电喷共轨柴油发动机故障的诊断与维修技巧

电喷共轨柴油发动机故障的诊断与维修技巧

Skill diagnosis and repair EFI diesel engine fault

Perkins电喷共轨柴油发动机起动困难

Perkins injection common rail diesel engine starting difficulty

故障的症状与现象：Perkins起动机和发动机均有正常起动转速，但不着火；或者有时经过多次长时间的起动方可着火。

Symptoms and of failure: Perkins starter and engine has a normal starting speed, but not on fire; or sometimes after starting more than long time can fire.

造成起动困难的主要故障原因：燃油管路有空气。

The main failure causes the starting difficulties: the fuel lines for air.

故障的排除方法与处理：燃油管路排空气。

Troubleshooting and fault treatment of exhaust air: fuel line.

造成此故障的原因分析：Perkins柴油发动机采用共轨系统，油路排空气相对困难一些，往往操作人员感觉到空气排除干净的，实际还是没有彻底排干净。根据实际使用情况来看，应该松开油泵回油螺栓来排空气，必要时可松开高压油管，利用起动机带动发动机空转来排空气；如果仅仅是松开燃油滤清器的放气螺钉来排空气，可能不容易彻底排除燃油管路的空气，比较费力。

Analysis of the reasons causing the failure: Perkins diesel engine with common rail system, the oil exhaust air is relatively difficult, often operating staff feel the air out clean, practical or not completely discharged. According to the actual situation, should loosen the oil pump oil return bolt to exhaust the air, may be necessary to loosen the high-pressure tubing, the starter to engine idle to exhaust the air; if only the bleeder screws loosen the fuel filter to exhaust the air, may not be easy to remove the fuel line of the air, more laborious.

故障的症状与现象：起动机和珀金斯发动机均有正常起动转速，但不着火。

The phenomenon of fault symptoms and were: the starter and Perkins normal engine starting speed, but not on fire.

造成的主要故障原因：柴油管路或油水分离器堵塞。

The main failure causes: Diesel pipeline or oil-water separator jam.

故障的排除方法与处理：清理柴油管路或油水分离器、对有水分离器进行放水，必要时更换，最后要对油路进行彻底排空气。

Troubleshooting and fault treatment: clean diesel pipeline or oily water separator, the water separator for water, replace if necessary, and finally to the circuit is completely exhaust air.

造成此故障的原因分析：目前，我国的柴油品质还不能完全满足Perkins电喷共轨系统的柴油机对于柴油品质的要求，因此，Perkins电喷共轨发动机的柴油滤清器或油水分离器要经常保养，其保养周期要比其它的发动机大大缩短。（还有一种情况，如果进油软管或回油软管内径太细太长导致进回油进回油不畅，比较严重的也会使发动机启动困难或无法起动。此时，需要更换符合要求的进回油管，内径最好12毫米以上）。

Analysis of the reasons causing the failure: at present, China's diesel quality still can not fully meet the diesel engine Perkins injection common rail system for diesel quality requirements, therefore, Perkins injection common rail diesel engine cleaner or oil-water separator to regular maintenance, the maintenance period should be shortened greatly than other engine. (there is another situation, if the oil inlet hose or oil return hose diameter is too small too long lead into the oil back into the poor oil return, serious will also cause the engine is difficult to start or not start. At this time, need to be replaced to meet the requirements of the inlet and outlet oil pipe diameter of 12 mm or more), the best.

故障的症状与现象：起动机和发动机均有正常起动转速，但不着火。

The phenomenon of symptom and fault: the starter and engine had normal starting speed, but not on fire.

造成的主要故障原因：Perkins柴油发动机ECU存在故障码。

The main fault reasons: Perkins ECU diesel engine fault codes.

故障的排除方法与处理：清除故障码。

Troubleshooting and fault treatment: clear fault code.

造成此故障的原因分析：此发动机从机械方面检查均正常，用诊断仪诊断发现有“水温传感器”、“轨压传感器”、等一些故障显示，清除故障码后，发动机顺利起动。这种情况估计是维修或操作人员对电控系统的接插件进行了带电插拔的操作，这样系统会产生故障码储存在ECU中，系统起保护作用会限制一些功能甚至无法起动。

Analysis of the reasons causing the failure: the engine from the mechanical tests were normal, with diagnostic found "temperature", "rail pressure sensor", and some other fault display, clear fault code, engine start smoothly. This estimate is connector repair or the operator of electronic controlled system is a hot plug operation, this system generates a fault code is stored in ECU, the system play a protective role will restrict some functions can not even start.

故障的症状与现象：起动机和发动机均有正常起动转速，但不着火。

The phenomenon of symptom and fault: the starter and engine had normal starting speed, but not on fire.

造成的主要故障原因：Perkins发动机线束损坏或接插件接触不良。

The main fault reasons: Perkins engine wire harness damaged or bad connector.

故障的排除方法与处理：更换发动机线束或重新拔插各接插件（注意：此时一定要先关闭电源）。

Troubleshooting and fault handling: the replacement of the engine wire harness or re plug the connector (Note: at this time must first turn off the power).

造成此故障的原因分析：发动机线束损坏的几率不大，接触不良的情况比较多。在各接插件接触不良的原因没有排除之前，不要轻易更换发动机线束。此时，可借助诊断仪诊断出故障发生的大概区域，再进行排除。

Analysis of the reasons causing the failure: the engine wire harness the damage probability is not big, more bad situation. Before each connector contact bad reason has not ruled out, do not change the engine wiring harness. At this time, with a range of diagnostic fault, then excluded.

故障的症状与现象：康明斯起动机和发动机均有正常起动转速，但不着火。

Fault symptoms and phenomenon: Cummings starter and engine has a normal starting speed, but not on fire.

造成的主要故障原因：油泵安装正时不对或飞轮不匹配。

The main failure causes: pump installed incorrectly or flywheel does not match the timing.

故障的排除方法与处理：重新安装油泵或更换匹配的飞轮。

Troubleshooting and fault handling: flywheel re install the pump or replace matching.

造成此故障的原因分析：这种情况一般出现在更换过油泵或飞轮的发动机上，对于油泵有安装正时要求的发动机，油泵安装必须正确；另外，如果更换飞轮，必须使用周围带有信号感应孔的原配飞轮。

Analysis of the reasons causing the failure: this situation usually occurs in replacing the pump or the flywheel of the engine, installation is required for the engine oil pump, oil pump must be installed correctly; in addition, if the replacement of the flywheel, must be used with a signal induction holes around the original with flywheel.

故障的症状与现象：起动机和康明斯发动机均有正常起动转速，但不着火。

Symptoms and phenomenon: have the starter and Cummins engine normal starting speed, but not on fire.

造成的主要故障原因：油泵压力控制阀（PCV）插件位置装错。

The main failure causes: oil pressure control valve (PCV) plug-in loading the wrong position.

故障的排除方法与处理：重新拔插安装（先关闭电源）。

Troubleshooting and fault handling: re plug installation (turn off the power first).

造成此故障的原因分析：这种情况一般出现在拆卸过油泵或PCV阀接插件的发动机上。其采用的是电装的油泵，PCV阀有两个，接插件位置容易混淆，安装时需看好记号，一般是线上扎有颜色的胶带的靠飞轮端。

Analysis of the reasons causing the failure: this situation usually occurs in removing a pump or valve connector on the engine of PCV. It is used in oil pump electrical equipment, PCV valve has two, the connector position easily confused, when installation should be valued mark line, usually tied with colored tape on the flywheel side.

故障的症状与现象：起动机和沃尔沃发动机均有正常起动转速，但不着火。

Symptoms and phenomenon: have the starter and Volvo engine normal starting speed, but not on fire.

造成的主要故障原因：沃尔沃NE（转速）传感器和G(凸轮轴)传感器同时故障。

The main failure causes: the Volvo NE (speed) sensor and G (CAM) sensor fault.

故障的排除方法与处理：更换。

Troubleshooting and fault treatment: the replacement.

造成此故障的原因分析：这种情况一般出现得不多。用沃尔沃诊断仪检测会有NE（转速）传感器和G(凸轮轴)传感器同时故障的显示。

Analysis of the reasons causing the failure: this situation usually occurs not more. With Volvo diagnosis instrument will have NE (speed) sensor and G (CAM) show the sensor at the same time fault.

故障的症状与现象：沃尔沃起动机和发动机均有正常起动转速，但不着火。

Fault symptoms and phenomenon: Volvo starter and engine has a normal starting speed, but not on fire.

造成的主要故障原因：高压共轨管故障。

The main fault reasons: high pressure common rail tube failure.

故障的排除方法与处理：更换。

Troubleshooting and fault treatment: the replacement.

造成此故障的原因分析：此故障有时是轨压传感器故障，有时是油轨压力控制阀故障，如果轨压控制阀一直处于打开状态，轨压就无法建立，从而无法起动。

Analysis of the reasons causing the failure: the failure is sometimes rail pressure sensor fault, sometimes is the fuel rail pressure control valve failure, if the rail pressure control valve has been opened, rail pressure cannot be established, thus unable to start.

故障的症状与现象：沃尔沃起动机无转速。

Fault symptoms and phenomenon: Volvo starter without speed.

造成的主要故障原因：无电源、电压不足或起动机故障。

The main fault reasons: no power supply, voltage or starter fault.

故障的排除方法与处理：接通电源或更换沃尔沃起动机或对电瓶充电。

Troubleshooting and fault handling: switch on the power or replacement of Volvo starter or to charge the battery.

造成此故障的原因分析：沃尔沃起动机电流过大会烧坏或齿圈无法与飞轮啮合；电压不足，发动机达不到起动转速。

Analysis of the reasons causing the failure: Volvo starter current will burn out or ring gear and flywheel cannot; voltage is insufficient, the engine is not up to the starting speed.

故障的症状与现象：起动机和发动机均有正常起动转速，但不着火。

The phenomenon of symptom and fault: the starter and engine had normal starting speed, but not on fire.

造成的主要故障原因：空挡开关或离合器开关故障

The main failure causes: neutral position switch or clutch switch fault

故障的排除方法与处理：更换。

Troubleshooting and fault treatment: the replacement.

造成此故障的原因分析：此故障应该属于整车故障。

Analysis of the reasons causing the failure: the failure should belong to the whole vehicle fault.

二、Perkins发动机功率不足。

Two, Perkins engine power shortage.

故障的症状与现象：高速上不去，油耗高，排气管冒黑烟或篮烟。

The phenomenon of fault symptoms and do not go on: high speed, high fuel consumption, exhaust smoke cigarettes or basket.

造成的主要故障原因：进气管路漏气或有异物堵塞。

The main failure causes: the intake pipe leakage or blockage.

故障的排除方法与处理：找出漏气位置，排除漏气故障，或清除堵塞。

Troubleshooting and fault handling: identify the leak location, eliminate leakage fault, or clear a jam.

造成此故障的原因分析：此时车在低速状态下一般无明显症状，高速时油门踩到底发动机转速达不到最高转速，如果是堵塞且严重的情况下，高速时排气管产生大量蓝色或黑色浓烟。车载故障灯低速时不亮，高速时会开始闪，用诊断仪检测有“进气压力传感器电压过低”的故障显示，清除异物后，故障排除；如果是漏气，故障灯一般不会显示，可能造成进气管路漏气的地方有多处，如进气管垫片损坏，进气压力温度传感器安装不密封，中冷器连接橡胶管漏气，增压器连接橡胶管漏气等。

Analysis of the reasons causing the failure: when the car at low speeds generally no symptoms, when high pedal engine speed is not up to the maximum speed, if it is blocked and severe cases, high speed exhaust pipe produces a large number of blue or black smoke. Low speed vehicle fault lamp does not light, high speed will begin to flash, use the "fault diagnosis instrument air pressure sensor voltage too low" display, cleared eyewinker, troubleshooting; if it is leaking, the fault lamp generally will not display, may cause the inlet pipeline leak has many, such as the inlet pipe gasket damaged, the inlet pressure and temperature sensor installation is not sealed, intercooler connecting rubber pipe leakage, turbocharger connecting rubber pipe leakage etc..

故障的症状与现象：Perkins发动机无力。

Fault symptoms and phenomenon: Perkins engine powerless.

造成的主要故障原因：Perkins进气温度传感器（压力）故障。

The main fault reasons: Perkins intake air temperature sensor (pressure) fault.

故障的排除方法与处理：更换进气温度（压力）传感器。

Troubleshooting and fault handling: to replace the intake temperature (pressure) transducer.

造成此故障的原因分析：此Perkins故障用诊断仪检测有：“进气温度（压力）传感器电压过低”的显示。

Analysis of the reasons causing the failure: the Perkins fault diagnosis instrument is: "the intake air temperature (pressure) show the sensor voltage too low".

故障的症状与现象：发动机无力，油耗高，有时突然熄火。

Fault symptoms and phenomenon: Engine powerless, high fuel consumption, sometimes suddenly stops.

造成的主要故障原因：燃油管路泄漏或空气有进入。

The main failure causes: fuel pipeline leakage or air into.

故障的排除方法与处理：排除燃油管路泄漏，并排空气。

Troubleshooting and fault handling: remove the fuel pipe leakage, side by side air.

造成此故障的原因分析：此故障一般在行驶中，由于燃油管路出现泄漏的地方，有时有空气进入燃油管路导致发动机功率下降，若情况严重还会导致发动机突然熄火。因此，显要解决漏气问题，再排空气。

Analysis of the cause of this fault: the fault generally in motion, because the fuel pipeline leakage place, sometimes with air into the fuel line causing the engine to power down, if severe cases can lead to sudden engine flameout. Therefore, a solve the problem of gas leakage, and then exhaust air.

故障的症状与现象：沃尔沃发动机运行中突然无力，油耗高。

Fault symptoms and phenomenon: Volvo engine operation suddenly weak, high fuel consumption.

造成的主要故障原因：沃尔沃喷油器横腔漏油。

The main failure causes: Volvo injector cavity leakage.

故障的排除方法与处理：重新安装或更换喷油器及横腔。

Troubleshooting and fault handling: re install or replace the fuel injectors and horizontal cavity.

造成此故障的原因分析：此故障发生中。这是由于安装沃尔沃喷油器横腔时，安装不当所造成。不当的安装导致横腔与喷油器接触处不密封或磨损严重而产生燃油泄漏，会造成发动机无力的现象。

Analysis of the reasons causing the failure: the failure of. This is due to the installation of Volvo injector cavity, caused by improper installation. Improper installation in horizontal cavity in contact with the injector is not sealed or serious wear and fuel leakage, will cause the engine to phenomenon.

故障的症状与现象：沃尔沃加速无力，有时突然熄火。

Fault symptoms and phenomenon: Volvo accelerate the powerless, sometimes suddenly stops.

造成的主要故障原因：燃油管路或柴滤堵塞。

The main fault causes the fuel lines or fuel filter clogging.

故障的排除方法与处理：清除堵塞。

Troubleshooting and fault handling: to remove the plug.

造成此故障的原因分析：经常发生堵塞、油路不畅的地方一般也是在柴滤或油水分离器。

Analysis of the reasons causing the failure: often blocked, circuit poor place is generally in the filter or oil-water separator.

故障的症状与现象：沃尔沃转速高速上不去，行驶途中有时会忽然熄火。

Fault symptoms and phenomenon: Volvo speed up not to go, the road sometimes abrupt flameout.

造成的主要故障原因：燃油进油软管弯曲压瘪。

The main failure causes: fuel oil inlet hose bending deflated.

故障的排除方法与处理：理直进油软管，固定好位置，且软管不宜太长。

Troubleshooting and fault handling: straight into the oil hose, fixed position, and the hose should not be too long.

造成此故障的原因分析：进油管弯曲压瘪会导致进油不畅，发动机运行时，用故障诊断仪诊断有显示：燃油压力控制阀电压过低或过高。

Analysis of the reasons causing the failure: inlet pipe bending deflated leads to an oil poor, when the engine is running, fault diagnostic display: the fuel pressure control valve voltage is too low or too high.

故障的症状与现象：康明斯发动机抖动，声音异常，加速无力，排气管冒黑烟。

Fault symptoms and phenomenon: Cummings engine jitter, abnormal sound, accelerate the powerless, black smoke exhaust pipe.

造成的主要故障原因：个别缸喷油器不工作或工作不良。

The main failure causes: individual cylinder injector does not work or bad work.

故障的排除方法与处理：先断缸试验，判别出不好的喷油器，进行更换。

Troubleshooting and fault treatment: first broken cylinder test, determine the injector is not good, the replacement.

造成此故障的原因分析：此故障应该是燃油品质不好或有脏随燃油东西进入喷油器，导致喷油器阀卡死，无法正常工作。

Analysis of the reasons causing the failure: the failure should be the fuel quality is not good or dirty into the injector fuel with things, lead to the injector valve stuck, unable to work.

故障的症状与现象：康明斯发动机抖动，声音异常，加速无力，排气管冒黑烟。

Fault symptoms and phenomenon: Cummings engine jitter, abnormal sound, accelerate the powerless, black smoke exhaust pipe.

造成的主要故障原因：个别缸喷油器线束故障。

The main failure causes: individual cylinder injector harness fault.

故障的排除方法与处理：更换喷油器线束。

Troubleshooting and fault handling: replace injector wiring harness.

造成此故障的原因分析：此故障一般是喷油器线束接触不良或断路引起，用诊断仪检测会有“TWV输出断路”的故障显示。

Analysis of the reasons causing the failure: the failure is usually injector harness or poor contact caused by open circuit, with diagnostic instrument testing would have "TWV output open circuit" fault display.

故障的症状与现象：康明斯发动机达到1100转以上开始间歇发耸。

Fault symptoms and phenomenon: Cummings engine reach to more than 1100 began with intermittent hair.

造成的主要故障原因：冷却液温度传感器故障。

The main failure causes: the coolant temperature sensor fault.

造成此故障的原因分析：此故障是冷却液温度传感器塑料体断裂导致接触不良，传感器信号时有时无，这样就使燃油系统的供油不稳定，且转速开不上，最多只能到1700转，更换了冷却液温度传感器，故障排除。

Analysis of the reasons causing the failure: the failure is the coolant temperature sensor plastic fracture resulting in poor contact, the sensor signal sometimes no, such that the fuel supply system instability, and the speed can not open, only up to 1700 rpm, replacing the coolant temperature sensor, troubleshooting.

康明斯油门踏板加速无反应。

Cummins pedal no response.

故障的症状与现象：康明斯发动机起动后，踩油门无反应。

Fault symptoms and phenomenon: Cummings after starting the engine, the throttle response.

造成的主要故障原因：电子油门故障。

The main failure causes: electronic throttle fault.

故障的排除方法与处理：更换电子油门。

Troubleshooting and fault handling: the replacement of electronic throttle.

造成此故障的原因分析：此故障有时可能会是电子油门接插件接触不良，更换前，先重新拔插（关闭电源）试试，排除接触不良的故障后再更换。需要注意的是，电源打开后，系统会有一个约5秒的自检过程，如果此时立刻起动发动机踩油门，即便电子油门无故障可能也会瞬间无反应的现象，几秒后可恢复正常。

Analysis of the reasons causing the failure: the failure may sometimes be electronic throttle bad connector, replacing the front, to re plug (power off) try, troubleshooting poor contact after the replacement. Attention is required, the power to open, the system will check a process about 5 seconds, if you immediately start the engine throttle, even if the electronic throttle fault may be instant nonresponse phenomenon, after a few seconds to restore normal.

故障的症状与现象：康明斯发动机起动后，踩油门无反应。

Fault symptoms and phenomenon: Cummings after starting the engine, the throttle response.

造成的主要故障原因：整车线束电子油门接线碰线短路。

The main failure causes: vehicle wiring harness wiring touch line short circuit of electronic throttle.

故障的排除方法与处理：检查电子油门接线，排除短路故障。

Troubleshooting and fault handling: check the electronic throttle wiring, short-circuit fault exclusion.

造成此故障的原因分析：此故障用诊断仪检测有电子油门故障的显示，并且无法清除。

Analysis of the reasons causing the failure: the failure diagnosis instrument with electronic throttle fault display, and cannot be removed.

道依茨油底壳有柴油。

Deutz oil pan of diesel.

故障的症状与现象：拔出油标尺可以明显看出柴油且能闻到柴油味。

Symptoms and of failure: pull out the oil dipstick can be obviously seen diesel and can smell of diesel fumes.

造成的主要故障原因：道依茨喷油器雾化不良。

The main failure causes: DEUTZ injector atomization.

故障的排除方法与处理：更换道依茨喷油器。

Troubleshooting and fault treatment: the replacement of Deutz fuel injector.

造成此故障的原因分析：道依茨喷器雾化不良导致燃油不能完全燃烧，由气缸进入油底壳。

Analysis of the reasons causing the failure: poor DEUTZ preventer atomized fuel cannot complete combustion, of a cylinder into the oil sump.

故障的症状与现象：拔出油标尺可以明显看出柴油且能闻到柴油味。

Symptoms and of failure: pull out the oil dipstick can be obviously seen diesel and can smell of diesel fumes.

造成的主要故障原因：道依茨高压油泵内部泄漏。

The main fault reasons: internal DEUTZ high-pressure pump leakage.

故障的排除方法与处理：更换道依茨油泵。

Troubleshooting and fault treatment: the replacement of Deutz pump.

造成此故障的原因分析：高压油泵内部泄漏，燃油会从齿轮室进入油底壳。

Analysis of the reasons causing the failure: high-pressure pump internal leakage, the fuel from the gear chamber into the oil sump.

故障的症状与现象：拔出油标尺可以明显看出柴油且能闻到柴油味。

Symptoms and of failure: pull out the oil dipstick can be obviously seen diesel and can smell of diesel fumes.

造成的主要故障原因：道依茨气门阀盘损坏。

The main failure causes: DEUTZ valve disc damage.

故障的排除方法与处理：更换气门并研磨。。

Troubleshooting and fault treatment: the replacement of the valve and grinding..

造成此故障的原因分析：气门阀盘损坏会导致喷入气缸内的进气无法进行压缩，燃油无法燃烧，由气缸进入油底壳。

Analysis of the reasons causing the failure: valve disc damage can lead to spray into the air in the cylinder can not be compressed, not burn fuel, the cylinder into the oil sump.

油水混合

Oil-water mixture

故障的症状与现象：机柴油里有大量的水或水箱里有大量柴油。

Fault symptoms and phenomenon: there are a lot of diesel engine diesel large amounts of water or water tank.

造成的主要故障原因：气缸盖故障。

The main failure causes: the cylinder cover fault.

故障的排除方法与处理：更换气缸盖。

Troubleshooting and fault treatment: the replacement of the cylinder cover.

造成此故障的原因分析：此故障一般出现的柴油机中，因为其缸盖内有燃油回油道，可能是气缸盖内有砂眼或水道与油道穿通造成油水混合。

Analysis of the reasons causing the failure of diesel engine: the fault generally appear in, because the fuel oil cylinder head back in, may be the cylinder cover has hole or channel through which oil and oil-water mixture.

故障的症状与现象：油底壳里有水。

The phenomenon of symptom and fault: the oil pan with water.

造成的主要故障原因：气缸盖或气缸垫或机体故障。

The main failure causes: the cylinder head or cylinder pad or the fault.

故障性质：机械故障。

Fault properties: mechanical failure.

故障的排除方法与处理：先进行压水检查，确定故障后再更换。

Troubleshooting and fault handling: go to the water pressure check, to determine the fault after the replacement.

造成此故障的原因分析

Analysis of the reasons causing the failure

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