Shanghai Diesel Engine 6114 Series Installation guide

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 （m

3

/h）＞1450

额定空气质量流量

Rated air mass flow （m

3

/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 m

2

材料：铝 Material: Aluminum

散热面积

Dissipating area: 20 m

2

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: 62m

2

材料：铝 Material: Aluminum

散热面积

Dissipating area: 55m

2

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

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.

3. 高压减压器

High-pressure regulator

1) 连接到高压减压器的管路布置合理，没有干涉的可能。

The tube connected to the regulator should be arranged reasonably

without any interference.

2) 高压减压器燃气出口方向不能向上，以防止燃气中的油倒流进入高

压减压器。

The NG outlet of the regulator should not face up so as to prevent oil in

NG from returning to the regulator.

3) 高压减压器连接到发动机进气歧管的平衡管安装长度需大于

500mm，以防止回火进入高压减压器，且平衡管需要有夹箍固定。

The length of bias, which connects the regulator to the intake manifold,

should be longer than 500mm in order to prevent the backfire from

extending into the regulator, and the bias is need to be secured.

4) 高压减压器燃气出口管路要求能够承受-80℃的低温。高压减压器和

热交换器之间的燃气管路需有足够的弯曲以承受热膨胀。

The NG tube from the regulator outlet should be able to endure

temperature as low as -80℃. And the NG tube between the regulator

outlet and the heat exchanger should have adequate curve to allow

thermal expansion.

5) SDEC 强烈建议将高压减压器上的卸压装置（PRD）出口用通风管引

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.

图 10 Figure 10 图 11 Figure 11

图 12 Figure 12

PRD, extended!

Vent away

4. 热交换器

Heat exchanger

热交换器的水路和气路需要交叉流动（图 13），热交换器出水回到发动机进

水口。

Coolant and NG flows should cross inside the heat exchanger (Figure 13), and

coolant from the outlet of the heat exchanger returns to the coolant inlet on the

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.

3) 氧传感器的安装孔朝上或者斜向上，安装尺寸为 M18×1.5（图 14）。

The hole (M18×1.5) in the exhaust tailpipe for installing the sensor

must face up or oblique up (displayed in Figure 14).

图 14 & Figure14

UEGO sensor

4) 氧传感器线束及接插件应尽量远离排气管，不能被烧结的可能。

The wiring and connectors of the UEGO sensor should be away form

exhaust tailpipe as far as possible in order to avoid being burn.

5) 氧传感器尽量靠近增压器。

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.

图 15 Figure 15

图 16 Figure 16

T

em

p

erature senso

r

Air filter

Compressor

7. 安装要求

Installation requirement

1) 在高压电磁阀上游的管路中应安装手动安全阀，并且手动安全阀最

多旋转 1/4 圈即能完全关闭燃气。

A manual valve should be available in upstream of the high-pressure

lock-off. Fuel delivering can be completely stopped by turning the

manual valve 1/4 turn at most.

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.

4) 高压燃气管路建议采用 Ø8mm 的不锈钢管。

It is recommended to utilize stainless steel pipe with diameter of 8mm

for the high-pressure NG tube.

5) 燃气滤清器、高压电磁阀、高压减压器、热交换器的进出口连接管

管径须正确选择，参照图 18。

Diameters of inlet and outlet tubes of the NG filter, high-pressure

lock-off, regulator, and heat exchanger should be proper, shown in

Figure 18.

图 18 Figure 18

6) 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.

7)

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。

NG tube is as short as possible, and clamps are needed to prevent the

tube from shock.

9) 所有燃气管路连接完成后须检漏。

All NG tube need checking for leakages after installed.

10) 废气门控制阀的连接正确，如图 19。

The waste gate valve must be connected correctly as shown in Figure

19.

图 19 Figure 19

Connector

To turbocharger

Compressed air

8. 尺寸（表 6）

Size (Table 6)

表 6 Table 6

高压减压器燃气进口

CNG Inlet of regulator

M14×1.5-6g

高压减压器燃气出口

CNG outlet of regulator

M18×1.5-6g

热交换器燃气进口

CNG inlet of heat exchanger

M18×1.5-6g

高压减压器燃气进口不锈钢管

Stainless inlet tube of regulator

Ø8mm

高压减压器燃气出口不锈钢管

Stainless outlet tube of regulator

Ø12mm

高压减压器进/出水管（内径）

Coolant inlet/outlet hose of regulator (inner diameter)

Ø 10mm

热交换器进/出水管（内径）

Coolant inlet/outlet hose of heat exchanger (inner diameter)

Ø 10mm

高压电磁阀进/出口

Inlet/outlet of high-pressure lock-off

9/16-18UNF-2B

高压燃气滤清器进/出口

Inlet/outlet of NG filter

9/16-18UNF-2B

注：表中的高压电磁阀和燃气滤清器的接头尺寸只对来自上柴的高压电磁阀

和燃气滤清器有效。

Note: The sizes of the connectors listed in the table are only applicable for the

high-pressure lock-off and NG filter provided by SDEC.

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.

Connecting to ground

Rubber cushion

图 20 Figure 20

2. 线束布置。

Wiring layout

1) 线束应保证接地可靠。

Connect the wiring to ground reliably.

2) 线束应远离高温零部件（如排气系统、增压器、空压泵排气管路），

以避免受热变形。

Keep the wiring far away from any high temperature parts (such as the

exhaust system, turbocharger, and outlet pipe of the turbo compressor),

so as to avoid being deformed by heat.

3) 线束布置合适，不得受力。

Dispose the wiring properly without any force.

4) 线束应有必要的支撑，且有预防磨损的措施。

Support the wiring where necessary, and prevent them from wear.

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).

图 21 Figure 21 图 22 Figure 22

Sealed!

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).

图 23 Figure 23

Plugged!

7) 线束及所有接插件需要防水、防油、防尘和防腐蚀。

The wiring and all connectors should be free of water, oil, dust and erosion.

3. 故障灯及诊断接口布置

Layout of the malfunction indication lamp (MIL) and diagnostic connector

发动机故障灯应置于易于驾驶员观察之处，诊断接头要便于与计算机连接。

MIL should be located at the place where driver can observe easily, and the

diagnostic connector is placed to have easy connection with the computer.

4. 如用户需使用怠速提升或 J1708 功能，可向上柴咨询。J1708 功能主要用作与

自动变速箱通讯。

The customer can inquire for the function of J1708 from SDEC if you intend to

use fast idle function or 1708 function. J1708 function is mainly used for the

communication with automatic transmission.

5. 电子脚踏板连接，见图 24。

Refer to Figure 24 for electronic foot pedal connection.

图 24 Figure 24

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Shanghai Diesel Engine 6114 Series Installation guide

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