潍柴燃气电控系统安装及布置要求规范OH12.pdf

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1、OH1.2 CNG 安装及布置要求规范 Rev-02 1安装及布置要求规范安装及布置要求规范Application Requirements for SystemOH1.2 CNG伍德沃德控制器有限公司2006 年 4 月Application Requirements for SystemOH1.2 CNG伍德沃德控制器有限公司2006 年 4 月OH1.2 CNG 安装及布置要求规范 Rev-02 2一、线束 Wiring harness1.关于图纸的中特殊说明 Requirements from wiring diagram:一、线束 Wiring harness1.关于图纸的中特殊说明

2、 Requirements from wiring diagram:1)主机厂应该对系统线束的质量及布置进行有效的设计及控制；OEM has engineeringcontrol of the engine and ignition wiring harness.2)导线的材料需遵循 SAE-J1292，J1128，J2202 中的标准；Material of wiring shouldbe followed SAE-J1292,J1128,J2202 recommendations.3)系统动力接地和数字/模拟接地应分开接到电池负极；Proper sized ground wiresand

3、separation of analog/digital grounds separate from power grounds.4)ECM 针脚 X3 和 W3 必须常通电以保持 ECM 的记忆功能，只有在紧急情况下或车辆维修时而不得不断开的情况下，才能断开这两个针脚的电源。ECM pins X3 and W3require battery power all the time for keep alive memory.Any devices thatremove power from these pins should only be activated during service o

4、f thevehicle or in emergency.5)ECM 到点火模块的线束、转速传感器线束以及氧传感器信号线应包以铝质屏蔽层，屏蔽层的末端应尽量接近 ECM，同时需接到电池负极；Use a shielded aluminumcable to protect the spark index,spark trigger,spark return,cam and/orcrank signals,and vehicle speed signals.Connect the drain at one locationpreferably near the ECM,and ties these

5、to the power ground.6)所有未使用的接插件的孔需堵以防水塞；Install plugs in all unused cavitiesof connectors.7)诊断线必须使用双绞线，以减少电磁干扰；Diagnostic wires should be twistedto reduce the electromagnetic coupling.8)按图纸要求使用合适的保险丝及继电器；Proper sized fusing should be employedas denoted on the Woodward harness drawing.9)有空调的车辆上，空调信号开

6、关需安装。Install A/C switch should be included.2.系统接地 System grounding2.系统接地 System grounding1)ECM、ICM 及系统数字、模拟地需接至同一接地点，如发动机、底盘，强烈建议直接接到电池负极；Proper ECM and ICM case grounding to same point,just likechassis or engine.Its strong suggested to grounding battery negativepoint.2)接地线遵循越短越好的原则；Grounding wires

7、should be as short as possible.3)接地线的应选用截面大于 25mm2 的导线，长度应小于 50cm。接点处应该加以星形垫片防止松动，并同时能穿透油漆保护层。Grounding should be connected witha minimum of 2.5mm2 cable with less than 50 cm in length to the case mountingbolt utilizing a star washer to penetrate any painted surface.3.关于线束在整车上的布置 Wiring harness layo

8、ut on vehicle3.关于线束在整车上的布置 Wiring harness layout on vehicle1)为避免高温，线束不允许布置在排气管侧；Wiring harness should never be placedin exhaust side in order to prevent high temperature.2)每个接插件及导线的连接应能承受至少 20N 的拉力而不会松动甚至脱落；Eachconnector and wiring cant be disconnected within 20N force.3)线束固定可靠，并有防止磨损的措施；Wiring harn

9、ess should be mounted reliablyto prevent wear and tear.4)线束安装后没有受力现象；There is no force to the connector or wiring.5)线束必须防水防油；Wiring harness can prevent water and oil corroded.OH1.2 CNG 安装及布置要求规范 Rev-02 36)线束的温度等级应不低于 125，同时应具备良好的抗氧化能力；Temperaturegrade of wiring is suitable for engine compartment hea

10、t rating(125).7)线束的走向合理，利于日后的维修；The layout of wiring harness should bereasonable in order to maintain conveniently.8)发动机故障灯必须易于司机看见且工作正常。诊断连接线必须放置在方便的位置，而且能够与电脑连接，工作正常。Check engine light should be visible todriver and work.Diagnostic connection should be available in locationaccessible,and should wo

11、rk with PC tool.二、高压切断阀 HPLO二、高压切断阀 HPLO1)高压切断阀必须可靠固定在底盘上；HPLO should be fixed on chassis in properway.2)连接到高压切断阀的管路应尽可能短，如果太长，则应加装固定扣以防止管路抖动甚至共振；The pipe connecting to HPLO should be as short as possible toprevent resonance.3)连接到高压切断阀的管路必须布置合理，不能有干涉的可能；Pipes connected toHPLO should be mounted in pr

12、oper way and there is no possibility to be wearand tear.三、调压器 Regulator三、调压器 Regulator1)连接到调压器的管路布置合理，没有干涉的可能。Pipes or hoses connected toRegulator should be mounted in proper way and there is no possibility tobe wear and tear.2)调压器到进气歧管的偏平衡管质量可靠，不易老化或脱落，并没有干涉的可能。Thehose between manifold and regulato

13、r has good quality and its impossibleto be wear and tear.3)偏平衡管需有足够的长度以防止回火，并且调压器上偏平衡管接头需固定。Thebias line of the regulator should be properly installed between MAP pointand regulator and have a flame arrestor as required on the print.The hoseshould have adequate length and control for variation of lo

14、cation in MAPbias barb fitting on regulator.4)泄气口出口需用管子接到发动机舱外部，以满足相关国家规定。PRD outlet shouldbe piped outside engine compartment and meet country specific codes.5)调压器燃气出口方向不能向上，并且底部不能向上，以防止燃气中的机油倒流进入调压器。The outlet line should not go in upward direction to prevent oilin gas from running back to regulat

15、or and causing problems.Regulator shouldnot be mounted upside down to prevent oil from fouling regulator.6)调压器出口管路需能承受-80C 的低温。调压器出口和热交换器之间的管路需有足够的弯曲以承受热膨胀。Hose/pipe from outlet of regulator should be able tohandle-80 C without degredation.The pipe between regulator outlet andheat exhanger should ha

16、ve loop or adequate bends to allow for thermalexpansion of piping.7)平衡管接头在调压器径向上没有特殊要求，这样使得调压器具有一定的通用性。Biasline to regulator should be allowed to be connected to regulator regardlessOH1.2 CNG 安装及布置要求规范 Rev-02 4of radial positioning of ITT bias location.ITT bias location is not controlledso this is i

17、mportant point so that bias line can mount on all regulators.四、热交换器 Heat Exchanger四、热交换器 Heat Exchanger1)热交换器的安装位置合理以防止振动。Heat exchanger should be mounted inproper location and not engine mounted and have good bracket withoutvibration problems.2)热交换器天然气出入口和冷却水出入口的方向正确。The flowing direction of gasand

18、 water is correct.3)断开通过热交换器、调压器以及节温器的进入到发动机的冷却水，测量通过这些部件的冷却水的流量。流进流出热交换器的冷却水的温度应该用热电偶测量。Flow ratethrough heat exchanger/regulator/thermostat on coolant side should be checkedby disconnecting return to engine and measuring flow rate into calibratedvolume for measured period of time(or some other met

19、hod to measure flowrate).Temperature of the heat exchanger water inlet/outlet should be checkedwith thermocouple on vehicle.五、节温器 Thermostat五、节温器 Thermostat1)节温器必须安装在合适的位置，而不能安装在发动机上,安装节温器的支架应能防震。The location of mounting the thermostat should be in correct place andnot engine mounted,and bracket for

20、 thermostat should not cause excessivevibration.六、燃料计量阀 FMV六、燃料计量阀 FMV1)FMV 的安装位置合理可靠。FMV should be mounted in proper location.2)连接到 FMV 的管路及线束可靠，无干涉可能。Hoses connected to FMV areimpossible to be wear and tear.3)压通式单通阀的安装位置必须便于检查压力。Schrader valve should beaccessible to check pressure.4)从燃料计量阀出口到混合器的管

21、路尽可能短。The hose between FMV outlet andmixer should be as short as possible.七、电子节气门 Flotech七、电子节气门 Flotech1)节气门的安装位置合理可靠。Flotech should be mounted in proper way.2)节气门的线束及接插件布置合理。Wiring and connector of Flotech should beproperly fixed.八、防喘振阀 Surge valve九、废气控制阀 WGCV八、防喘振阀 Surge valve九、废气控制阀 WGCV1)废气控制阀应

22、安装于垂直方向 10 度之内；Mounting of the WGCV should be securewithin 10 degree in the vertical.2)废气控制阀应安装于发动机温度较低的一侧，其周围的环境温度不能超过 125。WGCV should be mounted on engine cold side.The temperature around it shouldOH1.2 CNG 安装及布置要求规范 Rev-02 5be lower than 125.3)特别注意，连接至废气控制阀的管路正确无误。Hose between WGCV and WG shouldb

23、e connected correctly and reliably.十、点火模块 ICM十、点火模块 ICM1)ICM 有防振防水措施。Shock and water protection of ICM.2)通风良好。Good aeration.3)外壳接地。Ground connection to the shell.4)安装在发动机较冷的一侧。Mounted in cool side.十一、ECM十一、ECM1)ECM 有防振防水措施。Shock and water protection of ECM.2)通风良好。Good aeration.3)外壳接地。Ground connecti

24、on to the shell.4)确认 ECM 中为最新的主机厂认可的软件。Software version in ECM is proper andup to date.十二、油门脚踏板 Foot Pedal十二、油门脚踏板 Foot Pedal1)由于油门脚踏板距离发动机较远，故其线束的布置应充分考虑其合理性；The wireof foot pedal is long so the allocation rationality of this wire should beconsidered.十三、氧传感器 UEGO十三、氧传感器 UEGO1)氧传感器的安装位置对系统工作的正确性很重要，

25、故其安装必须按照要求严格执行；The allocation of UEGO sensor in very important for system performanceand the following requirement should be followed.2)安装在离增压器出口或排气弯管下游 35 倍排气管直径的地方。The UEGO sensorshould be mounted 3-5 diameters down stream of turbocharger outlet.3)氧传感器不能安装在排气管弯管处。UEGO sensor should never be mounte

26、d in thebend of exhaust pipe.4)如果车辆安装有排气制动装置，氧传感器必须安装在此装置的后方。The sensorshould be mounted downstream of any exhaust brake.5)满足上述前提下，氧传感器尽量靠近增压器。UEGO sensor should be mounted asclose as possible to turbocharger based on N0.1 and 2 comments.6)氧传感器安装在排气管（周向）背向发动机一侧。UEGO sensor should be mountedthe side

27、far from engine.7)氧传感器线束及接插件应尽量远离排气管，不能有被烧结的可能。Wiring andconnector of UEGO sensor should be far from exhaust pipe to prevent to benodulized.十四、TMAP 传感器十四、TMAP 传感器1)安装方法及注意事项见 OH1.2 CNG 维护保养及维修手册 Allocation of TMAPsensor is included in OH1.2 maintenance and repair manual.OH1.2 CNG 维护保养及维修手册 Allocatio

28、n of TMAPsensor is included in OH1.2 maintenance and repair manual.2)TMAP 传感器应安装在进气歧管直管处，严紧安装在弯管处 Never install TMAPOH1.2 CNG 安装及布置要求规范 Rev-02 6sensor on bend.3)TMAP 传感器的安装位置必须和台架试验时相同。TMAP sensor should always beinstalled in same location as during dyno testing.十五、PTP 传感器十五、PTP 传感器同 TMAP 传感器 Same a

29、s TMAP sensor.十六、点火线圈 Coil十六、点火线圈 Coil1)点火线圈的选择需得到伍德沃德公司的批准，并合理安装，同时若有需要点火线圈需接地。Coil should be of Woodward approved type and mounted properly toengine and coil grounded if required.2)如果选择直接插入式点火线圈，对于胶套的设计以及质量要求较高。安装后空气间隙应小于 1mm，但同时也应能在发动机很热的条件下能顺利拔出。注意：点火线圈安装后不能接近发动机金属部件。If coil is coil-on-plug desi

30、gn then it should be mountedwith properly designed boot with high quality rubber,air gap of less than about1 mm,but removable once engine is hot.Coil housing should not be in closeproximity to sharp metal ground.3)如果选择间接插入式点火线圈，即使用独立的高压线，需遵循下列原则 If coil ismounted off plug and secondary lead wire is

31、used then the following guidelinesshould be followed.?点火线圈应远离发动机金属支架以防止火花击穿 Coil housing is not close tosharp metal bracket for spark breakdown through coil case.?高压线的长度应尽可能短，长度不能超过 250mm。Ensure that the cable lengthis as short as possible and does not exceed 250mm.?高压线的任何部位都应远离发动机金属部件至少 10mm。Secure

32、 the cables aminimum of 10mm from the engine ground.?高压线的弯曲半径不小于 50mm。Ensure that the bend radius of the cable(ifapplicable)is at least 50mm.十七、转速传感器 CAM sensor十七、转速传感器 CAM sensor1)安装后传感器和信号盘的间隙为 1-2mm.Gap between CAM sensor and flywheelshould be 1-2mm.2)转速传感器的安装尽可能远离启动电机，以避免启动时启动电机对转速传感器造成电磁干扰，导致启动

33、困难；CAM sensor should be installed as far as possiblefrom starter to reduce electromagnetic.3)在启动转速和最高转速下测量 CAM 传感器的信号。如果电池损坏导致发动机启动转速下降，那么在传感器和信号盘距离最近的情况下，信号应大于 1.3Vpp。在最高发动机转速下，传感器距离最小时，信号应小于 70Vpp。如果由于传感器距离过大或过小、启动转速过低、发动机最高转速过大等原因而导致传感器信号超出上述范围，那么就需找出原因并重新调整。同时，测得的飞轮上齿的电压需在振幅+/-10%之内。We shouldalw

34、ays capture the CAM signal from vehicle for cranking and max.governorrunning,and save for baseline.Worst case signal should be 1.3 Vpp at lowestcrankingspeed(dead battery),closestsensorlocationbytoleranceallowed,and warm sensor(lowest signal).Also largest signal should beOH1.2 CNG 安装及布置要求规范 Rev-02 7

35、around 70 Vpp when engine is at highest possible operating speed and closestgap by allowed tolerance.If signals are outside this range for gap tolerance(sensor closest and farthest),lowest cranking speed,highest engine speed,etc.then we need to study situation and give special approval.Magnitudeof v

36、oltage measured from shifted/extra tooth and surrounding teeth should beall within+/-10%amplitude.十八、火花塞 Spark Plugs十八、火花塞 Spark Plugs1)火花塞间隙需为指定的值，中心电极和火花塞地之间需平行而没有弯曲。GAP ofspark plug is approved size.With this GAP the center electrode and groundshould be parallel and not bend.十九、燃气滤清器 Fuel Filter十

37、九、燃气滤清器 Fuel Filter1)高压关断阀前需安装 CNG 的气体滤清器，同时要满足系统手册中指定的过滤效率（滤除 95的 0.3-0.6 微米的微粒）。CNG gas filter should be installed beforeHPLO.This gas filter should have proper filtration efficiency as calledout in OH1.2 systems manual(remove 95%aerosols in 0.3-0.6micron range).二十、冷却水 Coolant二十、冷却水 Coolant1)冷却水中必

38、须加防冻液以保证-40C 不结冰。Coolant must include anti-freezeand have a minimum freeze rating of a minimum of-40 C.二十一、排气系统 Exhaust System二十一、排气系统 Exhaust System1.催化转化器按指示箭头方向安装。Correct direction of catalyst.2.建议给催化转换器设置一个单独的隔热室。Suggest to set a separate heatinsulation room for catalyst converter.3.对排气管包一层隔热层。E

39、xhaust pipe should be covered with heat-protectionmaterial.4.应有措施有效降低发动机机舱温度。The temperature of engine room should bedecreased as lower as possible.5.如有条件检查标定点的排气背压，以确认测量值和检测工具中的值相近。Check theexhaust backpressure downstream of UEGO sensor to make sure its close toPC Tool.二十二、增压及中冷 Boost and Intercool

40、er二十二、增压及中冷 Boost and Intercooler1)空气滤清器安装在合适的位置，并带有空气滤网。Air cleaner mounted in anaccessible location and air inlet screen installed.2)进气管路尽量短并不能有锐角弯曲。Air intake pipe length is as short aspossible and Sharp bends avoided.3)空气进气管路材料不会生锈。Air intake piping constructed of a non-corrosivematerial.4)所有连接管

41、路的卡箍结实可靠。Heavy duty clamps used to secure air connectorpiping.5)连接废气控制阀和废气阀的管路连接正确可靠。Hose between WGCV and WG shouldOH1.2 CNG 安装及布置要求规范 Rev-02 8be connected correctly and reliably.6)中冷器前后的管路连接可靠。Pipes before and after intercooler should beconnected correctly and reliably.7)从 PTP 到废气控制阀的管路连接可靠，并无干涉可能。Hose between PTP and WGCVshould be connected in proper way to prevent wear and tear.8)整个进气部分的管路无漏气的可能。No leaking of each connection.