is combusted.
Repair or replace.
Diesel engine emits white smoke
◆ Fuel system contains water.
Clean the fuel tank and the filter, and use the qualified diesel.
◆ Cylinder valve is worn.
Replace the worn parts.
◆ The fuel nozzle involves poor atomization so that the diesel mist drop fails to be combusted in
the combustion chamber.
Calibrate the fuel injector and the fuel supply advance angle.
Diesel engine emits black smoke
◆ Exhaust back pressure is too high or the exhaust pipeline is blocked.

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Diminish the exhaust pipe bend and remove dust on the muffler.
◆ Fuel spraying is delayed.
Adjust the advance angle of fuel injection.
◆ Fuel injector works poorly or is damaged.
Remove the fuel injector for cleaning and checkup.
◆ Diesel is of poor quality or improper grade.
Replace the diesel.
◆ Cylinder liner and piston assemblies are worn seriously.
Replace the worn parts.
2.9.6 High/low lubricating oil pressure
Oil pressure is too high
◆ Oil pressure indicator fails.
Replace the indicator.
◆ Oil viscosity is too high.
Select the oil of required grade and preheat the engine in case of startup in winter.
◆ The clearance is too small at the pressure lubricated location or the oil fine filter is blocked.
Adjust the clearance at the lubricated location and clean or replace the oil filter.
◆ Pressure limiting valve is not adjusted properly.
Readjust the elasticity of the pressure limiting valve spring to allow oil pressure to fall down to
the required value.
Oil pressure is too low
◆ Oil pump is worn or the gasket is damaged.
Repair the oil pump and replace the gasket.
◆ Oil sucked into the oil pump is too small.
Check oil level, add oil, and clean oil pump strainer.
◆ Oil leakage is serious.
Check if lubrication pipe cracks, and check and adjust the fit clearance of bearings at the
crankshaft, camshaft or others as required.
◆ Oil filter or cooler is blocked.
Check and clean oil filter and cooler.
◆ Oil viscosity is too low.
Select the oil of proper grade as required.
◆ Pressure limiting valve is not adjusted properly.
Clean the pressure limiting valve, and adjust or replace the spring.

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◆ The oil pressure reading is too low.

Check and replace the oil pressure sensor and oil pressure gauge.
2.9.7 High lubricating oil consumption
◆ Oil viscosity is not proper.
Select the proper lubricating oil.
◆ The negative pressure in the combustion chamber is too high so that the oil leaks into the
combustion chamber.
Find out the causes of high negative pressure and adjust accordingly.
2.9.8 High coolant temperature
◆ Coolant is not selected properly or water is insufficient.
Select and add the proper coolant until it rises up to the required level.
◆ Water radiator is blocked.
Use a thin steel sheet to push the radiating fin back to the original place carefully and restore it
straight and flat, and then clean it with compressed air or water gun.
◆ Water temperature gauge or warning lamp makes wrong indication.
Use a surface thermometer to measure the temperature at the water temperature sensor, and
then observe if the water temperature gauge indication is in line with the actual temperature.
◆ Fan rotates too slowly, and the blade deforms or is installed reversely.
The fan belt, if loose enough, may slip, resulting in low speed of the fan and poor air supply
effect. If this situation occurs, adjust the fan belt tightness accordingly; if the rubber layer is
aged and damaged, or the fibrous layer fractures, replace. If the fan blade deforms, replace.
◆ Cooling water pump fails.
Replace the water pump.
◆ Thermostat fails.
Replace the thermostat.
◆ Cylinder gasket is damaged.
Replace the cylinder gasket.
◆ Diesel engine runs at an overload.
Reduce the engine load.

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