当前位置:首页 >> 机械/仪表 >>

潍柴动力欧三发动机案例Weichai Power Euro III Engine Trouble Case


蓝擎欧Ⅲ高压共轨柴油机
Landking Guo III High Pressure Common Rail Diesel Engines

故障诊断与案例分析
Failure Diagnosis and Case Analysis

潍柴动力股份有限公司
Weichai Power Holding Co.Lt

d.

目 录 Content
一、概 述
Introduction

二、故障诊断与案例分析
Failure Diagnosis and Case Analysis g y

三、常见零部件故障分析
Failure Analysis of Common Parts

第 2页 共 页

一、概 一 概 述 Introduction

1.1高压共轨系统概述
Introduction of High Pressure Common Rail System g y
潍柴动力蓝擎欧Ⅲ柴油机 Weichai Power Landking Guo III Diesel Engines 率先采用先进的德国BOSCH(博世)电控高压共轨系统。 Initiatively applying advanced Germany HOSCH electronically controlled high pressure common rail system BOSCH高压共轨系统具有可靠性高、经济省油、安全舒适、 高智能化的特点 BOSCH high pressure common rail system has features of high reliability, economy reliability economy, safety, comfort and highly intelligentizing. 可以满足国Ⅳ、国Ⅴ排放标准的要求 Can meet the requirement of Guo Ⅳ、 Ⅴ emission standard 蓝擎欧Ⅲ系列柴油机按照欧洲研发流程开发,采用国际先进的铸造、加工、装配设备和工艺, 配套零部件采取全球供应链采购模式,经过了充分的产品验证才推向市场,保证了产品的优秀 品质。 Landking Guo III series diesel engines are developed in accordance with Europe R&D process, adopting internationally advanced casting, machining, assembling equipment and process. Fittings purchasing adopts global supply chain mode. The engines fully verified are put i t the market, which ensure the excellent quality. ifi d t into th k t hi h th ll t lit 10万台潍柴动力蓝擎欧Ⅲ柴油机市场保有量深得用户好评, 100,000 market share of Weichai Power Landking Guo III diesel engines enjoys high popularity among customers customers.
第 4页 共 页

1.1高压共轨系统概述
Introduction of High Pressure Common Rail System

BOSCH电控高压共轨系统原理图

1.1高压共轨系统概述
Introduction of High Pressure Common Rail System

共 轨 管 CR+ 喷 油器injector

高压油泵 High pressure fuel pump

ECU
蓝擎欧Ⅲ电控高压共轨系统实物图 Landking Guo III Electronically Controlled High Pressure Common Rail Picture

1.1高压共轨系统概述
Introduction of High Pressure Common Rail System g y
潍柴动力蓝擎欧Ⅲ柴油机Weichai Power Landking Guo III diesel engines: 可靠性更高——比机械泵柴油机的故障率低63% Much higher reliability--- Failure rate is 63% less than that of mechanical pump engine 经济性更好——同等情况下比国Ⅱ机械泵车辆百公里油耗低5-10% p p Much more economical--- Fuel consumption per 100 km is less 5-10% than that of mechanical pump vehicle at the same condition 保养成本更低——与机械泵柴油机相比,按每年行驶18万公里计算,10L 机低 1650元/年、 12L机低828元/年 Much lower maintenance cost--- 10 L engine is less 1650 RMB/Year than mechanical pump engine, and 12 L engine is less 828 RMB/Year (calculating by 180,000 km/Year) 油品适应性更强——与机械泵柴油机相比,对杂质、水的过滤能力更强,对油品无特 殊要求, 且燃油系统三包期更长 Much better suitability of oil – Compared with mechanical pump engines, it has more powerful ability to filter impurity and water. There’s no special requirement about oil brand. brand The period of “Three Guarantees” for fuel system is much longer. Three Guarantees longer

第 7页 共 页

1.1高压共轨系统概述
Introduction of High Pressure Common Rail System g y
第一:振动小、噪声低-----可靠性更高 1. Low vibration and noise----much higher reliability

机型 model

噪声(分贝) noise (db)

振动 vibration

对比WD615提速性 能 Speed-up performance compared with WD615

驾驶400公里 疲劳程度 400km-driving fatigue

WD615 WP10 WP12

115 97 96 提高10% Improving by 10% 提高35% Improving by 35%
第 8页 共 页

100% 63% 50%

1.1高压共轨系统概述
Introduction of High Pressure Common Rail System g y
共轨管 common rail pipe 高压油泵 High pressure fuel pump 手压输油泵 Hand transfer pump 滤清器 Fuel filter

ECU

1.1高压共轨系统概述
Introduction of High Pressure Common Rail System
第二:油耗低 2. Low fuel consumption 潍柴动力充分利用电控高压共轨系统的控制功能,开发了 系列节油新技术,推出了省油专属 潍柴动力充分利用电控高压共轨系统的控制功能 开发了一系列节油新技术 推出了省油专属 技术产品: Weichai makes good use of the control function of electronically controlled high pressure common rail system to develop a series of new fuel-saving technology, and push out exclusive f l l i fuel-saving t h l i technology products: d t WP多功率省油开关 WP multi-power fuel-saving switch 省油1 + 1(省油恒温扇+省油断缸技术) fuel-saving 1+1 (fuel-saving constant temperature fan + fuel-saving fuel-cut technology) 个性化动力 personalization power 卡车超级动力、卡车标准动力、搅拌车专用动力、起重机专用动力、客运专用动力、公交专用动力等 Super truck power, standard truck power, dedicated mixer lorry power, dedicated crane power, dedicated bus power, dedicated city bus power, etc.

1.1高压共轨系统概述
Introduction of High Pressure Common Rail System
第三、保养成本更低 3. Much lower maintenance cost 国Ⅱ柴油机保养周期为1万公里,而蓝擎欧Ⅲ柴油机保养周期3万公里

Maintenance interval of Guo II diesel engines is 10,000km, while that of Landking Guo III diesel engines is 30 000km 30.000km.

WP10 对比 WD615 WP10 VS WD615 WD615: VS.
以常用标准载重公路运输车为例,按一年运行18万公里计算,WP10较WD615可节省保养费用1650元。

Take the common standard load highway transportation vehicle as an example, WP10 can save 1650RMB maintenance expenses compared with WD615 (calculating by 180,000 km/year)

1.1高压共轨系统概述
Introduction of High Pressure Common Rail System
保养项目(套/台) Maintenance item (set/unit) 柴油粗滤芯fuel coarse filter core+精滤芯fine filter core+除水放心滤滤芯 trustworthy dewater filter core (个piece) 机油滤芯 oil filter core(个piece) 机油oil(L) 万公 保养费用 3万公里保养费用maintenance expenses of 30,000km (元RMB) 年保养费用合计total 一年保养费用合计total maintenance expenses for one year(元RMB) 定 额 quota WP10 WD615 备 注 note

3

334

26

2 24

40 534 908+80 =988

40 355 421×3 =1263

5928

7578

(1)WP10保养周期为3万 公里,但每1万公里需 换一次机油滤芯 The maintenance interval of WP10 is 30000km, but oil filter core should be replaced once every 10000km (2)WD615保养周期为1 万公里; The maintenance interval of WD615 is 10000km (3)WP10采用蓝擎欧 ⅢCH 4专用机油。 ⅢCH-4专用机油。 WP10 applies Landking Guo III CH-4 special oil

1.1高压共轨系统概述
Introduction of High Pressure Common Rail System
第三、保养成本更低

3. Much lower maintenance cost
以常用标准载重公路运输车为例,按一年运行18万公里计算,WP12较 WD12可节省828元。 Take the common standard load highway transportation vehicle as an example, WP12 can save 828RMB maintenance expenses compared with WD12 (calculating by 180,000 km/year)

1.1高压共轨系统概述
Introduction of High Pressure Common Rail System
WP12 对比 WD12 WP12 VS.WD12
保养项目(套/台) Maintenance item (set/unit) 柴油粗滤芯fuel coarse filter core+精滤芯fine filt +精滤芯fi filter core+除水放心滤滤芯 trustworthy dewater filter core (个piece) 个p 机油滤芯 oil filter core (个piece) 机油oil(L) 3万公里保养费用 maintenance expenses of 30,000km(元RMB) 一年保养费用合计total maintenance expenses for i f one year(元RMB) 定额 quota 3 WP12 334 WD12 26 备注 note (1)WP12保养周期为3万 公里,但每1万公里需 公里 但每1万公里需 换一次机油滤芯; The maintenance interval of , WP12is 30000km, but oil filter core should be replaced once every 10000km (2)WD12保养周期为1万 公里; The maintenance interval of WD12 is 10000km (3)WP12采用蓝擎欧Ⅲ CH-4专用机油。 WP12 applies Landking Guo III CH 4 special oil CH-4 i l il

2

82

40

36

770 1186+164 =1350 1350 8100

430 496×3 =1488 8928

1.1高压共轨系统概述
Introduction of High Pressure Common Rail System
第四、油品适应性更强 4. Much better suitability of oil 高效增强过滤器: Intensifier filter with high efficiency 蓝擎欧Ⅲ装有高效柴油滤清器,对柴油中杂质过滤能力强,有效保护了燃油系统 Landking Guo III engine is equipped with high efficiency fuel filter which has a better ability to filter impurity in fuel to effectively protect fuel system.

fuel coarse, fine filter core r

rustworth dewate filter hy er Tr

Fuel l
除 水 放 心 滤

柴 油粗 、 精 滤芯

1.1高压共轨系统概述
Introduction of High Pressure Common Rail System
除水放心滤

Trustworthy dewater filter
“除水放心滤”可以去除柴油中95%以上的水份。 除水放心滤 去除柴油中 的水份

It can dewater more than 95% water in diesel.
“除水放心滤”具有高效的油水分离功能,用户可以放心使用;

It has the high-efficiency f h th hi h ffi i function of fuel-water separation, and users can use it at ti f f l t ti d t ease.
“除水放心滤”安装在车辆车架的明显位置上,方便司机排气、泵油;

It is assembled on the obvious position of vehicle frame to facilitate drivers’ venting air and pumping fuel.
“除水放心滤”带有大容量透明水杯,耐低温性能良好,方便司机观察水位并及时放水;

It has high-volume transparent water cup with good low temperature resistance high volume low-temperature performance, which is convenient for drivers to observe water level so as to drain off water in time.
“除水放心滤”带有手压泵,车辆具有手压泵双保险。 除水放 滤 带有手压泵 车辆具有手压泵双保险

It is equipped with hand pump, and the vehicle has hand pump double insurance.

1.1高压共轨系统概述
Introduction of High Pressure Common Rail System
特别提示:

Special attention:
请经常观察“除水放心滤”的水位情况并及时放水;

Please often observe the water level of “trustworthy de ate filter” a d d a o water in t ust o t y dewater te and drain off ate time.
请注意“除水放心滤”滤芯更换周期与柴油粗滤芯、精 滤芯相同;

Pay attention that replacing interval of “trustworthy dewater filter” filter core should be same as that of fuel coarse and fine filter cores.
请注意“除水放心滤”滤芯可用蓝擎欧Ⅲ柴油粗滤芯代 用,但“除水放心滤”滤芯不可代用蓝擎欧Ⅲ柴油粗滤 芯。 。

Pay attention that “ trustworthy dewater filter” filter core can be replaced by Landking GuoIII fuel coarse filter core, but it can’t substitute for Landking GuoIII fuel coarse filter core core.

二、故障诊断与案例分析

Failure Di F il Diagnosis and C i d Case A l i Analysis

第 18页 共 页

故障诊断与排除原则
Failure Diagnosis and Removal Principle
柴油机出现故障时,采用先易后难逐 排除法 柴油机出现故障时,采用先易后难逐一排除法

When diesel engine is failure, removal method of “easy first and difficult later” one by one should be applied.
在未弄清楚问题前,不要轻易更换任何配件 在未弄清楚问题前 不要轻易更换任何配件

Don’t rashly replace any fitting before find out problems.
在未弄清楚问题前,不要轻易清除闪码,请注意记录闪码! 在未 清楚 前 轻 清除闪 请 意 闪

Don’t rashly get rid of blinking code before find out problems. Please note that do record blinking code.

第一类故障:柴油机无法启动
Failure type1: Diesel engine can’t be started yp g
故障排除步骤: Failure removal procedures: 1、根据闪码灯读取闪码,确定故障点,若无法 确定转下一步。 Read blink R d bli k code according t bli k li ht t d di to blink light to make sure failure. Turn to next step if the failure can’t be confirmed. 闪码的读取有两种途径: 闪 的读 有 种途径 Two ways to read blink code: 通过故障诊断仪读取; 故 诊断仪读取; Read through failure diagnosis equipment; 或通过柴油机闪码灯的闪码读取 or read through blink code light .

WP-VDS100故障诊断仪

执行元件—故障灯 执行元件 故障灯

第一类故障:柴油机无法启动
Failure type1: Diesel engine can’t be started can t
闪码得读取: Read blink code: ? 诊断开关每给出一个脉冲信号,闪码灯报一个闪码;诊断开关一直导通时,闪码灯常亮!

The blink code light gives a blink code every time when the diagnosis switch sends a pulse signal. When the diagnosis switch is through, the blink code light is on.
? ? ECU错误内存最多存储10个错误;亮灭0.5s1s

ECU err memory can save 10 errs at most, on and off 0.5s1s.
每个 每个闪码由3位组成,位与位之间间隔1秒。例如:321 成 与 间间 秒 例

Every blink code consists of three digits, and the time interval between each digit is 1 second. For instance: 321


灭 0.5s 05

1s

第一类故障:柴油机无法启动
Failure type1: Diesel engine can’t be started can t
手动清除闪码的方法

The method to get rid of blink code by hand:
? 在T15导通前就按下(接通)故障诊断开关,接着打开钥匙开关(T15接通),维持诊 断开关4-8秒后释放。 Press down the failure diagnosis switch before T15 is through then turn on the key through, switch(T15 is through), and keep the diagnosis switch on for 4-8 seconds, then release. ? 若不能删除某个闪码,则为当前故障。 If some blink code can not be deleted, that is the current failure. ? 需要先清除硬件故障,再清除ECU故障内存。 Get rid of hardware failure first, then clear ECU failure memory. y ? 如果无法排除闪码,请尽快通知专业人员处理。 If the blink code can not be deleted, should inform professional people to take care of it asap. 敬请注意: Special attention: 排除完故障后,请用设备或手动将闪码清除 After the failure is removed, please clear the blink code by equipment or by hand.

第一类故障:柴油机无法启动
Failure type1: Diesel engine can’t be started can t

闪码灯 故障诊断开关

Blink code light

Failure diagnosis switch

点火钥匙 开关

Ignition key switch

起动机

starter

第一类故障:柴油机无法启动
Failure type1: Diesel engine can’t be started can t
2、检查档位是否处于空档位置、空档开关是否正常;检查副 熄火开关(车下熄火开关)是否正常,若仍无法起动转下 一步。 步
Inspect if the shift is in neutral position, and the switch of neutral shift is normal or not; Inspect if the auxiliary flameout switch (it is under the vehicle) is normal. Turn to the next step if it still can not be started.

空档开 关

3、检查整车起动线路及电瓶是否正常,若仍无法起动转下一 Neutral shift switch 检查整车起动线路 电瓶是否 常 若仍无法起动转下 步。
Inspect whether the whole vehicle start line and battery jar are normal or not. Turn to the next step if it still can not be started.

4、判断起动机工作是否正常,如问题仍未解决,应进一步检 判断起动机 作是否 常 如问题仍未解决 应进 步检 查柴油机转动是否灵活,配气正时是否正确等。若仍无法 起动转下一步。
Diagnose whether the starter works normally or not. If the problem still can’t be solved should further inspect if the diesel engine solved, rotates freely or not, valve timing right or not. Turn to the next step if it still can’t be started.

Stop motion switch 车下停车开关

5、检查低压油路是否有气、漏气或堵塞现象。若仍无法起动 转下 步 转下一步
Inspect if the low pressure fuel passage is entering air, leakages air, or blocked. Turn to the next step if it still can’t be started.

第一类故障:柴油机无法启动
Failure type1: Diesel engine can’t be started can t
6、联系特约维修站维修人员,使用专业设备 按以下 步骤检测: Contact C t t people f l from special repair station t use i l i t ti to professional equipment to inspect as follows: 使用故障诊断仪检查飞轮信号盘与油泵凸轮信号盘 是否同步(数据流检测同步信号48)。若仍无法起 动转下一步;图 动转下 步 图 Failure diagnosis equipment used to inspect if the flywheel signal panel and fuel pump camshaft signal panel are synchronous (the synchronous signal of data stream is 48) Turn to the next step if 48). it still can’t be started. 使用故障诊断仪进一步检查是否正常建立轨压,如 轨压不正常,有可能是喷油器、共轨管、高压油泵 、ECU引起,请参考《部件故障分析》。 ECU引起,请参考《部件故障分析》。 Failure diagnosis equipment used to further inspect if the rail pressure built is normal. If the rail pressure is abnormal, it’s probably caused by injector, common rail, high pressure fuel pump and ECU, and reference to Parts Failure Analysis Camshaft speed sensor 凸轮轴转速传感器

曲轴转速 传感器 crankshaft rotary transducer k h ft t t d

第一类故障:柴油机无法起动
案例一、柴油机无法起动案例描述 1、整车无闪码,起动线路、起动机、电瓶正常,用起动机多次带动柴油机均无法起动, 因此排除起动系统故障 2、进一步检查低压及高压部分油路,并排除油路内空气,可以顺利起动;但熄火5分钟 后,再次出现起动困难现象,检查发现油路内仍有空气,因此确定低压油路存在进空 气现象。 3、经仔细对低压油路部件逐一检查,发现燃油粗滤器进油口螺纹处有损伤,空气进入油 路,从而导致柴油机无法正常起动。

案例分析
装配不当或频繁拆装导致燃油低压油路密封不严

案例处理
更换燃油粗滤器或更换低压低压油路部件至密封性良好。

Failure type1: Diesel engine can’t be started
Case I : Description of the Case that Diesel Engine Can’t be Started 1. The whole vehicle doesn’t have blink code. Start line, starter and battery jar are all normal, but , yj , the start can’t start the diesel engine. Therefore, the start system can be diagnosed that no failure. 2.Further inspect low and high pressure fuel passage, and remove air, then it can be started. But after 5-minute flameout, the difficulty in starting appears again. Inspect the fuel passage and 5 minute find that there’s still air, therefore, air leakage in the low pressure fuel passage is confirmed. 3.Through careful inspection for parts in the low pressure fuel passage, it’s found that there’s damage in the thread of fuel inlet of fuel coarse filter and air enters the fuel passage which filter, passage, results in the diesel engine can’t be stated. Case analysis y mproper assembling or frequently disassembling and assembling result in that low pressure passage seal is not tight Remedy Replace fuel coarse filter or low pressure passage parts to make sure good seal

第一类故障:柴油机无法起动
Failure type1: Diesel engine can’t be started can t
粗滤的进油口螺纹有损伤, 且进油口有细微裂纹 There s There’s damage in the thread of fuel inlet of fuel coarse filter, and fine crack in fuel inlet

放气螺 栓
手压泵

Air deflation bolt

Hand pump 栓 Fuel return hollow bolt

回油空心螺

第一类故障:柴油机无法起动
案例二、柴油机无法起动案例描述 1、起动时,起动机没反应,无闪码。检查副熄火开关、空挡开关正常; 起 起 机 检查 熄火 空 2、检查起动机连接线束、电瓶均正常; 3、用电瓶直接联通起动机检查,起动机工作正常; 3、进一步检查电瓶到ECU的四根电源线是否接通,当拆下整车线束测量电压 后发现这四根电源线还是接通的,都是24伏电压,符合要求。检查T15开关后 电压正常,整车K线电压也正常; 4、拆下整车线束插头后发现整车线束接插件与ECU针脚处有烧焦痕迹,检查 ECU 的针脚发现其中1个针脚(1.37、1.51)已经被烧断,ECU无电压输出, 由此判断ECU已经损坏。 案例分析 ECU插接件接触不良或密封件失效进水或电压过高等原因造成烧坏(经了解客户该车 曾焊接过车架,由于焊接时,ECU插头未拔掉造成烧毁) 案例处理 更换ECU

Failure type1: Diesel engine can’t be started
Case 2 : Description of the Case that Diesel Engine Can’t be Started
1.When start, starter doesn’t respond, and no blink code. Auxiliary flameout switch and neutral shift switch are normal; d t l hift it h l 2.Inspect starter connecting wire and battery jar, and they are normal; 3.Inspect when battery jar is connecting with starter, and the starter works normally; 4.Further inspect if th b tt 4 F th i t the battery j gets th jar t through th f h the four wires of ECU Aft measuring voltage, i f ECU. After i lt the four wires proved are power-on with 24v, which meets the requirement. T15 switch is inspected to be in normal voltage, and the whole vehicle K wire is also normal; 5.It’s found that there’s scorch track between whole vehicle wiring harness plug connector and ECU stitch when dismantle whole vehicle wiring harness plug. After inspection, it’s found that 11 stitches (1.37、1.51)have been burnt out. There’s no voltage output from ECU, hereby, it’s confirmed that ECU has been damaged.

Case analysis
ECU plug connector looses contact or seals fails resulting in water leakage or overtension, which leads to burning down( the vehicle was once welding frame, but ECU plug was not plucked when welding, which caused burning down)

Remedy
Replace ECU

第一类故障:柴油机无法启动
Failure type1: Diesel engine can’t be started

1.70针脚被烧断 1.70 1 70 stitch was burnt out

损坏的ECU插接件:发现整车插排 针脚有一个粗针已经断掉,其他粗 针脚已经生锈。 Damaged ECU plug connector: One of whole vehicle plug stitches broke, and other thick stitches rust.

第 类故障 柴油机无法起动 第一类故障:柴油机无法起动
1.3、柴油机无法起动案例描述

1、起动机正常运转,柴油机无法起动。 2、检查低压油路发现油箱结蜡,造成燃油失去流动性,堵塞油路和滤芯。 3、询问客户知在北京提车时加注-10#柴油,回到辽宁停车后次日无法起动, 因当时辽宁比北京地区气温更低,辽宁地区当时需加注-35#柴油。 案例分析 未根据不同环境温度选择不同标号的柴油,柴油结蜡导致进油管堵塞。 跨温差较大区域运行车辆应根据实际情况及时更换符合气温要求的柴油 案例处理 疏通油路,更换-35#柴油

Failure type1: Diesel engine can’t be started
Case 3 : Description of the Case that Diesel Engine Can’t be Started
1.The starter can work normally, but the engine can’t be started. can t 2.After inspection, it’s found that there’s paraffin deposit in the low pressure fuel passage, which caused no fluidity of fuel resulting in blocking fuel passage and filter core. 3. 3 Inquiry that the customer fills up -10#fuel when get the vehicle in Beijing but it can’t be 10#fuel Beijing, can t started next day after stopped in Liaoning. Because the temperature of Liaoning is much lower than that of Beijing, and -35#fuel should be filled up in Liaoning.

Case analysis
They don’t choose different brand fuel according to different temperature, and paraffin deposit leads to fuel pipe blocking. The required fuel should be replaced in time according to actual status when blocking the vehicle is running trans-regionally with large temperature difference

Remedy
Dredge fuel passage, and replace with -35# fuel

第一类故障:柴油机无法起动
1.4、柴油机无法起动案例描述 1、柴油机起动时马达运转正常,柴油机正常转动但无法起动,无闪码。 2、查看低压油路油压正常、高压油泵的出油正常--说明供油量是充足的。 3、将各缸喷油器回油管依次松开观察喷油器的回油量。经对比观察发现, 除了第三缸喷油器回油量很大以外,其他各缸的喷油器都基本没有回油 —说明第三缸喷油器损坏,更换后正常。

案例分析
含水量较高的劣质柴油会造成喷油器针阀磨损后密封不严。 含水量较高的劣质柴油会造成喷油器针阀磨损后密封不严 喷油器如果泄漏过大则可能导致无法启动。

案例处理
更换喷油器,加装除水放心滤。

Failure type1: Diesel engine can’t be started
Case 4 : Description of the Case that Diesel Engine Can’t be Started
1. The motor works normally when the engine starts. The engine rotates normally, but can’t be started, and no blink code. 2. Inspect if the fuel voltage of low pressure fuel passage is normal, fuel outlet from high pressure fuel pump is normal---proves that fuel delivery is sufficient. 3. Loose fuel return pipe of each injector and observe fuel return delivery. After contrast observing, all the injectors don’t return fuel except the injector of the third cylinder returns a lot of fuel---proves that the injector of the third cylinder is damaged, and back to normal after replaced Case analysis Poor quality f l with hi h water content can cause i j t needle-valve wore and ti htl P lit fuel ith high t t t injector dl l d tightless sealing. If the injector leakages too much, the engine can’t be started. Remedy R d Replace injector, and add trustworthy dewater filter

第一类故障:柴油机无法起动 Failure type1: Diesel engine can’t be started yp g

损 坏 的 喷 油 器 Damaged injector

左侧为原车上用油 The left is the original fuel used 右侧为正常油。 The right is normal fuel

第一类故障:柴油机无法起动
1.5、柴油机无法起动案例描述

1、起动系统、低压油路均正常,无闪码。上述其他方法仍无法排除。 2、用诊断仪检查,轨压达不到起动压力160bar,检查共轨管限压阀无泄漏,喷油器正常 3、断开高压油泵出油管,用起动机带动柴油机,发现高压油泵两个出油口都出油,但油 3 断开高压油泵出油管 用起动机带动柴油机 发现高压油泵两个出油口都出油 但油 柱一高4.5cm一低不足2cm。经过目测对比,发现该油泵供油能力不足(柴油机转 速200-250转/分,高压油泵出油油柱约4-5cm为正常)。

案例分析
含水量较高的劣质柴油导致高压油泵柱塞损坏

案例处理
更换高压油泵 加装除水放 滤 更换高压油泵,加装除水放心滤。

Failure type1: Diesel engine can’t be started
1.The starting system and low pressure fuel passage are normal, and no blink code. The above methods can t remove the failure can’t failure. 2. Failure diagnosis used to inspect that rail pressure can’t reach the starting pressure of 160bar Inspect that CR pressure limiting valve doesn’t leakage, and injectors are normal. 3. 3 Cut off fuel outlet pipe of high pressure fuel pump and start the engine through starter It’s pump, starter. It s found that two fuel outlets of high pressure fuel pump can deliver fuel, but the high fuel pillar is 4.5cm, the low is mere 2cm. Contrast through eyeballing to find that the fuel pump can’t supply sufficient fuel (the engine speed is 200 250r/min and the normal fuel pillar should be 4 5cm) 200-250r/min, 4-5cm)

Case 5 : Description of the Case that Diesel Engine Can’t be Started

Case analysis
Poor quality diesel with high water content leads to damage of high pressure fuel pump f f plunger

Remedy
Replace high pressure fuel pump, and add trustworthy dewater filter

第一类故障:柴油机无法起动
Failure type1: Diesel engine can’t be started can t

油品对比情况 Fuel b F l brand contrast d t t

高压油泵柱 塞损坏
HP fuel pump plunger is g damaged

第二类故障:柴油机起动困难(能起动,但较困难)
Failure type 2: The diesel engine starts with difficulty (can start, but with difficulty)
故障排除步骤:Failure removal procedures:

高原、高寒
第一步:是否是因高原、高寒原因引起 第 步 是 是 高原 高寒原 引起 1st step: If it is caused by plateau or paramos 第二步:读取闪码,确定故障点,若无闪码转下一步 2nd step: Read the blink code and confirm the failure Turn to the code, failure. next step if there’s no blink code. 第三步:检查起动机是否正常及电瓶电量是否充足,若仍不能顺利起 动转下一步 3rd step: Inspect that if the starter is normal, electricity of the battery jar is sufficient. Turn to the next step if it still can’t be started smoothly. 第四步:检查低压油路是否正常,若仍不能顺利起动转下一步 第四步:检查低压油路是否正常 若仍不能顺利起动转下一步 4th step: Inspect whether low pressure fuel passage is normal or not. Turn to the next step if it still can’t be started smoothly. 第五步:进一步检查柴油机转动是否灵活,配气正时是否正常 若 仍不能顺利起动转下一步 5th step: Further inspect whether the engine rotates normally or not, valve timing normal or not. Turn to the next step if it still can’t be started smoothly smoothly.
起动机

闪 码 灯

第二类故障:柴油机起动困难(能起动,但较困难)
Failure type 2: The diesel engine starts with difficulty (can start, but with difficulty) start
第六步:检查曲轴转速传感器和凸轮轴转速传感器及插头是否损坏、 牢固、清洁,若仍不能顺利起动转下一步。 6th step: Inspect whether crankshaft rotary transducer and camshaft p p y speed sensor and their plugs are damaged, firmed, clean or not. Turn to the next step if it still can’t be started smoothly. 第七步:联系特约维修站维修人员,使用专业设备按以下步骤检测。 7th step: C t t special repair station people, and use professional t Contact i l i t ti l d f i l equipment to inspect as follows: 使用故障诊断仪检查飞轮信号盘与油泵凸轮信号盘是否同步(数 据流检测同步信号48)。若还无法起动转下一步。 Use failure diagnosis equipment to check if flywheel signal panel and fuel pump camshaft signal panel are synchronous (the synchronous signal of data stream is 48 ). Turn to the next step if it still can’t be started. 使用故障诊断仪检查进一步检查是否正常建立轨压,如轨压不正 常,有可能是喷油器、共轨管、高压油泵、ECU引起,请参考《 常 有可能是喷油器 共轨管 高压油泵 ECU引起 请参考《 常见部件故障分析》。 Use failure diagnosis equipment to further inspect whether rail pressure is built normally. If not, it’s probably caused by injector, CR, HP fuel pump and ECU, Please refer to Common Parts Failure Analysis

WP-VDS100故障诊断仪 Failure diagnosis

第二类故障:柴油机起动困难(能起动,但较困难)
Failure type 2: The diesel engine starts with difficulty (can start, but with difficulty) 柴油机上安装两个转速传感器,分别在飞轮壳和高压油泵外侧。功能分别为:曲轴位置 传感器和判缸传感器。电控发动机的喷油正时取决于这两个传感器。有一个信号丢失, 则出现柴油机启动困难,如果出现柴油机不能起动情况,两个信号全部丢失
Diesel engine is equipped with two speed sensors, one is on the flywheel and the other is on the outboard of HP fuel pump. Their functions are crankshaft position sensor and cylinder judging sensor respectively. The injection timing of electronically controlled engine is decided by the two sensors. If one lost signal, the engine starts with difficulty. If the engine can’t be started, the two signals lost. 曲轴转速传感 器 crankshaft rotary transducer

凸轮轴转速传感 p 器 Camshaft speed sensor

第二类故障:柴油机起动困难(能起动,但较困难)
2.1、柴油机起动困难(能起动,但较困难)案例描述 1、按上述步骤检查后未发现问题。 按上述步骤检查后未发现问题 2、用诊断仪检查同步信号能够显示48,但是反应时间较长(超过3秒),对曲轴 转速传感器进行检查,发现传感器表面、飞轮信号孔很脏,擦拭干净后重新安装, 故障排除。 障

案例分析
异物导致了传感器不能及时准确识别飞轮上的信号孔位置

案例处理
清除异物,保证传感器的正确识别 清除异物 保证传感器的正确识别

第二类故障:柴油机起动困难(能起动,但较困难)
Failure type 2: The diesel engine starts with difficulty (can start, but with difficulty)
2.1. Case description 1. No p ob e s a e found ou a e inspection as the abo e p ocedu es o problems are ou d out after spec o e above procedures. 2. Use failure diagnosis to inspect the synchronous signal displaying 48, but responding time is relatively long (exceeds 3 seconds). Inspect crankshaft rotary transducer and find that the sensor surface and flywheel signal hole are very dirty. Clean them, then install again, the failure is removed.

Case analysis
Impurity caused that the sensor can’t identify the position of the signal hole on the flywheel very timely and precisely.

Remedy
Clean away impurity to ensure sensors right identification

第二类故障:柴油机起动困难(能起动,但较困难)
Failure type 2: The diesel engine starts with difficulty (can start, but with difficulty)

?

损坏的传 感器

第二类故障:柴油机起动困难(能起动,但较困难)
2.2、柴油机起动困难(能起动,但较困难)案例描述 1、柴油机起动困难,而且在将要起动的一瞬间柴油机发出很大的“咔咔” 声,车起动后转速只能达到1500转/min,柴油机进入跛行回家状态,闪码灯亮 2、读取闪码为112——曲轴转速传感器故障,经过检查发现曲轴转速传感器插头 2 读取闪码为112——曲轴转速传感器故障,经过检查发现曲轴转速传感器插头 松动。重新安装后,故障排除。

案例分析
插头接触不良(其余可能的原因还有忘记连接该传感器或传感器失效)

案例处理
重新连接该传感器(或是更换新的传感器)

第二类故障:柴油机起动困难(能起动,但较困难)
Failure type 2: The diesel engine starts with difficulty (can start, but with difficulty) 2.2. Case description
1. The diesel engine starts with difficulty, and it makes the great sound “Kaka” one moment when it’s going to start. After starting, the speed can only reach 1500r/min; the engine is in the status of Limp-home, and the blink code light is on. 2. Read the blink code of 112– the failure is crankshaft rotary transducer. After inspection, it’s Found that crankshaft rotary transducer plug looses. After reinstalled, the failure is removed.

Case analysis
The plug looses contact (other possible reasons: forgot to connect the sensor or the sensor f il ) fails)

Remedy
Reconnect the sensor (or replace with a new sensor)

第二类故障:柴油机起动困难(能起动,但较困难)
Failure type 2: The diesel engine starts with difficulty (can start, but with difficulty) yp g y( , y)

未安装Not installing

未安装 Not installing

Failure type 3: After the engine’s started, it’s flameout automatically 检查步骤 Inspection Steps:
第 步:读取闪码,确定故障点,若无法确定转 第一步:读取闪码,确定故障点,若无法确定转 下一 步。
1st step: Read blink code and confirm the failure. Turn to the next step if can’t confirm it.
故障诊断开 关

第二步:首先要检查低压油路是否漏气、堵塞( 包括回油管路),进、排气是否正常,若问 题不能解决转下一步。
2nd step: Firstly inspect if low pressure fuel passage leakages air or blocked (including fuel return pipe), check if air intake and exhaust is normal. Turn to the next step if the problem can’t be solved. l d

第三步:检查线路、各传感器、插头是否损坏, 若问题不能解决转下 步 若问题不能解决转下一步。
3rd step: Inspect if wires, sensors and plug is damaged. Turn to the next step if the problem can’t be solved.
手 压 泵
回油空 心螺栓

放气 螺栓

第三类故障:柴油机起动后自动熄火
Failure type 3: After the engine’s started, it’s flameout automatically engine s started it s
故障排除步骤 Inspection Steps: 第四步:联系特约维修站维修人员,使用专业设备按以下步 骤检测 检测 4th step: Contact special repair station people, and use professional equipment to inspect as follows: 使用故障诊断仪检查飞轮信号盘与油泵凸轮信号盘是否 同步(数据流检测同步信号48)。若问题不能解决转下 一步。 Use failure diagnosis equipment to check if flywheel signal panel and f l pump camshaft signal panel are i l l d fuel h ft i l l synchronous (the synchronous signal of data stream is 48 ). Turn to the next step if the problem still can’t be solved. 使用故障诊断仪检查进一步检查是否正常建立轨压,如 轨压不正常,有可能是喷油器、共轨管、高压油泵、ECU 引起,请参考《部件故障分析》。 Use failure diagnosis equipment to further inspect whether rail pressure is built normally. If not, it’s probably caused by injector, CR, HP fuel pump and ECU, Please refer to Parts Failure Analysis

WP-VDS100 WP VDS100故障诊断仪

第 类故障 柴油机起动后自动熄火 第三类故障:柴油机起动后自动熄火
3.1、柴油机起动后自动熄火案例描述 1、柴油机熄火后无法起动,无任何闪码。 2、检查油箱无柴油,重新加入柴油后,排低压油路空气后,仍无法起动。 3、检查高压油路,松开油泵端的两个高压油管接口,用起动机带动,发现无燃油排出。 确认高压泵内有空气。用手折住回油管,再次用起动机带动排气,到有油从接口端 排出,重新连接好,起动正常。 案例分析 由于油箱内油量过少造成回油溅起的气泡被吸入油路, 由于油箱内油量过少造成回油溅起的气泡被吸入油路 造成低压油路和高压泵内有油有气。 案例处理 加足柴油、按照案例描述排除故障。

Failure type 3: After the engine’s started, it’s flameout automatically
3.1. Case description
1. After engine flameout, it can’t be started, no blink code. 2. Inspect that no fuel in the fuel tank; refill fuel and deflate air from low pressure fuel passage, it still can’t be started. 3. Inspect HP fuel passage, and loose the two HP fuel pipe tie-in at the end of fuel pump, then rotate by starter and found that no fuel is drained out. It’s confirmed that there’s air in HP fuel pum Again, the starter used to help deflate air until fuel is drained out from the tie-in, then reconnect them, the starting is back to be normal. Case analysis Because of inadequate fuel in the tank air bubble caused by fuel return are sucked into the fuel tank, passage, which leads to air and fuel existing in low pressure fuel passage and HP pump. Remedy Fill up enough diesel, and remove the failure according to the case description

第三类故障:柴油机起动后自动熄火
3.2、柴油机起动后自动熄火案例描述

1、柴油机工作一段时间就会无力熄火,停车一段时间后又恢复正常,再过一段时间 又熄火。 2、读取闪码为242 2、读取闪码为242——水温过高。 水温过高。 3、检查水路正常,但用诊断仪检查发现起动后水温迅速达到107℃左右,实测水温只 有65℃。确定水温传感器损坏,导致ECU获得的水温信号错误,进入自我保护模式 负荷时自动熄火。 负荷时自动熄火 案例分析

传感器损坏后,给ECU传送错误信号,ECU判断错误,使柴油机进入自保护状态 案例处理 更换水温传感器

Failure type 3: After the engine’s started, it’s flameout automatically
3.2. Case description
1. The engine works for a while, then flameout, stops for a while, then back to be normal, but a moment later, flameout again later again. 2. Read the blink code displaying242--- water temperature is too high. 3. Inspect that water passage is normal, but failure diagnosis used to inspect and find that water temperature rapidly i t t idl increase t about 107℃ after starting, but the water temperature actually to b t ft t ti b t th t t t t ll measured is only 65℃. Hereby, it’s confirmed that water temperature sensor is damaged, which leads to wrong water temperature signal ECU got, then the engine enters to self-protection mode and fl d flameout when l d t h load. Case analysis When the sensor is damaged, it sends a wrong signal to ECU. ECU judges wrongly to make the engine enter self-protection mode. Remedy R d Replace water temperature sensor

第三类故障:柴油机起动后自动熄火
Failure type 3: After the engine’s started, it’s flameout automatically yp g , y

水温传感器 Water temperature sensor

第 55页 共 页

第三类故障:柴油机起动后自动熄火
Failure type 3: After the engine’s started, it’s flameout automatically engine s it s
3.3、柴油机起动后自动熄火案例描述

1、柴油机启动正常,柴油机转速自动升降,然后熄火。闪码灯亮。 2、读取闪码为324——车速信号问题。用户反映之前由于里程表坏, 在排查时动过车速传感器, 3、更换车速传感器后,试车正常,故障排除。 案例分析

车速传感器损坏 案例处理

更换传感器或屏蔽车速信号

Failure type 3: After the engine’s started, it’s flameout automatically
3.3. Case description
1.The 1 The engine starts normally but the speed is up and down automatically then flameout The blink normally, automatically, flameout. code light is on. 2. Read blink code displaying 324—the speed signal has some problems. The customer reflects that the th speed sensor was t d touched when fi th mileage counter. h d h fix the il t 3. After replace the vehicle speed sensor, trial-run is normal. The failure is removed. Case analysis

The vehicle speed sensor is damaged Remedy

Replace sensor and shield vehicle speed signal

第三类故障:柴油机起动后自动熄火
3.4、柴油机起动后自动熄火案例描述 1、柴油机起动后1-2秒自动熄火,同时柴油机抖动,转速上到540转马上就掉下的现象, 柴油机起动后 秒自动熄火 同时柴油机抖动 转速上到 转马上就掉下的 象 无闪码。 2、检查低压油路和高压油路无泄漏或者回油油管被压扁现象。 3、拆开喷油器回油管路、共轨管回油管路(PRV),起车观察发现,当柴油机有爆发 声音时,从共轨管回油管路喷出一股油。 4、连接诊断仪发现,轨压上升到440bar后落到280bar,然后在280至320bar之间波动。 由此确定共轨管限压阀损坏。

案例分析
共轨管限压阀失效

案例处理
更换共轨管

Failure type 3: After the engine’s started, it’s flameout automatically
3.4. Case description
1. After the engine starting for 1-2 seconds, it’s flameout automatically. At the same time, the engine i dith i i is dithering, and th speed rapidly i d the d idl increases t 540 r/min, th d to / i then decrease i immediately. di t l 2. Inspect low pressure fuel passage and HP fuel passage and find that no leakage or fuel return pipe squeezed. 3. Dismantle th f l return pipe of i j t 3 Di tl the fuel t i f injectors and PRV th start th vehicle and fi d th t th ’ d PRV, then t t the hi l d find that there’s fuel sprays out from the fuel return pipe of CR when the engine has explosion sound. 4. Connect the failure diagnosis and find that rail pressure rise to 440bar then down to 280bar, then fluctuate between 280-320bar. Hereby, it’s confirmed that pressure limiting valve of CR is damaged.

Case analysis
Pressure limiting valve of CR fails

Remedy
Replace CR R l

第三类故障:柴油机起动后自动熄火
Failure type 3: After the engine’s started, it’s flameout automatically
3.5、柴油机起动后自动熄火案例描述

1、柴油机运行中突然熄火,无法再次启动,打点火开关无反应。 2、检查电源无异常,供电线路均有电,但连接诊断设备不能通讯。 3、用万用表测1.04针脚无电压,判定ECU损坏。 3 用万用表测1 04针脚无电压 判定ECU损坏 案例分析

插头接触不良、密封件失效进水或电压过高等原因造成ECU烧坏 案例处理 更换ECU

第三类故障:柴油机起动后自动熄火
Failure type 3: After the engine’s started, it’s flameout automatically engine s started it s

轨压传感器

Rail pressure sensor Pressure limiting valve 压力限制阀 轨压传感器 进油口 fuel inlet

Failure type 3: After the engine’s started, it’s flameout automatically
3.5. Case description
1. The engine is flameout suddenly when running, can’t be started again, no response even if open ignition switch. switch 2. Inspect the power supply is normal, and the wire has electricity, but the diagnosis equipment connected can’t be communicated. 3. Use 3 U multimeter t measure 1.04 stitch with no voltage. Hereby, it’s confirmed that ECU lti t to 1 04 tit h ith lt H b it’ fi d th t is damaged. Case analysis The plug looses contact, sealing parts fails leading to water leakage or over-high voltage, which cause ECU to damaged. g

Remedy
Replace ECU

第三类故障:柴油机起动后自动熄火
3.6、柴油机起动后自动熄火案例描述 1、柴油机运行中突然熄火,仍能启动,但熄火现象依然存在,无闪码。 2、检查钥匙开关正常(如钥匙开关短路、断路均有可能造成上述现象) 3、检查ECU电源线束正常(如电源断路可能造成上述现象) 4、检查付熄火开关(车下熄火开关),发现连线绝缘胶皮磨破搭铁,造 成ECU接收到熄火信号。

案例分析 线束固定不好,磨损后造成信号短路,给ECU 提供错误信号 案例处理 重新连线,故障排除

Failure type 3: After the engine’s started, it’s flameout automatically
1. The engine’s flameout suddenly when running, but still can be started again. However, The flameout still exists, and no blink code. , 2. Inspect the key switch is normal (If the key switch is short circuit or open circuit, which probably cause the above problem. 3 spec CU power 3. Inspect ECU po e wire is normal ( the po e is ope c cu , which p obab y cause the e s o a (If e power s open circuit, c probably e above problem.) 4. Inspect the auxiliary flameout switch (under-vehicle flameout switch ) and find wire insulate rubber wore out, which cause that ECU receives flameout signal.

3.6. Case description

Case analysis
Since the wire is not fixed when it’s wore out it causes signal’s short circuit and the wrong fixed, it s out, signal s circuit, signal is transmitted to ECU.

Remedy y
Reconnect the wire, and remove the failure

Sensor wire harness
Water temperature sensor
水温传感器

传感器线束

Oil pressure sensor
机油压力传感器

Camshaft speed sensor
凸轮轴转速传感器

曲轴转速传感器

crankshaft rotary transducer

Air inta pressu sensor ake ure r

轨压传感器

Rail pressure sensor

进气压 压力传感器

第四类故障:柴油机冒黑烟
Failure type 4: The engine exhausts black smoke yp g
故障排除步骤 Failure removal steps: 第一步:检查空气滤芯及进排气管路、气门间隙是否正常,若 正常转 下一步。 常转 步 1st step: Inspect if air filter and air intake and exhaust pipe, valve clearance are normal. Turn to the next step if normal 第二步:检查增压器是否工作正常。若正常转下一步。 2nd step: Inspect if turbocharger is working normally. Turn to the next step if normally 第三步:检查柴油质量是否正常。若正常转下一步 3rd step: Inspect if diesel quality is normal. Turn to the next step if normal.

第四类故障:柴油机冒黑烟
Failure type 4: The engine exhausts black smoke
故障排除步骤Failure removal steps: 第四步:联系特约维修站维修人员,使用专业设备按以下步骤检测。 4th step: Contact special repair station people, and use professional equipment to inspect as follows: 使用故障诊断仪检查飞轮信号盘与油泵凸轮信号盘是否同步(数据流检测同步信号48) 。若仍冒黑烟转下一步。 Use failure diagnosis equipment to check if flywheel signal panel and fuel pump camshaft signal panel are synchronous (the synchronous signal of data stream is 48 ). Turn to the next step if it’s still black smoking. 使用故障诊断仪检查进一步检查是否正常建立轨压,如轨压不正常,有可能是喷油器、 共轨管、高压油泵、ECU引起,请参考《部件故障分析》。 Use failure di U f il diagnosis equipment t further inspect whether rail pressure i b ilt i i t to f th i t h th il is built normally. If not, it’s probably caused by injector, CR, HP fuel pump and ECU, Please refer to Parts Failure Analysis

第四类故障:柴油机冒黑烟
4.1、柴油机冒黑烟案例描述

1、柴油机在运转过程中突然冒黑烟,驾驶员立即停车。此后难启动,起动时冒黑烟。 2、按照上述第一、二、三步检查均正常 3、用故障诊断仪检查,起动时轨压只能达到160bar。 4、检查低压油路、共轨管、高压油泵正常,检查喷油器发现第2缸喷油器回油量异常 判断该喷油器故障。

案例分析

喷油器针阀磨损严重,燃油雾化不良 案例处理

更换喷油器

Failure type 4: The engine exhausts black smoke
4.1. Case description
1. The engine’s flameout suddenly when running, then the driver stop the vehicle immediately. Afterwards, it’s difficult to start again, and black smoking when start. 2. Conduct inspection according to the above 3 steps, and all are normal. 3. Use failure diagnosis to inspect: the rail p g p pressure can only reach 160bar when start. y 4. Inspect that low pressure fuel passage. CR and HP fuel pump are normal. Inspect injectors and find that the second cylinder fuel returning is abnormal. Hereby, it’s confirmed that the injector fails.

Case analysis
Injector needle valve is seriously damaged, and fuel atomization is poor.

Remedy
Replace injector

第四类故障:柴油机冒黑烟
Failure type 4: The engine exhausts black smoke yp g

Injector binding post 喷油器接线柱

第四类故障:柴油机冒黑烟
4.2、柴油机冒黑烟案例描述

1、柴油机冒黑烟,检查空气滤芯及气路畅通、增压器正常。 2、检查低压油路及油品,发现柴油里有水。拆检喷油器发现,油头有水锈 可判定为由于柴油中有水导致六只喷油器针阀生锈卡死。 判定为 柴油中有水 致六 喷油 针阀生锈卡 案例分析

油品不合格,油中有水,且未加装除水放心滤, 导致喷油器针阀锈蚀卡死,燃油雾化不良 案例处理

更换合格柴油,更换喷油器,加装除水放心滤

Failure type 4: The engine exhausts black smoke
4.2. Case description
1.The 1 Th engine exhausts bl k smoke, b t i i h t black k but inspect th t air filt air passage and t b h t that i filter, i d turbocharger work k normally. 2. Inspect low pressure fuel passage and fuel quality, and find there’s water in diesel. Dismantle injectors and find incrustation on the head. Hereby, it’s confirmed that water in the diesel leads to the six injector needle valves rusting and stuck.

Case analysis
Unqualified fuel, fuel mixing water, and no trustworthy dewater filter lead to Injector needle valve rusting and stuck, poor fuel atomization.

Remedy
Replace with qualified diesel and injectors, add trustworthy dewater filter

第四类故障:柴油机冒黑烟
Failure type 4: The engine exhausts black smoke yp g

喷油器已经 生锈 Injectors rust

第四类故障:柴油机冒黑烟
Failure type 4: The engine exhausts black smoke
4.3、柴油机冒黑烟案例描述 1、柴油机重载时冒黑烟,空载时不冒黑烟,无闪码。停车时检查空气滤芯及气路、检 查增压器正常。 2、检查油路与油品无问题。 3、用故障诊断仪监测柴油机的进气压力、转速、轨压、喷油量,当重载加速时进气压 力达到1.5公斤(绝对压力)后瞬间降到0.6公斤,转速下降、冒黑烟,断定气路有问 题。对气路逐一检查发现空滤器之后的一段橡胶软管较软,高档加速时被吸扁,导致 气 检 现 后 橡胶软管较软 高档加 被 扁 致 柴油机进气不足 案例分析 进气管路中橡胶软管太软,高档加速时被吸扁,导致柴油机进气不足 案例处理

更换进气软管

Failure type 4: The engine exhausts black smoke
4.3. Case description
1. The engine exhausts black smoke when heavily load, but no black smoke when no-load, and no code. After stop the vehicle, inspect air filter , air passage and turbocharger are normal. 2. Inspect fuel passage and fuel quality with no problems. 3. Use failure diagnosis to monitor air intake pressure, speed, rail pressure and fuel delivery: when g y speed-up with heavy load, the air intake pressure can reach 1.5 kg (absolute pressure), but rapid decrease to 0.6kg, and speed also decreases with black smoke. Hereby, it’s confirmed that air p passage has some p g problem. After careful inspection, it’s found a p p , piece of rubber tube behind the a filter becomes soft and sucked to be squeezed when speed-up, which cause inadequate air-intake

Case analysis
The rubber tube is so soft that sucked to squeezed when speed-up, which results in inadequate air-intake.

Remedy
Replace air-intake tube air intake

第四类故障:柴油机冒黑烟
Failure type 4: The engine exhausts black smoke yp g

第五类故障:柴油机动力不足
Failure type 5: Insufficient power
检查步骤 Inspection steps 第一步:配装多功率省油开关的车辆,检查开关档位是否在正确位置 1st step; For the vehicle equipped with multi power fuel saving switch inspect if the multi-power fuel-saving switch, power shift is on the right position. 第二步:读取闪码,若无闪码转入下一步 2nd step: read blink code, and turn to the next step if no blink code. 第三步:检查低压油路与油质是否正常,若正常转下一步。 3rd step: Inspect if low pressure fuel passage and fuel quality is normal Turn to the next normal. step if normal. 第四步:检查空气滤芯、进气管路、增压器工作是否正常,若正常转下一步。 4th step Inspect if air filter air intake passage and t rbocharger work normall T rn to step: filter, air-intake turbocharger ork normally. Turn the next step if normally. 第五步:检查气门间隙是否正常,若正常转下一步 5th step: Inspect if valve clearance is normal. Turn to the next step if normal. 第六步:检查各传感器插头、油门踏板插头、整车线束是否接触良好,若正常转下一步。 6th step: Inspect if each sensor plug, accelerator pedal plug and whole vehicle wire harness connect well. Turn to the next step if normal.

第五类故障:柴油机动力不足
Failure type 5: Insufficient p yp power
检查步骤Inspection steps 第七步:联系特约维修站维修人员,使用专业设备按以下步骤检测。 7th step: Contact special repair station people, and use professional equipment to inspect as follows: 使用故障诊断仪检查飞轮信号盘与油泵凸轮信号盘是否同步(数据流检测同步信号48)。 若仍动力不足转下一步。 Use failure diagnosis equipment to check if flywheel signal panel and fuel pump camshaft signal panel are synchronous (the synchronous signal of data stream is 48 ). Turn to the next step if still Insufficient power power. 使用故障诊断仪检查进一步检查是否正常建立轨压,如轨压不正常,有可能是喷油器、共 轨管、高压油泵、ECU引起,请参考《部件故障分析》。 Use failure diagnosis equipment to further inspect whether rail pressure is built normally normally. If not, it’s probably caused by injector, CR, HP fuel pump and ECU, Please refer to Parts Failure Analysis 配装多功率省油开关的车辆,检查开关档位是否失效 配装多功率省油开关的车辆,检查开关档位是否失效。 For the vehicle equipped with multi-power fuel-saving switch, inspect if the power shift fails.

第五类故障:柴油机动力不足
5.1、柴油机动力不足案例描述

1、行驶过程中转速到达1500转时出现转速不稳,整车抖动现象,继续踩油门踏板转速 不再提升,表现出动力不足,闪码灯亮。 2、读取闪码为114——曲轴转速传感器信号异常 2 读取闪码为114 曲轴转速传感器信号异常 3、使用诊断仪进行检测,发现在原地踩踏板加速时,当转速超过1500转时同步信号出 现跳动情况,不能稳定在48 ,检测曲轴转速传感器线束正常,断定曲轴转速传感器失效 案例分析

柴油机高速运转时,曲轴转速传感器信号不稳定 案例处理 更换曲轴转速传感器

Failure type 5: Insufficient power
5.1. Case description
1. When the speed reaches 1500r/min in the process of driving, it appears unsteady speed, and the h l th whole vehicle dith i hi l dithering. Th speed can’t b i The d ’t be increased even if k d keep stepping on accelerator. t i l t It shows Insufficient power with blink code light on. 2.Read blink code displaying 114--- crankshaft rotary transducer signal is abnormal. 3. Use failure di 3 U f il diagnosis to i i inspect and fi d that step on accelerator to speed-up when the vehicle d find h l d h h hi l stays still; the synchronous signal’s bouncing when the speed exceeds 1500r/min, can’t keep at 48 The crankshaft rotary transducer wire harness inspected is normal. Hereby, it’s confirmed that the crankshaft rotary transducer fails.

Case analysis
When the engine runs at high speed, crankshaft rotary transducer signal is not stable.

Remedy R d
Replace crankshaft rotary transducer

第五类故障:柴油机动力不足
Failure type 5: Insufficient p yp power

Crankshaft rotary transducer 曲轴转速传感器

第五类故障:柴油机动力不足
Failure type 5: Insufficient power
5.2、柴油机动力不足案例描述 Case description 1、柴油机动力不足,无闪码 Insufficient power, no blink code. I ffi i t bli k d 2、检查多功率省油开关,发现转换档位时动力性无变化,断定开关失效 Inspect multi-power fuel-saving switch and find no change about power when change shift. It’s confirmed that the switch fails. 案例分析

Case analysis
多功率省油开关失效 multi-power fuel-saving switch falis 案例处理 更换多功率省油开关 Replace multi-power f l R l li fuel-saving switch i i h

Remedy

第五类故障:柴油机动力不足
5.3、柴油机动力不足案例描述
1、车辆重载时动力不足,转速上升到1500转就上不去了。 2、读取闪码为253——低压油路供油不畅。 3、检查油箱、油管、滤芯,滤芯没有含水现象,油箱通气阀未堵塞, 3 检查油箱 油管 滤芯 滤芯没有含水现象 油箱通气阀未堵塞 但低压油管有弯折现象 案例分析

油管内径过小(要求内径≥Φ12mm)或弯折造成供油不畅
案例处理

将弯折处修复

Failure type 5: Insufficient power
5.3. Case description
1. The power is insufficient with heavy load, and the speed can only increase to 1500r/min. 2. Read blink code displaying 253—fuel supply in the low pressure passage is difficult. 3. Inspect fuel tank, fuel pipe and filter core and find that filter doesn’t mix with water the fuel tank is not blocked, but the low pressure fuel pipe is curved.

Case analysis
Too small inside diameter of fuel pipe (required id ≥Φ12mm) or curved pipe caused unsmooth fuel supply

Remedy
Restore the curved place

第五类故障:柴油机动力不足
Failure type 5: Insufficient power

打褶部位

正常 normal

第五类故障:柴油机动力不足
Failure type 5 Insufficient po e a u e ype 5: su c e power 5.4、柴油机动力不足案例描述
1、柴油机动力不足,无闪码 2、检查油路及油品也都正常。 3、检查空气滤芯及进气管路发现中冷器下端裂开了大约15cm的口子 3 检查空气滤芯及进气管路发现中冷器下端裂开了大约15cm的口子 案例分析

进气管路漏气
案例处理

更换中冷器

Failure type 5: Insufficient power 5.4. Case description
1. Insufficient power, no blink code. 2. Fuel passage and quality are inspected to be normal. 3. Inspect air filter and air-intake pipe and find the lower end of intercooler splits for about 15cm opening

Case Analysis

Air-intake pipe leakages air

Remedy
Replace intercooler

第五类故障:柴油机动力不足
Failure type 5: Insufficient power

中冷器开裂 intercooler splits

第五类故障:柴油机动力不足
5.5、柴油机动力不足案例描述

1、柴油机运行一段时间出现加不上油现象,但是不限制转速, 转速能够慢慢上来,闪码灯亮。 2、读取闪码为143——3缸喷油器线束开路 2 读取闪码为143 3缸喷油器线束开路 3、更换喷油器线束后正常。

案例分析

线束接线柱连接处螺母未拧紧或单缸喷油器线束断路

案例处理 首先拧紧该缸线束螺母,如没有效果则更换喷油器线束解决

Failure type 5: Insufficient power
5.5. Case description
1. Fuel can’t filled up when the engine runs for a while, but the speed is not restricted. 2. The blink code is 143– the third cylinder injector wire harness is y j open circuit. 3、After replace injector wire harness, it’s normal.

Case analysis
The nut at the wire harness binding post is not screwed down or the injector wire is open circuit.

Remedy
Firstly screw down the nut, if it doesn’t work, replace injector wire harness to solve the problem.

第六类故障:柴油机跛行回家
Failure type 6: Limp-home Limp home
故障排除步骤 Failure removal steps: 第 步:读取闪码。 第一步:读取闪码。 1st step: Read the blink code. 第二步:根据闪码确定故障并排除,若仍不能排除进入下 步。 第二步:根据闪码确定故障并排除,若仍不能排除进入下一步。 2nd step: To confirm the failure according to blink code. Turn to the next step if can’t remove the failure. 第三步:检查低压油路是否堵塞严重,油品标号是否符合环境温度要求,若不能排除进入 下一步。 p p p p g y , 3rd step: Inspect if the low pressure fuel passage is seriously blocked, fuel meets the requirement of ambient temperature. Turn to the next step if can’t remove the failure.

第六类故障:柴油机跛行回家
Failure type 6: Limp home Limp-home
检查步骤Failure removal steps: 第 步 联 特约 修 第四步:联系特约维修站维修人员,使用专业设备按以下步骤检测。 修 员 使用 设备按 步骤检 4th step: Contact special repair station people, and use professional equipment to inspect as follows: 使用故障诊断仪检查飞轮信号盘与油泵凸轮信号盘是否同步(数据流检测同步信号48 )。若不能排除转下一步。 ) 若不能排除转下 步 Use failure diagnosis equipment to check if flywheel signal panel and fuel pump camshaft signal panel are synchronous (the synchronous signal of data stream is 48 ). Turn to the next step if the problem still can’t be solved. 使用故障诊断仪检查进一步检查是否正常建立轨压,如轨压不正常,有可能是喷油器 、共轨管、高压油泵、ECU引起,请参考《部件故障分析》。 Use failure diagnosis equipment to further inspect whether rail pressure is built normally. If not, it’s probably caused by injector, CR, HP fuel pump and ECU, Please refer to Parts Failure Analysis

第六类故障:柴油机跛行回家
6.1、柴油机跛行回家案例描述

1、柴油机启动后最高转速只能达到1500转,闪码灯亮。 2、读取闪码为134——共轨限压阀打开 3、启动后首次踩油门能达到额定转速,柴油机在启动的几秒内实际轨压大 于设定轨压, 断定回油管路不畅通,检查发现油箱内回油管堵塞

案例分析 回油管路堵塞造成回油不畅,导致轨压超出限定值 回油管路堵塞造成回油不畅 导致轨压超出限定值 案例处理

疏通回油管路

Failure type 6: Limp-home
6.1. Case description
1.The max.speed can only reach 1500r/min after the engine starts, and the blink code light is on. 2.The blink code is 134– CR pressure limiting valve opens 3. After starting, step on accelerator for the first time, and it can reach rated speed. In the first seconds the actual rail pressure value exceeds setting value Hereby it’s confirmed that seconds, value. Hereby, it s the fuel return passage is not smooth. Through inspection, it’s found that the fuel return pipe of fuel tank is blocked. Case analysis The blocked fuel return passage leads to unsmooth fuel return, which cause rail pressure exceeding the setting value. Remedy Clean fuel return passage

第六类故障:柴油机跛行回家
6.2、柴油机跛行回家案例描述 1、车辆运行中出现最高转速1500转,闪码灯亮 2、读闪码为134——共轨限压阀打开 3、检查油路,低压油路正常,同时发现油品颜色异常 3 检查油路 低压油路正常 同时发现油品颜色异常 4、用诊断仪检测轨压,轨压迅速升到1800bar然后降到760bar, 判定共轨管限压阀正常,进一步判定流量计量单元损坏。

案例分析 油品质量差导致流量计量单元阀门卡死在常开位置

案例处理 更换流量计量单元或高压油泵,清理油路更换燃油

Failure type 6: Limp-home Limp home
6.2. Case description
1.It 1 It appears the max speed of 1500r/min when running and the blink code light is on max.speed running, on. 2. The blink code is 134– CR pressure limiting valve is open. 3. Inspect fuel passage: low pressure fuel passage is normal, but fuel color is abnormal. 4. 4 Use failure diagnosis to monitor rail pressure: it rapidly increases to 1800bar then decreases 1800bar, to 760bar. Hereby, it’s confirmed that CR pressure limiting valve is normal, but metering unit is damaged.

Case analysis

Poor quality fuel leads to metering unit valve stuck

Remedy
Replace metering unit or HP fuel p p, clean fuel p p g pump, passage and replace fuel. g p

第六类故障:柴油机跛行回家
Failure type 6: Limp home Limp-home
流量计量单元故障metering unit failure

流量计量单元 metering unit 排除方法:检修线路,确认是流量计量单元或轨压传感器故障 Removal method: check and repair wire to judge metering unit failure or rail wire, pressure sensor failure.

第六类故障:柴油机跛行回家
6.3、柴油机跛行回家案例描述

1、柴油机启动后最高转速1500转,闪码灯亮 2、码为231——进气压力传感器电压超出上限门槛值,233 ——进气温度传感器电压超出上限门槛值 3、检查发现进气压力温度传感器线束插头松动 案例分析

进气压力温度传感器线束插头松动或进气压力传感器损坏

案例处理 将进气压力温度传感器线束插头重新安装

Failure type 6: Limp-home
6.3. Case description
1. The max.speed is 1500r/min after starting, and the blink code light is on. 2. The blink code of 231– The voltage of air-intake pressure sensor exceeds upper limit value. The blink code of 233– The voltage of air-intake temperature exceeds upper limit value. pp 3. Through inspection, it’s found that the wire harness plug of air-intake pressure temperature looses.

Case analysis
The wire harness plug of air-intake pressure temperature looses or the air-intake pressure sensor is damaged.

Remedy
Reinstall the plug

第六类故障:柴油机跛行回家
Failure type 6: Limp home Limp-home
进气压力传感器 air-intake pressure air功能:可以检测进气压力和温度 sensor

第六类故障:柴油机跛行回家
6.4、柴油机跛行回家案例描述

1、行驶过程中偶尔出现闪码灯常亮,转速最高达到1500转,闪码灯亮 2、读取闪码为254——油路进油阻力太大 3、检查低压油路,发现从油箱出来至粗滤的进油路有弯折的地方 3 检查低压油路 发现从油箱出来至粗滤的进油路有弯折的地方

案例分析

低压油路弯折导致进油不畅

案例处理 疏通或更换低压油管

Failure type 6: Limp-home
6.4. Case description
1. The blink code light is on now and then when running. The max. speed can reach 1500r/min, g g p , and the blink code light is on. 2. The blink code is 254—fuel feeding resistance is too huge. 3. Inspect low pressure fuel passage and find that fuel passage from fuel tank to fuel coarse filter is curved.

Case analysis
Curved fuel passage leads to unsmooth fuel feeding.

Remedy
Clean or replace low pressure fuel pipe

第六类故障:柴油机跛行回家
6.5、柴油机跛行回家案例描述 1柴油机启动后最高转速1500转,闪码灯亮 1柴油机启动后最高转速1500转 闪码灯亮 2、读取闪码为134——共轨限压阀打开。 3、检查低压油路,短接油路排除低压油路问题 4、高压油路的检查, 4 高压油路的检查 方法一:检查喷油器回油量,发现第6缸回油量异常,更换第6缸喷油器后正常。 方法二:用故障诊断仪做高压测试,可看出2200转的时候实际轨压根本达不到 设定值目标1300bar,相差了近400bar,表明高压系统存在泄漏的地方,断缸 设定值目标1300b 相差了近400b 表明高压系统存在泄漏的地方 断缸 测试发现第6缸喷油器工作能力差。 案例分析 喷油器问题 案例处理 更换喷油器

Failure type 6: Limp-home
6.5. Case description
1.The max. speed can reach 1500r/min, and the blink code light is on. 2. The blink code is 134– CR pressure limiting valve opens. 3. Inspect low pressure fuel passage 4. Inspect HP fuel p p passage g Method 1: Inspect fuel return of injector, and find that 6th cylinder fuel return is abnormal; after replacing the 6th cylinder injector, it’s normal. Method 2: Use failure diagnosis to test HP: when the speed is 2200r/min, the actual rail p g p , pressure can’t reach the setting value of 1300bar, 400bar less. That proves that there’s leakage in HP system After fuel-cut test, it’s found the 6th cylinder injector works badly.

Case analysis C l i
Injector failure

Remedy
Replace i j t R l injector

第六类故障:柴油机跛行回家
Failure type 6: Limp-home yp p
Fine filter Gear pump outlet back pressure 齿轮泵出口背压: < 9.0 bar 绝对压力 Absolute pressure 精滤 Injector fuel return back pressure 喷油器回油背压: 0~1bar 相对压力 Absolute pressure 喷 Pressure limiting valve 油 器 限压阀 rail 油 轨 by-pass valve 旁通 阀 溢流阀 Spillover valve 零 油 CPN2 CPN2.2 量 孔 粗滤 油泵回油背压: 油泵回油背压 <1.2 bar绝 绝 Coarse filter 对压力 HP fuel passage : 高压油路: 低压油路 高压共轨油路原理图 Low pressure fuel passag Schematic diagram of HP CR fuel passage ECU冷却盘 油量计量单 元 metering unit

过压保护阀 Overpressure protection

Gear pump inlet back pressure 齿轮泵进口压力: 0.35~1.00bar 绝 对 压力 手油 泵 Hand pump

第七类故障:柴油机怠速不稳
Failure type7: Idle speed is not stable yp p
故障排除步骤 Failure removal steps: 第一步:读取闪码,确定故障点,若无法确定转下一步。 1st step: Read the blink code and confirm the failure. Turn to the next step if can’t confirm. 第二步:检查低压油路是否正常,若不能排除转下一步。 2nd step: Inspect if low pressure fuel passage is normal. Turn to the next step if can’t remove the failure. 第三步:检查各类传感器插头、线束是否正常,若不能排除转下一步 3rd step: Inspect if each sensor plug and wire harness are normal. Turn to the next step if can’t remove the f il ’ h failure.

第七类故障:柴油机怠速不稳
Failure type7: Idle speed is not stable
故障排除步骤Failure removal steps: 第四步:联系特约维修站维修人员,使用专业设备按以下步骤检测。 4th step: Contact special repair station people, and use professional equipment to inspect as follows: 使用故障诊断仪检查车速传感器工作是否正常,若不能排除转下一步 Use failure diagnosis equipment to inspect if vehicle speed sensor is normal. Turn to the next step if can’t remove the failure. 使用故障诊断仪检查进一步检查是否正常建立轨压,如轨压不正常,有可能是喷油器、 共轨管、高压油泵、ECU引起,请参考《部件故障分析》。 Use failure diagnosis equipment to further inspect whether rail pressure is built normally. If not, it’s probably caused by injector, CR, HP fuel pump and ECU, Please refer to Parts Failure Analysis

第七类故障:柴油机怠速不稳
7.1、柴油机怠速不稳案例描述

1、柴油机启动后怠速不稳,无闪码。 2、检查低压油路、传感器插头、线束均正常 3、用故障诊断仪读取车速信号,在车辆静止状态下, 有车速信号存在,并且在0-7km/h不停上下变化。

案例分析

车速传感器信号不稳定造成柴油机怠速不稳 案例处理

更换合格的车速传感器,如该车不使用该传感期则可以将车速信号屏蔽 更换合格的车速传感器 如该车不使用该传感期则可以将车速信号屏蔽

Failure type7: Idle speed is not stable
7.1. Case description

1. The idle speed is not stable after starting, no blink code. 2. Inspect that low pressure fuel passage, sensor plug and wire harness are normal. 3. Use failure diagnosis to read vehicle speed signal: when the vehicle is at idle state, the speed signal exists, and fluctuates between 0—7km/h. Case analysis

Unstable vehicle speed sensor signal caused unstable idle speed.

Remedy Replace with qualified vehicle speed sensor. If the vehicle doesn’t use sensor, the speed signal can b shielded. be hi ld d

第八类故障:柴油机始终运行在1000转 Failure type 8: The engine is always at 1000r/min
故障排除步骤 Failure removal steps: 第一步:读取闪码,确定故障点 1st step: Read the blink code and confirm the failure. 第二步:根据闪码排除故障。 2nd step: Remove the failure according to blink code. 第三步:检查电子油门踏板插头是否松脱、接错或短路 3rd step: Inspect if electric accelerator pedal plug looses, wrongly connected or short circuit. 第四步:检查电子油门踏板是否失效。 4th step: Inspect if the electric accelerator pedal fails.

第八类故障:柴油机始终运行在1000转
8.1、柴油机始终运行在1000转案例描述

1、柴油机启动后转速始终运行在1000转,油门踏板不起作用,闪码灯亮 2、读取闪码为221——油门踏板信号异常 3、检查电子油门踏板插头正常, 4、使用诊断仪检测油门踏板电压,两倍关系不成立,检查线路连接正常, 判定油门踏板传感器故障 案例分析

油门踏板传感器故障,导致信号错误 案例处理 更换油门踏板

Failure type 8: The engine is always at 1000r/min
8.1. Case description
1. The speed is always at 1000r/min after starting; the accelerator pedal doesn’t work; the blink code light is on. 2. The blink code is 221--- the accelerator pedal signal is abnormal. 3. Inspect that the electric accelerator p p pedal p g is normal plug 4. Use failure diagnosis to inspect accelerator pedal voltage: it’s not the twice voltage. Inspect that the wire connecting is normal. Hereby, it’s confirmed that it’s the accelerator pedal sensor failure.

Case analysis
The accelerator pedal sensor failure leads to wrong signal.

Remedy
Replace accelerator p p pedal

第八类故障:柴油机始终运行在1000转
Failure type 8: The engine is always at 1000r/min
电子油门踏线松脱或接错 重新拔插或检查油门接线是否正确,重新接线
The electric accelerator pedal wire looses or wrongly connecting. Re-plug or inspect if the accelerator wire is right, then reconnect.

电子油门接插件进水 用工具把接插件吹干再起动
The electric accelerator plug connector leakages water: dry it, then restart.

注意:更换油门时,需要同一型号的油门。 Note: Replace the accelerator with the same model

第九类故障:其他故障
9.1、行车时油门时有时无(水温过高激活过热保护)案例描述

1、柴油机工作一段时间后油门踏板失效,停车一段时间后又恢复正常,再过一 段时间又会出现同样的问题。柴油机水温在启动后会迅速达到107℃左右。 2、经检查水泵皮带松弛,引起水温高,进入过热保护模式。 案例分析 电控柴油机独特的智能保护功能,柴油机水温高时油门踏板失效。 待停车一段时间水温降下来后,油门又会恢复正常。 案例处理 张紧皮带(排除传感器故障)

Failure type 9 : Other failures
9.1. Description of the Case that accelerator works now and then when driving

(overheat protection is activated when water temperature is too high)
1. The accelerator pedal fails when the engine works for a while, back to normal after stop for a while, then fails again. The water temperature rapidly increases to about 107℃ after starting. 2. After inspection, it’s found that the water pump pulley looses resulting in too high water temperature, and the engine enters overheat protection mode.

Case analysis
The unique intelligent protection function of the electronically controlled diesel engine is that the accelerator fails when water temperature is too high. When the temperature is down, the accelerator’s back to normal.

Remedy
Tighten b lt (remove th sensor f il ) Ti ht belt ( the failure)

第九类故障:其他故障
Failure type 9 : Other failures
? 注意:皮带装好后用钳子将皮带张紧轮的销子 拔出,即实现了自动张紧。 Note: Aft install the belt, ll t the i f N t After i t ll th b lt pull out th pin of belt tensioner with pliers to realize automatic tension.

皮带松 Belt looses

第 116页 共 页

第九类故障:其他故障
9.2、柴油机怠速振动大案例描述

1、该车配装WP10.300N系列柴油机,法士特RTO 11509F变速箱, 后桥速比4.42,柴油机原怠速为550rpm 2、柴油机怠速时与变速箱、驾驶室发生共振 案例分析

柴油机转速550rpm为该车的一个共振点 案例处理 将该车怠速调整为620rpm,问题解决

Failure type 9 : Other failures
9.2. Description of the case that vibration at idle speed is huge
1. The vehicle is equipped with WP10.300N series engine, Fast RTO 11509F gear box rear axle ratio: 4.42, original idle speed of the engine: 550rpm 2. When the engine is at idle speed, it takes place resonance vibration with gear box and the operator cabin. Case analysis

The speed of 550rpm is the resonance vibration point of this engine. Remedy The idle speed is adjusted to 620rpm, then the problem is solved.

第九类故障:其他故障
9.3、柴油机怠速振动大案例描述

1、车速60km/h左右柴油机转速1300r/min左右时整车抖动大 2、停车时柴油机没有高速抖动现象

案例分析

行车过程中,柴油机与整车传动系统发生共振

案例处理 更换整车传动轴

Failure type 9 : Other failures
9.3. Description of the case that vibration at idle speed is huge

1. When the vehicle speed is about 60km/h, and the engine speed is about 1300r/min, the vehicle is seriously dithering. 2. 2 The engine doesn t dither after stop the vehicle. doesn’t vehicle

Case analysis y

The engine and whole vehicle transmission system is resonance vibration when driving driving.

Remedy
Replace vehicle transmission shaft

三、部件故障分析 三 部件故障分析
Parts Failure Analysis

共轨系统主要部件 main parts in common rail system

共轨系统主要部件 main p parts in common rail system y

柴油滤清器

3.1、喷油器 injector
故障表现:动力不足、冒黑烟、启动困难、跛行回家故障 Fault: insufficient power, black smoke exhaust, difficult to start and limp-home fault 附:喷油器工作原理图 injector working principle picture

3.1.1喷油器故障分析表
序号 1 故障类型 喷油器雾化不良 原因分析 油头处积碳严重 处理方法 清理,如故障不能消 清理 如故障不能消 除,更换喷油器 更换喷油器 备注

2

喷油器不喷油

针阀卡死在关闭状态

3

喷油器油头处滴油

针阀卡死在常开位置或喷油 器针阀磨损造成密封不 严 回油柱塞锥面磨损密封不严

更换喷油器

4

单个喷油器回油量大或与 其它喷油器差别较大 喷油器铜套或垫片变形损 坏 喷 接线柱螺帽松动造成喷油 器线束松动或磨破与 缸盖短路 喷油器电磁阀损坏

更换喷油器

5 6

安装时定位不准造成变形或 拧紧时用力过大 螺帽、线束固定不牢

更换铜套或垫片 固定好螺帽、线束

安装时注意 定位

7

短路或其它原因形成大电流 烧坏

更换喷油器

喷油器电阻 0.9欧姆 0 9欧姆

3.1.1 Table about analysis of injector fault
No. 1 Fault type atomization of injector is t i ti fi j t i bad Injectors don’t inject fuel j j Cause Carbon d C b deposit heavily on it h il fuel head Needle valve is locked in closed state Needle valve is locked at usual position or needle valve of injector is worn and its sealing isn’t tight Fuel return plunger taper is worn and its sealing isn't d it li i 't tight Inexact orientation lead to distort or tighten with big strength when installing Screw cap and wiring g harness cannot fasten firmly Remedy clean replace injector l l i j t if fault cannot be removed Replace injector p j Remarks

2

3

fuel head of injector drip fuel

Replace injector

4

Fuel return amount per injector is great or it is very different from other ones

Replace injector

5

Injector Bronze cover or washer i di t t d or h is distorted damaged
Screw cap of connection pole is loose, which causes wiring harness of injector is loose or worn and cylinder head is short circuit

Replace bronze cover or washer

pay attention to orientation when installing

6

fasten screw cap and wiring harness

7

electromaqnetism valve of injector is damaged

Turnoff or big electric current is burnt because of other causes

Replace injector

resistance of injector is 0.9 ohm

3.1.2喷油器故障分析
故障现象:动力不足、冒黑烟、启动困难、跛行回家故障 1、喷油器雾化不良 、喷油器雾化不良 原因:油头处积碳严重 (右图) 处理:清理,如故障不能消除,更换喷油器 2、喷油器不喷油 原因:喷油器卡死在关闭状态(下图) 处理:更换喷油器

3.1.2 analysis about injector fault
Fault: insufficient power, block smoke exhaust, difficult to start and limp-home fault 1、atomization of injector is bad 、 cause: carbon deposit heavily on fuel head (right picture) Remedy: clean, replace injector if the fault cannot be removed. 2、injector doesn t inject fuel doesn’t cause: injector is locked in closed state remedy: replace injector

3.1.2喷油器故障分析
故障表现:动力不足、冒黑烟、启动困难、跛行回家故障 3、喷油器油头处滴油 、喷油器油头处滴油 原因:针阀卡死在常开位置或喷油器针阀磨损造成密封不严 处理:更换喷油器 4、单个喷油器回油量大或与其它喷油器差别较大 原因:回油柱塞锥面磨损密封不严 处理:更换喷油器

3.1.2 Analysis about injector fault
Fault: insufficient power, black smoke exhaust, difficult to start and limp-home fault 3、flow fuel on fuel head of injector 、 Cause: needle valve is locked in usual position or needle valve of injector is worn Remedy: replace injector 4. Fuel return amount in every injector is big or there is big different from other injectors Cause: fuel return plunger taper is worn Remedy:replace injector

3.1.2喷油器故障分析
故障表现:动力不足、冒黑烟、启动困难、跛行回家故障 5、喷油器铜套或垫片变形损坏 、喷油器铜套或垫片变形损坏 原因:安装时定位不准造成变形或拧紧时用 力过大 处理:更换铜套或垫片 6、接线柱螺帽松动造成喷油器线束松动或磨破与缸盖短 路 原因:螺帽、线束固定不牢 处理:固定好螺帽、线束

3.1.2 Analysis about injector fault
Fault: insufficient power, black smoke exhaust, difficult to start and limp-home fault 5. 5 Bronze cover or washer of injector is distorted and damaged Cause: distortion because of inexact orientation or tighten with great strength when installing them Remedy: replace bronze cover or waher

6. Screw cap of connection pole is loose, which causes wiring harness of injector is loose or worn and cylinder head is short circuit Cause: screw cap and wiring harness is not fastened Remedy: fasten screw cap and wiring harness.

3.1.2 Analysis about injector fault
故障表现:动力不足、冒黑烟、启动困难、跛行回家故障 Fault: insufficient power, block smoke exhaust, difficult to start, and limp home limp-home fault 7、喷油器电磁阀损坏 原因:短路或其它原因形成大电流烧坏 处理:更换喷油器 7. Electromagnetism valve of injector is g j damaged Cause: turnoff or big electric current is burnt because of other causes. Remedy: replace injector

3.2高压油泵 3.2高压油泵 high pressure fuel pump
柴油进口(来自滤器) Diesel fuel inlet (from filter) 流量计量单元 Flow metering unit 高压油出口 High pressure 柴油出口(到油箱) fuel outlet Diesel fuel outlet (to fuel tank) 溢流阀 Overflo w valve 凸轮轴 camshaft

齿轮泵 ZP5 Gear pump ZP5 柴油出口(到滤器) Fuel outlet (to filter)

初始机油注油口阀盖 初始机油注油 阀盖 Initial oil filler valve cap 凸轮轴相位传感器: DG6 Camshaft Camshaft phase sensor 柴油进口(自油箱) DG6 Fuel inlet (from fuel tank)

3.2.1高压油泵故障分析表 3.2.1高压油泵故障分析表

序号 1

故障类型 高压油泵出油 管不出油

原因分析 柱塞腔内有空气、齿 轮泵内部有空气或柱 塞磨损 线束插头接触不好、 流量计量单元损坏 插头松动

处理方法 排除空气或更 换高压油泵

备注 潍柴各种泵集成 的输油泵有两 种旋向,需注 意不能混淆 流量计量单元 电阻为 2.6~3.15欧姆

2

流量计量单元 常开 流量计量单元 插头接触不 良 高压油泵正时 齿轮正时不 正确

重新拔插插头 或更换流量 计量单元 重新拔插

3

4

油泵安装时齿轮正时 出错

重新按照工艺 要求调整

3.2.1 Table for analysis of high pressure fuel pump
No. 1 Fault type Cause Remedy remarks

fuel outlet pipe of there is air in plunger high pressure or gear pump, or fuel pump can plunger is worn supply fuel

Remove air or There are 2 replace high rotation pressure direction in gear fuel pump p p, pump, do not confuse

2

Connection of Bnc pull out and insert resistance of flow flow metering connector plugs of bnc metering unit is unit is often wiring harness is bad, ii h i b d connector t 2.6~3.15ohm open and flow metering unit is damaged plugs again or replace flow metering unit nit

3

connection of flow metering unit is bad

Bnc connector plugs is loose

pull out and insert again

4

timing of timing timing of gear is wrong re-adjust as gear of high when installing fuel requirement pressure pump of technics fuel pump is wrong

3.2.2高压油泵故障分析
故障表现:不能起动、启动困难、跛行回家故障 1、高压油泵出油管不出油 、高压油泵出油管不出油 原因:柱塞腔内有空气、齿轮泵内部有空气或柱塞磨损 处理:排除空气或更换高压油泵 2、流量计量单元常开 原因:线束插头接触不好、流量 计量单元损坏 处理:重新拔插插头或更换流量 计量单元

3.2.2 Analysis about high pressure fuel pump
Fault: can not be started, difficult to start and limp-home 1、Fuel outlet pipe of High pressure fuel pump cannot supply fuel Cause: there is air in cavity of plunger or gear pump or plunger worn Remedy: remove air or replace high pressure pump

2. Flow metering unit is often open. Cause: contact of bnc connector plugs of wiring harness is bad, and flow metering unit is damaged. Remedy: pull out and insert bnc connector plugs or replace flow metering unit.

3.2.2高压油泵故障分析 3.2.2高压油泵故障分析
Analysis about high pressure fuel pump fault y g p p p
故障表现:不能起动、启动困难、跛行回家故障 Fault: can not be started, difficult ot start and fault of limp-home 3、流量计量单元插头接触不良 、流量计量单元插头接触不良 原因:插头松动 处理:重新拔插 3. Connection of bnc connector plugs of flow metering unit is bad Cause: bnc connector plugs is loose Remedy: pull out and insert again 4、高压油泵正时齿轮正时不正确 原因:油泵安装时齿轮正时出错 处理:重新按照工艺要求调整 4. The ti i 4 Th timing of timing gear of hi h f ti i f high pressure fuel pump is wrong Cause: timing of gear is wrong when installing fuel i t lli f l pump. Remedy: re-adjust as requirement of technics

3.3共轨管 3.3共轨管 common rail pipe

压力限制阀 Pressure limiter l li it valve

进油口 Fuel inlet

轨压传感器 Rail pressure sensor

3.3.1共轨管故障分析表
序号 故障类型 原因分析 处理方法 备注

1

泄压阀异常 泄露

泄压阀密封不严或泄 压阀弹簧失效造成 轨压不到1600bar 就有燃油从泄压阀 泻出 插头接触不良、轨压 传感器损坏

更换泄压阀 或共轨管

轨压不能 常建 轨压不能正常建 立

2

轨压传感器 故障

重新拔插插 头或更换轨 压传感器

轨压不稳,无规 律;怠速时轨压 传感器信号电压 1V左右。

3.3.1 Table about analysis of common rail pipe fault
No. Fault type Cause Remedy Remarks

1

Sealing of pressure Pressure released valve is released bad or spring of valve pressure released leaks valve in invalid, abnormall which cause fuel y releases from pressure released valve when rail pressure doesn’t reach 1600bar

Replace pressure released valve or common rail pipe il i

Rail pressure cannot be set up abnormally

2

Fault of Rail pressure sensor

Connection of bnc connector plugs is b d i bad, and rail d il pressure sensor is damaged

pull out and insert bnc connector plugs again or replace rail pressure sensor

Instable and illogical rail pressure: signal voltage of rail sensor is about 1V at idling speed

3.3.2共轨管故障分析
故障表现:启动困难、跛行回家故障 1、泄压阀异常泄露 、泄压阀异常泄露 原因:泄压阀密封不严或泄压阀弹簧失效造成轨压不到1600bar就有燃油从泄压 阀泻出 处理:更换泄压阀或共轨管 2、轨压传感器故障 原因:插头接触不良、轨压传感器损坏 处理:重新拔插插头或更换轨压传感器

3.3.2 Analysis about fault of common-rail pipe commonFault: difficult to start and fault of limp-home 1.Pressure released valve leaks abnormally Cause: Sealing of pressure released valve is bad or spring of pressure released valve in invalid, which cause fuel releases from pressure released valve when rail pressure doesn’t reach 1600bar doesn t Remedy: replace pressure released valve or common-rail pipe. 2.Fault of Rail pressure sensor Cause: Connection of bnc connector plugs is bad, and rail pressure sensor is damaged Remedy: pull out and insert bnc connector plugs again or replace rail pressure sensor

3.4

ECU

3.4.1 ECU故障分析表
序号 1 故障类型 诊断仪与ECU通讯失 败、钥匙上电闪码 灯和冷起动灯不自 检 K线无电压 ECU针脚弯曲或折 断 ECU被大电流击穿 原因分析 ECU烧坏 处理方法 更换ECU 备注

2 3

1.89针脚线路问题 拔插ECU插头时 操作不规范

检查1.89线路 顺直针脚或 更换 ECU

一般为24V

4

线路短路或焊接 更换ECU 时未将ECU插头 时未将 插头 拔掉 进入导电液体 清理液体或更 换ECU

注意ECU线路的 靠性 进行 可靠性、进行 焊接时注意防 护ECU 线束增加密封圈 注意防水

5

ECU针脚短路

3.4.1 Table about analysis of ECU fault
No. 1 Fault type
communication between diagnostic and ECU is failure and blink code light and cold started light cannot self-check

Cause ECU is burnt

Remedy replace ECU

remarks

2

K li has not line h t voltage ECU stitch is folded ECU is hit by big electric current

There is wrong Th i with 1.89 stitch line
Wrong operation when pull out and insert bnc connector plugs

check 1.89 h k 1 89 line Replace ECU

usually 24V ll

3

4

Turnoff or didn t didn’t pull out ECU bnc connector plugs Flow into Conductive C d ti electricity liquid

Replace ECU

Caution reliability of ECU line, and protect ECU when jointing

5

ECU stitch is turnoff

Clean liquid or Add sealing ring on wiring replace l harness, and ECU
caution waterproof

3.4.2 ECU故障分析
故障表现:柴油机不能启动、熄火故障 1、诊断仪与ECU通讯失败、钥匙上电闪码灯和冷启动灯不自检 、诊断仪与 通讯失败、钥匙上电闪码灯和冷启动灯不自检 原因:ECU烧坏 处理:更换ECU

2、K线无电压 (一般为23.5V左右) 原因:1.89针脚线路问题 处理:检查1.89线路

3.4.2 Analysis about ECU fault
Fault: engine cannot be started, flameout 1.Communication between diagnostic and ECU is failure,electric blink code light and cold started light cannot self-check. Cause: ECU is burnt. Remedy: replace ECU

2. K line has no voltage (usually about 23.5 ) g Cause: 1.89 stitch line is wrong. Remedy: check 1.89 line

3.4.2 ECU故障分析
故障表现:柴油机不能启动、熄火故障 3、ECU针脚弯曲或折断 、 针脚弯曲或折断 原因:拔插ECU插头时操作不规范 处理:顺直针脚或更换ECU 4、ECU被大电流击穿 原因:线路短路或焊接时未将ECU 插头拔掉 处理:更换ECU (注意ECU线路的可靠性、进行焊接时注意防护ECU ) 5、ECU针脚短路 原因:进入导电液体 处理:清理液体或更换ECU (线束增加密封圈注意防水 )

3.4.2 Analysis about ECU fault
Fault: engine cannot be started, and flameout 3. ECU stitch is folded Cause: there is wrong operation when pull out and insert ECU bnc connector plugs. Remedy: replace ECU 4、ECU is hit by big electric current Cause: line turnoff or did not pull out ECU bnc connector plugs Remedy: replace ECU ( R d l (caution that i h reliability of ECU line, and protect ECU when jointing ) 5、ECU stitch turnoff Cause: be flowed into conductive electricity liquid Remedy: clean liquid or replace ECU ( add sealing ring on wiring harness and pay attention to be waterproof)

3.5 传感器、线束

sensor and wiring harness

机油温度压力传感器 Oil temperature and p pressure sensor

进气温度压力传感器
Air intake temperature and pressure sensor

曲轴转速传感 Crankshaft C k h ft speed sensor

水温传感器
Water temperature sensor

轨压传感器
Rail pressure p sensor

凸轮轴转速传感 Camshaft speed sensor

3.5.1各类传感器功能分析表
Table of function of sensor

3.5.2 传感器、线束故障分析表
Analysis table for fault of sensor and wiring harness
序号 No. 1 故障类型 Fault type 传感器硬件损坏
Sensor hardware is damaged

原因分析 Cause 安装时造成插头损坏或传感 器本体外形损坏
bnc connector plugs or sensor shell is damaged when installing

处理方法 Remedy 更换新传感器 Replace a new sensor

备注

2

传感器电气特性 不正确
Electric f t El t i feature of f sensor is wrong

传感器由于电路原因损坏 Because of electrocircuit, Sensor is damaged. 未插牢或操作时损坏插头 Insert untightly or damage bnc connector plugs when operating

更换新传感器 Replace a new sensor 重新拔插或更换 线束
Pull out and insert again or replace wiring harness

3

线束插接件接触 不良或损坏
Insert part of wiring harness is bad or damaged

4

线束断路、短路
Turnoff and short circuit of wiring i it f i i harness

接线胶皮磨损或线束断开 Connection rubber worn of Wiring harness broken

防护或更换线束
Protect or replace wiring harness ii h

3.5.3传感器 、线束故障分析

1、传感器硬件损坏 、传感器硬件损坏 原因:安装时造成插头损坏或传感 器本体外形损坏 处理:更换新传感器 2、传感器电气特性不正确 、传感器电气特性不正确 原因:传感器由于电路原因损坏 处理:更换新传感器 3、线束插接件接触不良或损坏 原因:未插牢或操作时损坏插头 处理:重新拔插或更换线束

未安装

3.5.3 Analysis about sensor and wiring harness fault y g
1、Sensor hardness damaged Cause: bnc connector plugs or sensor shell damaged when installing Remedy: Replace a new sensor sensor. 2、Wrong electric feature of sensor Cause: because of electrocircuit sensor electrocircuit, is damaged Remedy: replace a new sensor 3. Insert part of wiring harness is bad or damaged Cause: Insert untightly or damage bnc connector plugs when operating. Remedy: insert and pull out again or replace wiring harness

未安装

3.5.3传感器 3.5.3传感器 、线束故障分析
Analysis about sensor and wiring harness fault

4、线束断路、短路 、线束断路、短路 原因:接线胶皮磨损或线束断 开 处理:防护或更换线束 4. Turnoff and short circuit of wiring harness Cause: connection rubber worn or wiring harness broken. Remedy: protect or replace wiring harness

3.5.4 传感器检查指导
检查部件 曲轴转速传 感器(安装 在飞轮上) 检测项目 传感器两针脚 间电阻 2.23-2.19波形 2 23-2 19波形 (怠速) 标准值 770-950欧姆

3.5.4 Guide for sensor inspection p
Assembly A bl Camshaft speed sensor (installed (i t ll d on the flywheel) Item I resistance between 2 stitches of sensor 2.23-2.19 wave shape(idling speed) Standard S d d numeral value l l 770-950 ohm

3.5.4传感器检查指导
检查部件 凸轮轴转 速传感器 (安装在 飞轮上) 检测项目 2.09与地线之间 电压(怠速) 传感器两针脚间 电阻 2.09-2.10波形( 2 09 2 10波形( 怠速) 标准值 3.2-4.9伏 770-950欧姆

3.5.4 Guide for sensor inspection
Assembly Camshaft speed sensor (installed on flywheel) Item voltage between 2.09 and ground line(idling speed) resistance between 2 stitches of sensor 2.09-2.10 wave shape(idling speed) d) Standard numeral value 3.2-4.9 V

770-950 ohm

3.5.4传感器检查指导
检查部件 流量计量单 元(安装在 高压油泵左 上方) 检测项目 流量计量单元 的电阻 数据流(怠速 时电流) 3.09—3.10怠 速时的电压波 形 标准值 2.60-3.15欧姆(环境温度20 ℃) 1380 1420mA 1380~1420mA

3.5.4 guide for sensor inspection
Assembly Flow metering unit (installed up and left side of high pressure pump) Item resistance of flow metering unit data flow (electric current in idling speed) 3.09—3.10 voltage wave shape in idling speed Standard numeral value 2.60-3.15 h ( 2 60 3 15 ohm(environmental t i t l temperature 20 ℃) t 1380~1420mA

3.5.4 Guide for sensor inspection
Assembly Rail pressure sensor (installed near right side) Item 2.14-2.12 voltage (T15上电) 2.14-2.12 voltage (idling speed) Rail pressure(idling p g speed) Changed range ( voltage of rail p pressure sensor) Standard numeral value 0.5V 1.2~1.5V 340~450bar 0.5~4.5伏(0bar~1800bar)

3.5.4传感器检查指导
检查部件 水温传感器 (安装在出水管 上) 检测项目 2.15-2.16之 间在不同水温 时电阻特性( 见右图, Rnom为标准 值, 值,Rmin为 为 允许的最小值 ,Rmax为允 许的最大值) 标准值

3.5.4 guide for sensor inspection
Assembly water temperature sensor (installed on the water outlet pipe) Item resistance feature from 2.15 to 2.16 in different water temperature p (right picture) ,Rnom is standard numeral value Standard numeral value

3.5.4传感器检查指导
检查部件 进气温度压力传 感器(安装在进气 管上) 检查项目 2.36 2.25 2.36-2.25 间在不同 温度时电阻特性(见 右图) nominal 为正常值 minimum 为允许的 最小值,maximum 最小值 i 为允许的最大值 标准值

3.5.4 Guide for sensor inspection
Assembly air inlet temperature and pressure sensor (installed on air intake pipe) Item resistance feature from 2.36-2.25 in different temperature (right picture) nominal i standard i l is t d d numeral value, Standard numeral value

3.5.4传感器检查指导
检查部件 进气压力传 感器 检测项目 2.34-2.25之间 电压(怠速) 2.34-2.25之间 电压 标准值 0.5~0.8伏

3.5.4 Guide for sensor inspection
Assembly Assembl air inlet pressure sensor Item voltage from 2.34 to 2.25( idling speed) Voltage from 2.34 to 2.25 Standard numeral value n meral al e 0.5~0.8 V

3.5.4传感器检查指导
检查部件 机油温度传感 器 检测项目 2.28-2.24之间 的在不同温度时 电阻特性(见右图 ,nominal为标准 值,minimum为 允许的最小值, maximum为允许 的最大值) 标准值

3.5.4 Guide for sensor inspection
Assembly oil temperature sensor Item resistance feature of 2.28- 2.24 in different temperature (right picture), nominal is standard value Standard numeral value

3.5.4传感器检查指导
检查部件 机油压力传 感器 检测项目 2.27-2.24之 间电压 标准值

3.5.4 Guide for sensor inspection
Assembly Assembl oil pressure sensor Item Voltage of 2.27 -2.24 Standard numeral value n meral al e

3.5.4 传感器检查指导 Guide for sensor inspection p
检查部件 Assembly Assembl 进气加热继电器 Air intake heating relay l 检测项目 Item 标准值 Standard n meral value numeral al e

23~29伏 (V) 1.55-1.59电压 (T15上电,进气加热工作时 ) Voltage of 1.55-1.59

3.6油门踏板 accelerator pedal p

3.6.1油门踏板故障分析表
序号 1 2 3 故障类型 油门接插件接触不良 油门接线短路、断路 油门接线短路 断路 油门踏板开度异常:不 踩时有开度,或踩到底 踩时有开度 或踩到底 不到100%(描述不规范 ) 原因分析 插接不牢 接线胶皮磨损或 线束断开 踏板输出电压不 符合ECU要求 处理方法 重新拔插 防护 更换踏板 APP1:0.753.84V 3 84V APP2:0.3751.92V 备注

4

油门信号2倍电压关系不 成立

踏板不符合要求

排除线路原 信号1为信号2 因后更换踏 的两倍( 板 电压)

3.6.1 Table about accelerator pedal fault
No. 1 Fault type Inserting part of accelerator is not good Turnoff and short circuit of accelerator opening of accelerator pedal is abnormal Cause Insert untightly Remedy Pull out and insert again protection 备注

2

Connection rubber worn or wiring harness broken That pedal output voltage cannot reach requirement of EUC

3

replace pedal

APP1:0.753.84V APP2:0.3751.92V 1 92V

4

Double voltage relationship of accelerator is failure

Pedal cannot reach Replace pedal Signal1 is the requirement after double remove signal cause of 2(voltage) line

3.6.2油门踏板故障分析
故障表现:柴油机始终在1000转运转、怠速高 1、油门接插件接触不良 、油门接插件接触不良 原因:插接不牢 处理:重新拔插 2、油门接线短路、断路 原因:接线胶皮磨损或线束断开 处理:防护 3、油门踏板开度异常: 不踩时有开度,或踩到底不到100% 原因:踏板输出电压不符合ECU要求 处理:更换踏板

3.6.2 analysis about accelerator pedal fault
Fault: engine runs at speed of 1,000r/min always, and idling speed is high 1. 1 Accelerator parts contacts bad Cause: insert untightly. y p g Remedy: pull out and insert again 2. Turnoff and short circuit of accelerator connection Cause: connection rubber worn or wiring harness broken y Remedy: protection 3. Opening of accelerator pedal is abnormal Cause: that pedal output voltage cannot reach requirement of ECU f C Remedy: replace pedal.

3.6.2 油门踏板故障分析 Fault analysis about accelerator pedal
故障表现:易造成柴油机1000转、怠速高 4、油门信号2倍电压关系不成立 、油门信号 倍电压关系不成立 原因:踏板不符合要求或线路问题 处理:排除线路原因、更换踏板

Fault performance: Diesel engine operates with 1000r, and idling speed i hi h d is high. 4. Double voltage relationship of accelerator signal is failure. g Cause:pedal cannot reach the requirement. Remedy: Remove line problem and remove pedal.

谢谢 谢谢! Thank Th k you! !
第 182页 共 页


相关文章:
更多相关标签: