Maintenance Manual For WP12 Diesel Engine

蓝擎 WP12 系列柴油机维修手册
Maintenance Manual for LandkingWP12 Series Diesel Engine
编写：Composed by
校对：Proofread by
审核：Verified by
审定：Audited by
批准：Approved by
Maintenance Manual for LandkingWP12 Series Diesel Engine
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潍柴动力股份有限公司
Weichai Power Co., Ltd
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蓝擎 WP12.440 柴油机
Landking WP12.440 Diesel Engine
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Special Attention
○ 柴油机的操作人员在操作之前，必须认真阅读柴油机的使用保养说明书，严格遵守使用保养说明书
规定的操作与保养规程；
The engine operator must read the manual before attempting to operate the diesel engine,adhere to follow the
operation and maintenance routine rules in this manual;
○ 本柴油机出公司时已按试验规范严格进行出公司试验，不得随意调整 ECU 数据，加大柴油机功
率。否则我公司将不实行三包，敬请用户注意；
The diesel engine has been carried out strict according to test specifications,it is forbidden to change or
adjust the ECU data privately.Otherwise our company will not do warranty,the user should be noted.
○ 增压器转子为高速旋转部件，在机器运转时，严禁任何可移动物体（例如手、工具、棉纱等）接近
涡轮增压器的进口，以免对人身或机器造成损害；对转子组件，除涡轮增压器专业维修人员或经潍柴特
许的专业维修站点外不得拆卸；
The rotor shaft of turbocharger is a high speed rotating component,any movable object(such as hand
tools,cotton,etc) is ont allowed to be close to turbocharger inlet,so as not to cause damage to persons or
machine;the rotor assembly,except of turbocharger qualified service person and professional service site,others
can not disassemble it
○ 重要螺栓限制使用次数（如 WP12 系列柴油机连杆螺栓为一次性使用螺栓），不得超过限定次数重
复使用；
The use frequency of important bolts can not overtake the limit(As WP12 series diesel engine connecting rod
bolt can only be used for one time)
○ 向柴油机添加的机油或燃油，其牌号必须符合使用保养说明书的规定，并经专用的清洁滤清器过滤，
燃油要经过 72 小时以上沉淀；在每次开车前，必须确认冷却液和机油的加入量是否符合要求；
Designation of engine oil and fuel filled in the diesel engine must comply with the regulations in the
manual,and also must be through filter,fuel need more than 72H to precipitate,must confirm whether the
quantity of coolant and oil meet requirements before star the engine.
○ 禁止柴油机在无空气滤清器的情况下工作，防止空气未经过滤就进入气缸；
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Diesel engine is prohibited to operated without air filter,preventing unfiltered air enter into cylinder
○ 用户在使用新机时，应进行 50 小时试运转；
Before using a new engine,50 hours test run should be carried out
○ 柴油机冷车启动后应徐徐提高转速，不应猛然使其高速运转，也不宜长期怠速；大负荷运转后，不
应立即停车（特殊情况除外），应低速运转 5～10 分钟后停车；
After the engine is cold stared,the speed should be increased gradually,It is forbidden to run the engine in
high speed suddenly and in idling for a long time.After running in high load,you should not stop the engine
immediately(except special situation),and you should run in low load about 5~10 minute,the stop it.
○ 停车后如果运转环境有可能低于 0℃，而且机器中未使用防冻添加剂的冷却液时，应将水箱和柴油
机中的冷却液放净；
After the engine is stopped,if the ambient temperature is lower than 0℃ and the coolant without antifreeze is
used,the coolant in water tank and in the diesel engine should be drained off
○ 电气系统各部件的检修必须由电气专业技术人员进行；
The examining and repairing of all parts in electrical system should be carried out by specialized operator
○ 电控系统各部件的检修必须由我公司维修站专业人员进行；
The examining and repairing of all parts in electrical control system should be carried out by specialized
operator from our maintenance station
○ 为防止锈蚀，柴油机出公司时进行油封，一般柴油机的油封期为一年，凡超过一年的应进行检查
并采取必要的补充措施。
To prevent rust,oil seal is made before leaving factory.Generally the oil seal period is one year.One year
later,the engine should be checked and adopted necessary complement measures.
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前言
Preface
WP12 蓝擎系列柴油机是潍柴动力股份有限公司采用全新设计理念开发的满足国Ⅲ排放法规并具
备国Ⅳ潜力的高速柴油机。该系列柴油机具有结构紧凑，使用可靠，动力性、经济性等技术指标优良，
起动迅速，操作简单和维护方便等优点。是重型汽车的理想动力。
WEICHAI POWER CO.,LTD adopts complete new design idea to develop LandkingWP12 series diesel
engine,meting Euro III emission regulation.It is the high-speed diesel engine with the potential meeting Euro
IV.This diesel engine has good technical indexes of compact structure,good reliability and power, economy,
etc. and advantage of rapid starting,simple operation and easy maintenance,etc.It is the ideal power for
heavy-duty vehicles.
本手册主要包括 WP12 柴油机使用中注意事项﹑维护保养方法﹑常用的检查调整及常见故障的诊断
排除等内容。编制过程中，力求系统全面，简单实用。需要指出的是判断柴油机故障是一项仔细工作,
需要一定的知识经验，在未基本弄清原因之前,一般不要对柴油机乱拆乱卸,否则不仅不能排除故障,反而
会因拆卸后装配不当造成更严重的故障。特别是电控系统、增压器等关键零部件,维修检查要有专用的仪
器设备,因此没有经验和条件的用户不要对其随意进行拆卸调整。
This manual include WP12 diesel use precautions,maintenance,diagnostics and maintenance methods
commonly used to check,adjustment and trouble shooting. Preparation process seek comprehensive system and
simple practical.It should be noted that the judgment of diesel engine problem is a careful work,it requires
certain knowledge and experience.Before basic ascertain the reasons,usually do not indiscriminate demolition of
diesel engine,otherwise, not only the fault can not be excluded, but more serious faults can be caused because of
improper assembly.Especially the electronic control system, turbocharger and other key components,
maintenance and inspection of equipment must apply special equipment,Therefore inexperienced and conditions
users do not arbitrarily disassemble adjustment.
本手册所介绍的为蓝擎 WP12 系列柴油机基本机型。随着产品的开发、改进与新产品的不断投产，
维修保养手册所包含的内容可能有所滞后，用户（或销售商）为获得最新产品信息，应访问潍柴
http://www.weichai.com 网站。
The Landking WP12 series diesel engine in this manual is basic model,With continuous development of
the products,the structure will be improved.The content of of this manual is not very new,please user(or
distributors) go to our net http://www.weichai.com for latest production information.

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欢迎用户对产品提出进一步改进的建议与意见。
Welcome user’s further suggestions for modification of products.
2007 年 3 月
Mar,2007
目录
Contents
标记说明 Label Definitions
第一章柴油机使用说明---------------------------------------------2
Chapter I Diesel engine instructions for use
第二章柴油机维护保养指南-------------------------------------------------------------6
Chapter II Diesel Engine Maintenance Guide
第三章柴油机保养内容-------------------------------------------------------------------8
Chapter III Diesel engine maintenance content
第四章柴油机几大系统示意图----------------------------------------------------------16
Chapter IV Schemtic Diagrams of Engine Main Systems
第五章柴油机强力螺栓的扭紧力矩和扭紧方法-------------------------------------23
Chapter V Tightening torque and tightening method of the diesel engine powerful bolt
第六章柴油机所用的燃料油、润滑油、冷却液和辅助材料----------------------26
Chapter VI Fuel, lubricating oil, coolant and auxiliary materials
第七章电气部分----------------------------------------------------------------------------29
Chapter VII Electrical parts
第八章主要零部件的调整与更换-------------------------------------------------------32
Chapter VIII Adjustment and replacement of major parts
第九章柴油机典型故障及处理----------------------------------------------------------37
Chapter IX Typical failure and treatment of diesel engine
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第一章柴油机使用说明
1.1 WP12 系列柴油机型号含义

Signification of WP12 Series Diesel Engine Type Code
WP12 X XXX XX XX XX
燃料代号 Fuel code
变形代号 Engine modification code
排放阶段代号 Emission tier code
功率 Power
用途 Usage
产品系列代号 Product series code
1.2 新柴油机使用须知
Operating Notice for New Diesel Engine
◆新柴油机在使用的最初60小时（或3000公里）内应限制柴油机的负荷不应超过标定负荷的75% 。
Within the first 60 hours (or 3,000 km), the load of new diesel engine shall not exceed 75% of the rated load.
◆首次换油期的规定 Provision of the first oil replacement period
对于年行驶里程不到 2 万公里的汽车，首次换油期：1000～1500 公里；
For the vehicle with running mileage less than 20,000 km per year, the first oil replacement period is 1,000~1500 km;
对于年行驶里程超过2万公里的汽车，首次换油期：1500～2000公里。
For the vehicle with running mileage more than 20,000 km per year, the first oil replacement period is 1,500~2000 km.
◆按使用说明书的相关规定进行日常的维护与保养。
The daily maintenance is done in accordance with the relating provisions in Operation Manual.
1.3柴油机的启封 Unseal of Diesel Engine
当柴油机包装箱打开以后，用户首先按出厂装箱清单清点柴油机及其附件，检查柴油机外表有无损伤，
连接件是否松动等，然后再进行下述工作：
Upon opening of the packing box, the user shall check up the diesel engine and accessories there in according to the Ex-work
Packing List, and check the diesel engine for damaged surface or loose connecting fittings, and then execute the
following:
◆擦拭外露件的防锈层，以及防蚀剂等；
Wipe the anticorrosive layer and anticorrosive agent off the exposed parts;
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◆放出燃油滤清器以及燃油系统零部件内部的油封油（也允许燃油系统的油封油不经放出而启动，但必须
只有当燃油系统的油封油被消耗完，正常柴油已供应到才允许发动机加负荷运行）。但用户注意，柴油机
的油封期为一年，凡超过1年的应进行检查并采取必要的补充措施。Drain off the seal oil in from fuel filter and
the parts and components of fuel system (It may be allowed to start the engine without draining off the seal oil in fuel
system. Provided the seal oil in fuel system is exhausted and normal fuel is supplied for use, it is allowed to run the engine with
load.). But the user shall notice that the oil seal period is one year, inspection and necessary actions should be taken if the
period exceeds one year.
◆转动飞轮并向进气管内喷溶剂，直到驱尽气缸内油封油为止。
Rotate the flywheel and spray solvent to the air inlet pipe till seal oil in cylinder is exhausted.
◆向增压器进排气孔喷溶剂，直到驱尽油封油为止。
Spray the solvent to the outlet and inlet of supercharger till seal oil is exhausted.
◆根据厂方与用户的协约，对油底内未注油的应按规定加油；对油底出厂时已注满含有
磨合促进剂的机油时建议用户行驶 2000km（或运行 50 小时）后放出旧油换新油。
With reference to the agreement between the manufacturer and the user, in case of the sump without oil, oil should be
added as per the regulation; and in case of the sump with full oil for run-in, the old oil should be replaced with new one
after having traveling 2000km (or running 50h).
◆ 按厂方与用户的协议，出厂时如根据用户需要，已加注满冷却液的，启封时应检查冷
却液性能，如果防冻能力是满足-30 C 或-35 C 的，其 PH 值为 7~8（中性），总硬度值为
5~15°d [9~15°f(硬度)]，则可以使用这些冷却液，如果不合乎要求，则应放出，重新加注含防冻添加剂的冷
却液。
With reference to the agreement between the manufacturer and the user, if the engine has been filled with coolant fully as
required by the user, inspect the performance of coolant when unsealing. Providedthat its antifreeze capacity meets -30℃
or -35℃, PH value is 7~8 (neutral), and the total hardness is 5~15°d［9~15°f(hardness)］, those coolant can be used. Or the
coolant, if unsatisfactory, should be drained off and replaced with the coolant with antifreeze additive.
1.4起动前的准备工作 Preparation before Starting
◆ 检查冷却液面 Inspect coolant level
如果发动机已装在汽车上或者台架上，任何时候都能通过膨胀水箱上的玻璃视孔看到冷却液面，如
冷却液不够时，可打开加液口盖加入冷却液。在打开带有卸压阀和排气按钮的加液口盖时，如果发动机
处于热状态，要打开盖子就必须先按下排气按钮。切忌在发动机处于较热状态时往里加入大量冷却液而
因为冷热变化大而损害零件。如果在非常情况下没有冷却液，允许缓缓加入温度不太低的冷水，从加液
口加入冷却液直到溢出为止。起动发动机在发动机运转情况下（1000 r/min）继续将冷却液加满直到液面
稳定，最后盖上加液口盖。
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In case that the engine is installed on vehicle or engine bed, the coolant level can be observed from the glass observation hole on
expansion tank at any time. If the coolant is inadequate, open the filler cap and fill coolant. When opening the filler cap with
pressure relief valve and exhausting button, if the engine is in hot state, press the exhausting button before opening the cap. It is
forbidden to fill plenty of coolant, when the engine is still in relatively hot state, in order to prevent the parts from the damage due
to sudden temperature change. If there is no coolant in some abnormal case, it is allowed to slowly fill cold water at not very low
temperature. The coolant should be filled from the filler till the coolant overflows. Start the engine and continue to fill coolant till its
level is stable with engine running at speed of 1,000r/min, and finally cover the filler cap.
◆检查燃油液面
Inspect fuel level
如果发动机已装在汽车上，应打开电源开关，从燃油表上检查燃油液面或者检查燃油箱。
In case that engine is installed on vehicle, turn on the power switch, and inspect the fuel level from fuel gauge or check the fuel
tank.
◆ 检查发动机机油液面
Inspect oil level

机油液面应在油尺的上、下刻度线之间，必要时从机油加注口添加机油。
The oil level shall be located between the upper and lower graduation lines, and fill oil from the filler when necessary.
◆ 检查柴油机各种附件的连接是否可靠，并排除不正常的现象。检查起动系统电路连线是否正常，蓄电
池充电是否充足。然后开启燃油箱阀门，用燃油粗滤器上的手压泵排除燃油系统中的空气。
Inspect all accessories on diesel engine for reliable connection, and remove the unusual phenomenon. Inspect the
starting system circuit for normal connection and the battery for sufficient power. Then open the fuel tank valve, loosen the
deflating screw on coarse fuel filter, and exhaust the air in fuel system with hand pump on the coarse filter.
1.5柴油机的起动 Starting
◆在汽车上将电源开关、电钥匙都处在起动位置，将变速杆放在空档位置，开始起动发动机。Set power switch
and electrical key of the vehicle to starting position, and set gear shift to neutral position, then begin to start the engine.
◆踩下离合器踏板和油门踏板，转动电钥匙起动柴油机，若发动机在 5~10 秒内起动不了，则应等 1 分
钟后再重复上述起动过程。但如果连续三次不能起动时，应停止起动，待找出原因并排除故障之后再进
行起动。发动机起动后，要注意各仪表读数，机油压力表应立即显示压力。注意不能使冷发动机以高速
运转，要先怠速运转一段时间，但怠速运转时间不能过长。Press down clutch pedal and accelerator pedal, turn the
electric key to start the engine. If the enginecan not be started within 5~10 seconds, repeat the said starting process after one
minute. In case of three times of continuous failures in starting, stop the starting, and restart after troubleshooting. Upon
starting, notice the readings of all instruments. The engine oil pressure gage shall display pressure immediately. Pay attention
not to run the cold engine at high speed. At first run the engine at idle speed for a certain time but not too long.
◆ 低温条件下起动柴油机应使用辅助起动装置，通过继电器使电子加热法兰工作，从而实现-30℃环境下
顺利起动。
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Use auxiliary starting device during starting at low temperature. By using relay, enable the electronic heating flange to
operate, so as to realize smooth starting at -30℃ environment.
1.6柴油机的运转 Running of Diesel Engine
◆ 柴油机起动后，先怠速运转几分钟，然后将转速提高到 1000-1200 r/min，并加上部分负荷，只有当
出水温度高于 60 C ，机油温度高于 50 C 时才允许进入全负荷运转。负荷和转速的增加应逐渐进行，尽
量避免突加和突卸负荷。
After starting, at first run the engine at idle speed for several minutes, then increase the speed to 1,000-2,000r/min, and add
some load. Only when the water temperature is over 60℃ and oil temperature of oil is over 50℃ , can it be allowed
to run with full load . The load and speed shall be increased gradually, and sudden increase and decrease of them is
avoided as possible.
◆ 柴油机在 60h 磨合期以内（跑第一个 3000km），宜于在中等负荷以下工作,汽车不带拖车。
Within the 60-hours running-in period (the first 3,000 km driving), the diesel engine is apt to work under medium load, the
vehicle without trailer.
◆ 在斜坡上行驶要及时减速，在大扭矩工况不宜长期工作。也不宜使负载太小，转速太低，因为这时
容易出现窜机油等故障。
When driving on slope, it shall be slowed down in time. It is not suitable to work under large torque for a long time. The load can
not be too small, and the speed can not be too low. This may cause oil smoke, or other trouble.
◆ 柴油机在正常使用时，允许以额定功率和额定转速连续运转，但如果以额定转速的 105%与额定功率
的 110%运转，则最多允许 20 分钟。柴油机在卸负荷之后应怠速运转 1~2 分钟方可停车。
When in normal operation, the diesel engine is allowed to run at rated power and rated speed. But when at 105% of rated speed
and at 110% of rated power, it is allowed to run for 20 minutes at most. After unloading, run the diesel engine at idle for
1~2 minute(s), then shut down.
◆ 使用中应随时注意的参数值和检查部位：
In operation, pay attention to the parameter values and points for inspection at any time.
润滑油主油道压力 350~500 kPa。
Pressure of main oil passage: 350~500 kPa.

油底壳机油温度〈110 C 。
Temperature of oil in sump: < 110℃.

冷却液出口温度 80+5 C ，不得超过 95 C 。
Temperature of coolant outlet: 80+5℃ , not exceeding 95℃.
涡轮后排气温度〈550 C
Temperature after turbine: < 600℃.

中冷后进气温度 55  5 C 。
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Inlet temperature after intercooler: 50~55℃.

检查排气颜色，以此鉴别喷油器的工作质量和使用负荷情况，如果烟色严重不好，应停车检查。
Inspect the color of exhaust to identify the performance quality of fuel injector and operating load. If the color of smoke is rather
out of condition, shut down the engine and conduct inspection.
注意检查柴油机有无漏水、漏气、漏油现象，如发现应停车排除。
Inspect diesel engine for water, air and oil leakage. If found, stop the engine and remove it.
◆ 柴油机的下列特征操作人员应该了解：
The operator should acknowledge the following features of diesel engine:

A．扭矩最大时燃油消耗较低，转速增加燃油消耗上升。
When the torque is at maximum, the fuel consumption is low. The fuel consumption increases with the increase of
engine speed.
B．扭矩在发动机中速范围（1200~1600 r/min）达到最佳值。
The torque reaches its ideal value within medium speed range (1,200~1,600 r/min) of diesel engine.
C．发动机功率随转速增加而增加，在标定转速时达到标定功率。
The power of diesel engine increases with the increase of speed, and reaches its rated power at rated speed.
◆ 在寒冷环境下运转注意事项；
Precautions for running in cold environment:
1、燃料油：按冬季室外温度不同，选用不同牌号的柴油。
Fuel: In accordance with different outdoor temperature, select diesel fuel of different brands.
2、润滑油：按季节选择不同粘度的润滑油。
Oil: According to the season, select the oils of different viscosity.

3、冷却液：冷却系统加入防冻添加剂，随室外温度不同，选用不同的牌号和不同数量。
Coolant: Add anti-freeze additive into cooling system. According to the different outdoor temperature, select
different brand and quantity of coolant.
4、起动：冬季必要时可采用辅助起动器。柴油机起动后待油压水温正常后方能加负荷高速运转。
Starting: In winter, use auxiliary starting device when necessary. After starting, the diesel engine can not be loaded and operate
at high speed when the oil pressure of and water temperature of are normal.
5、蓄电池在寒冷季节开始之前，一定检查电解液液位、粘度和单位电压，如果柴油机长期不用并处
于很低的温度下，应把蓄电池取下，储存于较温暖的室内。
Prior to starting in cold season, users should inspect the electrolyte level, viscosity and unit voltage of battery. If the diesel
engine is stored in cold environment for a long time, remove the battery and store it in a warm room.
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6、停车：在寒冷气候下停车时，应先卸除负荷，然后以怠速运转 1~2 分钟，待一切温度下降后方可
停车，注意停车之后有防冻添加剂的冷却液绝不允许放掉。如果冷却液中未加入防冻添加剂，则
必须打开机体上、机油冷却器盖上、散热器、进水管等处的放水阀或水堵，放尽冷却液以防止发
动机冻裂。
Shut down: When shutting down in cold climate, unload the engine first, then run at idle for 1~2 minute(s). When the
temperature of water and oil become decreasing, shut it down. Pay attention to that the coolant with anti-freeze additive can not be
drained off after shutting down. If there is no anti-freeze additive in coolant, open the drain valves or water blocks of engine body,
engine oil cooler cover, radiator and water inlet pipe, to drain off the coolant in order to prevent the engine from frost cracking.
第二章柴油机维护保养指南
Chapter II: Guide for Maintenance of Diesel Engine
2.1日常维护 Daily Maintenance

◆检查冷却液液面、机油液面、燃油液面；需要加注润滑脂处是否充足；
Inspect coolant level, oil level and fuel oil; and sufficient grease;
◆检查油、水、气有无泄漏；
Inspect for oil, water and air leakage;
◆外接件、附件的联结、紧固是否良好；
Inspect external connectors and accessories for connection and security;
◆风扇、皮带是否过紧、过松；
Inspect that fan belt is too tight or too loose;
◆柴油机的油压；
Inspect oil pressure;
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◆柴油机的水温；
Inspect water temperature;
◆柴油机的排气温度、颜色、声音、振动是否正常，转速是否平稳；
Inspect that exhaust temperature, color, sound and vibration are normal condition, and rotary speed is stable.
2.2 定期保养并做好保养记录
Periodic maintenance and Records

表 2-1 汽车配套三类使用条件
Three categories of operating conditions with vehicle
（WGⅠ类）（WGⅡ类）（WGⅢ类）
使用条件恶劣（气候严寒或酷热，含年行驶里程不年行驶里程超过

6×104km的远距
尘量高，短距离运输，在工地使用以及公足 6×104km，短中距离运
离运输汽车
共汽车，市政工程车，扫雪车，消防车）输（用于送货） Annual running mileage of
4
或汽车年行驶里程不足 2×104km 或年工 Annual running mileage of the vehicle more than
6×10 km
6×104km
作时间不足 600h for long distance
Under severe operating condition (e.g. cold the vehicle less than 6×10 km,, transportation.
for short- or medium-distance
or hot weather, high dust content,
short-distance transportation, service in transportation (for goods).
construction site and bus, municipal

engineering vehicle, snow sweeper, fire
bridge vehicle), annual running mileage of the
vehicle less than 2×104km or annual operated
time less than 600h.
表 2-2 保养周期
Maintenance period
表 2-3 汽车保养制度的机油换油期
Oil change intervals of car maintenance system
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使用条件
Operating
(WGⅠ) (WGⅡ) (WGⅢ)
condition
项目
Item
行驶1000～1500km时
行驶30～50h 行驶1500～2000km时行驶1500～2000km时
第1次检查
Running Running Running
The first inspection
1,000~1,500km or 1,500~2,000km 1,500~2,000km
30~50h
每隔5000km
例行检查 4
每隔150h 每隔1x10 km 每隔1.5x10 km
Periodical inspection Every 5,000km or 4
Every 1.5×10 km
150h Every 1×10 km
每隔1x10 km
1级保养每隔300h 4 4
每隔2x10 km 每隔3x10 km
Level 1 maintenance 4 4
Every 1×10 km or Every 2×10 km Every 3×10 km
300h
每隔2x10 km 4 4
2级保养每隔600h 每隔4x10 km 每隔6x10 km
Level 2 maintenance 4 4
Every 4×10 km Every 6×10 km
Every 2×10 km or
600h
4
每隔4x10 km 4 4
Level 3 maintenance 4 4 4
1,200h
4
每隔8x10 km 4 4
Level 4 maintenance 4 4 4
2,400h
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表 2-4 柴油机保养规范
Maintenance Specification
柴油机保养项目第一次例行 1级 2级 3级 4级
The first Periodical Level 1 Level 2 Level 3 Level 4
Maintenance items
inspection inspection maintenance maintenance maintenance maintenance
更换机油 ● ● ● ● ● ●
Replace oil
更换机油滤清器或滤芯 ● 每次更换机油时
Replace oil filter or filter element When replacing oil every time
检查调整气门间隙 ● ● ● ● ●
Inspect and adjust valve clearance
更换燃油滤清器芯 ● ● ● ●
Replace fuel filter element
检查冷却液容量并加足 ● ● ● ● ● ●
Inspect coolant capacity and fill
紧固冷却管路管夹 ●
Fasten cooling pipe clamp
紧固进气管路、软管和凸缘连接件
Fasten connecting parts of air inlet pipe, ● ● ● ● ●
hose and flange
检查空滤器保养指示灯或指示器
Inspect air filter maintenance light or ● ● ● ●
indicator
清洗空滤器的集尘杯(不包自动排尘式)
Clean dust pocket of air filter r(except ● ● ● ● ●
auto dust exhaust style)
清洗空滤器主滤芯当指示灯亮时
Clean air filter main element When indicator light comes on
更换空滤器主滤芯参看说明书有关规定
Replace air filter main element Refer to the relevant provisions in the manual
更换空滤器安全滤芯清洗5次主滤芯以后
Replace air filter safety element After 5 times of cleaning of main filter element
检查、紧固三角皮带 ● ● ● ● ● ●
Inspect and fasten V belt
检查增压器轴承间隙 ●
Inspect supercharger bearing clearance
检查、调整离合器行程 ● ● ● ● ● ●
Inspect and adjust clutch travel
注：●需要保养标记
Note: ● requiring maintenance required.
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第三章柴油机保养内容
Chapter III: Maintenance Contents of Diesel Engine
3.1日常保日常保养Daily Maintenance
● 检查冷却液液面，水温。
Inspect coolant level and water temperature.
【文字】玻璃视孔观察冷却液面，冷却液不够时，可打开加水口盖加入冷却液。
From the glass observation hole observe coolant level. If the coolant is inadequate, open the filler cap and fill coolant.
● 检查机油液面。Inspect oil level

【文字】当油面低于油尺的下刻线或高于油尺的上刻线时，决不允许开动柴油机。
在柴油机停车后检查油面，至少等 5 分钟后进行，使机油有充分时间流回油底壳。
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油尺低位至高位的油量差为 3 升。
When the level is under the lower graduation line or above the upper graduation line of dipstick, it is forbidden to start the
diesel engine.
After shutting down, inspect the level at least five minutes later; let the oil have enough time to flow back to the sump.
The oil difference between low position and high position of dipstick is 3 liters.
● 检查燃油液面。附图：（需绘制燃油表）Inspect fuel level.
● 检查三漏。附图：Inspect for air, water and oil leakage. Attached diagram:

【文字】整机无漏水，漏气，漏油现象。The whole engine is free from leakage of water, air and oil.
检查风扇。附图：Inspect fan. Attached diagram:

【文字】目视检查风扇叶片有无损坏，连接螺栓是否紧固。
Visually inspect fan blade for damage and connecting bolt for tightness.
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● 检查皮带。附图：Inspect the belt

【文字】皮带通过皮带张紧轮自动张紧，用户通过手压皮带检查皮带的松紧。
The belt is tensioned automatically with its belt tensioner, so the user can inspect its tightness by hand-pressing.
● 检查排气颜色是否正常。附图：Inspect exhaust gas for normal color. Attached diagram:

【文字】正常排气颜色为淡灰色。颜色出现变化应检查原因并排除。
The normal color is light grey. If the color changes, find the reason and remove it.
● 检查声音是否正常。Inspect for normal sound.
● 检查转速、振动是否正常。Inspect for normal speed and vibration.
3.2 各级保养的保养内容
除完成日常保养内容外还应增加下列内容：Maintenance Content of Different Levels

● 更换柴油机油。附图：Replace oil. Attached diagram:
【文字】拧下油底壳底部的放油螺塞，将机油放净，再旋上放油螺塞；
Screw off the oil drain plug on sump bottom, drain off the oil, and then screw in the oil drain plug;
打开加油口盖，从机油加注口加入机油，观察油尺刻度，直到达到要求，再装上加油口盖。
Open the oil filler cap, fill the oil from the oil filler, observe the scale of dipstick till it meets the requirement, and then close the
oil filler cap.
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更换机油滤清器或滤芯。附图：Replace oil filter or filter element. Attached diagram:

【文字】更换机油滤清器时按以下步骤操作: Replace oil filter in the following steps:
A.卸下旧的机油滤清器；Dismantle the old oil filter;
B.向新滤清器中注满干净的机油；Fill clean oil to the new filter fully;
C.安装新机油滤清器前在胶垫上涂抹机油；Apply oil on the rubber pad before installing the new oil filter;
D.胶垫接触到基座后，再拧紧3/4～1圈，使其密封；When the cushion reaches the base seat, tighten 3/4~1 turn to make it
sealed;
E.起动柴油机检查是否漏油。Start the diesel engine, and inspect for oil leakage.
检查、调整进排气门间隙。Inspect and adjust inlet and exhaust valve clearance.

【文字】检查、调整进排气门间隙按以下步骤操作: Inspect and adjust inlet and exhaust valve clearance in the
following steps:
A. 柴油机冷车状态下,正盘车(按柴油机运转方向)到1,6缸上止点。此时飞轮上的刻槽与观察孔盖板上的指
针对齐。In cold state of diesel engine, positively turn (in the direction of diesel engine rotation) to the top dead centers of No.1 and
No.6 cylinders. AT that time, the carving groove on flywheel should be aligned with the pointer on observation hole cover.
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B. 拆下缸盖上的气门摇臂罩,判断1缸或是6缸处压缩冲程(处于压缩冲程的气缸进排气门与摇臂间都有间
隙)。Dismantle air valve rocker cover from cylinder head, judge that the No.1 or No.6 cylinder is in compressed stroke (with
cylinder in compressed stroke, there is clearance between inlet and exhaust valves and rockers).
C. 按表 3-1 用塞尺检查气门桥上平面与气门摇臂间的间隙。WP12 柴油机要求进气门间隙
0.4mm；排气门间隙 0.6mm。若间隙过大或过小,可通过调整摇臂上的调整螺栓来达到上述间隙要
求。
As per Table 3-1, inspect the clearance between the upper surface of valve bridge and the valve rocker with feeler
gauge. The WP12 diesel engine requires: the clearance of inlet valve is 0.4mm; that of exhaust valve 0.6mm. In case the
clearance is too large or too small; the above requirements for clearance may be met by adjusting the adjusting bolt on
rocker.
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调整螺栓
冷态进气门间隙 0.4mm 冷态排气门间隙 0.6mm
D. 检查完 1 缸或 6 缸后,再正盘车 360°,使 6 缸或 1 缸处于工作冲程,检查调整剩余的气门。
After inspecting No.1 cylinder or No.6 c ylinder, then positively turn for 360°to make No.6 or No.1 cylinder be in operating
stroke, and inspect and adjust the rest valves.
表 3-1(Table 3-1)
1 缸 2 缸 3 缸 No.3 4 缸 5 缸 6 缸
No.1 cylinder No.2 cylinder No.4 No.5 No.6

对
cylinder cylinder cylinder cylinder
1缸压缩冲程进排气门进气门排气门进气门排气门不能调整
No.1 cylinder Inlet and Inlet exhaust Inlet exhaust Can't be
compressed exhaust valves valves adjusted
valves valves
stroke valves
6缸压缩冲程不能调整排气门排气门进排气门
进气门进气门
No.1 cylinder Can't be Inlet and exhaust Inlet and
compressed adjusted exhaust Inlet Inlet exhaust
valves
stroke valves valves
valves valves
于带 EVB 辅助制动装置的排气门，其间隙调整步骤如下：
For the exhaust valve with EVB auxiliary brake device, its clearance adjusting procedures are as follows:
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排气门及 EVB 间隙调整
活塞位于压缩上止点位置 Piston is located at the position of compressed top dead center.

松开螺母1 Loosen adjusting nut No.1
调整调整螺栓1，直到与气门桥的接触间隙为0
Adjust adjusting bolt No.1, until the clearance with valve bridge is 0.
松开螺母 2 Loosen adjusting nut No.2
调整调整螺栓2，在调整螺栓2与气门桥之间插入0.6mm塞尺
Adjust adjusting screw No.2, and insert a 0.6mm feeler gauge between adjusting bolt No.2 and valve bridge.
调整调整螺栓2，至小活塞到底为止，夹住塞尺
Adjust adjusting bolt No.2, until the small piston reaches the bottom and clamps the feeler gauge.
调整气门间隙0.6mm，转动调整螺栓直到塞尺无间隙，保持此状态，锁紧螺母
Adjust valve clearance 0.6mm, turn the adjusting bolt until there is no clearance for feeler gauge,keep this state, and
lock the nut.
调整调整螺栓1，在气门桥与调整螺栓1之间插入0.4mm塞尺
Adjust adjusting bolt No.1, insert a 0.4mm feeler gauge between valve bridge and adjusting bolt No.1.
调整调整螺栓1，至小活塞到底夹住塞尺为止，保持此状态，锁紧螺母
Adjust adjusting bolt No.1, until the small piston reaches the bottom and clamps the feeler gauge, keep this state, and
lock the nut.
再次检查气门间隙，必要时再进行调整。
Reinspect the valve clearance, readjust it when necessary.

更换燃油滤清器芯。附图：Replace fuel filter element.
【文字】更换燃油滤清器芯时按以下步骤操作: Replace fuel filter element in the following steps:
A. 卸下旧的燃油滤清器芯；如果安装在粗滤器上的集水器皿还可以再用，请将集水器皿取下。
Dismantle the old fuel filter element. Remove the water collector installed on coarse filter if reused.
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B. 润滑封口。
Lubricate the seal lips.

C. 用手拧上滤清器直至封口与接口结合。
Turn the filter with hand until the seal is closed with interface.
D. 继续用手拧滤清器直至滤清器牢固安装（大约 3/4 圈）。
Continue to turn the filter with hands until the filter is installed solidly (about 3/4 turns).
E. 排气直至无气泡出现。
Deflate until there is no bubble.

F. 进行泄漏试验。Conduct leakage test.
检查进气系统，附图：Inspect air inlet system.

【文字】检查进气胶管是否老化有裂缝，环箍是否松动。必要时紧固或更换零件，确保进气系统密封性。
Inspect inlet hose for aging and crack, and clip for looseness. Fasten or replace part, when necessary, in order to ensure sealing
of inlet system.
检查空气滤清器滤芯 Inspect air filter element
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【文字】柴油机最大允许进气阻力为 7kPa，柴油机必须在标定转速和全负荷运转时检查最大进气阻
力，当进气阻力达到最大允许限值时，应按制造厂的规定清洁或更换滤芯。
The max. permitted inlet resistance of diesel engine is 7kPa, and the max. inlet resistance of diesel engine must be inspected
with the engine running at rated speed and with full load. When the inlet resistance reaches the max permitted limited
value, clean or replace the element in accordance with the provision of manufacturer.
注意：决不允许在没有空滤器时使用发动机，否则灰尘和杂质进入柴油机会导致发动机早期磨损。
Caution: It is forbidden to operate engine without air filter, or entrance of dust and impurity into the engine will result in
early wear.
从空滤器中拆下空滤芯，轻拍端面使灰尘落下，也可用压缩空气反吹（由内向外吹）。
Dismantle the element from air filter, and bat the end face slightly in order to make the dust fall down, or blow it reversely
with compressed air (blow from inside to outside).
注意：不得吹破滤纸 Caution: Do not blow through the filter paper.

不得用水和油清洗滤纸 Do not clean the filter paper with water and oil.
不得用力拍打或敲打滤芯 Do not bat or knock the element heavily.
3.3柴油机长期存放时的维护保养 Maintenance during Long-Term Storage
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清洁柴油机；Clean the diesel engine;

● 防护工作：Protective work:
○ 暖机后放出机油，清洗机油滤清器，加防锈油；
After warm-up, drain off the oil, clean oil filer and fill rust proof oil;
○ 放出燃油，重新加入防锈混合油；
Drain off the fuel, and fill with rust proof mixed oil;
○ 放水，加入带防锈剂的冷却液；
Drain off the water, and fill with coolant contained with rust proof agent;
○ 开机并空转 15～25 分钟；
Start and run at idling for 15~25 minutes;

○ 放净机油、燃油、冷却液；
Drain off all the oil, fuel and coolant;

○ 对其他部位进行防护；
Protect the other parts.

● 存放期间的防护：
Protection in storage period:

○ 用盖子或所塑料布捆扎封堵个油、气、水的进出口；用气象防锈膜封存整台柴油机。
Block all the oil, air and water inlets and outlets with cap or banded plastic cloth; and seal up the whole diesel engine with
weather rust proof film.
● 如果需要运输则应该外加包装。Add external package if transportation is needed.
第四章柴油机几大系统示意图
Chapter IV: Schemtic Diagrams of Engine Main Systems
4.1 燃油系统 Fuel System

WP12系列国四柴油机采用了Bosch公司的高压共轨系统,使发动机能够满足最高1600bar的喷油压力，实现
燃油量与正时的灵活控制，达到低排放与低油耗。
WP12 Series Euro III diesel engine applies high pressure common rail system made by Bosch Company, which enables engine to
meet the max. fuel injection pressure of 1,600bar, to realize the flexible control of fuel quantity and timing; resulting in low emission and
low fuel consumption.
共轨式电控燃油喷射技术是一种全新的技术，因为它集成了计算机控制技术、现代传感检测技术以
及先进的喷油结构于一身。它不仅能达到较高的喷射压力、实现喷射压力和喷油量的控制，而且能实现
27
预喷射和后喷，从而优化喷油特性形状，降低柴油机噪声和大大减少废气的排放量。The common-rail
electronically-controlled fuel injection technology is a brand-new one,for it combines computer control technology, modern sensing
and detecting technology and advanced fuel injection structure. It can not only reach comparatively high injection pressure,and realize
the control of fuel injection pressure and quantity, but can also conduct pre-injection and post-injection, so as to optimize the characteristic
shape of fuel injection, decrease the noise of diesel engine and reduce emission greatly.
共轨系统对燃油油路要求较高，低压油路（油箱粗滤精滤，回油）、高压油路（高压油泵共
轨管高压油管喷油器）都要保证密闭。图 4-1 为 WP12 系列国四柴油机电控共轨系统；图 4-2 为
WP12 系列国四柴油机高压油泵。
The rail system has higher standard on fuel lines. The low pressure fuel line (fuel tank →coarse filter → fine filter, scavenge) and high
pressure oil line (high pressure fuel pump → rail pipe → high pressure fuel pipe → fuel injector) all need to be sealed. Figure 4-1 shows
the electronically controlled rail system of WP12 Series Euro III diesel engine; Figure 4-2 shows the high pressure fuel pump of
WP12 Series Euro III diesel engine.
图 4-1 WP12 系列国四柴油机电控共轨系统

Electronical controlled common rail system of WP12 Series Euro IV diesel engine
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High pressure fuel outlet

Diesel fuel inlet (to filter)
Diesel fuel outlet (to fuel tank)
Fuel metering valve
Overflow valve
camshaft
Lub oil inlet (optional)
Diesel fuel inlet (to filter)
Initial oil filling inlet valve cap
Gear pump ZP5 Camshaft phase sensor: DG6
Diesel fuel inlet (from fuel tank)
图 4-2 WP12 系列国四柴油机高压油泵
High pressure fuel injection pump of WP12 Series Euro IV diesel engine
4.1.1回油 Scavenge
安装回油管时应避免与汽车的高温部件接触（如排气管，涡轮增压器、废气回流管等）。回油管内不允许
存在节流区域。回油管不可接触锋利的边缘，不可折成尖角，更不可被扭曲。回油管的不当安装会引起燃
油泄漏到发动机上。
Avoid scavenge pipe, when installed, from contacting with vehicle components and parts of high temperature (such as exhaust pipe,
turbocharger, exhaust scavenge pipe).There should be no throttling area in the scavenge pipe. The pipe can not be in touch with sharp
edge, be folded into sharp corner, or twisted. The unsuitable installation of scavenge pipe may result in fuel leakage to engine.
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图 4-3 回油方式
Scavenge
WP12系列柴油机的回油是经过气缸盖的内部回油（图4-3）。在这种喷油器安装孔在气缸盖内的方式中，
必须确保回油能够完全密封。
The scavenge of WP12 Series diesel engine is the internal scavenge through cylinder head (Figure 4-3). In this manner that the installing
hole of fuel injector is in the cylinder head,ensure scavenge is sealed fully.
4.1.2 柴油粗滤器组件 Fuel coarse filter assembly

柴油粗滤器功能 Function of fuel coarse filter
粗滤系统是安装在油箱油路的下游，它会将流过它的水和微小颗粒从柴油中分离出来（利用它的多
层介质构造）。分离出来的水会被收集到位于过滤器底部的集水器皿之中。然后通过放水塞流出。如果
在粗滤器顶部安装了电加热器，那么当油流过粗滤器的时候，它将会被 350W 的加热器加热。
The coarse filter system is installed in the downstream of fuel tank line. It is used to separate the water and minor granules
passing it from the fuel (with its multilayer medium structure). The separated water is collected in a water collector at the bottom of
filter, and then flows out through drain plug. Provided an electric heater is installed on the top of coarse filter, the fuel, when passing
the coarse filter, is heated by 350W heater.
30
图 4-4 柴油滤清器组件
Fuel filter component
1 进油口 inlet 2 过滤器盖 filter cover 3 手泵 hand pump 4 放气螺丝 deflate screw 5 安装用法兰 flange 6
加热器 heater
7 出油口 outlet 8 旋压过滤器 Spinning filter 9 集水器 water sump 10 排水螺丝 drain screw 11 出油口
outlet
注意：当更换旋压粗滤器或对输油管进行重装时，那么需要给粗滤器进行排气。
Note:when replace coarse filter or reassemble fuel pipe,need drain out air inside coarse filter
粗滤器排气步骤（如图 4-5 所示）为：
Coarse filter exhaust air step (as shown in Figure 4-5)
1、停止发动机 stop engine 2、卸下放气螺丝 Remove the deflate screw
3、使用手泵打气直到有油从放气螺丝中冒出 Using a hand pump until oil emerges from the pump
bleed screw 4、重新上紧放气螺丝 tighten deflate screw
31
图 4-5 粗滤器排气
注意：当集水器满了或旋压过滤器已经替换,则需要将收集到的水放出
Note:when water sump full or spinning filter replaced,need drain out water
集水器放水步骤（如图 4-6 所示）为：
Step of drain out water(hown in Figure 4-6)
1．打开集水器（1）底部的放油塞（2）让水排净；
1.open water sump plug on bottom,drain out water
2．重新上紧放油塞。
2.assemble plug
图 4-6 集水器放水
4.2 润滑系统
Lubricate system
润滑系统的功能是减磨、冲洗、冷却和防锈，机油的使用应根据公司标准的规定选用。多级机油更
有利于冷起动性能，应优先选用。全年使用的多级机油如 15W40 等也仅可以在规定的温度范围内使用。
对于偶尔的低温情况可以采取措施预热机油，或者更换与环境温度相适应的机油。
The function of lubricate system is grinding,washing,cooling and preventing from rust,The use of oil
should be in accordance with the provisions of company standards.Multi-grade engine oil is more conducive to
cold starting performance, should be preferred.Multi-grade oil such as 15W40 used throughout the year, can
only be used within a predetermined temperature range.For occasionally low temperatures can take steps to
preheat the oil, or replace the ambient temperature compatible oil.
32
注意：WP12 系列柴油机均不允许使用 CE、CD、CC、CB、CA 级润滑油。每次换机油时同时要更
换机油滤芯！
Note: WP12 series diesel engines are not allowed to use the CE, CD, CC, CB, CA grade lubricants.
Replace the oil filter every time at the same time you change the oil!
WP12 系列柴油机主要是压力润滑，机油泵通过集滤器，将机油由油底壳中吸入，压向机油滤清器
和机油冷却器，通过油路系统到达润滑位置。绝大部分油量到达主轴承并由此通过曲轴上的油孔，到达
连杆轴承。气缸套表面和活塞销是由喷嘴喷油来实现润滑。气门操纵系统、增压器、共轨油泵、空压机、
中间齿轮轴承同样是通过油管和油槽实现压力润滑。活塞顶部是通过喷嘴喷油到内冷油腔冷却；机油是
通过机油冷却器由冷却水来冷却。机油循环系统的机油压力是通过机油泵体内的限压阀来调整的。如图
4-7 为 WP12 系列柴油机油路示意图。
WP12 Series diesel engine is mainly pressure lubrication, the oil is sucked from the oil pan through
strainer by oil pump,pressed to oil filter and oil cooler,Reaches the lubricating position by oil system.Most of
the oil reaches the main bearings and through the hole on the crankshaft,reach connecting rod bearing.Surface
of the cylinder and the piston pin is achieved by the nozzle to get lubrication.Valve operating system,
turbocharger, common-rail pump, air compressor, the intermediate gear bearing achieve pressure lubrication
through the tubing and sump.Top of the piston use oil injected into inner oil chamber by nozzle to achieve
cooling,oil use oil cooler surrounded by coolant to achieve cooling.Oil pressure in oil circulation system use oil
pump pressure limiting valve body to adjust.Figure 4-7 is for the WP12 Series diesel oil schematic
柴油机起动时，由于机油温度低，粘度较大，机油压力短时间内会偏高，但随着柴油机水温升高，
机油温度上升，机油压力会逐渐下降。当柴油机满负荷水温在 80℃～95℃时，正常机油压力为 350 kPa～
550kPa。
When the diesel engine is started, because the oil temperature is low, the oil viscosity is large, the oil
pressure in a short time will be high.But with the diesel engine water temperature rise, oil temperature rise, oil
pressure will gradually decline.When the engine working at full load and temperature is between 80 ℃ ~
95 ℃, the normal engine oil pressure is 350 kPa ~ 550kPa
33
主油道
凸
轮机
缸分
轴油
盖流
轴压中冷
空动阀
挺承力增间却
压力
柱传压齿器
机输
摇推感器轮
出
臂杆曲器轴
共轴
支轴承
机轨
架轴
体油机
承压
冷泵油
差
却滤
摇喷阀
油清
臂嘴
路压器
座连
力
杆调
轴节
承阀机油泵
油底壳
图 4-6 WP12 系列柴油机油路示意图
WP12 Series diesel oil schematic
4.3 冷却系统
4.3 Cooling System
冷却系统的功能是保证柴油机在适宜的温度下连续工作。强制循环冷却为迅速达到运转温度提供了
最好的保证，WP12 系列柴油机冷却系统如图 4-7 所示。
Function of the cooling system is to ensure that diesel engine operate continuously at a suitable
temperature.Forced circulation cooling offers the best guarantee to quickly reach operating temperature,WP12
Series diesel engine cooling system as shown in Figure 4-7
4.3.1 水泵
4.3.1 Pump
34
WP12 系列柴油机上水泵安装在柴油机前端，柴油机进出水室均布置在气缸体排气侧，回水腔在上，
进水腔在下。出水管终端有双联式节温器，两个节温器布置在出水管内部，结构紧凑。节温器有两个出
口，一路通往水箱，另一路通往水泵进水口即为小循环。当冷却水温度在 83℃时开始开启，至 95℃时全
开，这时冷却水全部经过散热器冷却后由水泵打入机体，但当冷却水温度低于 83℃时节温器切断上述通
路，冷却水直接进入水泵进口，使柴油机尽快升温，达到运行要求的热状态，避免低温磨损，延长柴油
机的使用寿命。
The WP12 Series diesel engine pump is installed in the engine front end,Diesel engine inlet and outlet of
the water chamber are arranged in the exhaust side of the cylinder block,water return chamber is on top,water
inlet chamber is on bottom.Outlet pipe terminal has a duplex thermostat,two thermostat arranged in the inside of
outlet pipe,compact structure.The thermostat has two exits, one way leading to the tank, and the other leading to
the small circulation pump inlet.When the cooling water temperature is at 83 ℃ beginning to open, fully open
to 95 ℃,Then the water is pumped into the engine body after cooled by cooling radiator.But when the cooling
water temperature is below 83 ℃ thermostat cuts off the passage,Cooling water go into the pump inlet directly,
let engine heat up as soon as possible,to achieve operational requirements of the thermal state,Avoid low
temperature wear and extend the life of diesel engines.
图 4-7 WP12 系列柴油机冷却路线图
Figure 4-7 WP12 Series diesel engine cooling system
4.3.2 膨胀水箱
4.3.2 expansion tank
35
此部件由整车厂配装，柴油机出公司时不带。一个冷却系统的冷却效率及功能在很大程度上取决于该
系统是否附带系统压力或是否无气泡，这两种特性主要受膨胀水箱活力的影响。膨胀水箱的具体作用是：
This member is fitted by the vehicle plant,not assembled when engine come out of company.Cooling
efficiency and the function of the system largely depends on whether the system is supplied with the system
pressure, or whether no bubbles inside.These two features is mainly influenced by dynamic expansion tank.The
main function of expansion tank is as follow:
◆接收加热时膨胀的冷却液
Receiving heated expansion coolant
◆接收从通风管路同空气一起溢出的冷却液，并分离出系统中的空气
Receive coolant overflow from the ventilation pipe together with air,and separate the air in the system
◆储备一定量的冷却液用于补偿泄漏损失
Reserve a certain amount of cooling fluid to compensate for leakage losses
◆冷却系统的稳压和限压
Regulate and limit the cooling system pressure
◆方便冷却液的加注或液面检查
Easy to fill or check the coolant level
WP12 系列柴油机的所有冷却系统都必须安装有一个独立或半独立的膨胀水箱。膨胀水箱内压力应
保持在 50kPa，位置至少高于柴油机及散热器 400mm，处于整个冷却系统循环水路的最高点。如有必要，
膨胀水箱设计时应考虑在内部增加隔板，从而避免加速、减速及转弯时冷却液剧烈晃动。
All cooling systems on WP12 Series diesel engine must assemble an independent or semi-independent
expansion tank.Expansion tank internal pressure should be maintained at 50 kPa,The position is at least 400mm
above the diesel engine and the radiator,at the highest point of the entire cooling system.If necessary, internal
partitions should be considered in expansion tank design,to avoid coolant shaking while acceleration,
deceleration and cornering of whole units.
膨胀水箱容量应大于或等于加入冷却系液体总量的 15%，而空气容量大约为冷却系总加入量的 7～
12%。这就说明：初次加注冷却液时，最多只能加到膨胀水箱的 60%，其余 40%供冷却液膨胀用。
Expansion tank capacity should be equal or 15% greater than the total filled coolant capacity. The air
volume is nearly 7~12% of total coolant capacity.This means: The first time filling the coolant, can only reach
to 60% of the expansion tank volume, and the remaining 40% is used for coolant expansion.
36
4.3.3 风扇
4.3.3 Fan
WP12 系列柴油机基本型采用环形塑料风扇，风扇传动采用硅油离合器传动（即粘性传动）形式。
根据用户需要，也可以采用刚性传动。粘性风扇是一种通过双金属感温元件实现由温度控制风扇工作，
所以不仅有节能的效果，更重要的是保证柴油机有良好的热状态，对柴油机的运行和使用寿命都有明显
的优点。
WP12 Series diesel engine adapts annular plastic fan,fan drive use silicone oil clutch transmission
(viscosity driving) form.According to user requirement,can also use rigid transmission.Viscous fan function is
achieved by the temperature control using bimetal temperature sensing element,so not only energy-saving
effect,the more important point is to ensure good thermal state of the diesel engine,has obvious advantages for
the diesel engine operation and service life.
4.4 进排气系统
4.4 Intake and exhaust system
三段式排气管，增压器中置。采用电子加热法兰取代火焰预热起动装置，可以有效解决冬季冷起动
过程中冒“白烟”的现象，并实现-30℃环境下顺利工作。如图 4-7 为 WP12 系列欧Ⅲ柴油机进气管示意图，
图 4-8 为排气系统示意图。
Three-stage exhaust, turbocharger is located in center.Adapts electronic heating flange replace flame
preheating starting device.Can effectively solve the "white smoke" phenomenon in the winter cold star,And this
can achieve a smooth work at -30 ℃ situation. Figure 4-7 is the WP12 Euro Ⅲ Series Diesel Engine intake
pipe schematic,Figure 4-8 is a schematic view of an exhaust system.
图 4-7 WP12 系列国四柴油机进气管
Figure 4-7 WP12 Series diesel engine intake manifold
37
图 4-8 WP12 系列国四柴油机排气系统
Figure 4-8 WP12 Series diesel exhaust system
4.5 国四 BOSCH 后处理系统
4.5 IV BOSCH SCR system
38
这套系统的目的就是：准时、准量的喷射尿素，并保证尿素在 SCR 箱内完全发生化学反应，保证
NOx 的排放浓度达到国四排放法规要求。
Purpose of the system is:inject AdBlue at punctual time and exact amount,and ensure AdBlue take
complete chemical reaction in SCR box,guarantee NOx emission concentration can reach national IV emission
regulations.
后处理系统主要包括：尿素箱、尿素泵、喷嘴、SCR 箱，除了这些还包括控制器 EDC17、尿素管路、
各种传感器及尿素的加热系统。
SCR system include AdBlue tank,AdBlue pump,nozzle,SCR box,and except these,also include controller
EDC17, AdBlue piping, various sensors and AdBlue heating system
为什么需要加热系统？因为尿素水溶液-11℃易结晶，尤其在冬天，一旦尿素结晶，不仅影响尿素的
喷射，造成 NOx 排放不达标，甚至会涨破尿素管路、尿素泵等。所以，当环境温度较低时，需要对尿素
管路、尿素泵、尿素箱内的尿素溶液进行加热。
Why the heating system is need?Because AdBlue solution is easy crystallized at -11 ℃,especially in the
winter, once the AdBlue is crystallized,not only affects the AdBlue injection,the NOx emissions will out of
standard,even broke up AdBlue piping, pumps.Therefore, when the ambient temperature is low, heating is need
for AdBlue pipeline, pump, AdBlue solution in AdBlue tank
尿素管路主要包括吸液管（尿素箱到泵）、回液管（泵到尿素箱）、压力管（泵到喷嘴）。
AdBlue pipeline includes pipettes (AdBlue tank to the pump), the liquid return pipe (pump to the AdBlue
tank), pressure pipes (pump to the nozzle).
4.5.1 尿素箱
4.5.1 AdBlue tank
39
上图是尿素箱的外观，尿素箱主要包括箱体外壳、传感器总成。传感器总成包括液位传感器、尿素
箱温度传感器及尿素管路接口（吸液管、回液管接口、水加热管路）。将传感器总成左旋或者右旋，可
以拆卸下来。如下图：
The figure above is the appearance of the AdBlue tank,AdBlue tank includes tank shell, the sensor
assembly.The sensor assembly includes level sensors, AdBlue tank temperature sensor, AdBlue pipe interface
(pipette, the liquid return pipe interfaces, water heating pipe).Rotate left-handed or right-handed sensor
assembly can be removed. As shown below:
40
尿素管路接口（吸液管、回液管）可以通过箭头标识进行识别，箭头指向代表尿素的流动方向：
AdBlue pipe interface (pipette, the liquid return pipe) can be identified by arrow logo,arrow pointing
means AdBlue flow direction:
传感器接口主要包括液位传感器（地线、信号线）、尿素箱温度传感器（地线、信号线），接插件
针脚定义及参考电压，如下：
41
Sensor interface includes level sensor (ground, signal line), urea tank temperature sensor (ground, signal
line),connector pin definitions and the reference voltage are as follows:
4.5.2 尿素泵
4.5.2AdBlue pump
尿素泵外观及放置规范：
AdBlue pump appearance and placement specification:
42
从尿素泵的外观来看，尿素泵主要包括：三个管路接口、12 孔电器接口。管路接口下方分别标注
着“INLET、BACKLET、OUTLET”，分别表示“吸液管、回液管、压力管”接口，所以，通过观察管路接
口下方的英文标识，即可判断管路接口。
According to the appearance of AdBlue pump,it includes three line interface and 12-hole electrical
interfaces.The bottom of line interfaces are marked with "INLET, BASKET, OUTLET",represent "a pipette, the
liquid return pipe, pressure pipe" Interface,so you can determine the line interface by observing the English
identification below the line interface
基本安装规范：管路接口竖直朝上，前、后倾斜角度不得超过 45°，左、右旋转也不得超过 45°。
Basic installation specification:keep interface line up vertically,Front and rear tilt angle not exceeding
45 °, left and right rotation must not exceed 45 °
12 孔电器接口中的 1、7 针脚没有使用，仅使用了余下的 10 个针脚，主要包括：尿素泵、压力传
感器、换向阀、尿素泵加热电阻丝。针脚定义及电器参考参数如下：
1、7 pin in 12 hole electrical interface is not used,only use the remaining 10 pins,includes AdBlue
pump,pressure sensor,AdBlue pump heating resistance wire. pin assignments and electrical parameters are as
follows:
43
部件尿素泵对应 ECU 工作时对 T15 上电，但 SCR 系统不开路电压开路时，常态电
comp 针脚编针脚地电压工作时的常态电压值（V）（V）阻
onent 号 ECU pin （V） T15 switch on,SCR system Open the normal
AdBlue Ground does not work,the normal circuit resistance
pump pin voltage voltage value voltage
number during
operation
K24（电
源正）
2 4.9~5 4.9~5 5
Power
positive
K78（信
Pressu
号线）
re 3 0.5~4.5 约 0.8V —— ——
Signal
sensor
line
K77（电
源负）
4 0~0.3 0~0.3 0
Power
negative
Heatin
resista 5、6 —— —— 0 —— 6Ω
nce
wire
AsBlu 8 K07 0 0 0
Resistance
e
9 K73 24 24 24 between pins
pump
8,9：0.8MΩ
motor 10 K93 —— 约 8.5 3.5
44
11 K30 —— 24 24 Resistance
Valve between pins

12 K08 —— 24 0
11,12：22Ω
4.5.3 喷嘴
4.5.3.nozzle
喷嘴属于电器件，工作原理类似于电控发动机的喷油器，由 EDC17 通过控制喷嘴内部的电磁阀来
实现喷嘴的打开或关闭。
Nozzles belong to the electrical device,It works like electronically controlled engine injectors,By
controlling the solenoid valve inside the nozzle to achieve the nozzle opening or closing in EDC17
电器件耐高温性能较差，而喷嘴直接接触高温排气管，为避免喷嘴被高温损坏，要求喷嘴必须接发
动机冷却水管路，通过发动机冷却水对喷嘴时时冷却。
High temperature performance of electrical items is poor,and the nozzle contact with hot exhaust pipe
directly,to avoid damage to the nozzle by high temperature,nozzle must be connected to the engine cooling
water circuit,cooling nozzle by engine cooling water time to time.
45
喷嘴在排气管上可以任意角度安装吗？
Nozzle can be installed in the exhaust pipe at any angle or not.
为更好的保护喷嘴，保证尿素喷射、雾化效果，避免尿素直接喷到排气管壁上，喷嘴在排气管径向、
轴向的安装都有角度要求。
To better protect the nozzle,ensure AdBlue injection and atomization,avoid spraying AdBlue directly into
the exhaust pipe wall,nozzle has installation angle requirement on diameter and axial direction of exhaust pipe.
水平方向
如上图，从排气管截面来看，推荐安装在绿色区域（45~85°，275~315°），不推荐安装在橙色区域
（315~45°），禁止安装在红色区域（85~275°）。橙色区域由于热流上升，温度比较高；而红色区域，
尿素沉积物有可能堵塞喷嘴。
As shown above, from a cross-sectional view of the exhaust pipe,recommend to be installed in the green
zone (45 ~ 85 °, 275 ~ 315 °),installation is not recommended in the orange area (315 ~ 45 °),and is
46
prohibited in the red zone (85 ~ 275 °).Because heat rises in orange area, a relatively high temperature;in red
area, AdBlue deposits can clog the nozzles.
4.5.4 SCR 箱
4.5.4 SCR tank
SCR 箱是尿素与尾气中 NOx 充分混合、发生化学反应的场所，此化学反应的进行必须满足两个基
本条件：催化剂，温度高于 200℃。如果这两个条件不能满足，那么喷射的尿素不仅无法反应，尿素在
一定温度下还会分解出氨气，排到大气中造成更严重的污染。
SCR tank is the place that AdBlue mix with NOx and take chemical reaction.This chemical reaction must
meet two basic conditions:catalyst,temperature higher than 200 ℃.If these two conditions is not met,the
injected AdBlue can not take reaction, also AdBlue will decompose ammonia at certain temperature exhaust
into the atmosphere cause more pollution.
SCR 箱主要结构包括：催化剂、载体和封装。催化剂均匀的涂抹在载体上。
SCR tank structure include: catalyst carrier and package.The catalyst is evenly coated on the carrier.
SCR 箱主要分为两类：桶式和箱式，主要是为适应不同车辆的配置要求。其中，受空间影响，桶
式主要安装在客车上。
CR tank is divided into two kinds: bucket and box, to adapt to different vehicle configure
requirements.Because influenced by space,bucket is mainly used on bus.
47
国四推广前期，喷嘴底座、传感器底座、喷嘴下游排气管等部件均由整车厂加工完成。由于尿素易
结晶、腐蚀性的特点，要求排气管选用不锈钢材料，内表面光滑，喷嘴底座的加工也较复杂，增加了整
车厂的生产成本，且可靠性偏差。所以，潍柴推出了集成式 SCR 箱，将喷嘴底座、传感器底座集成到
SCR 上，如下图。
In early days of IV promotion,nozzle base, a sensor base, downstream of the nozzle exhaust pipe and
other components are completed by OEM.Since AdBlue is easy to crystallize and corrosive characteristics,
exhaust pipe is required to choose stainless steel with smooth inner surface,the processing of nozzle base is also
more complex,increase production costs of OEM,also low reliability.so WEICHAI introduce integrated SCR
tank,the nozzle base and sensor base are integrated on SCR tank.
如果客户要求更换 SCR 箱，有哪些基本要求？
If the customer request to replace SCR tank, what are the basic requirements?
由于尿素的反应依赖于 SCR 箱内的温度，增压器后排气管的长度不应超过 2.5 米，如果排气管过
长，建议对排气管采取保温措施。
48
Since the AdBlue reaction depends on the temperature inside the SCR tank,turbocharger rear exhaust pipe
length should not be more than 2.5 meters,if the exhaust pipe is too long, it is recommended to take insulation
measures for exhaust pipe.
同时，由于 SCR 箱内填充有载体，一定程度上增大了排气背压，但排气背压也是有要求的，否则
会造成发动机故障：SCR 箱最大压力损失不得超过 15kPa（其中，在涡轮排气口处测得的总系统最大背
压不应超过 20kPa）。
Meanwhile, since the SCR tank is filled with a carrier,increased exhaust back pressure,exhaust back
pressure also have requirement,otherwise may cause engine failure:SCR tank maximum pressure loss must not
exceed 15kPa( total system maximum back pressure measured in the turbine exhaust port shall not exceed
20kPa)
4.5.6 传感器
4.5.6 sensors
后处理系统包括的传感器：尿素液位传感器、尿素箱温度传感器、尿素泵压力传感器、上游排气温
度传感器、氮氧浓度传感器（NOx 传感器）和环境温度传感器。早期潍柴国四产品还有下游温度传感器，
但随着产品优化升级，后期国四发动机将此传感器取消。
Sensors in SCR system include AdBlue level sensor, AdBlue tank temperature sensors, AdBlue pump
pressure sensors,upstream exhaust pipe temperature sensor, NOx concentration sensor and the ambient
temperature sensor.Early in Weichai IV products also have downstream temperature sensor,But with the
optimization and upgrading of products,this sensor will be canceled.
尿素液位温度传感器、压力传感器的在尿素箱、尿素泵章节已经简单介绍，本章节主要介绍上游排
气温度传感器、氮氧浓度传感器和环境温度传感器。
AdBlue level sensor and AdBlue pump pressure sensors are already introduced in AdBlue tank and
AdBlue pump section,this section mainly introduce upstream exhaust pipe temperature sensor, NOx
concentration sensor and the ambient temperature sensor.
传感器安装位置：
Sensor installation location:
49
环境温度传感器的安装位置应远离热源和污泥的重度污染区，
避免阳光直射，
推荐安装在车架底盘、
发动机进气口或整车镜面处。
Ambient temperature sensor mounting location should be away from heat and severe polluted sludge,
avoid direct sunlight,recommend to mount in frame chassis, engine air intake or the mirror plane of vehicle.
NOx 传感器用于监测、计算排气中的 NOx 浓度，通过 CAN 总线将 NOx 浓度发送给 EDC17。NOx
传感器在尾气管上的倾斜角度推荐为 90º（±10º），如图下图(a)所示。传感器及传感器控制模块的安装
位置如下图(b)所示。
NOx sensor is used for monitoring, calculating the concentration of NOx in exhaust gas,via CAN bus to
sent the NOx concentration to EDC17.The inclination angle of NOx sensor in the exhaust pipe is recommended
90º (± 10º),as shown in the following figure (a).Installation position of sensors and sensor control modules is
as shown in the following figure (b).
50
每种传感器的电器参数是多少？有什么样的安装要求？
What is the electrical parameters for each sensor and what is the installation requirements?
上游温度传感器有两种结构，一种结构如图所示，传感器末端有 90°直角弯，另一种是直线结构。
接插件形状由实际情况确定。
Upstream exhaust temperature sensor has two structure,one structure is shown in figure,the end of sensor
has 90°right angle.Another structure is a straight line.Connector shape is determined by the actual situation.
51
环境温度传感器和水温传感器为同一款热敏电阻传感器：外界温度的变化引起传感器电阻值发生变
化，传感器两端电压也发生改变。通过标定不同的温度下对应的电压值，来测得外界环境温度。
Ambient temperature sensor and water temperature sensor are same thermistor sensor,outside temperature
changes cause changes in sensor resistance value,the voltage across the sensor is also changed.Ambient
temperature can be measured by different voltage value calibrated at different temperature.
电器件传感器针脚编 ECU 针正常电压开路电压常温下的电

Electrical
parts 号脚（V）（V）阻值
Sensor pin ECU Normal Open Resistance
number pin voltage circuit value at
voltage normal
52
temperature
上游排温传 2 K82 0 0 约 215Ω
感器
1 K81 0.3-4.7 5
Upstream
exhaust
temperature
sensor
环境温度传 1 K39 0.2-4.9 5 约 2.9kΩ

感器
2 K60 0 0
Ambient
temperature
sensor
NOx 传感器控制模块与传感器头之间的线束长度为 608mm±8mm ，电源线连接整车电源开关、T15
开关之间，与 OBD 诊断接口共用 10A 保险，传感器控制模块工作温度范围为-40℃～105℃。
The harness length between NOx sensor control module and the sensor head is 608mm ± 8mm,power
cable connect vehicle power switch and T15 switch,share 10A Insurance with OBD diagnostic interface, the
operating temperature range of sensor control module is -40 ℃ ~ 105 ℃.
53
4.5.7 后处理加热系统
4.5.7 SCR heating system
后处理系统的加热包括两类：水加热、电加热。
SCR system heating include water heating and electric heating.
水加热：尿素箱使用发动机冷却液进行加热，当尿素箱温度低于某一温度，同时发动机冷却液温度
达到 55℃时，ECU 打开冷却液电磁阀，控制热的冷却液流经尿素箱对尿素进行加热解冻。
Water heating:AdBlue tank is heated using the engine coolant,when the AdBlue tank temperature is
below a certain value, and the engine coolant temperature reaches 55 ℃, ECU open coolant solenoid
valve,control heat coolant flow through AdBlue tank to heat AdBlue.
54
冷却液电磁阀要求：为防止冷却液流入线束内，线圈及线束接口应朝上安装，冷却液开关电磁阀为
常闭型电磁阀，工作环境温度为-40~80℃，工作电压 24V，工作压力 0.07MPa~1.6MPa，最大允许电流
10A，消耗功率 12W，切换频率≥0.5Hz，吸合电压≥17V，断开电压≤6V。
Coolant solenoid valve requirements:in order to prevent the coolant flow into harness,coil and wiring
harness connector should be facing upward,coolant solenoid valve is normally closed solenoid valve,working
environment temperature is -40 ~ 80 ℃,operating voltage is 24V,working pressure is 0.07MPa ~ 1.6MPa,the
maximum allowable current 10A,power consumption is 12W,switching frequency ≥0.5Hz, pull-in voltage ≥
17V, disconnect voltage ≤6V.
电加热：尿素泵及三根管路通过加热电阻丝进行加热，当检测到外界环境温度较低，且没有后处理
加热相关故障时，ECU 控制加热继电器闭合，开始加热。
Electric heating:AdBlue pump and three pipes are heated by heating resistance wire,when a low ambient
temperature is detected,and no fault in SCR heating system,ECU control the heating relay to get closed, begin
heating.
55
T15 上电初期，ECU 会按照一定规律主动闭合后处理加热主继电器 1 及其他 4 个继电器，通过检
测电压的变化，对继电器、加热电阻丝进行故障检测。
At the beginning of T15 power on,ECU will follow certain rules to close main heating relay 1 and the
other four relays actively,detect relay and heating resistance wire fault by detecting the voltage change.
第五章柴油机重要螺栓的扭紧力矩和扭紧方法
Tightening torque and tightening methods for diesel important bolts
5.1 主轴承螺栓
5.1 main bolts
14 根 M18 螺栓螺纹及承压面装配前涂润滑油，按图 5-1 次序分 6 次拧紧。第 1 次用低扭矩风动

扳手拧紧；第 2 次达到 80N·m；第 3 次达到 140N·m；第 4 次按次序旋扭 70°；第 5 次按次序再旋扭 70°；
第 6 次按次序再旋扭 70°。允许使用 2 次（包括首次安装）。
Total 14 M18 bolt threads and bearing surface should be coated with lubricant before assembly,follow
figure 5-1,6 steps.1st use low torque pneumatic wrench to tight;2nd reaches 80N.m;3rd reached 140N.m;4th
rotate 70°by order;5th rotate another 70°by order;6th rotate another 70°by order.can only be used for 2
times(include the first assemble)
56
图 5-1 主轴承螺栓拧紧次序
Main bearing bolt tightening sequence
5.2 气缸盖螺栓
5.2 cylinder head bolts
气缸盖螺栓拧紧次序如图 5-2 所示，

cylinder head bolt tightening sequence shown in Figure 5-2
1、拧紧编号 1～14 为 M12×1.5 的辅助螺栓（双头螺柱）
1.Tighten auxiliary bolts No. 1 to the 14 M12 × 1.5(Stud)
2、拧紧编号 15～38 为 M14×2 的主螺栓
2.Tighten main bolt No. 15 to 38 M14 ×12
图 5-2 气缸盖螺栓拧紧次序
Cylinder head bolt tightening sequence
用手动或单头气动扳手时，按顺序将气缸盖对中，将主螺栓螺纹部位、承压面、辅助螺栓螺母承压面及
螺纹加润滑油。
When using manual or pneumatic single head wrench,the bolt threads and surface pressure of main bolts,
bearing surface and thread of auxiliary bolt and nut should add oil.
57
① 以（60±6）Nm 的力矩拧紧主螺栓。
tightening main bolt with torque (60±6) Nm
② 以（25±3）Nm 的力矩拧紧副螺母。
Tightening auxiliary nuts with torque （25±3)Nm
③ `以 120°±5°的角度拧副螺母。用一个色点标记其位置。
Rotate auxiliary nuts by 120°±5°.use a color dot mark its position
④ 以 120°±5°的角度拧主螺栓。用一个色点标记其位置。
Rotate main bolts by 120°±5°.use a color dot mark its position
⑤ 以 120°±5°的角度再拧副螺母。用一个色点标记其位置。
Rotate auxiliary nuts by 120°±5°.use a color dot mark its position

⑥ 以 120°±5°的角度再拧主螺栓。用一个色点标记其位置。
Rotate main bolts by 120°±5°.use a color dot mark its position
气缸盖主螺栓、辅助螺栓、副螺母均允许使用 3 次（包括首次安装）。
cylinder head main bolts, the auxiliary bolt, nut are allowed to use 3 times(Including the first assemble)
5.3 连杆螺栓
5.3 connecting rod bolts
手拧紧：先拧靠，再用 115N·m 的力矩对称拧紧，最后各转 90°±5°。
Hand tighten: symmetric 115N·m of torque tightening,finally, each turn 90°±5°
自动板手拧紧：先拧靠，再用 80N·m 的力矩对称拧紧，最后各转 153°±5°。
Pneumatic wrench tighten:symmetric 80N·m of torque tightening,finally, each turn 153°±5°
注意：连杆螺栓不允许重复使用。
Note:connecting rod bolts are not allowed to reuse
连杆螺栓拧紧到位后，漆封。
Tighten the connecting rod bolts, paint seal

5.4 飞轮螺栓
5.4 Flywheel bolts
20
手拧紧：飞轮螺栓在螺纹及承压面加润滑油后，装入螺纹孔对角拧靠，拧紧力矩为 105 0 N·m；
然后转 270°±5°角。
58
Hand tighten:add oil to threads and bearing surface of flywheel bolts,the assemble in threaded hole
20
screwed by diagonal,tighten torque 105 0 N.m,then rotate 270°±5°
5.5 其余螺栓、螺母扭紧力矩和扭紧方法
5.5 the remaining bolt, nut tightening torque and tightening methods
表 5-1
螺栓规格扭紧技术要求允许使用次数（包括

螺栓名称总长 mm
Bolt Tighten technical 首次安装）
Bolts Name Length
Specifications requirements frequency of use
曲轴箱副螺栓
Crankcase deputy M8-8.8 8Nm+30° 25,110 2
bolts
曲轴皮带轮螺栓
M12×1.5-10.9 45Nm+135° 75 2
Crankshaft pulley bolt
扭振减振器螺栓
Torsional vibration M10-8.8 15Nm+30° 30 2
damper bolt
飞轮螺栓
M16×1.5-10.9 105Nm+270° 120 2
Flywheel bolts
空压机紧固螺栓
1×30 板
Compressor fastening M10-8.8 40Nm
2×40 飞轮壳
bolt
空压机齿轮固定螺母
Air compressor gear M20×1.5 200+50Nm 2
fixing nut
惰齿轮螺栓销
M12×1.5-10.9 105Nm 90
Idler gear bolt pin
59
共轨泵齿轮固定螺母
Common Rail pump M24 250+50 Nm 2
gear fixing nut
喷油器夹紧螺栓
M8-8.8 8Nm+90° 50 3
Injector clamp bolt
凸轮轴齿轮螺栓
M8-8.8 8Nm+120° 30 2
The cam gear bolts
活塞冷却喷嘴螺栓
Piston cooling nozzle M10 30Nm 25
bolt
排气歧管螺栓
Exhaust manifold M10 15Nm+60° 65 2
bolts
水泵螺栓
M10-8.8 最大 46Nm 4×80
Pump Bolts
表 5-2
螺栓规格
螺栓规格扭紧技术要求扭紧技术要求
螺栓名称 Bolt
Bolt Tighten technical Tighten technical
Bolts Name Specification
Specifications requirements requirements
s
标准 M6 螺栓
8.8 8Nm 10.9 13Nm
Standard M6 bolts
标准 M8 螺栓
8.8 22Nm 10.9 31Nm
Standard M8 bolts
标准 M10 螺栓
8.8 39Nm 10.9 58Nm
Standard M10 bolts
60
标准 M12 螺栓
8.8 70Nm 10.9 100Nm
Standard M12 bolts
注：① 角度值为扭紧到规定力矩后再扭转的角度。
② 本机上各部位所用螺栓、螺母的强度等级都有相应要求，相同规格不同强度等级的螺栓、螺母
不得任意错装、调换。不允许超过重复使用次数，否则会造成严重后果。
Note:① Angle means the torsion angle after tightening to the specified torque value
② All bolt, nut used on this machine has a corresponding intensity level requirements.Different intensity
levels of the same size of bolts and nuts are not allowed to exchange arbitrarily.Also can not excess reused
times,otherwise it will cause serious consequences
第六章柴油机所用的燃料油、润滑油、冷却液和辅助材料
Chapter VI fuel, lubricating oil, coolant and auxiliary materials used for diesel engine
6.1 燃用油
6.1 Fuel
夏季：0 号柴油（GB252）
Summer:No. 0 diesel (GB252)
冬季：一般用-10 号轻柴油（GB252）。但当大气温度低于-20°C 时应选用-20 号柴油，室外温度低
于-30°C 时，应选用-35 号柴油。

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Winter:General use -10 light diesel oil (GB252).But when the air temperature is below -20°C should
chose -20 # diesel.When the outdoor temperature is below -30°C, -35 # diesel should be used.
6.2 发动机润滑油
6.2Engine oil.
发动机润滑油容量：36L，但润滑油容量是以油尺记号为依据。
Engine Oil Capacity: 36L,however, lubricating oil capacity is based on the dipstick mark
润滑油的选用：为了使您的柴油机安全可靠的运行，请选用 15W/40CF-4 或 20W/40CF-4 级润滑油。
其中 15W/40CF-4 可在-15°C~+30°C 的范围内使用，20W/40CF-4 可在-10°C~+30°C 的范围内使用（推荐
使用潍柴专用机油）。
Selection of lubricants:to confirm diesel engine operation safe and reliable,please choose 15W / 40CF-4
20W / 40CF-4 level lubricants.15W / 40CF-4 can be used in range of -15°C ~ + 30°C,20W / 40 CF-4 can be
used in range of -10°C ~ + 30°C
6.3 张紧轮的润滑
6.3Tensioner lubrication
张紧轮的润滑应采用汽车通用锂基润滑脂（参见 GB5671-85 标准）。
Tensioner lubrication should use common automotive lithium grease(See GB5671-85 standard)
6.4 发动机冷却系统的防冻添加剂
6.4Engine cooling system antifreeze additive
采用的防冻添加剂为乙烯乙二醇，允许用国产长效防冻添加剂代用，但质量必须可靠，其具体使用
方法可参照有关说明。推荐近期国内可供使用的长效防冻添加剂有以下两种：
Antifreeze additive choose ethylene glycol,it is allowedto use domestic long-lasting antifreeze additive as
replacement,but the quality must be reliable,its specific usage can refer to the relevant instructions.
Recommended antifreeze additives for long-term availability is recommended as following:
JFL－336 型长效防冻添加剂 JFL-336 long-acting anti-freeze additive
FD－30#长效防冻添加剂 FD-30 # Long antifreeze additive
需要说明的是：对于使用长效要按照有关要求进行定期更换。
It should be noted that, for long-term use replacement should be in accordance with the relevant
requirements of periodic
62
防冻添加剂的计算（供参考）Calculation antifreeze additive(for reference)
冷却液总量：40L（在装入的发动机带散热器时）Total Coolant: 40L(When the engine is equipped with
the radiator)
目前防冻的检查温度：－20ºC Currently antifreeze Check temperature: -20º
要求达到的最低防冻温度：－30ºC The minimum temperature required to achieve antifreeze: -30ºC
计算方法：在横坐标上找到冷却液的总量“40L”这一点，过这点作线，找到与上述的－20ºC 和－30ºC
斜线的交点 1 和 2（见图 6-1）。
Calculation Method:find The total amount of coolant "40L"point on abscissa,make line over this point,
find the above -20ºC and -30ºC oblique intersection 1 and 2
对于上述的差值 4L，再按多添加 50%的量进行计算，这个多添加 50%的量是必要的。因为在防冻
添加剂加注之前，必须放出一部分冷却液，这样一来，放出的这一部分冷却液中的防冻添加剂也同时被
放出。
For the above-described difference 4L,then calculate following add the amount of more than 50% ,Because
before filling antifreeze additive must release part of the cooling liquid,as a result, this part of the anti-freeze
coolant additive release also being released
所以添加的防冻添加剂的量为 4L+50%  4L=6L。
Therefore, the amount of additive antifreeze is 4L + 50% 4L = 6L.
63
2
4
6
8
10
12
13.5 14
16
17.5 18
20
22
24
26
28
6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56
图 6-1 防冻添加剂计算图
Figure 6-1 antifreeze additive calculation map
6.5 辅助材料
6.5 auxiliary materials
表1
序号 NO. 名称 Name 颜色 Color 用途与应用 Uses and Applications
涂在平滑的金属表面防止咬合 Coated in smooth
Molykotte Pulver metal surface to prevent seizure

1 黑色 Black
（细钼粉）例如：涂在气缸套外表面等 For example: painted at
the outer surface of the cylinder
在润滑油压力建立之前起润滑作用 Function as
lubrication before the establishment of lubricating oil

Molykotte G.u.plus 深灰色
2 pressure
（二硫化钼油剂） Dark gray
例如：涂在进气门杆上等 For example: coated on
intake valve stem, etc.
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表 2 柴油机施胶参考清单
Table 2 diesel gumming reference list
牌号 Trademark 主要用途 main purpose 施胶部位列举 Sizing site 补充说明 Supplement
飞轮壳螺栓 Flywheel housing

bolts
凸轮轴止推片螺栓 Camshaft
thrust washer bolts
凸轮轴正时齿轮螺栓 Camshaft
timing gear bolt
中间惰轮螺栓 Intermediate idler
涂在螺纹表面固持， bolt
前端盖螺栓 Front cover bolts
防止震松，中等力度
乐泰 242 机油滤清器座螺栓 Oil filter seat
bolt
Coated at threaded 机油冷却器螺栓 Oil Cooler Bolt
Loctite 242 作为可选项，可以采用
surface,prevent shock, 机油冷却器调节阀的螺塞 Oil
cooler regulator valve plug DriLoc204 螺纹预涂胶进
moderate intensity 油泵回油管固定装置的螺栓 oil
return pipe fixtures bolt 行预涂。
空压机轴端螺纹 Compressor
shaft thread As an option,can use
集滤器螺栓 Strainer bolt
thread pre-glued
传感器和线束固定装置的螺栓
sensor and wiring harness fixtures DriLoc204 to precoating
bolts
涂在螺纹外表面锁
紧、密封和防止震松
乐泰 262
Applied to the threaded 气缸盖副螺栓 cylinder head
deputy bolts
Loctite 262 outer surface,Locking,
sealing and prevent
shock
乐泰 271 防松紧固
堵油孔的碗形塞 Bowl-shaped
plug on oil hole
Loctite 271 Locking fastening
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用于芯子与孔之间的
乐泰 277 密封
其余的碗形塞 other bowl-shaped
plug
Loctite 277 Sealing between the
core and the holes
用于密封缸盖顶部表
面
乐泰 270
推杆管－缸盖
For sealing the top Push rod -cylinder head
Loctite 270
surface of the cylinder
head
气缸体与曲轴箱结合面 Cylinder
乐泰 518（510 起涂在光亮的金属表 block and crankcase joint surface
的更新产品）面密封作用机体前面与前端盖 Front body
and the front cover,后端面与飞轮
壳连接板 rear face and the
Loctite 518 Painted at bright metal flywheel housing connecting plate
机油滤清器座与曲轴箱结合面
surface as sealing Oil filter holder and crankcase
joint surface
function 水泵后盖－机体前端面 Pump
cover - front end face of the body
飞轮壳连接板－飞轮壳 Flywheel
housing connecting plate -
flywheel housing
气缸体与机油冷却器盖结合面
Cylinder block and oil cooler
cover joint surface
气缸体与机油加油管结合面
Cylinder block and oil filler tube
joint surface
第七章电气部分
Chapter VII Electrical part
电气系统包括发电机、起动机、电子控制单元（ECU）、电加热法兰、水温表传感器、机油压力传
感器、进气温度压力传感器、转速传感器及继电器等。
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Electrical system includes generator, starter, electronic control unit (ECU), electric heating flange, water
temperature sensors, oil pressure sensor, intake air temperature pressure sensors, speed sensors and relays, etc.
7.1 ECU
7.1 ECU
采用 BOSCH 的电子控制单元（图 7-1），具有稳定的系统处理能力；多层次的系统保护和纠错措施，
提高发动机的可靠性和安全性；采用 CAN 和 K 总线可以实现与整车电控单元的自由通信，更人性化地
实现整车故障诊断和报警处理。
Using BOSCH electronic control unit (Figure 7-1),having a stable system capacity;multi-level system
protection and corrective action,improve engine reliability and safety;using CAN and K-bus can communicate
freely with the vehicle's electronic control unit,more humane to achieve vehicle fault diagnosis and alarm
handling.
图 7-1 ECU 外形图
Figure 7-1 ECU Dimensions
7.2 发电机
7.2 Generator
WP12 系列柴油机发电机额定电压为 28V，带有晶体管调节器。发电机在汽车上与蓄电池并联工作，
工作时发电机自激磁。发电机电路图见图 7-2。
WP12 Series diesel generator rated voltage is 28V,with transistor regulator.Generator works in parallel
with batteries in whole units,generator can do self-excitation while operating.Generator circuit diagram is
shown in Figure 7-2.

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图 7-2 发电机原理图
Figure 7-2 Schematic Generator
发电机在安装、接线时要注意：pay attention to generator installation and wiring
◆必须充分冷却 It must be sufficiently cooled
◆必须防尘、防溅、防油 Must be dust-proof, splash-proof,oil-proof
◆检查电机皮带的张紧 Check the motor belt tension
◆只能与电压调节器和蓄电池连接运行 It can only be connected with the voltage regulator and battery
7.3 起动机
7.3 Starter
WP12 系列柴油机起动机为电磁控制、齿轮传动、以摩擦片式单向器传递扭矩的直流起动机，功率
5.4kW。起动机电路图见图 7-3。
WP12 Series diesel engine starter is electromagnetic control mode, gear drive,use friction plate type
one-way transfer torque,power is 5.4kW.Starter circuit diagram is shown in Figure 7-3.
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图 7-3 起动机电路图
Figure 7-3 starter circuit diagram
为了起动机保证无故障运行，应注意：
In order to ensure trouble-free operation of the starter,should pay attention to the following items:
◆对喷溅水、道路泥浆、机油加以防护，必要时要装防护板
Should be protected from splash of water, mud roads, oil,If necessary, equip with a protective plate
◆防高温，起动机壳体的许用温度不大于 100℃
Against Heat,allowable temperature of Starter housing is no more than 100 ℃
◆如果驾驶员监控不到起动过程（例如发动机安装在尾部的商用车），为保护起动机和防止打齿，
必须安装起动继电器，起动继电器电流容量应大于 80A，在柴油机开始正常运转后立即切断起动机电路；
起动继电器的轴线应与地面平行，且垂直于车辆运行方向，以防由于振动和冲击等原因而使起动机意外
啮合。
If the driver can not monitor the start process,to protect and prevent starter fight tooth,the starter relay must
be installed,start relay current capacity should be greater than 80A,after diesel start function cut off the starter
circuit immediately;Axis of starter relay should be parallel to the ground,and perpendicular to the running
direction of the vehicle,to prevent unexpected engagement because of vibration and shock.
7.4 机油压力传感器
7.4 Oil Pressure Sensor

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机油压力感应塞的工作温度为-25～100℃，测量范围 0～550kPa，报警压力为 25～40kPa（当压力降
低时触点闭合），报警器通断功率最大 5W，额定电压 6～24V，感应塞的接口尺寸见图 7-4。
Oil pressure sensor plug operating temperature range is -25 ~ 100 ℃,measuring range is 0 ~ 550kPa,
alarm pressure range is 25 ~ 40kPa,maximum power of alarm is 5W,rated voltage is 6～24V,sensor plug
interface dimensions is shown in Figure 7-4
图 7-4 机油压力感应塞接口图
Figure 7-4 oil pressure sensor plug connector Figure
7.5 水温表传感器
7.5 Water temperature sensor
水温表传感器的工作温度为-25～120℃，分为普通和带报警两种结构，带报警的传感器报警温度
96±3℃。水温表传感器允许外力扭矩 19.6N.m，额定电压 6～24V，水温表传感器的接口尺寸见图 7-5。
Water temperature sensor operating temperature range is -25 ~ 120℃,divided into two structures with
normal and alarm,alarm temperature sensor alarm value is 96±3℃.Water temperature sensor allows external
torque 19.6N.m,rated voltage is 6～24V,connection size of water temperature sensor is shown in Figure 7-5.
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图 7-5 水温表传感器接口图
Figure 7-5 water temperature sensor interface Fig
第八章主要零部件的调整与更换
Adjustment and Replacement of Main Parts and Components
8.1 冷却系统
Cooling system
◆更换皮带；
Replace belt:
用开口扳手夹住皮带张紧轮上的焊接螺母，使皮带张紧轮旋转，让皮带张紧轮的两个小孔轴线对齐，
并迅速用小圆销插入，使皮带张紧轮不能复位，这样就可以拆下 6 槽和 10 槽皮带。
Clamp the welding nut on belt tension pulley with open end wrench, and make the belt tension pulley turn, align the axes of two small
holes on the belt tension pulley, and insert small cylindrical pin promptly, to enable the belt tension pulley not to reposition, and remove the belt
from groove 6 and groove 10.
换上新皮带，拔下小圆销，皮带自动张紧。
Replace with new belt, pull out the small cylindrical pin, and the belt will tension automatically.
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◆ 更换水泵；
◆ Replace water pump:

① 按更换皮带方法拆下 10 槽多楔带；
② 用扳手拆下皮带张紧轮；
③ 用扳手拆下皮带惰轮；
④ 用扳手拆下水泵与机体 5 个连接螺栓；
⑤ 换上新水泵，注意涂胶密封；并按④、③、②、①顺序安装。
1. Remove 10-groove poly V-belt as per the method for replacing belt;
2. Dismount belt tension pulley with wrench;
3. Dismount belt idler pulley with wrench;
4. Dismount 5 connecting bolts between water pump and engine body with wrench;
5. Replace with new water pump, seal with sealant; and install in the order of ④③②①
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Belt tension pulley belt idler pulley connecting bolt
8.2 润滑系统
Lubricating System
◆ 更换机油冷却器芯；
◆ Replace oil cooler element:

① 13mm 套筒扳手
13mm sleeve wrench
② 松开机油冷却器盖上的一圈 M8 螺栓，并拆下机油冷却器盖（拆卸前要放掉发动机内的冷却液）。
Loose M8 bolt on oil cooler cover for one turn, and dismount the oil cooler cover (before dismounting,
drain off the coolant from engine).
清理机油冷却器盖和机身密封结合面。
Clean mating faces of oil cooler cover and engine body seal
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Bolt mating face
③ 13mm 套筒扳手
13mm sleeve wrench
松开机油冷却器芯 4 根 M8 螺栓。
Loose 4 pieces of M8 bolts on the oil cooler element.
拆下机油冷却器芯，并清理干净机身上机油冷却器芯法兰结合面。
Dismount oil cooler element, and clean oil cooler element flange mating face on engine
body.
Bolt mating face

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④ 13mm 套筒扳手
13mm sleeve wrench
安装新的机油冷却器芯，并拧紧机油冷却器芯 4 根 M8 六角螺栓。
Mount new oil cooler element, and tighten 4 pieces of M8 hex bolts on oil cooler element.
注：螺栓拧紧前须在螺纹部位涂乐泰 242 密封胶。
Note: Before tightening the bolts, apply LOCTITE 242 sealant on the thread.
⑤ 13mm 套筒扳手
13mm sleeve wrench
安装机油冷却器盖，并拧紧外围所有 M8 六角螺栓。
Mount oil cooler cover, and tighten all the M8 hex bolts
◆ 更换机油泵：
◆ Replace the oil pump:
注意：更换机油泵时不要破坏曲轴前油封
Note: When replacing the oil pump, do not damage to the front oil seal of
crankshaft.
① 13mm 套筒扳手 16mm 开口扳手
13mm sleeve wrench, 16mm open end wrench.
拆下油底壳，拆机油集滤器。
Dismount sump, and dismount oil strainer.
② 10mm 开口扳手
10mm open end wrench
松开吸油管固定压板。
Loose oil suction pipe press clamp.
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③ 按照更换皮带的方法拆下皮带
Remove belt as per belt replacement method.
④ 18mm 套筒扳手
18mm sleeve wrench
拆下曲轴皮带轮和减振器
Dismount crankshaft belt pulley and the shock absorber.
Crankshaft belt pulley bolt shock absorber
⑤13mm 套筒扳手
13mm sleeve wrench

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拆下前盖板四周 M8 螺栓，拆下前盖板，注意不要破坏曲轴前油封。
Dismount M8 bolts around front cover, then dismount the front cover, and pay attention
not to damage the front oil seal of crankshaft.
⑥ 16mm 套筒扳手
16mm sleeve wrench
拆下把机油泵安装在曲轴箱上的 3 个 M10 的六角螺栓
Dismount 3 pieces of M10 hex bolts which fix oil pump on crankshaft box.
⑦ 拆下机油泵 Dismount oil pump.
⑧ 换上新的机油泵，清理曲轴箱与机油泵结合面处
Replace with new oil pump, clean the mating faces between crankshaft box and oil pump
⑨按⑦、⑥、⑤、④、③、②、①顺序安装上新的机油泵。
Mount the new oil pump in the order of ⑦⑥⑤④③②① .
Oil pump mounting bolt Oil pump mounting bolt
8.3 燃油系统
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Fuel system
◆更换喷油器：
Replace injector:
① 13mm、10mm 套筒扳手
13mm and 10mm sleeve wrench
松开摇臂罩四周 5 个 M8 六角螺栓，拆下摇臂罩；同时松开喷油器压紧块 M8 六角螺栓，取下喷油
器压紧块。
Loose 5 pieces of M8 hex bolts around rocker cover, and dismount rocker cover;
meanwhile, loose M8 hex bolt on injector press block, and dismount injector press block.
②19mm、22mm 开口扳手
19mm and 22mm open end wrench
松开高压进油接头。
Loose high pressure fuel inlet joint.
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Press block bolt High pressure fuel inlet joint
③用专用工装取出喷油器
Take out injector with special tool
Special tool
④清洁喷油器座孔，将新的喷油器装入喷油器座孔
Clean injector seat hole, and put a new injector into the seat hole
⑥装内接式高压连接
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Mount the internal connecting high pressure connection
高压燃油经过气缸盖内部的进油接头通向喷油器。在对一个标准的进油接头进行适当的高压密封时，
最小需要 12kN 的预压紧力，最大允许 22kN。过大会引起进油接头过载而发生泄漏。安装进油接头时，
O 型圈和螺纹副应涂油。螺牙和轴肩需涂油，推荐使用矿物油。如果 O 型圈和螺纹已事先表面润滑，那
么就不需涂油。
The high pressure fuel leads to injector through the oil inlet joint in the cylinder head.When applying appreciate high
pressure seal to a standard oil inlet joint, the min. 12kN pre-tightening force is needed, and its max. is 22kN. The excessive
pressure will result in leakage due to overload of oil inlet joint. When mounting the oil inlet joint, O ring and thread pair shallbe
applied with oil. The screw thread and shaft shoulder shall be applied oil. The mineral oil is recommended. If the surfaces of O
ring and thread have been lubricated in advance, then it doesn't need to apply oil.
由于进油接头的侧向密封力，随意安装会使喷油器受到不恰当的应力（由进油接头产生的侧向力使喷
油器弯曲），这是危险的。从以前的实践中得出拧紧5步法是最合适的，这样使得喷油器的受力变形最小。
Due to the lateral sealing force of oil inlet joint, the random mounting will make the
injector bear inappropriate stress (the lateral force caused by oil inlet joint may bend the injector). This is very
dangerous. The previous practice of 5-step method is most suitable,
which minimizes deformation of injector caused by force.
进油接头拧紧5步法推荐如下：
The recommended 5-step method for tightening oil inlet joint is as follows:
(1) 把喷油器插入气缸盖。确保喷油器各个定位正确，并与密封圈正确接触，用3Nm的扭矩扭紧喷油
器的夹紧螺栓。
Insert injector into cylinder head. Ensure all the injectors are correctly located and contact with the seal ring
correctly, and then tighten clamping bolt of injector with 3N.m torque.
(2) 然后松开喷油器夹紧螺栓,使其对喷油器的轴向力为0并确保喷油器在气缸盖内正确定位，
Loose injector clamping bolt, zero its axial force towards injector, and ensure that injector
is located correctly in cylinder head.
(3) 用15-20Nm的力矩预紧高压进油接头(螺母)。这个力对旋转喷油器使其对准油孔来说是必要的。
Pre-tighten the high pressure fuel inlet joint (nut) with 15-20N.m torque. It is necessary
for this force to turn injector and align with the fuel hole.
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(4) 用8Nm+90°喷油器夹紧螺栓。
Use 8N.m+90°injector clamping bolt.
(5) 用50-55Nm的力矩拧紧高压进油接头(螺母)。
Tighten high pressure fuel inlet joint (nut) with 50-55N.m torque.
◆高压进油接头,O形密封圈及密封垫圈仅使用一次
High pressure oil inlet joint, O ring and seal washer can be used once only.
第九章柴油机典型故障及处理
Typical Troubles and Remedy
WP12 系列柴油机是在严格的质量保证体系下设计和生产制造的，每一台出厂的柴油机都经过规定
的测试。同时柴油机又是一种精密机械，其功效要得到长久保证，与正常的维护保养密不可分。引起柴
油机早期失效，一般有以下几个原因：
WP12 Series diesel engine is designed and manufactured under strict quality insurance system. Each
delivered diesel engine has been tested according to relevant regulation. Meanwhile, the diesel engine is a kind
of precision mechanism, so proper maintenance should be such conducted that its function and efficiency can be
ensured for long term. The following are the reasons that result in early failure of diesel engine:
◆违章操作，管理和使用不善
Operate against the regulations, and manage and use inappropriately;
◆不按规定进行维护和保养甚至以修代养；
Do not maintain in accordance with the regulations, even replace maintenance with repair
◆配件制造不良，特别是贪图便宜购买到假冒伪劣产品，将大大缩短柴油机的寿命；
Fittings are not well manufactured, especially for sake of saving money, sham and shoddy products
purchased, which shorten the service life of diesel engine greatly;
◆燃油和润滑油牌号选用不当或不合格。
Brand selection for fuel and oil is inappropriate or unqualified.
9.1 诊断方法
Diagnostic method
柴油机故障常用的诊断方法一般有：
Generally, common diagnostic methods for diesel engine troubles are:

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◆观察法：通过观察柴油机的排烟等故障特征，判断故障情况（图 9-1）
Observation: Judge fault condition by observing fault feature such as exhaust smoke of diesel engine
(Figure 9-1).
◆听诊法：根据柴油机异常声音凭听觉判断故障部位性质及程度（图 9-2）
Stethoscopy: Judge the location, feature and extent of fault by hearing according to the abnormal sound of
diesel engine (Figure 9-2).
图 9-1 观察法图 9-2 听诊
Figure9-1 observation Figure 9-2 Stethoscopy
◆断缸法：停止某缸工作，借以判断故障是否出现在该缸。断缸法一般是向怀疑出现故障的气缸停
止供油，比较断缸前后发动机的状态变化，为进一步查找故障部位或原因缩小范围
Cylinder shut-down: Stop a certain cylinder, and judge whether this cylinder has fault or not. Usually, with
method, stop oil supply to the cylinder in doubt, and compare the condition of the engine before and after
shut-down, to reduce the scope for finding the fault position or reason further.
◆ 比较法：对某些总成或零部件，采用更换的办法确定是否存在故障。
Comparison: For certain assembly or parts and components, use replacement method to determine the
fault
注意：1. 判断柴油机故障形成的原因是一项很仔细工作，在未基本弄清原因之前，对柴油机不得乱
拆乱卸，否则不仅不能消除故障，反而会因拆卸后装配不当造成更严重的故障。
Note: 1.It is a very careful work to judge the reason of diesel engine fault, so before elementally getting
familiar with the cause, do not dismount or dismantle diesel engine. Or this can not remove the fault, and
contrarily, may result in further serious fault dueto improper assembly after disassembly.
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2. 对高压油泵、增压器等关键零部件，维修检查不仅要有专用的仪器设备，还需要具有一定经验的
人员，因此没有经验和条件的客户不要对其随意进行拆卸调整。
For the vital parts and components, such as high pressure fuel pump and supercharger, maintenance and
inspection need not only special instrument and equipment, but also experienced personnel. So the user without
experience and condition can not disassemble and adjust them at will.
9.2 常见故障及排除
Common Troubles and Remedy
9.2.1 柴油机不能起动
Diesel engine can not start
1. 起动机不工作
Starter is inoperative
WP12 系列起动机由 ECU 控制，正常工作时，ECU 输出一个电流驱动起动继电器，继电器接通后电
瓶带动起动机起动。出现故障时主要是对空档的检查。
WP12 Series starter is controlled by ECU. Under normal condition, ECU outputs a current to drive the starting relay. When the relay is
closed, battery drives the starter to start. When there is fault, mainly inspect the neutral position.
检查时有几个要素：空档开关、起动继电器、电瓶、车下停车开关的关联。
Factors for inspection: neutral position switch, starting relay, battery, and conjunction of
shut-down switch under vehicle.
◆检查是否挂在空档位置
Inspect whether gear shift is at neutral position.
起车前，首先检查档位手柄是否挂在空档位置
Before starting, inspect whether the gear shaft handle is at neutral position.
◆检查车下停车开关的位置（应处于断开状态）
Inspect the position of shut-down switch under vehicle (in shut-down state).
车下停车开关做成点动式，并且能自动复位，检查此开关是否正常
The shut-down switch under vehicle is inching style, and can be reset automatically.
Inspect this switch for normal condition.
若此开关不是自动复位式，应检查此开关是否在接通状态
If this switch is not the automatic resetting style, inspect whether this switch is at ON
position.
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◆检查空档开关及接线是否完好，试着使用紧急起动（点火开关持续按下 5 秒以上）
Inspect neutral position switch and its wiring for condition, and try to use the emergency
starting (press the ignition switch for more than 5 seconds continuously)
对于起动机受 ECU 控制的发动机，起动时 ECU 先根据空档开关传来的信号判定是否挂在空档位置。
当空档开关损坏或接线连接不良时，ECU 接收不到空档信号，起动机是不工作的。
For the engine of which the starter is controlled by ECU, during starting, the ECU judges
whether the gear shift is at neutral position with help of the signal transmitted from neutral
position switch. When the neutral position switch is damaged or wiring bad, the ECU can not
receive any neutral position signal, and then the starter does not operate.
◆检查电瓶电压是否过低，以致不能带动起动机
Inspect whether battery voltage is too low to drive the starter.
一般电瓶电压为 24V，太低则不能带动起动机工作，可以用万用表的电压档进行检查或用故障诊断
仪读取实际值“电池电压”。
Normally the battery voltage is 24V. If it is too low, the starter can not be driven to work.
By using multimeter at voltage range or with the fault diagnostic apparatus, measure the actual value of
“battery voltage”.
◆起动机继电器及接线是否完好
Inspect whether the starter relay and its wiring are good.
检查接线柱表面氧化物是否太多，接线柱表面螺栓是否松动或断裂
Inspect the terminal surface for deposit oxide, and for loose or cracked bolt.
◆检查起动机是否已烧坏
Inspect whether the starter has been burnt out. 点火钥匙开关
用万用表检查起动机继电器是否正常
Inspect with multimeter whether the starter relay is normal. Ignition key switch
◆点火开关及起动开关是否已坏
Inspect whether ignition switch and starting switch are damaged.
将点火钥匙旋至 ON 档，看仪表盘灯是否亮
Turn ignition key to ON position, and check that panel light comes on.
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将点火钥匙旋至起动档，检查起动机是否有动作（此时是在其它原因排除的前提下）
Turn ignition key to starting position, and check that the starter operates (at this time, the
other reasons have been excluded)
starter
2 轨压无法建立（起动机能正常工作，但无法起动）
Rail pressure can not be established (the starter can work normally but can not be started)
Deflating bolt
Return oil hollow bolt
Hand pump
◆检查油箱油位是否过低
Inspect whether the fuel level in fuel tank is too low.
此原因比较容易忽略，要引起注意
Pay attention to this reason that is easy to be neglected.
◆检查手油泵是否工作正常
Inspect whether hand pump operates normally.
用手压动手油泵看是否正常
Press hand pump with hand, and check whether it is normal.
◆检查低压油路是否有气，并排空气(有时低压油路泄漏不明显，需要仔细检查)
Inspect whether there is air in low pressure line, and exhaust the air (sometimes, the
leakage of low pressure line is not obvious, so inspect carefully).

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排气方法：主要排粗滤里面的空气。松开粗滤上的放气螺栓，用手压动粗滤器上的手压泵，直至放
气螺栓处持续出油为止
Deflating method: Mainly deflate the air in coarse filter. Loosen the deflating bolt on
coarse filter. Manually press the hand pump on coarse filter until fuel flows out continually at
the deflating bolt.
低压油路空气排净后仍不能起动柴油机，则判断高压油路有空气，也需要排出高压油路的空气
If the diesel engine still can not be started after the air in low pressure line is deflated, it
may be judged that there is air in high pressure line. Deflate the air in the high pressure line.
排气方法：松开某缸高压油管，用起动机带动柴油机运转直至高压油管持续出油为止！（不建议经
常拆卸高压油管接头！）
Deflating method: Loosen high pressure pipe of a certain cylinder, and drive the diesel
engine to run with starter until the fuel flows out continually from high pressure pipe. (To
disassemble the high pressure pipe joint frequently is not recommended.)
◆检查高压油路有无泄漏
Inspect whether there is leakage in high pressure fuel line.
这种情况一般较为明显，检查高压油管接头螺帽是否有松动，若是，拧紧。
Usually, this case is very obvious. Inspect whether the joint nut of high pressure fuel pipe
is loose, and if any, tighten it.
◆检查油路是否通畅，检查柴油滤清器是否堵塞，建议及时更换柴油滤芯。
Inspect whether the fuel line is through, and whether fuel filter is blocked. It is
recommended to replace fuel filter element in time.
检查方法：松开精滤出口螺栓，用起动机带动柴油机运转，看是否有柴油喷出或流出，若只有少量
柴油流出，则可以判定滤芯堵塞，此时需要更换滤芯
Inspection method: Loosen the outlet bolt of fine filter, drive the diesel engine to operate
with starter, and check whether fuel is jetted or flows out. If only a few fuel flows out, then it
means the filter element is blocked, and the filter element needs to be replaced.
◆检查轨压传感器初始电压值是否在 500mV 左右，或设定轨压是否为 30-50Mpa。测量方法为：
Inspect whether the initial voltage value of rail pressure sensor is about 500mV, or the set
rail pressure is 30-50MPa or not. The measuring method is:

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进入故障诊断仪操作界面，选中“实际值”,点击下一步
Enter into the fault diagnostic apparatus operating interface, select “Actual value”, and
click “Next”.
Select required function
Click >> to continue
Identification
Fault Omit the fault memory in fault storage
Storage
Executing element
Function test
select required function
此时会出现所有的“实际值”选中“蓄压管压力传感器电压”“额定油轨压力”
At this time, select “Accumulation pipe pressure sensor voltage” and “Rated fuel rail
pressure” in the displayed “Actual values:
engine speed
rated rail pressure
real rail pressure
accumulation pipe sensor voltage
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若不正常首先检查接插件是否牢靠，若没有问题，则可能是轨压传感器坏
If not normal, inspect whether the connector is reliable or not. If it is out of question, the
rail pressure sensor may be damaged.
若无检查设备，可以拔掉轨压传感器接插件尝试再起动（起车后会进入“跛行回家”模式）
If there is no inspection equipment, disconnect the connector of rail pressure sensor, and
try to restart (After starting, it comes into “limp-home” mode)
◆检查流量计量单元是否完好，拔掉流量计量单元接插件尝试再起动
Inspect whether the flow metering unit is good, disconnect the connector of flow metering
unit, and try to restart
① 首先观察是否有明显的硬件损伤、插接件连接是否牢靠
First, visually check hardware for obvious damage, and connector for reliable connection.
②连接故障诊断仪进行 Meter-unit 测试
Connect the fault diagnostic apparatus, and carry out the Meter-unit test.
进入故障诊断仪操作界面，选中“功能测试”，点击下一步
Enter into the fault diagnostic apparatus operating interface, select “Function test”, and
click “Next”.
下一步
进入功能测试子界面，选中“配量单元测试”，点击下一步；
nexnex
Enter into the function test sub-interface, select “Meter-unit Next

nexn test”, and click “Next”.
ex
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下一步
next
此时会出现测试条件界面，操作者确认条件符合，点击下一步，开始测试；
At this time, it will display the test condition interface, if operator confirms that the
condition is fitted, click Next, and start the test;
测试结束后，显示油量计量单元是否正常。
Upon completion of test, it displays whether the flow metering unit is normal.
3 喷油器线束、传感器线束、整车线束接插件未插好或者线束断路或短路
Connectors of injector wiring harness, sensor wiring harness and complete vehicle wiring
harness badly connected, or wiring harness short-circuited or open circuited
◆检查接插件的安装，用万用表(最好接“线路检查仪”)按照线路图的指针定义检查线路的通断
Inspect installation of connector, and inspect circuit continuity with multimeter (it is better
to connect “Circuit Checker”) as per circuit diagram.
Water temperature sensor
水温传感器
机油压力传感器
Oil pressure senor Camshaft speed sensor 凸轮轴转速传感器 Camshaft speed sensor
Camshaft speed
sensor
曲轴转速传感器
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线路检查仪
Crankshaft speed sensor
Intake pressure
Rail pressure senor
senor
喷油器接线
Injector wiring
3 流量计量单元接插件
曲轴信号和凸轮轴信号丧失 Flow metering unit connector
Crankshaft and camshaft signal lost
柴油机上安装两个转速传感器，分别在飞轮壳和高压油泵外侧。功能分别为：曲轴位置传感器和判
缸传感器。电控发动机的喷油正时取决于这两个传感器。出现柴油机不能起动的情况，两个信号全部丢
失。
There are two speed sensors on the diesel engine, on the outside of flywheel housing
and high pressure fuel pump respectively. They may be functionally divided into tow
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type: crankshaft position sensor and cylinder judging sensor. The fuel injection timing of
electronically controlled starter is determined by the two sensors. When the diesel engine can
not start, both of the signals are missing.
◆两信号全部丢失可能的原因
Possible cause for loss of both signals
⑴ 传感器损坏，线束短路或断路
Sensor is damaged, and wiring harness is short-circuited or open-circuited.
⑵ 传感器固定不牢，造成传感器与感应齿之间间隙过大或过小(一般为 1±0.5mm)
排除方法：检查传感器是否损坏，线束是否连接良好，传感器是否松动等
Sensor is not fixed reliably, resulting in too large or too small clearance between sensor
and sensing tooth (usually 1±0.5mm).
Remedy: Inspect sensor for damage; wiring harness for connection; and sensor for
looseness.
◆拆装高压油泵及飞轮后的安装应严格按照相关工艺文件执行，以确保信号同步
Reinstall the dismounted high pressure fuel pump and flywheel strictly in accordance with
relevant workmanship document so as to ensure signal synchronization.
Camshaft speed sensor Crankshaft speed sensor
9.2.2 起动困难
Difficult to start
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发动机起动困难的原因及排除方法：
Cause and remedy for difficult engine starter:
◆柴油机较长时间没有运转：回油管要伸在柴油液面下
Diesel engine has not operated for a long time: Extend the return pipe to under fuel level.
◆低压管路有少量空气：排气
There is a little air in low pressure line: Deflating
◆曲轴转速信号、凸轮轴信号太弱，同步判断时间较长：查找具体原因，重新调整
The crankshaft speed signal and camshaft signal are too weak, and the synchronous
judging time is relatively long: Find the specific reasons, and adjust again.
◆环境温度太低，预热装置失效：检查加热法兰接线是否正常或更换预热装置
The ambient temperature is too low, and pre-heating device fails: Inspect heating flange
wiring for condition, or replace pre-heating device.
◆柴油、机油品质太差未达标：更换标准油品
The quality of fuel and engine oil is too bad to meet the standard: Replace with standard
product.
◆起动机或飞轮齿圈打齿：更换起动机及飞轮齿圈
The starter or flywheel gear ring is tooth hit: Replace the starter or flywheel gear ring.
◆活塞环、缸套磨损或气门密封不严：更换活塞环、缸套或气门座、气门
The piston ring or cylinder liner is worn, or valve seal is not tight: Replace piston ring,
cylinder liner, valve seat or valve.
◆排气制动蝶阀卡死在关闭状态，导致排气不畅：更换蝶阀
The deflating brake butterfly valve is jammed at closed position, resulting in difficult
exhaust: Replace the butterfly valve.
9.2.3 发动机功率不足
Engine power is inadequate
跛行回家：发动机带故障运行的一种模式。ECU 检测到发动机出现了故障，但不会立即停车，而是
会限制发动机的功率，使发动机转速只能增加到 1500 转，司机能将车开到就近的维修站进行维修。
Limp-home: This a kind of mode in which engine runs with fault. When ECU detects fault
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in engine, it does not shut down the engine immediately, but limits engine power, and increases engine
speed to 1,500r/min only. The driver can drive the vehicle to the nearby maintenance station for maintenance
and repair.
1 喷油器出现故障
Injector defective
喷油器出现故障，一般分为机械故障和接线故障
The faults in injector can usually be divided into mechanical fault and wiring fault.
机械故障为：针阀卡死，由于柴油中污物较多或进水腐蚀，针阀卡死在喷油器内，不能动作。（注
意：ECU 可能不报错！）
Mechanical fault: Needle valve is seized due to excessive dirt in fuel or water corrosion.
The needle valve is seized in the injector, and can not move.(Caution: ECU may not report
this fault!)
接线故障为：线束由于振动、磨损等原因，连接断开或直接搭在缸盖上与地短接。ECU 会报错。
Wiring fault: Wire is broken or bonded directly on cylinder head and shorted to ground.
ECU reports this fault.
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injector terminal
2 水温、机油温、进气温度过高
Temperature of water, oil and inlet air is too high
水温、机油温、进气温度过高时，ECU 会进入过热保护功能，限制发动机功率。
在排除故障之前，首先要排除传感器及仪表的反映失真情况。
When temperature of water, oil and inlet air is too high, ECU enters into overheat
protection function, and limits the engine power.
Before removal of the trouble, eliminate the distortion of sensor and instrument first.
◆造成水温高的原因及排除方法
Cause and remedy for too high water temperature
① 水箱水面过低：检查有无漏水处，加水 The water level in water tank is too low: Inspect for water
leakage, and fill water.
② 风扇转速过慢或不转：检查风扇传动部件 The fan rotates at very low speed or fails to rotate:
Inspect fan driving components.

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③ 水箱堵塞：检查水箱，清理或修复 The water tank is blocked: Inspect the water tank, and clean or
repair.
④ 水泵皮带松弛：按规定调整张紧力 The water pump belt is loose: Adjust the tension force as per the
regulations.
⑤ 水泵垫片损坏，水泵叶轮磨损：检查并修复或更换 The water pump gasket is damaged, and the
water pump impeller is worn: Inspect and repair or replace.
⑥ 节温器故障：更换 The thermostat is defective: Replace.
⑦ 水管密封件损坏，漏入空气：检查水管、接头、垫片等，更换损坏件
The water pipe seal is damaged, and air penetrates: Inspect the water pipe, joint, gasket,
etc., and replace the damaged part.
◆机油温度过高的原因及排除方法
Cause and remedy for too high oil temperature
① 油底壳油面低或缺油：检查油面及漏油处，修复并加油
The sump is at low oil level or lack of oil: Inspect oil level and find oil leaking point,
repair and fill oil.
② 水温高：检查上述造成水温高的原因并排除之
The water temperature is high: Find the reason for high water temperature, and remove it.
③ 机油冷却器流通不畅：检查并清理
The circulating of oil cooler is bad: Inspect and clean.
◆进气温度过高的原因及排除方法
Cause for too high inlet air temperature
3 同步信号出错
Synchronous signal faulty
出现该问题时，一般是一个传感器的信号失效。
If this fault takes place, usually signal of one sensor is in failure.
通过闪码灯读出闪码，查看闪码表查找具体原因，排除方法同 9.2.1-4
Read the flash code from the flash code light, and check the flash code table to find the
specific reason, and remove the trouble as per Para. 9.2.1-4.
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4 流量计量单元故障
Flow metering unit defective
流量计量单元是控制轨压的执行机构，安装在高压油泵上，它出现问题以后，高压油
泵会以最大的能力向共轨管供油，此时共轨管上的泄压阀一般会打开，柴油机会有“咔咔”的噪音。
轨压传感器出现问题也会有类似的现象。
The flow metering unit is the actuator to control rail pressure, and is mounted on the high
pressure fuel pump. When it has fault, the high pressure fuel pump will take all the efforts to
supply fuel to rail pipe. Usually, the relief valve on rail pipe is open at that time, and there is
Click noise from the engine. If the rail pressure sensor has fault, similar phenomenon will take place.
Flow metering unit
◆排除方法：检修线路，确认是流量计量单元或轨压传感器故障，通知办事处处理
Remedy: Examine and repair the circuit, and confirm that there is fault in flow metering
unit or rail pressure sensor, and inform the office for handling.
5 燃油管路泄漏引起轨压异常波动
Abnormal fluctuation of rail pressure due to leakage of fuel line
在车运行过程中，会出现车速不稳，车有向前一窜一窜的现象出现。
The vehicle runs at unstable speed move forward with sudden leaps
◆排除方法：
Remedy:
首先断电一分钟重新起动，若问题仍然存在则检查燃油管路密封性并排除
First, turn off the power for one minute and restart. If the fault still exists, inspect the
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sealing of fuel line and remove it.
6 传感器故障
Sensor is defective
进气压力传感器是 ECU 用来估算进气量的传感器（安装在进气管上），水温传感器是
用来判断发动机热负荷的传感器（安装在水泵上），轨压传感器是用来检测共轨管的燃油压力（安
装在共轨管上）。
Air inlet pressure sensor is the sensor (mounted on air inlet pipe) used by ECYU to estimate inlet air
volume. Water temperature sensor is the sensor (mounted on the water pump) used to judge the thermo load of
engine. Rail pressure sensor is the sensor (mounted on the rail pipe) used to detect the fuel pressure of rail pipe.
Water temperature senor rail pressure sensor
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Intake pressure sensor
◆排除方法
Remedy
检查进气温度压力、水温、轨压传感器，看接插件是否牢靠
Inspect the sensors of air inlet temperature and pressure, water temperature and rail
pressure, and check that connector is reliable.
注：出现 1、3、4、5、6 故障时，柴油机进入“跛行回家”模式。
Note: When faults 1，3，4，5，6 takes place, the diesel engine will enter into
“Limp-home” mode.
9.2.4 发动机始终运行在 1000 转
Engine runs at speed of 1,000r/min always
此时油门失效：ECU 通过踏板电位计给出的信号来判断负荷，当踏板出故障时，出
于安全考虑，ECU 会控制柴油机会自动回到 1000 转的怠速。
At this time, the accelerator fails: The ECU judges the load from the signal given by pedal
potentiometer. If there is fault in pedal, for the sake of safety, ECU controls the diesel engine to
return to the idling speed of 1,000r/min automatically.
◆电子油门踏线松脱或接错
The pedal wire of electronic accelerator is loose or connected wrongly
重新拔插或检查油门接线是否正确，重新接线
Pull out and insert again or inspect the wiring, and connect the wire again.
◆电子油门接插件进水
There is water penetration in connector of electronic accelerator
用工具把接插件吹干再起动
Blow the connector dry with tool first, then start.
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注意：更换油门时，需要同一型号的油门
Caution: The accelerator should be replaced with that of the same type.
9.2.5 发动机怠速游车
Engine idle hunting
◆发动机游车的原因及排除方法：
Cause and remedy for engine hunting
① 喷油器工作不正常：检查各缸喷油器及线束；
The injector does not operates properly: Inspect the injector and wiring harness of each
cylinder.
② 具有车速传感器的整车，停车时有车速信号输入：检查车速表及车速传感器信号
及接线；
For the complete vehicle with speed sensor, there is still the input speed signal during
parking: Inspect the speedometer, the speed sensor signal and the wiring.
③ 燃油质量差含水或蜡质：清洗燃油系统，更换燃油滤清器；
The fuel is of bad quality, and contains water or waxiness: Clean the fuel system, and
replace the fuel filter.
④ 燃油低压油路漏入空气：检查油管及接头密封性，排除空气；
The air leaks into low pressure fuel line: Inspect the sealing of fuel pipe and joint, and
deflate the air.
⑤ 喷油嘴雾化不稳定：检查并修复。
The atomization of oil nozzle is not stable: Inspect and repair.

注：由于水温低引起的怠速上升是 ECU 正常的功能。有其他负载时（如打开空调），
怠速会自然提升 100 转。
Note: Idle speed increase due to low water temperature is normal function of ECU. When there is the other load
(for example, air conditioning on), the idling speed increases by 100r/min automatically.
后处理系统典型故障
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对于发动机本体故障，比如启动困难、泄压阀打开、动力不足等，国四与国三电控机的故障原理及
排查方法基本相同，所以不再详细介绍，请参考“国三电控发动机故障排查手册”。由于国四发动机增加
了“排放不达标会限制发动机扭矩”的功能，所以，处理国四动力不足、扭矩限制故障时，就要把后处理
相关故障考虑在内。
For the engine failure, such as difficulty in starting, pressure relief valve opens, low power, etc,the fault
principle and troubleshooting is same for III and IV,so no details about that,please refer to the "China III
electronically controlled engine troubleshooting manual".Since China IV engine adds "Emissions
non-compliance will limit engine torque" function,Therefore, when deal with low power, torque limit fault on
IV engine, the relevant fault about SCR system should be taken into account.
尿素箱相关故障
AdBlue tank failures
尿素箱主要包括箱体外壳和液位温度传感器总成，传感器较易出现故障，常见故障为：液位显示不
准确，温度显示异常，及故障灯常亮并报出液位温度传感器故障等。引起这类故障的原因主要是：传感
器损坏，传感器接插件虚接、短路，及相关线束故障。有时，液位温度传感器与潍柴要求电器参数不匹
配（比如，客户自主采购尿素箱而没有通知潍柴）也会造成液位、温度异常，甚至报出传感器故障，这
时候可以使用 EOL 重新标定尿素液位、温度传感器，或者将传感器换成潍柴指定产品。EOL 标定尿素
液位、温度传感器办法，参见下图：
AdBlue tank includes tank shell and temperature&level sensor assembly,sensor is easy to get failure,the
common failure are level display inaccurate,abnormal temperature display,fault lights lit and report the level of
temperature sensor fault.The main cause of such failures is sensor damage,sensor connectors virtual connection,
short circuit, and the related wiring harness malfunction.Sometimes, level and temperature sensor electrical
parameters do not match the requirements of Weichai(For example, customers purchase AdBlue tank autonomy
without notice Weichai),also cause level, temperature anomalies, or even report sensor failure,now the AdBlue
level and temperature sensor can be calibrated by EOL,or transfer sensor to WEICHAI designated products.
The method of calibration AdBlue level and temperature sensors by EOL is shown in figure below.
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1. 按照实际传感器图纸参数，计算浮子在最低点和最高点时的高度差。将该差值等分为 7 份，并在
传感器上标上刻度；
according to the actual sensor drawing parameters,calculate the height of the float at the lowest point and the
highest point.divided the height into 7 parts, and marked the scale on sensor;
2. 将传感器接插件安装好后，T15 上电；
Install the sensor connector,then T15 switch on
3. 然后用万用表测量浮子到达每一刻度时信号针脚的电压值，并记录；
Then use multimeter to measure the voltage on signal pin when the float reach every scale,record it.
4. 最后将“电压—高度”值对应填到上图“表 1”中，同时把高度值换算成百分比，填到“表 2”中。
Finally,fill the voltage-height value to Table 1,and transfer the height to percentage,fill Table 2.
注：考虑到实际使用情况，在标定尿素液位电压时，要将最低点电压往高液位的电压上靠一下，如
最低点 53mm 时电压 4430mV，最好标定电压标为 4415mV。因为，直接标定为 4430mV，即使浮子在最
低点时，尿素液位百分比也不容易显示为 0%。
Note:Taking into account the actual usage,during the voltage calibration of AdBlue level,the voltage on the
lowest point should move a little step to the voltage on high level.For example,the lowest point of 53mm with
voltage 4430 mV,the better calibration voltage should be labeled 4415mV.Because, if it is directly calibrated to
4430 mV,even if the float at the lowest point,AdBlue level is not easy to shown 0%.
1. 标定温度时，需要获得整车厂提供的尿素箱温度传感器各个温度下对应的电阻值，如下图所示；
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During temperature calibration,resistance values at various temperature of AdBlue temperature sensor should be
supplied bu OEM,As shown below.
2. 实际 ECU 内部有 3650Ω 的分压内阻，与温度传感器电阻串联，只要计算出传感器电阻上的分压
即可。如图二所示：例如，计算 25℃时的标定电压：U=3300/(3300+3650)*5000mV=3602mV。
Actual ECU has internal 3650Ω,in series with the temperature sensor resistance,only need calculate the part
voltage on sensor resistance.For example, the calibration voltage is calculated at 25 ℃:
U=3300/(3300+3650)*5000mV=3602mV.
3. 选取从 85 度到-40 度的 16 个点，将计算后的值一一标定在上图“表 3”中即可。
Choose 16 points from 85 degrees to -40 degrees, then fill the calculated value to Table 3 one by one.
注：当然，尿素液位的也可以通过计算标定，方法与温度类似，液位传感器 ECU 内部电阻也是 3650Ω，
整个电路也是 5V 电压，计算公式与温度标定方法相同。
Note: Of course, the level of urea can also be calculated calibration method is similar to the temperature,
liquid level sensor ECU internal resistance is 3650Ω, the entire circuit voltage is 5V, the same formula and
temperature calibration methods.
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当然，除了这些，也有可能出现尿素液位低、尿素泄露、尿素质量差等故障，这时候一定要及时添
加标准尿素溶液，并将泄露管路修复。否则会影响排放，超过 50 小时后限制发动机扭矩
Of course, in addition to these, there may appear lower level of urea, urea leaks, failures and poor quality
of urea, this time we must add the standard urea solution in a timely manner, and to repair leaking pipes.
Otherwise it will affect emissions, more than 50 hours after the limit engine torque
尿素液位传感器电压高于上限（低于下限）——传感器接插件退针
Urea level sensor voltage above the upper limit (less than the lower limit) - return sensor connector pin
闪码故障类型故障名称 P码
445 当前故障尿素液位传感器电压高于上限 P203D
Flash Fault type Fault Name P code

code
445 The current Urea level sensor voltage is higher than the P203D
fault upper limit
故障现象：
故障灯、OBD 灯常亮，报出闪码 445（尿素液位传感器电压高于上限），仪表中尿素液位的显示不
准确。
Symptom:
Fault lights, OBD lights lit, quoted flash code 445 (urea level sensor voltage is higher than the upper limit),
urea level meter display inaccurate.
故障机理：
如果整车出厂前没有此故障，车辆运行一段时间后报出此故障，一般是由于传感器线束或接插件开
路引起，请检查传感器接插件 1 号针脚（ECU 针脚 K57）是否出现开路、与电源短路的故障。如果不能
解决，进一步检查其他针脚、线束是否有故障。
Failure mechanisms:
If the factory before the vehicle does not have this fault, running for some time after the vehicle reported
this failure, usually due to the sensor wiring harness connector open or cause, please check the sensor connector
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pin 1 (ECU pin K57) whether there is an open circuit, short-circuit and power supply failure. If not, further
examination of the other pin wiring harness is defective.
可能原因：
 传感器接插件或整车线束大插头退针；
 线束开路或虚接；
 K57 与电源短路；
 传感器损坏，或传感器参数与潍柴要求不匹配。
Possible Causes:
 sensor or vehicle harness connector plug large needle back;
 K57 for short to power;
实际解决方法与步骤：
1) 从简单入手，检查故障率最高的地方：传感器接插件和线束；
2) 拔下传感器接插件后，发现个别针脚退针，造成线束开路；
3) 重新固定插针后，故障灯熄灭，尿素液位显示正常。
4) 故障消除。
Practical solutions and procedures:
1) From simple start checking where the highest failure rate: sensor connector and harness;
2) Unplug the sensor connector, found that individual pin back needle, resulting in open wiring
harness;
3) re-fixed pins, fault light extinguished, urea level display properly.
4) failure to eliminate.
结论：
尿素液位温度传感器接插件退针，导致液位信号线 K57 针脚开路。
in conclusion:
Urea level temperature sensor connector back needle, resulting in empty signal line K57 pin open.
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尿素液位、温度显示异常——传感器参数与潍柴要求产品不匹配
Urea level, temperature display abnormal - Sensor parameter does not match the requirements of the product
and Weichai
无 —— —— ——
故障现象：
尿素液位显示不准确（比如，尿素很少时，仪表显示尿素 100%），尿素温度与当前环境温度差别
很大，且没有报出相关传感器故障。
Symptom:
Urea level display inaccurate (for example, less urea, urea meter displays 100%), urea temperature and the
current ambient temperature varies greatly, and no reported failures associated sensors.
故障机理：
这种故障一般是由于尿素箱传感器与潍柴指定的不匹配，或者整车最近更换过尿素箱，但尿素箱内
部的传感器与原车出厂前的型号不同。传感器的电器参数不同，导致数据标定不匹配，液位温度显示错
误。
Failure mechanisms:
Such failures are generally due to the urea tank sensor and Weichai specified does not match the vehicle or
recently replaced urea tank, but urea tank sensor inside the factory with the original car models are different.
Different electrical parameters of the sensor, resulting in the calibration data does not match the level
temperature error is displayed.
可能原因：
 客户更换了尿素箱，与原车尿素箱不同；
 整车厂配套时，自主采购尿素箱，但没有通知潍柴技术人员重新标定数据；
 传感器或相关线束被损坏，导致电器参数变化（这种可能性较小），但没有报出传感器相
关故障；
Possible Causes:
 tank different;
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recalibration data;
likely), but did not report the sensor-related fault;
1) 检查尿素箱及传感器，核实与原车尿素箱是否相同；
2) 发现尿素箱属于不同厂家；
3) 更换尿素箱：安装与原车相同尿素箱后，液位、温度示数正常。
4) 故障解决。
1) Check the box and urea sensor, check with the original car urea tank is the same;
2) found that the urea tank belonging to different manufacturers;
3) Replace the urea tank: Installation with the original car the same urea tank, the liquid level,
temperature indication of normal.
4) troubleshooting.
结论：
客户更换的尿素箱与原车尿素箱不同，造成电器参数不匹配，安装与原车相同尿素箱后，故障解决。
也可以不更换尿素箱，只需重新标定 ECU 即可，使用 EOL 标定尿素液位温度的方法，参见 2.1 章节内
容。
in conclusion:
Customer replaceable urea tank with the original car different urea tank, causing electrical parameters do
not match, the installation of the original car the same urea tank after troubleshooting. You may not replace the
urea tank, simply re-calibrated ECU can use EOL urea level temperature calibration method, see chapters 2.1.
尿素液位、温度显示异常——ECU 针脚内电阻过大
Urea level, the temperature display inner exception --ECU pin resistance is too large
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无 —— —— ——
故障现象：
此车为国四试装样车，尿素液位、温度显示不准确，很少的尿素时，仪表显示尿素液位 100%；用
EOL 测得环境温度 21℃时，尿素箱温度却达 42℃，明显不符。没有尿素液位传感器的其他故障。
Symptom:
This car is the four countries test equipment like cars, urea level, temperature display is not accurate when
the little urea, urea level meter display 100%; with EOL measured at ambient temperature 21 ℃, urea tank
temperature has reached 42 ℃ , it is clearly incompatible. No other fault urea level sensor.
故障机理：
这种故障一般是因为尿素箱与潍柴指定产品不符导致，但也有特殊情况：比如线路电阻值过大，ECU
内阻过大或者其他电器故障。
Failure mechanisms:
Such failure is usually because of incompatible products specified Weichai urea tank and cause, but there
are special cases: for example, the line resistance value is too large, ECU internal resistance is too large, or other
electrical fault.
可能原因：
 尿素箱与潍柴指定产品不符；
 传感器相关线束内阻过大；
 ECU 传感器针脚两端内阻过大；
Possible Causes:
1) 检查尿素箱及传感器，核实是否为潍柴指定尿素箱；
2) 发现尿素箱正常，然后检查传感器线束：正常接通，电阻也正常；
3) 测量 ECU 尿素液位温度传感器 K57 和 K52、K80 和 K64 之间的电阻值均为 3.675kΩ，
明显高于旧 ECU 的内阻，测量多台新 ECU 后，内阻都 3.675kΩ
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4) 联系潍柴技术人员，发现新版 ECU 内阻都变成 3.675kΩ，但 ECU 内标定数据却没有
及时更新，所以需要刷写最新数据；
5) 刷写数据后，故障解决。（未来出厂的发动机 ECU 及数据都是最新的，所以不会再出
现这类故障）
1) Check the urea tank and sensor, verify that the specified Weichai urea tank;
2) found that the urea tank is normal, then check sensor harness: Normal ON resistance is also
normal;
3) Measure the resistance level of urea ECU temperature sensor K57 and K52, K80 and K64
values are between 3.675kΩ, significantly higher than the resistance of the old ECU, measuring
more than a new ECU, resistance are 3.675kΩ
4) Contact Weichai technicians found the new ECU resistance have become 3.675kΩ, but in
the ECU calibration data but does not update, you need to brush to write the latest data;
5) After writing brush data, troubleshooting. (Future factory engine ECU and the data is up to
date, so that such failures will not occur again)
结论：
ECU 内部电阻发生改变，但 ECU 数据没有重新标定，与新版 ECU 不符。当前，所有数据已经更新，
所以基本不会再有 ECU 内阻导致液位、温度不准的故障了。
另：遇到这样故障也可以使用 EOL 重新标定尿素液位温度传感器，标定方法参考上面内容。
尿素泵故障
尿素泵的故障主要有两个方面，机械故障与电器故障。电器故障一般指 12 孔接插件相关的电器件故
障，包括尿素泵电机、尿素压力传感器、换向阀及尿素泵加热电阻丝，故障率相对较高；机械故障指尿
素泵堵塞、尿素泵内部机械件故障引起的建压失败等。总之，与 SCR 尿素压力相关的故障，首先要检查
尿素管路是否接错、堵塞、泄露，尿素泵是否堵塞等。
in conclusion:
ECU internal resistance changes, but the ECU re-calibration data is not, and does not match the new ECU.
Currently, all of the data has been updated, so basically there will be no resistance ECU lead level, the
temperature must not broken down.
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Another: encountered such a failure can also use EOL recalibration urea level temperature sensor
calibration method with reference to the content above.
Urea pump failure
Urea pump failure has two main aspects, mechanical failure and electrical failure. Electrical fault generally
refers to the 12-hole connectors associated electrical device failures, including pump motor urea, urea pressure
sensor, valve and urea pump heating resistance wire, relatively high failure rate; mechanical failure refers urea
pump blocked, the internal mechanical pump urea component failure caused by failure to build pressure and the
like. In short, with the urea SCR stress-related failures, we should first check whether the urea line wrong,
blockage, leakage, urea pump is blocked and the like.
尿素换向阀执行高端开路——尿素泵 12 孔接插件退针
Urea perform high-end valve open - urea pump connector back needle hole 12
452 当前故障尿素换向阀执行高端开路 ——
451 当前故障尿素泵电机驱动开路 ——
故障现象：
故障灯、OBD 灯常亮，尿素不消耗。
Symptom:
Fault lights, OBD lights lit, do not consume urea.
故障机理：
尿素换向阀在尿素泵 12 孔接插件内，由 EDC17 控制，它的作用是：为防止尿素溶液残留在管路和
泵内，每次发动机熄火后，换向阀工作，90 秒内将管路内的尿素溶液倒吸回尿素箱。像这种同时报出多
个故障，且在同一个接插件内，接插件出现故障的可能行较大，比如锁片松动导致退针，或者接插件进
水等。
Failure mechanisms:
Urea in the urea pump valve connector hole 12 by EDC17 control, its role is: to prevent the urea solution
remaining in the piping and pumps after each engine flameout, valve work, the tube within 90 seconds urea
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solution within the suck back road urea tank. Like this quote both the multiple failures, and in the same
connectors, connector fault line may appear larger, such as the locking plate loose lead back needle, connector
or water and the like.
可能原因：
 接插件松动或退针；
 接插件进水；
 相关线束故障。
Possible Causes:
1) 检查尿素泵接插件；
2) 发现接插件内个别针脚退针；
3) 将退针的线束修复后，故障消除。
1) Check the urea pump connector;
2) found within individual connector pin back needle;
3) the needle back harness repair the fault eliminated.
结论：
尿素泵接插件退针，导致换向阀、尿素泵电机的开路故障。
in conclusion:
Urea pump connector back needle, leading to an open valve failure, urea pump motor.
SCR 尿素压力建立错误——尿素泵内部机械故障
SCR urea pressure build-up error - urea mechanical failure inside the pump
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441 当前故障 SCR 尿素压力建立错误 ——
故障现象：
每次跑车几分钟到几十分钟后，故障灯、OBD 灯常亮，就会报出 441（SCR 尿素压力建立错误）的
故障，尿素不消耗。
Symptom:
Each car a few minutes to tens of minutes after the fault light, OBD lights lit, it will report a 441 (SCR urea
pressure build error) failure, do not consume urea.
故障机理：
尿素喷射前，尿素泵将尿素建立到 9bar 的压力，通过尿素泵内的压力传感器进行检测。当发动机启
动之后，尿素泵多次尝试对尿素建压，如尿素压力仍达不到 9bar，就会报出此故障。此故障的导致原因
一般为：尿素量过少、尿素管路接反、吸液管堵塞或漏气、压力管泄露等，极少数是因为尿素泵故障。
Failure mechanisms:
Before the injection of urea, the urea urea establish 9bar pump pressure detected by the pressure sensor
inside the pump urea. When the engine starts, urea, urea pump several attempts to build pressure, such as urea
pressure still could not 9bar, this failure will be reported. The cause of this failure is generally: too small amount
of urea, urea pipeline reversed, pipette blockage or leak, leaking pressure pipes, etc., because of a handful of
urea pump failure.
可能原因：
 尿素量过少；
 吸液管接错、堵塞或漏气；
 压力管泄露；
 尿素泵堵塞或者尿素泵机械故障。
Possible Causes:
 urea pump mechanical failure.
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1) 检查尿素液位是否足量；
2) 检查尿素管路是否接错、接反；
3) 检查吸液管是否弯折、堵塞；
4) 检查吸液管、压力管是否存在泄露的痕迹；
5) 以上没有问题后，检查尿素泵接口是否有明显堵塞现象；
6) 更换尿素泵后，故障消除，尿素正常建压。
1) Check if a sufficient amount of urea level;
2) Check the urea pipe is wrong, reversed;
3) Check whether the pipette bent blockage;
4) Check the pipette, pressure pipes for leaks traces;
5) above is no problem, check whether the interface has obvious urea pump clogging;
6) After replacing the urea pump, failure to eliminate urea normal build pressure.
结论：
一般情况下，尿素管路接错、堵塞、泄露容易引起此故障，但这次的故障是因为尿素泵内部的机械
故障，无法正常吸尿素，导致建压失败。
喷嘴故障
喷嘴的结构相对简单，所以涉及到的故障也比较典型，主要有：
喷嘴电磁阀故障：接插件、线束损坏，造成开路、短路等；电磁阀线圈烧毁，可以通过测量电阻进
行判断。
喷嘴机械故障：由于添加的尿素质量差，或者喷嘴老化，造成尿素喷嘴磨损（往往会造成尿素消耗
高）；由于尿素结晶或其他颗粒物质进入，导致喷嘴堵塞；或由于其他原因，造成喷嘴变形、断裂等。
以上，凡是会影响尿素喷射及排放的故障，都有可能限制发动机扭矩。
in conclusion:
Under normal circumstances, urea pick the wrong line, clogging, leakage prone to this failure, but this
failure is due to a mechanical failure inside the pump urea, urea absorption can not be normal, resulting in
failure to build pressure.
Nozzle failure
Nozzle structure is relatively simple, involving the failure also typical, are:
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Nozzle solenoid valve failure: connectors, wiring harness damage, resulting in open circuit, short circuit;
solenoid valve coil burned, can be judged by measuring the resistance.
Nozzle mechanical failure: due to the addition of the difference between urea quality or nozzle aging,
resulting in urea nozzle wear (often caused by urea high consumption); Because urea crystals or other
particulate matter to enter, resulting in nozzle clogging; or for other reasons, causing the nozzle deformation,
fracture.
Above, that may affect the breakdown of urea injection and emissions are likely to limit engine torque.
SCR 尿素喷嘴驱动高端对电源短路——喷嘴针脚线束故障
SCR urea nozzle drive high-end short to power - nozzle pin wiring harness malfunction
453 当前故障 SCR 尿素喷嘴驱动高端对电源短路 P2049
故障现象：
故障灯、OBD 灯常亮，并报出 453（SCR 尿素喷嘴驱动高端对电源短路）的故障。
Symptom:
Fault lights, OBD lights lit, and report to the 453 (SCR urea nozzle driving high-end short to power)
failure.
故障机理：
尿素喷嘴电磁阀有两个针脚，K09、K10 对应接插件编号 2、1，，K10 指电磁阀的驱动高端，K09
驱动低端。此故障指的就是 K10 针脚与电源短路，请检查 K10 接插件及线束。
Failure mechanisms:
Urea nozzle solenoid valve has two pins, K09, K10 correspond connector number 2,1,, K10 means high
drive solenoid valve, K09 driving the low end. This failure refers to K10 pins short to power, please check the
K10 connector and wiring harness.
可能原因：
 接插件故障，导致 K10 电源短路；
 K10 相关线束故障，导致与外部电源短路。
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Possible Causes:
 y short circuit;
1) 检查喷嘴接插件，没有损坏或短路；
2) 测量 K10 针脚电压，约 24V，超出正常范围；
3) 检查整车线束大插头，发现喷嘴 K10 线束与其他带电线束短路；
4) 修复线束后，故障消除。
1) Check the nozzle connector, no damage or short circuit;
2) measuring the K10 pin voltage is about 24V, outside the normal range;
3) Check the vehicle harness large connector found nozzle K10 harness and other live harness short
circuit;
4) After the repair wiring harness, the failure to eliminate.
结论：
整车线束大插头中的喷嘴线束（K10）与电源短路。
in conclusion:
Harness vehicle wiring harness large connector nozzle (K10) and short to power.
尿素消耗量较大——添加劣质尿素，导致喷嘴磨损泄露
Large consumption of urea - urea adding inferior, resulting in leakage of the nozzle wear
—— —— —— ——
故障现象：
客户反应，尿素消耗量偏高，与燃油消耗比远大于 1/20。没有他其他相关故障。
Symptom:
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Customer response, high consumption of urea, and fuel consumption ratio is much larger than 1/20.
Without his other faults.
故障机理：
如果没有报故障，能说明后处理系统的线束、电器件等基本正常。可能出现的原因就是：尿素管路
泄露、尿素泵泄露、尿素箱泄露等，还有就是尿素喷嘴磨损，导致尿素从喷嘴处泄露。
Failure mechanisms:
If not reported fault, can explain treatment system wiring harness, electrical parts and other normal.
Possible reason is: urea pipeline leaks, leaking pump urea, urea tank leaks, etc., there is a urea nozzle wear,
resulting in leakage of urea from the nozzle.
可能原因：
 管路及相关电器件出现尿素泄露；
 喷嘴磨损，导致尿素喷射量增加。
Possible Causes:
 nt.
1) 检查尿素箱、尿素泵、尿素管路等是否有尿素泄露的痕迹；
2) 如果没有尿素泄露，就启动车辆，使车辆保持较高功率运行，使排气温度达到尿素泵
建压的最低温度 200℃，EOL 检测尿素泵压力直到稳定在 9bar 左右；
3) 发动机不要熄火，保持发动机继续怠速运行；
4) 将尿素喷嘴取出排气管，观察喷嘴是否有泄露情况；
5) 更换新的尿素喷嘴后，故障解决。
1) Check the box urea, urea pumps, piping, etc. Is there a urea urea leak traces;
2) If there is no leakage of urea, to start the vehicle, the vehicle to maintain a high power
operation, the exhaust gas temperature reaches a minimum temperature of urea pump voltage
build 200 ℃, EOL detection urea pump until the pressure stabilized at around 9bar;
3) Do not turn off the engine, keep the engine continues to run at idle;
4) remove the urea nozzle exhaust pipes, nozzles for leaks observe the situation;
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5) Replacement of the urea nozzle, troubleshooting.
结论：
车主因为添加了劣质尿素，导致喷嘴磨损严重，柱塞密闭性差，有泄露尿素的现象。
in conclusion:
Owners because of poor quality of urea is added, resulting in serious wear nozzle, plunger tightness is poor,
there is leakage of urea phenomenon.
SCR 箱及排气管故障
SCR 箱内有载体和催化剂，如果发生故障可能会造成排放不达标，限制发动机扭矩等。主要有以下
几类：
催化剂失效：由于 SCR 箱被撞击，或者被其他物质污染覆盖（比如黑烟中的颗粒），造成催化还原
效率降低，最终造成排放不达标，限制发动机扭矩；
SCR 箱堵塞：SCR 箱变形或因其他原因堵塞，造成排气背压高，严重者会出现冒黑烟、发动机转速
抖动、动力不足等故障，同时排放也会受到影响。
排气管被腐蚀：由于尿素溶液具有腐蚀性，所以我们要求排气管使用不锈钢材料，且内表面光滑，
尽可能减少排气管焊接口。如果排气管不能满足以上要求，就有可能造成尿素在排气管上残留、腐蚀，
造成排气管损坏。
SCR tank and exhaust pipe failure
SCR catalyst carrier and inside there, if a failure occurs may cause emissions of non-compliance, limit
engine torque and the like. Mainly the following categories:
Spent catalyst: Because SCR tank is hit, or contamination by other substances covered (such as black
smoke particles), resulting in reduced efficiency of the catalytic reduction, ultimately resulting in emissions of
non-compliance, limit engine torque;
SCR box blockage: SCR box deformed or otherwise blocked, resulting in high exhaust back pressure, there
will be serious black smoke, the engine speed jitter, lack of motivation, such as failure, but emissions will also
be affected.
Exhaust pipe corrosion: Because urea solution is corrosive, so we require the use of stainless steel exhaust
pipes and smooth inner surface to minimize exhaust pipe welding mouth. If the exhaust pipe can not meet the
above requirements, it may cause residual urea in the exhaust pipe, corrosion, resulting in damage to the exhaust
pipe.
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排气管生锈、腐蚀——排气管没有按照潍柴要求进行加工、安装
Exhaust pipe rust, corrosion - no exhaust pipe in accordance with Weichai requirements for processing,
installation
—— —— —— ——
故障现象：
客户反馈，排气管约 1 个多月时间就腐蚀坏掉，更换排气管后仍然如此。
Symptom:
Customer feedback, the exhaust pipe of about more than one month time to corrosion broken, remains so
after the replacement of the exhaust pipe.
故障机理：
尿素溶液有很强的腐蚀性，所以喷嘴下游排气管的加工要求：材料为不锈钢，内表面非常光滑，且
不允许有焊接痕迹，减少管路接口。如果达不到以上要求，就容易造成尿素残留，腐蚀排气管。
Failure mechanisms:
Urea solution has a strong corrosive, so the processing requirements downstream of the nozzle exhaust
pipe: made of stainless steel, the inner surface is very smooth, and does not allow any traces of welding,
reducing line interface. If you can not reach the above requirements, it is easy to cause urea residues, corrosion
of the exhaust pipe.
可能原因：
 排气管材料问题，抗腐蚀性差；
 排气管内表面不光滑，造成尿素残留结晶；
 排气管内部有焊接痕迹；
 排气管连接口较多。
Possible Causes:
ea crystallization;
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1) 检查排气管是否符合加工安装要求；
2) 发现排气管为普通铁，且加工粗糙；
3) 更换符合标准的排气管后，故障消除。
1) Check the exhaust pipe installation meets the requirements of the processing;
2) found that the exhaust pipe of ordinary iron and rough machining;
3) Replace the standard exhaust pipe, failure to eliminate.
结论：
此故障就是因为排气管的加工、安装不符和潍柴要求导致。为避免这类故障，潍柴推出了集成式 SCR
箱，参见第一章的介绍。
in conclusion:
This failure is because the exhaust pipe processing, installation and does not match the requirements of
Weichai lead. To avoid such failures, Weichai launched integrated SCR box, see the introduction of the first
chapter.
SCR 箱实际平均转换效率低于阈值 1（阈值 2）—— SCR 箱老化和结晶
SCR box actual average conversion efficiency lower than the threshold value 1 (threshold 2) - SCR tank aging
and crystallization
431 当前故障 SCR 实际平均转换效率低于阈值 1，排放 P0420

超5
432 当前故障 SCR 实际平均转换效率低于阈值 2，排放 P0420
超7
故障现象：
故障灯、OBD 灯常亮，尿素喷射正常，没有其他相关故障。
Symptom:
Fault lights, OBD lights lit, urea injection is normal, there is no other fault.
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故障机理：
这两个故障是指尾气中 NOx 浓度较大，已经超出了国四法规要求。如不及时修复，就会导致发动机
扭矩限制。
Failure mechanisms:
This fault is two large exhaust NOx concentration, the four countries have exceeded regulatory
requirements. If not repaired in time, it will cause the engine torque limit.
可能原因：
 发动机原始排放劣化：后处理系统上游，从增压器出来后的尾气的排放太差；
 SCR 箱劣化，导致转换效率低；
 尿素喷射量误差大，实际喷射量比设定值少；
 油品不好。
Possible Causes:
-treatment system from the turbocharger
exhaust emissions out after bad;
1) 首先检查、判断发动机原始排放是否严重恶化，比如严重冒黑烟等；
2) 检验油品是否合格；
3) 检查尿素喷嘴是否堵塞、泄露，导致喷射量控制不准；
4) 检查 SCR 箱是否老化或结晶，是否被炭烟覆盖、堵塞等；此车 SCR 箱使用时间较长，
内有较多结晶物，覆盖了催化剂导致转化效率低；
5) 更换新的 SCR 箱后，故障消除。
1) first checks to determine whether the serious deterioration of the engine raw emissions, such as severe black
smoke and the like;
2) test oil is qualified;
3) Check the urea nozzle clogging, leakage, resulting in the injection quantity control are not allowed;
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4) Check the box if SCR aging or crystallization, would have been covered with soot, clogging; this car SCR
tank using a longer time, there are more crystals, covering the catalyst resulting in low conversion efficiency;
5) After replacing the SCR tank, failure to eliminate.
结论：
此故障是因为 SCR 箱老化、结晶，导致转化效率低，从而排放不达标。有时，尿素喷射量过少，明
显低于设定值（比如因为喷嘴故障），也会引起此故障。
in conclusion:
This failure is because the SCR tank aging, crystallization, resulting in low conversion efficiency, and
emissions of non-compliance. Sometimes, the urea injection amount is too small, significantly lower than the
set value (such as nozzle failure), can also cause this problem.
尿素管路故障
后处理系统共包括 3 段尿素管路，最容易出现 3 类故障：管路堵塞、管路泄露及管路弯折。
管路堵塞：一般由于尿素结晶或者尿素质量差引起，会影响尿素喷射和建压，造成排放不达标；
管路泄露：原因主要两种，管路接口型号不符或者接口密封不好，导致尿素泄露；管路老化或磨损，
造成尿素泄露。
管路弯折：管路弯折会造成尿素建压失败或者喷射故障，导致排放不达标。
Urea fault line
Aftertreatment system includes a total of 3 section of the urea line, the most prone to failure three
categories: line blockage, leaking pipes and pipe bending.
Pipe blockage: Usually due to poor quality of urea or urea crystals caused, and will affect the construction
of a urea injection pressure, resulting in emissions of non-compliance;
Pipeline leak: two main reasons, the line does not match the interface type or interface seal is not good,
resulting in leakage of urea; pipeline aging or wear and tear, resulting in leakage of urea.
Pipe bending: bending pipe causes pressure to build urea injection failure or malfunction, resulting in
emissions of non-compliance.
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SCR 尿素压力建立错误—— 压力管路泄露
SCR urea pressure build-up error - pressure pipeline leak
441 当前故障 SCR 尿素压力建立错误 ——
故障现象：
故障灯、OBD 灯常亮，NOx 排放超标，尿素不能正常喷射。
Symptom:
Fault lights, OBD lights lit, NOx emissions exceeded, urea is not normal injection.
故障机理：
当排气管温度达到建压的最低温度时，尿素泵就开始尝试建压，并检测所有尿素管路及尿素泵、喷
嘴是否存在泄露或堵塞的故障。如果长时间尿素压力达不到 9bar，ECU 就怀疑有尿素泄露，并报出此故
障，后处理系统停止工作。
Failure mechanisms:
When the exhaust pipe temperature reaches a minimum temperature build pressure, urea pump began to try
to build pressure, and detects all of urea and urea pump piping, nozzles for leaks or blockage fault exists. If the
pressure is less than urea long 9bar, ECU suspected leak of urea, and report out this failure, post-processing
system to stop working.
可能原因：
 尿素管路接错，或吸液管有尿素泄露；
 压力管有泄露；
 尿素泵故障
Possible Causes:
1) 检查吸液管是否有接错、泄露、弯折的地方；
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2) 检查压力管是否泄露；
3) 发现，压力管与尿素泵接口密封较差，有尿素泄露；
4) 重新连接、加固后，再次跑车后，故障消失。
1) Check whether the pipette wrong, leakage, bending place;
2) Check pressure pipe for leaks;
3) found that pressure pipes and urea pump interfaces poorly sealed, leak urea;
4) Reconnect, after reinforcement, after the car again, the fault disappears.
结论：
尿素压力管泄露，导致尿素泵内压力迟迟达不到 9bar，所以就报出此故障。一般情况，管路的泄露
或堵塞容易引起此故障，如果确认管路正常后，不排除尿素泵本身故障。
in conclusion:
Urea pressure tube leak, resulting in delays in the pump pressure urea reach 9bar, so we reported this fault.
Generally, pipeline leaks or blockage likely cause of this failure, if confirmed pipeline is normal, do not rule out
urea pump itself is faulty.
上次驾驶循环 SCR 未排空—— 司机操作故障
Not emptying the last driving cycle SCR - operating fault driver
447 当前故障上次驾驶循环 SCR 未排空 ——
故障现象：
司机 T15 上电后，故障灯、闪码灯常亮，读取闪码 447（上次驾驶循环未排空），之前没有此故障
的。
Symptom:
The driver T15 after power failure lights, flash lights lit code, read flash code 447 (the last drive cycle is
not empty), not before this failure.
故障机理：
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为防止尿素残留在管路和泵内结晶，造成堵塞或对尿素泵造成损坏，要求司机熄火后，90 秒内不得
切断整车电源。在这 90 秒内，尿素泵继续工作，将管路、尿素泵内的尿素倒吸回尿素箱。如果司机没有
按照要求操作，比如过早关闭整车开关，就会导致此故障。
Failure mechanisms:
Urea remaining in the pipeline and the pump crystallization, causing blockage or damage to the pump urea,
asked the driver to turn off after prevention can not cut off the vehicle power supply within 90 seconds. In those
90 seconds, urea pump continues to operate, the tubing, pump the urea urea urea suck me back. If the driver
does not operate according to requirements, such as premature closure of the vehicle switch will cause this
failure.
可能原因：
 司机违规操作；
Possible Causes:
1) 询问司机上次驾驶熄火后，是否等到 90 秒后才关闭的整车开关；
2) 司机关闭整车开关过早，没有达到 90 秒；
3) 再次启动后，下次驾驶循环熄火后，司机正确操作，故障消除。
1) ask the driver to drive after the last flame, whether to wait 90 seconds before switching off
the vehicle;
2) Close the vehicle driver switch prematurely, did not reach 90 seconds;
After starting 3) again after the next drive cycle stall, the driver for correct operation, failure to
eliminate.
结论：
发动机熄火后，司机应该 90 秒后再关闭整车电源开关。在温度较高时，此故障影响不大，但如果在
冬天温度较低时，有可能导致残留在管路、尿素泵内的尿素结晶，造成堵塞甚至损坏尿素泵。
in conclusion:
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After the engine flameout, the driver should turn off 90 seconds after the vehicle power switch. At higher
temperatures, this failure has little effect, but if the winter at low temperatures, may cause residual urea crystals
in the pipelines, pump urea, urea clog or even damage the pump.
传感器相关故障
Sensor related failures
这里的传感器主要指上游排气温度传感器、环境温度传感器和 NOx 传感器。
Here mainly refers to the upstream exhaust sensor temperature sensor, ambient temperature sensor and
NOx sensor.
上游排气温度传感器和环境温度传感器：主要有两类故障，一类是传感器电压信号高于上限或者低
于下限，高于上限一般是由于线束、接插件开路或与电源短路引起，低于下限一般是线束、接插件与地
短路引起；另一类是温度示数不准，这时候就要考虑传感器安装是否到位，安装位置是否合适，或者传
感器是否损坏。环境温度传感器有故障时，会影响尿素的加热功能，造成尿素结晶、尿素泵堵塞等，上
游排温传感器出现故障时会造成尿素喷射控制失效，尾气排放不达标等。总之，所有造成排放不达标的
故障，如果不及时修复，都将导致扭矩限制。
Upstream of the exhaust gas temperature sensor and the ambient temperature sensor: There are two types
of fault, one is the sensor voltage signal is above or below the upper limit, above the upper limit is generally due
to the wiring harness, connectors, open or short circuit caused the power supply, below the lower limit general
wiring harness, connectors and ground short circuit; the other is the number of allowed temperature shown, this
time we should consider whether the sensor is mounted in place, the installation location is appropriate, or the
sensor is damaged. When the ambient temperature sensor is faulty, it will affect the heating function of urea,
urea resulting crystals urea pump blockage can cause failure of the urea injection control, exhaust emissions of
non-compliance and other upstream exhaust temperature sensor failure. In short, all the emissions that cause the
failure of non-compliance, if not repaired in time, will lead to a torque limit. .
NOx 传感器：这个传感器出现故障时，测得的氮氧浓度无法经过 AT101 报文发送给 EDC17，就会
报出“AT101 报文超时的故障”，一般主要是由于接线问题引起：NOx 传感器有 4 根线连接整车线束，分
别为电源正、电源负、通讯 CAN 地、通讯 CAN 高，请检查这四根线束及及插件的电压是否正常，线束、
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接插件是否有开路、短路等故障。在保证线束、接插件没有故障的前提下，可以怀疑 NOx 传感器是否损
坏，尝试更换 NOx 传感器进行确认。
NOx Sensor: When the sensor fails, the nitrogen-oxygen concentration can not be measured through
AT101 packet to EDC17, will report a "AT101 packet timeout failure", the general is mainly due to wiring
problems caused by: NOx sensor There are four cable vehicle wiring harness, power supply, respectively
positive and negative power supply, communication CAN, the CAN communication is high, check the voltage
and these four harness and plug-ins is normal, wire harnesses, connectors if there is an open, short circuit fault.
In ensuring the wiring harness, connectors no fault of the premise, you can suspect the NOx sensor is damaged,
try to replace the NOx sensor to confirm.
SCR 催化剂上游温度传感器电压信号高于上限—— 上游排温传感器线路开路
SCR catalyst upstream temperature sensor signal voltage is higher than the upper limit - the upstream exhaust
temperature sensor wire open
—— 当前故障 SCR 催化剂上游温度传感器电压信号高 ——

于上限
故障现象：
故障灯、闪码灯常亮，报出 SCR 催化剂上游温度传感器电压信号高于上限故障，使用 EOL 测量上
游排气温度，示数明显不准确，且不变化。
Symptom:
Fault lights, flashing lights lit, reported SCR catalyst upstream temperature sensor voltage signal is higher
than the upper limit of failure, use EOL measured upstream exhaust gas temperature, the indication is obviously
not accurate and does not change.
故障机理：
上游排气温度传感器及相关线路、接插件故障，导致传感器开路。当检测到此故障时，EOL 测得的
上游排气温度为默认值。
Failure mechanisms:
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Upstream of the exhaust gas temperature sensor and related wiring, connectors failure, resulting in open
sensor. When this fault is detected, EOL measured upstream of the exhaust gas temperature to the default
values.
可能原因：
 上游排温传感器接插件、线路开路；
 传感器老化、损坏；
 传感器 ECU 大插头线路故障，导致传感器开路；
Possible Causes:
1) 检查上游排温传感器接插件；
2) 检查传感器线束是否正常导通；
3) 发现传感器线束由于磨损导致断开，接好后正常，故障消除。
Practical solutions and procedures：
1) Check the upstream exhaust temperature sensor connector；
2) Check the sensor harness is normal conduction；
3) found that sensor harness due to wear resulting in disconnection, connect the normal, the fault is
cleared。
结论：
所有报出“传感器电压高于上限”的故障，基本都是指传感器开路（极少情况是与电源短路引起），
一般要检查接插件、线束是否正常导通，传感器是否漏接等。此故障，是因为传感器线束与底盘长时间
摩擦，导致线路中断。
In conclusion：
All reported "sensor voltage above the upper limit," the fault, basically refers to the open sensor (in rare
cases cause a short circuit and power supply), to check the general connectors, wiring harness whether normal
conduction, the sensor is bobble like. This failure is because the sensor harness and chassis long friction,
causing the line break.

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环境温度信号不可信—— 环境温度传感器安装位置错误
Ambient temperature signal implausible - ambient temperature sensor installed in the wrong place
235 当前故障环境温度信号不可信 ——

code
235 The current Ambient temperature signal can not be ——
fault trusted
故障现象：
车辆运行一段时间后，故障灯、闪码灯常亮，并爆出 235（环境温度信号不可信）的故障。
Fault phenomenon：
After the vehicle running for some time, fault lights, flashing lights lit, and burst 235 (ambient temperature
signal untrusted) fault.
故障机理：
环境温度用来测量当前的大气温度，如果 ECU 检测环境温度明显不符，比如过高或者过低，就会报
出此故障。此故障的导致原因一般为：环境温度传感器安装位置错误（比如装在发动机仓内，离热源太
近）、传感器线路电阻异常、传感器本身故障。
Failure mechanism：
Ambient temperature for measuring the current temperature of the atmosphere, if the ECU detects the
ambient temperature does not match the obvious, such as too high or too low, this failure will be reported. The
cause of this failure is usually: ambient temperature sensor is installed in the wrong place (for example, installed
in the engine compartment, near heating), abnormal sensor line resistance, the sensor itself is faulty.
可能原因：
 环境温度传感器的安装位置错误；
 传感器的线路电阻太大；
 环境温度传感器损坏；
Possible Causes：
 Mounting position Ambient temperature sensor error；
 The sensor circuit resistance too big；

127
 Ambient temperature sensor is damaged；
1) 检查环境温度传感器安装位置是否符合要求；
2) 发现传感器在发动机仓内，且距离发动机太近；
3) 按照要求，调整环境温度传感器安装位置后，故障消除。
1) Check the ambient temperature sensor mounting location meets the requirements；
2) sensor found in the engine compartment, and the distance too close to the engine；
3) as required, to adjust the ambient temperature sensor mounting position, failure to eliminate。
结论：
环境温度传感器安装位置错误，不仅会报出此故障，还可能影响尿素箱及管路的加热功能。安装要
求参考传感器章节。
In conclusion：
An ambient temperature sensor is installed in the wrong place, not only reported this fault may also affect
the urea tank and pipe heating. Installation Requirements section reference sensor.
CAN 接受帧 AT101 超时错误—— 氮氧浓度传感器接线错误
CAN receive frames AT101-out error——Nitrogen-oxygen concentration sensor wiring error.
421 当前故障 CAN 接收帧 AT101 超时错误 ——

code
421 The current CAN receive frames AT101-out error ——
fault
故障现象：
闪码灯、OBD 灯常亮，并报出 421（CAN 接受帧 AT101 超时错误）。
Fault phenomenon：
Flash code lights, OBD lights lit, and report to the 421 (CAN accept frames AT101-out error).
故障机理：
氮氧浓度传感器测得 NOx 浓度后，不断地将测量结果通过 CAN 总线中的 AT101 报文发送给 ECU，
如果 ECU 接收不到 AT101 报文，就会报出此故障。

128
Nitrogen-oxygen concentration sensor after the NOx concentration measured continuously the
measurement results via the CAN bus of the packets sent to the ECU AT101, AT101 if the ECU does not receive
the packet, this failure will be reported.
可能原因：
 氮氧传感器接线故障，导致 AT101 没有发送出去；
 氮氧传感器损坏；
 CAN 总线网络故障；
Possible Causes：
 nitrogen oxygen sensor wiring failure, causing AT101 was not sent；
 nitrogen oxide sensor is damaged；
 CAN bus network fault；
1) 检查氮氧传感器中 4 根针脚电压（1、2、3、4 号针脚应分别为 24V、0V、2.2V、2.8V），
判断是否存在接错、开路、短路等故障；
2) 发现接插件中，1 号电源针脚电压为 0，不正常；
3) 将 1 号电源接好后，故障消除。
1) Check the nitrogen-oxygen sensor voltage 4-pin (pins 1,2,3,4 should respectively 24V, 0V, 2.2V,
2.8V), determine whether there is wrong, open circuit, short circuit fault；
2) connectors found in the No. 1 power supply pin voltage is 0, abnormal；
3) The power supply 1 is connected, the fault is cleared。
结论：
遇到这样的故障，首先检查氮氧传感器各接线是否正常。如果接线正常，可尝试更换氮氧传感器，
检查氮氧传感器是否损坏。
In conclusion：
129
Encountered such a failure, first check the wiring nitrogen oxygen sensor is normal. If the wiring is normal, try
to replace the nitrogen-oxygen sensor, NOx sensor check for damage.
加热系统故障
加热系统包括水加热和电加热，其中电加热由于继电器较多（5 个）、线束较多、加热电阻丝较多，
所以故障率较高。主要表现为继电器损坏、加热电阻丝开路及线束开路、短路等。
eating system failure
Heating system consists of water and electric heating, electric heating which more since the relay (5),
harness more resistive heater, which is why a high failure rate. Mainly for relays damaged, open and heated
resistance wire harness open circuit, short circuit and so on.
参考上图，五个继电器共用电源输出针脚 K90（ECU 常供电 24V），T15 上电后的初期，ECU 会对
电加热系统进行故障自检：
With reference to the map, five common power supply relay output pins K90 (ECU constant power supply
24V), the initial T15 after power, ECU electric heating system will self-test fault：
130
加热电阻丝的故障自检 1：首先，继电器 1 闭合（K94 变为 0V），其他继电器全部保持断开状态（控
制针脚电压与 K90 电压相同，都为 24V），正常情况下，K58、K36、K20、K33 的电压约 24V。如果测
得某一跟管路的电压不正常，就会报出相关管路“加热电阻丝无负载”或“加热电阻丝短路”等故障，需检
查各加热电阻丝、及 K58、K36、K20、K33 是否出现开路、短路等故障；
Heating resistance wire fault detection 1: First, relay 1 is closed (K94 becomes 0V), all other relay stays
open (voltage control pins K90 same voltage are 24V), under normal circumstances, K58, K36, voltage K20,
K33 about 24V. If measured with a line voltage is not normal, it will report the associated piping "resistive
heater no load" or "resistive heater short circuit" faults, the need to check the heating resistance wire, and K58,
K36, K20 , K33 whether there is open circuit, short circuit fault;
继电器故障检测：ECU 能够检测各继电器是否正确安装，如果继电器漏装、损坏或线路故障，就
会报出“某尿素管路加热继电器开路、短路等”故障，这时就要检查相关继电器、线束及接插件是否正
常。
Relay Fault detection: ECU can detect the relay is installed correctly, if the relay missing equipment,
damage, or line failure, will be reported "a urea pipe heating relay opens, shorts and other" fault, then we should
check the relevant relays, wiring harness and connectors are normal.
水加热的故障主要有：水加热电磁阀线束、接插件故障；水加热电磁阀机械故障，比如磨损、卡死
等，可能会导致尿素箱加热失效、尿素箱温度过低；也有可能导致尿素箱持续加热、尿素温度过高，尿
素挥发导致排放不达标；水加热管路弯曲、堵塞，管路及接口泄露、堵塞等，会造成加热失效或冷却液
泄露。
131
Water heating failures are: water heating solenoid valve wiring harness connector failure; water heating
solenoid valve mechanical failure, such as wear, seizure, etc., may result in a urea tank heating failure, urea tank
temperature is too low; could also lead to a urea tank continuous heating, the temperature is too high urea, urea
volatilization resulting in emissions of non-compliance; water heating pipe bending, clogging pipes and
interface leakage, blockage can cause failure of the heating or cooling fluid to leak.
尿素箱过度加热—— 尿素箱水加热电磁阀卡死
Urea tank overheating——Urea tank water heating solenoid valve stuck
446 当前故障尿素箱过度加热 P2043

code
446 The current Urea tank overheating P2043
fault
故障现象：
跑车一段时间后，闪码灯、OBD 灯常亮，并报出 446（尿素箱过度加热）故障。
Fault phenomenon：
After the car for some time, the flash code lights, OBD lights lit and report 446 (urea tank overheating)
fault。
故障机理：
尿素箱通过发动机冷却液进行加热，由 EDC17 控制水加热的电磁阀。由于尿素 75℃易挥发，所以
尿素箱的温度不可以太高。如果水加热电磁阀不能正常关闭，导致发动机冷却液一直对尿素箱加热，就
可能导致尿素箱温度过高，并报出此故障；其他导致尿素箱温度高的原因，也会报出此故障。
Urea tank is heated by the engine coolant water is heated by the EDC17 control solenoid valve. Since urea
75 ℃ volatile, so the urea tank temperature is not too high. If the water is heated solenoid valve can not be
shut down, causing the engine coolant has been on the urea tank is heated, it could lead to a urea tank
132
temperature is too high, and report out this failure; other causes urea tank temperature is high, this failure will
be reported.
可能原因：
 尿素箱水加热电磁阀卡死，处于常开状态；
 尿素箱温度传感器故障。
Possible Causes：
 urea tank water heating solenoid valve stuck, in a normally open state；
 urea tank temperature sensor failure。
1) 检查尿素箱的实际温度，确定温度传感器的真实性；
2) 检查尿素箱水加热电磁阀，发现处于常开状态；
3) 更换新的尿素箱水加热电磁阀后，故障消除。
1) Check the actual temperature of the urea tank, to determine the authenticity of the temperature
sensor；
2) Check the urea tank water heating solenoid valve found in a normally open state；
3) replacement of the urea tank water heating solenoid valve, the fault is cleared。
结论：
水加热电磁阀卡死，或者水加热电磁阀选错为常开型（应该为常闭），就可能导致尿素箱温度过高。
In conclusion：
Water heating solenoid valve stuck, or the wrong water heating solenoid valve is normally open (must be
normally closed), it could lead to a urea tank temperature is too high.
尿素管加热继电器开路—— 尿素管路及尿素泵加热继电器漏装
Water heating solenoid valve open- urea and urea pump heating pipeline leak relay means
461 当前故障尿素管加热继电器开路 ——
133
463 当前故障尿素加热主继电器开路 P3043
465 当前故障尿素泵加热继电器开路 P3033

code
461 Urea tube heating relay opens ——
The current
fault
463 Urea primary heating relay opens P3043
The current
fault
465 Urea pump heating relay opens P3033
The current
fault
故障现象：
故障灯、OBD 灯常亮，并报出尿素加热主继电器、尿素管路加热继电器、尿素泵加热继电器开路的
故障。
Fault phenomenon：
Fault lights, OBD lights lit and reported the main relay heating urea, urea pipe heating relay, open relay
urea pump heating failure.
故障机理：
继电器 1 就是“尿素加热主继电器”，继电器 2、3、4 是“尿素管路加热继电器”，继电器 5 是“尿素泵
加热继电器”，如果以上继电器漏装或线路损坏，就会报出开路的故障。
Failure mechanism ：
Relay 1 is the "primary heating urea relay" relay 2,3,4 is "urea pipe heating relay", relay 5 is "urea pump
heating relay", if the above relay missing equipment or wiring damage, will be reported in the open
malfunction.
可能原因：
 继电器漏装；
 继电器相关线束、接插件故障。
Possible Causes：
 Relay missing equipment；
 relay associated wiring harness, connectors fault。
1) 检查以上 5 个继电器安装情况；
134
2) 将 5 个继电器正确安装后，故障消除。
1) Check the installation more than five relay；
2) After the five relays installed correctly, the fault is cleared。
结论：
后处理的电加热部分包括 5 个继电器，4 段加热电阻丝。5 个继电器漏装或出现线路故障，就会报出
相应故障。
In conclusion：
Electric heating portion after the treatment including five relays, 4-stage heating resistance wire. 5 relay
missing equipment or line failure occurs, it will report the corresponding fault.
尿素管加热电阻丝开路—— 尿素管路及尿素泵加热电阻丝漏装
Urea resistance wire heating pipe open - urea and urea pipeline pump heating resistance wire missing
equipment
464 当前故障尿素管加热电阻丝开路 ——
465 当前故障尿素泵加热电阻丝开路 P3083

code
464 The current Urea pipe heating resistance wire open ——
fault
465 The current Urea pump heating resistance wire open P3083
fault
故障现象：
故障灯、OBD 灯常亮，并报出尿素管加热电阻丝、尿素泵加热电阻丝开路的故障。
Fault phenomenon：
Fault lights, OBD lights lit and reported the urea tube heating resistance wire, resistance wire heating urea
pump open circuit failure.
故障机理：
135
如果尿素管路、尿素泵仅仅接了加热继电器，而没有连接加热电阻丝，或者电阻丝没有完全按照针
脚图要求连接，ECU 也能够检测出此故障。
If urea line, urea pump heating only pick up the relay, but not connected to the resistance heating wire,
resistance wire or pin is not completely in accordance with the requirements of the connection diagram, ECU
can detect the failure.
可能原因：
 加热电阻丝漏接；
 K58、K36、K20、K33 没有按照针脚图接线，或者有开路的故障。
 其他接线没有完全按照针脚图接线要求。
Possible Causes：
 resistive heater bobble；
 K58、K36、K20、K33 not in accordance with the pin wiring diagram, or open circuit failu。
 other wiring diagram is not fully in accordance with the pin wiring requirements。
1) 检查电阻丝是否安装；
2) 正确连接电阻丝，保证 K58、K36、K20、K33 也连接正确，故障消除。
1) Check the resistance wire is installed；
2) resistance wire is properly connected to ensure K58, K36, K20, K33 are connected correctly, the fault
is cleared.
结论：
ECU 不仅能检测加热继电器故障，也能检测加热电阻丝的故障，如漏接加热电阻丝，或 K58、K36、
K20、K33 接线错误，就报出此故障。
In conclusion:：
ECU can detect not only the heating relay failure, can also detect resistive heater failure, such as bobble
resistive heater, or K58, K36, K20, K33 wiring error, reported this fault.
136
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蓝擎 WP12 系列柴油机维修手册

Weichai Power Co., Ltd

Landking WP12.440 Diesel Engine

operation and maintenance routine rules in this manual;

○ 本柴油机出公司时已按试验规范严格进行出公司试验，不得随意调整 ECU 数据，加大柴油机功

can not disassemble it

○ 重要螺栓限制使用次数（如 WP12 系列柴油机连杆螺栓为一次性使用螺栓），不得超过限定次数重

bolt can only be used for one time)

应立即停车（特殊情况除外），应低速运转 5～10 分钟后停车；

operator from our maintenance station

later,the engine should be checked and adopted necessary complement measures.

本手册主要包括 WP12 柴油机使用中注意事项﹑维护保养方法﹑常用的检查调整及常见故障的诊断

users do not arbitrarily disassemble adjustment.

本手册所介绍的为蓝擎 WP12 系列柴油机基本机型。随着产品的开发、改进与新产品的不断投产，

distributors) go to our net http://www.weichai.com for latest production information.

Welcome user’s further suggestions for modification of products.

标记说明 Label Definitions

Chapter I Diesel engine instructions for use

1.1 WP12 系列柴油机型号含义

燃料代号 Fuel code

变形代号 Engine modification code

排放阶段代号 Emission tier code

产品系列代号 Product series code

磨合促进剂的机油时建议用户行驶 2000km（或运行 50 小时）后放出旧油换新油。

却液性能，如果防冻能力是满足-30 C 或-35 C 的，其 PH 值为 7~8（中性），总硬度值为

Inspect oil level

运转，要先怠速运转一段时间，但怠速运转时间不能过长。Press down clutch pedal and accelerator pedal, turn the

出水温度高于 60 C ，机油温度高于 50 C 时才允许进入全负荷运转。负荷和转速的增加应逐渐进行，尽

的 110%运转，则最多允许 20 分钟。柴油机在卸负荷之后应怠速运转 1~2 分钟方可停车。

Pressure of main oil passage: 350~500 kPa.

Temperature of oil in sump: < 110℃.

Temperature of coolant outlet: 80+5℃ , not exceeding 95℃.

Temperature after turbine: < 600℃.

Inlet temperature after intercooler: 50~55℃.

The operator should acknowledge the following features of diesel engine:

Oil: According to the season, select the oils of different viscosity.

6、 停车：在寒冷气候下停车时，应先卸除负荷，然后以怠速运转 1~2 分钟，待一切温度下降后方可

Chapter II: Guide for Maintenance of Diesel Engine

2.1日常维护 Daily Maintenance

Periodic maintenance and Records

Three categories of operating conditions with vehicle

（WGⅠ类） （WGⅡ类） （WGⅢ类）

使用条件恶劣（气候严寒或酷热，含 年行驶里程不 年行驶里程超过

construction site and bus, municipal

Oil change intervals of car maintenance system

Chapter III: Maintenance Contents of Diesel Engine

Inspect coolant level and water temperature.

● 检查机油液面。Inspect oil level

● 检查燃油液面。附图：（需绘制燃油表）Inspect fuel level.

● 检查三漏。附图：Inspect for air, water and oil leakage. Attached diagram:

检查风扇。附图：Inspect fan. Attached diagram:

● 检查皮带。附图：Inspect the belt

● 检查排气颜色是否正常。附图：Inspect exhaust gas for normal color. Attached diagram:

除完成日常保养内容外还应增加下列内容：Maintenance Content of Different Levels

更换机油滤清器或滤芯。附图：Replace oil filter or filter element. Attached diagram:

检查、调整进排气门间隙。Inspect and adjust inlet and exhaust valve clearance.

C. 按表 3-1 用塞尺检查气门桥上平面与气门摇臂间的间隙。WP12 柴油机要求进气门间隙

6、停车：在寒冷气候下停车时，应先卸除负荷，然后以怠速运转 1~2 分钟，待一切温度下降后方可

（WGⅠ类）（WGⅡ类）（WGⅢ类）

使用条件恶劣（气候严寒或酷热，含年行驶里程不年行驶里程超过

轨管高压油管喷油器）都要保证密闭。图 4-1 为 WP12 系列国四柴油机电控共轨系统；图 4-2 为

1、停止发动机 stop engine 2、卸下放气螺丝 Remove the deflate screw

WP12 系列柴油机基本型采用环形塑料风扇，风扇传动采用硅油离合器传动（即粘性传动）形式。