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

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.Ltd.
目录
Content
一、概述 Introduction
二、故障诊断与案例分析
Failure Diagnosis
g and Case Analysis
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
g Pressure Common Rail System
y
潍柴动力蓝擎欧Ⅲ柴油机 Weichai Power Landking Guo III Diesel Engines
¾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
¾BOSCH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,
reliability economy
economy,
safety, comfort and highly intelligentizing.
¾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
¾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
ifi d are putt iinto
t the
th market,
k t which
hi h ensure the
th excellent
ll t quality.
lit
¾10万台潍柴动力蓝擎欧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
Introduction of High Pressure Common Rail System
BOSCH电控高压共轨系统原理图
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
y
潍柴动力蓝擎欧Ⅲ柴油机Weichai Power Landking Guo III diesel engines：
¾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
¾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%
Much more economical--- Fuel consumption p per
p 100 km is less 5-10% than that of
mechanical pump vehicle at the same condition
¾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)
¾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 The period of “Three
brand. Three Guarantees”
Guarantees for fuel system is much longer.
longer
第 7页共页
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）振动对比WD615提速性驾驶400公里

noise (db) vibration 能疲劳程度
Speed-up 400km-driving
performance fatigue
compared with
WD615
WD615 115 100%
WP10 97 提高10% 63%

Improving by 10%
WP12 96 提高35% 50%
Improving by 35%
第 8页共页
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
第二：油耗低
2. Low fuel consumption
z 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
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
l i ffuel-saving
l i ttechnology
h l products:
d t
¾ WP多功率省油开关
WP multi-power fuel-saving switch
¾ 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)
z 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.
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
30.000km.
000km
WP10 对比 WD615：
WD615 WP10 VS
VS. WD615
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)
保养项目（套/台）定额
WP10 WD615 备注 note
Maintenance item (set/unit) quota
柴油粗滤芯fuel coarse filter （1）WP10保养周期为3万
core＋精滤芯fine filter 公里，但每1万公里需
core+除水放心滤滤芯 3 334 26 换一次机油滤芯
trustworthy dewater filter The maintenance interval of
core （个piece） WP10 is 30000km, but
机油滤芯 oil filter core should be
2 40 40 replaced once every
oil filter core（个piece） 10000km
机油oil（L） 24 534 355 （2）WD615保养周期为1
万公保养费用
3万公里保养费用maintenance 万公里；
908＋80 421×3 The maintenance interval of
expenses of 30,000km
＝988 =1263 WD615 is 10000km
（元RMB）
（3）WP10采用蓝擎欧
年保养费用合计total
一年保养费用合计total ⅢCH-4专用机油。
ⅢCH 4专用机油。
maintenance expenses for 5928 7578 WP10 applies Landking Guo
one year（元RMB） III CH-4 special oil
第三、保养成本更低
3. Much lower maintenance cost
¾ 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)
WP12 对比 WD12 WP12 VS.WD12
保养项目（套/台）定额 WP12 WD12 备注

Maintenance item (set/unit) quota note
柴油粗滤芯fuel coarse filter 3 334 26 （1）WP12保养周期为3万
＋精滤芯fi filt
core＋精滤芯fine filter 公里但每1万公里需
公里，但每1万公里需
core+除水放心滤滤芯换一次机油滤芯；
trustworthy dewater filter The maintenance interval of
core （个piece）
个p WP12is 30000km,, but oil
机油滤芯 2 82 40 filter core should be
replaced once every
oil filter core
10000km
（个piece）（2）WD12保养周期为1万
机油oil（L） 36 770 430 公里；
The maintenance interval of
3万公里保养费用 1186＋164 496×3
WD12 is 10000km
maintenance expenses of ＝1350
1350 =1488 （3）WP12采用蓝擎欧Ⅲ
30,000km（元RMB） CH-4专用机油。
一年保养费用合计total 8100 8928 WP12 applies Landking Guo
maintenance
i expenses for
f III CH
CH-44 special
i l oil
il
one year（元RMB）
第四、油品适应性更强
4. Much better suitability of oil
¾ 高效增强过滤器：
Intensifier filter with high efficiency
9 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 filterr core
Trrustworth
Fuell
柴油粗、精滤芯
除水放心滤
hy dewate
er filter
¾ 除水放心滤
Trustworthy dewater filter
9 “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.
9 “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
h the
th high-efficiency
hi h ffi i ffunction
ti off fuel-water
f l t separation,
ti and
d users can use it att
ease.
9 “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.
9 “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
high volume transparent water cup with good low
low-temperature
temperature resistance
performance, which is convenient for drivers to observe water level so as to drain
off water in time.
9 “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.
z 特别提示：
Special attention:
¾ 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
t ust o t y de
dewater
ate filter”
te a and
dddrain
a o off water
ate in
time.
¾ 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.
¾ 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
F il
Failure Di
Diagnosis
i and
dCCase A
Analysis
l i
第 18页共页
故障诊断与排除原则
Failure Diagnosis and Removal Principle
¾ 柴油机出现故障时，采用先易后难逐
柴油机出现故障时，采用先易后难逐一排除法
排除法
When diesel engine is failure, removal method of “easy first and difficult
later” one by one should be applied.
¾ 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.
¾ 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:
yp Diesel engine
g can’t be started
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。
R d blink
Read bli k code
d according
di t blink
to bli k light
li ht to
t
make sure failure. Turn to next step if the WP-VDS100故障诊断仪
failure can’t be confirmed.
¾ 闪码的读取有两种途径：
闪的读有种途径
Two ways to read blink code:
9 通过故障诊断仪读取；
故诊断仪读取；
Read through failure diagnosis equipment;
9 或通过柴油机闪码灯的闪码读取
or read through blink code light . 执行元件故障灯
执行元件—故障灯
Failure type1: Diesel engine can’t
can t be started
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
05
0.5s
1s
can t be started
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
through, then turn on the key
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.
can t be started
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
can t be started
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 空档开
be started. 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
检查整车起动线路电瓶是否常若仍无法起动转下 Neutral shift switch
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 Stop motion switch
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。车下停车开关
Diagnose whether the starter works normally or not. If the problem
still can’t be solved,
solved should further inspect if the diesel engine
rotates freely or not, valve timing right or not. Turn to the next step
if it still can’t be started.
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.
can t be started
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： Camshaft speed sensor
C t t people
Contact l from
f special
i l repair
i station
t ti t use
to
professional equipment to inspect as follows: 凸轮轴转速传感器
¾ 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
动转下步图
动转下一步；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) 48). Turn to the next step if
it still can’t be started.
¾ 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 曲轴转速
传感器
crankshaft
k h ft rotary
t transducer
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 batteryy jar j are all normal,, but
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
5 minute flameout, the difficulty in starting appears again. Inspect the fuel passage and
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
filter, and air enters the fuel passage
passage, which
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
can t be started
粗滤的进油口螺纹有损伤，
且进油口有细微裂纹
There s damage in the thread

There’s
of fuel inlet of fuel coarse
filter, and fine crack in fuel
inlet
放气螺 Air deflation bolt

栓
手压泵
回油空心螺
Hand pump 栓
Fuel return hollow bolt
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
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 d neutral
t l shift
hift switch
it h are normal;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 F th iinspectt if th
4.Further the bbattery
tt jjar gets
t th
through
h th
the ffour wires
i off ECU
ECU. Aft
After measuring
i voltage,
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
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:
1．70针脚被烧断
One of whole vehicle plug stitches
1．70
1 70 stitch
broke, and other thick stitches rust.
was burnt out
第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
1.The starter can work normally, but the engine can’t
can t be started.
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 Inquiry that the customer fills up -10＃fuel
3. 10＃fuel when get the vehicle in Beijing
Beijing, but it can’t
can t be
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.
blocking The required fuel should be replaced in time according to actual status when
the vehicle is running trans-regionally with large temperature difference
Remedy
Dredge fuel passage, and replace with -35# fuel

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。

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
P lit ffuell with
ith hi
high
h water
t content
t t can cause iinjector
j t needle-valve
dl l wore and
d titightless
htl
sealing. If the injector leakages too much, the engine can’t be started.
R
Remedy
d
Replace injector, and add trustworthy dewater filter

Failure type1:
yp Diesel engine
g can’t be started
损左侧为原车上用油
坏 The left is the original fuel
的 used
喷
油右侧为正常油。
器 The right is normal fuel
Damaged injector
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，加装除水放心滤。
更换高压油泵加装除水放滤
1.The starting system and low pressure fuel passage are normal, and no blink code. The above
methods can
can’tt remove the failure
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 Cut off fuel outlet pipe of high pressure fuel pump
3. pump, and start the engine through starter
starter. It’s
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
200-250r/min,
250r/min and the normal fuel pillar should be 4
4-5cm)
5cm)
Case analysis
Poor quality diesel with high water content leads to damage off high pressure fuel
f pump
plunger
Remedy
Replace high pressure fuel pump, and add trustworthy dewater filter
can t be started
油品对比情况高压油泵柱
F l brand
Fuel b d contrast
t t 塞损坏
HP fuel pump
plunger is
damagedg
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,
code and confirm the failure.
failure Turn to the
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，若仍不能顺利起闪
动转下一步码
3rd step: Inspect that if the starter is normal, electricity of the 灯
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
Failure type 2: The diesel engine starts with difficulty (can start,
start but with difficulty)
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:
p Inspect
p whether crankshaft rotary y transducer and camshaft
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:
t C t t special
Contact i l repair
i station
t ti people,
l and d use professional
f i l
equipment to inspect as follows: WP-VDS100故障诊断仪
¾ 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 Failure diagnosis
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.
¾ 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
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 rotary transducer
crankshaft
凸轮轴转速传感
器 Camshaft speed
p sensor
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
2.1. Case description
1. Noopproblems
ob e s a are
e found
ou d ou
out a
after
e inspection
spec o as the
e abo
aboveepprocedures.
ocedu es
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

损坏的传
感器
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）
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 fails)
f il )
Remedy
Reconnect the sensor (or replace with a new sensor)

Failure type
yp 2: The diesel engine
g starts with difficulty
y (can
( start,, but with difficulty)
y)
未安装Not 未安装
installing Not installing
Failure type 3: After the engine’s started, it’s flameout automatically
检查步骤 Inspection Steps:

第一步：读取闪码，确定故障点，若无法确定转
第步：读取闪码，确定故障点，若无法确定转
下一步。
故障诊断开
1st step: Read blink code and confirm the 关
failure. Turn to the next step if can’t confirm it.
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，放气
若问题不能解决转下一步。
若问题不能解决转下步螺栓
3rd step: Inspect if wires, sensors and plug is 手
压回油空
damaged. Turn to the next step if the problem 心螺栓
can’t be solved. 泵
第三类故障：柴油机起动后自动熄火
Failure type 3: After the engine’s
engine s started,
started it’s
it s flameout automatically
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:
¾ 使用故障诊断仪检查飞轮信号盘与油泵凸轮信号盘是否 WP VDS100故障诊断仪
WP-VDS100
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
i l panell and
d ffuell pump camshaft
h ft signal
i l panell are
synchronous (the synchronous signal of data stream is
48 ). Turn to the next step if the problem still can’t be
solved.
¾ 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。

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

tank, air bubble caused by fuel return are sucked into the fuel
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
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

1. The engine works for a while, then flameout, stops for a while, then back to be normal, but
a moment later,
later flameout again
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
t
temperaturet rapidly
idl iincrease tto about
b t 107℃ after
ft starting,
t ti but
b t the
th water
t temperature
t t actually
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 d flflameoutt when
h lload.d
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.
R
Remedy
d
Replace water temperature sensor

Failure type
yp 3: After the engine’s
g started,, it’s flameout automaticallyy
水温传感器
Water
temperature
sensor
第 55页共页
engine s started, it’s
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
1.The
1 The engine starts normally
normally, but the speed is up and down automatically
automatically, then flameout
flameout. The blink
code light is on.
2. Read blink code displaying 324—the speed signal has some problems. The customer reflects that
th speed
the d sensor was ttouched
h d when
h fifix th
the mileage
il counter.
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

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

1. After the engine starting for 1-2 seconds, it’s flameout automatically. At the same time, the
engine
i iis dith
dithering,
i andd th
the speed d rapidly
idl iincreases tto 540 r/min,
/ i ththen ddecrease iimmediately.
di t l
2. Inspect low pressure fuel passage and HP fuel passage and find that no leakage or fuel return
pipe squeezed.
3 Di
3. Dismantle
tl th
the ffuell return
t pipe
i off iinjectors
j t and d PRV
PRV, th
then start
t t th
the vehicle
hi l andd fifind
d th
thatt th
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
R l
Replace CR
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
engine s started,
started it’s
轨压传感器
Rail pressure sensor

轨压传感器
Pressure limiting valve
压力限制阀进油口
fuel inlet

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 U
3. Use multimeter
lti t tto measure 1.04
1 04 stitch
tit h with
ith no voltage.
lt Hereby,
H b it’sit’ confirmed
fi d that
th t ECU
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
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

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. Inspect
3 spec ECUCU po
power e wiree iss normal
o a ((If the
e po
power
e is
s ope
open ccircuit,
cu , which
c pprobably
obab y cause thee
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.
Case analysis
Since the wire is not fixed

fixed, when it’s
it s wore out
out, it causes signal’s
signal s short circuit
circuit, and the wrong
signal is transmitted to ECU.
Remedy
y
Reconnect the wire, and remove the failure

传感器线束
Sensor wire harness
Water temperature sensor Oil pressure sensor

Camshaft speed sensor
水温传感器机油压力传感器凸轮轴转速传感器
曲轴转速传感器
crankshaft rotary transducer

Air inta
ake pressu
轨压传感器
Rail pressure sensor

进气压
压力传感器
ure sensorr
第四类故障：柴油机冒黑烟
Failure type
yp 4: The engine
g exhausts black smoke
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
常转下一步。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.
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:
¾ 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.
¾ 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》。
U ffailure
Use il di
diagnosis i equipment
i t to
t further
f th inspect
i t whether
h th railil pressure iis b
built
ilt
normally. If not, it’s probably caused by injector, CR, HP fuel pump and ECU, Please
refer to Parts Failure Analysis
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
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
g to inspect:
p the rail p
pressure can only
y reach 160bar when start.
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
Failure type
yp 4: The engine
Injector binding post

喷油器接线柱
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
1.The
1 Th enginei exhausts
h t bl
black
k smoke,
k b butt iinspectt th
thatt air
i filt
filter, air
i passage and
d tturbocharger
b h 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
Failure type
yp 4: The engine
喷油器已经
生锈
Injectors rust
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
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
g to monitor air intake pressure, speed, rail pressure and fuel delivery: y when
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
passage
p g has some p problem. After careful inspection,
p , it’s found a 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
air intake tube
Failure type
yp 4: The engine
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
multi power fuel-saving
fuel saving switch,
switch inspect if the
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.
normal Turn to the next
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:
step Inspect if air filter,
filter air-intake
air intake passage and turbocharger
t rbocharger work
ork normally.
normall Turn
T rn to
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.
Failure type
yp 5: Insufficient p
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。
as follows:
¾ 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。
camshaft signal panel are synchronous (the synchronous signal of data stream is 48 ).
Turn to the next step if still Insufficient power
power.
¾ 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
¾ 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.
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
2、读取闪码为114——曲轴转速传感器信号异常
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
1. When the speed reaches 1500r/min in the process of driving, it appears unsteady speed, and
th whole
the h l vehiclehi l dith
dithering.
i Th
The speed d can’t
’t b
be iincreased
d even if kkeep stepping
t i on accelerator.
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
3. U ffailure
il di
diagnosisi to iinspect and
d fifind
d that
h step on accelerator
l to speed-up
d when
h the
h vehicle
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.
R
Remedy
d
Replace crankshaft rotary transducer

Failure type
yp 5: Insufficient p
power
Crankshaft rotary transducer
曲轴转速传感器
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
I
Insufficient
ffi i t power, no blink
bli k code.
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
Remedy
更换多功率省油开关
R l
Replace multi-power
li f l
fuel-saving
i switch
i h
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

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

打褶部位
正常 normal
Failure
a u e type
ype 5
5: Insufficient
su c e po power
e
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

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
中冷器开裂
intercooler
splits
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
2、读取闪码为143——3缸喷油器线束开路
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
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
y injector
j wire harness is
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
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一步。
第二步：根据闪码确定故障并排除，若仍不能排除进入下步。
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 Inspect
3rd step: p if the low p
pressure fuel p
passage
g is seriouslyy blocked,, fuel meets the
requirement of ambient temperature. Turn to the next step if can’t remove the failure.
Failure type 6: Limp
Limp-home
home
检查步骤Failure removal steps:
第步联特约修
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:
¾ 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
）若不能排除转下步
）。若不能排除转下一步。
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.
¾ 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
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
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
seconds, the actual rail pressure value exceeds setting value
value. Hereby
Hereby, it’s
it s confirmed that
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

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
Limp home
1.It
1 It appears the max
max.speed
speed of 1500r/min when running
running, and the blink code light is on
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 Use failure diagnosis to monitor rail pressure: it rapidly increases to 1800bar
4. 1800bar, then decreases
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
p metering
g unit or HP fuel p
pump,
p, clean fuel p
passage
g and replace
p fuel.
Limp-home
home
流量计量单元故障metering unit failure
流量计量单元
metering unit
¾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
wire, to judge metering unit failure or rail
pressure sensor failure.
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
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
pp limit value.
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

Limp-home
home
功能：可以检测进气压力和温度
进气压力传感器 air-
air-intake pressure sensor
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

1. The blink code light
g is on now and then when running. g The max. speed
p can reach 1500r/min,,
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

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1300b
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
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
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
p HP fuel ppassage 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
g to test HP: when the speed
p is 2200r/min,, the actual rail 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.
C
Case analysis
l i
Injector failure
Remedy
R l
Replace iinjector
j t
Failure type
yp 6: Limp-home
p
Injector fuel return back pressure
Fine filter 喷油器回油背压: 0~1bar
精滤相对压力
Gear pump outlet back pressure Absolute pressure
齿轮泵出口背压: < 9.0 bar 喷 Pressure
油 limiting valve
绝对压力器限压阀
Absolute pressure
rail 油
轨
过压保护阀 by-pass valve 油量计量单

旁通元 metering
Overpressure protection 阀 unit
溢流阀
Gear pump inlet back pressure Spillover valve
齿轮泵进口压力: 零
0.35~1.00bar 绝对 ECU冷却盘油 CPN2.2
CPN2
压力量
手油粗滤孔
油泵回油背压 <1.2 bar绝
油泵回油背压: 绝
泵
Hand pump Coarse filter 对压力 HP fuel passage
: 高压油路:
高压共轨油路原理图低压油路
Low pressure fuel passag
Schematic diagram of HP CR fuel passage
第七类故障：柴油机怠速不稳
Failure type7:
yp Idle speed
p is not stable

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
h failure.
f il
Failure type7: Idle speed is not stable
故障排除步骤Failure removal steps:

as follows:
¾ 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.
¾ 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
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
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 be
b shielded.
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
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.
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

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
p that the electric accelerator p
pedal p
plug
g is normal
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
p accelerator p
pedal
¾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.
¾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
Ti ht belt
Tighten b lt ((remove th
the sensor ffailure)
il )
• 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。
N t After
Note: Aft iinstall
t ll th
the b
belt,
lt pullll outt th
the pin
i off
belt tensioner with pliers to realize
automatic tension.
皮带松
Belt
looses
第 116页共页
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
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.

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
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 The engine doesn
2. doesn’tt dither after stop the vehicle.
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
序号故障类型原因分析处理方法备注
1 喷油器雾化不良油头处积碳严重清理，如故障不能消
清理如故障不能消
除，更换喷油器
2 喷油器不喷油针阀卡死在关闭状态更换喷油器
3 喷油器油头处滴油针阀卡死在常开位置或喷油更换喷油器

器针阀磨损造成密封不
严
4 单个喷油器回油量大或与回油柱塞锥面磨损密封不严更换喷油器
其它喷油器差别较大
5 喷油器铜套或垫片变形损安装时定位不准造成变形或更换铜套或垫片安装时注意

坏拧紧时用力过大定位
6 喷
接线柱螺帽松动造成喷油螺帽、线束固定不牢固定好螺帽、线束
器线束松动或磨破与
缸盖短路
7 喷油器电磁阀损坏短路或其它原因形成大电流更换喷油器喷油器电阻
烧坏 0 9欧姆
0.9欧姆
3.1.1 Table about analysis of injector fault
No. Fault type Cause Remedy Remarks
1 atomization
t i ti off injector
i j t is i Carbon
C b deposit
d it heavily
h il on clean
l replace
l injector
i j t
bad fuel head if fault cannot be
removed
2 Injectors
j don’t inject
j fuel Needle valve is locked in Replace
p injector
j
closed state
3 fuel head of injector drip Needle valve is locked at Replace injector

fuel usual position or needle
valve of injector is worn
and its sealing isn’t tight
4 Fuel return amount per Fuel return plunger taper is Replace injector
injector is great or it is worn andd its
it sealing
li isn't
i 't
very different from other
tight
ones
5 Injector Bronze cover or Inexact orientation lead to Replace bronze pay attention to
washer
h iis di
distorted
t t d or distort or tighten with cover or washer orientation
when
damaged big strength when
installing
installing
6 Screw cap of connection pole Screw cap and wiring
g fasten screw cap and
is loose, which causes harness cannot fasten wiring harness
wiring harness of injector
firmly
is loose or worn and
cylinder head is short
circuit
7 electromaqnetism valve Turnoff or big electric Replace injector resistance of
of injector is current is burnt because injector is
0.9 ohm
damaged of other causes
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
doesn’tt inject fuel
cause: injector is locked in closed state
remedy: replace injector
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
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
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
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
Fault: insufficient power, black smoke exhaust, difficult to start and limp-home
fault
5 Bronze cover or washer of injector is distorted and
5.
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.
Fault: insufficient power, block smoke exhaust, difficult to start, and limp
limp-home
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
7. Electromagnetism
g valve of injector
j is
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
高压油出口
柴油进口（来自滤器） High pressure
柴油出口（到油箱）
fuel outlet
Diesel fuel inlet (from filter)
流量计量单元 Diesel fuel outlet (to
Flow metering unit 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）初始机油注油口阀盖
初始机油注油阀盖
Fuel outlet (to filter) Initial oil filler valve cap
凸轮轴相位传感器: DG6
柴油进口（自油箱） Camshaft
C amshaft phase sensor
Fuel inlet (from fuel DG6
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
1 高压油泵出油柱塞腔内有空气、齿排除空气或更潍柴各种泵集成

管不出油轮泵内部有空气或柱换高压油泵的输油泵有两
塞磨损种旋向，需注
意不能混淆
2 流量计量单元线束插头接触不好、重新拔插插头流量计量单元
常开流量计量单元损坏或更换流量电阻为
计量单元 2.6～3.15欧姆
3 流量计量单元插头松动重新拔插
插头接触不
良
4 高压油泵正时油泵安装时齿轮正时重新按照工艺

齿轮正时不出错要求调整
正确
3.2.1 Table for analysis of high pressure fuel pump
No. Fault type Cause Remedy remarks
1 fuel outlet pipe of there is air in plunger Remove air or There are 2
high pressure or gear pump, or replace high rotation
fuel pump can plunger is worn pressure
supply fuel direction in gear
fuel pump pump,
p p, do not
confuse
2 flow metering Connection of Bnc pull out and insert resistance of flow
unit is often connector plugs of bnc metering unit is
open wiring
i i harness
h is
i bad,
b d connector
t 2.6～3.15ohm
and flow metering unit plugs again
is damaged or replace
flow metering
unit
nit
3 connection of Bnc connector plugs is pull out and
flow loose insert again
metering
unit is bad
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
y about high
g ppressure fuel pump
p p fault
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. Th
4 The timing
ti i off timing
ti i gear off hi
high
h
pressure fuel pump is wrong
Cause: timing of gear is wrong when
i t lli ffuell pump.
installing
Remedy: re-adjust as requirement of
technics
3.3共轨管
3.3 共轨管 common rail pipe
压力限制阀进油口轨压传感器

Pressure Fuel inlet Rail pressure
li it valve
limiter l sensor
3.3.1共轨管故障分析表
1 泄压阀异常泄压阀密封不严或泄更换泄压阀轨压不能常建

轨压不能正常建
泄露压阀弹簧失效造成或共轨管立
轨压不到1600bar
就有燃油从泄压阀
泻出
2 轨压传感器插头接触不良、轨压重新拔插插轨压不稳，无规

故障传感器损坏头或更换轨律；怠速时轨压
压传感器传感器信号电压
1V左右。
3.3.1 Table about analysis of common rail pipe fault
No. Fault type Cause Remedy Remarks
1 Pressure Sealing of pressure Replace Rail pressure

released released valve is pressure cannot be set
valve bad or spring of released up abnormally
pressure released
leaks valve in invalid,
valve or
abnormall which cause fuel common
y releases from rail
il pipe
i
pressure released
valve when rail
pressure doesn’t
reach 1600bar
2 Fault of Rail Connection of bnc pull out and Instable and
pressure connector plugs insert bnc illogical rail
sensor i bad,
is b d and
d rail
il connector pressure:
plugs again
pressure sensor or replace
signal voltage
is damaged rail of rail sensor
pressure is about 1V at
sensor 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-
common-rail pipe
Fault: 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
doesn t reach 1600bar
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
1 诊断仪与ECU通讯失 ECU烧坏更换ECU

败、钥匙上电闪码
灯和冷起动灯不自
检
2 K线无电压 1.89针脚线路问题检查1.89线路一般为24V
3 ECU针脚弯曲或折拔插ECU插头时顺直针脚或

断操作不规范更换 ECU
4 ECU被大电流击穿线路短路或焊接更换ECU 注意ECU线路的

时未将
时未将ECU插头
插头靠性进行
可靠性、进行
拔掉焊接时注意防
护ECU
5 ECU针脚短路进入导电液体清理液体或更线束增加密封圈
换ECU 注意防水
3.4.1 Table about analysis of ECU fault
No. Fault type Cause Remedy remarks
1 communication between ECU is burnt replace

diagnostic and ECU is
failure and blink code ECU
light and cold started
light cannot self-check
2 K li
line has
h nott There is
Th i wrong check
h k 1.89
1 89 usually
ll 24V
voltage with 1.89 line
stitch line
3 ECU stitch is Wrong operation when Replace ECU
pull out and insert
folded bnc connector
plugs
4 ECU is hit by big Turnoff or didn

didn’tt Replace ECU Caution
electric current pull out ECU reliability of
bnc ECU line,
connector and protect
plugs ECU when
jointing
5 ECU stitch is turnoff Flow into Clean liquid or Add sealing ring
C d ti
Conductive replace
l on wiring
electricity ECU harness, and
caution
liquid
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:
R d replacel ECU ((caution
i that
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进气温度压力传感器曲轴转速传感

Oil temperature
p and Air intake temperature
pressure sensor and pressure sensor C k h ft
Crankshaft
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
No. Fault type Cause Remedy
1 传感器硬件损坏安装时造成插头损坏或传感更换新传感器
Sensor hardware is 器本体外形损坏 Replace a new
damaged bnc connector plugs or sensor sensor
shell is damaged when
installing
2 传感器电气特性传感器由于电路原因损坏更换新传感器
不正确 Because of electrocircuit, Replace a new
Electric
El t i feature
f t off Sensor is damaged. sensor
sensor is wrong
3 线束插接件接触未插牢或操作时损坏插头重新拔插或更换
不良或损坏 Insert untightly or damage 线束
Insert part of wiring Pull out and insert
bnc connector plugs when again or replace
harness is bad or
operating wiring harness
damaged
4 线束断路、短路接线胶皮磨损或线束断开防护或更换线束

Turnoff and short Connection rubber worn of Protect or replace
circuit
i it off wiring
ii wiring
i i harness
h
Wiring harness broken
harness
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
未安装
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
3.5.3 Analysis
y about sensor and wiring
g harness fault
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,
electrocircuit sensor
is damaged
Remedy: replace a new sensor
3. Insert part of wiring harness is bad or 未安装

damaged
Cause: Insert untightly or damage
bnc connector plugs when operating.
Remedy: insert and pull out again or
replace wiring harness
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
检查部件检测项目标准值
曲轴转速传传感器两针脚 770-950欧姆

感器（安装间电阻
在飞轮上）
2.23-2.19波形
2 23-2 19波形
（怠速）
3.5.4 Guide for sensor inspection
p
A
Assembly
bl I
Item S d d numerall value
Standard l
Camshaft resistance 770-950 ohm
speed between 2
sensor stitches of
(i t ll d on
(installed sensor
the
2.23-2.19 wave
flywheel)
shape（idling
speed）
3.5.4传感器检查指导
凸轮轴转 2.09与地线之间 3.2-4.9伏
速传感器电压（怠速）
（安装在
传感器两针脚间 770-950欧姆
飞轮上）
电阻
2.09-2.10波形（
2 09 2 10波形（
怠速）
Assembly Item Standard numeral value
Camshaft voltage between 3.2-4.9 V
speed 2.09 and ground
sensor line（idling
(installed speed）
on
resistance 770-950 ohm
flywheel)
between 2
stitches of sensor
2.09-2.10 wave
shape（idling
speed）
d）

流量计量单流量计量单元
元（安装在的电阻 2.60-3.15欧姆（环境温度20 ℃）
高压油泵左
上方）数据流（怠速 1380～1420mA
1380 1420mA
时电流）
3.09—3.10怠
速时的电压波
形
3.5.4 guide for sensor inspection
Flow resistance of
metering flow metering 2 60 3 15 ohm（environmental
2.60-3.15 h （ i t l ttemperature
t 20 ℃）
unit unit
(installed up
data flow 1380～1420mA
and left side
(electric
of high
current in idling
pressure
speed)
pump)
3.09—3.10
voltage wave
shape in idling
speed
Rail 2.14－2.12 voltage 0.5V
pressure （T15上电）
sensor
(installed 2.14－2.12 voltage 1.2～1.5V
near right （idling speed）
side) Rail p
pressure（idling
g 340～450bar
speed）
Changed range 0.5～4.5伏（0bar～1800bar）
（ voltage of rail
pressure sensor）
p
水温传感器 2.15－2.16之
（安装在出水管间在不同水温
上）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)
3.5.4 guide for sensor inspection
water resistance
temperature feature from
sensor 2.15 to 2.16
（installed on in different
the water outlet water
pipe） temperature
p
(right picture)
，Rnom is
standard
numeral value
检查部件检查项目标准值
进气温度压力传 2.36 2.25 间在不同

2.36-2.25
感器(安装在进气温度时电阻特性(见
管上) 右图)
nominal 为正常值
minimum 为允许的
最小值
最小值，maximumi
为允许的最大值
air inlet resistance feature

temperature and from 2.36-2.25 in
pressure sensor different
(installed on air temperature (right
intake pipe) picture)
nominal
i l iis standard
t d d
numeral value，

进气压力传 2.34－2.25之间 0.5～0.8伏
感器电压（怠速）
2.34－2.25之间
电压
Assembl
Assembly Item Standard numeral
n meral value
al e
air inlet voltage from 0.5～0.8 V
pressure 2.34 to 2.25（
sensor idling speed）
Voltage from
2.34 to 2.25
机油温度传感 2.28－2.24之间
器的在不同温度时
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)
oil resistance
temperature feature of 2.28－
sensor 2.24 in different
temperature
(right picture)，
nominal is
standard value

机油压力传 2.27－2.24之
感器间电压
Assembl
Assembly Item Standard numeral
n meral value
al e
oil pressure Voltage of 2.27
sensor －2.24
3.5.4 传感器检查指导
Guide for sensor inspection
p

Assembl
Assembly Item Standard n
numeral
meral value
al e
进气加热继电器 1.55－1.59电压 23～29伏 (V)
Air intake heating （T15上电，进气加热工作时
relay
l ）
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
1 油门接插件接触不良插接不牢重新拔插
2 油门接线短路断路
油门接线短路、断路接线胶皮磨损或防护
线束断开
3 油门踏板开度异常：不踏板输出电压不更换踏板 APP1：0.75-
踩时有开度或踩到底
踩时有开度，或踩到底符合ECU要求 3 84V
3.84V
不到100%（描述不规范 APP2：0.375-
） 1.92V
4 油门信号2倍电压关系不踏板不符合要求排除线路原信号1为信号2

成立因后更换踏的两倍（
板电压）
3.6.1 Table about accelerator pedal fault
No. Fault type Cause Remedy 备注
1 Inserting part of Insert untightly Pull out and

accelerator is not insert
good again
2 Turnoff and short circuit Connection rubber protection
of accelerator worn or wiring
harness broken
3 opening of accelerator That pedal output replace pedal APP1：0.75-
pedal is abnormal voltage cannot 3.84V
reach APP2：0.375-
requirement of 1 92V
1.92V
EUC
4 Double voltage Pedal cannot reach Replace pedal Signal1 is

relationship of the requirement after double
accelerator is failure 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 Accelerator parts contacts bad

1.
Cause: insert untightly.
y pull
Remedy: p out and insert again
g
2. Turnoff and short circuit of accelerator

connection
Cause: connection rubber worn or wiring
harness broken
y protection
Remedy:
3. Opening of accelerator pedal is abnormal

Cause: that pedal output voltage cannot reach
requirement off ECU
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
d iis hi
high.
h
4. Double voltage relationship of
accelerator signal
g is failure.
Cause：pedal cannot reach the
requirement.
Remedy: Remove line problem
and remove pedal.
谢谢
谢谢！
Th k you!!
Thank
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蓝擎欧Ⅲ高压共轨柴油机

Landking Guo III High Pressure Common Rail

机型 model 噪声（分贝） 振动 对比WD615提速性 驾驶400公里

WD615 115 100%

WP10 97 提高10% 63%

保养项目（套/台） 定额 WP12 WD12 备注

fuel coarse, fine filterr core

Ignition key switch

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

There s damage in the thread

放气螺 Air deflation bolt

Case 2 : Description of the Case that Diesel Engine Can’t be Started

Dredge fuel passage, and replace with -35# fuel

Case 4 : Description of the Case that Diesel Engine Can’t be Started

Replace injector, and add trustworthy dewater filter

故障排除步骤：Failure removal procedures:

Clean away impurity to ensure sensors right identification

2.2. Case description

Reconnect the sensor (or replace with a new sensor)

检查步骤 Inspection Steps:

3.1. Case description

Because of inadequate fuel in the tank

3.2. Case description

Replace water temperature sensor

3.3. Case description

The vehicle speed sensor is damaged

Replace sensor and shield vehicle speed signal

3.4. Case description

Pressure limiting valve of CR fails

Rail pressure sensor

3.5. Case description

3.6. Case description

Since the wire is not fixed

Reconnect the wire, and remove the failure

Water temperature sensor Oil pressure sensor

crankshaft rotary transducer

Rail pressure sensor

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

Injector binding post

Replace crankshaft rotary transducer

Crankshaft rotary transducer

5.3. Case description

Restore the curved place

5.4. Case description

Air-intake pipe leakages air

Clean fuel return passage

Poor quality fuel leads to metering unit valve stuck

流量计量单元故障metering unit failure

The wire harness plug of air-intake pressure temperature looses or the

Reinstall the plug

6.4. Case description

Curved fuel passage leads to unsmooth fuel feeding.

Clean or replace low pressure fuel pipe

过压保护阀 by-pass valve 油量计量单

故障排除步骤 Failure removal steps:

故障排除步骤Failure removal steps:

7.1. Case description

1. The idle speed is not stable after starting, no blink code.

Unstable vehicle speed sensor signal caused unstable idle speed.

8.1. Case description

The accelerator pedal sensor failure leads to wrong signal.

The speed of 550rpm is the resonance vibration point of this engine.

The idle speed is adjusted to 620rpm, then the problem is solved.

机型 model 噪声（分贝）振动对比WD615提速性驾驶400公里

保养项目（套/台）定额 WP12 WD12 备注

2 喷油器不喷油针阀卡死在关闭状态更换喷油器

3 喷油器油头处滴油针阀卡死在常开位置或喷油更换喷油器

5 喷油器铜套或垫片变形损安装时定位不准造成变形或更换铜套或垫片安装时注意

序号故障类型原因分析处理方法备注

1 高压油泵出油柱塞腔内有空气、齿排除空气或更潍柴各种泵集成

4 高压油泵正时油泵安装时齿轮正时重新按照工艺

压力限制阀进油口轨压传感器

序号故障类型原因分析处理方法备注

1 泄压阀异常泄压阀密封不严或泄更换泄压阀轨压不能常建

2 轨压传感器插头接触不良、轨压重新拔插插轨压不稳，无规

1 诊断仪与ECU通讯失 ECU烧坏更换ECU

3 ECU针脚弯曲或折拔插ECU插头时顺直针脚或

4 ECU被大电流击穿线路短路或焊接更换ECU 注意ECU线路的

机油温度压力传感器进气温度压力传感器曲轴转速传感

4 线束断路、短路接线胶皮磨损或线束断开防护或更换线束

检查部件检测项目标准值

曲轴转速传传感器两针脚 770-950欧姆

检查部件检测项目标准值

检查部件检测项目标准值

检查部件检测项目标准值

检查部件检测项目标准值

序号故障类型原因分析处理方法备注

1 油门接插件接触不良插接不牢重新拔插

4 油门信号2倍电压关系不踏板不符合要求排除线路原信号1为信号2