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Shanghai Diesel Engine 6114 Series Installation Manual

Repowering manual of cng engine
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上 柴 天 然 气 发 动 机 改 装 手册
（第 二 版）
Repowering Manual of CNG Engine of Shanghai
Diesel Engine Company, Ltd
(Second Edition)

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Summary of Contents for Shanghai Diesel Engine 6114 Series

  • Page 1 上 柴 天 然 气 发 动 机 改 装 手册 （第 二 版） Repowering Manual of CNG Engine of Shanghai Diesel Engine Company, Ltd (Second Edition)
  • Page 2 本手册仅用于指导上柴 6114 系列车用天然气发动机 （WOODWARD 新控制系统） 改装，主要内容包括了发动机进气系统、排气系统、冷却系统、燃料供给系统、 电气控制系统、发动机测试等的改装规范。 General This manual is only for guiding the repowering of 6114 series vehicle CNG engine (new WOODWARD control system) produced by Shanghai Diesel Engine Company, Ltd. (SDEC). It covers repowering specifications for intake system, exhaust system, cooling system, fuel...
  • Page 3 第一章 进气系统 Chart 1 Intake System 1. 空气滤清器应满足发动机要求（表 1） 。 The air filter should satisfy the engine requirement (Table 1). 表 1 Table 1 280 HP 230 /250 HP 空滤器 额定空气质量流量 额定空气质量流量 Air filter Rated air mass flow （m /h）＞1450 Rated air mass flow （m /h）＞1300: 2.
  • Page 4 Inner diameter﹥72mm Recommended diameter:>83mm 图 1 Figure 1 7. 在中冷器出口与发动机之间的进气管上需要一个 M10×1.5 的螺纹孔，用来 安装一个排气放气阀接头（图 2） 。 An M10×1.5 threaded orifice should be available in the intake tube between the intercooler and the intake manifold, which is for a waste gate adapter (Figure 2). M10×1.5 螺纹孔...
  • Page 5 第二章 排气系统 Chart 2 Exhaust System 1. 过高的排气背压会影响发动机正常工作，SDEC 强调发动机排气背压不超过 18kPa。 Engine will not work well with too high backpressure, and SDEC insists that the backpressure be lower than 18kPa. 2. 禁止安装任何排气制动装置。 It is prohibitive to install any exhaust break device. 3.
  • Page 6 第三章 冷却系统 Chart 3 Cooling System 整车散热应满足以下参数（表 3，图 4、5） 。 The heat dissipation of vehicle should satisfy the following parameters (Table 3, Figure 4, 5). 表 3 Table 3 项目 280 HP 230 HP/250 HP Item 散热面积 散热面积 中冷器 Dissipating area: 22 m Dissipating area: 20 m Intercooler 材料：铝...
  • Page 7 Recommended inner diameter :> 57mm 图 4 Figure 4 Recommended inner diameter :> 51mm 图 5 Figure 5 2. 风扇安装应满足以下要求（表 4、5,图 6） 。 Fan installation should meet the following requirements (Table 4，5, Figure 6). 表 4 Table 4 项目 280 HP 230/250 HP Item 直径...
  • Page 8 表 5 Table 5 项目 要求 备注 Item Requirement Remark 风扇叶尖线速度 不大于≤75m/s 标定工况 Speed of fan vane tip more than 75m/s Rated condition 风扇叶前边缘距散热器片尺寸 吸风式：Drawing mode: L1=50~150mm 图 6 Distance from the front vane side to Figure 6 radiator fins 风扇叶尖距导风罩径向尺寸...
  • Page 9 图 7 Figure 7 5. 如果采用串联冷却方式， 空-空中冷器必须放在气流的最上游， 以使温度最低 的空气流过中冷器。中冷器不能阻碍气流通过水箱（图 8） 。 Air-to-air intercooler must be arranged at the outmost upstream of airflow in order that the lowest temperature air can flow through the intercooler first if the series cooling method is adopted. Also intercooler arrangement cannot hinder air through the radiator (Figure 8).
  • Page 10 8. 冷却水需加防冻添加剂。 The antifreeze is needed in coolant. 9. 水箱牢靠固定在底盘上以防止剧烈抖动和对硬管连接头的过分挤压。 It is necessary to secure the intercooler on the chassis in order to avoid severe shock and its tube connection being compressed badly. 10. 发动机进水管用硬管连接，软管连接长度不超过 500 mm。 Tube is needed for connecting the engine coolant inlet, but the total length of a hose is less than 500 mm.
  • Page 11 第四章 燃料供给系统 Chart 4 Fuel system 1. 燃气滤清器 NG filter 安装的燃气滤清器必须能够过滤 95％的 0.3-0.6 微米的微粒，同时要能够过 滤燃气中的油。 The NG filter installed should be able to remove 95% particulate in 0.3-0.6 micrometer and oil in NG. 2. 高压电磁阀 High-pressure lock-off 高压电磁阀的工作电压是 24V，由发动机 ECU 直接控制。 The high-pressure lock-off works with 24V voltage, which is controlled by engine ECU directly.
  • Page 12 至车外，最好是车上方，如图 10、11、12 所示。 SDEC strongly suggests that the outlet of Pressure Reduction Device (PRD) on the regulator be extended to the outside of the engine compartment with a vent-pipe, preferably above the vehicle, displayed in Figure 10, 11, 12. Vent away 图...
  • Page 13 engine. 图 13 Figure 13 5. 氧传感器。 UEGO sensor 1) 氧传感器安装在离增压器出口 3-5 倍排气管直径的地方。 The OEGO senor must be mounted downstream of turbocharger 3 to 5 times the diameter of the exhaust tailpipe away from the turbocharger outlet. 2) 氧传感器不能安装在排气管弯管处。 The UEGO sensor can never be installed at any curve of the exhaust tailpipe.
  • Page 14 The UEGO sensor should be as close to the turbocharger as possible. 6. 温度传感器 Temperature sensor 温度传感器安装在发动机空滤器与增压器压气机进口之间的管路段， 位置尽 量靠近增压器，传感器接口尺寸为 M12×1.5，见图 15、16。 The temperature sensor must be mounted between the air filter and the compressor inlet, the closer to the compressor, the better, and the sensor thread is M12×1.5, displayed in Figure 15, 16.
  • Page 15 2) 燃气滤清器、高压电磁阀、高压减压器的安装位置参考图 17。 The locations of the NG filter, high-pressure lock-off and pressure regulator are shown in Figure 17. 图 17 Figure 17 3) 燃气滤清器、高压电磁阀、高压减压器以及热交换器需要稳定的安 装的车辆底盘上，以避免振动。 The NG filter, high-pressure lock-off, pressure regulator and heat exchanger should be installed securely on the chassis, in order to avoid shock.
  • Page 16 图 18 Figure 18 燃气滤清器、高压电磁阀、高压减压器、热交换器的布置和安装应 便于发动机的维修保养。 Convenient maintenance of the engine should be fully considered when making layout of the NG filter, lock–off and heat exchanger. 燃气滤清器、高压电磁阀、高压减压器的管路需按照标记安装。 The tube for NG filter, lock-off and regulator should be installed according to the marks on them. 8) 燃气管路布置应尽可能短，且应加装夹箍以防止管路振动。...
  • Page 17 Connector To turbocharger Compressed air 图 19 Figure 19 8. 尺寸（表 6） Size (Table 6) 表 6 Table 6 M14 × 1.5-6g 高压减压器燃气进口 CNG Inlet of regulator 高压减压器燃气出口 M18 × 1.5-6g CNG outlet of regulator M18 × 1.5-6g 热交换器燃气进口 CNG inlet of heat exchanger 高压减压器燃气进口不锈钢管...
  • Page 18 第五章 电气控制系统 Chart 5 Electric Control System 1. ECU 安装要求 Installation requirement of ECU 1) ECU 需要防水防振。 The ECU should be free from water and shock. 2) ECM 需安装橡胶防震垫，见图 20。 ECU needs rubber cushion, shown in Figure 20. 3) 外壳接地，见图 20。 Connect the ECU housing to ground, shown in Figure 20.
  • Page 19 5) 所有没有使用的线头和接插件需要密封，防止短路（如图 21、22） 。 It is necessary to seal all unused lines and connectors so as to avoid any short circuit as shown in Figure 21, 22). Sealed! 图 21 Figure 21 图 22 Figure 22 6) 所有接插件须防水密封（如图 23） 。 All connectors should be sealed against water (shown in Figure 23).
  • Page 20 5. 电子脚踏板连接，见图 24。 Refer to Figure 24 for electronic foot pedal connection. 图 24 Figure 24...
  • Page 21 第六章 其它安装与连接 Chart 6 Other Installations and Connections 1. 发动机的布置与安装 Engine Installation 发动机在运行时，横向倾角相对于水平面不超过 10º，纵向倾角相对于水平 面不超过 25º，因此，发动机在安装于底盘时: Since the engine cannot be angled more than 10º transversely or more than 25 longitudinal while running, the engine should be installed on the chassis in compliance with the requirement as follows: 1) 横向倾角α：0º（图...
  • Page 22 表 7 Table 7 压缩机进气管内径 内径 Diameter of compressor inlet Inner diameter: ≥ Ø19mm 压缩机出气管内径 内径 Diameter of compressor outlet Inner diameter: ≥ Ø14mm Material: steel or copper 3. 转向泵管路连接（表 8） 。 Connection of the pipe of steering pump (Table 8) 推荐带纤维的高压橡胶作为转向泵进油管和出油管的材料，...
  • Page 23 5. 整车电瓶最好庇护，以避免因雨水或易燃物体造成电瓶短路，见图 29，30。 It is better to provide the battery with a shelter in order to avoid short circuit in the battery caused by rain or inflammable stuff, as shown Figure 29, 30. Battery is easy to be short circuit because of rain or other factors.
  • Page 24 The positive line is easy to wear out and short circuit like this! 图 31 Figure 31 Having lining is better! 图 32 Figure 32 7. 起动马达和发电机的正极接线柱需要用橡胶冒保护，如图 33、34。 The positive terminal of the start motor and alternator need protection with rubber caps as shown in Figure 33, 34.
  • Page 25 8. 改装过程中，需要检查整车的电气线路，并更换老化或破损的电气线路，如 图 35。 In repowering, it is necessary to check the vehicle electric lines and replace the aged or broken as shown in Figure 35. Aged and broken line! Replace it like this! 图 35 Figure 35 9. 不允许随意在电瓶上接线,如图 36。 It is very important not to connect wirings onto battery at discretion as shown in Figure 36.
  • Page 26 第七章 安装注意事项 Chart 7 Notes for Installation 1. 用户开箱时请检查装箱单是否与箱内物品一致。 Every engine box has a packing list. Please check the accessory kit and spare parts kit according to the list for any missing or wrong parts when unpacking. 2. 不同发动机的随机附件不能混装。 Don’t install the accessories that are not for the engine. 3.
  • Page 27 Protection! 图 38 Figure 38 6. 与发动机及附件连接的管路在连接前须用压缩空气吹净，尤其要吹净管路中 的灰尘、铁屑。 All pipes should be blown well by compressed air to be especially free from dust and scrap iron before being connected to the engine and accessory parts. 7. 当对车身或者底盘焊接时，需拔去 ECU 接插件。 When the chassis or vehicle body is being welded, it is indispensable and important to remove the ECU connectors.
  • Page 28 第八章 发动机测试 Chart 8 Testing 1. 起动发动机之前，应检查机油和冷却液位置。 Inspect the levels of oil and coolant first before starting the engine. 机油液面为油尺最高刻线和最低刻线之间的 1/3 至 2/3 为宜，如图 39 所示。 It is better to have oil level in 1/3- 2/3 of the range between high and low level marks as illustrated in Figure 39.
  • Page 29 Ⅰ 附录 Appendix Ⅰ 上柴天然气发动机主要技术参数（表 9，10） 。 Main parameters of CNG engine (Table 9, 10) 表 9 Table 9 机型 Model T6114ZLQ4B T6114ZLQ3B 6CTL280-2 直列、四冲程、水冷、稀燃、预混合、增压中冷 型式 In-line, 4-stroke, water-cooled, lean burn, premixed, Type turbocharged with intercooler 气缸数 Number of cylinders 标定功率（...
  • Page 30 Table 10 表 10 机型 SC8DT230Q3 SC8DT250Q3 SC9DT280Q3 Model 直列、四冲程、水冷、稀燃、预混合、增压中冷 型式 In-line, 4-stroke, water-cooled, lean burn, premixed, Type turbocharged with intercooler 气缸数 Number of cylinders 标定功率（ kW ） 170 ×（ 1 ± 5% ） 184 ×（ 1 ± 5% ） 206 ×（...

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