Shanghai Diesel Engine 6114 Series Manual de usuario

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)

概述

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

system, electric control system and engine testing.

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

2. 空气滤清器安装在合适的位置，并带有空气滤网。

The air filter must be mounted in a reasonable location and air screen is needed.

3. 进气管路尽量短并不能有锐角弯曲。压气机进气阻力小于 5kPa，压气机出口

至混合器最大压降 13.6kPa。

The air intake piping is as short as possible and sharp curves are avoided. The

resistance before the compressor should be less than 5kPa, and the air pressure

drop between the compressor outlet and the mixer cannot be more than 13.6kPa.

4. 空气进气管路的材料不会生锈。

The material of the air intake piping is free from rust.

5. 空气进气管路连接可靠、没有泄漏。

The air intake piping is connected reliably without any leakage.

6. 与中冷器连接的管路尺寸（表 2,图1）。

The size of the piping connected to the intercooler (Table 2, Figure 1)

表2 Table 2

项目

Item

280 HP 230 HP/250 HP

中冷器前管径

Diameter of the tube between the

intercooler inlet and the

compressor

内径

Inner diameter﹥72mm

推荐直径

Recommended diameter:

>83mm

内径

Inner diameter﹥72mm

推荐直径

Recommended diameter:

>83mm

中冷器后管径

Diameter of the tube between the

intercooler outlet and the intake

manifold

内径

Inner diameter﹥72mm

推荐直径

Recommended diameter:

>83mm

内径

Inner diameter﹥72mm

推荐直径

Recommended diameter:

>83mm

280 HP 230 /250 HP

空滤器

Air filter

额定空气质量流量

Rated air mass flow （m3/h）＞1450

额定空气质量流量

Rated air mass flow （m3/h）＞1300:

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 threaded orifice

M10×1.5 螺纹孔

图2 Figure 2

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. 催化器需按使用说明正确安装（欧Ⅲ）。

The catalyst should be correctly installed according to the operation manual of

the catalyst (EURO Ⅲ).

4. 建议给催化器准备一个单独的隔热室。

It is suggested to equip the catalyst with a heat shield.

5. 最好在排气管周围包一层隔热材料。

It is better to cover the exhaust tailpipe with heat insulation material.

6. 排气管内径需大于 85mm（图 3）。

The inner diameter of exhaust tailpipe is required to be larger than 85mm (Figure

3).

Inner diameter of exhaust

tailpipe :> 85mm

图3 Figure 3

第三章冷却系统

Chart 3 Cooling System

1. 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

Item 280 HP 230 HP/250 HP

中冷器

Intercooler

散热面积

Dissipating area: 22 m2

材料：铝 Material: Aluminum

散热面积

Dissipating area: 20 m2

材料：铝 Material: Aluminum

中冷器出口温度与环境温度温差

Temperature deference between

intercooler outlet and ambient

≦15℃ ≦15℃

中冷器散热

Heat dissipation of intercooler

额定转速时

36 kW at rated speed

最大扭矩转速时

21 kW at max. torque speed

额定转速时

32 kW at rated speed

最大扭矩转速时

19 kW at max. torque speed

水箱

Radiator

散热面积

Dissipating area: 62m2

材料：铝 Material: Aluminum

散热面积

Dissipating area: 55m2

材料：铝 Material: Aluminum

水箱散热

Heat dissipation of radiator

额定转速时

111 kW at rate speed

最大扭矩转速时

81kW at max-torque speed

额定转速时

98 kW at rate speed

最大扭矩转速时

74kW at max-torque speed

发动机进出冷却液温差

Coolant temperature difference

between engine inlet and outlet

≦8℃ ≦8℃

水箱进水管管径

Diameter of the pipe between the

radiator inlet and the engine

推荐内径

Recommended inner

Diameter:>57mm

推荐内径

Recommended inner

Diameter:>57mm

水箱出水管管径

Diameter of the pipe between the

radiator outlet and the engine

推荐内径

Recommended inner

diameter:>51mm

推荐内径

Recommended inner

diameter:>51mm

膨胀水箱

Expansion tank 15L 15L

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

Item

280 HP 230/250 HP

直径、叶片数和材料

Diameter，number of

vanes and material

直径 Diameter: 650 mm

叶片数 Number of vanes: 10

材料：塑料 Material: plastic

直径 Diameter: 650 mm

叶片数 Number of vanes: 10

材料：塑料 Material: plastic

转速（在标定工况下）

Speed (at rated condition) 2700 r/min 2700 r/min

表5 Table 5

项目

Item

要求

Requirement

备注

Remark

风扇叶尖线速度

Speed of fan vane tip

不大于≤75m/s

more than 75m/s

标定工况

Rated condition

风扇叶前边缘距散热器片尺寸

Distance from the front vane side to

radiator fins

吸风式：Drawing mode: L1=50~150mm

图6

Figure 6

风扇叶尖距导风罩径向尺寸 A

Radial distance A from the vane tip

to wind-guider

A≦1.3% D，风扇与导风罩的同轴度不

大于 3mm

A≦1.3% D, coaxiality of fan and

wind-guider is not more than 3 mm

图6

Figure 6

D－风扇直径

D---fan diameter

风扇叶尖距导风罩轴向尺寸 C

Axial distance C from vane tip to

wind-guider

吸风式：Drawing mode: C=2/3B

B－风扇叶尖侧向投影宽度

B---Projection of vane tip

图6 Figure 6

3. 通过提高风扇扫过散热器芯的面积可以提高通过散热器芯的空气流量。最佳

匹配为风扇的直径等于或稍微小于散热器芯的最小尺寸。

Increasing the area of the fan sweeping over the core of radiator can increase the

airflow through the radiator. It is optimum that the diameter of fan equals to or is

a little smaller than the minimal size of the core of radiator.

4. 导风罩以最小阻力将气流从方形的散热器平稳导流到圆形的风扇（图 7）。

Wind-guider leads airflow to flow from quadrate shaped radiator to round shaped

fan smoothly with minimal resistance (Figure 7).

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).

6. 中冷器前不应有其他零部件，以避免阻碍空气流动，以利于空气流动通过中

冷器。对客车而言，建议将空气滤清器和中冷器布置在发动机不同侧。

It is not allowed to install any part before the intercooler in order to avoid

blocking airflow and promote airflow through the intercooler. For bus and coach,

it is suggested to place the intercooler and air filter at different sides of the

engine.

7. 发动机仓要通风良好，以利于降低发动机的温度。

The engine compartment should be well ventilated to reduce the engine

temperature.

图8 Figure 8

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.

11. 水管路连接如图 9。

Refer to Figure 9 for coolant hose connection.

图9 Figure 9

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