潍柴欧三柴油机电控培训教材

潍柴欧三电控培训教材
Weichai EUROIII Electronic Control

System Training
潍柴进出口公司培训部
Shandong Weichai import and export Co., LTD
目录 Catalog
潍柴欧三柴油机简介
1 Weichai EUROIII Engine introduction
柴油机结构特点
2 Engine structural characteristics
潍柴欧三高压共轨系统介绍
3 Common rail system introduction
整车功能介绍
4 Vehicle function introduction
故障诊断
5 Trouble diagnosis
一、潍柴欧三电控柴油机简介
1. Weichai EUROIII Engine introduction
产品简介产品特性
Produ
Special
ct
chara
Introd
• WP10 cteris
uctio
• WP12 tic
n
1.1 共轨国三产品规划 Product planning
新扩展产品
New product
产品系列 Model series 功率范围 Power range
WP13(4V) 480 ～ 550
WP12N(4V) 336 ～ 460
WP12(4V) 375 ～ 480
WP10N 270 ～ 336
WP10(4V) 375
WP10 270 ～ 375
WP7E30(4V) 210 ～ 300
WP6 180 ～ 240
WP4 165 功率 Power
150 200 250 300 350 400 450 500 550 PS

1.1.2 WP10 柴油机概述
 两气门 WP10 是 WD615 经典动力的再次升级，联合 AVL 和

BOSCH 重新开发，动力强劲，经济耐用
 已成为 11 米以上大型客车的标准配置
 排放：国Ⅲ / 国Ⅳ
 气门数： 2/4
 缸数： 6
 缸径： 126mm
 行程： 130mm
 排量： 9.726L
 功率范围： 240-336ps
 额定转速： 1900/2200rpm
1.1.2 WP10 summary
 WP10 （ 2 Valves ） series based on mature WD615 engines
 Developed together with AVL and BOSCH ， more powerful ,
reliable and economical.
 It has became the first choice for bus more than 11 meter.
 Emission ： Euro III/Euro IV

 Valve ： 2/4
 Cylinder ： 6
 Bore ： 126mm
 Stroke ： 130mm
 Displacement ： 9.726L
 Power range ： 240-336ps
 Rated speed ： 1900/2200rpm
1.1.3 WP10 国Ⅲ技术参数
WP10 Euro III specification
额定功率 / 转速最大扭矩 / 转速
单缸气门数 Rated power/speed Max torque/speed 技术路线
机型 Model
Valves Technical route
kW/rpm N.m/rpm
WP10series
WP10.270 199/2200 1100/1200 ～ 1600
WP10.290 213/2200 1160/1200 ～ 1600
WP10.310 2 228/2200 1180/1200 ～ 1600 电控高压共轨
WP10.336 247/2200 1250/1200 ～ 1600 Common rail
WP10.375 276/2200 1460/1200 ～ 1600
WP10.375 4 276/2200 1650/1200 ～ 1600
WP10Nseries
WP10.270N 199/1900 1270/1200 ～ 1500
电控高压共轨
WP10.300N 2 221/1900 1390/1200 ～ 1500
Common rail
WP10.336N 247/1900 1500/1200 ～ 1500
1.1.6 WP12 柴油机概述
 潍柴欧洲研发中心和奥地利 AVL 公司联合开发

 12 米以上大型豪华客车和重卡的理想动力
 在 WP12 机型上，通过增加缸径和行程，开始研发 WP13 系列发动机
。
 排放：国Ⅲ / 国Ⅳ
 气门数： 4
 缸数： 6
 缸径： 126mm
 行程： 155mm
 排量： 11.596L
 功率范围： 336-550ps
 额定转速： 1900/2100rpm
1.1.6 WP12 summary
 Weichai European R&D center and Austria AVL company

research together
 Ideal power for matching luxury bus and heavy duty truck
 Base on WP12, by enlarging the bore and stroke, successfully design the
WP13 series engine(127*165)
 Emission ： Euro III/Euro IV
 Valve ： 4
 Cylinder ： 6
 Bore ： 126mm
 Stroke ： 155mm
 Displacement ： 11.596L
 Power range ： 336-550ps
 Rated speed ： 2100/2300rpm
1.1.7 WP12 国Ⅲ技术参数
WP12 Euro III specification
额定功率 / 转速
最大扭矩 / 转速
Rated
单缸气门数 Max torque/speed 技术路线
机型 Model power/speed
Valves Technical route
kW/rpm N.m/rpm
WP12 系列 -WP12 series
WP12.375 276/2100 1500/1200 ～ 1500
WP12.400 294/2100 1780/1200 ～ 1500 电控高压共轨
4
WP12.440 323/2100 1920/1200 ～ 1500 Common rail
WP12.480 353/2100 1970/1200 ～ 1500
WP12N 系列 -WP12N series
WP12.336N 247/1900 1600/1000 ～ 1400
WP12.375N 276/1900 1800/1000 ～ 1400
电控高压共轨
WP12.400N 4 294/1900 1920/1000 ～ 1400
Common rail
WP12.430N 316/1900 2060/1000 ～ 1400
WP12.460N 338/1900 2110/1000 ～ 1400
WP13E30 系列 -WP13E30 series
WP13.480E30 353/1900 2110/1100 ～ 1400
WP13.500E30 368/2100 2100/1200 ～ 1500 电控高压共轨
4
WP13.530E30 390/2100 2220/1200 ～ 1500 Common rail
WP13.550E30 405/2100 2300/1200 ～ 1500
1.2 柴油机性能特点 Engine special characteristic
性能特点—智能节油 Economical
根据客车工况，对 ECU 进行精确标定，燃油经济性出色
Accurate calibration of the ECU under the passenger condition
性能特点—安全舒适 Comfortable
采用强化机体、优化选配硅油减振器、法兰连接式高压油泵、电控
调节预喷油量等措施，大幅降低了发动机的振动和噪声
Modified the engine block ， fuel pump and injector ， reducing
the engine vibration and noise
Noise Acceleratio Driving 500km degree of
Model Vibration
（ dB ） n fatigue
WD615 115 — 100%
WP10 97 ▲10% 63%
WP12 96 ▲15% 50%
1.2 柴油机性能特点 Engine special characteristic
能特点—动力强劲 Powerful
 提升低速扭矩，起步性能更优异
 Improve the torque at low speed, more excellent starting
performance
1110
950
二、 WP10 柴油机结构特点
WP10 structural characteristics
2.1 概述
Summary
2.2 WP10 结构特点介绍
WP10 Structure introduction
2.1 概述
Summary
1.WP10 系列柴油机是潍柴动力在斯太尔 WD615 柴油机
的基础上，采用 BOSCH 电控共轨系统自行开发设计的
WP10 basic on WD615 change the fuel supply and
injection system
2. 其外形结构和相关连接尺寸与原斯太尔 WD615 国 II 系
列柴油机基本相同，有良好的继承性和零部件通用性
Overall dimension and connecting dimension
generally the same
3. 具有原斯太尔国 II 系列柴油机的所有优点（可靠性好、
扭矩储备大、保养维修简便等等）
Inherited the original advantage
燃油系统 Fuel system
进排气系统
气缸体 A C Intake and
cylinde exhau
r block 构造
st
Structure
syste
m
E D 输出端
其他 Out
Oth put
er
2.2.1 燃油系统 fuel
system ★ 电控燃油供给系
统是采用 BOSCH
公司研发的二代
全新系统。共轨
管能承受
1600bar 的压力
★ Bosch ECU
system,1600bar
of pressure
★ 强烈建议把粗滤
器安装到整车上
★ Prefilter set on
the frame
2.2.3 法兰泵 Fuel pump
★
更改高压油泵和空压机同轴驱
动结构方式；采用法兰式驱动
高压油泵，油泵直接由齿轮传
动，运转平稳
★
Cancel the coupling system
★
无联轴器结构故障率降低
★
使得喷油提前角精度更高，减
少了震动，提高了可靠性，减
低了噪音
★
Reduce the failure rate
noise and vibration
2.2.4 进气电加热装置 Air heater system
车
用
Ⅲ
客
R
EU
卡车用
EUROⅡ
2.2.9 机油压力传感器 oil pressure sensor
WP10 机油压力传感器
WP10 engine oil pressure sensor
WD615 机油压力传感器
WD615 engine oil pressure sensor
给 ECU 提供信给仪表盘提供数据

号 To vehicle
To ECU
2.2.10 飞轮和飞轮壳 Flywheel and flywheel housing
WD615 WP10
★ 因装转速传感器，飞轮壳上增加转速传感器安装孔
★ Fitted speed sensor, to increase speed sensor
on the flywheel housing mounting holes
2.3.2 气缸盖 Cylinder head
 一缸一盖结构，方便用户
维修；采用 4 气门进排气结
构，降低排放
 喷油器安装孔在缸盖中间
 One cylinder one
head ， 4valves
 Injector in the middle of
the cylinder head
4 气门喷油器安装孔
4 valves Fixing hole
三、潍柴欧三高压共轨系统介绍
Common rail system introduction
3.1 欧三技术路线
EURO Ⅲ Technical route
3.2 共轨系统组成及原理（油路分析）
Common rail composing and principle
3.3 共轨系统主要部件
Key parts of common rail
3.4 传感器及线束
Sensors and wire
1.1 欧三技术路线概述 Summary
CRS
UIS UPS
1.2 共轨技术路线的特点
Common rail specific point
共轨特点： 1. 燃油喷射独立 - 单体泵凸轮轴控制

inject independent
2. 喷油精准控制定时、定量定次
injection accurate
3. 高压油泵噪声小
low noise
4. 油压与发动机转速无关
pressure no relationship with rpm
3.1.3 共轨系统的几个典型数据 Typical data
3.2.1 共轨系统原理介绍 Principle
3 共轨系统主要部件 Key parts of common rail
.1 电子控制单元 ECU
功能作用
Function
1. 接收各传感器信号，主要为模拟信号
和数字信号
Receive signal from sensor, digital
signal and analog signal
2. 对信号进行计算、处理以及评估
Calculate/dispose/estimate
3. 根据接收信息输出指令，控制各个执
行器（如喷油器、计量阀）工作
Control the actuator
4. 与其他电器单元进行通讯 –自动箱
Communicate with other equipment
1 电子控制单元 ECU
BOSH ECU circuit boards

型号 Model ： EDC7UC31
特性参数 Specifications ：
• Working Temperature ： -40 ～ 105 ºC
• Working voltage ： 24V （ 9 ～ 32V ）
• 接插件 Plug ： 141 针（ 16 ＋ 36 ＋ 89 ）
1. 尺寸 dimension ： 248×206×54mm3
• ECU 的 8 个固定螺栓扭矩 ECU connecting bolt torque ：
10±2Nm
sensor
Vehicle
fu
nct
ion
actuator
serial
nu
date mb
Product er
number
Working environment requirement
electromagnetic
Corrosive liquid interfer
ence
dust
Hot plug
oil
static electricity
water
temperature vibration
效模式 Failure mode
Mode Appearance Reason Solution
ECU 针脚腐蚀 function failure 线束接头进水查找泄露点并整改
Pin corrosion or cannot start Water into the Find out the leak
engine plug point and
repaire
ECU 数据刷错 The same as 数据出错重新刷数据
Flash wrong data above Wrong data Flash right data
ECU 内部电路损坏 The same as 电路过载更换 ECU
Internal circuit above Circuit overload Change ECU
damage
2 高压油泵 High pressure pump
要技术参数 main parameter

1. 直列双柱塞高压油泵 Inline double high pressure plunger pump
2. 集成 ZP5 齿轮输油泵 Integrated ZP5 gear fuel pump
3. 集成油量计量阀，并由之控制轨压。
Integrated fuel metering valve, and the control of rail pressure
4. 最大系统工作轨压 Max rail pressure ： 1600bar
5. 泵额定转速 Rated speed ： 1400r/min
6. 齿轮泵进口压力 gear pump inlet pressure ： 0.35~1bar
7. 齿轮泵出口压力 gear pump outlet pressure ：＜ 9bar
8. 油泵回油压力 pump return pressure ：＜ 1.2bar

高压油出口 high pressure
fuel outlet
柴油进口（自滤器） diesel inlet (from filter) 柴油出口（到油箱）
M-PROP 燃油计量 Diesel outlet (to fuel tank)
阀
M-PROP Fuel 溢流阀 overflow valve
metering
valve
凸轮轴
润滑油进口（可选）
Camshaft lubrication
oil inlet (optional)
柴油出口（到滤器）
Diesel outlet
(to filter) 初始机油注油口阀盖
Initial oil filling mouth cover
齿轮泵 ZP5 凸轮轴相位传感器 : DG6
Gear pump Camshaft speed sensor: DG6
柴油进口（自油箱）
Diesel inlet (from fuel tank)
2 高压油泵高压油
CPN2.2High pressure pump
泵
进油口
油量计量单元
柱塞
柱塞弹
簧
挺柱
凸轮轴
齿轮泵
.2 高压油泵 High pressure pump
量计量单元 Metering Unit （ MeU ）
控制进入柱塞的燃油量，从而控制共轨管压力
Control into the plunger fuel quantity, so as
to control common rail pipe pressure
比例电磁阀 Proportional solenoid valve
线圈电阻 electric resistance ： 2.6~3.15Ω
最大电流 current ： 1.8A
缺省状态 Default state ：全开（ limp home
）
3 高压油轨 Rail
Pressure limit valve(PLV)
Rail pressure sensor
Rail body
主要技术参数 Specification ：
 最大系统工作压力 Max pressure ： 1600bar
 限压阀打开压力 PLV opening pressure ： 1850bar
 限压阀打开限制：累计打开次数 < 50 次；
累计打开时间 < 5 小时
功能：存储高压燃油，抑止因油泵供油和喷油而产生的波动
Function: Storage of high pressure fuel , Suppression of fluctuation
4 压力限制阀 Pressure limit valve PLV
Valve body
O-ring
gasket
spring
Sealing block
piston
作用：控制油轨内的压力，当压力过大时阀门打开并泄压，同时发动机进
入跛行模式
Function ： Control rail pressure, when the pressure is too large
， the valve open and pressure release, at the same time the
engine into the limp home model
4 压力限制阀 PLV
跛行模式 :ECU 监测到某系统参数不正常时，出于保护整个的目的， ECU
会使整个系统运行在扭矩输出比较低的工况（限制轨压），这样
既能保护系统和驾驶者，又能让车辆仍然能行驶到就近的维修站
进行检查和维修
Limp home mode ： When ECU detects parameters is not normal,
ECU limits the engine output torque ， Max speed 1000 or
1500 rpm
DBV 关闭时 DBV 打开时

.5 喷油器 Injector
作用：将非常少量的高压燃油精确地喷入燃烧室。喷油量和喷油持续
时间是由系统压力和加电时间决定，受电控单元驱动。
Function:
A small amount of fuel injected into the combustion chamber of
the precise
技术参数 parameter ：
线圈电阻 resistance ： 230mΩ
最大加电时间
Maximum charging time ： 4ms
最大工作轨压
Max rail pressure ： 1600bar
部构造 internal structure
pressure High pressure
pressure
Control plunger
Fuel return
Solenoid valve
armature
High pressure fuel inlet
Nozzle needle
RBCP/SNS-Zheng
Nozzle opening Nozzle closing
喷嘴置位喷嘴开启喷嘴关闭
回油
线圈 coil
衔铁
armature
球阀 valve
释放控制孔高
Release control hole
压
连
Fuel inlet hole 接
管
针阀杆 plunger
嘴针阀压力环
ssure ring
喷孔 nozzle hole
高压低压
ailure mode
3.4 传感器及线束 Sensors and wire
No Name Abbreviation Function

.
1 Crankshaft sensor CRS Calculation of crankshaft position,
fuel injection quantity, injection timing
2 Camshaft sensor CAS Judgement on cylinder run time
3 Boost air sensor BPS Corrected fuel injection quantity
4 Coolant T sensor CTS Detection of water temperature
5 Rail P sensor RPS Detection of rail pressure, ensure
the normal work of fuel system
6 Pedal position APP The intent of the driver to ECU
sensor
7 Oil P sensor OPS Detection of oil pressure
8 Air P sensor APS Detection of air pressure

3.4.1 曲轴和凸轮轴传感器 CRS and CAS
原理 principle ：电磁感应 law of electromagnetic induction
功能 function ： 1 、曲轴（发动机）转速 crankshaft speed
2 、气缸上止点位置 TDC location of cylinder
如果该配件失效，会引起发动机启动困难等故障 The damage of it will cause
such trouble as engine difficult to start and so on.
1 、永磁铁 permanent magnet 2 、传感器壳体 sensor shell

3 、发动机外盖 engine cover4 、软铁芯 soft iron core
5 、线圈 coil 6 、传感线圈 sensing coil
凸轮轴传感器 CAS
同曲轴转速传感器
The same as CRS
Mounting bolt hole connector

Torque:8±2Nm
O-ring
coil
CRS ： 2.19-ground 2.23-signal
CAS ： 2.10-ground 2.09-signal

Coil resistance ： 860±86Ω (20℃)

Engine speed ≥50rpm Oscilloscope waveform can be measured
3.4.2 水温传感器 CTS
原理 principle ：
高灵敏度 NTC （负温度系数热敏电阻）电阻阻值随温度下降而增大。
Quick response NTC (negative temperature coefficient ), resistance value will increase
with decreasing temperature.
功能：提供水温信号，关系到发动机热保护、进气加热、电控风扇。
Function: to provide water temperature signal, which is related with engine heat
protection, intake heating, electrical control fan.
如果该配件损坏会引起发动机跛行回家等故障。
The damage of it will such trouble as engine limp home.
1 、电子接头 electrical connector 2 、壳体

shell 3 、 NTC 电阻 NTC ressitance4
、冷却液 coolant
3.4.2 水温传感器 CTS
CTS ： 2.26-ground 2.15-signal

Fix torque:23-25Nm
3.4.3 进气压力传感器 BPS
BPS 用于测量进气歧管内的绝对压力
。发动机的进气量是由进气
压力和发动机转速决定的。增压压力
传感器通常安装在涡轮增压器
之后。
Measurement of intake manifold

absolute pressure
Engine air inlet quantity is
determined by the
intake pressure and
engine speed decision
3.4.3 进气压力传感器 BPS
BPS ： 2.25-ground 2.34- pressure signal

2.33-ECU 5V 2.36-NTC thermistors
3.4.4 油门踏板传感器 APP
3.4.5 轨压传感器 RDS
功能 : 测量共轨管中的燃油压力，最高共轨压力可达 1800bar ，能保证油压控制稳
定，属于闭环控制
Measurement of the fuel pressure in the common rail, the highest common rail
pressure can reach 1800bar, can guarantee the stability of closed loop
control of hydraulic control,
connector
O-ring
Sensing element
共轨压力传感器：共轨系统中最关键的传感器
Common rail pressure sensor: the key sensor in common rail
system
• 精确测量对系统有效运行至关重要 accurate measurement is very important for

effective operation
• 测量精度为满量程的 2 ％ measurement precision is 2% of full scale
• 瞬时响应要求高 high instantaneous response
• 一旦损坏，必须起用应急备份功能，按设定值替代。会引起发动机跛行回家故障。
• In case of any damage, standby function will be activated which will substitute it
with a set value. The damage of it will cause such trouble as limp home and so
• on.
压力变化 pressure change
• 皮膜上的金属层形状变化（ 1500bar － 1mm ） shap change of metal
layer on film （ 1500bar － 1mm ）
• 电阻变化 resistance change
• 电阻桥上的电压变化（ 0~70mv － > 0.5~4.5v ）
• voltage change on resistance bridge （ 0~70mv － > 0.5~4.5v ）
RDS ： 2.12-ground 2.14- signal

2.13-ECU 5V
3.4.6 机油压力传感器 OPS
功能：装机油泵之后 ,
检测机油压力及
温度
3.4.7 连接线束 wire
Sensor wire
CTS: 冷却水温度传感器 OPS: 机油压力传感器 CaS: 凸轮轴位置传
感器
CrS: 曲轴转速传
感器
RPS: 轨压传感器
BPS: 增压压力传感器
Injector wire
喷油器线束
injector
油量计量单元线束 MeU
预留线束接头 The reserved wiring harness connector
★ 白色（ 2.03 ）：
★ ECU 的电源输出（ 24v ）
★ 灰色（ 2.06 ）：
★ 接排气制动电磁阀
★ 橙色（ 2.11 ）：
★ 接空调压缩机继电器
★ 蓝色（ 2.29 ）：
★ 接排气制动开关，控制蝶
阀的打开
2.03(white)-ECU 24V 2.06(gray)- exhaust brake Electromagnetic valve

2.11(orange)-AC relay 2.29(blue)-exhaust brake switch
4.6 多功率省油开关 Multiple state switch
功能：根据车辆的不同工况选择发动机的特性曲线与传动系匹配，在满足
动力性的前提下，保证燃油经济性。
Function ： It can select engine’s characteristic curve to be
matched with drive train according to different operating
conditions of vehicles to meet individuation and diversified
matching of engine and to solve the contradiction between
engine’s dynamic property and economy.
原理：限制发动机的扭矩 Limit the engine torque
目前潍柴用到的多功率省油开关可实现重载、中载、空载三档功率转换。
Mode ： Light-Middle-heavy
第*页
4.6 多功率省油开关 Multiple state switch
第*页
4.7 发动机指示灯
指示发动机的故障码。（手动清除故障
闪码灯
）
Fault diagnosis Blink code lamp
油中有水
指当粗滤中水位到达报警水位时点亮，提
示醒司机及时放水。
灯 Water in fuel
进气加热
指发动机进气预热系统起作用时常亮，进
示气预热完成后，闪烁三次熄灭
灯。
In take air heating
MIL 灯后处理故障灯。
SCR system fault diagnosis
第*页
五、故障诊断 Trouble
diagnosis
5.1 故障检测工具
Tools
5.2 典型故障及排除
Typical failure cases introduction
5.3 故障诊断仪使用
Introduction trouble diagnosis device
1 故障检测工具 Tools
1.2 故障诊断方法 Diagnostic method
1. 观察法：通过观察柴油机的排烟等故障特征，判断故障情况
2. 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
1. Inspections: Observation of diesel engine exhaust
2. Listening: Diesel engine abnormal noise
3. 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
4. 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
3.Shutting down one cylinder:
Comparison of before and after shutting down
cylinder engine state changes, to further find
out the fault position
4. Comparison: Instead of a part , Observation of
fault whether or not to continue
5. 故障诊断灯：当车出现故障时，可以通过整车仪表盘上的闪码灯
读出闪码，参照闪码表初步判断错误原因
读-记-清-读-记
6. 专用工具：故障诊断仪
故障诊断仪可以进行较进一步的判断
5.Read the fault diagnosis lamp information
6.Use diagnosis device
闪码灯
故障诊断开关
Caution ！
1. 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；
2. 对高压油泵、增压器等关键零部件，因此没有
经验和条件的客户不要对其随意进行拆卸调整
。
1. Prohibit removing any parts, before you
get the trouble reason.
2. Cannot disassemble key components e.g.
fuel pump, turbocharger.
典型故障及排除
pical failure cases introduction
故障一：柴油机不能起动
Engine can not start
故障二：柴油机起动困难
Engine start difficultly
故障三：柴油机功率不足
Engine no power
故障四：发动机始终运行在 1000 转
Engine run at 1000rpm
故障五：柴油机怠速游车
Engine hunting at idle speed
5.2.1 柴油机不能起动 Engine can not start
A 起动机不工作
Starter cannot work
车下停车开关
1. 检查是否挂在空档位置
2. 检查车下停车开关的位置（应处断开状态
）
3. 检查空档开关（一般安装在变速箱
上）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）变速箱
1.Gear position
2. Compartment start/stop switch
3.Check Neutral position switch
空档开关
2.1 柴油机不能起动 Engine can not start
A 起动机不工作
Starter cannot work
4. 检查电瓶电压是否过低，以致
不能带动起动机
5. 起动机继电器及接线是否完好
6. 检查起动机是否已烧坏
7. 点火开关及起动开关是否已坏
4.Check battery voltage
5.Starter relay 起动机
6.Starter run normally

点火钥匙
7.Start switch 开
关
B 轨压无法建立 Cannot reach rail pressure
1. 检查油箱油位是否过低 check fuel level of tank
2. 检查手压泵是否工作正常 check hand pump
3. 检查低压油路是否有气，并排空气
check low pressure fuel line and exhaust air
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
exhaust air: Unscrew the release bolts of the filter, by hand pressure the
same filter on the hand pump, until the release at the bolt
continuous oil. Release bolt
Hand pump
4. 高压油路有空气，也需要排出高压油路的空气
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！）
5. 检查高压油路有无泄漏
6. 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
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
4. The high pressure oil passage of air, also need to discharge the air
pressure circuit
5. Check the high-pressure fuel leaking
6.check fuel filter is clogged, timely replacement of diesel filter
7. 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 300-500bar （用 KTS 故障诊断仪），若不正常首
先检查接插件是否牢靠。若无检查设备，可以拔掉轨压传感器接
插件尝试再起动
8. 检查流量计量单元是否完好，拔掉接插件尝试再起动
7.Check the voltage of the RPS(500mV),check the plug connector
firmly
8.Check the MeU
C 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 wire problem
1. 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
With a multimeter according to the circuit diagram of the pointer
definition checking line on-off
线路检查仪
2.1 柴油机不能起动
D 曲轴信号和凸轮轴信号丧失
CRS or CAS 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情况，两个信号全部丢失
Engine can not start, the two signal lost, check the sensors.
D 曲轴信号和凸轮轴信号丧失
CRS or CAS signal lost
 两信号全部丢失可能的原因
① 传感器损坏，线束短路或断路
② 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
注：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
Signal lost reasons:
① sensors damaged, short circuit or open circuit
② The sensor is not firmly fixed, causing the sensor and the
induction between the tooth gap is too large or too small
(1±0.5mm)
Caution: High pressure oil pump flywheel assembly and disassembly
and installation should be strictly in accordance with the
relevant process documents, to ensure synchronization
signal
博世柴油共轨系统诊断高级培训
案例 1 Example 1
车辆信息 Vehicle information
车型：重型卡车，配置四气门 6 缸发动机
博世燃油系统部件： EDC7UC31 电控单元 , CPN2.2 油泵， CRIN2 喷油器和锻造轨
整车配置： ECU 控制的起动继电器，空档开关，刹车开关，离合器开关，节油开关，
排气制动， CAN 通讯， ECU 控制的空调压缩机继电器，空气预热继电器，
预热灯，闪码灯，故障灯，副起动开关以及车下停止开关，无发动机制
动
故障信息 Failure Information
拧钥匙时马达转动，但是车辆无法起动 Starter can run ， but cannot start
the engine
行驶里程
车辆已运行 25 万公里，没有过大修，正常保养
The vehicle has run 250000 kilometers, without overhaul, maintenance
故障码信息
无任何故障码 No P code
推荐排查步骤 Checking step
1. 连接诊断仪，拧钥匙打马达时，读取数据流 , 主要关注发动机转速，同步状态
量，轨压
名称打马达时的数据
set rail p 轨压设定值 hPa 550000
Actual rail p 轨压实际值 hPa 110000
engine speed 发动机转速 rpm 179
synchronized signal 同步状态量 48
MeU current 燃油计量阀电流 mA 1224
2. 松开油泵出油口，分别连接高压工具。打马达看油泵建压能力
两个柱塞出油的压力分别为 387bar,375bar Fuel pump outlet Pressure-
387Bar,375Bar
3. 打马达测量喷油器的回油量
几乎没有回油 injector no return back fuel
4. 松开高压油轨的回油管，打马达看有没有油流出
发现有大量的油成股流出 PLV –lots of return back fuel
5. 判断为限压阀产生泄漏，更换后解决
故障原因
油轨限压阀泄漏导致轨压无法建立 PLV broken ,cannot built rail pressure
5.2.2 柴油机起动困难 Engine start difficultly
 Failure reason and diagnostic method
①柴油机较长时间没有运转：回油管要伸在柴油液面下
② 低压管路有少量空气：排气
③ 曲轴转速信号、凸轮轴信号太弱，同步判断时间较长：重新调整
④ 环境温度太低，并且预热装置失效：更换预热装置
⑤柴油、机油品质太差未达标：更换标准油品
⑥ 起动机或飞轮齿圈打齿：更换起动机及飞轮齿圈
⑦ 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
⑧ 排气制动蝶阀卡死在关闭位置，导致排气不畅：更换蝶阀
1.Engine long time no running-put the return pipe under the fuel level.
2.Air in low pressure fuel line-exhaust air
3.CRS-CAS signal are weak-adjust the sensor again
4.Ambient temperature is too low and Grid is not good-change the grid
5. The poor quality of diesel-change good quality diesel
6. Starter or Flywheel ring gear tooth breaking –change them all
7.Piston ring/liner/valve damaged-change
8.Exhaust break butterfly valve stuck-change
2.3 柴油机功率不足 Engine no power
A 喷油器出现故障 injector trouble
喷油器出现故障，一般分为机械故障和接线故障
 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！）
 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。
 Two type injector failure
 1. Wiring fault –wiring damage or disconnecting
 2. failure of machine- Needle valve can not move
判断方法 diagnostic method ：
1. 怠速不稳，听柴油机声音异常
Idle speed unstable
2. 利用断缸法或高压油管触感法判断
shut down one cylinder
3. 利用故障诊断仪做加速测试判断
Use diagnosis device
2.3 柴油机功率不足
B 水温、机油温、进气温度过高
Temperature of water/oil/intake air 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
 Water temperature, oil temperature, air inlet
temperature is too high, ECU will enter the
overheat protection function, limit the
engine power.
 造成水温高的原因及排除方法
 Water tem too high reason and diagnostic method
① 水箱水面过低：检查有无漏水处，加水
② 风扇转速过慢或不转：检查风扇传动部件
③ 水箱堵塞：检查水箱，清理或修复
④ 水泵皮带松弛：按规定调整张紧力
⑤ 水泵垫片损坏，水泵叶轮磨损：检查并修复或更换
⑥ 节温器故障：更换
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 surface in the water tank is too low
• Fan speed is too slow or not
• Radiator plugging
• Water pump belt relaxation
• Water pump gasket damage
• Thermostat damage 7. Water seal damage, leakage into the air
 机油温过高的原因及排除方法
 Oil tem. too high reason and diagnostic method
① 油底壳油面低或缺油：检查油面及漏油处，修复并加油
② 水温高：检查上述造成水温高的原因并排除之
③ 机油冷却器流通不畅：检查并清理
1. Oil pan level low or lack of oil
2. Water temperature too high
 Oil cooler flow not good
 进气温度过高的原因及排除方法
 Intake air tem too high reason and diagnostic method
检查中冷器的散热能力
Check cooler cooling capacity
C 流量计量单元故障 MeU failure
流量计量单元是控制轨压的执行机构，安装在油泵上，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。
It has the problem of high pressure oil pump, with the
greatest capacity to the common rail fuel supply, the
common rail pipe pressure relief valve will open,
diesel has the opportunity to "KaKa" noise.
流量计量单
元
D 燃油管路泄漏引起轨压异常波动
Fuel oil pipeline leakage caused rail pressure fluctuation
在车运行过程中，会出现车速不稳，车有向前一窜一窜现象出现
。
In the running process, there will be speed instability, car
forward a channeling channeling phenomenon.
 排除方法 Solve method ：
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 off one minute to start again, if the problem still exists,
check the fuel lines for sealing and exclusion
E 传感器故障 sensor problem

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（安装在出水管上
），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
）
 排除方法：
检查进气温度压力、水温、轨压传感器，看接插件是否牢靠
Check the intake temperature and pressure, water temperature, rail
pressure sensor connector, to see whether firm
案例 3
车辆信息
车型：牵引车，配置四气门 6 缸发动机
博世燃油系统部件： EDC7UC31 电控单元， CPN2.2 油泵， CRIN2 喷油器和锻造轨
动
故障信息
车辆在踩油门时故障灯亮起，发动机限速。起动和怠速均正常，但踩油门即出现故
障
行驶里程
车辆运行 15000 公里，之前保养过一次
故障码信息
P1011 （闪码 2-5-1 ）轨压偏差超出上限门槛值
P1012 （闪码 2-5-2 ）轨压偏差超出上限门槛值并且喷油量超限
故障代码可以删除，删除后原地试车怠速正常，在踩油门时故障灯亮，故障代码重
复出现
Diesel Systems
Internal | RBCD/QMM3-Zh | 27/02/2012 | © Robert Bosch GmbH 2012. All rights reserved, also regarding any disposal, exploitation,
reproduction, editing, distribution, as well as in the event of applications for industrial property rights.
推荐排查步骤
1.车辆起动，测量齿轮泵前端压力 2. 测齿轮泵后 3. 测量精滤
为 0.9bar.( 绝对压力 ) 精后
滤的
2. 车辆起动，测量齿轮泵后精滤前前压
的压力压力
为 8bar.( 绝对压力 ) 力
3. 车辆起动，测量精滤后的压力
为 7.8bar.( 绝对压力 )
（这里可以判断精滤前后压差为 0
.2bar ，没有堵塞）
4. 检查高压泵进油口的滤网
堵塞
故障原因
油泵进油螺管的滤网堵塞 1. 测量齿
轮
泵
前
端
压
力
Diesel Systems
4 发动机始终运行在 1000 转 Engine run at 1000rpm
 电子油门踏线松脱或接错
重新拔插或检查油门接线是否正确，重新接线
 电子油门接插件进水
用工具把接插件吹干再起动
1. Electronic throttle pedal line loose or wrong
2. Water get into the connector of
pedal.
注意：更换油门时，需要同一型号的油门。
Replace accelerator, need the same
type accelerator
案例 4
车辆信息
车型：牵引车，配置四气门 6 缸发动机
动
故障信息 Information
车辆上电后故障灯点亮，起动后发动机转速维持在 1000 转左右，踩油门没有反应
Lamp flash, engine speed 1000rpm, accelerator pedal cannot work
行驶里程
车辆运行 98500 公里，无大修，正常保养
故障码信息
故障码 P0698 （闪码 1-3-1 ）供电模块 3 电压低于下限门槛值
The power supply module 3 is below the lower threshold voltage
故障码 P100E （闪码 1-3-4 ）油轨限压阀被冲开 PLV open
熄火后上电，故障码 P100E 可以删除， P0698 无法删除，但起动后，故障码 P100E
又重新报出 P100E can clear ,P0698 cannot ,after starting,P100E
come again
Diesel Systems
推荐排查步骤
1. 断开 ECU 的 213 和 177 针脚的线束连
接
测量 213 或 177 针脚的对地电压
为 5V 2.13-ground 5V
2. 断开 ECU 的 177 针脚和轨压传感器供
电
线的线束连接，测量线束端对地电压 3. 断开连线后 2. 断开连线后
为 5V A-ground 5V 测量对地电压测量对地电压
3. 断开踏板 177 供电线插头，测量此针
脚的对地电压
为 5V 1.77-ground 5V X X
4. 断开踏板 1 供电线插头，测量此线束 B
端的对地电压 A
为 0V B-ground 0V X X
5. 判断为踏板供电线对地短路故障 , 重
新包裹线束后故障解决 1. 断开连线后 2. 断开连线后
pedal U short current 测量对地电压测量对地电压
故障原因
踏板供电线对地短路造成故障产生
Pedal power lines fault caused by
short circuit to ground
Diesel Systems
2.5 怠速游车 Hunting at idle speed
 柴油机游车的原因及排除方法 reason and solve
method ：
①喷油器工作不正常：检查各缸喷油器及线束
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
③ 燃油质量差含水或蜡质：清洗燃油系统，更换燃油滤清器
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
⑤ 喷油嘴雾化不稳定：检查并修复
1. The fuel injector is not normal –check the injector
 Get the speed signal when stoped-check the vehicle
speed sensor and wire
 Fuel oil of poor quality-change fuel
 Low pressure fuel oil leak into the air-fix the pipe
 Atomizing nozzle instability-check it and repair
案例 5 Example 5
车辆信息
车型：牵引车，配置两气门 6 缸发动机
动
故障信息 Failure information
当地温度 -10 摄氏度，车辆起动后怠速抖动，有异响，冒灰白烟，运行时无法达到
最高转速 Ambient T= -10℃ idle speed vehicle vibration ， cannot
reach rated speed
行驶里程
该车行驶了 10 万公里，刚刚进行过大修
故障码信息
无任何故障码 No P code
Diesel Systems
推荐排查步骤
1. 连接诊断仪，起动车辆，在原地运行下读取数据流
Pedal 踏板开度为 0% Pedal 踏板开度为 100%
名称
Min 最小 Max 最大 Min 最小 Max 最大
Coolant T 水温 (°C) 70 70 72 72
Fuel injection 10.92 11.20 33 35
quantity 喷油量 (mg/H
)
轨压设定值 (MPa) 47.3 47.3 94.4 94.4
Rail P set
轨压实际值 (MPa) 47.0 47.0 94.1 94.1
Rail P actual
进气增压压力 (hPa) 992 992 1489 1489
Boost air P
发动机转速 (rpm) 586 612
2384 2385
Engine speed
同步状态量 48 48 48 48 48
synchronized signal
Diesel Systems
推荐排查步骤
2. 进行断缸测试 Cylinder cut off test
所断缸名称第1缸第2缸第3缸第4缸第5缸第6缸
发动机转速 RPM 1386 1384 1496 1385 1383 1384
3. 将第 3 缸喷油器与第 4 缸对换，再进行断缸测试
Will the third cylinder and the fourth cylinder swap, then the cylinder cut off test
所断缸名称第1缸第2缸第3缸第4缸第5缸第6缸
发动机转速 RPM 1382 1383 1492 1381 1382 1384
4. 判断为第三缸气缸机械原因，首先排查起门间隙，发现气门间隙过大
Judge for the third cylinder mechanical reasons, first check the door gap, found the valve
clearance is too large
障原因
三缸气门间隙过大 , 导致此缸燃烧不好造成
ird cylinder valve clearance is too large, resulting in the cylinder combustion caused by bad
Diesel Systems
总结
summary
 潍柴动力国三系列柴油机采用 Bosch 公司的第二代高压
：
共轨系统。高压共轨系统对油路（包括低压油路和高压油
路）要求较高，很多问题都是由油路问题引起的
 整车线束问题也是主要的故障源
 出现故障时，应先考虑此两方面的原因
 Many problems are caused by fuel line
 Vehicle wiring harness is also the main source of
failure
 When a fault occurs, should first consider the two
reasons
5.3 故障诊断仪使用
Introduction trouble diagnosis device
WP-VDS100 故障诊断仪介绍
Introduction of WP-VDS100 Trouble Diagnosis Device
•
随着，国Ⅲ柴油机的推广，我们用于国Ⅱ柴油机的故障诊断方法已经不能够完全适应国Ⅲ柴油机
了。 With the popularization of Euro Ⅲ, the trouble diagnosis method for Euro Ⅱ engine is not
applicable for Euro Ⅲ engine.
•
对国Ⅲ柴油机柴油机来说，机械故障可以用国Ⅱ的方法来排除，但国Ⅲ柴油机的电控共轨
部分的故障得借助于专业的诊断工具。 For Euro Ⅲ engine, mechanical trouble can be removed
by Euro Ⅱ method, but trouble of electrical-control common rail should be removed with the help
of specialized diagnosis tool.
WP-VDS100 故障诊断仪
WP-VDS100 故障诊断仪所能实现的功能
The Function of WP-VDS100 Trouble Diagnosis Device
1 、读取故障码 trouble code reading

2 、清除故障码 trouble code removal
3 、数据流 data flow
4 、故障排除指南 trouble removal instruction
5 、执行元件测试 actuator components test
6 、功能测试 function test
7 、系统信息 system information
8 、冻结帧 freeze frame
9 、环境变量 environment variable
AA/PDT6
WP-VDS100 故障诊断仪的硬件组成：
Components of WP-VDS100 Trouble Diagnosis Device Hardware:
1 、故障诊断仪本体 Trouble diagnosis device
迷你打印机
miniprinte
打印纸出口 r
Print paper 指示灯
outlet
in
di
触摸屏 screen c
X-431 主机
at
校屏键 hot X-431 host or
key
开机键
powe SMARTBOX
r key （诊断测试盒）
(diagnosis test box)
诊断仪技术参数 Diagnosis device technical
parameter
操作系统： LINUX 操作平台 Operating system: LINUX operating
platform
内存： 16M Storage: 16M
CF 卡： 64M CF card: 64M
主机 I/O ：标准出串口 / 并口 Host I/O: standard COM/parallel port
主机电源： DC12V Host power: DC12V
主机功率：约 9W Host power: about 9W
打印机：微型高速热敏打印机 Printer: mini high-speed thermal
printer
打印机接口：标准并口 Printer connection: standard parallel port
环境温度： 0—50℃ Ambient temperature: 0—50℃
相对湿度：﹤ 90% Relative humidity: ﹤90%
X-431 硬件图框 X-431 hardware frame drawing
运行 LINUX 操作系统的计算机或掌
上电脑 pocket
computer or
computer operating 上位机是一个运行 LINUX 操作系统的计算
LINUX system 机系统 , 运行诊断程序；下位机是
SMARTBOX （诊断测试盒），匹配计算
串口通信机与汽车 ECU 的电平、频率信号逻辑等
COM ；上下位机之间通过串行接口进行连接；
co SMARTBOX （诊断测试盒）与汽车 ECU
m 之间通过电缆连接。 The upper
mu machine in the frame drawing is a
nic computer system operating LINUX
SMARTBOX ati
system which operates diagnosis
on
program; the lower machine in the
frame drawing is SMARTBOX
(diagnosis test box), which matching
the computer with battery of vehicle
通信电缆 ECU, frequency signal logic and so
Communication on. The upper one connects with
cable lower one by COM communication;
SMARTBOX (diagnosis test box)
connects vehicle ECU by
汽车 ECU vehicle ECU communication cable.
测试主线 Master Line for Test
连接转换接头端
Transfer
connector
end
连接诊断仪端
Diagnosis
devic
e end
外用电源连接口 external power connector

测试接头 Test Connector
与测试主线相
标准 OBD 接口连
Standard 一
OBD 端
con Connection
nect wit
or h
tes
t
ma
ste
r
lin
e
en
d
交流电源转接线（ 220V ）
AC Power Connection Line (220V)
外用电源连接口 external power connector

直流电源连接线（ 12V ） DC Power Connection
Line (12V)
正极
Positiv
负极
外用电源连接口
Negativ
External power
connec
tor
其它诊断接口 Other Diagnosis Connector
正极
p
o
负极 s
i
Negative
t
p
i
标准 K 线 vo
l
O e
K line e
B
p
D o
接圆形诊断
l
接
口 e
口
Stan Round
d d
a i
a
r g
d n
读卡器（用于下载升级程序） Card Reader (for
Download Update Program)
其它硬件及信息 Other Hardware and Information
打印机 Printer
光盘 Disc
序列号及密码 Serial number and password
使用说明书及保修单等 Operation manual and warranty sheet
USB 电缆 USB cable
CF 卡（存储诊断程序和数据） CF card (to store diagnosis program and
data)
序列号（ 98024******* ）及密码条（经销商编号统一为 86M ）
Serial number （ 98024******* ） and code bar (code for all dealers is
86M)
升级网址（ http://www.x431.com)
Updating website （ http://www.x431.com)
等等 and so on
WP-VDS100 的操作
WP-VDS100 Operation
WP-VDS100 故障诊断仪所能实现的功能
The function of WP-VDS100 trouble diagnosis device

1 、读取故障码 Trouble code reading

2 、清除故障码 Trouble code removal

3 、数据流 Data flow

4 、故障排除指南 Trouble removal instruction

5 、执行元件测试 Actuator component test

6 、功能测试 Function test

7 、系统信息 System information

8 、冻结帧 Freeze frame

9 、环境变量 ( 暂时没有） environment variable (not now)
AA/PDT6
启动诊断程序后显示车型选择界面
Vehicle Choice Interface after starting Diagnosis Program
Vehicle Type Choice
Page up Page down

back help
选择潍柴标志进入版本选择菜单
Version Choice Menu Interface after Choosing Weichai
Diagnosis software version choice

Weichai vehicle trouble diagnosis device
(WP_VDS100) V10.01 system
This program is applicable for diagnosing

Weichai Euro Ⅲ electrical-control system
based on EDC7UC31.
Page up Page enter
on
back help
选择版本后进入下载界面
Enter Download Interface after Choosing Version
System and SMARTBOX Initiation
SMARTBOX reset [success]

SMARTBOX check [success]
Downloading diagnosis software
[success]
Enter
点击确定后进入潍柴软件系统选择界面为
Enter Weichai Software System Interface
after Clicking “Enter” System Choice
Weichai Power Engine System
Page up Page On
Home back print help
page
点击菜单进入功能主菜单
Click Menu into Function Main Menu
Function Choice
Trouble code reading
Trouble code removal
Data flow
Trouble removal instruction
Actuator component test
Function test
System information
Freeze frame
Page up Page On
Home page back print help
1 、选择“读取故障码”功能，读取 ECU 储存故障
1. Click “trouble code reading” to read trouble stored in ECU
Trouble Code
538 too high supercharger sensor voltage not finished;
current;
light off;
671 too high common rail sensor voltage not finished;
current;
light off;
1017 metering unit open voltage not finished;
current;
light off;
1722 engine exhaust brake valve open voltage not finished;
current;
light off;
14 too high coolant sensor voltage not finished;

current;
light off;
Page up Page On
Home page bac print help
k
1 、选择“读取故障码”功能，读取 ECU 储存故障
1. Click “trouble code reading” to read trouble stored in ECU
Trouble Code
14 too high voltage of coolant sensor not
finished;
current;
light off;
288 too high voltage of intake temperature sensor not finished;
current;
light off;
237 too low voltage of accelerator pedal sensor 1 not finished;
current;
light off;
251 too low voltage of accelerator pedal sensor 2 not finished;
current;
light off;
1382 short circuit of power by intake heating not finished;

no trouble;
Page up Page On
Home page bac print help
k
2 、选择清除故障码，清除 ECU 内存中的故障信息
2. Click “trouble code removal” to remove trouble information stored in ECU
Function Choice
Data flow
Function test
System information
Freeze frame
Page up Page On
2 、选择清除故障码，清除 ECU 内存中的故障信息
2. Click “trouble code removal” to remove trouble information stored in ECU
Trouble Code Removal
Remove the recorded trouble code?
Yes No.
清除故障码 Trouble Code Removal
Successful trouble code removal
Yes
清除故障码 Trouble Code Removal
此时点击“确定”即可。
Click the “Yes” to remove code.
Successful trouble code removal 清除故障码后应该再次读取故障码，此
时的显示信息为 ECU 内部当
前故障，根据这些故障信息
去判断发动机的故障点所在
Read trouble code again after
removing trouble code.
Yes The information shown
now is the current trouble
inside ECU. Judge the
engine trouble as per
these trouble information.
3 、选择“数据流”功能，然后选择需要测得的数据流，执行显示
3. Click “data flow” and choose wanted data flow
Function Choice
Data flow
Function test
System information
Freeze frame
Page up Page On
3 、选择“数据流”功能，然后选择需要测得的数据流，执行显示
3. Click “data flow” and choose wanted data flow
Data flow
Battery voltage 1.96V
Engine running speed 100 r/min
Accelerator pedal location sensor 1 0.49V
Accelerator pedal location sensor 2 0.49v

Calculated accelerator pedal location 1.25
Fuel pre-injection time 100 ms
Main injection time 100 ms
Injection quantity 2.00 mg
page up page on record drawing-1

home page back print help
选择“数据流”功能，然后选择需要测得的数据流，执行显示
Click “data flow” and choose wanted data flow
Data flow
Rated fuel rail pressure 1.00MPa
Actual fuel rail pressure 1.00MPa
Pressure storage pipe pressure sensor voltage

0.49V
Fuel adjustment unit open 100mA
Fuel quantity metering unit pulse ratio duty
1.00%
Coolant temperature sensor voltage 0.49v
Coolant temperature -263.14℃
Atmosphere pressure sensor voltage 0.49v

选择“数据流”功能，然后选择需要测得的数据流，执行显示
Click “data flow” and choose wanted data flow
Data flow
Atmosphere pressure 100 hPa
Actual assistant pressure 100 hpa
Intake pressure, temperature 0.49V
Intake temperature -263.14℃

Engine oil temperature -263.14℃
Fuel temperature -263.14℃
Driving speed 1.00 Km/h
Engine control trouble indicator ---

4 、选择“故障排除指南”功能，以“功率不足”为例
4. Click “trouble removal instruction”; Take “insufficient power” as an
example
Function Choice
Data flow
Function test
System information
Freeze frame
Page up Page On
4 、选择“故障排除指南”功能，以“功率不足”为例
4. Click “trouble removal instruction”; Take “insufficient power” as an
example
Trouble Removal Instruction

Engine does not run
Difficult start
Black smoke
Insufficient power
page up Page on
选择需要观察的项目，然后按确定执行
Choose Wanted Item and Click “enter”
Data flow
Engine speed
Actual rail pressure
Water temperature
Intake temperature
Intake pressure
Fuel injection quantity
Metering unit current
Accelerator pedal location
Page up Page on enter

选择需要观察的项目，然后按确定执行
Choose Wanted Item and Click “enter”
Data flow
Engine running speed 600r/min
Actual rail pressure 714.4 bar
Water temperature 81.26℃
Intake temperature 29.96℃

Intake pressure 700 hpa
Fuel injection quantity 111.16 mg
Metering unit current 1 mA

5 、选择“执行元件测试”功能，以“故障灯”功能为例
5. Click “actuator component test”; Take “trouble indicator” as
an example
Function Choice
Data flow
Function test
System information
Freeze frame
Page up Page On
5 、选择“执行元件测试”功能，以“故障灯”功能为例
5. Click “actuator component test”; Take “trouble indicator” as
an example
Movement Test
Exhaust throttle valve of engine braker
Trouble indicator
Cold starting indicator
Page up Page On
动作测试 Movement Test
Movement Test
Actuator sends pulse or not?
Diagnosis home page

动作测试 Movement Test
Movement Test
Actuating time now.

Start actuator?
Yes
执行元件 -- 排气制动
Actuator Component—Exhaust Valve Brake
在电喷发动机中，排气制动是由发动机 ECU 电子控制器来进行控制的。

当接通仪表板上的排气制动开关时， ECU 便得到一个信号，然后通过继电器控制排
气制动电磁阀工作， ECU 会根据当前的工况通过程序计算来做出决定是否决定执行。
这是为了在有效地得到排气制动的同时保护发动机以及相关装置。（排气制动一般发
动机转速在 800 转 / 分以上时起作用）。
For electrical injection engines, EVB is controlled by ECU. When EVB switch
of gauge panel is on, ECU will get a signal and control EVB electro-magnetic valve
working by relays. ECU will decide whether to actuate or not by computing as per
current working condition. This is for effective getting EVB as well as protection of
engine and related device. (Generally, EVB works only at 800 r/min or more.)
执行元件 -- 冷启动灯
Actuator—Cold Starting Light
在环境低温下（ 0℃ 以下），发动机通过进气管中的进气温
度传感器感知进气的温度，当温度低于 0℃ 时，加热指示灯发亮；此
时由发动机 ECU 控制器控制的加热继电器工作，通过装在发动机进
气管内的加热法兰的栅栏对进气进行加热，加热的时间取决于进气的
温度，加热完成后加热指示灯熄灭，此时可起动发动机。
Intake temperature is gotten by intake temperature sensor when
the ambient temperature is low （ below 0 ℃). When the
temperature is below 0 ℃, heating indicator is on. At this time,
heating relay controlled by engine ECU begins to work. The intake
is heated by fence of heating flange inside intake manifold. The
heating time is decided by the intake temperature. After heating,
heating indicator is off. Thus, engine can start now.
执行元件—故障灯
Actuator Component--- Trouble Indicator
6 、选择“功能测试”功能，以执行“加速测试”为例
6. Click “function test”; Take “speed accelerating test” as an example
Function Choice
Data flow
Function test
System information
Freeze frame
Page up Page On
6 、选择“功能测试”功能，以执行“加速测试”为例
6. Click “function test”; Take “speed accelerating test” as an example
Function Test
Information of starting trouble
Compression test
Comparison of idle speed and running speed
High pressure test
Accelerating test
Metering unit test
Page up Page On
加速测试 Accelerating Test
Accelerating Test
Starting premise:
Engine is at idle speed and working temperature;
1.
All electrical appliances are closed;

2.
Engine stopping brake has been strained

3.
Note: before testing, stamp clutch pedal once and

loosen (manual gear box)
Yes
Accelerating Test
Test is being done.

Cylinder 1 has been cut off.
Please wait.
Diagnosis home page

Accelerating Test
Cylinder 1 speed : 1299 r/min

Cylinder 2 speed: 1283 r/min
Cylinder 5 speed: r/min
Cylinder 6 speed: r/min
Diagnosis home page

Accelerating Test
Cylinder 1 speed : 1299 r/min

Yes Print
起动故障信息测试
Starting Trouble Information Test
在发动机起动时，不正确的轨压，转速信号，同步信号的缺失，都可导致发动
机无法起动。通过这个测试可发现导致无法起动的原因。
When engine starts, wrong rail pressure, or any loss of speed signal, synchronic
signal can result in engine not starting. The cause of not starting can be found
by this test.
测试条件：发动机无法起动
Test premise: engine cannot start
测试方法：起动机带动发动机运转约五秒钟。
Test method: engine is driven by starter for about 5 seconds.
VDS100 可读出发动机无法起动的原因，
VDS100 can read the cause of engine not starting.
如：无转速信号等。
e.g. no speed signal and so on.
压缩测试原理
Working Principle of Compression Test
如果存在气缸漏气现象 , 活塞运动速度在上止点前会因漏气，阻力变小而加快；相反
活塞速度在上止点之后会因漏气，膨胀能量损失而减慢。通过捕捉活塞在上止点前后一定角度间
的经过时间（速度越快，时间间隔越短），可以反映出该气缸的密封性能。 If cylinder head
leaks air, the moving speed of piston will increase before TDC due to air leakage and
resistance decreasing. However, the moving speed of piston will reduce after TDC due to air
leakage and expansion energy loss. By testing the time of piston moving within certain angle
before and after TDC (the faster it moves, the shorter interval it has), we can know the sealing
of cylinder head.
•
压缩测试时， ECU 停止对发动机的喷油
•
During compression test, ECU will stop fuel injection
•
起动机带动发动机运转 Engine runs driven by starter.
•
诊断仪同时测量各缸压缩，膨胀阶段的转速，来判断每个缸的工作情况。如果某个缸的转速与其
他的缸相差很大，可以判断此缸有问题 Diagnosis device can measure the running speed of
each cylinder at compression and expansion stroke to tell the working condition of each
cylinder. If the speed of certain cylinder is greatly different from that of other cylinders, it can
be told that this cylinder is in trouble.
高压测试 High Pressure Test
 增加设定点的压力
 Increase pressure at set point
测量压力建立时间
设定压力 set pressure
Measure pressure establish time
实际压力
 减少设定点压力 actual pressure
 Decrease pressure at set point
测量压力消失时间
Measure pressure disappear time
 在不同的转速，轨压下进行测量
 Measure the following at different speed,
rail pressure
高压系统泄漏
轨内压力 Pressure
High pressure system leakage

喷油器回油多
More return fuel of fuel injector
高压泵 / 控压阀泄漏
High pressure pump/pressure
limit valve leakage
低压供给效率（滤清器塞，
预压泵效率
Low pressure supply efficiency
(filter plug, pre-pressure pump Time/ 时间
efficiency)
高压测试 High Pressure Test
高压测试是通过 ECU 触发，按设定的诊断程序来对轨内压强进行升

压和降压，观察系统的执行能力，通过结果数据来综合评估系统的各液
压器件的性能。
High pressure test conducts pressure increase and decrease in rail as per set diagnosis
program by ECU. It studies the actuation ability of system and gives a comprehensive
evaluation on various hydraulic appliances performance by gotten data.
怠速比较测试 Idle Speed Comparison Test
怠速比较测试时， VDS100
提供特定发动机转速（如 700RPM)
，同时 ECU 取消发动机怠速控制
功能，读取各缸转速。 During idle
speed comparison test, VDS100
provides certain engine speed (like
700RPM), and at the same time
ECU cancels engine idle speed
control function and read speed of
each cylinder.
加速测试是用来对每缸工作性能进行评估。测试中关闭某一气缸点火的同时触发
发动机加速 ,( 例如对于 6 缸机，当关掉第 1 缸机时，只有 2,3,4,5,6 缸机在正常工作 ), 我们
可以得到失去第 1 缸机的加速数据。同样我们可以得到失去 2,3,4,5,6 缸机的加速数据。这
些数据可以拿来对比，评判某一缸的性能。 ( 如若第 1 缸的喷油量出现问题而比其他缸明显
少，那么在失去第 1 缸时发动机加速性能就明显比失去其他缸时快。因为在失去其他某一缸
做测试时，该喷油量不足的缸参与了工作） Accelerating test is used to evaluate working
performance of each cylinder. During the test, close the ignition of certain cylinder which
activates engine acceleration at the same time (e.g. when close Cylinder 1 of a 6-cylinder
engine, only Cylinder 2,3,4,5,6 work normally), we can get the accelerating data of the lost
Cylinder 1. Similarly, we can get the accelerating data of lost Cylinder 2,3,4,5,6 by the
same way. These data can be used to compare and recognize the performance of certain
cylinder. (if fuel injection quantity of Cylinder 1 is obviously less than that of others, the
engine accelerating performance of losing Cylinder 1 will be faster than that of losing other
cylinders. It is because that the lost cylinder with insufficient fuel quantity works when it is
closed.)
加速测试
Test procedures
主要步骤
Shut off Cyl. 3
Shut off Cyl. 4

Shut off Cyl. 1
Shut off Cyl. 2

 deactivate one injector
Engine speed
关闭一个喷油器
 increase quantity
Speed
发动机加速
 measure engine speed
测量速度
 sequential deactivating of
every injector
关闭一缸测试完后
，再依次关闭其他缸
，进行同样的试验
关闭 1 缸发动机转速达到 1400 第 3 缸功效太高 ( 太多喷油量 ,…) or

rpm Engine speed 其他缸功效太低 ( 缸盖漏气 ,…) the power
reaches 1400 rpm efficient of Cylinder 3 is too high
when closing (too much injected fuel, …) or pow
Cylinder 1 er efficient of other cylinders is
too low (cylinder head leaks, …)
关闭 2 缸发动机转速达到 1405
rpm
Engine speed reaches 1405
rpm when closing 测试值和最低限值比较
Cylinder 2 Comparison of test value and mini
limit value
rpm
( 第 3 缸不工作时，发动机转速
太低 ) Engine speed
reaches 1200 rpm
when closing
Cylinder 3 (when
该缸可能有问题，进一步检查
Cylinder 3 does
This cylinder might in trouble.
not
rpm work, engine Further check is needed.
Engine speedspeed is too
reaches 1395low)
rpm when closing
Cylinder 4.
流量计量单元测试 Metering Unit Test
计量单元诊断（高压油泵）
ring unit diagnosis (high pressure fuel pump)
现象：发动机怠速抖动，转速波动大，失速。
ble symptom: engine shakes at idle speed; running speed fluctuates greatly;
故障，当前只能更换高压泵总成。
se of trouble, replace high pressure fuel pump assembly at present
修站可通过轨压实验检测 meter-unit 的好坏。
situation of meter-unit can be tested by rail pressure test at service station.
过 meter-unit 在不同范围所对应的压力变化检测出其它故障。
r trouble can be detected by corresponding pressure change within different meter-unit ranges.
检测仪在两个恒定的转速和一个负荷变化的状态下检测 meter-unit 的变化所对应的轨压变化

Diagnosis device can detect rail pressure change caused by meter-unit change at two constant speed
and variable load.
断缸测试
Cylinder Stopping Test
断缸测试的原理同机械泵的相同
The theory of cylinder stop test is the same
as that of mechanical pump.
7 、选择 " 系统信息 " 功能，读 ECU 显示系统信息为
7. Click “system information” and
Read ECU system information
Function Choice
Trouble storage device
Trouble storage memory deletion function
Actual value
Actuator component
Recognition
Function test
System information
Page up Page On
7 、选择 " 系统信息 " 功能，读 ECU 显示系统信息为
7. Click “system information” and
Read ECU system information
Version Information
Vehicle/engine information
Vehicle identity code: VEH-ID-NO
Last maintenance time: VMS0
User definition 1: VMS1
User definition 2: P_532_V42-PCB14
User definition 3:
User definition 4:
User definition 5:
Engine model: TESTER-NO

Engine data part No: 108844SA_V42-14_M35
Order No.: EDC7UC31-14C0
Engine test time: 69-84-68
Program making time: 68-65-84
Engine EXW No.: WD618-440
Engine configuration No.: VMS2
Yes Print
、选择 " 冻结帧 " 功能，显示
Click “Freeze Frame”, Showing the following:
Function Choice
Data flow
Function test
System information
Freeze frame
Page up Page On
、选择 " 冻结帧 " 功能，显示
Click “Freeze Frame”, Showing the Following:
Freeze Frame
Read freeze frame by click trouble code
Yes
击确定后显示故障码，点击故障码则显示冻结帧信息
er Clicking “Yes”, Trouble Code Comes Up
er Clicking Trouble Code, Freeze Frame Comes Up
Trouble Code
0140 Supercharger voltage exceeds upper limit value
0b10 Rail pressure sensor voltage exceeds upper limit value
0ac2 Fuel metering device open circuit
03a2 Emission fan has not signal
01b0 Coolant temperature senor voltage exceeds upper limit
value
06d0 Intake temperature sensor voltage exceeds upper limit
value
0061 Voltage of accelerator pedal 1 is less tan lower limit value
0071 Voltage of accelerator pedal 2 is less than lower limit
value
Page up Page On
击确定后显示故障码，点击故障码则显示冻结帧信息
er Clicking “Yes”, Trouble Code Comes Up
er Clicking Trouble Code, Freeze Frame Comes Up
Freeze Frame
Trouble No. 3a2

Running speed: 1472.00 RPM
Accelerator pedal: 32.55%
Intake pressure: 1090 hpa
Rail pressure: 752.62 bar
Water temperature: 77℃
Fuel injection quantity: 20 mg/cyc
Intake temperature: 30℃
Atmosphere pressure: 0.98 bar
Oil temperature: 84℃
Battery voltage: 24.27 V
Yes Print
、主菜单选择下翻页后选择 " 环境变量 " 功能，显示：
. Click “Environment Variable” after Choosing “Page On”,
Showing the Following:
Function Choice
Environment variable
Time information
Page up Page On
、主菜单选择下翻页后选择 " 环境变量 " 功能，显示：
. Click “Environment Variable” after Choosing “Page On”,
Showing the Following:
Environment Variable
Read environment variable by clicking trouble code
Yes
点击确定后显示故障码，点击故障码则显示环境变量信息
After Clicking “Yes”, Trouble Code Comes Up.
After Clicking Trouble Code, Environment Variable Comes Up
Trouble Code
0140 Supercharger voltage exceeds upper limit value
0b10 Rail pressure sensor voltage exceeds upper limit value
0ac2 Fuel metering device open circuit
03a2 Emission fan has not signal
01b0 Coolant temperature senor voltage exceeds upper limit
value
06d0 Intake temperature sensor voltage exceeds upper limit
value
0061 Voltage of accelerator pedal 1 is less tan lower limit value
0071 Voltage of accelerator pedal 2 is less than lower limit
value
Page up Page On
点击确定后显示故障码，点击故障码则显示环境变量信息
After Clicking “Yes”, Trouble Code Comes Up.
After Clicking Trouble Code, Environment Variable Comes Up
Environment Variable
The first record of environment variable
Trouble No. 3a2
Speed: 1472.00 RPM
Vehicle speed: 0 km/h
Water temperature: 77 ℃
The last record of environment variable

Trouble No. 3a2
Speed: 1472.00 RPM
Vehicle speed: 0 km/h
Water temperature: 77 ℃
Yes Print
谢谢！

潍柴欧三柴油机电控培训教材

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潍柴欧三柴油机电控培训教材

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潍柴欧三电控培训教材

Weichai EUROIII Electronic Control

WP12N(4V) 336 ～ 460

WP12(4V) 375 ～ 480

WP10N 270 ～ 336

WP10 270 ～ 375

WP7E30(4V) 210 ～ 300

WP6 180 ～ 240

WP4 165 功率 Power

150 200 250 300 350 400 450 500 550 PS

 两气门 WP10 是 WD615 经典动力的再次升级，联合 AVL 和

 Emission ： Euro III/Euro IV

 潍柴欧洲研发中心和奥地利 AVL 公司联合开发

 Weichai European R&D center and Austria AVL company

给 ECU 提供信 给仪表盘提供数据

共轨特点： 1. 燃油喷射独立 - 单体泵凸轮轴控制

BOSH ECU circuit boards

要技术参数 main parameter

DBV 关闭时 DBV 打开时

High pressure fuel inlet

No Name Abbreviation Function

8 Air P sensor APS Detection of air pressure

1 、永磁铁 permanent magnet 2 、传感器壳体 sensor shell

Mounting bolt hole connector

CRS ： 2.19-ground 2.23-signal

CAS ： 2.10-ground 2.09-signal

Coil resistance ： 860±86Ω (20℃)

1 、电子接头 electrical connector 2 、壳体

CTS ： 2.26-ground 2.15-signal

Measurement of intake manifold

BPS ： 2.25-ground 2.34- pressure signal

• 精确测量对系统有效运行至关重要 accurate measurement is very important for

RDS ： 2.12-ground 2.14- signal

2.03(white)-ECU 24V 2.06(gray)- exhaust brake Electromagnetic valve

6.Starter run normally

 水温、机油温、进气温度过高时， ECU 会进入

E 传感器故障 sensor problem

发动机转速 RPM 1386 1384 1496 1385 1383 1384

所断缸名称 第1缸 第2缸 第3缸 第4缸 第5缸 第6缸

发动机转速 RPM 1382 1383 1492 1381 1382 1384

1 、读取故障码 trouble code reading

1 、故障诊断仪本体 Trouble diagnosis device

外用电源连接口 external power connector

外用电源连接口 external power connector

Vehicle Type Choice

Page up Page down

Diagnosis software version choice

This program is applicable for diagnosing

System and SMARTBOX Initiation

SMARTBOX reset [success]

14 too high coolant sensor voltage not finished;

1382 short circuit of power by intake heating not finished;

Trouble Code Removal

Remove the recorded trouble code?

Trouble Code Removal

Successful trouble code removal

Trouble Code Removal

Battery voltage 1.96V

Engine running speed 100 r/min

Accelerator pedal location sensor 1 0.49V

Accelerator pedal location sensor 2 0.49v

Fuel pre-injection time 100 ms

Main injection time 100 ms

给 ECU 提供信给仪表盘提供数据

所断缸名称第1缸第2缸第3缸第4缸第5缸第6缸