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Shangchai W Series Engine Troubleshooting Guidelines V

Dec. 15, 2017

This is the part five of Shangchai W Series Engine Troubleshooting Guidelines. This part contains fault No 14 Fuel Transfer Pump Fault, No. 15 Fuel Injector Fault and No 16 Turbocharger Fault which will teach you how to correct the fuel transfer pump fault and fuel injector fault.


Shangchai W Series Engine Troubleshooting Guidelines V

 

No. 14 Fuel Transfer Pump Fault

 

 

Fault feature

 

Possible cause

 

Correction

 

 






Not enough fuel supply

 

 

(1) Wear or break of the check-valve.

 

(2) Wear of the piston.

 

(3) Fuel leak at the fuel pipe joint(s).

 

(4) Block at the fuel inlet joint strainer.

 

(5) Lack of fuel due to the piston seizure.

 

(6) Fuel leak at the transfer pump.

 

 

Replace the fuel transfer pump.

 

Replace the fuel transfer pump.

 

Re-tighten the joint(s).

 

Clean the strainer.

 

Replace the fuel transfer pump.

 

Check the fuel transfer pump, and replace the pump if necessary.

 

 

No. 15 Fuel Injector Fault

 

 

Fault feature

 

 

Possible cause

 

Correction

 

 








A little or no fuel injected.

 

(1) There is air in the fuel supply system.

 

(2) Seizure of the fuel injector nozzle(s).

 

(3) Abnormal fuel supply from the fuel injection pump.

 

(4) Oil leak at high-pressure fuel pipe(s).

 

(5) Wear of fuel injector nozzle(s).

 

 

Prime the fuel system.

 

Let a professional serviceman check and replace the nozzle assembly(s).

 

Refer to fuel injection Pump Fault for troubleshooting.

 

Tighten the pipe lockout and replace the pipes with crack, make replacement if required.

 

Let a professional serviceman replace the nozzle assembly(s).

 

 

Too low fuel injection pressure.

 

 

(1) Lose pressure regulating screw.

 

(2) Deformation or break of the pressure regulating spring.

 

(3) Seizure of needle valve(s).

 

 

Let a professional serviceman readjust the screw to the defined pressure and tighten the locknut.

 

Let a professional serviceman replace the injector spring.

 

Let a professional serviceman replace the nozzle assembly(s).

 

 




Too high fuel injection pressure.

 

 

(1) Pressure regulating spring force too high.

 

(2) Seizure of the needle valve(s).

 

(3) Block of the injection holes.

 

 

Let a professional serviceman readjust the spring force.

 

Let a professional serviceman replace the nozzle assembly(s).

 

Let a professional serviceman check and clean the injection holes. Replace the injector(s) if necessary.

 

 





Fuel leak at fuel injector.

 

 

(1) Break of pressure regulating spring(s).

 

(2) Damage of needle valve facing(s).

 

(3) Seizure of needle valve(s).

 

(4) Deformation of tightening cap(s).

 

(5) Poor contact between nozzle and injector body.

 

 

 

Let a professional serviceman replace the spring(s).

 

Let a professional serviceman replace the nozzle assembly(s).

 

Let a professional serviceman replace the nozzle assembly(s).

 

Let a professional serviceman replace the cap(s).

 

Let a professional serviceman repair or replace the nozzle assembly(s). replace the injector(s) if required.

 

 





Poor fuel atomization

 

 

(1) Decay of pressure regulating spring force or break of spring(s).

 

(2) Wear of fuel injector nozzle seat surface(s).

 

(3) There is impurity on the fitting plane of fuel injector nozzle assembly(s).

 

(4) Deformation or wear of nozzle assembly(s).

 

(5) Seizure of needle valve(s).

 

 

Let a professional serviceman replace the spring(s).

 

Let a professional serviceman repair or replace the nozzle assembly(s).

 

Let a professional serviceman clean the nozzle.

 

Let a professional serviceman replace the nozzle assembly(s).

 

Let a professional serviceman replace the nozzle assembly(s).

 

 

Fuel spray in line or fuel dripping.

 

 

(1) Carbon deposit at nozzle holes and block of injection holes.

 

(2) Wear of needle valve seat surface(s).

 

(3) Seizure of needle valve(s).

 

 

Let a professional serviceman clean the injection holes. Replace the nozzle assembly(s) if necessary.

 

Let a professional serviceman replace the nozzle assembly(s).

 

Let a professional serviceman replace the nozzle assembly(s).

 

 

 

The surface of needle valve is burn or blue-black.

 

 

The engine is overheating.

 

Check the cooling system and do not over-load the engine for a long time. Let a professional serviceman check the nozzle assembly(s) and make replacement if necessary.

 

 

No. 16 Turbocharger Fault

 

 

Fault feature

 

 

Possible cause

 

correction

 

The engine cannot reach, the rated power.

 

 

(1) Wear of the turbocharge bearing.

 

(2) There is dirt on the blades and housing of the compressor.

 

(3) Too much carbon deposit at the black of the blades and seal ring of the turbine and compressor and turbine.

 

 

Let a professional serviceman replace the bearing.

 

Let a professional serviceman clean the turbocharger.

 

Let a professional serviceman clean the turbocharger.

 

 

 

The exhaust color is abnormal. There is black smoke (not enough of inlet air.)

 

 

(1) There is dirt on the compressor.

 

(2) Air leak at the compressor.

 

 

Let a professional serviceman clean it.

 

Let a professional serviceman check the seal condition and remove the air leak problem.

 

 

Blue smoke

 

 

(1) The elastic seal ring is lack of elasticity or over wear.

 

(2) The oil return passage in the middle housing blocked or deformed.

 

 

Let a professional serviceman replace the seal ring.

 

Let a professional serviceman clean and repair the middle housing.

 

 

Abnormal noise and vibration

 

 

(1) Surge of the compressor, and large amplitude when the turbocharger vibrates (one of the reason is that there is serious dirt in compressor is that there is serious dirt in compressor inlet passage, air inlet pipe and turbine outlet passage).

 

(2) Incorrect assembly(lack of dynamic balance of turbine and compressor impellers, or collision between rotating parts and fixed parts)

 

(3) The turbine impeller or compressor impeller is damaged by foreign material.

 

(4) Collision of the turbine impeller to its housing due to deformation of the housing.

 

(5) There is foreign material in the passage of the turbine housing.

Abnormal noise can be heard at idle.

 

 

Let a professional serviceman clean the turbocharger.

 

Let a professional serviceman check and repair the turbocharger. Replace the turbocharger. Replace the turbocharger if necessary.

 

Let a professional serviceman inspect the turbocharger. Replace the turbocharger if necessary.

 

Let a professional serviceman inspect the turbocharger. Check the intake and exhaust system.

 


The impeller of turbine or/and compressor cannnot rotate or not spin freely.



Serious deposit on the turbine, back of compressor impeller and seal ring.


Let a professional serviceman clean the turbocharger. Check the engine for poor combustion and oil leak.



Bearing burn and collision bwtween impellers and their housings.



(1) Too dirty oil, too low oil pressure or block of oil pipe.


(2) Too high oil inlet temperature.


(3) Damage of the dynamic balance of the impellers of the turbine and compressors or incorrect assembly.


(4) Hight exhaust temperature and over speed of turbocharger.


(5) Deformation of the turbine housing.



Check the lubricating system and change the oil and oil filter.


Find the cause and take measures to reduce oil temperature.


Let a professional serviceman check and make dynamic balance.


Check whether there are serious gas leak, deformation and block of the exhaust manifold or pipe, repair and clean them.


Check and find the cause. Replace the turbocharger if necessary.



Speed drop, intake pressure drop, air leakage or abnormal noise.



(1) Wear of the turbochager bushing, collision of the turbocharger impellers with their housings.


(2) The compressor intake paasage is dirty, blocked or leaks.



Let a professional serviceman repair the turbocharger. Replace the turbocharger if necessary.


Let a professional serviceman clean the trubocharger. Tighten joints and clamps.



 

 

 

 For more troubleshooting guielines information, please visit:


Shangchai W Series Engine Troubleshooting Guidelines

Shangchai W Series Engine Troubleshooting Guidelines II

Shangchai W Series Engine Troubleshooting Guidelines III

Shangchai W Series Engine Troubleshooting Guidelines IV


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