重型卡車進氣系統(tǒng)-中英文版2015-10

0EngineApplicationDepartmentofC&CTrucksCo.,Ltd.ResearchInstitute

陶兵文2015年10月

TaoBingwenOctober,2015進氣系統(tǒng)簡介AirIntakeSystemIntroduction1第一部分進氣系統(tǒng)簡介Chapter1AirIntakeSystemIntroduction第二部分關鍵件特性Chapter2KeyComponentsCharacter第三部分進氣系統(tǒng)保養(yǎng)Chapter3AirIntakeSystemMaintenance目錄

Contents2環(huán)境空氣AmbientAir進氣系統(tǒng)AirIntakeSystem中冷系統(tǒng)InterCoolingSystem發(fā)動機燃燒Engine干凈、干燥、充足的空氣一、

進氣系統(tǒng)簡介Chapter1、

AirIntakeSystemIntroductionClean,dry,plentyofairAirIntakeSystem：Provideenoughdry&cleanairtoengine.MainParameters：IndicatorAlertRestriction:Enginecanaffordlimitedairinletrestrictionwhilerunningatratedpower,andwesetthemax.valueasalertpointforindicator,normallyit’s6.25kPaforHDtruck.InitialRestriction:Therestrictionofanewandfreshairintakesystemwhilerunningatrattedflow.

DustHoldingCapacity:Thetotaldustholdingcapacitywhenindicatoralert.Itwillimpacttheserviceinterval.進氣系統(tǒng)：為發(fā)動機稀薄燃燒提供充足的、干凈的、干燥的空氣。進氣系統(tǒng)配套參數說明：報警阻力：發(fā)動機額定流量下，可以承受一定的進氣阻力，該阻力即為進氣進氣阻力限值，一般重卡阻力限值為：6.25kpa（25英寸水柱）；原始阻力：干凈空濾，在額定流量下進氣系統(tǒng)的阻力值。系統(tǒng)容灰量：氣系統(tǒng)阻力由原始阻力達到報警阻力時，系統(tǒng)儲塵量。該參數決定空濾保養(yǎng)周期。3一、

進氣系統(tǒng)簡介One、

AirIntakeSystemIntroduction進氣系統(tǒng)主要組成如下：高位引氣管總成/空氣濾清器總成減震波紋軟管/塑料導向管路進氣塑料管/進氣軟管壓力報警傳感器發(fā)動機空氣入口Engineairinlet高位引氣管Highinletpipe排水閥

Waterdrainvalve空氣濾清器

Aircleaner排塵閥Dustdrainvalve壓力報警傳感器Pressuremonitorsensor波紋管Bellow空氣入口Airinlet塑料導向管路Plasticguidepipe預過濾旋流管組Pre-CleaningTubes（vortextubes）進氣塑料管Plasticpipe進氣橡膠軟管RubberhoseMaincomponentsofairintakesystem:Highinletpipe&AircleanerBellow&PlasticguidepipePlasticpipe&RubberhosePressuremonitorsensor項目

Contents控制指標

Parameter系統(tǒng)濾清效率FiltrationEfficiency≥99.9%預過濾灰塵效率DustPre-filterEfficiency≥80%預過濾濾水效率Water

Pre-filterEfficiency≥80%系統(tǒng)原始阻力InitialRestriction≤3.5Kpa容灰量DustHoldingCapacity≥16Kg報警壓力AlertRestrictionPressure3.8Kpa4第一部分進氣系統(tǒng)簡介Chapter1AirIntakeSystemIntroduction第二部分關鍵件特性Chapter2KeyComponentsCharacter第三部分進氣系統(tǒng)保養(yǎng)Chapter3AirIntakeSystemMaintenance目錄

Contents5排水閥

Waterdrainvalve高位引氣管高位引氣管采用旋流管結構，共集成108個旋流管，集成了排灰閥和排水閥，具有高效率的預過濾作用，預過濾灰塵效率：≥80%，預過濾水效率：≥80%。HighinletpipeHighinletpipeintegrates108vortextubes,dustdrainvalveandwaterdrainvalve,havehighefficiencypre-filterfunction,pre-filterdustefficiency:morethan

80%,pre-filterwaterefficiency:morethan

80%.排塵閥

Dustdrainvalve旋流管Vortextubes二、鍵件特性Chapter2、KeyComponentsCharacter6旋流管利用管路中空氣流體邊流動邊旋轉離心的作用，使得密度較大的灰塵與密度較小的空氣分離，達到初步凈化空氣的作用。VortextubesUsingtheairflowinvortextubes,makesdustandairseparatebytheeffectofrotatingcentrifugal,reachtheroleofpreliminaryfilterair.原理圖principlefigure二、鍵件特性Chapter2、KeyComponentsCharacter7空氣濾清器總成在聯合卡車產品型普中，空氣濾清器總成按照類型可分為普通型、沙漠型和PowerCore型。目前，伊朗車型使用的是沙漠型空氣濾清器。AircleanerInC&Ctruckproductmodel,aircleanercanbedividedintoordinary,desertandPowerCoreaccordingtothetype.Atpresent,deserttypeaircleanerisusedforIranvehicle.普通型Ordinarytype沙漠型DeserttypePowerCore型PowerCore

type二、鍵件特性Chapter2、KeyComponentsCharacter空氣濾清器總成普通型空氣濾清器主要由空濾殼體、主濾芯、安全濾芯、以及其他附屬結構等組成，是進氣系統(tǒng)重要組成部分，空濾總成過濾效率99.5%。主濾芯：由濾紙構成主要過濾部件安全濾芯：在安裝和更換主濾芯時，或在主濾芯偶然損壞時防止灰塵進入發(fā)動機。一般用無紡布或濾紙。8AircleanerOrdinarytypecleanerassemblyiscomposedofanairfilterhousing,aprimaryfilterelement,asafetyfilterelement,andsoon,isanimportantpartofairintakesystem,itfilterefficiencyismorethan99.5%.Primaryfilter:thefilterpaperconstitutemainfilterpartsSafetyfilter:preventdustintotheenginewheninstallandreplacetheprimaryfilter,orwhenmainfilteraccidentaldamage.Generalthematerialisnon-wovenorfilterpaper.空氣入口濾芯保養(yǎng)指示說明空氣出至發(fā)動機真空排塵閥螺栓安裝支架塑料殼體安全濾芯主濾芯保養(yǎng)端蓋普通型空氣濾清器結構示意圖和原理圖Ordinarytypeaircleanerstructure&principlefigure清潔空氣出口Cleanairoutlet臟空氣入口Dirtyairintlet安全濾芯Safetyfilter主濾芯Primaryfilter二、鍵件特性Chapter2、KeyComponentsCharacter9PowerCore型空氣濾清器結構示意圖PowerCoretypeaircleanerfilterstructurefigure安全濾芯端蓋鎖扣抽拉式端蓋濾芯保養(yǎng)手柄主濾芯附件安裝點高效預濾管預過濾排水管真空排灰閥注塑殼體集成安裝支架

濾芯

保養(yǎng)端蓋空氣濾清器總成PowerCore型空氣濾清器主要由空濾殼體、主濾芯、安全濾芯、預過濾裝置、以及其他附屬結構等組成。PowerCore型空氣濾清器采用美國唐納森專利技術，單位體積濾材面積是普通纖維濾材面積的2倍，直流式進氣方式，有效降低氣流阻力。AircleanerPowerCoretypeaircleanerismainlycomposedofahousing,amainfilterelement,asafetyfilterelement,apre-filterdevice,andotherancillarystructures.AndPowerCoretypeaircleaneradoptsDonaldsonpatentedtechnologyfromUS,thefilterareaperunitvolumeis2timesoftheordinaryfiberfilterarea,DCtypeairinletmode,effectivelyreducetheflowresistance.二、鍵件特性Chapter2、KeyComponentsCharacter10空氣濾清器總成沙漠型空氣濾清器主要應用于風沙多，空氣中含塵濃度大，灰塵顆粒細小的場所，提高濾清效率和保養(yǎng)周期。按照預過濾原理主要分為旋流管式和油浴式兩種。聯合卡車采用旋流管式沙漠型空濾濾清器，總成分上腔體、下腔體。下腔體：預過濾，帶旋流管，將大的灰塵離心分離掉，需要經常維護；上腔體：濾清器，帶紙質濾芯，過濾掉其余的灰塵。AircleanerDeserttypeaircleanerismainlyusedindesertsand,dustconcentrationintheair,dustparticlessmallplace,improvetheefficiencyoffiltrationandmaintenancecycle.Dividedintotowkinds:vortextubeandtheoilbathtypeaccordingtothepreliminaryfilterprinciple.C&Ctruckusingvortextubedesertaircleaner,ithastowhousing:upperhousingandbelowhousing.Belowhousing:Prefilterwithvortextubes,separatethelargedirtbycentrifugaleffect,needregularmaintenance;Upperhousing:Filterwithpaperfilter,separatetherestofthedust上腔體Upperhousing下腔體Belowhousing安全濾芯Safetyfilter主濾芯Primaryfilter保養(yǎng)端蓋Servicefilter集灰杯罩Collectiondustcover排塵閥Dustdrainvalve沙漠型空氣濾清器結構示意圖Deserttypeaircleanerstructurefigure排塵閥這是一個薄的彈性橡膠袋，它裝在集灰杯罩的底部。可在輕微的壓力作用下，袋底部的槽自動打開，則卸掉了所積聚的灰塵。Dustdrainvalvewhichisathinelasticrubberbag,installedatthebottomofthecollectiondustcover.Slotofrubberbagcanopenautomaticallyunderslightpressure,dustinitisputoff.二、鍵件特性Chapter2、KeyComponentsCharacter11空氣濾清器總成旋流管式沙漠型空氣濾清器采用旋流管式預過濾，靠離心力作用除去空氣中的絕大部分雜質，該結構集成在總成下腔體；經過下腔體預濾的空氣再進入上腔體，經過主濾芯和安全濾芯精濾后輸送給發(fā)動機。AircleanerDeserttypeaircleanerwithvortextubesforpre-filteritcanremovemostoftheimpuritiesintheairbycentrifugaleffect,thestructureareintegratedinbelowhousing;Afterbelowhousingfilter,thentheairintotheupperhousing,theairisintoengineafterfilteredfurtherbyflowfromtheprimaryfiltertosafetyfilter.注意：1.右圖所示兩處襯墊需定期檢查2.集灰杯中的灰塵距離旋流管底部的距離不得小于25mm，否則會影響預過濾效率，同時也可能導致旋流管堵塞。Note：1.Thetwosealinggasketsasshownonrightfigureneedtocheckregularly;2.Thedustincollectiondustcupdistanceatthebottomofthevortextubesmustbe≥25mm,otherwiseitwillaffectthefiltrationefficiency,itmayalsoleadtoblockagesinvortextube.沙漠型空氣濾清器原理圖Deserttypeaircleanerprinciplefigure清潔空氣出口Cleanairoutlet臟空氣入口Dirtyairintlet安全濾芯Safetyfilter主濾芯Primaryfilter旋流管Vortextubes密封襯墊Sealinggasket密封襯墊Sealinggasket集灰杯罩Collectiondustcup二、鍵件特性Chapter2、KeyComponentsCharacter12第一部分進氣系統(tǒng)簡介Chapter1AirIntakeSystemIntroduction第二部分關鍵件特點Chapter2KeyComponentsCharacter第三部分進氣系統(tǒng)保養(yǎng)Chapter3AirIntakeSystemMaintenance目錄

Contents壓力報警傳感器Pressuremonitorsensor131檢查進氣阻力檢查進氣系統(tǒng)壓力報警系統(tǒng)是否已經報警指示。只有當進氣系統(tǒng)的壓力報警傳感器達到了最大報警值才更換濾芯；該報警值在出廠時完成設置。或者按照保養(yǎng)周期進行相應保養(yǎng)。聯合卡車進氣系統(tǒng)壓力報警會在駕駛室儀表盤上顯示。1ChecktheRestrictionChecktherestrictionleveloftheaircleanerfilterserviceindicator.Replacethefilteronlywhentherestrictionlevelhasreachedthemaximumrecommendedbyengineorequipmentmanufactureroronaregularserviceschedule.C&Ctruckairintakesystemrestrictionpressurealertwillbedisplayedonthecabdashboard.空氣濾清器保養(yǎng)Aircleanermaintenance三、進氣系統(tǒng)保養(yǎng)Chapter3、AirIntakeSystemMaintenance142EmptytheCollectionDustCoverandChecktheDustDrainValvesSwitchofftheengine.RemovetheDustDrainValvesandcleanoutanydustfoundinthedroptube.Makesurethevalveisflexibleandnotinverted,damagedorplugged.Replaceitifdamagedorifitlookslikeanyofthesephotos.AdamagedormissingDustDrainvalvewilldisruptthedesignedflowofairthroughtheaircleaner.2清理集灰杯罩和排塵閥中的灰塵關閉發(fā)動機。拆卸排塵閥并清理里面的灰塵。確認排塵閥仍有彈性，沒有損壞或堵塞，如果已破損或出現如右圖所示的狀態(tài)，請更換排塵閥。破損的排塵閥或排塵閥丟失會擾亂空氣濾清器中的氣流流動，且臟空氣會從這里進入。破損或已堵塞的排塵閥，甚至丟失Damaged、pluggedormissingDustDrainvalvephotos空氣濾清器保養(yǎng)Aircleanermaintenance三、進氣系統(tǒng)保養(yǎng)Chapter3、AirIntakeSystemMaintenance153InspectthePre-CleaningTubesWiththedustcoverremoved,checkthetubes.Generally,thetubesareself-cleaningandneednoservice,butunderunusualcircumstances,pluggingcanoccur.Avisualinspectionisusuallyadequate.Ifthetubescarrylightdust,removeitwithastiffbrush.Ifpluggingwithfibrousmaterialisevident.Cleanitwithcompressedairorwaternohotterthan72°C.3檢查清理預濾系統(tǒng)管路當集成罩拆下后，需檢查里面的管路。一般情況下，管路具有自潔功能，不需要維護，但在特殊情況下，會有堵塞情況發(fā)生，所以建議每次進行目測檢查。如果管路里面有少量灰塵，請用較硬的毛刷去除；如果明顯發(fā)現被某些纖維物質堵塞，請用壓縮空氣或溫度不超過72°C的水清理掉?？諝鉃V清器保養(yǎng)Aircleanermaintenance下腔體Belowhousing集灰杯罩Collectiondustcover排塵閥Dustdrainvalve密封襯墊Sealinggasket用5kg力的壓縮空氣吹掃或者高壓水沖洗Blowthetubeswith5kgpressureairorwaterforpre-cleanercleaning.三、進氣系統(tǒng)保養(yǎng)Chapter3、AirIntakeSystemMaintenance164RemovethePrimaryFilterandVisuallyInspecttheSafetyFilterUnlatchtheservicecovertoremovetheprimaryfilter.Visuallyinspectthesafetyfilterbutdonotremovethefilterunlessitisdamagedordueforchange-out.Thesafetyfiltershouldbereplacedeverythreeprimaryfilterchanges.4拆卸主濾芯并目測檢查安全濾芯松開鋼絲彈簧卡扣，拆下濾芯保養(yǎng)端蓋。抽出主濾芯，目測檢查安全濾芯，如果發(fā)現安全濾芯破損或者變形，請更換該濾芯；除了這種情況外，在保養(yǎng)主濾芯時請不要拆卸安全濾芯。當主濾芯已經更換3次時，安全濾芯需更換1次?？諝鉃V清器保養(yǎng)Aircleanermaintenance上腔體Upperhousing安全濾芯Safetyfilter主濾芯Primaryfilter保養(yǎng)端蓋Servicefilter當需要拆下或更換安全濾芯時，請迅速處理，或者用干凈布密封空氣濾清器出口處，以防止臟污或雜質進入發(fā)動機進氣管路。Whenreplacingsafetyfilter,itshouldbedoneimmediatelyorthecleanairoutletshouldbesealed.Useacleanclothtoavoidcontaminantbeingintroducedtotheengineduringservice.三、進氣系統(tǒng)保養(yǎng)Chapter3、AirIntakeSystemMaintenance175AlwaysCleantheInsideoftheFilterHousingDirtleftintheaircleanerhousingisharmfultoyourengine.Useaclean,dampclothandchecktowipetheinsideofthehousingbeforefittingthenewfilter.Blocktheoutlettubeoftheaircleanerusingasmalldampenedtowelpriortoproceedingwithcleaningthesealsurfacetoavoidcontaminatingtheinductionsystem.5記得清理空氣濾清器殼體內表面滯留在空濾殼體中的雜質污垢對發(fā)動機危害大。在安裝新濾芯，請先用干凈濕潤的布堵住空氣濾清器出口，然后用干凈濕潤的布將殼體內部表面擦拭干凈。這樣做，可以防止保養(yǎng)時造成隨進氣系統(tǒng)管路的污染，保護發(fā)動機?？諝鉃V清器保養(yǎng)Aircleanermaintenance6清理密封襯墊表面使用不合格的密封襯墊或密封襯墊使用不合理是發(fā)動機進氣系統(tǒng)污染的一個重要原因。需確保襯墊安裝表面以及其配合的表面沒有臟污，沒有凸出的硬物結構，否則應清楚這個臟污和突出物結構在裝配密封襯墊6CleantheGasketSealingSurfacesAnimpropergasketsealisoneofthemostcommoncausesofenginecontamination.Makesurethatallhardeneddirtridgesarecompletelyremoved,bothonthebottomandtopoftheaircleanerhousing.三、進氣系統(tǒng)保養(yǎng)Chapter3、AirIntakeSystemMaintenance187InspectyourOldFilterCheckforUnevenDirtPatternsYouroldfilterhasvaluablecluestodustleakageorgasketsealingproblems.Adustpatternonthefilter’scleansideisasignthattheoldfilterwasnotfirmlysealedorthatadustleakexists.Identifythecauseofanyleakandrectifyitbeforeinstallinganewfilter.7觀察舊濾芯并檢查表面非正?；覊m滯留情況你的舊濾芯可能顯示著漏灰或密封不良的問題現象?；覊m分布在濾芯出氣一側，說明該濾芯沒有固定牢固或者存在漏灰的問題。找出漏灰的原因并采取措施規(guī)避，然后裝上新的濾芯?？諝鉃V清器保養(yǎng)Aircleanermaintenance8仔細觀察新濾芯請目視檢查新濾芯，特別要仔細檢查開口端的密封表面。對于徑向密封的濾芯，在觀察時不要擦碰到密封表面。因為密封面在出廠時涂有潤滑劑，以方便安裝和拆卸。堅決不要使用破損的濾芯。8InspecttheNewFilterVisuallyinspectthenewfilter,payingspecialattentiontothesealingareawhichisinsidetheopenend.Asyouinspectthefilter’sRadialSealtakecarenottowipethesealingsurface.Thefactoryhasplacedadrylubricantonthesealwhichaidsininstallationandremoval.NEVERinstalladamagedfilter.三、進氣系統(tǒng)保養(yǎng)Chapter3、AirIntakeSystemMaintenance199InserttheNewFilterProperlyCarefullyseatsafetyfilterintopositionbeforeinstallingtheprimaryfilter.Seatthefilterbyhand,makingcertainitiscompletelyinsertedintotheaircleanerhousingbeforesecuringthecoverinplace.Tocompleteatightseal,applypressurebyhandattheouterrimofthefilter,nottheflexiblecenter.Neverusetheservicecovertopushthefilterintoplacesincenocoverpressureisrequiredtoholdtheseal.Usingthecovertoapplypressurecoulddamagethehousingandcoverfasteners,andwillvoidthewarranty.Ifthenewfilterisnotfullyinplace,removethecoverandpushthefilterfurtherintotheaircleanerwithhandpressureontheouterrim.Thecovershouldthengoonwithnoextraforce.Thensecuretheservicecover.9正確的安裝新濾芯在安裝主濾芯之前請先裝好安全濾芯。手工安裝要確保濾芯安裝到位，然后裝好端蓋。為保證濾芯的密封，安裝時用雙手對稱按壓濾芯端部邊緣，按壓時不要手持濾芯筒體中間。禁止用端蓋壓濾芯的形式安裝，否則會損壞殼體或端蓋上的彈簧扣。如果濾芯沒有完全壓裝到位，需拆下端蓋，重新安裝上述方法壓裝。當維護端蓋能夠輕松地安裝上去，說明濾芯已經安裝到位，可以緊固端蓋上的彈簧扣?？諝鉃V清器保養(yǎng)Aircleanermaintenance三、進氣系統(tǒng)保養(yǎng)Chapter3、AirIntakeSystemMaintenance2010InspectAirCleanerSystemMakesurerestrictionindicatorsareresetandinproperworkingorder.Verifythatallmountingbands,clamps,bolts,andconnectionsintheentireaircleanersystemaretight.Checkforholesinpipingandrepairorreplaceasneeded.Anyleaksintheintakepipingwilladmitdustdirectlytotheengine.Annualreplacementofaircleanersystemgasketsisrecommended.10檢查空氣濾清系統(tǒng)確認進氣系統(tǒng)報警指示燈已恢復重置，并工作正常。檢查系統(tǒng)所有箍帶，管夾、螺栓和線束接頭都已連接牢固；檢查破損的管路修理或更換已經完成；進氣管路的任何泄露都會導致灰塵直接進入發(fā)動機。建議每年更換一次發(fā)動機進氣系統(tǒng)所有的密封襯墊。空氣濾清器保養(yǎng)Aircleanermaintenance三、進氣系統(tǒng)保養(yǎng)Chapter3、AirIntakeSystemMa