福田CNG维修手册-中英对照

--1-福田汽油∕CNG两用燃料汽车修理手册ServiceManualforFotonGasoline/CNGDualFuelVehicle一、Exon1.552-I.OperatingprincipleofExon1.55system..................................................................................-2-二、主要零部件技术参数及修理..............................................................................................-3-II.Technicalparameterandrepairofmainparts..........................................................................-3-2.1ECU3-2.1CNGECU......................................................................................................................-3-2.2MAP传感器4-2.2MAPsensor....................................................................................................................-4-2.3转换开关5--5-2.4VTT-D1喷轨6--6-2.5减压器7--7-2.6压力表8-gauge................................................................................................................-8-2.7加气阀9-2.7CNGrefillingvalve........................................................................................................-9-2.8低压过滤器9-2.8Lowpressurefilter.........................................................................................................-9-2.9高压电磁阀10-2.9Highpressuresolenoidvalve.......................................................................................-10-2.10水温传感器 .-11-2.10Watertemperaturesensor...........................................................................................-11-三、常见故障现象及缘由分析................................................................................................-12-III.Commonfaultsymptomsandcauseanalysis.......................................................................-12-一、Exon1.55系统工作原理OperatingprincipleofExon1.55systemExon1.55系统是一种燃气多点挨次喷射供气系统。系统工作时，燃气电脑以原车喷油信号为根底输入信号，同时取得发动机水温、燃气温度计燃气压力等参数校正后，确定适时喷气量(喷气脉宽)，由燃气喷轨向发动机气缸供气。一般状况下，发动机使用汽油启动，当发在各个条件满足的状况下切换到燃气状态工作，此时，汽油喷油嘴掌握信号被切断，燃气电脑驱动喷轨开头工作。除掌握燃气喷轨工作以外，Exon1.55系统电脑还包括其他一些功能Exon1.55PC机及外接口，可设置、显示并检测系统的工作状态。Exon1.55systemisamulti-pointsequentialfuelinjectionsystem.Whenthesystemworks,theCNGcomputerinputssignalsonthebasisofinjectionsignaloftheoriginalvehicle,anddeterminestheappropriateinjectionquantity(CNGinjectionpulsewidth)afterobtainingtheenginewatertemperature,CNGpressuredisplayedontheCNGthermometerandotherparametercorrection,andtheCNGinjectionrailsuppliesCNGtotheenginecylinders.Generally,theenginestartsusinggasoline.Whentheenginerunsandthechange-overswitchisplacedinCNGmode,theCNGcomputerwillautomaticallydetecttheswitchconditionsstoredinthecomputer.Underallconditionsmet,theenginewillswitchtotheCNGstatetowork,atthistime,thegasolinenozzlecontrolsignalwillbecutoff,andtheCNGcomputerwilldrivetheinjectionrail.InadditiontocontrollingtheCNGinjectionrail,theExon1.55systemcomputerincludessomeotherfunctionssuchasCNGdisplayandautomaticswitchbetweenfuelandCNG.Besides,theoperatingstatesofthesystemcanbeset,displayedanddetectedthroughthePCequippedwithExon1.55systemsoftwareandtheexternalinterface.Exon1.55系统组成部件：Exon1.55systemcomponents:——减压器Decompressor——喷轨Injectionrail——高压电磁阀Highpressuresolenoidvalve——压力表Pressuregauge——MAP传感器MAPsensor——水温传感器Watertemperaturesensor——气温传感器Airtemperaturesensor——燃气线束CNGharness——ECUCNGECU——转换开关Change-overswitchExonIVECU构造图ECUStructureDiagramofExonIVSystem发动机转速Enginespeed发动机水温Enginewatertemperature燃气温度CNGtemperature压力传感器信号Pressuresensorsignal氧传感器信号Oxygensensorsignal液位传感器信号Fluidlevelsensorsignal转换开关Change-overswitch

燃气喷嘴1CNGnozzle1燃气喷嘴2CNGnozzle2燃气喷嘴3CNGnozzle3燃气喷嘴4CNGnozzle4燃气电磁阀CNGsolenoidvalve

汽油电脑Gasolinecomputer汽油喷嘴Gasolinenozzle笔记本电脑Laptop二、主要零部件技术参数及修理TechnicalparameterandrepairofmainpartsExon1.55系统的构成主要包括以下部件：燃气ECU，MAP传感器，转换开关，喷轨，减压TheExon1.55systemmainlycomprisesthefollowingcomponents:CNGECU,MAPsensor,change-overswitch,injectionrail,decompressionvalveassembly(highpressuresolenoidvalve,watertemperaturesensorandpressuregauge),filter,CNGrefillingvalve,CNGcylinder,CNGpipeandwaterpipe.2.1ECUCNGECUECUECU气的正常运转。ServedasthegeneralcommanderofCNGsystem,theCNGECUcoordinateswiththefuelECUtocontrolthenormaloperationofenginefuelandCNG.产品名称Productname

ECU

参数Parameter-3---10-重量Weight输入电压重量Weight输入电压Inputvoltage工作温度Operatingtemperature最大工作电流Maximumoperatingcurrent闪存Flashmemory防护等级Degreesofprotection360g8-16VDC-20℃-+100℃10A48kbIP54*Repair损坏缘由Damagecauses故障现象Faultsymptoms修理、保养方法RepairandmaintenancemethodsMAP传感器MAPsensor

高温Hightemperature供电电压不稳Unstablesupplyvoltage猛烈的敲击震惊Violentknockandvibration燃油燃气都不能正常工作，有缺缸现象，油气来回跳BothfuelandCNGfailtoworknormally,thecylinderisshort,andtheCNGjumpstoandfro.供电电源牢靠，接地结实Thepowersupplyworksreliablyandisgroundedsecurely.固定结实Fixsecurely.安装位置温度不能过高Thetemperatureofmountingpositionscannotbetoohigh.MAPECU。燃气ECU通过真空度推断发动机的状态；通过减压器压力信号修正喷气时间和设置最低压力功能(实际压力低于设定值，燃气自动切换到燃油)的实现。产品名称ProductnameMAP传感器MAPsensor参数ParameterTheMAPsensorfeedsthecollectedvacuumdegreesignalanddecompressorpressuresignalbacktotheCNGECU.TheCNGECUjudgestheenginestatethroughthevacuumdegrees;theCNGECUcorrectstheinjectiontimeandsetstherealizationoftheminimumpressurefunction(theactualpressureisbelowthesetvalue,andtheCNGautomaticallyswitchesto产品名称ProductnameMAP传感器MAPsensor参数Parameter工作电压Operating工作电压Operatingvoltage工作温度Operatingtemperature进气压力Intakepressure气体压力CNGpressure5VDC0.2bar-2.5bar0.2bar-4bar*Repair损坏缘由Damagecauses故障现象Faultsymptoms

内部芯片进水Inflowofinternalchips供电电压不稳定Unstablesupplyvoltage猛烈的敲击震惊等Violentknockandvibration,etc.MAPGasP显示不准TherealtimedataofMAPandGasParedisplayedinaccuratelyonthetestingsoftware.低气量时燃气不能自动切换到燃油TheCNGcannotautomaticallyswitchtofuelatlowCNGquantity.影响到现有的喷气量Thecurrentinjectionquantityisaffected.1. 查看传感器安装位置是否略高于进气歧管Checkwhetherthemountingpositionofthesensorisslightlyhigherthantheintakemanifold.修理、保养方法 2. MAP和GasP的连接软管是否接反、松动Repairandmaintenance CheckwhethertheconnectinghosebetweenMAPandGasPismethods installedreverselyandloosened.3. 安装位置的温度是否太高Checkwhetherthetemperatureofthemountingpositionistoohigh.转换开关Change-overswitch(1)实现油气间的自由切换RealizethefreeswitchbetweenfuelandCNG.(3)维护保养提示(3)Maintenanceprompt

显示钢瓶气量(2)Displaythecylindervolume.(4)可操作进入强制气启动模式(4)ItcanentertheforcedCNGstartingmode.产品名称产品名称Productname转换开关Change-overswitch特点Features1、显示钢瓶气量Cylinder1、显示钢瓶气量Cylindervolumedisplay2、油气自由切换FreeswitchbetweenfuelandCNG3、紧急操作功能Emergencyfunction4、维护保养提示Maintenanceprompt5、触摸式Touchable6、体积小，安装简便Smallvolumeandeasyinstallation*Repair损坏缘由Damagecauses故障现象Faultsymptoms修理、保养方法RepairandmaintenancemethodsVTT-D1喷轨

接插件虚接Virtualconnectionofconnector人为损坏Artificialdamage燃油燃气都无法正常工作BothfuelandCNGfailtoworknormally.指示灯不亮，无法转气Theindicatorlightisoff,causingswitchfailure.指示灯显示不准Theindicatorlightdisplayisinaccurate.外壳损坏Thehousingisdamaged.查看接插件是否结实牢靠Checkwhethertheconnectorissecureandreliable.检查电源线是否有电Checkwhetherthepowerlinehaselectricity.更换Replaceit.VTT-D1injectionrail喷轨将减压器出来的低压气体分别喷入发动机气缸内。TheinjectionrailinjectsthelowpressureCNGfromthedecompressorintotheenginecylindersrespectively.*修理*Repair损坏缘由Damagecauses

使用过程中的正常磨损Normalwearingduringusing气体中杂质加剧喷轨内阀片等零部件的磨损TheimpuritiesintheCNGaggravatethewearingofthevalvein故障现象Faultsymptoms修理、保养方法

theinjectionrailandotherparts.接插件不牢、短路等缘由造成的线圈烧坏Coilburninglosscausedduetoinsecurity,shortcircuit,etc.ofconnector缺缸、加速无力Cylindershortageandpowerlessacceleration发动机怠速不稳，加速发闷Unstableengineidlespeedandtightacceleration废气Exhaust1. 定期检查，更换低压过滤器Regularlycheckandreplacethelowpressurefilter.Repairandmaintenance 2. 依据要求定期清洁喷轨methodsRegularlycleantheinjectionrailaccordingtotherequirement.减压器Decompressor将气瓶内的高压气体减成低压气体。产品名称ProductnamePOT技术参数Technicalparameter燃料类型Fueltype重量Weight工作压力Operatingpressure工作温度Operatingtemperature最大流量产品名称ProductnamePOT技术参数Technicalparameter燃料类型Fueltype重量Weight工作压力Operatingpressure工作温度Operatingtemperature最大流量MaximumflowCNG1.6kg200bar52m3/h二级减压减压方式SecondaryDecompressionmodedecompression一级压力Primarypressure二级压力Secondarypressure安全阀压力Safetyvalvepressure出厂设定压力Factorypressure加热方式Heatingmode1.3-2.6bar12bar2±0.1bar水循环加热Waterheatingcycling*修理*Repair损坏缘由Damagecauses故障现象Faultsymptoms修理、保养方法Repairandmaintenancemethods压力表Pressuregauge

膜片老化变形Aginganddeformationofmebrane内部零部件磨损等Wearing,etc.ofinternalparts输出压力过高或过低Toohighortoolowoutputpressure发动机怠速不稳，加速无力等Unstableidlespeed,powerlessacceleration,etc.ofengine发动机加速发闷Tightengineacceleration定期检查，更换膜片Regularlycheckandreplacethemebrane.依据要求调整输出压力(120-180kpa)Adjusttheoutputpressure(120-180kpa)accordingtotherequirement.压力表把测到的气瓶压力信号反响给燃气ECU，燃气ECU依据压力信号，把气瓶内剩余气量在转换开关上反响给用户。另外用户也能在压力表上直接看到气瓶内压力。ThepressuregaugefeedsthemeasuredcylinderpressuresignalbacktotheCNGECU,andtheCNGECUfeedstheremainingCNGinthecylinderbacktotheusersonthechange -overswitchaccordingtothepressuresignal.Moreover,userscandirectlyseethepressureinthecylinderonthepressuregauge.产品名称Product产品名称Productname高压压力表Highpressuregauge参数Parameter工作电压Operatingvoltage输出信号Outputsignal工作温度Operatingtemperature工作压力Operatingpressure12VDC0-5V200bar*Repair损坏缘由Damagecauses

压力表插头地线搭铁不良Poorpressuregaugeconnectorgrounding压力表进水、漏气InflowandCNGleakageofpressuregauge故障现象Faultsymptoms修理、保养方法Repairandmaintenancemethods

气量显示不准InaccurateCNGquantitydisplay漏气CNGleakage检查压力表插头地线搭铁状况Checkthepressuregaugeconnectorgrounding.用万用表量压力表输出压力的信号线电压是否正确，从而推断压力表是否损坏(白色为压力表信号线)参照下表Useamultimetertomeasurewhetherthesignallinevoltageofthepressureoutputtedfromthe pressuregaugeiscorrect,tojudgewhetherthepressuregaugeisdamaged(thewhitereferstothesignallineofthepressuregauge).Refertothefollowingtable.压力(MPa)Pressure(MPa)电压(V)Voltage(V)0-40-14-81-28-122-312-163-416≤4-5钢瓶压力和输出电压对应关系Relation钢瓶压力和输出电压对应关系RelationbetweenthecylinderpressureandoutputvoltageCNGrefillingvalve加气阀串联在高压管路上。TheCNGrefillingvalveisinstalledonthehighpressurepipeinseries.注：在使用过程中，留意接头是否有漏气。Note:PayattentiontocheckingthejointforCNGleakageduringusing.*修理*Repair更换Replacement低压过滤器Lowpressurefilter低压过滤器将减压器出来的低压气体进展过滤。ThelowpressurefilterfiltersthelowpressureCNGfromthedecompressor.注：要定期更换Note:Regularlyreplace.产品参数产品参数Productparameter低压过滤器Lowpressurefilter参数Parameter过滤级别Filter过滤级别Filterlevel工作温度Operatingtemperature最大工作压力Maximumoperatingpressure输出流量Outputflow10μm-40℃-+120℃5bar40m3/h*Repair定期更换Regularreplacement高压电磁阀HighpressuresolenoidvalveECU掌握其开闭。燃油时，高压电磁阀关闭，燃气时，高压电磁阀翻开。Servedasaswitchonthehighpressurepipe,thehighpressuresolenoidvalveiscontrolledbytheCNGECU.Thehighpressuresolenoidvalveisclosedduringfueling,whileopenedduringgassing.产品名称Product产品名称Productname高压电磁阀Highpressuresolenoidvalve参数Parameter额定工作电压Ratedoperatingvoltage公称通径Nominaldiameter工作温度Operatingtemperature工作压力Operatingpressure12VDCΦ4mm200bar*Repair损坏缘由Damagecauses故障现象Faultsymptoms

线圈烧坏Coilburningloss接插件不牢、短路等缘由造成的线圈烧坏Coilburninglosscausedduetoinsecurity,shortcircuit,etc. ofconnector转气熄火Switchingoff发动机燃油时，熄火后高压电磁阀不关闭Whentheengineisfueled,thehighpressuresolenoidvalveisnotclosedaftershutdown.修理、保养方法Repairandmaintenancemethods水温传感器

定期检查各高压接头是否漏气RegularlycheckallhighpressurejointsforCNGleakage.定期检查插头是否虚接Regularlychecktheconnectorforvirtualconnection.2.10WatertemperaturesensorECU。燃气ECU通过水温信号修正喷气时间和设置最低水温功能(实际水温低于设定值，燃气自动切换到燃油)的实现。ThewatertemperaturesensorfeedsthecollectedrealtimewatertemperaturesignalbacktotheCNGECU.TheCNGECUcorrectstheinjectiontimeandsetstherealizationoftheminimumwatertemperaturefunction(theactualwatertemperatureisbelowthesetvalue,andtheCNGautomaticallyswitchestofuel)throughthewatertemperaturesignal.水温传感器产品名称Productname

Watertemperaturesensor

工作原理Operatingprinciple阻值Resistance

参数ParameterThethermistortemperaturereduceswiththeincreasedresistance.25℃时，100k±5%100k±5%at25℃*修理*Repair损坏缘由Damagecauses故障现象Faultsymptoms

长时间使用，传感器搭铁不好Thesensorisgroundedpoorlywhenbeingusedforalongtime.传感器线磨损，接插件虚接Thesensoriswornandtheconnectorisvirtuallyconnected.安装时用力过大，将传感器拧断Thesensoristwistedoffduetoexcessiveforceduringinstallation.水温显示不准，严峻的不能切换Thewatertemperatureisdisplayedinaccurately,andswitchcannotberealizedwhenserious.低温切换到燃气时，发动机怠速不稳TheengineisunstableinidlespeedwhenbeingswitchedtoCNGmodeatlowtemperature.最低温度的功能不能实现Theminimumtemperaturefunctioncannotberealized.1. 查看水温传感器的搭铁是否结实，接插件是否插牢修理、保养方法 CheckwhetherthegroundingofthewatertemperaturesensorisRepairandmaintenance secureandcheckwhethertheconnectorisconnectedsecurely.methods 2. 查看传感器是否损坏Checkthesensorfordamage.三、常见故障现象及缘由分析Commonfaultsymptomsandcauseanalysis故障现象Faultsymptoms

缘由分析(检修挨次由上至下)Causeanalysis(theoverhaulsequenceisfromtoptobottom)1、储气瓶是否有气、瓶阀是否完全翻开 检查

解决方法Solutions常，转气熄火NormaloperationduringstartingandshutdownduringswitchoffuelChecktheCNGcylinderforCNGandcheck Checkwhetherthecylindervalveisopenedfully.2、高压管路连接有误(包括各接头漏气)、电磁检查阀是否能翻开 CheckCheckwhetherthehighpressurepipeisconnectedwrong(includingCNGleakageofjoints)andcheckwhetherthesolenoidvalvecanbeturnedon.3、减压器出来低压气体压力是否在范围内、减检查压器是否加热(LPG加热要求很高) CheckCheckwhetherthelowpressureCNGpressurefromthedecompressoriswithintherangeandcheckwhetherthedecompressorisheated(theLPGheatingrequirementisveryhigh).4、喷轨是否能翻开，转换瞬间是否有气体喷出检修Checkwhethertheinjectionrailcanbeopened OverhaulandinjectCNGinthemomentofswitching.5、燃气ECU是否采集到原车喷油脉宽 检修CheckwhethertheCNGECUcollectsthefuel Overhaulinjectionpulsewidthoftheoriginalvehicle.6、喷油嘴线束上电源线和信号线是否接反 检查、调整Checkwhetherthepowerlineandsignallineon Checkthenozzleharnessareconnectedreversely. adjustment7、燃气喷油信号喷油器端和原车电脑端接反 检查、调整Check whether the CNG injection signal Checkinjector end is connected reversely to the adjustmentcomputerendoftheoriginalvehicle.8燃气线路插接件是否插牢是否导通(喷轨插检查头、电磁阀插片) CheckCheckwhethertheCNGlineconnectorisconnectedsecurelyandison(injectionrailplugandsolenoidvalveliner).

andand9ECU(缺缸)CNGECU(cylindershortage)

检修或更换Overhaul orreplacement10、混合比调试不适宜(过稀或过浓) 从调整Themixingratioisadjustedimproperly(too Readjustmentthinortoothick).11、燃气线束点火钥匙线接的位置错误 检查调整Thewiringpositionoftheignitionkeyofthe CheckCNGharnessiswrong. adjustment1、点火系统是否正常，是否有失火现象 检修Check whether the ignition system works Overhaulnormallyandwhetherthereisfirephenomenon.

and速不稳UnstableidlespeedatCNGstatePowerlessaccelerationandobviousabruptnessfeelingatCNGstate

2、空气滤清器，节气门体是否太脏 检察、清洗或更换Checkwhethertheairfilterandthrottlebody Check, cleaning oraretoodirty. replacement3、喷轨各缸是否喷气，喷气是否正常 检修Checkwhetherallinjectionrailcylindersinject OverhaulCNGnormally.4、减压阀真空管是否连接原车进气支管 检修Check whether the vacuum pipe of the Overhauldecompressionvalveisconnectedtotheintakebranchoftheoriginalvehicle.5、混合比调试不适宜(过浓或过稀) 从调整Themixingratioisadjustedimproperly(too Readjustmentthickortoothin).6、最小脉宽调试不适宜 从调整The minimum pulse width is adjusted Readjustmentimproperly.1、加速时是否有瞬间失火现象 检修Checkwhetherthereisinstantfirephenomenon Overhaulduringacceleration.2、空气滤清器，节气门体是否太脏 检察、清洗或更换Checkwhethertheairfilterandthrottlebody Check, cleaning oraretoodirty. replacement3、火花塞、高压线是否漏电等点火系统故障 检修Checkthesparkplugandhigh-tensioncablefor Overhaulelectricleakageandotherignitionsystemfaults.4、储气瓶压力过低或瓶阀未完全翻开 检查CheckwhethertheCNGcylinderpressureis Checktooloworwhetherthecylindervalveisnotopenedfully.5、减压阀出来低压压力过低或加热不好(LPG) 调整、检修Check whether the low pressure from the Adjustmentdecompressionvalveistooloworwhetherthe overhaulheatingispoor(LPG).6、减压阀真空管是否连接原车进气支管 检查Check whether the vacuum pipe of the Check

and四、燃气工作正常，

decompressionvalveisconnectedtotheintakebranchoftheoriginalvehicle.7、喷轨喷嘴过小，导致供气缺乏 检修Theinjectionrailnozzleistoosmall,resulting OverhaulininsufficientCNGsupply.8、喷轨的最大流量满足不了发动机功率要求 更换大流量喷轨Themaximumflowoftheinjectionrailfailsto Replacewithalargemeettheenginepowerrequirement. flowinjectionrail.9、混合比调试不适宜(过浓或过稀) 从调整Themixingratioisadjustedimproperly(too Readjustmentthickortoothin).1、燃油时是否有同样现象 检查Check whether there is same phenomenon Checkduringfueling.2、空气滤清器，节气门体是否太脏 检察、清洗或更换Checkwhethertheairfilterandthrottlebody Check, cleaning oraretoodirty. replacement3、发动机气门间隙是否太小 检查、调整空挡滑行时熄火NormaloperationofCNGandshutdownduringneutralslidingCheckwhethertheenginevalveclearanceistoo Checksmall. adjustment4、喷轨的最大流量满足不了发动机功率要求 更换Themaximumflowoftheinjectionrailfailsto Replacementmeettheenginepowerrequirement.

and5、发动机高速掉到怠速过程中，约1200转恢复供气时，混合比调试不适宜(过稀或过浓)Intheprocessoftheenginereducingfromhighspeedtoidlespeed,whentheenginerestoresCNGsupplyatabout1,200rpm/min,themixingratioisadjustedimproperly(toothinortoothick).

MAP表里找准该点，进展调整FindthispointontheMAPga