濰柴電噴案例（WEICHAIEFICASE）WEIFANG336AND375EDC7CASECOMMONFAULTTYPESFAULT1DIESELENGINEDOESNOTSTARTORSTARTDIFFICULTFAULTTWOENGINEPOWERSHORTAGEMAXIMUMSPEED150016001700FAULTTHREEENGINE1000RPMASSOCIATEDWITHTHEACCELERATORPEDALFAULTFOURLIMPHOMEENGINEMAXIMUMSPEEDCANONLYREACH1500FAULTFIVEUNSTABLECRUISEFAULTSIXFLASHCODELIGHTISALWAYSONFAULTSEVENSUDDENLYFLAMEOUTDURINGOPERATIONFAULT1DIESELENGINEDOESNOTSTARTORSTARTADONOTSTARTTHEDIESELENGINEISACOMPRESSIONIGNITIONINTERNALCOMBUSTIONENGINESMOOTHSTARTINGOFDIESELENGINENOTONLYALARGEAMOUNTOFFUELISREQUIREDTOBEINJECTEDINTOTHECYLINDERAFTERSUFFICIENTATOMIZATIONITALSOREQUIRESTHATTHEAIRINTHECYLINDERBECOMPRESSEDTOACERTAINTEMPERATUREANDPRESSUREONLYINTHISWAYCANTHEDIESELENGINEBESPONTANEOUSCOMBUSTIONTHEREFORE,THEDIESELENGINECANNOTSTARTSMOOTHLYTHEREASONSAREGENERALLYONTHESTARTINGSYSTEM,THEELECTRONICALLYCONTROLLEDFUELSYSTEM,THEINTAKEANDEXHAUSTSYSTEM,ORTHEDIESELENGINECLEARANCECUSTOMERMAYBEACCOMPANIEDBYFAILURECHARACTERISTICSANALYZEANDJUDGEACCORDINGTOTHEPROCEDURE11STARTERDOESNOTWORKFORTHESTARTER,CONTROLLEDBYTHEECUVEHICLEATBOOTTIME,ECUCHECKSTHENEUTRALSIGNALFIRSTTHEN,ACURRENTISSTARTEDTODRIVETHESTARTINGRELAYAFTERTHERELAYISSWITCHEDON,THEBATTERYDRIVESTHESTARTERTHEREARESEVERALFACTORSINTHEINSPECTIONNEUTRALSWITCH,STARTERRELAY,BATTERY,ANDTHEPARKINGSWITCH01CHECKWHETHERITISINNEUTRALPOSITION01CHECKTHEPOSITIONOFTHEPARKINGSWITCHSHOULDBEINASTATEOFDISCONNECTION0,1CHECKTHENEUTRALSWITCHUSUALLYMOUNTEDONTHETRANSMISSIONANDWHETHERTHEWIRINGISINGOODCONDITIONTRYUSINGEMERGENCYSTARTINGIGNITIONSWITCHCONTINUESFORMORETHAN5SECONDSTRANSMISSIONCASENEUTRALSWITCHDOWNSTOPSWITCH01CHECKWHETHERTHEBATTERYVOLTAGEISTOOLOWTODRIVETHESTARTER0,1STARTERRELAYSANDWIRINGAREINGOODCONDITION01CHECKTHATTHESTARTERISBURNEDOUT01ISTHEIGNITIONSWITCHANDTHESTARTERSWITCHOUTOFORDERIGNITIONKEYSWITCHCASE1SHAANXIWP10336TRACTORENGINECANNOTBESTARTEDSTARTERISNOTTURNEDINSPECTIONPROCESSWHENTHEKEYSWITCHPOSITIONISREACHEDSELFCHECKINGLAMPSELFTESTNOTETHATTHEECUISPOWEREDONCHECKTHE140LINEVOLTAGECHECKTHEIGNITIONCIRCUIT161WITHOUTVOLTAGEANDFINDTHATTHEINSURANCEISBURNTOUTAFTERREPLACINGANINSURANCE,ELECTRIFYBUTSTILLUNABLETOSTART,ANDREPORTED“MAINRELAYERROR“RECONNECTTHEMAINRELAYAFTERWIRINGANDTROUBLESHOOTCASE2SHAANQITRACTORWP10336THEENGINEDOESNTSTARTTHESTARTERDOESNTTURNINSPECTIONPROCESSWHENYOUREACHTHEKEYSWITCHPOSITION,CHECKTHELAMPSELFCHECKNOTETHATTHEECUISPOWEREDON140AND161WIRINGHAVEVOLTAGEOUTPUT,RELAY137LINESHAVEVOLTAGEPERMEABILITYBUTTHE151LINEISNOTGROUNDEDLOOPCANNOTBEFORMEDTOSEPARATE151GROUNDLINE,THENORMALSTARTCASE3SHAANQITRACTORWP10336THEENGINEDOESNTSTARTTHESTARTERDOESNTTURNINSPECTIONPROCESSWHENTHEKEYSWITCHPOSITIONISREACHED,THESELFCHECKINGLAMPISNOTSELFCHECKINGNOTETHATECUISNOTPOWEREDON140AND161HAVEVOLTAGEDETECTIONOFTWOPUBLICHIGHENDLINES,104AND203ARENOVOLTAGEOUTPUT,PRELIMINARYJUDGMENTECUINTERNALDAMAGEAFTEREXCHANGINGECU,THEECUFAULTISCONFIRMEDTROUBLESHOOTINGAFTERREPLACINGNEWECUCASE4SHAANQITRACTORWP10336THEENGINECANNOTSTARTSTARTERISNOTTURNEDINSPECTIONPROCESSWHENTHEKEYSWITCHPOSITIONISREACHEDSELFCHECKINGLAMPDOESNOTSELFCHECKNOTETHATECUISNOTPOWEREDONINVESTIGATIONFOUNDTHATTHEVEHICLELINEBURNEDOUT,THEUSERINTHEBATTERYLINEWILLBEPOSITIVEANDNEGATIVECOUNTERBURNOUTLINESANDECU12RAILPRESSURECANNOTBEESTABLISHEDSTARTERNORMAL,BUTCANNOTSTARTDATASTREAMACTUALRAILPRESSURECOMMONRAILSYSTEMREQUIRESHIGHERFUELCIRCUITLOWPRESSUREOILCIRCUITOILTANKROUGHFILTERFINEFILTRATION,RETURNOIL,HIGHPRESSUREOILCIRCUITHIGHPRESSUREOILCOMMONRAILHIGHPRESSURETUBINGINJECTORMUSTENSUREAIRTIGHTANYLINKHASAPROBLEMRAILPRESSURECANNOTBEESTABLISHEDPROPERLYPROMPTTHEHOSTPLANTTOATTACHGREATIMPORTANCETOTHEENTIREFUELCIRCUITNOTETHEFIRSTSTARTOFTHEVEHICLEMUSTBECARRIEDOUTINTHELOWPRESSUREOILCIRCUITANDTHEHIGHPRESSURECIRCUITFOREXHAUSTANDOILFILLINGINSPECTIONMETHOD01CHECKTANKLEVELISTOOLOW01CHECKHANDPUMPISWORKINGPROPERLY0,1CHECKTHEOILCIRCUITISCLEAR,CHECKTHEDIESELFILTERISBLOCKED,ITISRECOMMENDEDTOREPLACETHEDIESELFILTERINSPECTIONMETHODRELEASETHEFILTEROUTLETBOLT,DRIVETHEDIESELENGINEWITHTHESTARTER,ANDCHECKWHETHERTHEDIESELOILISEJECTEDORDISCHARGEDIFONLYASMALLAMOUNTOFDIESELOILISDISCHARGED,THEFILTERCORECANBEBLOCKED0,1,CHECKWHETHERTHELOWPRESSUREAIRCIRCUIT,SIDEAIRSOMETIMESLOWPRESSUREOILLEAKAGEISNOTOBVIOUS,NEEDTOBECAREFULLYCHECKEDEXHAUSTMAINLYDRAINTHEAIRINSIDELOOSENBOLTSONTHEAIRSTRAINER,HANDPRESSUREPUMPROUGHFILTERONTHEHAND,UNTILTHEAIRBOLTCONTINUEDOILSOFARHANDPRESSUREPUMPBLEEDBOLTOILRETURNHOLLOWBOLT0,1,LOWPRESSURECIRCUIT,AIREXHAUSTSTILLCANNOTSTARTTHEDIESELENGINE,THENDETERMINETHEHIGHPRESSUREAIRCIRCUITITALSONEEDSTOEXHAUSTTHEAIROFTHEHIGHPRESSURECIRCUITEXHAUSTMETHODLOOSENACYLINDERHIGHPRESSURETUBINGDRIVETHEDIESELENGINEWITHASTARTERUNTILTHEHIGHPRESSUREPIPECONTINUESTORUNOUTITISNOTRECOMMENDEDTOREMOVETHEHIGHPRESSURETUBINGJOINTSFREQUENTLY01CHECKTHEHIGHPRESSURECIRCUITFORLEAKSINVESTIGATIONMETHODIFTHEHIGHPRESSUREAIRPIPEISDISCHARGED,THERAILPRESSURECANNOTBEESTABLISHED,THENITISNECESSARYTOCONSIDERWHETHERTHEINJECTORFAULTTHEWP10SERIESCANDISASSEMBLETHEINJECTORRETURNPIPEANDDRIVEWITHTHESTARTERTOOBSERVETHEABNORMALRETURNUNDERNORMALCIRCUMSTANCESINFRONTOFTHECARTHEINJECTORSHOULDBEFREEOFOILANDGASIFTHEREISITCANBEJUDGEDASTHELEAKAGEOFTHEINJECTORUSUALLYDUETOOILPROBLEMS01CHECKWHETHERTHEINITIALVOLTAGEOFRAILPRESSURESENSORISAROUND05VORSETTHERAILPRESSUREIS350500BAR,IFNOTNORMAL,FIRSTCHECKTHECONNECTORISRELIABLEWITHOUTINSPECTIONEQUIPMENTUNPLUGTHERAILPRESSURESENSORCONNECTORANDTRYRESTARTING01CHECKTHATTHEFLOWMEASUREMENTUNITISINGOODCONDITION,UNPLUGTHECONNECTORANDTRYTOSTARTAGAINWHENTHECONNECTOROFTHEFLOWMEASURINGUNITISPULLEDOUT,WHENSTARTING,THEOILPUMPWILLSUPPLYOILTOTHECOMMONRAILPIPEWITHTHELARGESTOILSUPPLYNOTECHECKTHERAILPRESSUREBUILDUPCHECKTHECONDITIONOFRAILPRESSUREANDCONNECTTHEFAULTDIAGNOSISINSTRUMENTTHETRACKPRESSUREISDETERMINEDBYDETECTINGTHECHANGEOFRAILPRESSUREINTHEDATASTREAMUSUALLYTHETHEORETICALVALUEOFRAILPRESSURESHOULDBE0BARINTHECONDITIONOFNOTMOVINGBUTINTHEACTUALPROCESS10BAROR15BARMAYBEDETECTED,WHICHCANBETRIEDWITHOUTRAILPRESSUREWHENTHEVEHICLEISSTARTED,WHENTHERAILPRESSUREISBETWEEN350500BARECUCONTROLSINJECTORFUELINJECTIONITISPOSSIBLEFORTHEENGINETOSTARTINGENERAL,NOFAULTISREPORTED13MORETHANTHEFUELINJECTORSTUCK,CANNOTSTARTTHECARWHENTWOORMOREINJECTORSAPPEAR,TWOCARDSARESTUCKNOINJECTIONTIMECANNOTSTARTCASEYUTONGBUS,STARTERCANSTART,BUTTHEENGINECANNOTSTARTTHEDETECTIONCIRCUITISNORMALWHENTHESTARTERDRIVESTHERAILPRESSUREISUPTO400BARBUTSTILLCANNOTSTARTCHECKVALVE,PUSHRODANDVALVEARENORMALPRELIMINARYJUDGMENTOFMORETHANTWOINJECTORFAILUREAFTERSWITCHINGTHEINJECTORTROUBLESHOOTING14CRANKSHAFTSIGNALANDCAMSHAFTSIGNALLOSTSYNCHRONIZATIONSIGNALERRORTWOSPEEDSENSORSAREINSTALLEDONTHEDIESELENGINE,RESPECTIVELY,ONTHEFLYWHEELHOUSINGANDTHEHIGHPRESSUREOILPUMPTHEFUNCTIONSARECRANKSHAFTPOSITIONSENSORANDCYLINDERHEADSENSORTHEINJECTIONTIMINGOFANELECTRONICALLYCONTROLLEDENGINEDEPENDSONTHETWOSENSORSIFALLTWOSIGNALSARELOST,ADIESELENGINEWILLNOTSTARTCAMSHAFTSPEEDSENSORCRANKSHAFTROTATESPEEDSENSOR14LOSSOFCRANKSHAFTSIGNALANDCAMSHAFTSIGNALALLPOSSIBLELOSSOFTWOSIGNALSSENSORDAMAGE,WIRINGHARNESSSHORTCIRCUITOROPENCIRCUITTHESENSORISNOTFIRMLYFIXED,WHICHMAKESTHEGAPBETWEENTHESENSORANDTHEINDUCTIONTOOTHTOOLARGEORTOOSMALLUSUALLY105MMRULEOUTCHECKTHATTHESENSORISDAMAGEDANDWHETHERTHEWIRINGHARNESSISCONNECTEDPROPERLYWHETHERTHESENSORISLOOSEORNOTNOTETHEDISASSEMBLYANDASSEMBLYOFHIGHPRESSUREOILPUMPANDFLYWHEELSHALLBECARRIEDOUTINSTRICTACCORDANCEWITHTHERELEVANTPROCESSDOCUMENTSTOENSURETHESYNCHRONIZATIONOFTHESIGNALSTWODIESELENGINEDIFFICULTTOSTARTCAUSESANDTROUBLESHOOTINGOFDIESELENGINESTARTINGUPTHEDIESELENGINEDOESNOTRUNFORALONGTIMETHERETURNPIPESHALLBEEXTENDEDUNDERTHEDIESELLEVELLOWPRESSUREPIPELINEHASALITTLEAIREXHAUSTAIRTHECRANKSHAFTSPEEDSIGNALANDCAMSHAFTSIGNALARETOOWEAK,ANDTHESYNCHRONIZATIONTIMEISLONGREADJUSTTHEAMBIENTTEMPERATUREISTOOLOWANDTHEPREHEATERISINVALIDREPLACETHEPREHEATINGDEVICETHEQUALITYOFDIESELOILANDENGINEOILISTOOPOORTOMEETTHEREQUIREMENTSREPLACESTANDARDOILTHESTARTERORFLYWHEELGEARRINGGEARANDFLYWHEELRINGGEARREPLACETHESTARTERTHEPISTONRINGANDCYLINDERLINERWEARORVALVESEALTHEREPLACEMENTOFTHEPISTONRINGANDCYLINDERLINERORVALVESEATANDVALVETHEEXHAUSTBRAKEBUTTERFLYVALVESTUCKINTHECLOSEDPOSITION,RESULTINGINPOOREXHAUSTVALVEREPLACEMENTTOTHEFUELTANKINTOTHERETURNPIPEDIAMETERANDPRESSUREDOESNOTMEETTHEDESIGNREQUIREMENTSCASE1YUTONGBUSWP10336REFLECTSLONGSTARTINGTIMEMAINTENANCEPROCESSAFTERINSPECTION,THERAILPRESSUREBUILDUPPROCESSISTOOSLOWCHECKTHEOILCIRCUIT,FOUNDTHATTHELOWPRESSUREOILPIPELINEISTOOTHIN,THEINNERDIAMETEROFABOUT6MMMINIMUM12MMLESSTHANWEIFANGREQUIREMENTSALLLOWPRESSUREOILPIPESREQUIREDBYCUSTOMERSTOREPLACETHEOILPIPEINTHEFUELTANKWILLBEACTIVATEDAFTERREPLACEMENTCASE2SHAANXIWP10336TRACTOR,REFLECTINGTHEDIFFICULTTOSTARTOVERHAULPROCESSFOUNDTHATTHE“CRANKSIGNALISNOTCREDIBLE“FAULT,ANDTHEREISADIFFICULTSTARTFAULTITISFOUNDTHATTHEDIMENSIONOFTHEMOUNTINGHOLEOFTHECRANKSHAFTROTATIONSPEEDSENSORONTHEFLYWHEELHOUSINGISBIASEDCAUSESTHECRANKSHAFTSENSORTOBEINSTALLEDTHEDEVIATIONOFTHESIGNALHOLEONTHEFLYWHEELCAUSESTHECRANKSHAFTSIGNALTOBEUNRELIABLE“REPLACEFLYWHEELHOUSING,TROUBLESHOOTINGFAULTTWOINSUFFICIENTPOWEROFDIESELENGINE21INJECTORFAILURETHEINJECTORISOUTOFORDERGENERALLYDIVIDEDINTOMECHANICALANDWIRINGFAULT01MECHANICALFAILUREFORWHENTHENEEDLEVALVEISJAMMED,THENEEDLEVALVEISSTUCKINTHEINJECTORBECAUSETHEDIRTINTHEDIESELOILISMOREORTHEWATERISCORRODEDNOTICEECUMAYNOTBEWRONG01WIRINGFAULTFORBECAUSEOFVIBRATION,WEARANDTEAR,THEWIRINGISDISCONNECTEDORDIRECTLYCONNECTEDTOTHECYLINDERHEADANDSHORTEDTOTHEGROUNDECUWILLMAKEAMISTAKE01IDLEINSTABILITY,LISTENTOTHEABNORMALSOUNDOFDIESELENGINES01USINGBROKENCYLINDERMETHODORHIGHPRESSURETUBINGTACTILEMETHODTOJUDGE01USINGAFAULTDIAGNOSISINSTRUMENTTOSPEEDUPTESTDECISIONSCASEWP10290TRACTORREFLECTENGINEPOWERSHORTAGEUNABLE。OVERHAULPROCESSAFTERINVESTIGATIONTROUBLEFREECODEPRELIMINARYANALYSISISANOILCIRCUITORGASPATHFAILUREUSINGTHEFAULTDIAGNOSISINSTRUMENTTODO“ACCELERATEDTEST“,WEFOUNDTHEFIFTHCYLINDERWORKINGCAPACITYISPOOR,ANDAFTERFIFTHCYLINDERINJECTORREPLACEMENT,TROUBLESHOOTINGREMARKSDATAANALYSISOFACCELERATEDTESTINDATAANALYSIS,ADIFFERENCEOF50GENERALLYSPEAKING,ITCANBEREGARDEDASAFAIRLYGOODWORKABILITYADIFFERENCEOF50QUESTIONSNEEDTOBECONSIDEREDIFYOUCANTDO“ACCELERATEDTEST“,YOUCANMANUALLYJUDGETHEFAULTBYBREAKINGTHECYLINDERSPECIFICMETHODTURNOFFTHEPOWERSW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NOTFINDFAULT,RESEATINGSENSORTROUBLESHOOTINGAFTERDRIVINGFORAPERIODOFTIMETHESAMEFAULTOCCURREDAGAINRETESTTHEPRESSUREOFTHEAIRPRESSURESENSORISTOOLOW“TROUBLESHOOTINGAFTERREPLACINGTHEAIRPRESSURESENSORFAULTTHREEENGINE1000RPMTHEECUJUDGESTHELOADBYSIGNALSFROMTHEPEDALPOTENTIOMETERWHENTHEPEDALISOUTOFORDERFORSAFETYREASONS,THEECUWILLCONTROLTHEAUTOMATICIDLINGOFTHEDIESELENGINETO1000RPMREASONANALYSIS01ELECTRONICTHROTTLEPEDALLINELOOSEORWRONGREPLUGTHETHROTTLEORCHECKWHETHERTHEWIRINGISCORRECT,REWIRING01MEASURETHEVOLTAGEANDRESISTANCEOFTHEHIGHANDLOWENDOFTHEACCELERATORPEDAL,ANDDETERMINEWHETHERITISALINEPROBLEMNORMALLY,TWOHIGHENDVOLTAGESARE5VOLTSIFNOT5VOLTSYOUNEEDTOFINDLINEFAULTS01ELECTRONICTHROTTLECONNECTOR,WATERINLETTOOL,PLUGCONNECTOR,DRYANDRESTART0,1ACCELERATORPEDALQUALITYPROBLEMS,REPLACETHEACCELERATORPEDALNOTEYOUNEEDTHESAMETYPEOFACCELERATORWHENYOUCHANGETHETHROTTLECASE1HONGYANWP10290DUMPTRUCKWHENTHEVEHICLEISRUNNINGATIDLESPEEDAFTERAFEWMINUTES,THESPEEDWILLBEAUTOMATICALLYINCREASEDTO1000RPMANDTHEFAULTLIGHTISONINSPECTIONPROCESSAFTERCHECKING,THEENGINEREPORTEDTHATTHEACCELERATORPEDAL1AND2VOLTAGESIGNALSARENOTCREDIBLE“AFTERYOUDELETETHEFAULTCODE,STARTTHEENGINEATTHEBEGINNINGOFTHEOPERATIONNORMALLY,AFEWMINUTESLATERTHESPEEDISAUTOMATICALLYINCREASEDTO1000RPMANDTHEFAULTLIGHTISONANALYZETHEPROBLEMOFTHETHROTTLEPEDALLINEMEASURETHEACCELERATORPEDAL2HIGHENDWIRINGVOLTAGEIS5VOLTS,BUTTHEREISNOREVERSEJOINTBUCKLEPARKINGSTATUS,HARNESSCONNECTIONNORMALBUTAFTERSTARTINGTHEVEHICLEVEHICLEVIBRATIONLOOSEJOINTCAUSEVOLTAGEINSTABILITYAFTERFIXINGTHEJOINTWITHADHESIVETAPE,REMOVETHETROUBLEFAULTFOURLIMPINGHOMEWHATSTHEMEANINGOFLIMPINGHOMEAPATTERNOFENGINETROUBLERUNNINGHOMEECUDETECTEDAFAULTINTHEENGINEBUTNOTIMMEDIATELYSTOP,BUTWILLLIMITTHEPOWEROFTHEENGINE,SOTHATTHEENGINESPEEDCANONLYREACH1500RPM,THEDRIVERCANDRIVETOTHENEARESTREPAIRSTATIONFORMAINTENANCEITSASELFPRESERVATIONMODELSEVERALTYPESOFFAILURESFREQUENTLYENCOUNTEREDINSERVICEONTHEMARKETTHATCANCAUSELAMENESSTOANDFROMHOME41OILCIRCUITPROBLEMTHEOILCIRCUITINCLUDESLOWPRESSUREOILCIRCUITANDHIGHPRESSUREOILCIRCUITLOWPRESSUREOILINLETBLOCKINGTHEOILSHORTAGEANDTHEOILRETURNLINEISPRESSEDANDCANCAUSETHELIMPHOMEFAILUREMODETHEHIGHPRESSUREOILLEAKAGE,FLOWMEASUREMENTUNITFAULT,DAMAGE,HIGHPRESSUREOILPUMPINJECTORINTOTHEOILLEAKORINJECTORNEEDLESTUCKCANALSOCAUSEFAILURETOLIMPHOMECASESHAANXIWP10336TRACTORDURINGTHERIDE,THEFAULTYLIGHTSSUDDENLYSHONEATTHESAMETIMETHEREWILLBENOOILPHENOMENONTHESPEEDCANONLYREACH1500RPMAFTERPARKINGRESTARTNORMALAGAINRUNNINGADISTANCEANDTHESAMEFAULTINSPECTIONPROCESSAFTERINSPECTION,REPORTED“RAILPRESSUREDEVIATION“OR“EXCESSIVEFUELINJECTION“INVESTIGATIONFOUNDTHATTHEOILPIPEJOINTISFOLDED,ANDAFTERPROCESSINGTHETUBINGTROUBLESHOOTINGREMARKTHERAILPRESSUREDEVIATIONEXCEEDSTHELIMITORTHEQUANTITYOFFUELINJECTIONEXCEEDSTHELIMIT,WHICHISATYPICALMALFUNCTIONOFOILSUPPLYGENERALFAULTFORAROADRUNNINGNORMALLY,BUTUPHILLWILLSUDDENLYINCREASEINNONOILANDTHEFLASHINGCODELIGHTISONBROADANDUPHILLWILLSUDDENLYINCREASEINNONOIL,LIGHTANDFLASHCODEPARKINGISNORMALAFTERRESTARTING,BUTTHEFAULTOCCURSAGAINDURINGOPERATION