先做人 后做事 品质改变世界

SY215 T3 Engine-4M50
（training reference material after sales)

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contents
1. Necessary of tier3 engine upgrade

2. Summary of electricity spray engine

3. Fuel supply system

4. Electronic control system

5. Engine oil lubrication system

6. Maintenance and care 2

 先做人 后做事 品质改变世界

1. Engineering machine exhaust gas has been a very serious problem today.

<reason>
Inappropriate fuel management <result>
(water, dust, impurity) Air pollution
No periodic equipment maintenance. exhaust pollution Reduce efficiency
Wrong equipment operation. Reduce the machine life
Increase shut down time
Increase the maintenance cost

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2. Engineering machine diesel engine face to the surroundings change

2.《to diesel engine’s requirements 》
・ Reduce the consumption of diesel. Protect from air temperature.
Increase economic performance.
・Consider environment nearby. Reduce the noise.
・Raise the engine output performance. Increase the work quantity of excavator.
・Reduce the waste gas emission. Reduce the influence to environment and human.
（ＮＯｘ・ＰＭ・ＣＯ・ＨＯ）
⇒ meet the tier 3 exhaust gas standard.

To reach the above objective, must use an engine that have good
performance, high fuel spray, waste gas treatment technology.

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3.柴油机排气污染物及其危害
Diesel engine exhaust gas pollution and it’s harm
Exhaust characteristic of diesel engine:
Because the average mixture used in diesel engine is bigger than theory mixture. It’s exhausted CO and HC is obviously
lower than gasoline engine.
The exhausted NOX from two engine is about equal.
Combustion type of diesel engine is compression ignite. Mixed gas in the combustion house is not on average, some area
excess air factor is below 0.6, that lead to a lot of carbon smoke. So diesel engine’s PM exhaust is more higher than
gasoline engine.

PM’s mainly harm：

•NO X ： high concentration NO can cause paralysis and spasm of central nervous.NO2 is a kind of brown
gas with special irritant offensive smell. Poisoning symptoms is producing pulmonary edema, leading to
bronchiolitis at the same time. It can produce peroxide together with HC.
•PM: Once entering lungs, it will lead to not only cancer but also emphysema, slow disease, skin disease
and abnormal disease.
•Photochemical smog: it is formed from NOX and HC under the sun energy. it produced in the summer, in
the place that have plenty of waste gas, in the condition under the sun and no flowing air wind.it can lead
to reduce lung function, headache, paralysis, and even death.
•SO2:it was determined by the sulfur content. usually diesel engine SO2 is more than gasoline engine. SO2
have strong irritant to human body respiratory system.

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4.Measure meeting waste gas exhaust standard

ＮＯｘ
ＰＭ・black smoke
ＰＭ：generic of particles ＮＯ・ＮＯ２
black smoke：rest gas of burning

Harm to human body Place photochemical worse and

influence Lead to disease of respiratory system acid rain

Mak it combustion
Burning slowly with lower
measure completely. Perish all measure temperature.
the rest material.

Ultra-high pressure spray precise spray/ major spray delay

technology High pressure air supply variable turbocharger ＥＧＲ（exhaust gas recirculation）
Inlet air cooler(inter-cooler) Inlet air cooler(inter-cooler)

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6、Exhaust standard summary--- exhaust guideline contrast of diesel engine

exhaust limiting value

NOx PM Chinese Europe
implementation implement
exhaust standard (g/KW.h) (g/KW.h) date ation date
GB17691-2005
First stage
（amount to Europe Ⅰ standard） 8.0 0.36 2001 1992
Second stage
（amount to Europe Ⅱ standard） 7.0 0.15 2004 1996

Third stage
（amount to Europe Ⅲ standard） 5.0 0.10 2007 2000

Fourth stage
（amount to Europe Ⅳ standard） 3.5 0.02 2010 2006

Fifth stage
2.0 0.02 2012 2009
（amount to Europe Ⅴ standard）

After perform exhaust limiting value, from Europe Ⅰ to Europe Ⅱ, Nox reduced 72%, PT reduced
86%. Moreover, we can look on above: our country’s exhaust standard was backward
about three to eight years. Matter is worse than the standard in fact. That is one factor why developed
countries’ environment is better than our country.
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7、main measure to reduce diesel engine exhaust：

 Optimize and matching the combustion system
 Delay the fuel injection timing：this is the simplest and effective way to reduce NOX(condition is
high temperature and oxygen enrichment)
 Boost and boost inter cooler: turbocharger can improve the power performance, but will increase NOX
exhausted.
 exhaust gas recirculation（EGR）：it’s mechanism is filling a quantify burned gas to the cylinder through
exhaust pipe. Because the waste gas is too inert. It will not join in chemical reaction. The mixture gas was diluted in
cylinder, reduced the calorific value of gas. On the other hand, due to three atoms molecules such as H2O and CO2
contain in the waste gas has high heat capacity, increase the heat capacity of the mixture, so can be more effectively
reduce the peak temperature of the cylinder than the same amount of O2 and N2. Both of them can reduce the
maximum combustion temperature, thereby reduce the NOX emissions.
 High pressure electric fuel injection technology : at present there are mainly three type: Common rail , pump nozzle,
monomer pump.

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Struggle policy of stage Ⅲ to environment problem

◆constantly pursuit the limit of economy (fuel cost)
meet the emissions limits in future(new long time ·after new long time）
Waste gas exhaust economy
Reduce the pollution round of city Care two sides
（NOx CO HC PM reduction） Reduce fuel cost＝reduce CO2

Solution to higher levels of coordination of environment and economy…

Three big subject

Subject 1） Improve the basic the potential power of diesel engine

Subject 2） Select the most appropriate post-processing equipment

Subject 3） The deepening of comprehensive control

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Main technology for the emissions limits

achieve at the
Take integrity control technology ：
same time Integrated electronic
Have been used on ELF KR
control
・ Super environmental ・ Precise control and feedback control
・low fuel cost ・ Sensor technology
・high torque
・ Low noise

Fusion of the key

technology
Burn best Post processing
・ Burning injection system ・ＤＰＤ
Diesel Particulate Defuser
・ Burning system
・ High boost ・Ｄｅ‐ＮＯｘ catalytic

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Main technology for the emissions limits

(g/kWh) ※GVW3.5t beyond CV

0.25 For a long time
Inter-cooler turbochargerﾞ

Cooling EGRﾞ
0.18
New short-term
High pressure common rail type
PM Fuel injection system

Oxidation catalyst

VGS turbochargerﾞ
0.027 New long-term Continuous regenerative DPD
New short-term： emissions limits in 2003
New long-term： emissions limits in 2005
0.01 Urea catalytic ､NOxReduction catalyst
Premixed combustion （PCI）

After new long-term

0.7 2.0 NOx 3.38 4.5 (g/kWh)
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Main technology for the emissions limits

Corresponding technology emissions limits ‘74 ’77 ’79 ’83 ’89 ’94 ’97 ’02 ’05
improve the combustion chamber ● ● ● ● ● ● ● ● ●
Increase capacity, improve the compression ratio,
cooling the chamber ● ● ● ● ● ● ●
EGR/ Cooled EGR ● ● ● ●
Reduce the oil consumption ● ● ●
Injection time, injection rate, speed governor control
improvement
● ● ● ● ● ● ● ● ●
Nozzle improvement
High pressure jet ● ● ● ● ● ● ●
variable injection rate
Electronic governor/common rail system ● ● ● ● ● ●
Two level high pressure nozzle
variable injection rate(VE pump) ● ● ●
air intake and exhaust gate improvement ● ● ● ● ● ● ● ● ●
boost ● ● ● ● ● ● ●
Inter-cooler, variable inertial pressurization ● ● ● ● ● ●
Variable Nozzle Turbo Charger ● ● ● ● ●
Variable eddy current
Reduce the deviation ● ● ● ● ● ● ●
Startability improvement ● ● ● ● ● ●
Post
Oxidation catalyst ● ● ●
Continuous regenerative DPF ● ●
processing
NOx catalyst ●

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reduce NOx technology

project instructions

Nox reduction technology can be applied to most of the

① Cooled EGR
engine.

Through the first injection of common rail injection system, to

Control injection rate、
② injection time achieve the optimization of injection。
For combustion and NOx emission optimization。
NOx Purification rate is high。
subject: deterioration of fuel consumption，Sulphur catalyst
Nox catalytic
③ (Lean NOx Trap)
inhibit regeneration lead to catalytic sintering
The premise is that the sulfur content in fuel oil is only a few parts
per million.

NOx catalytic Nox catalytic system taking fuel as the reductant

④ (HC Reduction) subject：Low purification efficiency, fuel consumption worsen 。

NOx high purification efficiency. No fuel consumption worsen.

⑤ Urea-SCR subject：needs urea infrastructure, establish assured users added
urea method. Restrain ammonia loss.
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2. Summary of electronic fuel injection engine

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一. engine profile
•Suitable for 19～23texcavator output power and torque
•Import from Japan ，Rated power 118kW，Suit for China Ⅲ
Third stage（amount to Europe Ⅲ standard），High pressure
common rail system and EGRT System，widely used in
construction machinery。
Engine parameter
Manufacturer Mitsubishi hibiscus
model 4M50-TLC1G
Rated power 118kw/2000rpm
Max torque 580N.m/1600rpm
Capacity 4.899L
Oil injection system High pressure common rail
Max Speed 2150±25rpm/80Nm
idling 975±25 rpm/69Nm
Clinder diameter
4-114mm×120mm
and stroke length
vertical type,4 stroke,
tpye water-cooled diesel
engine
water-cooled EGR YES
Meight 518kg 15
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一. engine profile——engine structure

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一. Engine basic profile ----- horsepower curve

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一. Engine basic profile ——exhaust

• China perform stage 2 exhaust standard.

• stage 3 exhaust standard will be performed since 2016-4 （Sany stop producing stage 2
machine since 2015-12-30）
•the standard maybe same as EU Stage3A.

37-75KW 75-130KW 130-560KW

項目
project 単位
unit
Tier2 Tier3 Tier2 Tier3 Tier2 Tier3
NOx+HC g/kWh - 4.7 - 4.0 - 4.0
NOx g/kWh 7.0 - 6.0 - 6.0 -
HC g/kWh 1.0 - 1.0 - 1.0 -
CO g/kWh 5.0 5.0 5.0 5.0 3.5 3.5
PM g/kWh 0.4 0.4 0.3 0.3 0.2 0.2
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一. Engine basic profile ----fuel common rail system

High pressure injection fuel spray is better, more small

 超高喷射压力，使燃油雾化更好
particles
 Multi points injection（pre injection and post
injection ),multi injection, Burn more fully.

Common injection High pressure

fuel spray injection fuel spray

 Monitoring the engine speed、throttle

percentage and Temp of water ),and so
can control the injection quantity,
spray time, injection pressure， so to
keep the running optimal state.
 Electronic equipment supply diagnose
the state, to recognise the default of all
the parts ,and give alarm to operators.

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一. Engine basic profile ----fuel common rail system

 Basic on the case from related sensors

（engine speed、Temp of water and
position of EGR），To adjust the valve
opening by EGR controller, so that it can
adjust the exhaust gas flow.
 the engine combustion exhaust gas was
forced into the inhaling pipe of the engine to
reduce oxygen concentration in the
combustion chamber, reduce combustion
temperature. So as to reach the effect to
reduce Nox exhaust 。
 the engine combustion exhaust gas was
forced into the inhaling pipe of the engine to
reduce combustion temperature.，so that
improved volumetric efficiency.

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一. Engine basic profile ——intake valve structure

Four Intake valves and exhaust valves optimal design：

 Four valve and swirl inlet ，enhance suction flow rate and capacity dramatically；
 Swirl matching the common rail fuel；
 Injector and cylinder assemble vertically.
It make burning abundantly，engine running smoothly, so there are extraordinary
economic and comfortable.

4M50OHC 4 Valve 6D34OHV 2 Valve

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3 . Fuel supply system

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Fuel supply system chart

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Fuel supply system, low pressure pipe technical parameters

Role: except pressing the low pressure fuel to high pressure fuel, also ensure that there is
enough fuel in the process of rapid start and common rail pipe pressure rapidly rising,
continue to produce required system pressure in the high pressure common rail pipe.
aim：ensure oil delivery pipe inlet pressure

Allow the tube

Fuel tube diameter Allow pressure
length

≥10 mm ≤3 m
Fuel tank inlet
≥11 mm ≤6 m 0.5～1.0 bar
tubes
≥12 mm ≤9 m

Fuel tank return ≥ 9 mm ≤6 m

≤1.2 bar
tubes ≥10 mm ≤9 m

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Fuel supply system ----Spray pump

Plunger Inlet valve Outlet valve

Inlet
spring Outlet fuel(to fuel Inlet valve
common rail )
Plunger
tappet
overflow joint spring
valve
eccentric shaft tappet

eccentric shaft

Fuel meter
（MPROP）

Polygonal ring

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 1.MPROP (rail pressure control valve) 先做人 后做事 品质改变世界

Fuel supply system ----Spray pump

CAUTION

The supplypump pressurizes fuel and supplies it in a highly pressurized state.

•Fuel drawn from the fuel tank by the feed pump is not supplied directly to the plungers. It is
supplied first to the MPROP (rail pressure control valve), which controls the amount of fuel
reaching the plungers.
•If the fuel pressure exceeds a certain level, the overflow valve returns fuel to the inlet side of
the feed pump. This operation keeps the pressure of the fuel fed to MPROP, constant.
•Rotation of the eccentric drive shaft causes (via the tappets) up-down movement of the
plungers. Fuel in the plunger chambers is thus highly pressurized.

Be sure to connect the MPROP (rail pressure control valve) connector to the
engine harness before starting the engine. If the engine were started with the
MPROP connector not connected, control of the supply pump by the engine
elec- tronic control unit would not be possible and a fault would ensue.
•The MPROP receives fuel from the feed pump and feeds fuel to- ward the
plungers of the supply pump in such a quantity that the fuel pressure
corresponds to that required by the engine elec- tronic control unit.
•When the MPROP is not operating, i.e., when current is not flow- ing, fuel
flows at its maximum rate. When current flows, the pis- ton in the MPROP is
pressed down such that fuel is not fed toward the plungers.
•The engine electronic control unit controls the ratio of current-off time (duty
ratio).

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Fuel supply system ----Spray pump

• The common rail distributes to the injectors high-pressure fuel that has been fed from the supply pump.
Each flow limiter prevents an abnormal outflow of fuel. It does so by blocking the fuel passage in the event of fuel leakage from
the injection pipe or excessive injection of fuel from the injector.
The common rail pressure sensor is used in feedback control. It senses the fuel pressure inside the common rail and feeds a
corresponding signal to the electronic control unit.
If the fuel pressure in the common rail exceeds a certain, set level, the piston in the pressure limiting valve pushes and compresses
the spring such that fuel is able to escape. The pressure limiting valve thus prevents the fuel pressure from becoming higher than
the set pressure.
When the pressure limiting valve is activated, the common rail system is faulty and needs an inspection.

(1) Flow limiter

During normal operation, the piston moves (thus pushing and compressing the spring) to the extent necessary for one injection
quantity to pass through. The piston does not make contact with the seat at this time. When injection is complete, the piston is
returned to its initial position by the spring.
If the amount of fuel passing through the flow limiter becomes excessively great, the piston presses against the seat, thereby
closing the fuel passage and preventing an abnormal outflow of fuel.
When the piston has pressed against the seat, it does not return to its original position until the engine has been stopped and the
pressure in the common rail has come down. 27 27
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Control system----Multi-point injection

In accordance with electrical signals from the
engine electronic control unit, each injector
supplies high-pressure fuel from the common
rail to the relevant combustion chamber of
the engine at the optimal timing and in the
opti- mal quantity.
The injector is divided into the control
section and the injector section.

The control section consists of the

control chamber, magnet, valve spring,
armature plate, valve ball, valve body,
valve piston, orifice A, and orifice Z.
The valve piston is located between the
control section and the injec- tion
section.
The injection section consists of the nozzle
body, nozzle needle, nozzle spring, and
nozzle nut.
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 1.Operation 先做人 后做事 品质改变世界

Control system----Multi-point injection

(1.1) Injection not taking place

•With the magnet not energized, the ar- mature plate is
pushed up by the valve spring such that the ball seat is
closed.
•The high-pressure fuel acts upon the control chamber via
orifice Z. The same pressure acts upon the nozzle needle
•The fuel pressure acting on the nozzle needle cannot
overcome the valve pis- ton and nozzle spring, so the nozzle
needle stays in its downward-pushed position and injection
does not take place
•.

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Control system----Multi-point injection

(1.2) Start of injection

•When the magnet is energized, the re- sulting
electromagnetic force draws the armature plate
upward, causing the ball seat to open.
•Fuel in the control chamber passes through
the orifice A and ball seat and flows to the fuel
tank.

With the pressure in the control cham- ber reduced, the fuel
acting on the nozzle needle overcomes the valve piston and
nozzle spring, pushing up the nozzle needle such that injection
starts.
•If the magnet remains energized, the injection
rate reaches its maximum level.

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 When energization of the magnet先做人 后做事
is stopped, the armature 品质改变世界
plate is pushed downwar

Control system----Multi-point injection

(1.3) End of injection

• When energization of the magnet is

stopped, the armature plate is pushed
downward by the valve spring such
that the ball seat closes. At this time,
fuel flows into the control chamber via
orifice Z, pushing down the valve pis-
ton and nozzle needle such that injec-
tion finishes.

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4. Electronic control system

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Electronic control structure diagram

Input signals Engine electronic control unit Output signals

Engine speed sensor Injector magnetic valve

Cylinder recognition sensor Fuel injection control MPROP 1, 2(rail pressure
control valve)
Water temperature sensor

Engine
Boost pressure sensor Fuel injection quantity
Common rail pressure sensor control
Fuel temperature sensor
Warm-up acceleration Fuel injection timing
Intake air temperature sensor function control

Fuel injection pressure

Starter switch control
Accelerator pedal position sensor
Accelerator pedal switch Exhaust gas
Vehicle speed sensor recirculation valve Engine warning lamp
<with vehicle speed limitation function> control function
(See Gr17.)
Idling speed adjustment potentiometer Tachometer
<with Idling speed adjustment
function> Glow drive relay <Models
Warm-up switch with preheating function>
<Warm-up acceleration function>
Fuel injection rate adjustment resistor Starter continuous
Memory clear switch energization Glow plugs <Models with
prevention function preheating function>
Diagnosis switch
Multi-Use Tester connector Preheating Exhaust shutter 3-way
Air conditioner switch function magnetic valve <Models
<with air conditioner idle up function> with auxiliary brake
Transmission neutral switch function>
Idle up
<Models with auxiliary brake function> function Safety relay
Exhaust brake switch
Vehicle

<Models with auxiliary brake function> Fault diagnosis

function Electronic drive unit relay
Torque limit switch
<Models with torque cut function>
Power take-off switch
<Models with power take-off> Electronic control unit
<Models with auto shifter>
Power take-off adjustment resistor (engine speed signal)
<Models with power take-off> (accelerator pedal position
Idling up cancel switch sensor)
<Models with auto shifter>
Auxiliary brake cut switch Exhaust gas recirculation electronic
<Models with auxiliary brake function> drive unit

Exhaust gas recirculation valve

Machinery side electronic Motor
control unit Position sensor

CAN: Controller Area Network

CAN
communication

13E-12
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 Water temperature sensor Sensing of coolant temperature
Boost pressure sensor Sensing of boost pressure
先做人 后做事 品质改变世界
Common rail pressure sensor Sensing of common rail pressure
Fuel temperature sensor Sensing of fuel temperature

各部件功能 Intake air temperature sensor Sensing of intake air temperature

Senses that the engine is in starting condition with the starter switch in
Starter switch START position.
Accelerator pedal position sensor Sensing of extent of accelerator pedal depression
Sensing of released/pressed condition of accelerator pedal (ON with
Accelerator pedal switch pedal released)
Vehicle speed sensor
<with vehicle speed limitation function> Sensing of vehicle speed
Idling speed adjustment potentiometer
<with Idling speed adjustment function>
Acceleration of warm-up
Warm-up switch
Fuel injection rate adjustment resistor Correction of fuel injection rate
Diagnosis switch Output of diagnosis codes
Memory clear switch Deletion of diagnosis codes; output of past diagnosis codes
Multi-Use Tester connector Communication between Multi-Use Tester and common rail system
Air conditioner switch
<with air conditioner idle up function> ON when air conditioner is operating
Transmission neutral switch Detecting of neutral position in the transmission (OFF
<Models with auxiliary brake function> with transmission in neutral)
Exhaust brake switch
<Models with auxiliary brake function> Exhaust brake ON/OFF control

Torque limit switch <Models with torque cut function> Detection of 1st and reverse positions
Power take-off switch
<Models with power take-off> Operation of power take-off
Power take-off adjustment resistor
<Models with power take-off> Selection of power take-off map
Idling up cancel switch
<Models with auto shifter> Clearing of idling up status
Auxiliary brake cut switch
<Models with auxiliary brake function> Deactivating of auxiliary brake
Control of fuel injection rate, fuel injection quantity, and fuel injection
Injector magnetic valve timing
MPROP (rail pressure control valve) Control of fuel injection pressure
Engine warning lamp Indication of system abnormalities
Tachometer Indication of engine speed (in meter cluster)
Glow drive relay <Models with preheating function> ON/OFF control of glow plugs 34
 先做人 后做事 品质改变世界
electronic control system ----
electronic control injection
system
1.1 Fuel injection control
(1) Pilot injection

• Pilot injection entails the injection of an extremely small amount

of fuel ahead of the main injection.
• Pilot injection suppresses heat generation early in the injection
cycle and thus suppresses NOx generation and noise at the start
of combustion.

(2) Split injection control

• Split injection entails the injection of an extremely small amount

of fuel two or more times ahead of the main injection.
• Split injection increases the fuel’s combustibility and thus en-
hances the engine’s cold startability.

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Fuel injection rate adjustment resistor correction amount

1.1 Fuel injection quantity control
(1) Fuel injection quantity during engine startup

• During engine startup, the fuel injection quantity is determined in

accordance with the engine speed and coolant temperature.

(2) Basic fuel injection quantity

• The basic fuel injection quantity is determined in accordance

with the engine speed and throttle

opening.

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Fuel injection rate adjustment resistor correction amount

(1) Maximum injection quantity

• The maximum injection quantity is calculated from the engine

speed and boost pressure.

(1) Fuel injection rate adjustment resistor correction amount

• To limit inconsistency in the injection quantity, the injection quan-

tity is corrected by the fuel injection rate adjustment resistor.

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2.4 Fuel injection timing control

1.1 Fuel injection timing control
(1) Main injection timing

• The main injection timing is calculated from the fuel injection

quantity and engine speed.

(2) Pilot injection timing (pilot interval)

• The pilot injection timing is calculated from the fuel injection

quantity and engine speed.

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Fuel injection pressure control

1.1 Fuel injection pressure control
• The fuel injection pressure is calculated from the fuel injection
quantity and engine speed.

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3. Electronic Control Unit Connection Diagram

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3.2 Diagnosis code

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3.2 Diagnosis code

P0107: Atmospheric Pressure Sensor (warning lamp flashes: 19)
Atmospheric pressure sensor (incorporated into engine electronic control unit)
Generation condition voltage is below standard value (2 V).
Recoverability System recovers if signal becomes normal with starter switch in ON position.
• Control is effected using backup value of 101.3 kPa {1.03 kgf/cm2}.
(Exhaust emissions worsen.)
Control effected by electronic control unit • Exhaust gas recirculation control is stopped.
Service data 38: Atmospheric Pressure
Inspection
Other Replace engine electronic control unit.

P0108: Atmospheric Pressure Sensor (warning lamp flashes: 19)

Atmospheric pressure sensor (incorporated into engine electronic control unit)
Generation condition voltage is below standard value (4.7 V).
Recoverability System recovers if signal becomes normal with starter switch in ON position.
• Control is effected using backup value of 101.3 kPa {1.03 kgf/cm2}.
(Exhaust emissions worsen.)
Control effected by electronic control unit • Exhaust gas recirculation control is stopped.
Service data 38: Atmospheric Pressure
Inspection
Other Replace engine electronic control unit.

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3.2 Diagnosis code

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3.2 Diagnosis code

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3.2 Diagnosis code

P0121: Accel Pedal Check (Plausibility) (warning lamp flashes: 58)

Accelerator pedal position sensor output voltages 1 and 2 are outside standard
Generation condition range; or compared value is out of specification.
Recoverability System recovers if signal becomes normal with starter switch in ON position.
Control effected by electronic control unit – (Low output)
22: Accel Pedal Position (unfiltered), 23: Accel Pedal Position (filtered) 24:
Inspection Service data Accel Pedal Sensor Voltage 1, 25: Accel Pedal Sensor Voltage 2

P0122: Accel Pedal Sensor 1 (warning lamp flashes: 24)

Generation condition Accelerator pedal position sensor 1 voltage is below standard value.
Recoverability System recovers if signal becomes normal with starter switch in ON position.
Control effected by electronic control unit Control is effected using accelerator pedal position sensor 2.
22: Accel Pedal Position (unfiltered), 23: Accel Pedal Position (filtered) 24:
Inspection Service data Accel Pedal Sensor Voltage 1

P0123: Accel Pedal Sensor 1 (warning lamp flashes: 24)

Generation condition Accelerator pedal position sensor 1 voltage is below standard value.
Recoverability System recovers if signal becomes normal with starter switch in ON position.
Control effected by electronic control unit Control is effected using accelerator pedal position sensor 2.
22: Accel Pedal Position (unfiltered), 23: Accel Pedal Position (filtered) 24:
Inspection Service data Accel Pedal Sensor Voltage 1

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3.2 Diagnosis code

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3.2 Diagnosis code

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3.2 Diagnosis code

P0200: Injector Circuit 1 (warning lamp flashes: 82)

Injector magnetic valve circuit (No. 1 and No. 4 cylinder) is short-circuited, open-
Generation condition circuited, or overloaded.
Recoverability System recovers if signal becomes normal with starter switch in ON position.
• Faulty circuit is stopped, resulting in two-cylinder operation.
(Output is reduced, and exhaust emissions worsen.)
Control effected by electronic control unit • Exhaust gas recirculation control is stopped.
Actuator tests BB: Injector Test 1, BE: Injector Test 4
Electronic control unit connector 04 : Injector magnetic valve
Inspection Electrical equipment #582: Injector magnetic valve

P0201: Injector M/V-Cylinder 1 (Load) (warning lamp flashes: 37)

Generation condition Injector magnetic valve (No. 1 cylinder) is short-circuited or open-circuited.
Short circuit: System recovers (power is re-supplied to electronic control unit) if
signal becomes normal when starter switch is turned OFF  ON.
Open circuit: System recovers if signal becomes normal with starter switch in ON
Recoverability position.
• Exhaust gas recirculation control is stopped.
• Open circuit: Energization is stopped.
• Short circuit: Injector magnetic valves 1 and 4 are stopped.
Control effected by electronic control unit (Output is reduced, fuel economy worsens, and exhaust emissions worsen.)
Actuator test BB: Injector Test 1
Electronic control unit connector 04 : Injector magnetic valve
Inspection Electrical equipment #582: Injector magnetic valve

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3.2 Diagnosis code

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3.2 Diagnosis code

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3.2 Diagnosis code

P0222: Accel Pedal Sensor 2 (warning lamp flashes: 16)

Generation condition Accelerator pedal position sensor 2 voltage is below standard value.
Recoverability System recovers if signal becomes normal with starter switch in ON position.
Control effected by electronic control unit Control is effected using accelerator pedal position sensor 1.
22: Accel Pedal Position (unfiltered), 23: Accel Pedal Position (filtered) 25:
Inspection Service data
Accel Pedal Sensor Voltage 2

P0223: Accel Pedal Sensor 2 (warning lamp flashes: 16)

Generation condition Accelerator pedal position sensor 2 voltage is above standard value.
Recoverability System recovers if signal becomes normal with starter switch in ON position.
Control effected by electronic control unit Control is effected using accelerator pedal position sensor 1.
22: Accel Pedal Position (unfiltered), 23: Accel Pedal Position (filtered) 25:
Inspection Service data
Accel Pedal Sensor Voltage 2

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3.2 Diagnosis code

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3.2 Diagnosis code

P0251: Common Rail Pressure Defect (warning lamp flashes: 36)
Difference between target rail pressure and actual rail pressure is above standard
Generation condition value.
System recovers (power is re-supplied to electronic control unit) if signal becomes
Recoverability normal when starter switch is turned OFF  ON.
• Injection quantity is limited. (Output is reduced.)
Control effected by electronic control unit • Exhaust gas recirculation control is stopped.
Actuator test B9: Fuel Leak Check
• Air-bleeding of fuel system (See Gr13A.)
• Fuel piping (See Gr13A.)
• Fuel filter (See Gr13A.)
Inspection Other • Supply pump (Have work performed by Bosch.)
• Pressure limiting valve (Have work performed by Bosch.)
• Injectors (Have work performed by Bosch.)

P0253: Common Rail Pressure Defect (warning lamp flashes: 22)

Generation condition Actual rail pressure is below standard value.
Recoverability System recovers if signal becomes normal with starter switch in ON position.
• Engine stopped.
Control effected by electronic control unit • Exhaust gas recirculation control is stopped.
Actuator test B9: Fuel Leak Check
• Air-bleeding of fuel system (See Gr13A.)
• Fuel piping (See Gr13A.)
• Fuel filter (See Gr13A.)
Inspection Other • Supply pump (Have work performed by Bosch.)
• Pressure limiting valve (Have work performed by Bosch.)
• Injectors (Have work performed by Bosch.)

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3.2 Diagnosis code

P0254: Common Rail Pressure Defect (warning lamp flashes: 23)
Actual rail pressure is high even with delivery rate of zero; or actual rail pressure is
Generation condition above standard value.
System recovers (power is re-supplied to electronic control unit) if signal becomes
Recoverability normal when starter switch is turned OFF  ON.
• Injection quantity is limited. (Output is reduced.)
Control effected by electronic control unit • Exhaust gas recirculation control is stopped.
Inspection Other Supply pump (Have work performed by Bosch.)

P0335: Engine Revolution SNSR (warning lamp flashes: 15)

Generation condition Engine speed sensor emits no pulses or too many pulses.
Recoverability System recovers if signal becomes normal with starter switch in ON position.
Control is effected using cylinder recognition sensor. (Output
Control effected by electronic control unit decreases owing to reduced control accuracy.)
Service data 01: Engine Revolution
Electronic control unit connector 05 : Engine speed sensor
Inspection Electrical equipment #263: Engine speed sensor

P0340: Camshaft Position SNSR (warning lamp flashes: 12)

Generation condition Cylinder recognition sensor emits no pulses or too many pulses.
Recoverability System recovers if signal becomes normal with starter switch in ON position.
Control effected by electronic control unit Control is effected using engine speed sensor.
Service data 01: Engine Revolution
Electronic control unit connector 06 : Cylinder recognition sensor
Inspection Electrical equipment #320: Cylinder recognition sensor

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3.2 Diagnosis code

P0380: Relay for Glow Relay (Warning lamp flashes: 26)

Generation condition Glow drive relay short or open circuit, or overload

Recoverability System recovers if signal becomes with starter switch ON position.
Control effected by electronic control unit Glow control is stopped.
Service data 8D: Glow Relay
Actuator test AF: Relay for Glow Relay
Inspection Electronic control unit connector 11 : Glow drive relay
Electrical equipment #201: Glow drive relay

P0381: Glow Lamp (Warning lamp flashes: 89)

Generation condition Glow indicator lamp short or open circuit, or overload
Recoverability System recovers if signal becomes with starter switch ON position.
Control effected by electronic control unit Normal control
Service data 8E: Glow Relay Indicator Lamp
Inspection
Actuator test B0: Glow Indicator Lamp

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3.2 Diagnosis code

P0403: EGR1 (Warning lamp flashes: 67)
One of the following conditions occurs:
• Short-circuit or open-circuit occurs in the EGR motor.
• Open-circuit occurs in the EGR position sensor.
Generation condition • Communication error in line between EDU and EGR valve (Target position
data out of the specified range, no data received, etc.)
• Abnormal power supply voltage (overvoltage or undervoltage)
• Motor or sensor faulty: System recovers if signal becomes normal when the
starter switch is turned from OFF to ON. (ECU Power is turned on again)
• Communication error or abnormal power supply: System recovers if signal be-
Recoverability comes normal with the starter switch in ON position.
• Exhaust gas recirculation control is stopped.
Control effected by electronic control unit • Injection quantity is limited.
Service data 1F: EGR Position
Actuator test A1: EGR 1
Inspection Electrical equipment #530: EGR valve

P0506: Idle Volume (warning lamp flashes: 21)

Generation condition Idling speed adjustment potentiometer voltage is below standard value.
Recoverability System recovers if signal becomes normal with starter switch in ON position.
Control effected by electronic control unit Control is effected with auto idle permanently selected.
Inspection Service data 3B: Idle Volume Voltage

P0605: ECU System (Hardware) (warning lamp flashes: 33)

Generation condition Circuit (hardware power supply) in electronic control unit is abnormal.
System recovers if signal becomes normal with starter switch in ON position.
Recoverability System does not recover unless diagnosis code is deleted.
Control effected by electronic control unit Engine is stopped.
Inspection Other Replace engine electronic control unit.

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3.2 Diagnosis code

P0615 : Starter Safety Relay (Over Load) (warning lamp flashes : 48)
Generation conditions Safety relay overload
Recoverability System recovers if signal becomes with starter switch ON position.
Control effected by electronic control unit Starter continuous energization prevention function is suspended.
Service data 8F: Starter safety relay
Actuator test B1: Starter safety relay
Inspection Electronic control unit connector 09 : Starter safety relay
Electrical equipment #201: Starter safety relay

P0616 : Starter Safety Relay (Low) (warning lamp flashes : 48)

Generation conditions Safety relay circuit shorted to ground or open-circuited.

Recoverability System recovers if signal becomes with starter switch ON position.
Control effected by electronic control unit Starter continuous energization prevention function is suspended.
Service data 8F: Starter safety relay
Actuator test B1: Starter safety relay
Inspection Electronic control unit connector 09 : Starter safety relay
Electrical equipment #201: Starter safety relay

P0617 : Starter Safety Relay (High) (warning lamp flashes : 48)

Generation conditions Safety relay circuit shorted to power supply.

Recoverability System recovers if signal becomes with starter switch ON position.
Control effected by electronic control unit Starter continuous energization prevention function is suspended.
Service data 8F: Starter safety relay
Actuator test B1: Starter safety relay
Inspection Electronic control unit connector 09 : Starter safety relay
Electrical equipment #201: Starter safety relay

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3.2 Diagnosis code

1171: Q Adjustment Resistor (Low) (warning lamp flashes: 34)
Generation condition Fuel injection rate adjustment resistor voltage is below standard value (0.2 V).
Recoverability System recovers if signal becomes normal with starter switch in ON position.
Control effected by electronic control unit Control is effected using backup value (No. 1). (Output is slightly reduced.)
Service data 3E: Q Adjustment Resistor No.
Inspection Electronic control unit connector 07 : Fuel injection rate adjustment resistor
Electrical equipment #828: Fuel injection rate adjustment resistor

P1172: Q Adjustment Resistor (High) (warning lamp flashes: 34)

Generation condition Fuel injection rate adjustment resistor voltage is above standard value (4.8 V).
Recoverability System recovers if signal becomes normal with starter switch in ON position.
Control effected by electronic control unit Control is effected using backup value (No. 1). (Output is slightly reduced.)
Service data 3E: Q Adjustment Resistor No.
Inspection Electronic control unit connector 07 : Fuel injection rate adjustment resistor
Electrical equipment #828: Fuel injection rate adjustment resistor

P1200: Injector Circuit 2 (warning lamp flashes: 82)

Injector magnetic valve circuit (No. 2 and No. 3 cylinder) is short-circuited, open-
Generation condition circuited, or overloaded.
Recoverability System recovers if signal becomes normal with starter switch in ON position.
• Faulty circuit is stopped, resulting in two-cylinder operation. (Output is re-
duced, and exhaust emissions worsen.)
Control effected by electronic control unit • Exhaust gas recirculation control is stopped.
Actuator tests BC: Injector Test 2, BD: Injector Test 3
Electronic control unit connector 04 : Injector magnetic valve
Inspection Electrical equipment #582: Injector magnetic valve

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3.2 Diagnosis code

P1251: Common Rail Pressure M/V 1 (warning lamp flashes: 63)

Generation condition Current flowing to MPROP (rail pressure control valve) is above standard value.
System recovers (power is re-supplied to electronic control unit) if signal becomes
Recoverability normal when starter switch is turned OFF  ON.
• Injection quantity is limited. (Output is reduced, fuel economy worsens, and
exhaust emissions worsen.)
Control effected by electronic control unit • Exhaust gas recirculation control is stopped.
Actuator test B9: Fuel Leak Check
Electronic control unit connector 08 : MPROP (rail pressure control valve)
Inspection Electrical equipment #574: MPROP (rail pressure control valve)

P1255: Common Rail Pressure M/V 1 (warning lamp flashes: 63)

Generation condition MPROP (rail pressure control valve) voltage is below standard value.
System recovers (power is re-supplied to electronic control unit) if signal becomes
Recoverability normal when starter switch is turned OFF  ON.
• Injection quantity is limited. (Output is reduced, fuel economy worsens, and
exhaust emissions worsen.)
Control effected by electronic control unit • Exhaust gas recirculation control is stopped.
Actuator test B9: Fuel Leak Check
Electronic control unit connector 08 : MPROP (rail pressure control valve)
Inspection Electrical equipment #574: MPROP (rail pressure control valve)

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3.2 Diagnosis code

P1256: Common Rail Pressure M/V 1 (warning lamp flashes: 63)
Generation condition MPROP (rail pressure control valve) voltage is above standard value.
High voltage: System recovers if signal becomes normal with starter switch in ON
position.
Short circuit: System recovers (power is re-supplied to electronic control unit) if
Recoverability
signal becomes normal when starter switch is turned OFF  ON.
• Injection quantity is limited. (Output is reduced, fuel economy worsens, and
exhaust emissions worsen.)
Control effected by electronic control unit • Exhaust gas recirculation control is stopped.
Actuator test B9: Fuel Leak Check
Electronic control unit connector 08 : MPROP (rail pressure control valve)
Inspection Electrical equipment #574: MPROP (rail pressure control valve)

P1335: Revolution & Position Sensor (warning lamp flashes: 14)

Engine speed sensor and cylinder recognition sensor emit no pulses or too many
Generation condition pulses.
Recoverability System recovers if signal becomes normal with starter switch in ON position.
Control effected by electronic control unit Injectors are turned OFF. (Engine is stopped.)
Service data 01: Engine Revolution
Electronic control unit connector 05 : Engine speed sensor, 06 : Cylinder recognition sensor
Inspection Electrical equipment #263: Engine speed sensor, #320: Cylinder recognition sensor

P1562: Sensor Supply Voltage 1 (warning lamp flashes: 81)

Circuit voltage (sensor supply voltage 1) in electronic control unit is below standard
Generation condition value.
Recoverability System recovers if signal becomes normal with starter switch in ON position.
Control effected by electronic control unit No specific control is effected. Failure occurs only to circuit abnormality.
Inspection Service data 24: Accel Pedal Sensor Voltage 1, 3B: Idle Volume Voltage

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3.2 Diagnosis code

P1563: Sensor Supply Voltage 1 (warning lamp flashes: 81)

Circuit voltage (sensor supply voltage 1) in electronic control unit is above standard
Generation condition value.
Recoverability System recovers if signal becomes normal with starter switch in ON position.
Control effected by electronic control unit No specific control is effected. Failure occurs only to circuit abnormality.
Inspection Service data 24: Accel Pedal Sensor Voltage 1, 3B: Idle Volume Voltage

P1567: Sensor Supply Voltage 2 (warning lamp flashes: 81)

Circuit voltage (sensor supply voltage 2) in electronic control unit is below standard
Generation condition value.
Recoverability System recovers if signal becomes normal with starter switch in ON position.
Control effected by electronic control unit No specific control is effected. Failure occurs only to circuit abnormality.
Service data 25: Accel Pedal Sensor Voltage 2, 26: Boost Pressure
Inspection
Electrical equipment #318: Boost pressure sensor

P1568: Sensor Supply Voltage 2 (warning lamp flashes: 81)

Circuit voltage (sensor supply voltage 2) in electronic control unit is above standard
Generation condition value.
Recoverability System recovers if signal becomes normal with starter switch in ON position.
Control effected by electronic control unit No specific control is effected. Failure occurs only to circuit abnormality.
Service data 25: Accel Pedal Sensor Voltage 2, 26: Boost Pressure
Inspection
Electrical equipment #318: Boost pressure sensor

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3.2 Diagnosis code

P1572: Sensor Supply Voltage 3 (warning lamp flashes: 81)
Circuit voltage (sensor supply voltage 3) in electronic control unit is below standard
Generation condition value.
Recoverability System recovers if signal becomes normal with starter switch in ON position.
Control effected by electronic control unit No specific control is effected. Failure occurs only to circuit abnormality.
Service data 0C: Difference Common Rail Pressure
Inspection
Electrical equipment #319: Common rail pressure sensor

P1573: Sensor Supply Voltage 3 (warning lamp flashes: 81)

Circuit voltage (sensor supply voltage 3) in electronic control unit is above standard
Generation condition value.
Recoverability System recovers if signal becomes normal with starter switch in ON position.
Control effected by electronic control unit No specific control is effected. Failure occurs only to circuit abnormality.
Service data 0C: Difference Common Rail Pressure
Inspection
Electrical equipment #319: Common rail pressure sensor

P1577: Segment Sensor Supply Voltage (warning lamp flashes: 81)

Generation condition Cylinder recognition sensor supply voltage is below standard value (0 V).
Recoverability System recovers if signal becomes normal with starter switch in ON position.
Control effected by electronic control unit No specific control is effected. Failure occurs only to circuit abnormality.
Service data 01: Engine Revolution
Electronic control unit connector 07 : Cylinder recognition sensor
Inspection Electrical equipment #320: Cylinder recognition sensor

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3.2 Diagnosis code

P1578: Segment Sensor Supply Voltage (warning lamp flashes: 81)
Generation condition Cylinder recognition sensor supply voltage is above standard value (5 V).
System recovers (power is re-supplied to electronic control unit) if signal becomes
Recoverability normal when starter switch is turned OFF  ON.
Control effected by electronic control unit No specific control is effected. Failure occurs only to circuit abnormality.
Service data 01: Engine Revolution
Electronic control unit connector 07 : Cylinder recognition sensor
Inspection Electrical equipment #320: Cylinder recognition sensor

P1605: ECU System (EEPROM) (warning lamp flashes: 33)

Generation condition Reading or writing error occurs during access.

System recovers (power is re-supplied to electronic control unit) if signal becomes
Recoverability normal when starter switch is turned OFF  ON.
Control effected by electronic control unit No specific control is effected. Failure occurs only to circuit abnormality.
Inspection Other Replace engine electronic control unit.

P1606: ECU System (Software) (warning lamp flashes: 33)

• System overload occurs.
Generation condition • Task execution time exceeds limit duration.
System recovers (power is re-supplied to electronic control unit) if signal becomes
Recoverability normal when starter switch is turned OFF  ON.
Control effected by electronic control unit Engine is stopped.
Inspection Other Replace engine electronic control unit.

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3.2 Diagnosis code

P1625: EDU Relay (warning lamp flashes: 84)

Generation condition Electronic drive unit relay is short-circuited, open-circuited or overloaded.

Recoverability System recovers if signal becomes normal with starter switch in ON position.
Control effected by electronic control unit Exhaust gas recirculation control is stopped. (Emissions will increase)
Service data 90: EDU Power Relay
Actuator test B2: EDU Relay
Inspection Electronic control unit connector 10 : Exhaust gas recirculation relay
Electrical equipment #201: Exhaust gas recirculation relay

P1630: CAN (EGR) (warning lamp flashes: 95)

No communication with exhaust gas recirculation electronic drive unit (no CAN
Generation condition message for a certain period of time; CAN communication bus OFF)
Recoverability System recovers if signal becomes normal with starter switch in ON position.
Control effected by electronic control unit Exhaust gas recirculation control is stopped. (Emissions will increase)
Inspection Actuator test A1: EGR1

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5. oil lubrication system

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oil lubrication system -----summary

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oil lubrication system -----oil pressure test

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6. other content

6.1 maintenance parts number and maintenance interval

6.2 used level of maintenance parts

6.3 damageable parts list

6.4 the judged method of engine overhaul

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6.1 保养件编码及保养周期

serial
Part NO. Name count maintenance interval supplier
number
Fuel coarse filter 2
1 13539818 subassembly 1 Every 500h HUAWEI
RCFA-5
2 B222100000729 Fuel filter 2040PM-OR 1 Every 500h HUAWEI
final diesel filter element
3 60176475 1 Third-level filter，Every 500h PINGHE
32F98-48740
final diesel filter element Forth-level filter，every 1000h，
4 60176475 1 PINGHE
32F98-48740 or one year
Main filter was replaced for
60207264 air filter safety element
5 1 three times, safety filter
R002543
element was changed once.
60207265 air filter main element
6 1 clean for six times，or 1000h
R002504 NM
7 60176476 oil filter element 34340-10101 1 At first 50h，every 500h PINGHE
Every 500h,filling into fuel
8 60249161 fuel clean agent 9049-01 1
tank（full fuel）

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6.2 fuel and coolant volume

fuel and coolant volume

Fuel tank 240L

Engine oil 24.5L
radiator 29L

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6.3 engine overhaul evaluation method

Overhaul period discretion
Ordinary engine’s overhaul discretion reference mainly accord to compression pressure decrease, engine
lubrication oil increase, and lubrication oil gas increase in exhaust. Otherwise, it is reference weather need
overhaul that output power decrease, fuel consumption increase, fuel pressure decrease, starting hardly, noise
increase etc. But these phenomenon is influenced by other factors, can’t be overhaul discretion reference
certainly. There are many phenomenon reflected compression pressure decrease showed in outside. It’s hard
to make a decision.
Compress pressure to descend the phenomenon of exterior presenting :
(1)Output power decrease.
(2)Fuel consumption increases.
(3)Lubricant consumption increases.
(4) Burn leaking of oil for leak increment when the abrasion of air cylinder, and piston...etc and
the machine ejects increment from the crankcase.( Pass the range estimation confirmation oil t)
(5)(6)Start to become difficult.
(7)The noise of each part of motor enlarges.
(8)Motor the exhaust color after the warm machine is excrescent.
Wait above-mentioned phenomenon mixture to appear.

It is the judgment greatly by 4 item, the ompression pressure be come lower for the abrasion of air
cylinder, and piston, and it is reasonable to take the comprehensive judgment reference other items.

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6.3 发动机大修的评判方法
Measuring Compression Pressure

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6.3 发动机大修的评判方法
Measuring Compression Pressure

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6.3 发动机大修的评判方法
Measuring Compression Pressure

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THE END

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