Weichai Engine WP10 [PDF]

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Contents Chapter I Maintenance for Landking WP10 Euro III Diesel Engines 1.1Regular Inspection for Landking Euro III Diesel Engines …………………….1 1.1.1 Cooling System ……………………………………………………………...1 1.1.2 Lubricating System ………………………………………………………….3 1.1.3 Fuel Supply System ………………………………………………………....6 1.1.4 Electrical System …………………………………………………….……..13 1.1.5 Mechanical Transmission System ………………………………….……17 1.2 Maintenance for Landking Euro III Diesel Engines …………………………19 1.2.1 Truck …………………………………………………………………….……19 1.2.2 Bus ……………………………………………………………………………20 1.2.3 Construction Machinery ……………………………………………………21 1.3 Attention Points for Operating Landking Euro III Diesel Engines …………24 1.3.1 Accelerator Pedal Operation of Euro Ⅲ Diesel Engines ……………...…24 1.3.2 Time Selection for Shifting the Gear ………………………………………24 1.3.3 Economical Speed of Diesel Engines …………………………………...25 1.3.4 Usage of WEVB ……………………………………………………………...26 1.4. The Way of Maintenance for Landking WP10 Diesel Engines ………….28 1.4.1 Replace Oil and Oil Filter ………………………………………………….28 1.4.2 Check and Adjust the Valve Clearance ………………………………….31 1.4.3 Replace Fuel Filter Element ………………………………………………..37 1.4.4 Check Air Filter Element …………………………………………………..38 Chapter II The key Process of Disassembling and Assembling WP10 Diesel Engine 2.1 The Assembly of Cooling Nozzle, Camshaft and Cylinder Liner …………41 2.1.1Installing Spray ……………………………………………………………..41 2.1.2Installing Camshaft …………………………………………………………42 2.1.3Installing Cylinder Liners …………………………………………………..43 2.2 The Pre-assembly and Assembly of Camshaft …………………………….44 2.3 The Assembly of Cylinder Block …………………………………………….46 2.4The Pre-assembly and Assembly of Connecting Rod and Piston …………48 2.5The Assembly of Timing Gear Housing ……………………………………...52 2.6The Assembly of Flywheel Housing and Flywheel ………………………..54 2.7 The Assembly of Front Oil Seal and Camshaft Timing Gear ……………..56 2.8 The Assembly of High Pressure Fuel Pump ………………………………58 2.9 Tightening Torque and Tightening Method of Main Bolts of Diesel Engine ……59



Chapter III Landking Euro III High Pressure Common Rail Diesel Engines—Failure Diagnosis and Case Analysis 3.1 Introduction of High Pressure Common Rail System …………………….61 3.2 Failure Diagnosis and Case Analysis ………………………………………..68 3.2.1 Failure Type1: Diesel Engine Cannot Be Started ……………………….68 3.2.1.1 Description of the Case That Diesel Engine Cannot Be Started (1)…72 3.2.1.2 Description of the Case That Diesel Engine Cannot Be Started (2)…73 3.2.1.3 Description of the Case That Diesel Engine Cannot BeStarted (3) …74 3.2.1.4 Description of the Case That Diesel Engine Cannot Be Started (4)…75 3.2.1.5 Description of the Case That Diesel Engine Cannot Be Started (5)…76 3.2.2 Failure Type 2: The Diesel Engine Starts with Difficulty … … … … … … 77 3.2.2.1Case Description (1) ………………………………………………...…….79 3.2.2.2 Case Description (2) ………………………………………………...……80 3.2.3 Failure Type 3: After the Engine’s Started, It Is Flameout Automatically …81 3.2.3.1 Case Description (1) ………………………………………………...……82 3.2.3.2 Case Description (2) ………………………………………………...……83 3.2.3.3 Case Description (3) ………………………………………………...……85 3.2.3.4 Case Description (4) ………………………………………………...……86 3.2.3.5 Case Description (5) ………………………………………………...……87 3.2.3.6 Case Description (6) ………………………………………………...……88 3.2.4 Failure Type 4: The Engine Exhausts Black Smoke …………………….89 3.2.4.1 Case Description (1) ………………………………………………...……90 3.2.4.2 Case Description (2) ………………………………………………...……91 3.2.4.3 Case Description (3) ………………………………………………...……92 3.2.5 Failure Type 5: Insufficient Power …………………………………………93 3.2.5.1 Case Description (1) ………………………………………………...……94 3.2.5.2 Case Description (2) ………………………………………………...……95 3.2.5.3 Case Description (3) ………………………………………………...……96 3.2.5.4 Case Description (4) ………………………………………………...……97 3.2.5.5 Case Description (5) ………………………………………………...……98 3.2.6 Failure Type 6: Limp-home ………………………………………………..99 3.2.6.1 Case Description (1) ………………………………………………...…100 3.2.6.2 Case Description (2) ………………………………………………...…101 3.2.6.3 Case Description (3) ………………………………………………...…102 3.2.6.4 Case Description (4) ………………………………………………...…103 3.2.6.5. Case Description (5) ……………………………………………...…104 3.2.7 Idle Speed Is Not Stable …………………………………………………105 3.2.8 The Engine Is Always at 1000r/min ……………………………………..106



3.2.9 Other Failures ……………………………………………………………..108 3.2.9.1Description of the Case That Accelerator Works Now and Then When Driving …………………………………………………………………………….108 3.2.9.2 Description of the Case That Vibration at Idle Speed Is Huge (1) …109 3.2.9.3 Description of the Case That Vibration at Idle Speed Is Huge (2) …110 3.3 Parts Failure Analysis ……………………………………………………….111 3.3.1 Injector ……………………………………………………………………...112 3.3.1.1 Table about Analysis of Injector Fault …………………………………113 3.3.1.2 Analysis about Injector Fault …………………………………………..114 3.3.2 High Pressure Fuel Pump ………………………………………………...116 3.3.2.1 Table for Analysis of High Pressure Fuel Pump ……………………..116 3.3.2.2 Analysis about High Pressure Fuel Pump ……………………………117 3.3.3 Common Rail Pipe ………………………………………………………..118 3.3.3.1 Table about Analysis of Common Rail Pipe Fault …………………...118 3.3.3.2 Analysis about Fault of Common Rail Pipe ………………………….119 3.3.4 ECU ……………………………………………………………………….119 3.3.4.1 Table about Analysis of ECU Fault ……………………………………..120 3.3.4.2 Analysis about ECU Fault ………………………………………………120 3.3.5 Sensor and Wiring Harness …………………………………………….122 3.3.5.1 Table of Function of Sensor ………………………………………….122 3.3.5.2 Analysis Table for Fault of Sensor and Wiring Harness ……………..123 3.3.5.3 Analysis about Sensor and Wiring Harness Fault ……………………123 3.3.5.4 Guide for Sensor Inspection ……………………………………………124 3.3.6 Accelerator Pedal …………………………………………………………129 3.3.6.1 Table about Accelerator Pedal Fault ………………………………….130 3.3.6.2 Analysis about Accelerator Pedal Fault ……………………………...131



Chapter I Maintenance for Landking WP10 Euro III Diesel Engines



1.1 Regular Inspection for Landking Euro III Diesel Engines 1.1.1 Cooling System



● Before starting the engine should check coolant level, check whether the cooling system is leaking or not. ● Check whether water temperature is at



the required



range or not when the engine is running. ● When water temperature is too high, please check: ①the tension of water pump belt ②the tension of fan belt ③thermostat



Diagram of water temperature in cab



1



Use liquid coolant when ambient temperature is below 4℃ !



Recommendation Long-acting liquid coolant



Brand



-25



-35



-45



Applied temperature



-25℃ above



-35℃ above



-45℃ above



Learning and thinking：



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1.1.2 Lubricating System



● Check the height of oil level before drive every day. ● How to check it? The vehicle is parking on the plain road, before start or stop for 15 minutes till the engine cools, pull out oil dipstick to check oil level: When the level is below the lower limit of oil dipstick or above the upper limit, it’s forbidden to start the engine. ● Before replace oil, firstly, loosen the whorl plug at the bottom of oil pan. After used oil is drained out, tighten the plug. Then open the oil filling cap to fill CF-4 oil up to the limit required, and then tighten the cap.



upper limit



lower limit



Learning and Thinking:



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The position of oil filling inlet



Oil filling inlet of 1st cylinder rocker arm cover



WP6/WP10/WP12 series WP12 series ● Recommend CF-4 oil to be used in Landking Euro Ⅲ diesel engines. High quality oil is allowed to replace low quality oil. The specification of common oil is as follows:



Viscosity grade Applied temperature



0W-30



5W-30



10W-30



15W-40



20W-50



-40～30℃ -30～35℃ -25～35℃ -20～40℃ -15～50℃



Please use right oil according to ambient temperature, otherwise, engine trouble can occur. Notice: WP10 diesel engine must use CF 15W/40 oil.



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Common sense: performances of different brands of oil at the temperature of -35°C



0W-30



5W-30



10W-30



Learning and thinking:



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10W-40



15W-40



1.1.3 Fuel Supply System



Landking Euro Ⅲ diesel engines apply high pressure CR made by Bosch, and parts of the main systems as the right Figure:



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Common rail



High pressure fuel pump Fuel injector



ECU Fuel filter



Learning and thinking:



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Deflating Air from Fuel Supply System



● Mixed air-fuel in the low pressure fuel passage could possibly be caused by new engines, old engines not used for a long time, or fuel tank empty, pipe leakage, which can result in difficult starting. Therefore, deflating air by hand before start is necessary as the following way: ① Make sure enough fuel in the tank before deflate air. ② loosen deflating bolt (refer to the right Figure ). ③ Press hand pump until no air bubble spraying out from the deflating bolt. ④ Tighten deflating bolt, then start the engine.



Don’t overexert loosening or tightening deflating bolt, so as to avoid damaging.



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Special attentions



● Don’t forcibly start engine by the starter before deflate air from the low pressure fuel passage, otherwise, the electric system could be damaged, and the starter even could be burnt out. ● Fuel must be filled in when fuel pointer reaches the red warning line, otherwise, air could easily penetrate into the fuel passage.



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Drain Water from Fuel Pre-filter



● If there’s water in the fuel supply system, high pressure fuel pump and fuel injector could be easily damaged or invalidated. ● Please periodically inspect whether there’s water in the filter cup of pre-filter or not, so as to drain water



Drain water from water collector



in time ● The method to drain water : ● Open drain plug (2) at the bottom of water collector (1) to drain off water; ● Tighten the drain plug again.



Lightly loosen or tighten the plastic plug, so as to prevent it from damaging



Learning and thinking:



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Special attentions



● Because of fuel quality differences in different places, about two-hour driving later, please inspect the water level of water collector after refill fuel. Fuel Selection



There’s no more special requirements about fuel quality for Landking Euro III diesel engines than that for mechanical pump diesel engines. Please try your best to avoid using low quality fuel !



Special attention:



● Recommend using qualified fuel to guarantee the quality of fuel filled.



Learning and thinking:



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Common sense



● Fuel brand doesn’t mean the ambient temperature the fuel can fit, but the freezing point at which the fuel can’t flow under certain temperature.



Learning and thinking:



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1.1.4 Electrical System



● Landking Euro III diesel engines are with ECU, sensors and electrically controlled fuel injectors, etc. Too high voltage or current can damage electrical system. Generators of Landking Euro III series diesel engines, with rated voltage of 28v have transistor regulators (breakdown diode). Therefore, please pay attention to the following aspects when electrically weld whole vehicle:



Cut off electricity supply before weld; Special generators for Landking Euro III engines must be used.



● Close the control switch of battery, and cut off negative electrode of battery jar. ● Pull out the wiring harness connecter connecting with ECU.



Pull out the collector as the following steps: ※ Push aside the locking slice of collector, and press it into its bottom. ※ Pull out the collector.



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Don’t shake to avoid ECU stitch bending. Identify positive and negative electrode of electricity supply when connect ECU with electricity supply to avoid ECU burning out.



● Welding operation



● Plug into the wiring harness collector connecting with ECU.



Plug into the collector in the following steps: ※



Gently and properly put the collector in the ECU



groove, and press it into its bottom ※



Shut down the locking slice.



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Notice: Not allowed to frequently pull out and plug the ECU collector, thereby avoiding influencing message connecting of ECU.



Learning and thinking:



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● Connect negative electrode of battery jar, open the control switch of battery. When pull out or plug ECU, pay attention to: ※



Cut off electricity supply



for ECU before pull out or plug ECU. Don’t touch ECU stitch by hand. ※



Don’t forcibly draw



electrical wire of whole vehicle or electric wiring harness. Hold the disconnection locking buckle when need to disconnect connectors. Don’t draw the electrical wire against damaging.



Learning and thinking:



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1.1.5 Mechanical Transmission System



● Inspect mechanical transmission system of external diesel engines before running, such as intensity and wearing of the belt. ● Belt can be automatically tightened through tension pulley. Press belt by hand to check tension of the belt.



Learning and thinking:



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Fan bracket Adding grease inlet



Learning and thinking:



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1.2 Maintenance for Landking Euro III Diesel Engines



● Proper maintenance can effectively prolong service life of diesel engines, decrease trouble rate and reduce cost.



※



Maintenance contents :



Replace fuel filter element and oil filter element; Clean and check air filter element. Replace it every 5 times of cleaning. ※



Maintenance interval:



Maintenance should be done in time at Landking Euro Ⅲ service stations according to the following requirements:



1.2.1 Truck



● Maintenance for highway trucks according to the following standard:



load



1stmaintenance



periodical maintenance



≤rated load



＞rated load



New vehicle run 3000 km or for 50 hrs (of the two situations, choose the first achieved one) Every 10,000 km or 500 hrs (of the two situations, choose the first achieved one)



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Every 10,000 km or 500 hrs (of the two situations, choose the first achieved one)



● Maintenance for non-highway truck (including cement mixing vehicle) according to the following standard:



load



1stmaintenance



periodical maintenance



≤rated load



＞rated load



New vehicle run for 50 hrs or 3,000 km (of the two situations, choose the first achieved one) Every 300 hrs or 2,0000 km (of the two situations, choose the first achieved one)



Every 200 hrs or 1,0000 km (of the two situations, choose the first achieved one)



1.2.2 Bus



● Maintenance for bus (city bus, dedicated bus for workers )according to the following standard:



1st maintenance Periodical maintenance



New vehicle run 50 hrs or 3,000 km (of the two situations, choose the first achieved one) Every 300 hrs or 10,000 km (of the two situations, choose the first achieved one)



Learning and thinking:



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● Maintenance for passenger bus, sight seeing bus according to the following standard:



1stmaintenance



Periodical maintenance



New vehicles run 3,000 km or 30 hrs (of the two situations, choose the first achieved one) Every 10,000 km or 300 hrs (of the two situations, choose the first achieved one)



1.2.3 Construction Machinery



● Maintenance for loader, excavating machine, road roller and crane, etc according to the following standard:



1st Maintenance



Periodical maintenance



New vehicle run for 50 hrs or 3,000 km (of the two situations, choose the first achieved one) Every 200 hrs or 10,000 km (of the two situations, choose the first achieved one)



Special attention:



● Please properly shorten periodical maintenance interval or mileage under severe work condition. Learning and thinking:



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● Operators of diesel engines must carefully read Operation and Maintenance Manual, and well understand the structure of diesel engines, strictly comply with the operation and maintenance stipulated in the Operation and Maintenance manual. ● Based on the maintenance requirements stipulated in the manual, please periodically inspect diesel engines and replace oil in accordance with work condition.



Learning and thinking:



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● Maintenance Guide for Landking Euro Ⅲ Diesel Engines ● Maintenance on mechanical system of Landking Euro Ⅲ Diesel Engines is similar with that of Euro II. ● For the trouble on electronically controlled system of Landking Euro Ⅲ Diesel Engines, users may go to Weichai Euro Ⅲ maintenance station nearby. Don’t dismantle or repair fuel supply system and electronically controlled system privately, so as to avoid unnecessary loss.



Special attention:



● When repair or replace components of diesel engines, pay attention to : Landking Euro III series diesel engines have high performance; therefore, maintenance should be done in accordance with Maintenance Manual and Parts Catalogue of Weichai Power Landking Euro III series diesel engines. Please purchase special fittings to ensure the performance, reliability and service life of diesel engines.



Learning and thinking:



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1.3 Attention Points for Operating Landking Euro III Diesel Engines 1.3.1 Accelerator Pedal Operation of Euro III Diesel Engines



● Landking Euro Ⅲ diesel engines adopt electroaccelerator pedal with electro-structure sensor inside. Recommend that users placidly accelerate or decelerate speed when drive to ensure more effective fuelsaving. 1.3.2 Time Selection for Shifting the Gear



● Operating points of diesel engines influence fuel economy, but gear selection when drive also has a great impact on fuel saving. Generally, high gear saves fuel. A. Shift the first gear to start. B. Before shift high gear, the speed of diesel engines should be accelerated to about 1200 r/min. C. In order to avoid high speed, but low gear, should positively shift high gear to make diesel engines run at the range of economical speed if work condition permitted.



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Special attention: ● For mechanical gear-box, whole vehicle matched with Landking Euro III diesel engines stop injecting fuel when sliding with shifting the gear, which is more fuel-saving than that when sliding with neutral gear. 1.3.3 Economical Speed of Diesel Engines



Diesel engine series



Economical speed



WP6



1200-1800



WP10, WP10N



1100-1600



WP12, WP12N



1100-1600



Learning and thinking:



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1.3.4 Usage of WEVB



● Recommend to use WEVB when run downward the long slope ( Weichai patent of safety brake system for engines) ● WEVB is controlled by electronically controlled unit. When WEVB works, the diesel engine doesn’t inject fuel to save fuel.



WEVB can’t work when the speed of diesel engines is less than 800 r/min.



● Four Special Attentions for Landking Euro III Diesel Engine Service of Weichai Power



● Forcible Maintenance Suggestion--- Forcible Maintenance should be done by Euro III maintenance station of Weichai Power in accordance with relevant requirements; ● Maintenance Suggestion---Maintenance should be done by Euro III maintenance station of Weichai Power; ● Fittings Suggestion--- Use special fittings provided by Euro III maintenance station of Weichai Power; 26



● Oil Suggestion--- Use special oil for Landking Euro III diesel engines provided by exclusive agency of fittings.



Learning and thinking:



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1.4. The Way of Maintenance for Landking WP10 Diesel Engines 1.4.1 Replace Oil and Oil Filter



● Replace the oil and oil filter to clean the impurities containing in oil. Note: The oil should be drained off when it is hot． ● Tool: 32 mm open-ended wrench ● Remove the whorl plug，prepare a container to collect 24 L of oil． Note：Hot oil can injure people.



Learning and thinking:



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※



Tool: The special wrench



for filter. ※



Clean the end surrounding



of the filter，and remove it. ※



Install the new oil filter



Note ： Adjust the seal ring and smear some lubricating oil on it while fitting the oil filter.



※



Tool:32mm open-



ended wrench ※



Check and clean the



screw thread and seal ring ， and then install the whorl plug. ※



Fill the clean oil up



to the upper limit, the capacity of the oil sump is 24L．



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Note：STEYR engine must use CF-4 15W/40 oil．



※



Run the engine at



idling speed and check the filter to find whether it leaks or not． ※



Stop the engine and



make the oil run into the sump from the upper parts 5 minutes later ， then check the oil level， fill oil up to the upper limit if necessary．



Learning and thinking:



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1.4.2 Check and Adjust the Valve Clearance



● Tool：13 mm sleeve wrench ● Disassemble 6 cylinder head covers． ● To o l ： 3 2 m m w r e n c h f o r turning the crankshaft ● Turn the flywheel until its scale and the mark on its housing are aligned, push the piston to the position of TDC of compression stroke of 1st cylinder (the intake and exhaust valve of 1 cylinder are closed)． ● Tool：Clearance gauge ● The clearance of intake valve is 0.30mm ● The clearance of exhaust valve is 0.40mm ● The clearance for WEVB system is 0.25mm.



Note: When check the clearance of valve，the engine should be at the cool condition-its temperature is less than 60℃ .When the clearance gauge glides between the top of valve rod and rocker arm and can be felt retarded and sticky, the measuring result is proper Learning and thinking:



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● After WEVB system is used, the adjustment method of exhaust valve clearance is as follows (see Fig. 2 for part serial numbers)



1. Valve clearance adjusting nut 2. Regulating bolt assembly 3. Exhaust valve rocker arm assembly 4. Steel ball 5. Valve rocker arm piston spring 7. Needle



6. Rocker arm piston



8. Ball valve spring 9. Valve rocker arm seat assembly



clearance adjusting screw 11. Hexagonal bolt 12. Support arm



Learning and thinking:



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10. Valve



● The cylinder piston to be adjusted is located on the top dead center of the compression travel. ● As shown in Fig. 2, loosen No. 2 adjusting bolt assembly. In case that the oil seal plane of exhaust valve rocker arm is not pressed, first by using No. 10 valve clearance adjusting screw at the push rod end, adjust the total valve clearance to 0.4 mm. Tighten check nut.



Fig. 2 Total Valve Clearance of



Fig. 3 End Valve Clearance of



Cold-State Exhaust Valve 0.4 mm



Cold-State Exhaust Valve 0.25mm



Learning and thinking:



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● Then as shown in Fig. 3, insert the clearance gauge between No. 5 valve rocker arm piston and the exhaust valve rod end or valve rod cap. By turning No. 2 regulating bolt, adjust the valve clearance to 0.25mm. Tighten check nut.



Caution: During adjustment, turn No. 2 regulating bolt until clearance gauge is clamped so that No. 5 valve rocker arm piston is pressed to its bottom. There is not clearance between No. 5 valve rocker arm piston and the piston installation hole bottom plane in exhaust valve rocker arm.



Learning and thinking:



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● Tools：6# screwdriver and 14mm double offset ring wrench ● The piston of 1st cylinder is at TDC of the compression stroke． ● Check and adjust the valve clearance as step



Step A



A (I-air intake Valve E-air Exhaust valve) ● Adjust the clearance by gauge and tighten the fixing nut of rocker arm， re-check the clearance till it meets the requirement． ● Turn the crankshaft 360° by the spanner；it can also be turned 360° after marking on the vibration damper. ● Adjust the valve clearance as step B ● Loosen the fixing nut of rocker arm，adjust the clearance by gauge then tighten the nut again



Step B



Learning and thinking:



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● Tool: 13mm sleeve wrench ● Install the gasket and cylinder head cover. ● The tightening torque of bolt is 23N•m (recommended).



Learning and thinking:



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1.4.3 Replace Fuel Filter Element



● Replace fuel filter element in the following steps: ● A. Dismantle the old fuel filter element. Remove the water collector installed on coarse filter if reused. ● B. Lubricate the seal lips. ● C. Turn the filter by hand until the seal is closed with interface. ● D. Continue to turn the filter with hands until the filter is installed solidly (about ¾ turns). ● H. Retighten when necessary ● E. Deflate until there is no bubble. ● F. Start Engine. ● G. Conduct leakage test. ● H. Retighten when necessary



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1.4.4 Check Air Filter Element



● The maximum air intake resistance of the engine should be 7kPa and inspection should be done at the rated speed and full load. When the resistance reaches the maximum limit allowed，the air filter element should be cleaned or replaced as per the maintenance guide from the manufacture.



● Caution: Don't blow off the air filtering paper Don't clean the air filtering paper by water and oil Don't beat the core forcibly．



Learning and thinking:



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● Note：It is not allowed to use the engine without air filter, otherwise the dust and impurity will cause early wearing of the engine.



● Remove the filter core from the air filter element and beat the side of the element lightly to make dust fall down, or blow the element backward (blow back from inside to outside) by compressed air．



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Chapter II The key Process of Disassembling and Assembling WP10 Diesel Engine



2.1. The Assembly of Cooling Nozzle, Camshaft and Cylinder Liner 2.1.1 Installing Spray Assembling process:



● Polish bottom of the cylinder block，blow branch oil passage hole and main and sub-passage of oil by compressed air, and clear the bottom of cylinder block. ● Install the cooling nozzles into the engine block by hollow bolts and matching seal rings, and then tighten them.



Notice ： ● Check the cooling nozzles to make sure that they don’t have impurities or dust. ● Adjust the position of cooling nozzle when tighten the hollow bolts to make sure that the spring cylindrical pin can be driven into pin hole when necessary by copper stick. ● Check whether the cooling nozzles (and the surface of the cylinder block) are hurt and have impurities.



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2.1.2 Installing Camshaft



● Clean the camshaft hole and smear lubricant used for cleaning. ● Cleaning the camshaft, inspecting whether the camshaft is hurt and then installing it through camshaft hole. ● Install camshaft thrusts, and then tighten hexagonal bolts. ● Smear cleaning lubricant on the thrusts and turn camshaft by hand to ensure that the camshaft can be turned smoothly and has no resistance. In the end, check the clearance of camshaft by hand. Notice： ● The camshaft bush must be checked whether it is hurt or not, and it isn’t allowed to use after repairing. ● Smear clean lubricant on the special tool of camshaft before installing the camshaft into camshaft hole in the cylinder block. ● Please be careful to avoid hurting camshaft bush when installing the camshaft into the camshaft hole. ● Coat the thread with thread locket



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2.1.3 Installing Cylinder Liners



● Clean cylinder holes and inner and outer surfaces of cylinder liner. ● Coat outer surface of cylinder liner with 0# Molybdenum disulfide Lube and install part of the cylinder liner into cylinder hole. ● Press cylinder liner into cylinder hole by cylinder liner pressing machine. ● Cylinder liner is 0.05~0.10mm higher than top surface of cylinder block. ● Check cylindrical and oval degree in cylinder hole



Learning and thinking:



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2.2 Pre-assembly and Assembly of Crankshaft Assembling processes:



● The flange needs heating up to 290℃ and its color turns to yellow. The gear of crankshaft needs heating up to 180℃. (Heating temperature is recommended in order to prevail in the assembly). ※



Notice: It isn’t allowed to assemble when the heating color of



flange and gear is purple. ● Remove burr of flat key and grooving and then drive into flat key, gear of crankshaft and flange. The cylindrical pin should be driven into the end of crankshaft. ● Put rivets into oblique oil holes of crankshaft, and then rivet them by special tools.



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Assembling processes:



● Cleaning the bottom surface of the cylinder block by cleaner 755 or industrial alcohol. ● Install main bearing shells and thrusts, and than smear oil. ● Lifting the crankshaft parts, with compressed air blowing holes of oil passage wipe main shaft neck and connecting rod journal with a towel, and then gently fall into the cylinder body. After that Install thrust. ※



Notice:



Check carefully whether crankshaft is scratched, and remove it when necessary. Oil groove of thrust should be towards crankshaft. ● Coat 510 sealant on the engine block surface (the connecting surface of crankcase), and sealant line should be continuous



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2.3 The Assembly of Cylinder Block Assembling processes:



● Insert oriented stick into holes of main bearing bolt as this figure position, lift crankcase and then turn it 180°, at last fall it into cylinder block gently along oriented stick. ※



Notice:



The matching NO. of crankcase and cylinder block should be unanimous. Orientational pin should be inserted in the right place. Prevent sleeve and seal ring falling during lifting. ● Knock the bottom of crankcase gently to make sure that the connecting surface of crankcase and cylinder block can be inserted into cylindrical pin and locked. ※



Notice: Please pay attention to the rule of “middle first, and then



both sides” when driving into cylindrical pin.



Learning and thinking:



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● Install crankshaft rear oil seal coated with sealant on the crankshaft. ※



Notice: Coat outer circle of rear oil seal with sealant. The line of



sealant should be continuous. ● Press oil seal into cylinder block by oil seal pressing tool. ※



Notice: Smear cleaning lubricant on the oil seal pressing tool.



● Take off the oriented stick, and then tighten main and auxiliary bolts of cylinder block.



Learning and thinking:



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2.4 The Pre-assembly and Assembly of Connecting Rod and Piston Assembling processes:



● 6 pistons within the same weight group are placed in the assembly stage. The weight group of piston is marked 10 g per group, which is G1, G2, G3, G4, and G5. The pistons within the same weight group are installed in the same engine. ● Heat the piston up to 60-80 ℃ ● The pre-assembly and assembly of piston and connecting rod: insert small head of connecting rod into inner lumen of piston so that small head hole of connecting rod and hole of piston pin are matched together, and then install piston pin and piston pin ring ※



Notice:



Direction of firebox and connecting rod. Coat cleaning lubricant before installing small head of connecting rod and piston pin. ● Install spiral spring oil ring, conical ring and double ladder ring of piston ring. ※



Notice:



Piston assembling sequence and mark. Small surface of conical ring is up and “TOP” surface of double ladder ring is up.



48



● The weight group of connecting rod is marked 29g per group, which is C, D, E, F, G, H, J, K, and L. The matching NO. of connecting rod body and connecting rod cap of every connecting rod must be unanimous. ● Remove connecting rod bolts and check whether the thread of connecting rod is damaged. Replace and check whether the matching NO. is right or not when necessary. ● Check whether the connecting rod shell is damaged before installing. Replace (do not repair) it when necessary. ● Clean inner surface of cylinder liner, crankshaft arm, piston and connecting rod and then coat clean lubricant. ● Turn crankshaft to ensure the crank arm in the right position.



※



Notice:



Check whether piston ring can be turned flexibly in the groove. There is 30°±5° between the opening of the 1st ring and axis of piston pin and there is 120° among 3 rings of a piston. 49



The parts of piston and connecting rod must be within the same weight group in an engine. Check whether connecting rod shell is hurt. Do not repair and reuse if it is hurt. Install parts of the piston and connecting rod as the sequence and tighten connecting rod bolts. ※



Notice:



The separating surface of the connecting rod shell cover should be towards oil cooler. The No. of piston must match with the No. of cylinder. The connecting rod cover must match with connecting rod body and can not be interchanged. Please be careful to avoid the connecting rod body to hurt crankshaft arm when assembling. Coat clean lubricant on the supporting surface and thread before tightening connecting rod bolts. Coat clean lubricant on the inner and outer surface of special tool which is used to install piston. Tighten connecting rod and piston as techniques requirement. Firstly turn crankshaft 120° and then tighten connecting rod bolts of cylinder 1 and 6; turn crankshaft 120° again, and then tighten connecting rod bolts of cylinder 2 and 5; at last turn crankshaft 120° for the 3rd time, and tighten connecting rod bolts of cylinder 3 and 4. 50



※



Notice:



Bolts per cylinder should be tightened alternately by hand. The torque is 120 Nm for the 1st time, turn bolts 90°±5° for the 2nd time. Replace those bolts that can not reach required torque range. Turn crankshaft flexibly.



51



2.5 The Assembly of the Timing Gear Housing Assembling processes:



● Check whether every combining surface of timing gear housing is hurt and remove grease after polishing and cleaning. ● Drive springy cylindrical pin into side, coat thread locking agents on thread parts of the double-headed thud, tighten it and clean excessive sealant. ● Tighten hexagonal bolts with seal gaskets Install refueling tube gasket and then refueling tube. Insert hexagonal bolts with springy gaskets and then tighten them. ● Polish, clean, remove grease and coat sealing glue on the combining surface of cylinder block and timing gear housing. ● Install medium gear shaft into middle gear, and then put them into timing gear housing. ● Install timing gear housing parts. Drive intermediate gear shaft into gear housing, insert hexagonal bolts with gaskets and tighten them. The level of the cover to the left groove.



52



※



Smear general lithium grease on the shaft.



※



Tightening torque: 60±5Nm.



※



Turn bolts 90°, and the torque range is 100~125Nm. Replace



those bolts than not reach required torque range. ● Install intermediate gear parts of oil pump, and then drive into intermediate gear shaft of oil pump. ※



Notice :



The convexity of intermediate gear parts of oil pump should be towards inside. Check whether the intermediate gear shaft of oil pump can be turned flexibly after installing. ● Install hexagonal bolts in the intermediate gear shaft of oil pump and tighten them. Tightening torque: 59+5 Nm (smear glue). Tighten all the M10 bolts. ● Check the clearance of gear.



53



2.6 The Assembly of Fly Wheel Housing and Fly Wheel The assembly of fly wheel housing:



● Polish, clean, remove grease and coat sealing glue on the surface of cylinder block and fly wheel housing. ● Lift fly wheel housing and pre-assemble fly wheel housing bolts. Notice: ※



Cylindrical pin of end back of cylinder block must match with



orientational hole which is below fly wheel housing. ※



Coat clean lubricant on



thread of bolts and supporting block. ※



Tighten bolts in twice by



hand, the 1st time: 40+20N•m, and the make a mark between bolts and fly wheel housing; the 2nd time: 110~140 Nm. Replace those bolts that can not reach required torque range. ※



Tightening sequence as the sequence in above figure.



※



Special notice: The fly wheel bolts of 4,5,6,7,8,9 are M12X60, the



bolts of 1, 2, 3, 10, 11, 12, 13 are M12X70.



54



The assembly of fly wheel:



● Fix tooth ring of fly wheel in the fly wheel by accessory bolts. ● Drive centripetal ball bearing into fly wheel axle hole and then install springy ring. Notice: ※



Clean outer round before drive into bearing, and coat Automobile



Lithium Grease on the inner hole of fly wheel. ● Install fly wheel and tooth ring of fly wheel in the crankshaft. Notice: ※



Coat antirust oil on the inner surface of the fly wheel.



● Insert fly wheel bolts and tighten them. Notice: ※



Coat lubricant on



thread of bolts and supporting block before inserting bolts. ※



Tighten bolts by hand.



Firstly pre- tighten these bolts symmetrically with a torque of 60~80Nm, and then turn them 90°±5°symmetrically in twice. The torque range is 230~280Nm. Replace those bolts that can not reach required torque range.



55



2.7 The Assembly of Front Oil Seal and Camshaft Timing Gear Assembling processes:



● Install front oil seal parts. ● Turn the engine block to the top dead center of cylinder 1 and 6. ● Turn engine block as rotary direction of crankshaft. The rotary direction is contra rotation when you stand towards the side of timing gear housing. ● Install the camshaft timing gear. The scale and mark of camshaft timing gear and OT scale and the mark on timing gear housing should be aligned. ● Tighten hexagonal bolts, and then make a mark between any bolt and gear housing. Notice: ※



Tighten symmetrically with a torque of 35Nm and then coat thread



with thread sealant. ※



Use hands to inspect the clearance of gears. (The control range of



clearance of gears is 0.034~0.265mm, and recommended inner control range is 0.10~0.25mm.



56



● Hit a pin into the front of the timing gear house. ● Install camshaft gear cover gasket and camshaft gear cover. ● Tighten inner hexagonal cylindrical head screws and matching saddle-shaped spring gaskets. Tighten (1) hexagonal nuts and matching spring gaskets.



Learning and thinking:



57



2.8 The Assembly of High Pressure Fuel Pump



Please check after installing



● Keep marks of the high pressure fuel pump gear and fuel pump flange in the same direction. ● Install fuel pump into gear house. ● Check whether the installing of step 2 is right or not through gear house viewing hole. ● If right, please tightening fuel pump nuts and viewing hole nuts.



58



2.9 Tightening Torque and Tightening Method of Main Bolts of Diesel Engine



Tightening Torque(N m)+Turning Angle



Name



Time of Reuse



Main bearing bolts M18



250+30 0



Connecting rod bolts M14*1.5



120+(90 ° +/-5 °)at the same time reach 170-250N.m



0



Main bolt for cylinder head M16



200+10+2*(90°+/-5°)at the same time reach 260-380N.m 0



3



Auxiliary nuts of cylinder head M12



90+10+2*(90°+/-5°)at the same time reach 120-160N.m 0



2



Bolt for fly wheel M14*1.5



60+20+2*(90°+/-5°)at the same time reach 230-280N.m 0



2



Bolt for flywheel housing M12



40+20+(120°+/-5°)at the same time reach 110-140N.m 0



2



Bolt for oil pump idler gear shaft M10



60+5 0



Bolt for camshaft gear M8



32-36



Bolt for timing idling gear M10



60+5N.m (at the same time reach 100-125N.m)



Bolt for pressing crankshaft belt pulley M10



60+10



Bolt for injector press plate M8



25



Pressing bolt for press plate of iron plate injector M8



15



Bolt for air exhaust pipe M10



50-70



Bolt for rocker-arm seat M12



100+10



Press nut for air compressor gear M18*1.5



200+20 0



Cylinder head



59



2



Press nut for fuel pump gear M24*1.5



450-500



Fixing bolt for tension pulley M16



195



Fixing bolt for fuel pump coupling bearing cover M8



25



Tension bolt for angel adjusting plate M12 / M14*1.5



130+20 / 0



Connecting bolt for coupling springy connecting piece M10 /M12



74 / 110



150+15 0



Torque requirement: tightening bolts as techniques requirement. 8.8 level：M6, M8, M10, M12, M14, M16, M18 Nm：9∽12；22∽30；45∽59；78∽104；124∽165；195∽257； 264∽354； 10.9 level：M6, M8, M10, M12, M14, M16, M18 N m ： 1 3 ∽ 1 6 ； 3 0 ∽ 3 6 ； 6 5 ∽ 7 8 ； 11 0 ∽ 1 3 0 ； 1 8 0 ∽ 2 1 0 ； 280∽330；380∽450；



60



Chapter III Landking Euro III High Pressure Common Rail Diesel Engines—Failure Diagnosis and Case Analysis 3.1 Introduction of High Pressure Common Rail System



Weichai Power Landking Euro III Diesel Engines ● Initiatively applying advanced Germany BOSCH electronically controlled high pressure common rail system ● BOSCH high pressure common rail system has features of high reliability, economy, safety, comfort and highly intelligentizing. ● Can meet the requirement of Euro Ⅳ, Ⅴ emission standard ● Landking Euro 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 into the market, which ensure the excellent quality. ● 100,000 market shares of Weichai Power Landking Euro III diesel engines enjoy high popularity among customers.



61



Landking Euro III electronically controlled high pressure common rail picture



Injector



High pressure fuel



ECU



Weichai Power Landking Euro III diesel engines： ● Much higher reliability--- Failure rate is 63% less than that of mechanical pump engine ● Much more economical--- Fuel consumption per 100km is less 5-10% than that of mechanical pump vehicle at the same condition ● Much lower maintenance cost--- 10L engine is less 1650RMB/Year than mechanical pump engine, and 12L engine is less 828RMB/Year (calculating by 180,000km/Year) ● 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 Guarantees” for fuel system is much longer. ● Low vibration and noise----much higher reliability 62



vibration



speed-up performance compared with WD615



400 km-driving fatigue



model



noise (db)



WD615



115



WP10



97



Improving by 10%



63%



WP12



96



Improving by 35%



50%



100%



● Low fuel consumption 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 fuel-saving technology products: ※



WP multi-power fuel-saving switch



※



Fuel-saving 1+1 (fuel-saving constant temperature fan + fuel-



saving fuel-cut technology) ※



Personalization power



Super truck power, standard truck power, dedicated mixer lorry power, dedicated crane power, dedicated bus power, dedicated city bus power, etc. Learning and thinking:



63



● Much lower maintenance cost ※



Maintenance interval of Euro II diesel engines is 10,000km, while



that of Landking, Euro III diesel engines is 30.000km. ※



WP10 VS. WD615



Take the common standard load highway transportation vehicle as an example, WP10 can save 1650RMB maintenance expenses compared with WD 615 (calculating by 180,000km/year)



Maintenance item (set/unit)



Quota



WP10



WD615



fuel coarse filter core＋fine filter core+trustworthy dewater filter core （piece）



3



334



26



oil filter core （piece）



2



40



40



oil（L）



24



534



355



maintenance expenses of 30,000 km （RMB） total maintenance expenses for one year （RMB）



908＋ 80＝ 988



5928



421×3 =1263



Note



（1）The maintenance interval of WP10 is 30000km, but oil filter core should be replaced once every 10000km （2）The maintenance interval of WD615 is 10000km （3）WP10 applies Landking Euro III CH-4 special oil



7578



● Much lower maintenance cost Take the common standard load highway transportation vehicle as an example, WP12 can save 828RMB maintenance expenses compared with WD12 (calculating by 180,000km/year) 64



WP12 VS.WD12 Maintenance item (set/unit)



Quota



WP12



WD12



fuel coarse filter core＋fine filter core+trustworthy dewater filter core （piece）



3



334



26



oil filter core （piece）



2



82



40



oil（L）



36



770



430



1186＋ 164＝ 1350



496×3 =1488



8100



8928



maintenance expenses of 30,000 km （RMB）



total maintenance expenses for one year（RMB）



Learning and thinking:



65



Note



（1）The maintenance interval of WP12is 30000 km, but oil filter core should be replaced once every 10000 km （2）The maintenance interval of WD12 is 10000 km （3）WP12 applies Landking Euro III CH-4 special oil



● Much better suitability of oil



Fuel coarse, fine filter core



Trustworthy dewater filter



● Intensifier filter with high efficiency ● Landking Euro III engine is equipped with high efficiency fuel filter which has a better ability to filter impurity in fuel to effectively protect fuel system.



● Trustworthy dewater filter ※



It can dewater more than 95% water in diesel.



※



It has the high-efficiency function of fuel-water separation, and



users can use it at ease. ※



It is assembled on the obvious position of vehicle frame to facilitate



drivers’ venting air and pumping fuel.



66



※



It has high-volume transparent water cup with good low-



temperature resistance performance, which is convenient for drivers to observe water level so as to drain off water in time. ※



It is equipped with hand pump, and the vehicle has hand pump



double insurance.



Learning and thinking:



Special attention: ※



Please often observe the water level of “trustworthy dewater filter”



and drain off water in time. ※



Pay attention that replacing interval of “trustworthy dewater filter”



filter core should be same as that of fuel coarse and fine filter cores. ※



Pay attention that “trustworthy dewater filter” filter core can be



replaced by Landking EuroIII fuel coarse filter core, but it can’t substitute for Landking EuroIII fuel coarse filter core.



Trustworthy dewater filter



67



3.2 Failure Diagnosis and Case Analysis



● When diesel engine is failure, removal method of “easy first and difficult later” one by one should be applied. ● Don’t rashly replace any fitting before find out problems. ● Don’t rashly get rid of blinking code before find out problems. Please note that do record blinking code.



3.2.1 Failure Type 1: Diesel Engine Cannot Be Started



Failure removal procedures: ● Read blink code according to blink light to make sure failure. Turn to next step if the failure can’t



WP-VDS10



be confirmed. ● Two ways to read blink code: Read through failure iagnosis equipment; or read through blink code light .



Actuator—fault light



Read blink code: ● 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 err memory can save 10 errs at most, on and off 0.5 s1s. ● Every blink code consists of three digits, and the time interval between each digit is 1 second. For instance: 321



亮



灭



68



The method to get rid of blink code by hand: ● Press down the failure diagnosis switch before T15 is through, then turn on the key switch (T15 is through), and keep the diagnosis switch on for 4-8 seconds, then release. ● If some blink code can not be deleted, that is the current failure. ● Get rid of hardware failure first, then clear ECU failure memory. ● If the blink code can not be deleted, should inform professional people to take care of it asap. Special attention:



After the failure is removed, please clear the blink code by equipment or by hand.



Air exhaust pipe is folded



Failure diagnosis switch



Blink code light



69



Ignition key switch



Starter



● 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. ● 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. ● Diagnose whether the starter works normally or not. If the problem still can’t be 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. ● 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.



Neutral shift switch



Stop motion switch



70



● Contact people from special repair station to use professional equipment to inspect as follows: ※



Failure diagnosis



equipment used to inspect if the Camshaft speed sensor



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. ※



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



Crankshaft rotary transducer



Learning and thinking:



71



3.2.1.1 Description of the Case That Diesel Engine Cannot Be Started (1)



● The whole vehicle doesn’t have blink code. Start line, starter and battery jar are all normal, but the start can’t start the diesel engine. Therefore, the start system can be diagnosed that no failure. ● 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 find that there’s still air, therefore, air leakage in the low pressure fuel passage is confirmed. ● 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 results in the diesel engine can’t be stated. Case



Improper assembling or frequently disassembling and assembling result in that low pressure passage seal is not tight Remed



Replace fuel coarse filter or low pressure passage parts to make sure good seal



There’s damage in the thread of fuel inlet of fuel coarse filter, and fine crack in fuel inlet



Hand pump



Fuel return hollow bolt



72



Air deflation bolt



3.2.1.2 Description of the Case That Diesel Engine Cannot Be Started (2)



● When start, starter doesn’t respond, and no blink code. Auxiliary flameout switch and neutral shift switch are normal; ● Inspect starter connecting wire and battery jar, and they are normal; ● Inspect when battery jar is connecting with starter, and the starter works normally; ● Further inspect if the battery jar gets through the four wires of ECU. After measuring voltage, 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; ● 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



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) Remed



Replace ECU



1.70 stitch was burnt out



73



Damaged ECU plug connector: One of whole vehicle plug stitches broke, and the other thick stitches rust.



3.2.1.3 Description of the Case That Diesel Engine Cannot Be Started (3)



● The starter can work normally, but the engine can’t be started. ● 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. ● Inquiry that the customer fills up -10＃fuel when get the vehicle in Beijing, but it 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



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 the vehicle is running trans-regionally with large temperature difference



Remed



Dredge fuel passage, and replace with



74



3.2.1.4 Description of the Case That Diesel Engine Cannot Be Started (4)



● The motor works normally when the engine starts. The engine rotates normally, but can’t be started, and no blink code. ● 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. ● 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



Poor quality fuel with high water content can cause injector needle-valve wore and tightless sealing. If the injector leakages too much, the engine can’t be started.



Remed



Replace injector, and add trustworthy dewater filter



Damaged injector



The left is the original fuel used The right is normal fuel



75



3.2.1.5 Description of the Case That Diesel Engine Cannot Be Started (5)



● The starting system and low pressure fuel passage are normal, and no blink code. The above methods can’t remove the failure. ● 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. ● Cut off fuel outlet pipe of high pressure fuel pump, and start the engine through starter. It’s found that two fuel outlets of high pressure fuel pump can deliver fuel, but the high fuel pillar is 4.5 cm, the low is mere 2cm. Contrast through eyeballing to find that the fuel pump can’t supply sufficient fuel (the engine speed is 200250r/min, and the normal fuel pillar should be 4-5cm). Case



Poor quality diesel with high water content leads to damage of high pressure fuel pump plunger Remed



Replace high pressure fuel pump, and add trustworthy dewater filter



HP fuel pump plunger is damaged



Fuel



brand



76



3.2.2 Failure Type 2: The Diesel Engine Starts with Difficulty Failure removal procedures:



1st step: If it is caused by plateau or paramos 2nd step: Read the blink code, and



Plateau, high and cold



confirm the failure. Turn to the next step if there’s no blink code. 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. 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.



Blink code



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. 6th step: Inspect whether crankshaft



Starter



rotary 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. 7th step: Contact special repair station people, and use professional equipment to inspect as follows: ● 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. ● 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 77



WP-VDS100 Failure diagnosis scanner



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.



Crankshaft



rotary



Camshaft speed sensor



Learning and thinking:



78



3.2.2.1 Case Description (1)



● No problems are found out after inspection as the above procedures. ● 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



Impurity caused that the sensor can’t identify the position of the signal hole on the flywheel very timely and precisel Remed



Clean away impurity to ensure sensors right identification



Damaged sensor



79



3.2.2.2 Case Description (2)



● 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 1500 r/min; the engine is in the status of Limp-home, and the blink code light is on. ● 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



The plug looses contact (other possible reasons: forgot to connect the sensor or the sensor fails) Remed



Reconnect the sensor (or replace with a new sensor)



Not installed



Not installed



Learning and thinking:



80



3.2.3 Failure Type 3: After the Engine’s Started, It Is Flameout Automatically Inspection Steps:



Inspection Steps: 1st step: Read blink code and confirm the failure. Turn to the next step



Fault diagnosis



if can’t confirm it. 2nd step: Firstly inspect if low pressure fuel passage leakages air or blocked (including fuel return pipe), check



Oil return hollow bolt



if air intake and exhaust is normal. Turn to the next step if the problem can’t be solved. 3rd step: Inspect if wires, sensors and plug is damaged. Turn to the next step if the problem can’t be solved. 4th step: Contact special repair



Hand pump



station people, and use professional equipment to inspect as follows: ● 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. ● 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 Failure diagnosis scanner



81



Air deflating bolt



3.2.3.1 Case Description (1)



● After engine flameout, it can’t be started, no blink code. ● Inspect that no fuel in the fuel tank; refill fuel and deflate air from low pressure fuel passage, it still can’t be started. ● Inspect HP fuel passage, and loose the two HP fuel pipe tie-ins 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 pump. 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



Because of inadequate fuel in the 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.



Remed



Fill up enough diesel, and remove the failure according to the case description



82



3.2.3.2 Case Description (2)



● The engine works for a while, then flameout, stops for a while, then back to be normal, but a moment later, flameout again. ● Read the blink code displaying242--- water temperature is too high. ● Inspect that water passage is normal, but failure diagnosis used to inspect and find that water temperature rapidly increase to about 107℃ after starting, but the water temperature actually 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 selfprotection mode and flameout when load.



Case



When the sensor is damaged, it sends a wrong signal to ECU. ECU judges wrongly to make the engine enter self-protection mode.



Remed



Replace water temperature sensor



83



Water temperature sensor



Learning and thinking:



84



3.2.3.3 Case Description (3)



● The engine starts normally, but the speed is up and down automatically, then flameout. The blink code light is on. ● Read blink code displaying 324—the speed signal has some problems. The customer reflects that the speed sensor was touched when fix the mileage counter. ● After replace the vehicle speed sensor, trial-run is normal. The failure is removed.



Case



The vehicle speed sensor is damaged



Remed



Replace sensor and shield vehicle speed signal



85



3.2.3.4 Case Description (4)



● After the engine starting for 1-2 seconds, it’s flameout automatically. At the same time, the engine is dithering, and the speed rapidly increases to 540 r/min, then decrease immediately. ● Inspect low pressure fuel passage and HP fuel passage and find that no leakage or fuel return pipe squeezed. ● Dismantle the fuel return pipe of injectors and PRV, then start the vehicle and find that there’s fuel sprays out from the fuel return pipe of CR when the engine has explosion sound. ● Connect the failure diagnosis and find that rail pressure rise to 440bar then down to 280bar, then fluctuate between 280320bar. Hereby, it’s confirmed that pressure limiting valve of CR is damaged.



Case



Pressure limiting valve of CR fails



Remed



Replace CR



86



3.2.3.5 Case Description (5)



● The engine is flameout suddenly when running, can’t be started again, no response even if open ignition switch. ● Inspect the power supply is normal, and the wire has electricity, but the diagnosis equipment connected can’t be communicated. ● Use multimeter to measure 1.04 stitch with no voltage. Hereby, it’s confirmed that ECU is damaged.



Case



The plug looses contact, sealing parts fails leading to water leakage or over-high voltage, which cause ECU damaged.



Remed



Replace ECU



Rail pressure



Rail pressure Pressure limiting valve



Fuel inlet



87



3.2.3.6 Case Description (6)



● The engine’s flameout suddenly when running, but still can be started again. However, the flameout still exists, and no blink code. ● Inspect the key switch is normal (If the key switch is short circuit or open circuit, which probably cause the above problem. ● Inspect ECU power wire is normal (If the power is open circuit, which probably cause the above problem.) ● Inspect the auxiliary flameout switch (under-vehicle flameout switch) and find wire insulate rubber wore out, which cause that ECU receives flameout signal.



Case



Since the wire is not fixed, when it’s wore out, it causes signal’s short circuit, and the wrong



Remed



Reconnect the wire, and remove the failure



Sensor wire harness Oil pressure sensor Water temperature sensor



Camshaft speed sensor Crankshaft rotary transducer



Air intake pressure sensor



Rail pressure sensor



88



3.2.4 Failure Type 4: The Engine Exhausts Black Smoke



Failure removal steps:



1st step: Inspect if air filter and air intake and exhaust pipe, valve clearance are normal. Turn to the next step if normal 2nd step: Inspect if turbocharger is working normally. Turn to the next step if normally 3rd step: Inspect if diesel quality is normal. Turn to the next step if normal. 4th step: Contact special repair station people, and use professional equipment to inspect as follows: ● 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. ● 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



89



3.2.4.1 Case Description (1)



● The engine’s flameout suddenly when running, then the driver stops the vehicle immediately. Afterwards, it’s difficult to start again, and black smoking when start. ● Conduct inspection according to the above 3 steps, and all are normal. ● Use failure diagnosis to inspect: the rail pressure can only reach 160bar when start. ● 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



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



Remed



Replace injector



Injector binding post



90



3.2.4.2 Case Description (2)



● The engine exhausts black smoke, but inspect that air filter, air passage and turbocharger work normally. ● 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



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



Remed



Replace with qualified diesel and injectors, add trustworthy dewater filter



Injectors rust 91



3.2.4.3 Case Description(3)



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



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



Remed



Replace air-intake tube



92



3.2.5 Failure Type 5: Insufficient Power Inspection steps



1st step; For the vehicle equipped with multi-power fuel-saving switch, inspect if the power shift is on the right position. 2nd step: Read blink code, and turn to the next step if no blink code. 3rd step: Inspect if low pressure fuel passage and fuel quality is normal. Turn to the next step if normal. 4th step: Inspect if air filter, air-intake passage and turbocharger work normally. Turn to the next step if normally. 5th step: Inspect if valve clearance is normal. Turn to the next step if normal. 6th step: Inspect if each sensor plug, accelerator pedal plug and whole vehicle wire harness connect well. Turn to the next step if normal. 7th step: Contact special repair station people, and use professional equipment to inspect as follows: ● 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. ● 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 ● For the vehicle equipped with multi-power fuel-saving switch, inspect if the power shift fails.



93



3.2.5.1 Case Description (1)



● When the speed reaches 1500r/min in the process of driving, it appears unsteady speed, and the whole vehicle dithering. The speed can’t be increased even if keep stepping on accelerator. It shows insufficient power with blink code light on. ● Read blink code displaying 114---crankshaft rotary transducer signal is abnormal. ● Use failure diagnosis to inspect and find that step on accelerator to speed-up when the vehicle 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



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



Remed



Replace crankshaft rotary transducer



Crankshaft rotary transducer



94



3.2.5.2 Case Description (2)



● nsufficient power, no blink code. ● Inspect multi-power fuel-saving switch and find no change about power when change shift. It’s confirmed that the switch fails.



Case



Multi-power fuel-saving switch fails



Remed



Replace multi-power fuel-saving switch



95



3.2.5.3 Case Description (3)



● The power is insufficient with heavy load, and the speed can only increase to 1500r/min. ● Read blink code displaying 253—fuel supply in the low pressure passage is difficult. ● 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



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



Remed



Restore the curved place



Tucked position



Normal



96



3.2.5.4 Case Description (4)



● Insufficient power, no blink code. ● Fuel passage and quality are inspected to be normal. ● Inspect air filter and air-intake pipe and find the lower end of intercooler splits for about 15cm opening



Case



Air-intake pipe leakages air



Remed



Replace intercooler



Intercooler splits



97



3.2.5.5 Case Description (5)



● Fuel can’t fill up when the engine runs for a while, but the speed is not restricted. ● The blink code is 143– the third cylinder injector wire harness is open circuit. ● After replace injector wire harness, it’s normal.



Case



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



Remed



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



98



3.2.6 Failure Type 6: Limp-home



Failure removal steps:



1st step: Read the blink code. 2nd step: To confirm the failure according to blink code. Turn to the next step if can’t remove the failure. 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. 4th step: Contact special repair station people, and use professional equipment to inspect as follows: ● 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. ● 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



99



3.2.6.1 Case Description (1)



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 the fuel return passage is not smooth. Through inspection, it’s found that the fuel return pipe of fuel tank is blocked.



Case



The blocked fuel return passage leads to unsmooth fuel return, which cause rail pressure exceeding the setting value.



Remed



Clean fuel return passage



100



3.2.6.2 Case Description (2)



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



Poor quality fuel leads to metering unit valve stuck



Remed



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



● Metering unit failure



Metering unit ※



Removal method: check and repair wire, to judge metering unit



failure or rail pressure sensor failure. 101



3.2.6.3 Case Description (3)



● The max speed is 1500r/min after starting, and the blink code light is on. ● 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. ● Through inspection, it’s found that the wire harness plug of air-intake pressure temperature looses.



Case



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



Remed



Reinstall the plug



● Air-intake pressure sensor



102



3.2.6.4 Case Description (4)



● The blink code light is on now and then when running. The max. speed can reach 1500r/min, and the blink code light is on. ● The blink code is 254—fuel feeding resistance is too huge. ● 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



103



3.2.6.5 Case Description (5)



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 passage 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 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



Injector failure



Remedy



Replace injector



104



3.2.7 Idle Speed Is Not Stable Failure removal steps:



● 1st step: Read the blink code and confirm the failure. Turn to the next step if can’t confirm. ● 2nd step: Inspect if low pressure fuel passage is normal. Turn to the next step if can’t remove the failure. ● 3rd step: Inspect if each sensor plug and wire harness are normal. Turn to the next step if can’t remove the failure. ● 4th step: Contact special repair station people, and use professional equipment to inspect as follows: ● Use failure diagnosis equipment to inspect if vehicle speed sensor is normal. Turn to the next step if can’t remove the failure. ● 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



105



Case description



● The idle speed is not stable after starting, no blink code. ● Inspect that low pressure fuel passage, sensor plug and wire harness is normal. ● 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 shielded.



3.2.8 The Engine Is Always at 1000r/min Failure removal steps:



1st step: Read the blink code and confirm the failure. 2nd step: Remove the failure according to blink code. 3rd step: Inspect if electric accelerator pedal plug looses, wrongly connected or short circuit. 4th step: Inspect if the electric accelerator pedal fails. 106



Case description



● The speed is always at 1000r/min after starting; the accelerator pedal doesn’t work; the blink code light is on. ● The blink code is 221--- the accelerator pedal signal is abnormal. ● Inspect that the electric accelerator pedal plug is normal ● 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 pedal



※



The electric accelerator pedal wire looses or wrongly connecting.



Re-plug or inspect if the accelerator wire is right, then reconnect. ※



The electric accelerator plug connector leakages water: dry it, and



then restart.



Note: Replace the accelerator with the same model



107



3.2.9 Other Failures 3.2.9.1. Description of the Case That Accelerator Works Now and Then When Driving



● 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. ● 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 belt (remove the sensor failure)



Note: After installing the belt, pull out the pin of belt tensioner with pliers to realize automatic tension.



Belt looses



108



3.2.9.2. 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 ● 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, and then the problem is solved



109



3.2.9.3 Description of the Case That Vibration at Idle Speed Is Huge (2)



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



Case analysis



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



Remedy



Replace vehicle transmission shaft



110



3.3 Parts Failure Analysis Main parts in common rail system



Main parts in common rail system



111



3.3.1 Injector



Fault: insufficient power, black smoke exhaust, difficult to start and limp-home fault Injector working principle picture



112



3.3.1.1 Table about Analysis of Injector Fault



No.



Fault type



Cause



Remedy



1



Atomization of injector is bad



Carbon deposit heavily on fuel head



Clean replace injector if fault cannot be removed



2



Injectors don’t inject fuel



Needle valve is locked in closed state



Replace injector



3



Fuel head of injector drip fuel



Needle valve is locked at usual position or needle valve of injector is worn and its sealing isn’t tight



Replace injector



4



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



Fuel return plunger taper is worn and its sealing isn’t tight



Replace injector



5



Injector Bronze cover or washer is distorted or damaged



Inexact orientation lead to distort or tighten with big strength when installing



Replace bronze cover or washer



6



Screw cap of connection pole is loose, which causes wiring harness of injector is loose or worn and cylinder head is short circuit



Screw cap and wiring harness cannot fasten firmly



Fasten screw cap and wiring harness



Electromagnetism valve of injector is damaged



Turnoff or big electric current is burnt because of other causes



Replace injector



7



113



Remarks



Pay attention to orientation when installing



Resistance of injector is 0.9 ohm



3.3.1.2 Analysis about Injector Fault Fault: insufficient power, block smoke exhaust, difficult to start and limp-home fault



● Atomization of injector is bad cause: carbon deposit heavily on fuel head （right picture） Remedy: clean, replace injector if the fault cannot be removed. ● Injector doesn’t inject fuel Cause: injector is locked in closed state Remedy: replace injector



● 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



● Fuel return amount in every injector is big or there is big different from other injectors Cause: fuel return plunger taper is worn



114



Remedy: replace injector



● 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 washer ● 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.



● Electromagnetism valve of injector is damaged Cause: turnoff or big electric current is burnt because of other causes. Remedy: replace injector My note:



115



3.3.2 High Pressure Fuel Pump



3.3.2.1 Table for Analysis of High Pressure Fuel Pump



No.



Fault type



1



Fuel outlet pipe of high pressure fuel pump can supply fuel



Cause



Remedy



Remarks



There is air in plunger or gear pump, or plunger is worn



Remove air or replace high pressure fuel pump



There are 2 rotation direction in gear pump, do not confuse



2



Flow metering unit is often open



Connection of Bnc connector plugs of wiring harness is bad, and flow metering unit is damaged



Pull out and insert bnc connector plugs again or replace flow metering unit



Resistance of flow metering unit is 2.6～3.15ohm



3



Connection of flow metering unit is bad



Bnc connector plugs is loose



Pull out and insert again



4



Timing of timing gear of high pressure fuel pump is wrong



Timing of gear is wrong when installing fuel pump



Re-adjust as requirement of technics



116



3.3.2.2 Analysis about High Pressure Fuel Pump Fault: can not be started, difficult to start and limp-home



● 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 ● 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. ● Connection of bnc connector plugs of flow metering unit is bad Cause: bnc connector plugs is loose Remedy: pull out and insert again ● The timing of timing gear of high pressure fuel pump is wrong Cause: timing of gear is wrong when installing fuel pump. Remedy: re-adjust as requirement of techniques



117



3.3.3 Common Rail Pipe



3.3.3.1 Table about Analysis of Common Rail Pipe Fault



No.



1



2



Fault type



Cause



Pressure released valve leaks abnormally



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



Replace pressure released valve or common rail pipe



Rail pressure cannot be set up abnormally



Connection of bnc connector plugs is bad, and rail 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



Fault of Rail pressure sensor



Remedy



118



Remarks



3.3.3.2 Analysis about Fault of Common Rail Pipe ※



Fault: difficult to start and fault of limp-home



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 Remedy: replace pressure released valve or common-rail pipe. ※



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



3.3.4 ECU



119



3.3.4.1 Table about Analysis of ECU Fault



No.



Fault type



Cause



Remedy



Remarks



1



Communication between diagnostic and ECU is failure and blink code light and cold started light cannot selfcheck



ECU is burnt



Replace ECU



2



K line has not voltage



There is wrong with 1.89 stitch line



Check 1.89 line



ECU stitch is folded



Wrong operation when pull out and insert bnc connector plugs



Replace ECU



4



ECU is hit by big electric current



Turnoff or didn’t pull out ECU bnc connector plugs



Replace ECU



Caution reliability of ECU line, and protect ECU when jointing



5



ECU stitch is turnoff



Flow into Conductive electricity liquid



Clean liquid or replace ECU



Add sealing ring on wiring harness, and caution waterproof



3



3.3.4.2 Analysis about ECU Fault Fault: engine cannot be started, flameout ※



Communication between



diagnostic and ECU is failure ， electric blink code light and cold started light cannot self-check.



120



Usually 24V



Cause: ECU is burnt. Remedy: replace ECU ※



K line has no voltage (usually about 23.5 )



Cause: 1.89 stitch line is wrong. Remedy: check 1.89 line ※



ECU stitch is folded



Cause: there is wrong operation when pull out and insert ECU bnc connector plugs. Remedy: replace ECU ※



ECU is hit by big electric current



Cause: line turnoff or did not pull out ECU bnc connector plugs Remedy: replace ECU (caution that reliability of ECU line, and protect ECU when jointing) ※



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)



121



3.3.5 Sensor and Wiring Harness



Oil temperature and pressure sensor



Air intake temperature and pressure sensor



Water temperature sensor



Crankshaft speed sensor



Rail pressure sensor



Camshaft speed sensor



3.3.5.1 Table of Function of Sensor



No.



Sensor



Function



System responses when it fails



1



Rail pressure sensor



It is one of the key sensors in common rail system, and it provides the pressure in common rail pipe



PRV opens, the temperature of return oil rises, and it runs limp-home.



2



Water temperature sensor



It provides the coolant temperature and is relevant to the function of air-intake heating and heat protection.



It runs limp-home.



3



Oil temperature and pressure sensor



It provides the parameters of oil pressure and temperature.



Oil pressure alarms



4



Air-intake temperature and pressure sensor



It provides the signals of crankshaft position and rotating speed.



Diesel engine discharges black smoke, white smoke, and runs limp-home.



5



Crankshaft speed sensor



It provides the signals of crankshaft position and rotating speed.



It is difficult to start and discharges smoke.



6



Camshaft speed sensor



It provides the signals of piston working position and camshaft rotating speed.



It is difficult to start and runs limp home.



122



3.3.5.2 Analysis Table for Fault of Sensor and Wiring Harness



No.



Fault type



Cause



Remedy



1



Sensor hardware is damaged



bnc connector plugs or sensor shell is damaged when installing



Replace a new sensor



2



Electric feature of sensor is wrong



Because of electro circuit, Sensor is damaged.



Replace a new sensor



3



Insert part of wiring harness is bad or damaged



Insert untightly or damage bnc connector plugs when operating



Pull out and insert again or replace wiring harness



4



Turnoff and short circuit of wiring harness



Connection rubber worn of Wiring harness broken



Protect or replace wiring harness



3.3.5.3 Analysis about Sensor and Wiring Harness Fault ※



Sensor hardness damaged



Cause: bnc connector plugs or sensor shell damaged when installing Remedy: Replace a new sensor. ※



Wrong electric feature of sensor



Cause: because of electro circuit, sensor is damaged Remedy: replace a new sensor ※



Insert part of wiring harness is



bad or damaged



123



Remark



Cause: Insert untightly or damage bnc connector plugs when operating. Remedy: insert and pull out again or replace wiring harness ※



Turnoff and short circuit of



wiring harness Cause: connection rubber worn or wiring harness broken. Remedy: protect or replace wiring harness 3.3.5.4 Guide for Sensor Inspection



Assembly Camshaft speed sensor (installed on the flywheel)



Item Resistance between 2 stitches of sensor



Standard numeral value 770-950 ohm



2.232.19 wave shape(idling speed)



124



Assembly



Item



Standard numeral value



Camshaft speed sensor (installed on flywheel)



Voltage between 2.09 and ground line （idling speed）



3.2-4.9 V



Resistance between 2 stitches of sensor



770-950 ohm



2.09-2.10 wave shape （idling speed）



Flow metering unit (installed up and left side of high pressure pump)



Resistance of flow metering unit



2.60-3.15 ohm（environmental temperature 20 ℃）



Data flow (electric current in idling speed)



1380～1420mA



125



Assembly



Item



Rail pressure sensor (installed near right side)



2.14－2.12 voltage (T15)



0.5V



2.14－2.12 voltage (idling speed)



1.2～1.5V



Rail pressure (idling speed)



340～450bar



Changed range (voltage of rail pressure sensor)



Assembly



Item



Water temperature sensor（ installed on the water outlet pipe）



Resistance feature from 2.15 to 2.16 in different water temperature (right picture) ，Rnom is standard numeral value



Standard numeral value



0.5～4.5V (0bar ～1800bar)



Standard numeral value



126



Assembly



Item



Air inlet temperature and pressure sensor (installed on air intake pipe)



Resistance feature from 2.362.25 in different temperature (right picture) nominal is standard numeral value，



Assembly



Item



Air inlet pressure sensor



Voltage from 2.34 to 2.25 （idling



Standard numeral value



Standard numeral value 0.5～0.8 V



speed） Voltage from 2.34 to 2.25



127



Assembly



Item



Oil temperature sensor



Resistance feature of 2.28－2.24 in different temperature (right picture) ，nominal is standard value



Assembly Oil pressure sensor



Assembly Air intake heating relay



Standard numeral value



Item



Standard numeral value



Voltage of 2.27－2.24



Item Voltage of 1.55－1.59



Standard numeral value 23～29 V



128



3.3.6 Accelerator Pedal



129



3.3.6.1 Table about Accelerator Pedal Fault



No.



Fault type



Cause



Remedy



1



Inserting part of accelerator is not good



Insert untightly



Pull out and insert again



2



Turnoff and short circuit of accelerator



Connection rubber worn or wiring harness broken



Protection



3



Opening of accelerator pedal is abnormal



That pedal output voltage cannot reach quirement of EUC



Replace pedal



APP1：0.753.84V APP2：0.3751.92V



4



Double voltage relationship of ccelerator is failure



Pedal cannot reach the requirement



Replace pedal after remove cause of line



Signal1 is double signal 2(voltage)



Learning and thinking:



130



Remark



3.3.6.2 Analysis about Accelerator Pedal Fault Fault: engine runs at speed of 1,000r/min always, and idling speed is high



● Accelerator parts contacts bad ※



Cause: insert untightly.



※



Remedy: pull out and insert again



● Turnoff and short circuit of accelerator connection ※



Cause: connection rubber worn or wiring harness broken



※



Remedy: protection



● Opening of accelerator pedal is abnormal ※



Cause: that pedal output voltage cannot reach requirement of ECU.



※



Remedy: replace pedal.



● Double voltage relationship of accelerator signal is failure. ※



Cause: pedal cannot reach the requirement.



※



Remedy: remove line problem and remove pedal.



Learning and thinking:



131