電噴共軌柴油發動機故障的診斷與維修技巧

Skill diagnosis and repair EFI diesel engine fault

Perkins電噴共軌柴油發動機起動困難

Perkins injection common rail diesel engine starting difficulty

故障的癥狀與現象：Perkins起動機和發動機均有正常起動轉速，但不著火；或者有時經過多次長時間的起動方可著火。

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.

造成起動困難的主要故障原因：燃油管路有空氣。

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

故障的排除方法與處理：燃油管路排空氣。

Troubleshooting and fault treatment of exhaust air: fuel line.

造成此故障的原因分析：Perkins柴油發動機采用共軌系統，油路排空氣相對困難一些，往往操作人員感覺到空氣排除干凈的，實際還是沒有徹底排干凈。根據實際使用情況來看，應該松開油泵回油螺栓來排空氣，必要時可松開高壓油管，利用起動機帶動發動機空轉來排空氣；如果僅僅是松開燃油濾清器的放氣螺釘來排空氣，可能不容易徹底排除燃油管路的空氣，比較費力。

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.

故障的癥狀與現象：起動機和珀金斯發動機均有正常起動轉速，但不著火。

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：柴油管路或油水分離器堵塞。

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

故障的排除方法與處理：清理柴油管路或油水分離器、對有水分離器進行放水，必要時更換，最后要對油路進行徹底排空氣。

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，我國的柴油品質還不能完全滿足Perkins電噴共軌系統的柴油機對于柴油品質的要求，因此，Perkins電噴共軌發動機的柴油濾清器或油水分離器要經常保養，其保養周期要比其它的發動機大大縮短。（還有一種情況，如果進油軟管或回油軟管內徑太細太長導致進回油進回油不暢，比較嚴重的也會使發動機啟動困難或無法起動。此時，需要更換符合要求的進回油管，內徑最好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.

故障的癥狀與現象：起動機和發動機均有正常起動轉速，但不著火。

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柴油發動機ECU存在故障碼。

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

故障的排除方法與處理：清除故障碼。

Troubleshooting and fault treatment: clear fault code.

造成此故障的原因分析：此發動機從機械方面檢查均正常，用診斷儀診斷發現有“水溫傳感器”、“軌壓傳感器”、等一些故障顯示，清除故障碼后，發動機順利起動。這種情況估計是維修或操作人員對電控系統的接插件進行了帶電插拔的操作，這樣系統會產生故障碼儲存在ECU中，系統起保護作用會限制一些功能甚至無法起動。

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.

故障的癥狀與現象：起動機和發動機均有正常起動轉速，但不著火。

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發動機線束損壞或接插件接觸不良。

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

故障的排除方法與處理：更換發動機線束或重新拔插各接插件（注意：此時一定要先關閉電源）。

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：發動機線束損壞的幾率不大，接觸不良的情況比較多。在各接插件接觸不良的原因沒有排除之前，不要輕易更換發動機線束。此時，可借助診斷儀診斷出故障發生的大概區域，再進行排除。

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.

故障的癥狀與現象：康明斯起動機和發動機均有正常起動轉速，但不著火。

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：油泵安裝正時不對或飛輪不匹配。

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

故障的排除方法與處理：重新安裝油泵或更換匹配的飛輪。

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

造成此故障的原因分析：這種情況一般出現在更換過油泵或飛輪的發動機上，對于油泵有安裝正時要求的發動機，油泵安裝必須正確；另外，如果更換飛輪，必須使用周圍帶有信號感應孔的原配飛輪。

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.

故障的癥狀與現象：起動機和康明斯發動機均有正常起動轉速，但不著火。

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：油泵壓力控制閥（PCV）插件位置裝錯。

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

故障的排除方法與處理：重新拔插安裝（先關閉電源）。

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

造成此故障的原因分析：這種情況一般出現在拆卸過油泵或PCV閥接插件的發動機上。其采用的是電裝的油泵，PCV閥有兩個，接插件位置容易混淆，安裝時需看好記號，一般是線上扎有顏色的膠帶的靠飛輪端。

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.

故障的癥狀與現象：起動機和沃爾沃發動機均有正常起動轉速，但不著火。

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：沃爾沃NE（轉速）傳感器和G(凸輪軸)傳感器同時故障。

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

故障的排除方法與處理：更換。

Troubleshooting and fault treatment: the replacement.

造成此故障的原因分析：這種情況一般出現得不多。用沃爾沃診斷儀檢測會有NE（轉速）傳感器和G(凸輪軸)傳感器同時故障的顯示。

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.

故障的癥狀與現象：沃爾沃起動機和發動機均有正常起動轉速，但不著火。

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：高壓共軌管故障。

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

故障的排除方法與處理：更換。

Troubleshooting and fault treatment: the replacement.

造成此故障的原因分析：此故障有時是軌壓傳感器故障，有時是油軌壓力控制閥故障，如果軌壓控制閥一直處于打開狀態，軌壓就無法建立，從而無法起動。

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.

故障的癥狀與現象：沃爾沃起動機無轉速。

Fault symptoms and phenomenon: Volvo starter without speed.

造成的主要故障原因：無電源、電壓不足或起動機故障。

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

故障的排除方法與處理：接通電源或更換沃爾沃起動機或對電瓶充電。

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：沃爾沃起動機電流過大會燒壞或齒圈無法與飛輪嚙合；電壓不足，發動機達不到起動轉速。

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.

故障的癥狀與現象：起動機和發動機均有正常起動轉速，但不著火。

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：空擋開關或離合器開關故障

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

故障的排除方法與處理：更換。

Troubleshooting and fault treatment: the replacement.

造成此故障的原因分析：此故障應該屬于整車故障。

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

二、Perkins發動機功率不足。

Two, Perkins engine power shortage.

故障的癥狀與現象：高速上不去，油耗高，排氣管冒黑煙或籃煙。

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：進氣管路漏氣或有異物堵塞。

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

故障的排除方法與處理：找出漏氣位置，排除漏氣故障，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：此時車在低速狀態下一般無明顯癥狀，高速時油門踩到底發動機轉速達不到最高轉速，如果是堵塞且嚴重的情況下，高速時排氣管產生大量藍色或黑色濃煙。車載故障燈低速時不亮，高速時會開始閃，用診斷儀檢測有“進氣壓力傳感器電壓過低”的故障顯示，清除異物后，故障排除；如果是漏氣，故障燈一般不會顯示，可能造成進氣管路漏氣的地方有多處，如進氣管墊片損壞，進氣壓力溫度傳感器安裝不密封，中冷器連接橡膠管漏氣，增壓器連接橡膠管漏氣等。

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..

故障的癥狀與現象：Perkins發動機無力。

Fault symptoms and phenomenon: Perkins engine powerless.

造成的主要故障原因：Perkins進氣溫度傳感器（壓力）故障。

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

故障的排除方法與處理：更換進氣溫度（壓力）傳感器。

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

造成此故障的原因分析：此Perkins故障用診斷儀檢測有：“進氣溫度（壓力）傳感器電壓過低”的顯示。

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

故障的癥狀與現象：發動機無力，油耗高，有時突然熄火。

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

造成的主要故障原因：燃油管路泄漏或空氣有進入。

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

故障的排除方法與處理：排除燃油管路泄漏，并排空氣。

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

造成此故障的原因分析：此故障一般在行駛中，由于燃油管路出現泄漏的地方，有時有空氣進入燃油管路導致發動機功率下降，若情況嚴重還會導致發動機突然熄火。因此，顯要解決漏氣問題，再排空氣。

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.

故障的癥狀與現象：沃爾沃發動機運行中突然無力，油耗高。

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

造成的主要故障原因：沃爾沃噴油器橫腔漏油。

The main failure causes: Volvo injector cavity leakage.

故障的排除方法與處理：重新安裝或更換噴油器及橫腔。

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

造成此故障的原因分析：此故障發生中。這是由于安裝沃爾沃噴油器橫腔時，安裝不當所造成。不當的安裝導致橫腔與噴油器接觸處不密封或磨損嚴重而產生燃油泄漏，會造成發動機無力的現象。

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.

故障的癥狀與現象：沃爾沃加速無力，有時突然熄火。

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

造成的主要故障原因：燃油管路或柴濾堵塞。

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

故障的排除方法與處理：清除堵塞。

Troubleshooting and fault handling: to remove the plug.

造成此故障的原因分析：經常發生堵塞、油路不暢的地方一般也是在柴濾或油水分離器。

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

故障的癥狀與現象：沃爾沃轉速高速上不去，行駛途中有時會忽然熄火。

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

造成的主要故障原因：燃油進油軟管彎曲壓癟。

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

故障的排除方法與處理：理直進油軟管，固定好位置，且軟管不宜太長。

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：進油管彎曲壓癟會導致進油不暢，發動機運行時，用故障診斷儀診斷有顯示：燃油壓力控制閥電壓過低或過高。

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.

故障的癥狀與現象：康明斯發動機抖動，聲音異常，加速無力，排氣管冒黑煙。

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：個別缸噴油器不工作或工作不良。

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

故障的排除方法與處理：先斷缸試驗，判別出不好的噴油器，進行更換。

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：此故障應該是燃油品質不好或有臟隨燃油東西進入噴油器，導致噴油器閥卡死，無法正常工作。

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.

故障的癥狀與現象：康明斯發動機抖動，聲音異常，加速無力，排氣管冒黑煙。

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：個別缸噴油器線束故障。

The main failure causes: individual cylinder injector harness fault.

故障的排除方法與處理：更換噴油器線束。

Troubleshooting and fault handling: replace injector wiring harness.

造成此故障的原因分析：此故障一般是噴油器線束接觸不良或斷路引起，用診斷儀檢測會有“TWV輸出斷路”的故障顯示。

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.

故障的癥狀與現象：康明斯發動機達到1100轉以上開始間歇發聳。

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

造成的主要故障原因：冷卻液溫度傳感器故障。

The main failure causes: the coolant temperature sensor fault.

造成此故障的原因分析：此故障是冷卻液溫度傳感器塑料體斷裂導致接觸不良，傳感器信號時有時無，這樣就使燃油系統的供油不穩定，且轉速開不上，最多只能到1700轉，更換了冷卻液溫度傳感器，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.

康明斯油門踏板加速無反應。

Cummins pedal no response.

故障的癥狀與現象：康明斯發動機起動后，踩油門無反應。

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

造成的主要故障原因：電子油門故障。

The main failure causes: electronic throttle fault.

故障的排除方法與處理：更換電子油門。

Troubleshooting and fault handling: the replacement of electronic throttle.

造成此故障的原因分析：此故障有時可能會是電子油門接插件接觸不良，更換前，先重新拔插（關閉電源）試試，排除接觸不良的故障后再更換。需要注意的是，電源打開后，系統會有一個約5秒的自檢過程，如果此時立刻起動發動機踩油門，即便電子油門無故障可能也會瞬間無反應的現象，幾秒后可恢復正常。

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.

故障的癥狀與現象：康明斯發動機起動后，踩油門無反應。

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

造成的主要故障原因：整車線束電子油門接線碰線短路。

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

故障的排除方法與處理：檢查電子油門接線，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：此故障用診斷儀檢測有電子油門故障的顯示，并且無法清除。

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

道依茨油底殼有柴油。

Deutz oil pan of diesel.

故障的癥狀與現象：拔出油標尺可以明顯看出柴油且能聞到柴油味。

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：道依茨噴油器霧化不良。

The main failure causes: DEUTZ injector atomization.

故障的排除方法與處理：更換道依茨噴油器。

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

造成此故障的原因分析：道依茨噴器霧化不良導致燃油不能完全燃燒，由氣缸進入油底殼。

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

故障的癥狀與現象：拔出油標尺可以明顯看出柴油且能聞到柴油味。

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：道依茨高壓油泵內部泄漏。

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

故障的排除方法與處理：更換道依茨油泵。

Troubleshooting and fault treatment: the replacement of Deutz pump.

造成此故障的原因分析：高壓油泵內部泄漏，燃油會從齒輪室進入油底殼。

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

故障的癥狀與現象：拔出油標尺可以明顯看出柴油且能聞到柴油味。

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：道依茨氣門閥盤損壞。

The main failure causes: DEUTZ valve disc damage.

故障的排除方法與處理：更換氣門并研磨。。

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

造成此故障的原因分析：氣門閥盤損壞會導致噴入氣缸內的進氣無法進行壓縮，燃油無法燃燒，由氣缸進入油底殼。

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

故障的癥狀與現象：機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：氣缸蓋故障。

The main failure causes: the cylinder cover fault.

故障的排除方法與處理：更換氣缸蓋。

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

造成此故障的原因分析：此故障一般出現的柴油機中，因為其缸蓋內有燃油回油道，可能是氣缸蓋內有砂眼或水道與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.

故障的癥狀與現象：油底殼里有水。

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

造成的主要故障原因：氣缸蓋或氣缸墊或機體故障。

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

故障性質：機械故障。

Fault properties: mechanical failure.

故障的排除方法與處理：先進行壓水檢查，確定故障后再更換。

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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