玉柴发动机电控EPR系统故障诊断手册.doc

Global Control Platform (GCP) Diagnostic Manual with Diagnostic Trouble Code Definitions电控EPR系统故障定义及诊断手册版本：V 1.12007-9-5广西玉柴机器股份有限公司技术中心电控部前 言尊敬的玉柴产品用户、产品服务工程师：首先感谢您选用玉柴机器股份有限公司的产品，并感谢您阅读电控EPR系统故障定义及诊断手册！玉柴的服务宗旨是：“倾我所有、尽我所能、竭诚用户、诚信天下”,为了更好地履行玉柴的服务宗旨，我们编印了电控EPR系统故障定义及诊断手册，希望本手册可以让用户更好地认识了解玉柴产品的结构与配置，让服务工程师方便、快捷的帮用户解决故障。本手册是根据玉柴电控EPR系统天然气发动机基本控制原理和控制策略编写的故障诊断手册，随着产品的不断改进提高和使用过程中不断出现的新故障，电控EPR系统故障定义及诊断手册中的有关内容将会有不同程度的变更，玉柴保留在不预先通知的情况下进行修改的权利，具体配置情况应以当时产品技术文件为依据，请用户和服务工程师注意本手册版本的变化。电控EPR系统故障定义及诊断手册由玉柴机器股份有限公司策划，玉柴技术中心电控部编制。其编写不足之处在所难免，敬请您多多指教，使之渐臻完善。谢谢！ 玉柴机器股份有限公司技术中心电控部 2007年6月1、专业术语缩写72、概述93、故障码信息通讯及显示103.1 诊断故障代码103.2 串行网络183.3 CAN184、闪码和故障指示灯输出195、故障标定设置/失效保护策略226、故障/诊断故障代码管理227、诊断测试287.1切断点火测试287.2 切断喷嘴测试297.3 点火测试297.4 电子节气门(DBW)测试307.5 外部电路电源测试317.6 压缩测试317.7 点火提前角控制测试327.8 怠速转速测试327.9 阻止燃料喷射/点火输入开关338、传感器参数348.1 进气温度/压力传感器(T-MAP)348.2 凸轮轴位置传感器348.3 水温传感器368.4环境传感器（内置环境湿度、温度、压力传感器）378.5油门传感器389、ECI EDIS软件使用方法介绍：399.1 软件的安装399.2 软件的使用409.3 常用参数在软件中的位置和名称，以及相应的意义459.4 曲线图的采集459.5 标定文件的写入4710、常见故障处理流程4910.1 发动机不能起动4910.2 常见故障代码和排除方法5111、 故障诊断代码描述53DTC 16- Crank and/or Cam Could Not Synchronize During Start53故障码16曲轴信号或凸轮轴信号启动时不能同步53DTC 107- MAP Low Voltage55故障码107进气岐管空气压力(MAP)电压低55DTC 108- MAP High Pressure57故障码108进气歧管压力高57DTC 111- IAT Higher Than Expected Stage 159故障码111IAT高于1级限值59DTC 112- IAT Low Voltage60故障码112IAT电压低60DTC 113- IAT High Voltage62故障码113IAT电压高62DTC 116- ECT Higher Than Expected Stage 164故障码116ECT高于1级限值64DTC 117- ECT/CHT Low Voltage65故障码117ECT/CHT电压低65DTC 118- ECT/CHT High Voltage67故障码118ECT/CHT电压高67DTC 121- TPS1 % Lower Than TPS2 %69故障码121TPS1比TPS2低69DTC 122- TPS1 Signal Voltage Low71故障码122TPS1信号电压低71DTC 123- TPS1 Signal Voltage High73故障码123TPS1信号电压高73DTC 127- IAT Higher Than Expected Stage 275故障码127IAT高于2级限值75DTC 129- BP Low Pressure76故障码129大气环境压力低76DTC 134- EGO Open/Lazy (HO2S1)78故障码134氧传感器开路/罢工78DTC 217- ECT Higher Than Expected 280故障码 217发动机冷却液温度高于2级限值80DTC 219- RPM Higher Than Max Allowed Governed Speed82故障码219发动机转速比最大允许调速转速高82DTC 221- TPS1 % Higher Than TPS2 %83故障码221TPS1比TPS2开度高83DTC 222- TPS2 Signal Voltage Low85故障码 222- TPS2 信号电压低85DTC 223- TPS2 Signal Voltage High87故障码 223- TPS2 信号电压高87DTC 236- TIP Active89故障码 236- TIP 传感器报错89DTC 237- TIP Low Voltage91故障码 237- TIP 电压低91DTC 238- TIP High Voltage93故障码238-TIP传感器电压高93DTC 311- Injector Driver #1 Open/Short-To-Ground95故障码 311- 1#喷嘴驱动端断路或与地短路95DTC 313、315、321、323、325、331、333、96335、341的诊断方法和故障处理流程请参考DTC31196DTC 312- Injector Driver #1 Short-To-Power97故障码 312- #1 Injector 驱动端与电源短路97DTC 314、316、322、324、326、332、334、336、98342的诊断方法和故障处理流程请参考DTC31298DTC 254- Knock 1 Excessive Signal99故障码 254-爆震传感器1信号太强99DTC 336-Crank Input Signal Noise101故障码 336曲轴输入信号有干扰101DTC 337-Loss of Crankshaft Input Signal103故障码 337 曲轴输入信号丢失103DTC 341-Camshaft Input Signal Noise104故障码 341 凸轮轴输入信号干扰104DTC 342-Loss of Camshaft Input Signal106故障码 342 凸轮轴输入信号丢失106DTC 562- Battery Voltage (V Bat) Low107故障码 562 电源电压低107DTC 563- Battery Voltage (V Bat) High109故障码 563 电池电压高109DTC 601- Microprocessor Failure - FLASH111故障码 601 微处理器失效111DTC 604- Microprocessor Failure - RAM113故障码 604 微处理器-随机存储器失效113DTC 606- Microprocessor Failure - COP115故障码 606 处理器-COP部分失效115DTC 642- Sensor Supply Voltage 1 Low (5Vext1)117故障码 642 提供给传感器的5伏参考电压1低117DTC 643- Sensor Supply Voltage 1 High (5Vext1)119故障码 643 输出的5V参考电压1高于预定值119DTC 650- MIL Open121故障码 650 故障灯开路121DTC 1111- RPM Above Fuel Rev Limit Level122故障码 1111 发动机转速高于燃料转速限制122DTC 1112- RPM Above Spark Rev Limit Level123故障码 1112 发动机转速高于点火限制转速123DTC 1151- Closed Loop High (LPG)124故障码 1151 LPG闭环修正量高124DTC 1152- Closed Loop Low (LPG)125故障码 1152 LPG闭环修正量低125DTC 1153- Closed Loop High (Natural Gas)126故障码 1153 NG闭环修正量高126DTC 1154- Closed Loop Low (Natural Gas)127故障码1154 NG闭环修正量低127DTC 1161-Adaptive Learn High (LPG)128故障码 1161 LPG自适应高128DTC 1511- AUX_PU1 High Voltage Fault129故障码 1511 模拟信号辅助通道PU1电压高129DTC 1512- AUX_PU1 Low Voltage Fault131故障码1512 辅助通道PU1电压低131DTC 1611- Sensor Supply Voltage (5Vext 1/2) Simultaneous Out-of-Range133故障码1611 传感器供给电压（5伏输出1/2）同时超出范围133DTC 1613-微处理器故障RTI 2135DTC 1614-微处理器故障RTI 3135DTC 1615-微处理器故障- 数模转换器135DTC 1616-微处理器故障- 中断135DTC 1628- CAN Address Conflict Failure137故障码 1628- CAN通讯地址冲突故障137DTC 1631- PWM1/Gauge1 Open/Ground Short139故障码 1631- PWM1/Gauge1 开路/对地短接139DTC 1632- PWM1/Gauge1 Short to Power141DTC 1632- PWM1/Gauge1 Short to Power142故障码 1632- PWM1/Gauge1 与电源短路142DTC 1633- PWM2/Gauge2 Open/Ground Short145DTC 1634- PWM2/Gauge2 Short to Power145DTC 1635- PWM3/Gauge3 Open/Ground Short145DTC 1636- PWM3/Gauge3 Short to Power145DTC 1641-蜂鸣器控制对地短路146DTC 1642- Buzzer Open147故障码 1642- 蜂鸣器开路147DTC 1643- Buzzer Control Short to Power149故障码 1643- 蜂鸣器控制与电源短路149DTC 1644- MIL Control Ground Short151故障码 1644- 故障指示灯控制地线短路151DTC 1645- MIL Control Short to Power152故障码 1645-故障指示灯控制与电源短路152DTC 2111: Unable to Reach Lower TPS153故障码 2111:不能达到较低TPS电压153DTC 2112:不能达到更高TPS155DTC 2115- FPP1 Higher Than IVS156故障码 2115：FPP1比IVS高156DTC 2120-FPP1无效电压和FPP2与IVS不一致158DTC 2122- FPP1 Voltage High159故障码 2122-FPP1 电压高159DTC 2300- Spark Coil #1 Primary Open/Short-to-Ground160DTC 2300- Spark Coil #1 Primary Open/Short-to-Ground161故障码2300-1#点火线圈初级线圈开路或短路接地161DTC 2301- Spark Coil #1 Primary Short-to-Power163故障码2301-1#点火线圈初级线圈与电源短接163DTC 2303- Spark Coil #2 Primary Open/Short-to-Ground164故障码2303-1#点火线圈初级线圈开路或短路接地164DTC 2304- Spark Coil #2 Primary Short-to-Power164故障码2304-2#点火线圈初级线圈与电源短接164DTC 2306- Spark Coil #3 Primary Open/Short-to-Ground164故障码2306-3#点火线圈初级线圈开路或短路接地164DTC 2307- Spark Coil #3 Primary Short-to-Power164故障码2307-3#点火线圈初级线圈与电源短接164DTC 2309- Spark Coil #4 Primary Open/Short-to-Ground164故障码2309-4#点火线圈初级线圈开路或短路接地164DTC 2310- Spark Coil #4 Primary Short-to-Power164故障码2310-4#点火线圈初级线圈与电源短接164DTC 2312- Spark Coil #5 Primary Open/Short-to-Ground164故障码2312-5#点火线圈初级线圈开路或短路接地164DTC 2313- Spark Coil #5 Primary Short-to-Power164故障码2313-5#点火线圈初级线圈与电源短接164DTC 2315- Spark Coil #6 Primary Open/Short-to-Ground165故障码2315-6#点火线圈初级线圈开路或短路接地165DTC 2316- Spark Coil #6 Primary Short-to-Power165故障码2316-6#点火线圈初级线圈与电源短接1651、专业术语缩写AL自适应学习CAN控制器局域网络CCPCAN标准协议CHT气缸盖温度CL闭环CNG压缩天然气DBW线性驱动（如电子节气门）DM诊断信息DMM多用途数字仪表（高阻抗，如汽车仪表）DST诊断工具DTC诊断故障代码DVOM数字伏特/欧姆表（万用表）ECIEControls公司ECIPPEControls公司（接口软件）专有的通讯协议ECM发动机控制模块ECT发动机冷却液温度ECU发动机控制单元EDISEControls公司显示及接口软件EGO排气氧传感器，典型的氧传感器为加热型EMWT排气岐管水温EPR电控调压器ERWT排气岐管出口温度ETB电子节气门ETC电子节气门控制FDR快速数据记录FMI失效模式指示器FO点火次序FP燃料压力FPP电子油门位置FRP燃料共轨管压力FRT燃料共轨管温度FSS故障快照FT燃料温度GCP综合控制平台HDGCP公路重型综合控制平台HEGO加热型排气氧传感器（同HO2S）HO2S加热型排气氧传感器IAC怠速空气控制IAT进气空气温度ICAV瞬时曲轴转角变化率IVS怠速确认开关LDGCP轻型综合控制平台（工业用，智能/逻辑线圈）LED发光二极管LPG液化石油气MAP进气歧管绝对压力MGCP船用综合控制平台MDGCP中型综合控制平台（工业用）mP微处理器Mfg制造商MIL故障指示灯NG天然气OBD随车在线诊断OEM原始设备制造商PC个人电脑PCU动力总成控制单元（模块）PFI进气口燃料喷射PGN参数组编号PWM脉宽调制RPM转速（转/分钟）Rx接收SAE汽车工程协会SA源地址SPFI进气口燃料顺序喷射SPN可疑参数代码Tach转速表TBI节气门体喷射TDC上止点TPS节气门位置传感器TSC扭矩/速度控制Tx发送UEGO宽域氧传感器（适用于稀燃发动机）VDC直流电压VR可变磁阻Vsw点火开关电压2、概述 该手册供原始设备制造商或EControls公司客户作为技术参考资料或培训资料，其中某些部分主要针对OEM讲述故障诊断系统。该手册适用于EControls公司工业用、船用及重型气体发动机的故障诊断，定义了基本故障代码及其处理程序。 该手册按如下方式编写：第一页：故障代码XXX-CAN 故障码 故障模式电路原理图l ECM输出/输入信号相关外部零件-确定发送信号给ECM的传感器或由ECM输出信号驱动的执行器l 故障检查条件-定义故障检查、诊断的条件l 故障激活（或触发）条件-定义故障激活的条件l 故障失效保护策略-定义故障激活后，推荐的发动机的失效保护策略。在某些情况下，标定工程师可以选择不同的保护策略l 排放或非排放关联故障该段定义其内部电路和其在控制系统中的作用该段描述故障激活条件第二页：故障处理流程故障代码XXX-CAN 故障码 故障模式小提示：对处理故障的一些有用的信息故障处理流程图辅助诊断信息1、。2、。是否3、故障码信息通讯及显示所有的故障码都可以通过安装在电脑中的EDIS接口软件显示。EDIS可以通过两种通讯协议与ECU交换数据：CAN或RS232（两者都利用ECIPP协议）。故障码可以通过CAN网络在基于CAN J1939协议的诊断工具或多功能显示单元中显示。3.1 诊断故障代码该手册中的故障所对应的数字故障码是参考SAE标准：推荐的故障代码定义 (SAE J2012)而编制的。虽然有标准可参考，标定工程师也可以在故障标定时设置一个新的故障代码。EDIS软件中所显示的故障码和故障指示灯闪码也会相应的改变。EDIS通过RS232或CAN与控制平台通讯。下表为根据J2012诊断故障代码标准定义和CAN1939诊断信息代码标准3而推荐的故障码:表1 推荐的串行故障码、闪码、J1939故障码故障描述J2012故障码GCP EDIS故障码/闪码故障代码设置1故障代码设置2故障代码失效模式指示故障代码失效模式指示MAP pressure highP010801081061610616MAP voltage lowP0107010710641064ECT voltage highP0118011811031103ECT voltage lowP0117011711041104ECT higher than expected stage 1P011601161101511015IAT voltage highP0113011310531053IAT voltage lowP0112011210541054BP pressure highP2229222910801080BP pressure lowP0129012910811081Vbat voltage highP056305631681516815Vbat voltage lowP056205621681716817Sensor supply voltage 1 highP064306431079310793Sensor supply voltage 1 lowP064206421079410794TPS1 voltage highP01230123513513TPS1 voltage lowP01220122514514TPS2 voltage highP0223022352019835202513TPS2 voltage lowP0222022252019845202514TPS1-2 higher than expectedP02210221510510TPS1-2 lower than expectedP01210121511511FPP1 voltage highP21222122913913FPP1 voltage lowP21232123914914FPP2 voltage highP21282128293293FPP2 voltage lowP21272127294294FPP1 higher than IVSP21152115910910FPP1 lower than IVSP21392139911911FPP2 higher than IVSP21162116290290FPP2 lower than IVSP21402140291291FPP1-2 higher than expectedP2126212691169116FPP1-2 lower than expectedP2121212191189118Oil pressure lowP0524052410011001Adaptive-learn gasoline bank1 highP0171017152266015202000Adaptive-learn gasoline bank1 lowP0172017252266005202001Closed-loop gasoline bank1 highP1155115552265515202040Closed-loop gasoline bank1 lowP1156115652265505202041Closed-loop gasoline bank2 highP115711570315202050Closed-loop gasoline bank2 lowP115811580315202051Closed-loop LPG highP1151115152265515202060Closed-loop LPG lowP1152115252265505202061Closed-loop NG highP115311530315202070Closed-loop NG lowP115411540315202071Adaptive-learn gasoline bank2 highP017401740315202010Adaptive-learn gasoline bank2 lowP017501750315202011Adaptive-learn LPG highP1161116152266015202020Adaptive-learn LPG lowP1162116252266005202021Adaptive-learn NG highP116311630315202030Adaptive-learn NG lowP116411640315202031Injector 1 open or short to groundP0261026165156515Injector 2 open or short to groundP0264026465256525Injector 3 open or short to groundP0267026765356535Injector 4 open or short to groundP0270027065456545Injector 5 open or short to groundP0273027365556555Injector 6 open or short to groundP0276027665656565Injector 7 open or short to groundP0279027965756575Injector 8 open or short to groundP0282028265856585Injector 9 open or short to groundP02850285056595Injector 10 open or short to groundP02880288056605Injector 1 coil shortedP0262026265166516Injector 2 coil shortedP0265026565266526Injector 3 coil shortedP0268026865366536Injector 4 coil shortedP0271027165466546Injector 5 coil shortedP0274027465566556Injector 6 coil shortedP0277027765666566Injector 7 coil shortedP0280028065766576Injector 8 coil shortedP0283028365866586Injector 9 coil shortedP02860286066596Injector 10 coil shortedP02890289066606Spark coil 1 primary open or short to groundP2300230003112685Spark coil 2 primary open or short to groundP2303230303112695Spark coil 3 primary open or short to groundP2306230603112705Spark coil 4 primary open or short to groundP2309230903112715Spark coil 5 primary open or short to groundP2312231203112725Spark coil 6 primary open or short to groundP2315231503112735Spark coil 7 primary open or short to groundP2318231803112745Spark coil 8 primary open or short to groundP2321232103112755Spark coil 9 primary open or short to groundP2324232403112765Spark coil 10 primary open or short to groundP2327232703112775Spark coil 1 primary shortedP2301230103112686Spark coil 2 primary shortedP2304230403112696Spark coil 3 primary shortedP2307230703112706Spark coil 4 primary shortedP2310231003112716Spark coil 5 primary shortedP2313231303112726Spark coil 6 primary shortedP2316231603112736Spark coil 7 primary shortedP2319231903112746Spark coil 8 primary shortedP2322232203112756Spark coil 9 primary shortedP2325232503112766Spark coil 10 primary shortedP2328232803112776ECT higher than expected stage 2P0217021711001100IAT higher than expected stage 1P011101111051510515IAT higher than expected stage 2P0127012710501050Knock1 sensor open or not presentP0327032773147314Unable to reach higher TPSP21122112517517Unable to reach lower TPSP21112111517517Gov1/2/3 interlock failureP1531153103152027031Fuel-pump high-side open or short to groundP0628062803113475Fuel-pump high-side short to powerP0629062903113476Loss of CAM input signalP0342034272347234CAM input signal noiseP0341034172327232CRANK input signal noiseP0336033663626362rank and/or cam could not synchronize during startP0016001663686368Microprocessor failure - COPP060606066293162931Microprocessor failure - RTI 1P161216126293162931Microprocessor failure - RTI 2P161316136293162931Microprocessor failure - RTI 3P161416146293162931Microprocessor failure - A/DP161516156293162931Microprocessor failure - InterruptP161616166293162931Microprocessor failure - FLASHP060106016281362813Microprocessor failure - RAMP060406046301263012Knock1 excessive or erratic signalP0326032673127312RPM higher than max allowed govern speedP021902195151551515RPM above fuel rev limit levelP111111115151651516RPM above spark rev limit levelP1112111251505150EGO1 open / lazyP013401345227371072410EGO2 open / lazyP0154015403152020810EGO3 open / lazyP0140014003152020910CHT higher than expected stage 1P152115211101611016CHT higher than expected stage 2P1522152211001100AUX analog Pull-Down 1 high voltageP151515150315202153AUX analog Pull-Down 1 low voltageP151615160315202154AUX analog Pull-Up 1 high voltageP1511151152020235202163AUX analog Pull-Up 1 low voltageP1512151252020245202164AUX analog Pull-Up 2 high voltageP1513151352020075202173AUX analog Pull-Up 2 low voltageP1514151452020075202174RS-485 Rx inactiveP16211621031031RS-485 Rx noiseP16221622031031RS-485 Rx bad packet formatP16231623031031RS-485 remote shutdown requestP16241624031031TIP high voltageP023802380311273TIP low voltageP023702370411274FP high voltageP0092009203943FP low voltageP0091009104944Catalyst inactive on gasoline (Bank 1)P0420042003152021110Catalyst inactive on LPGP1165116503152021310Catalyst inactive on NGP1166116603152021410MegaJector delivery pressure higher than expectedP117111710315202600MegaJector delivery pressure lower than expectedP117211720315202601MegaJector comm lostP1173117303152026031MegaJector voltage supply highP117411740315202603MegaJector voltage supply lowP117511750315202604MegaJector internal actuator fault detectionP1176117603152026012MegaJector internal circuitry fault detectionP1177117703152026012MegaJector internal comm fault detectionP1178117803152026012WGP voltage highP1131113103111923WGP voltage lowP1132113203111924Boost control overboost failureP0234023403116920Boost control underboost failureP0299029903116921TIP activeP0236023603116922FT high voltageP018301830311743FT low voltageP018201820311744Oil pressure sender low pressureP0524052410011001Oil pressure sender high pressureP0521052110001000Oil pressure sender high voltageP0523052310031003Oil pressure sender low voltageP0522052210041004Crank signal lossP0337033763646364J19