Failure Diagnosis and Case Analysis

Landking Guo III High Pressure Common
Rail Diesel Engines
Failure Diagnosis and Case

Analysis
Weichai Power Holding Co.Ltd.

Content
1. Introduction
2. Failure Diagnosis and Case Analysis
3. Failure Analysis of Common Parts

Introduction
1.1 Introduction of High Pressure Common Rail System
Weichai Power Landking Guo III Diesel Engines
Initiatively applying advanced Germany BOSCH electronically controlled high pressure

common rail system
BOSCH high pressure common rail system has features of high reliability, economy,
safety, comfort and highly intelligentizing.
Can meet the requirement of Guo emission standard
Landking Guo III series diesel engines are developed in accordance with Europe R&D
process, adopting internationally advanced casting, machining, assembling equipment
and process. Fittings purchasing adopts global supply chain mode. The engines fully
verified are put into the market, which ensure the excellent quality.
100,000 market share of Weichai Power Landking Guo III diesel engines enjoys high
popularity among customers.
CR+ injector
high pressure
fuel pump
ECU
Landking Guo III Electronically Controlled High

Pressure Common Rail Picture
Weichai Power Landking Guo III diesel engines
 Much higher reliability--- Failure rate is 63% less than that of mechanical pump
engine
 Much more economical--- Fuel consumption per 100 km is less 5-10% than that of
mechanical pump vehicle at the same condition
 Much lower maintenance cost--- 10 L engine is less 1650 RMB/Year than

mechanical pump engine, and 12 L engine is less 828 RMB/Year (calculating by
180,000 km/Year)
 Much better suitability of oil – Compared with mechanical pump engines, it has
more powerful ability to filter impurity and water. There’s no special requirement
about oil brand. The period of “Three Guarantees” for fuel system is much longer.
第 7页共页
1. Low vibration and noise----much higher reliability
model noise (db) vibration Speed-up 400km-driving

performance fatigue
compared with
WD615
WD615 115 100%
WP10 97 Improving 63%

by 10%
WP12 96 Improving 50%
by 35%
8
common rail
pipe
High pressure
fuel pump
Hand transfer
pump
Fuel filter
ECU
2. Low fuel consumption

 Weichai makes good use of the control function of electronically controlled high
pressure common rail system to develop a series of new fuel-saving
technology, and push out exclusive fuel-saving technology products:
 WP multi-power fuel-saving switch
 Fuel-saving 1+1 (fuel-saving constant temperature fan + fuel-saving fuel-cut
technology)
 Personalization power
 Super truck power, standard truck power, dedicated mixer lorry
power, dedicated crane power, dedicated bus power, dedicated city bus
power, etc.
3. Much lower maintenance cost

Maintenance interval of Guo III diesel engines is 10,000km, while that of
Landking
Guo III diesel engines is 30.000km.
WP10 VS. WD615

Take the common standard load highway transportation vehicle as an
example, WP10 can save 1650RMB maintenance expenses compared with
WD615 (calculating by 180,000 km/year)
Maintenance item (set/unit) quota WP10 WD615 note
fuel coarse filter core

fine filter core+trustworthy 3 334 26
dewater filter core piece (1) The maintenance interval
of WP10 is 30000km,
oil filter core piece 2 40 40 but oil filter core should
be replaced once every
oil 24 534 355 10000km
(2) The maintenance interval
maintenance expenses of 908+80= 421×3 of WD615 is 10000km
30,000km 988 =1263 (3) WP10 applies Landking
Guo III CH-4 special oil
total maintenance expenses for
5928 7578
one year
3. Much lower maintenance cost

 Take the common standard load highway transportation vehicle as an
example, WP12 can save 828RMB maintenance expenses compared
with WD12 (calculating by 180,000 km/year)
WP12 VS.WD12
quota WP12 WD12

Maintenance item (set/unit)
note
fuel coarse filter corefine 3 334 26 (1) The maintenance interval
filter core+trustworthy of WP12is 30000km, but
dewater filter core piece oil filter core should be
oil filter core 2 82 40 replaced once every
10000km
piece (2) The maintenance interval
oil 36 770 430 of WD12 is 10000km
1186+164 496×3 (3) WP12 applies Landking
maintenance expenses of Guo III CH-4 special oil
30,000km =1350 =1488
total maintenance expenses 8100 8928

for one year
4. Much better suitability of oil

 Intensifier filter with high efficiency
 Landking Guo III engine is equipped with high efficiency fuel filter which
has a better ability to filter impurity in fuel to effectively protect fuel
system.
Fuel coarse, Trustworthy

fine filter core dewater filter
• Trustworthy dewater filter

 It can dewater more than 95% water in diesel.
 It has the high-efficiency function of fuel-water separation, and users can use it
at ease.
 It is assembled on the obvious position of vehicle frame to facilitate drivers’
venting air and pumping fuel.
 It has high-volume transparent water cup with good low-temperature resistance
performance, which is convenient for drivers to observe water level so as to
drain off water in time.
 It is equipped with hand pump, and the vehicle has hand pump double
insurance.
 Special attention:
 Please often observe the water level of
“trustworthy dewater filter” and drain off
water in time.
 Pay attention that replacing interval of
“trustworthy dewater filter” filter core should
be same as that of fuel coarse and fine
filter cores.
 Pay attention that “ trustworthy dewater
filter” filter core can be replaced by
Landking GuoIII fuel coarse filter core, but
it can’t substitute for Landking GuoIII fuel
coarse filter core.
Failure Diagnosis
and Case Analysis
18
Failure Diagnosis and Removal Principle
When diesel engine is failure, removal method of “easy first and difficult
later” one by one should be applied.
 Don’t rashly replace any fitting before find out problems.
 Don’t rashly get rid of blinking code before find out problems. Please
note that do record blinking code.
Failure type1: Diesel engine can’t be started
Failure removal procedures:

1. Read blink code according to blink
light to make sure failure. Turn to next
step if the failure can’t be confirmed.
 Two ways to read blink code: WP-VDS100
 Read through failure diagnosis
equipment;
 or read through blink code light
Read blink code:
• The blink code light gives a blink code every time when the diagnosis switch
sends a pulse signal. When the diagnosis switch is through, the blink code
light is on.
• ECU erro memory can save 10 errs at most, on and off 0.5s - 1s.
• Every blink code consists of three digits, and the time interval between each
digit is 1 second. For instance: 321
0.5s
1s
The method to get rid of blink code by hand:

• Press down the failure diagnosis switch before T15 is through, then
turn on the key switch(T15 is through), and keep the diagnosis
switch on for 4-8 seconds, then release.
• If some blink code can not be deleted, that is the current failure.
• Get rid of hardware failure first, then clear ECU failure memory.
• If the blink code can not be deleted, should inform professional
people to take care of it asap.
Special attention:
After the failure is removed, please clear the blink code by
equipment or by hand.
Blink code
light
Failure
diagnosis switch
starter
Ignition key
switch
2. Inspect if the shift is in neutral position,
and the switch of neutral shift is normal or
not; Inspect if the auxiliary flameout switch
(it is under the vehicle) is normal. Turn to
the next step if it still can not be started.
3. Inspect whether the whole vehicle start neutral
line and battery jar are normal or not. shift
Turn to the next step if it still can not be switch
started.
4. Diagnose whether the starter works
normally or not. If the problem still can’t be
solved, should further inspect if the diesel Stop motion switch
engine rotates freely or not, valve timing
right or not. Turn to the next step if it still
can’t be started.
5. Inspect if the low pressure fuel passage is
entering air, leakages air, or blocked. Turn
to the next step if it still can’t be started.
6. Contact people from special repair Camshaft

station to use professional equipment speed sensor
to inspect as follows:
 Failure diagnosis equipment used to
inspect if the flywheel signal panel and
fuel pump camshaft signal panel are
synchronous (the synchronous signal
of data stream is 48). Turn to the next
step if it still can’t be started.
 Failure diagnosis equipment used to
further inspect if the rail pressure built crankshaft rotary
is normal. If the rail pressure is transducer
abnormal, it’s probably caused by
injector, common rail, high pressure
fuel pump and ECU, and reference to
Parts Failure Analysis
There’s damage in the thread
of fuel inlet of fuel coarse
filter, and fine crack in fuel
inlet
Air
deflation
bolt
Hand Fuel return

pump Hollow bolt
Damaged ECU plug connector:

One of whole vehicle plug stitches
broke, and other thick stitches
rust.
1-70 switch
was burnt out
Damaged
injector
The left is the original fuel used
The right is normal fuel
Fuel brand contrast
HP fuel pump
plunger is
damaged
Failure type 2: The diesel engine starts with difficulty (can start, but with difficulty)
Read out the blink

Failure removal procedures: code
1st step: If it is caused by plateau or paramos

2nd step: Read the blink code, and confirm the failure.
Turn to the next step if there’s no blink code.
3rd step: Inspect that if the starter is normal, electricity
of the battery jar is sufficient. Turn to the next step
if it still can’t be started smoothly.
4th step: Inspect whether low pressure fuel passage
is normal or not. Turn to the next step if it still can’t
be started smoothly.
5th step: Further inspect whether the engine rotates
normally or not, valve timing normal or not. Turn to
the next step if it still can’t be started smoothly.
the starter
6th step: Inspect whether crankshaft rotary

transducer and camshaft speed sensor and
their plugs are damaged, firmed, clean or
not. Turn to the next step if it still can’t be
started smoothly.
7th step: Contact special repair station people,
and use professional equipment to inspect
as follows:
 Use failure diagnosis equipment to check if
flywheel signal panel and fuel pump
WP-VDS100
camshaft signal panel are synchronous (the
synchronous signal of data stream is 48 ). Failure diagnosis
Turn to the next step if it still can’t be started.
 Use failure diagnosis equipment to further
inspect whether rail pressure is built
normally. If not, it’s probably caused by
injector, CR, HP fuel pump and ECU, Please
refer to Common Parts Failure Analysis
Diesel engine is equipped with two speed sensors, one is on the flywheel and
the other is on the outboard of HP fuel pump. Their functions are crankshaft
position sensor and cylinder judging sensor respectively. The injection timing
of electronically controlled engine is decided by the two sensors. If one lost
signal, the engine starts with difficulty. If the engine can’t be started, the two
signals lost.
Camshaft speed crankshaft rotary

sensor transducer
crankshaft
rotary
transducer
Not installing Not installing

Failure type 3: After the engine’s started, it’s flameout automatically
Inspection Steps:
1st step: Read blink code and confirm Read blink

the failure. Turn to the next step if code
can’t confirm it.
2nd step: Firstly inspect if low pressure

fuel passage leakages air or blocked
(including fuel return pipe), check if air
fuel
return
leakages
air intake and exhaust is normal. intake pipe
air
Turn to the next step if the problem

can’t be solved.
3rd step: Inspect if wires, sensors and

plug is damaged. Turn to the next
step if the problem can’t be solved.
Inspection Steps:
4th step: Contact special repair station people,
and use professional equipment to inspect
as follows:
 Use failure diagnosis equipment to check if WP-VDS100
flywheel signal panel and fuel pump
camshaft signal panel are synchronous (the
synchronous signal of data stream is 48 ).
Turn to the next step if the problem still can’t
be solved.
 Use failure diagnosis equipment to further
inspect whether rail pressure is built
normally. If not, it’s probably caused by
injector, CR, HP fuel pump and ECU, Please
refer to Parts Failure Analysis
Water
temperature
sensor
第 46页共页
Rail pressure
sensor
Pressure
limiting
valve fuel
inlet
Sensor wire harness
Water temperature Oil pressure sensor Camshaft speed sensor

sensor
crankshaft rotary
transducer
Air intake pressure
Rail pressure sensor

sensor
Failure type 4: The engine exhausts black smoke
Failure removal steps:

1st step: Inspect if air filter and air intake and exhaust pipe, valve clearance are normal.
Turn to the next step if normal
2nd step: Inspect if turbocharger is working normally. Turn to the next step if normally
3rd step: Inspect if diesel quality is normal. Turn to the next step if normal.
air filter valve clearance turbocharger


4th step: Contact special repair station people, and use professional equipment to
inspect as follows:
 Use failure diagnosis equipment to check if flywheel signal panel and fuel pump
camshaft signal panel are synchronous (the synchronous signal of data stream
is 48 ). Turn to the next step if it’s still black smoking.
 Use failure diagnosis equipment to further inspect whether rail pressure is built
normally. If not, it’s probably caused by injector, CR, HP fuel pump and ECU,
Please refer to Parts Failure Analysis
Injector
binding post
Injectors
rust
Failure type 5: Insufficient power
Inspection steps
1st step; For the vehicle equipped with multi-power fuel-saving switch,
inspect if the power shift is on the right position.
2nd step: read blink code, and turn to the next step if no blink code.
3rd step: Inspect if low pressure fuel passage and fuel quality is
normal. Turn to the next step if normal.
4th step: Inspect if air filter, air-intake passage and turbocharger work
normally. Turn to the next step if normally.
5th step: Inspect if valve clearance is normal. Turn to the next step if
normal.
6th step: Inspect if each sensor plug, accelerator pedal plug and whole
vehicle wire harness connect well. Turn to the next step if normal.
Inspection steps
7th step: Contact special repair station people, and use professional
equipment to inspect as follows:
 Use failure diagnosis equipment to check if flywheel signal panel and
fuel pump camshaft signal panel are synchronous (the synchronous
signal of data stream is 48 ). Turn to the next step if still Insufficient
power.
 Use failure diagnosis equipment to further inspect whether rail
pressure is built normally. If not, it’s probably caused by injector, CR,
HP fuel pump and ECU, Please refer to Parts Failure Analysis
 For the vehicle equipped with multi-power fuel-saving switch, inspect if
the power shift fails.
Crankshaft rotary
transducer
normal unnormal
intercooler
splits
Failure type 6: Limp-home

1st step: Read the blink code.
2nd step: To confirm the failure according to blink code. Turn to the next
step if can’t remove the failure.
3rd step: Inspect if the low pressure fuel passage is seriously blocked,
fuel meets the requirement of ambient temperature. Turn to the next
step if can’t remove the failure.

4th step: Contact special repair station people, and use
professional equipment to inspect as follows:
 Use failure diagnosis equipment to check if flywheel
signal panel and fuel pump camshaft signal panel are
synchronous (the synchronous signal of data stream is
48 ). Turn to the next step if the problem still can’t be
solved.
 Use failure diagnosis equipment to further inspect
whether rail pressure is built normally. If not, it’s probably
caused by injector, CR, HP fuel pump and ECU, Please
refer to Parts Failure Analysis
metering unit failure
metering
unit
Removal method: check and repair wire, to judge metering unit failure
or rail pressure sensor failure.
　　 air-intake pressure sensor

功能：可以检测进气压力和温度
Injector fuel return back pressure
Fine filter
0~1bar
Gear pump outlet back pressure < 9.0 bar Absolute pressure Pressure limiting valve
Absolute pressure rail
by-pass metering unit

valve
Overpressure protection
Spillover
valve
Gear pump inlet back
pressure 0.35~1.00bar
ECU CPN2.
2
Coarse filter : <1.2 bar
Hand pump
HP fuel passage
Low pressure
Schematic diagram of HP CR fuel passage fuel passage
Failure type7: Idle speed is not stable

1st step: Read the blink code and confirm the failure. Turn to the next
step if can’t confirm.
2nd step: Inspect if low pressure fuel passage is normal. Turn to the
next step if can’t remove the failure.
3rd step: Inspect if each sensor plug and wire harness are normal. Turn
to the next step if can’t remove the failure.

4th step: Contact special repair station people, and use professional
equipment to inspect as follows:
 Use failure diagnosis equipment to inspect if vehicle speed sensor is
normal. Turn to the next step if can’t remove the failure.
 Use failure diagnosis equipment to further inspect whether rail
pressure is built normally. If not, it’s probably caused by injector, CR,
HP fuel pump and ECU, Please refer to Parts Failure Analysis
Failure type 8: The engine is always at 1000r/min
1st step: Read the blink code and confirm the failure.
2nd step: Remove the failure according to blink code.
3rd step: Inspect if electric accelerator pedal plug looses, wrongly

connected or short circuit.
4th step: Inspect if the electric accelerator pedal fails.

The electric accelerator pedal wire looses or wrongly connecting. Re-plug

or inspect if the accelerator wire is right, then reconnect.
The electric accelerator plug connector leakages water: dry it, then
restart.
Note: Replace the accelerator with the same model

Failure type 9 : Other failures
9.1. Description of the Case that accelerator works now and then when driving (overheat
protection is activated when water temperature is too high)
Note: After install the belt, pull out the pin of

belt tensioner with pliers to realize
automatic tension.
Belt
looses
Parts Failure
Analysis
The main parts in common rail system
The main parts in common rail system
3.1 The injector
 Fault: insufficient power, black smoke exhaust, difficult to start and limp-home fault
The injector working principle picture

3.1.1 Table about analysis of injector fault
No. Fault type Cause Remedy Remarks
1 atomization of injector is bad Carbon deposit heavily on fuel clean replace

head injector if fault
cannot be
removed
2 Injectors don’t inject fuel Needle valve is locked in Replace injector
closed state
3 fuel head of injector drip fuel Needle valve is locked at usual Replace injector
position or needle valve of
injector is worn and its
sealing isn’t tight
4 Fuel return amount per injector is Fuel return plunger taper is Replace injector
great or it is very different worn and its sealing isn't
from other ones
tight
5 Injector Bronze cover or washer Inexact orientation lead to Replace bronze pay attention to
is distorted or damaged distort or tighten with big cover or orientation
when
strength when installing washer
installing
6 Screw cap of connection pole is Screw cap and wiring harness fasten screw cap
loose, which causes wiring cannot fasten firmly and wiring
harness of injector is loose
harness
or worn and cylinder head is
short circuit
7 electromaqnetism valve of Turnoff or big electric current Replace injector resistance of
injector is damaged is burnt because of other injector is
0.9 ohm
causes
3.1.2 analysis about injector fault
Fault: insufficient power, block smoke exhaust, difficult to start

and limp-home fault
1 atomization of injector is bad cause:
carbon deposit heavily on fuel head right
picture Remedy: clean, replace injector if
the fault cannot be removed.
2 injector doesn’t inject fuel
cause: injector is locked in closed state
remedy: replace injector
3.1.2 Analysis about injector fault
Fault: insufficient power, black smoke exhaust, difficult to start and limp-home
fault
3 、 flow fuel on fuel head of injector
Cause: needle valve is locked in usual position or needle valve of injector is
worn
Remedy: replace injector
4. Fuel return amount in every injector is big or
there is big different from other injectors
Cause: fuel return plunger taper is worn
Remedy ： replace injector
Fault: insufficient power, black smoke exhaust, difficult to start and limp-home
fault
5. Bronze cover or washer of injector is distorted and
damaged
Cause: distortion because of inexact orientation or tighten
with great strength when installing them
Remedy: replace bronze cover or waher
6. Screw cap of connection pole is loose, which causes

wiring harness of injector is loose or worn and cylinder
head is short circuit
Cause: screw cap and wiring harness is not fastened
Remedy: fasten screw cap and wiring harness.
Fault: insufficient power, block smoke exhaust, difficult to start, and limp-home
fault
7. Electromagnetism valve
of injector is damaged
Cause: turnoff or big
electric current is burnt
because of other causes.
Remedy: replace injector
3.2 high pressure fuel pump
High pressure
fuel outlet
Diesel fuel inlet (from filter)
Diesel fuel outlet (to
Flow metering unit fuel tank)
Overflow
valve
camshaft
Gear pump
ZP5
Fuel outlet (to filter)

Initial oil filler valve
cap
Camshaft phase sensor
Fuel inlet (from fuel DG6
tank)
3.2.1 Table for analysis of high pressure fuel pump
No. Fault type Cause Remedy remarks
1 fuel outlet pipe of there is air in plunger or Remove air or There are 2 rotation
high pressure gear pump, or plunger replace high direction in gear
fuel pump can is worn pressure fuel
supply fuel pump, do not
pump confuse
2 flow metering Connection of Bnc connector pull out and insert resistance of flow
unit is often plugs of wiring harness bnc connector metering unit is
open is bad, and flow metering plugs again or 2.6 ～ 3.15ohm
unit is damaged replace flow
metering unit
3 connection of Bnc connector plugs is pull out and

flow metering loose insert again
unit is bad
4 timing of timing timing of gear is wrong re-adjust as

gear of high when installing fuel requirement
pressure fuel pump of technics
pump is
wrong
3.2.2 Analysis about high pressure fuel pump
Fault: can not be started, difficult to start and limp-home
1 、 Fuel outlet pipe of High pressure fuel
pump cannot supply fuel
Cause: there is air in cavity of plunger or
gear pump or plunger worn
Remedy: remove air or replace high
pressure pump
2. Flow metering unit is often open.

Cause: contact of bnc connector plugs of
wiring harness is bad, and flow metering
unit is damaged.
Remedy: pull out and insert bnc
connector plugs or replace flow metering
unit.
3.2.2 Analysis about high pressure fuel pump fault
Fault: can not be started, difficult ot start and fault of limp-home
3. Connection of bnc connector plugs

of flow metering unit is bad
Cause: bnc connector plugs is loose
Remedy: pull out and insert again
4. The timing of timing gear of high

pressure fuel pump is wrong
Cause: timing of gear is wrong when
installing fuel pump.
Remedy: re-adjust as requirement of
technics
3.3 common rail pipe
Pressure Rail pressure

limiter valve Fuel inlet
sensor
3.3.1 Table about analysis of common rail pipe fault
No Fault type Cause Remedy Remarks

.
1 Pressure Sealing of pressure released Replace Rail pressure

released valve is bad or spring of pressure cannot be set
valve leaks pressure released valve in released up abnormally
invalid, which cause fuel
abnormally releases from pressure
valve or
released valve when rail common
pressure doesn’t reach rail pipe
1600bar
2 Fault of Rail Connection of bnc pull out and Instable and

pressure connector plugs is bad, insert bnc illogical rail
sensor and rail pressure sensor connector pressure:
plugs again
is damaged or replace
signal voltage
rail of rail sensor is
pressure about 1V at
sensor idling speed
3.3.2 Analysis about fault of common-rail pipe
Fault: difficult to start and fault of limp-home
1.Pressure released valve leaks abnormally

Cause: Sealing of pressure released valve is bad or spring of pressure
released valve in invalid, which cause fuel releases from pressure released
valve when rail pressure doesn’t reach 1600bar
Remedy: replace pressure released valve or common-rail pipe.
2.Fault of Rail pressure sensor

Cause: Connection of bnc connector plugs is bad, and rail
pressure sensor is damaged
Remedy: pull out and insert bnc connector plugs again or
replace rail pressure sensor
3.4 ECU
3.4.1 Table about analysis of ECU fault
No Fault type Cause Remedy remarks

.
communication between
1 diagnostic and ECU is failure
ECU is burnt Replace
and blink code light and cold ECU
started light cannot self-
check
2 K line has not voltage There is wrong with Check 1.89 Usually 24V
1.89 stitch line line
3 ECU stitch is folded Wrong operation when Replace ECU

pull out and insert
bnc connector plugs
4 ECU is hit by big Turnoff or didn’t Replace ECU Caution reliability of

electric current pull out ECU ECU line, and
bnc connector protect ECU
plugs when jointing
5 ECU switch is turn off Flow into Clean liquid or Add sealing ring on
Conductive replace wiring harness,
electricity liquid ECU and caution
waterproof
3.4.2 Analysis about ECU fault
Fault: engine cannot be started, flameout
1.Communication between diagnostic and ECU is

failure ， electric blink code light and cold
started light cannot self-check.
Cause: ECU is burnt.
Remedy: replace ECU
2. K line has no voltage (usually about 23.5 )

Cause: 1.89 stitch line is wrong.
Remedy: check 1.89 line
3.4.2 Analysis about ECU fault
Fault: engine cannot be started, and flameout
3. ECU stitch is folded

Cause: there is wrong operation when
pull out and insert ECU bnc connector
plugs.
Remedy: replace ECU
4 、 ECU is hit by big electric current
Cause: line turnoff or did not pull out ECU
bnc connector plugs
Remedy: replace ECU (caution that
reliability of ECU line, and protect ECU
when jointing )
5 、 ECU stitch turnoff
Cause: be flowed into conductive electricity liquid
Remedy: clean liquid or replace ECU ( add sealing ring on wiring harness and pay
attention to be waterproof)
3.5 sensor and wiring harness
Oil temperature Air intake

and pressure temperature Crankshaft
sensor and pressure speed
sensor sensor
Rail pressure
sensor
Water
temperature
sensor
Camshaft
speed sensor
3.5.1 Analysis table for fault of sensor and wiring harness
No. Fault type Cause Remedy
1 Sensor hardware is bnc connector plugs or sensor shell is Replace a new sensor
damaged damaged when installing
2 Electric feature of Because of electrocircuit, Replace a new sensor

sensor is wrong Sensor is damaged.
3 Insert part of wiring Insert untightly or damage Pull out and insert
harness is bad or bnc connector plugs when operating again or replace
damaged wiring harness
4 Turnoff and short circuit Connection rubber worn of Protect or replace

of wiring harness Wiring harness broken wiring harness
3.5.2 Analysis about sensor and wiring harness fault
1. Sensor hardness damaged

Cause: bnc connector plugs or sensor
shell damaged when installing
Remedy: Replace a new sensor.
2. Wrong electric feature of sensor

Cause: because of electrocircuit, sensor
is damaged
Remedy: replace a new sensor
connector
3. Insert part of wiring harness is bad or plugs
damaged
Cause: Insert untightly or damage
bnc connector plugs when operating.
Remedy: insert and pull out again or
replace wiring harness
3.5.2 Analysis about sensor and wiring harness fault
4. Turnoff and short circuit of wiring harness

Cause: connection rubber worn or wiring harness broken.
Remedy: protect or replace wiring harness
3.5.3 Guide for sensor inspection
Assembly Item Standard numeral value
Camshaft resistance 770-950 ohm

speed between 2
sensor stitches of
(installed on sensor
the flywheel)
2.23-2.19 wave
shape idling
speed.

Camshaft voltage between 3.2-4.9 V
speed 2.09 and ground
sensor line idling speed.
(installed
on
flywheel) resistance 770-950 ohm
between 2 stitches
of sensor
2.09-2.10 wave
shape idling
speed
3.5.3 guide for sensor inspection
Flow resistance of
metering flow metering 2.60-3.15 ohm - environmental temperature 20
unit unit
(installed up
and left side data flow 1380 - 1420mA
of high (electric current
pressure in idling speed)
pump)
3.09—3.10
voltage wave
shape in idling
speed

Rail 2.14 - 2.12 voltage 0.5V
pressure T15
sensor
(installed 2.14 - 2.12 voltage 1.2-1.5V
near right idling speed
side) Rail pressure idling 340-450bar
speed
Changed range 0.5- 4.5 ,0bar- 1800bar
voltage of rail
pressure sensor
3.5.3 guide for sensor inspection
water resistance
temperature feature from
sensor 2.15 to 2.16
installed on the in different
water outlet water
pipe temperature
(right picture)
Rnom is
standard
numeral
value
air inlet resistance feature

temperature and from 2.36-2.25 in
pressure sensor different
(installed on air temperature (right
intake pipe) picture)
nominal is standard
numeral value ，

air inlet voltage from 0.5- 0.8 V
pressure 2.34 to 2.25
sensor idling speed
Voltage from
2.34 to 2.25
oil resistance
temperat feature of 2.28 -
ure 2.24 in different
sensor temperature
(right picture)
nominal is
standard value

oil pressure Voltage of
sensor 2.27- 2.24

Air intake heating Voltage of 1.55-1.59 23-29 (V)
relay
3.5 accelerator pedal
3.6.1 Table about accelerator pedal fault
No. Fault type Cause Remedy Remark
1 Inserting part of Insert untightly Pull out and

accelerator is not insert
good again
2 Turnoff and short circuit Connection rubber Protection
of accelerator worn or wiring
harness broken
3 Opening of accelerator That pedal output Replace pedal APP1 ： 0.75-
pedal is abnormal voltage cannot 3.84V
reach APP2 ： 0.375-
requirement of 1.92V
ECU
4 Double voltage Pedal cannot reach Replace pedal Signal 1 is

relationship of the requirement after double
accelerator is failure remove signal
cause of 2(voltage)
line
3.6.2 analysis about accelerator pedal fault
Fault: engine runs at speed of 1,000r/min always, and idling speed is high
1. Accelerator parts contacts bad

Cause: insert untightly.
Remedy: pull out and insert again
2. Turn off and short circuit of accelerator

connection
Cause: connection rubber worn or wiring
harness broken
Remedy: protection
3. Opening of accelerator pedal is abnormal

Cause: that pedal output voltage cannot reach
requirement of ECU
Remedy: replace pedal.
3.6.2 Fault analysis about accelerator pedal
Fault performance: Diesel engine

operates with 1000r, and idling
speed is high.
4. Double voltage relationship of
accelerator signal is failure.
Cause ： Pedal cannot reach the
requirement.
Remedy: Remove line problem and
remove pedal.
Thank you for
enjoying it and
good bye!
第 129页共页

Failure Diagnosis and Case Analysis

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Failure Diagnosis and Case Analysis

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Landking Guo III High Pressure Common

Rail Diesel Engines

Failure Diagnosis and Case

Weichai Power Holding Co.Ltd.

2. Failure Diagnosis and Case Analysis

3. Failure Analysis of Common Parts

Weichai Power Landking Guo III Diesel Engines

Initiatively applying advanced Germany BOSCH electronically controlled high pressure

Can meet the requirement of Guo emission standard

Landking Guo III Electronically Controlled High

Weichai Power Landking Guo III diesel engines

 Much lower maintenance cost--- 10 L engine is less 1650 RMB/Year than

1. Low vibration and noise----much higher reliability

model noise (db) vibration Speed-up 400km-driving

WD615 115 100%

WP10 97 Improving 63%

2. Low fuel consumption

3. Much lower maintenance cost

WP10 VS. WD615

Maintenance item (set/unit) quota WP10 WD615 note

fuel coarse filter core

3. Much lower maintenance cost

quota WP12 WD12

total maintenance expenses 8100 8928

4. Much better suitability of oil

Fuel coarse, Trustworthy

• Trustworthy dewater filter

Failure removal procedures:

The method to get rid of blink code by hand:

6. Contact people from special repair Camshaft

Hand Fuel return

Damaged ECU plug connector:

Fuel brand contrast

Read out the blink

1st step: If it is caused by plateau or paramos

6th step: Inspect whether crankshaft rotary

Camshaft speed crankshaft rotary

Not installing Not installing

1st step: Read blink code and confirm Read blink

2nd step: Firstly inspect if low pressure

Turn to the next step if the problem

3rd step: Inspect if wires, sensors and

Water temperature Oil pressure sensor Camshaft speed sensor

Rail pressure sensor

Failure removal steps:

air filter valve clearance turbocharger

Failure removal steps:

Failure removal steps:

Failure removal steps:

metering unit failure

air-intake pressure sensor

Absolute pressure rail

by-pass metering unit

Failure removal steps:

Failure removal steps:

2nd step: Remove the failure according to blink code.

3rd step: Inspect if electric accelerator pedal plug looses, wrongly

4th step: Inspect if the electric accelerator pedal fails.

The electric accelerator pedal wire looses or wrongly connecting. Re-plug

Note: Replace the accelerator with the same model

Note: After install the belt, pull out the pin of

The injector working principle picture

1 atomization of injector is bad Carbon deposit heavily on fuel clean replace

Fault: insufficient power, block smoke exhaust, difficult to start

　　 air-intake pressure sensor