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Repair Manual of D10 Engine CONTENTS Chapter I The Working Principle of D10 Engine Section I Working Principle of Diesel Engine Section II Working Principle of Common Rail Engine Chapter II The Structure D10 Engine Section I Structure of Common Rail Engine Section II Electronic Control System of Common-rail Engine Section III Main Parts of Fuel System 14 Chapter III Assembling of D10 Euro III Series Diesel Engine 27 Chapter IV Disassembling and Assembling of Fuel System 51 Chapter V Troubleshooting of D10 Engine 89 Section I Failure of Starting 90 Section II Abnormal Sound from Engine 100 Section III Premature Abrasion 110 Section IV Too Low Pressure of Engine Oil .112 Section V Mixture of Oil and Water 117 Section VI Power Deficiency 120 Section VII High Water Temperature in Engine 127 Section VIII Water Return of Engine 131 Section IX Diesel on Oil Pan 133 Section X Black Smokes 134 Section XI White Smokes 137 Section XII Blue Smokes 140 Section XIII Serious Consumption of Engine Oil 142 Appendix I Procedures for Flash Code Diagnosis of Malfunction Lamp 144 Appendix II Flash code List for Malfunctions of High-pressure Common Rail Diesel Engine 145 Appendix III Circuit Diagram of High-pressure Common Rail Fuel Injection System Harness 159 Chapter I The Working Principle of D10 Engine Section I Working Principle of Diesel Engine Engine is the power source of automobile, which changes the energy in certain form into the mechanical energy The engine for automobile is a device which converts the thermal energy into the mechanical energy As the combustion is carried out inside the engine (i.e in the cylinder), the engine is also called internal combustion engine As for combustion modes, there are two kinds of internal combustion engines, i.e spark ignition engine (gasoline engine) and compression ignition engine (diesel engine) For the spark ignition engine, the gasoline and air are mixed at first, and then spark ignition is carried out at the proper time; for the diesel engine, the diesel oil is injected into combustion chamber in time and then mixed with air, so that the automatic combustion can be carried out with the help of high temperature arising from compression With high performance on compression and power, the diesel engines are extensively applied to heavy-duty trucks Fig 1-1 D10 Series Engine I Terms: Top Dead Center: The position where the piston top is located in cylinder when the piston is set at the outmost position away from the slewing center of crankshaft, namely when the piston is set at the highest position Bottom Dead Center: The position where the piston top is located in cylinder when the piston is set at the nearest position away from the slewing center of crankshaft, namely when the piston is set at the lowest position Stroke: It means the movement of piston from one dead center to the other dead center for one time Stroke of Piston: It means the distance of piston movement from one dead center to the other dead center Usually, it is expressed as the letter “S” During one circle of rotation of crankshaft, the piston will reciprocate in the cylinder for strokes Cylinder Capacity: It means the room formed by movement of piston from top dead center to bottom dead center The capacity of multi-cylinder engine is the capacity sum of all cylinders The engine capacity (also called displacement) indicates the capacity sum of all engine cylinders Capacity of Combustion Chamber: The room above piston top when the piston is located at top dead center is called combustion chamber The capacity of this room is called capacity of combustion chamber Total Capacity of Cylinder: It means the room of all cylinders above piston top (namely the capacity sum of cylinder and combustion chamber) when the piston is located at bottom dead center Compression Ratio: It means the ratio of capacity sum of cylinders to capacity of combustion chamber It indicates the degree of gas compression in cylinder when the piston is moving from bottom dead center to top dead center At present, the prevalent compression ratio of diesel engine is 16~21 II Working Cycle of Engine The working course of engine is composed of continuous processes, namely intake stroke, compression stroke, expansion stroke and exhaust stroke, and such a complete working course is called as a working cycle To make the engine run constantly, the working cycle must be carried out repeatedly During a working cycle, if the crankshaft rotates for two circles and the piston reciprocates for two times to cover four strokes, such an engine is called four-stroke engine While during one working cycle, if the crankshaft rotates for one circle and the piston reciprocates for one time to two strokes, such an engine is called two-stroke engine The working cycle of four-stroke engine is shown as follows: Fig 1-2 Schematic Diagram of Working Principle of Engine Intake Stroke: During it, the piston moves from top dead center to bottom dead center, the capacity above the piston is increased, the pressure in cylinder becomes lower than the atmospheric pressure and the pressed air is compressed into cylinder promptly At the same time, the intake valve is opened and the exhaust valve is closed When the piston arrives at the bottom dead center, the intake valve is closed and the air intake terminates Compression Stroke: When the piston arrives at the bottom dead center, the crankshaft will continue rotating under the effect of inertia force of flywheel and the piston can move upwards from bottom dead center At the same time, the intake and exhaust valves are closed and the air in cylinder is compressed into the combustion chamber When the piston arrives at the top dead center, the compression stroke completes The air pressure in cylinder will be about 2,800~2,600kpa Expansion Stroke: When the “compression stoke” finishes, the diesel oil is injected into the cylinder by the injector, the compressed combustible air mixture burns immediately, and the temperature as well as the pressure in cylinder increases sharply The piston is driven by the gas pressure to move downwards and make the crankshaft rotate to carry out expansion through connecting rod As the piston moves downwards, the pressure and temperature of gas decrease When the piston arrives at the bottom dead center, the expansion stroke terminates Exhaust Stroke: During this course, the piston moves upwards from bottom dead center, the exhaust valve is opened, and the waste gas is exhausted from cylinder under the effect of residual pressure of itself and upward movement of piston When the piston arrives at the top dead center, the exhaust valve is closed and the exhaust stroke terminates III Expansion Sequence When the crankshaft rotates for two circles, each cylinder will execute expansion for one time As D10 series diesel engine for heavy-duty truck has six cylinders To secure the stable operation of engine, the crankshaft has been specially designed and enables each cylinder to execute expansion at different times The expansion sequence of six-cylinder four-stoke engine is 1-5-3-6-2-4 Section II Working Principle of Common Rail Engine I Definition of Common Rail Technology The common rail technology refers to a fuel supply means, in which the generation course of injection pressure and injection course are completely separated in the closed-loop system consisting of the fuel supply pump, common rail component, and injector II Features of Common Rail Electronically-controlled Fuel Injection Technology It can not only help reach a relatively high injection pressure and achieve the control over the injection pressure and fuel injection quantity but also enable the pilot injection and sectional injection, which accordingly optimizes the fuel injection features, lowers the diesel engine noise and greatly reduces the discharge of the harmful ingredients in the exhaust gas Its features are as follows: Designed with advanced electronic control devices and high speed electromagnetic switch valves, facilitating the control over the fuel injection course and providing many controllable parameters, which benefit the whole course optimization of the combustion of the diesel engine The common rail fuel supply method is applied, which brings small pressure fluctuation of the fuel injection system, little interference between various injectors, relatively high control precision in the injection pressure and precise control over the fuel injection quantity The high speed electromagnetic switch valve with a high frequency can be controlled flexibly, which enables a wide adjustable range of the injection pressure of the fuel injection system and can also achieve the functions such as pilot injection more simply to offer effective means to the optimization of the fuel injection law of the diesel engine, improvement on the performance and reduction of the exhaust gas discharge The system structure can be transferred easily and is adaptable in a wide range, especially it is able to well match with all the light, medium and heavy-duty diesel engines nowadays, which shows a good prospect on the market Chapter II The Structure D10 Engine Section I Structure of Common Rail Engine The D10 Series diesel engine for heavy-duty truck can sufficiently meet the power requirements of 91 Series truck of corresponding tonnage as well as the requirements of other purposes such as engineering machinery It is also featured by compact structure, fine rigidity, reliable operation, long service life, good performance and well economical efficiency The structure features of diesel engine are summarized as follows: a One cylinder head matches with one cylinder, which is good for reliable operation and convenient removal b The oil injection pump is set at the left side (seen from the free end of engine), which is good for arrangement on vehicle c The built-in oil cooler is applied, working safely and reliably d All engines of this series are six-cylinder in-line engines, which are highly interchangeable and convenient for complete vehicle assembly The engine for automobile is mainly composed of crank connecting rod mechanism, distribution mechanism, fuel supply system, lubrication system, intake/exhaust system and starting system I Overview of Common Rail Engine In terms of the D10 engine of Euro III manufactured by China National Heavy Duty Truck Group Co., Ltd., with application of the most advanced design means and testing methods in the world and supported by the huge database of RICARDO and experienced designers, and with the help of the software such as three-dimensional finite element, WAVE combustion analysis and CFD hydrodynamic calculation analysis and components and parts testing equipment, the interior structures of important components and parts are originally designed, the interior structures of the engine body and cylinder head are improved qualitatively; on the basis of the WAVE combustion simulation, hydrodynamic calculation and optimal supercharger match, the combustion chamber, atomization and airflow are reasonably organized, the water flow and thermal load of the cylinder and cylinder head are improved fundamentally, and the thermal load and mechanical load are improved and its shockproof performance is greatly enhanced The key components and parts such as connecting rod, crankshaft, piston, piston ring, and bearing shell are optimized in material selection and key structural size, and the thermal and mechanical shock resistances are enhanced greatly, which underpins the reliability improving, noise reducing and power promoting The engine has a B10 service life not less than 12,000 hours, with a complete machine noise lower than 97 dB The application of generation electronically-controlled common rail fuel injection system and four-valve structure and its excellent combustion and air-inflation performance bring the engine a very high dynamic behavior With a constant engine displacement, the maximum power of the engine can reach up to 294 kW, namely, 400 hp The engine can satisfy the discharge requirement of Euro IV if the common rail pressure is slightly adjusted and necessary processing system is provided additionally while the installation dimensions of the complete machine keep unchanged, which greatly facilitates the matching of the main engine plants The structural features are summarized as follows: New generation of electronically-controlled common rail fuel injection system of Denso Noise being lowered to less than 97 dB (A) Lowering the combustion noise: One of the reasons for selecting the common rail fuel injection system is that the common rail system can better in controlling the engine noise; and the pilot injection is a very good means The pilot injection fuel being injected into the cylinder beforehand has adequate combustion readiness time, and the pilot injection fuel has a very small quantity, which brings little premixed fuel gas in the preliminary combustion This greatly improves the generally inevitable and inherent situation that the diesel engine has not only high preliminary combustion value and great combustion noise As a result, the pilot injection of the common rail fuel injection system can obviously lower the combustion noise In addition, the electronically-controlled common rail system can precisely compensate the unbalance between the fuel injections of various cylinders, which cannot be achieved by the mechanical pump and greatly improve the shock situation of the engine as a result Enhancing shock absorbing behavior and reducing noise: The improved design of the cylinder body and crankcase fully strengthens its rigidity; and through the three-dimensional finite-element vibratory response analysis and actual testing, it effectively reduces the vibration and noise of the cylinder body assembly, and noise radiation The noise reduction measures are fully weighed in designing the parts like rocker arm bonnet Shock absorbing measures: The crankshaft vibration damper is redesigned through analyzing the former torsional vibration system of the crankshaft JOCOBS Electronically-Controlled Brake System The engine is provided with the exhaust type brake device of Jacobs (U.S.A), working with the exhaust brake at the same time; when the engine speed reaches 2200r/min, a braking power not less than 146 kW can be obtained which obviously enhances the brake power of the vehicle and improves the vehicle security New generation of cold starting apparatuses The electronic control system can automatically indicate whether the engine is in a starting state, and automatically adjust the advance angle and fuel injection quantity in accordance with the air and water temperature, and therefore, the cold starting performance of the engine is obviously promoted The resistance air preheater can, under the control of the electronic control system, perform the heating in advance before the engine starts, and automatically continues to heat for some time in accordance with the engine speed after the engine runs, which not only greatly enhance the cold starting performance of the engine but also obviously reduce the phenomenon (inevitable for traditional diesel engines) in which the unburned diesel gives out white smoke in case of low temperature start Excellent driving and controlling performance The electronic control system can automatically adjust the fuel injection of the injection nozzle according to the different working conditions such as engine starting, idle speed, departure, acceleration, steady speed, neutral position, astern running, air conditioner using, and power take off, and thus the driving and controlling performance is greatly enhanced The electronic control system can, in accordance with the difference in the rotation speeds of various cylinders in operation, automatically balance the fuel injection quantities of various cylinders to make the rotation speeds of various cylinders in operation become exactly the same so as to enable the engine to achieve a very steady idle speed CEVB Technology As an auxiliary braking apparatus, the EVB system is an engine retarder and based on the traditional exhaust auxiliary braking apparatus of the butterfly valve, and it can further enhance the braking efficiency of the engine Fig 2-1 Outside View of Common Rail Engine II Fundamental Structure of Common Rail Engine Engine Body Based on the wide type cylinder body of the original design of Steyr in compliance with Euro II Emission Standard, the engine is greatly altered in order to further lower the engine noise, and significantly improved to promote the thermal load of the engine However, the improvement is mainly embodied by the alteration to the casting blank, and what is related to the machine tooling is altered little; and therefore, the cost of the cylinder body is equivalent to that of the cylinder body in compliance with Euro II Emission Standard Fig 2-2 Engine body, crankcase, and flywheel casing Main parts: Engine body Crankcase Flywheel casing Cylinder casing stud Rear oil seal Fuel injection pump bracket Cylinder head Thrust plate Hexagon bolt 10 Main bearing stud The dry type cylinder casing is applied to the engine body, and it is transition fit between the cylinder casing and the cylinder holes of the engine body The thin-wall cylinder casing is manufactured by abrasion-proof alloy cast iron, with a wall thickness of mm; and the testing of the cylinder casing demands the dedicated measuring unit The internal surface of the cylinder casing is covered by specially-made overlapping curves, and this brings good effect on the acceleration of running-in and abrasion-proof performance The front end of the engine body is connected to the timing gear chamber while its rear end is connected to the flywheel casing There is a conjunction surface for mounting the fuel injection pump bracket in the middle of the left side of the engine body; after the said bracket is mounted, the components will be processed, and the fuel supply pump bracket shall not be disassembled after the components are processed so as not to make the installation precision of the fuel supply pump be affected by the disassembly and reinstallation Crank-connecting Rod Mechanism Crankshaft: The crankshaft of the D10 series diesel engine is manufactured by steel die forging, with 42CrMo steel as its material The crankshaft has 12 balancing weights, a main journal of Ф100 mm and rod journal of Ф82 mm, and the width of each journal is 46 mm; and the crankshaft goes through the treatment of tufftride and has a good fatigue strength and abrasive resistance Crankshaft Vibration Damper: The silicon oil damper (outside diameter, Φ280 mm) is adopted, with good reliability and effect, and torsional-vibration amplitude is controlled within 0.2° Flywheel: The SAE1 flywheel is adopted, the gear ring has 136 teeth, and the matched clutch wearing-piece has a diameter of Φ430 mm Be noticed that it is clearance fit between the SAE1 flywheel and gear ring (16-hole flywheel) Piston: The forced cooling type of built-in oil-cooled gallery piston is applied, the piston is manufactured by MAHLE 142 with a higher thermal load resistance, and the small end of connecting rod is of wedge structure, which enhances the piston strength accordingly The first ring groove is inset by cast iron, which is required to have a good sticking to the piston only so as to guarantee a good adhesive strength and heat transfer effect The piston has two gas rings and one oil scraping ring; the first gas ring is the double ended trapezoidal tubbish ring in the cast-iron inset ring groove, and the working surface is plated with chromium-based ceramic, which benefits the running-in, anti-galling and antifriction effect The second gas ring is a surface-phosphatized complex-alloy tapered-face ring, with a ring height of mm, and the assembling clearance between the ring and ring groove is 0.08~0.115 mm The third ring is a coil-spring-loaded alloy cast iron oil ring, with a ring height of mm, and the double-edged surface is plated with chromium, with a strong oil scraping capability, and the clearance between the oil ring and ring groove is 0.04~0.075 mm The piston pin hole has a diameter of Ф50 mm and the complex molded lines are applied to the piston skirt to guarantee that the piston and the cylinder casing are well contacted with each other, and there is a 0.02 mm-thick spray coating of graphite for the skirt surface, which brings a good antifriction effect The compression height of piston is 80 mm, and the top land has a shallow ω-type combustion chamber The compression clearance after the piston is mounted in the cylinder is mm The piston is cooled by engine oil via injection nozzle Piston Pin: The round structure with a diameter of Ф50 mm is applied, and its internal and external surfaces both go through the treatment of carburizing and quenching, with a case hardness of 57~65HRC Connecting Rod: It is forged by means of forging die and the connecting rod body is thickened to bear a maximum combustion pressure of 160bar The connecting rod is 219 mm long, its big end is 46 mm wide, its small end is of wedge structure, and the thinnest part is about 29 mm The chamfer angle of the big end of the connecting rod is 45°, with application of zigzag positioning structure of 60°and two connecting-rod bolts of M14×1.5 for the connection, and the screwing up of the connecting-rod bolts shall be in conformity to the requirements of Rotation Angle Screwing Method The connecting-rod bolt has a performance grade of 12.9, 42CrAH being applied The rotation angle anti-loosening measures are applied to the connecting-rod bolts, and in accordance with the requirements, the connecting-rod bolts are not allowed to be reused or used beyond the limit so as to avoid fracture and collapse accidents of the machine The small end of the connecting rod is manufactured by steel-backed copper-aluminum alloy, with a thickness of 2.5 mm; and its lubrication groove is T-shaped, with a big pressure bearing surface The weight difference between the connecting rods in the same group in the installation is not more than 29g Connecting Rod Bearing Shell: The steel-backed unequal-thickness bearing shell with a new plating material (supplied by Miba) is applied to the connecting rod bearing shell; the upper and lower bearing shells use different material, the upper bearing shell is able to sustain a higher detonation pressure, and the two shells shall not be misplaced in the assembly Main Bearing Shell: The steel-backed equal-thickness bearing shell with a new plating material (supplied by Miba) is applied to the main bearing shell and can sustain a higher detonation pressure The seven main bearing shells share the same width, and are all universal and manufactured by the steel-backed tin-aluminum alloy, with a hardness of HV35~45 10 Flash Code 44 45 46 47 51 52 53 54 55 Malfunction Code Meanings of Code Action of ECU Malfunction Point Malfunction Phenomenon P1142 Low signal from potentiometer at idle speed Light off Open-circuit of 30AD14 signal wire P0617 Short-circuit to battery of startup switch Light on Open-circuit of 48SW2 and short-circuit to power supply at pin 48 P1530 Engine shutdown switch is seized and closed Light on 50SW4 ON Abnormal flameout of engine P0850 Malfunction for circuit of neutral gear switch Light on, and cruise stops Open-circuit of 66 SW9 (VS>80km/h) Poor function of PTO, exhaust brake and cruise, etc P0201 Open-circuit of fuel injector TWV1 output, and disconnection of fuel injector coil Light on, cruise stops, FCCB stops, and fuel limitation 70% Open-circuit of 103 TWV1 Poor output power, deterioration of exhaust performance, and increase of engine noise P0202 Open-circuit of fuel injector TWV5 output, and disconnection of fuel injector coil Light on, cruise stops, FCCB stops, and fuel limitation 70% Open-circuit of 105 TWV5 Poor output power, deterioration of exhaust performance, and increase of engine noise P0203 Open-circuit of fuel injector TWV3 output, and disconnection of fuel injector coil Light on, cruise stops, FCCB stops, and fuel limitation 70% Open-circuit of 104 TWV3 Poor output power, deterioration of exhaust performance, and increase of engine noise P0204 Open-circuit of fuel injector TWV6 output, and disconnection of fuel injector coil Light on, cruise stops, FCCB stops, and fuel limitation 70% Open-circuit of 139 TWV6 Poor output power, deterioration of exhaust performance, and increase of engine noise P0205 Open-circuit of fuel injector TWV2 output, and disconnection Light on, cruise stops, FCCB stops, and fuel limitation Open-circuit of 137 TWV2 Poor output power, deterioration of exhaust performance, Flash Code 56 57 57 57 58 58 58 Malfunction Code Meanings of Code of fuel injector coil Action of ECU 70% Malfunction Point Malfunction Phenomenon and increase of engine noise P0206 Open-circuit of fuel injector TWV4 output, and disconnection of fuel injector coil Light on, cruise stops, FCCB stops, and fuel limitation 70% Open-circuit of 138 TWV4 Poor output power, deterioration of exhaust performance, and increase of engine noise P2148 Short-circuit to battery of fuel injector COM1 / short-circuit to battery of TWV1, 3, and output Light on, cruise stops, FCCB stops, and fuel limitation 50% Short-circuit to +B of 106, 107 fuel injector COM1 / short-circuit to +B of 103, 104 and 105 Poor output power, deterioration of exhaust performance, and increase of engine noise P2147 Short-circuit to ground of fuel injector COM1 /short-circuit to ground of TWV1, 3, and output Light on, cruise stops, FCCB stops, and fuel limitation 50% Short-circuit to GND of 106, 107 fuel injector COM1 / short-circuit to GND of 103, 104, and105 Poor output power, deterioration of exhaust performance, and increase of engine noise P2146 Load open-circuit of fuel injector COM1 output /load open-circuit of TWV1, 3, Light on, cruise stops, FCCB stops, and fuel limitation 50% Open-circuit of 106, 107 fuel injector COM1 / open-circuit of 103, 104, and 105 Poor output power, deterioration of exhaust performance, and increase of engine noise P2151 Short-circuit to battery of fuel injector COM2 /short-circuit to battery of TWV2, 4, and output Light on, cruise stops, FCCB stops, and fuel limitation 50% Short-circuit to +B of 142, 143 fuel injector COM2 / short-circuit to +B of 137, 138, and139 Poor output power, deterioration of exhaust performance, and increase of engine noise P2150 Short-circuit to ground of fuel injector COM2 /short-circuit to ground of TWV2, 4, and output Light on, cruise stops, FCCB stops, and fuel limitation 50% Short-circuit to GND of 142, 143 fuel injector COM2 / short-circuit to GND of 137, 138, and 139 Poor output power, deterioration of exhaust performance, and increase of engine noise P2149 Load open-circuit of fuel injector COM2 output /load Light on, cruise stops, FCCB stops, and fuel limitation Open-circuit of 142, 143 fuel injector COM2 /open-circuit of 137, 138, and 139 Poor output power, deterioration of exhaust performance, Flash Code 59 59 61 61 62 62 63 Malfunction Code P0611 P0200 Meanings of Code open-circuit of TWV2, 4, and Action of ECU 50% Malfunction for charging circuit of condenser Light on, cruise stops, FCCB stops, fuel limitation 50% and pressure limitation-low Malfunction for charging circuit of condenser Light on, cruise stops, FCCB stops, fuel limitation 51% and pressure limitation-low Malfunction Point Inner malfunction of ECU Deterioration of output power and exhaust performance, and increase of engine noise Inner malfunction of ECU Deterioration of output power and exhaust performance, and increase of engine noise Engine shaking at idle speed, poor engine power in fully loaded situation, increases of fuel consumption than normal state P0301 Malfunction of Cylinder fuel system Light off, and system without action Fuel injector is damaged without injection (determined by FCCB) P0263 1# flow damper takes effect Light off, and system without action Damper takes effect and fuel injector stops supplying P0305 Malfunction of Cylinder fuel system Light off, and system without action Fuel injector is damaged without injection (determined by FCCB) P0266 5# flow damper takes effect Light off, and system without action Damper takes effect and fuel injector stops supplying P0303 Malfunction of Cylinder fuel system Light off, and system without action Malfunction Phenomenon and increase of engine noise Fuel injector is damaged without injection (determined by FCCB) Engine shaking at idle speed, poor engine power in fully loaded situation, increases of fuel consumption than normal state Engine shaking at idle speed, poor engine power in fully loaded situation, increases of fuel consumption Flash Code 63 64 64 65 65 66 66 Malfunction Code Meanings of Code Action of ECU Malfunction Point P0269 3# flow damper takes effect Light off, and system without action Damper takes effect and fuel injector stops supplying P0306 P0272 Malfunction of Cylinder fuel system Light off, and system without action Fuel injector is damaged without injection (determined by FCCB) 6# flow damper takes effect Light off, and system without action Damper takes effect and fuel injector stops supplying P0302 Malfunction of Cylinder fuel system Light off, and system without action Fuel injector is damaged without injection (determined by FCCB) P0275 2# flow damper takes effect Light off, and system without action Damper takes effect and fuel injector stops supplying P0304 Malfunction of Cylinder fuel system Light off, and system without action Fuel injector is damaged without injection (determined by FCCB) P0278 4# flow damper takes effect Light off, and system without action Damper takes effect and fuel injector stops supplying Malfunction Phenomenon than normal state Engine shaking at idle speed, poor engine power in fully loaded situation, increases of fuel consumption than normal state Engine shaking at idle speed, poor engine power in fully loaded situation, increases of fuel consumption than normal state Engine shaking at idle speed, poor engine power in fully loaded situation, increases of fuel consumption than normal state Flash Code 67 67 67 68 69 71 71 Malfunction Code P0193 P0192 Meanings of Code High signal from common rail pressure sensor Low signal from common rail pressure sensor Action of ECU Light on, cruise stops, fuel limitation 70%, and rail pressure limitation 80 Light on, cruise stops, fuel limitation 70%, and rail pressure limitation 80 Malfunction Point Malfunction Phenomenon Simultaneous open-circuit of 121AD4 and 132AD5 signal wire Poor output power, deterioration of exhaust performance (with black smokes), and increase of engine noise Simultaneous short-circuit to 134A-GND1of 121AD4 and 132AD5 signal wire Poor output power, deterioration of exhaust performance (with black smokes), and increase of engine noise Sensor is damaged and output voltage remains unchanged Poor output power, deterioration of exhaust performance (with black smokes), and increase of engine noise Common rail pressure exceeds 191MPa Poor output power, deterioration of exhaust performance, and white smokes Common rail pressure exceeds 180MPa Poor output power, deterioration of exhaust performance, and white smokes Signal from common rail pressure sensor keeps at intermediate range Light on, cruise stops, fuel limitation 70%, and rail pressure limitation 80 Common rail pressure exceeds upper limit Light on, cruise stops, fuel limitation 70%, and rail pressure limitation 80 P1089 Common rail pressure exceeds upper limit Light on, cruise stops, fuel limitation 70%, and rail pressure limitation 80 P0629 Short-circuit of PCV1 output, and short-circuit to battery Light on, cruise stops, and fuel limitation 70% Short-circuit to +B of 152, 153 PCV1 Deterioration of output power and exhaust performance, and increases of fuel consumption P0628 Open-circuit of PCV1 output, and short-circuit to Light on, cruise stops, and fuel limitation Open-circuit of 152, 153 PCV1 or short-circuit to GND Deterioration of output power and exhaust performance, P0191 P0088 Flash Code 72 72 73 73 76 76 Malfunction Code P2634 P2633 P0629 P0628 P2635 P1088 Meanings of Code ground Action of ECU 70% Short-circuit of PCV2 output, short-circuit to battery Light on, cruise stops, and fuel limitation 70% Open-circuit of PCV2 output/ short-circuit to ground Light on, cruise stops, and fuel limitation 70% Short-circuit to battery of PCV1 and PCV2 Light on, cruise stops, PTO stops, FCCB stops, fuel limitation 50%, and engine shuts down immediately Open-circuit of PCV1 and PCV2 output/ short-circuit to ground Light on, cruise stops, PTO stops, FCCB stops, fuel limitation 50%, and engine shuts down immediately Fuel supply pump control is overloaded Light on, cruise stops, fuel limitation 70% and rail pressure limitation 80 Fuel supply pump control exceeds pressure Light on, cruise stops, fuel limitation 70% and rail pressure limitation 80 Malfunction Point Malfunction Phenomenon and increases of fuel consumption Short-circuit to +B of 150, 151 PCV2 Poor output power, deterioration of exhaust performance, and increases of fuel consumption Open-circuit of 150, 151 PCV2 or short-circuit to GND Poor output power, deterioration of exhaust performance, and increases of fuel consumption Simultaneous short-circuit to +B of 152, 153, 150, 151 , PCV1 and PCV2 Poor engine output power with difficulty in startup, increases of fuel consumption, and deterioration of exhaust performance Simultaneous open-circuit of 152, 153, 150, 151, PCV1 and PCV2 or short-circuit to GND poor engine output power with difficulty in startup, increases of fuel consumption, and deterioration of exhaust performance Mechanical malfunction of pump in overloaded state Poor output power, deterioration of exhaust performance, increase of engine noise, and engine stall Exceeding rail pressure NPC>PFIN+15MPa Poor output power, deterioration of exhaust performance, increase of engine noise, and engine stall Flash Code 77 78 Malfunction Code Meanings of Code Action of ECU P1266 Fuel supply pump control without load Light on, cruise stops, fuel limitation 70% and rail pressure limitation 80 P0093 Fuel supply pump control without load, including fuel leakage Light on, cruise stops, fuel limitation 70% and rail pressure limitation 80 Malfunction Point Malfunction Phenomenon Pump control could not advance pressure Poor output power, deterioration of exhaust performance, and white smokes Pump without pressure, including fuel leakage Poor output power, deterioration of exhaust performance, and white smokes Appendix III Circuit Diagram of High-pressure Common Rail Fuel Injection System Harness D10 ECU D10 ECU 电 路图 Circuit Diagram 预热指示灯 空气加热器 Air heater Preheating indicator lamp 排气制动指示灯 Exhaust brake indicator lamp 故障指示灯 Malfunction indicator lamp 双扭矩空车指示灯 Dual-torque no-load indicator lamp 预热继电器 Preheating relay 主继电器 Main relay 起动继电器 Starter relay 起动马达 Starter motor 空档继电器 Neutral relay 转速传感器 Rotation speed sensor 判缸传感器 Crankshaft position sensor 加速踏板信号 Accelerator pedal signal 加速踏板信号 Accelerator pedal signal 进气压力传感器 Intake pressure sensor 机油压力传感 器 Engine oil pressure sensor 共轨压力传感器 Common rail pressure sensor 动力输出传感 器 Power take-off sensor 出水温度传感器 Water outlet temperature sensor 燃油回油温度 传感器 Fuel oil return temperature sensor 进气温度传感器 Intake temperature sensor 怠速量控制电 位器 Idle control potential device 车速传感器 Ground speed sensor 制动开关 Brake switch 制动继电器 Braking relay 排气制动开关 Exhaust brake switch 发动机停止开关 Engine stop switch 离合器开关 （常闭） Clutch switch (always closed) 制动开关（常闭） Brake switch (always closed) 空档开关（常 闭） Neutral switch (always closed) 动力输出开关 Power take-off switch 空调开关 Air conditioning switch 巡航主开关（按钮） Cruise main switch (button) 巡航-、设置 （按钮） Cruise-/set (button) 巡航+、复位（按钮） Cruise+/reset (button) 双扭矩开关 Dual torque switch 暖机开关（按钮） Warm-up switch(button) 倒档开关 Reversing switch 诊断开关 Diagnosis switch 拖挂车开关 Tractor-trailer switch 停止灯开关 Stop lamp switch 排气制动 Exhaust brake 排气制动继电器 Exhaust brake relay 泄气制动电磁 阀 Gassing brake solenoid valve （主继电器后） (After the main relay) 0.78A/只 0.78A/Piece 继电器1 Relay 24V 指示灯 （装车上） 24V Indicator lamp (installed on the vehicle) 诊断工具 Diagnosis tool 转速信号输出 Rotation speed signal output 泄气制动 Gassing brake 仪表等 Instrument and so on 燃油水分报警器传 感器（安装在粗滤 上） Water-in-fuel alarm sensor (installed on the primary filter) 线束图号 Harness Diagram No 插接器 Connector Schematic Diagram of AMP Plug Harness 喷油器所有屏蔽层搭铁点。 用两根 0.75 平方毫米棕色电线 The earthed contact of all shielding layers of fuel injector 合并压接 Φ6 的孔式金属端子 Using two 0.75mm2 brown wires which are compressed and connected with a Φ6 eyelet metal terminal 孔位号 Hole position No 线径 Wire diameter ECU 管脚 ECU bayonet 孔位定义 Hole position definition 主继电器 Main relay 屏蔽层 Shielding layer 护套 Sleeve PCV 继电器输出 PCV relay output 辅助制动继电器输出 Auxiliary brake relay output 备用 Standby 油水分离信号 Oil-water separating signal 油水分离 Oil water separation 喷油器地 Injector ground 插接器 Connector CAN1 诊断口 CAN1 Diagnosis Port 插件 Connector 端子 Terminal Look from the wire incoming end （Attention: there are figures on the connector if look from the wire outgoing end） Schematic Diagram of Sinotruck Plug Harness 红色 Red 标记 Mark 孔位号 Hole position No 线径 Wire diameter ECU 管脚 ECU bayonet 孔位定义 Hole position definition 主继电器 Main relay 喷油器屏蔽层 Shielding layer of fuel injector 经济运行指示灯 Fuel-saving operation indicator lamp PCV 继电器输出 PCV relay output 辅助制动继电器输出 Auxiliary brake relay output 备用 Standby Reference： STERY EuroⅡ Engine Maintenance Manual , Power System Sales Center (Hangzhou) of CHINA NATIONAL HEAVY DUTY TRUCK GROUP CO., LTD WD615 Series Diesel Engine Maintenance Training Manual, Hangzhou Automotive Engine Factory of CHINA NATIONAL HEAVY DUTY TRUCK GROUP CO., LTD WD615 Series Engine Spare Parts Identification Diagram Volume, Technical Center of CHINA NATIONAL HEAVY DUTY TRUCK GROUP CO., LTD ... Engine The working course of engine is composed of continuous processes, namely intake stroke, compression stroke, expansion stroke and exhaust stroke, and such a complete working course is called... injection course are completely separated in the closed-loop system consisting of the fuel supply pump, common rail component, and injector II Features of Common Rail Electronically-controlled Fuel... Coil Drive Current Drive Current Drive Current Fuel Outlet Measuring Hole FuelInlet Measuring Hole Fuel Rail Control Chamber Control Chamber Pressure Control Chamber Pressure Control Piston Control