oil carry over 随气排油量.doc

C o m m e r c i a l V e h i c l e S y s t e m s Air Compressor Oil Carry Over空压机随气排油量June 2007This document has been designed to assist operators of commercial vehicles and buses who haveconcerns about the level of oil carry over on a vehicle in their fleet. The document includes: An explanation of oil carry over, its possible causes and effects. Descriptions of a series of investigations which can be carried out to determine thecause of any oil carry over, incorporating a test to assess its level. In order to establish efficiently if the oil carry over is regarded as excessive and, if so, what thecause is, it is essential that the investigations are carried out in the order shown on the faultfindingCharts.此文件旨在协助一直关注商务车和公交车排油量的运营商。此文件包括：解释排油量出现的原因及影响。描述确定排油量的原因及评估调查。如果排油量过高，什么原因引起？为了更加有效，通过实施次序失效模式图，显示调查结果则至关重要。The information in the document has been prepared to suit all compressor sizes and vehicleapplications and so some generalisation is inherent to keep the document as simple as possible. 此文件的信息适用于所有尺寸空压机和装配车辆。因此，概括性文件应保持其原有的简易性。What is oil carry over?什么是随气排油量？All air compressors, reciprocating or rotary, using metallic components in contact with eachother, require the presence of oil to lubricate the contact areas otherwise excessive wear, oreven seizure, would take place. Inevitably some of this oil will get carried in the compressed airdelivered by the compressor and this is called oil carry over.采用金属零部件相互连接的往复式和旋转式空压机及所有类型的空压机都需要润滑连接区域；否则将会过度磨损，甚至抱缸。一些油必然会随着空压机压缩的空气排出，这则称为随气排油量。A compressor in good working order will produce only a small amount of oil carry over(obviously dependant on the size and output of the compressor) so that, normally, thecompressor and the system being supplied will be able to cope with it. However, problems startto arise when the compressor becomes worn or other external factors exist and the amount ofoil carry over increases. 良好状态的空压机将产生少量的排油（主要参照空压机的尺寸和输出）。因此，通常空压机和系统相互匹配。但是，当随着空压机磨损或其他因素，将会造成排油量增加。The oil in the compressed air can exist in various states:在多种情形中，压缩空气中存油：In a reciprocating compressor on a truck or bus, oil may be sucked past the piston ringsinto the air where it will quickly be turned into its vapour state by the increase intemperature during the compression phase. If the temperature of the compressed airbecomes excessive (typically above 220 C) the oil may be burnt forming carbon soot invery fine particles. 在卡车或者公交上的空压机中，空气压缩过程中油通过活塞环到达顶部。如果压缩空气温度过高（一般高于220度），油可能燃烧形成积碳。As the compressed air and oil carry over cool on leaving the compressor, the vaporised oilparticles combine forming an aerosol. Because of the complex composition of modernlubricating oils the aerosol contains particles of various sizes. If there are any carbon sootparticles present then they can become attached to the aerosols producing a blackmixture.压缩的空气和排油脱离空压机后而冷却，气态油粒子相互组合形成aerosol。由于润滑油复杂组织结构，aerosol包含了多种尺寸的粒子。如有炭黑粒子存在，则将会和aerosol形成一种黑色的混合物。As the compressed air cools further in the delivery pipe and the air dryer, the oil carriedover will normally condense into its liquid state. In the liquid state the oil is most easilyremoved from the compressed air by the contaminant filter in the air dryer cartridge.随着压缩空气在运送管路和干燥器中冷却，通常排油将会变成液态。在干燥器中液态油将很容易以压缩空气形式排除。The air drawn into the compressor will naturally contain a percentage of water vapour (itshumidity) and as the compressed air cools on exit from the compressor the water vapour willcondense. Any oil carry over in the compressed air can combine with this water to form anEmulsion.进入空压机的空气自然含有一定的水分（本身湿度）。随着空气排除冷却而液化。在压缩空气中的油和水混合形成一种油水混合物。Page 1 of 14Note: This publication is subject to alteration without notice. A printed copy of this document may not be the latest revision. Please check our website www.Knorr-BremseCVS.com for the latest update or contact your local Knorr-Bremse representative.KNORR-BREMSE SystemefrNutzfahrzeuge GmbH . MoosacherStrae 80 . 80809Munich . Germany . Tel: +4989 3547-0 . Fax: +49893547-2767 . www.Knorr-B . www.Knorr-BremseCVS.comCopyright 2007 Knorr-Bremse AG all rights reserved, including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as for copying and transferring.Y037387: EN: 000: MAX1: Released:Webmaster: 2008/02/27-19:18:24 Y037387- EN-00 0C o m m e r c i a l V e h i c l e S y s t e m s Factors external to the compressor which can influence oil carry over影响空压机排油的外部因素Excessive oil carry over from an air compressor can be caused by problems with componentsoutside the compressor such as:空压机过度排油可能是由于空压机外部零部件引起的问题。例如：m High rates of leakage in the air system causing high compressor duty cycle.空气系统中高频率漏油可能引起空压机高负荷。m A blocked engine air filter creating a high depression in the compressor inlet.空滤器堵塞在空压机吸气口可能引起进气阻力。m A damaged or incorrect engine air filter element or contaminated engine oil which cancause premature wear in the compressor.损坏的空滤器或者污染的油可能引起空压机过早磨损。Does oil carry over matter?随气排油量重要吗？Yes, for several reasons:重要。主要因为： If the compressor is not being adequately cooled (e.g. due to engine radiator blockageand/ or engine overheating) or is running on a high duty cycle (typically above 50% onload) such that the temperature of the compressed air is very high; this can have tworesults:如果空压机未充分冷却或者高负荷运行，这可能导致两种结果：例如压缩空气的温度过高。（未冷却例如：由于发动机散热片堵塞/发动机过热）（高负荷一般高于正常符合的50%）m The temperature in the cylinder may rise to a level where the lubricating oil presentnear the piston rings becomes vaporised allowing it to be drawn past the piston rings more easily due to its smaller particle size, resulting in higher oil carry over. 当润滑油上下运动，接近活塞环时将变成气体并很容易的通过，汽缸的温度可能升高，这样导致随气排油量升高。m The temperature in the compressor cylinder head may exceed the criticalTemperature at which oil is burnt. So if there is significant oil carry over, carbonDeposits will start to form in the cylinder head and delivery pipework, which in time can restrict the flow of compressed air causing the compressor to work harder, runeven hotter and create more oil carry over and carbon, leading to rapiddeterioration of the system.当油燃烧时，缸盖的温度将超过临界温度。如排油量过高，炭黑堵塞，可能引起空压机工作吃力，运行发热。随气排油量升高从而导致系统快速变形。 If there is significant oil carry over some of this oil may get past the contaminant filter inthe air dryer cartridge and contaminate the desiccant in the cartridge impairing its function.如排油量过高，一些油将会通过在干燥器中空滤器和干燥器墨盒从而消减其功能。 If the temperature of the air reaching the air dryer is sufficiently high some of the oil itcontains will remain in the aerosol state and the smaller particles will pass through theair dryer into the brake system components unless there is a coalescing or point-of-useoil filter fitted. Excessive oil in the compressed air can cause problems with electronicand small orifice components used on modern trucks and buses and, more importantly,damage the seals in any of the brake system valves.如果到达干燥器的空气温度过高，以aerosol形式存在的油和更小的粒子通过干燥器进入制动系统的零部件，除非安装冷凝聚式过滤器和储罐。过度排油可能引起用于卡车和公交后续元件问题，更甚会损坏制动系阀门的密封效果。 Any oil present in the compressed air leaving the compressor will combine withcondensed water in the air forming an emulsion. If there is an excessive quantity of thisemulsion, when it is expelled through the air dryer purge valve, it will cover thesurrounding area looking unsightly and making any necessary servicing in that area unpleasant. If the air dryer is fitted with a purge valve silencer this may become blockedpreventing the air dryer from functioning correctly.排出空气中含有的油与水形成一种油水混合物。如果当油水混合物从干燥器的放水阀排出，油水混合物含量过高将会周边部件失效。如果干燥器配装有放水阀清污器，这可能导致堵塞，造成干燥器失效。How do you know if you have an oil carry over problem with an air compressor?如何知道空压机排气随油量有问题？Knorr-Bremse has developed a faultfinding chart which, together with the methodologyexplained in this document, will assist you in determining if you have an oil carry over problem and, if so, what might be its cause. 克诺尔采用失效模式图方法解释说明文档，以帮助你确定是否有随气排油量问题？如果有，是什么原因引起的？NOTE: Before commencing any work on the vehicle read the Safety Advice below.备注：在开始着手有关车辆工作前，请阅读下面的安全提示。Page 2 of 14Note: This publication is subject to alteration without notice. A printed copy of this document may not be the latest revision. Please check our website www.Knorr-BremseCVS.com for the latest update or contact your local Knorr-Bremse representative.KNORR-BREMSE SystemefrNutzfahrzeuge GmbH . MoosacherStrae 80 . 80809Munich . Germany . Tel: +4989 3547-0 . Fax: +49893547-2767 . www.Knorr-B . www.Knorr-BremseCVS.comCopyright 2007 Knorr-Bremse AG all rights reserved, including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as for copying and transferring.Y037387: EN: 000: MAX1: Released:Webmaster: 2008/02/27-19:18:24 Y037387- EN-00 0C o m m e r c i a l V e h i c l e S y s t e m s Safety Advice安全提示Note: The safety advice listed below is applicable to general service and diagnostic work on airbraking systems and may not all be directly relevant to the activities and products described in thisdocument.注意：下列安全提示适用于制动系统一般服务和诊断性工作，可不直接适用于此文件中相关活动和描述产品。Before and whilst working on or around air braking systems and devices, the following precautions should be observed in addition to any specic advice given in this document:在开始着手制动系统和装置工作之前，应关注下列预防措施和此文件提供的具体建议。 Always wear safety glasses when working with air pressure.在气压工作环境下，要配戴防护镜。 Never exceed manufacturers recommended air pressures.禁止超过生产商建议的气压。 Never look into air jets or direct them at anyone.禁止探视喷头和将喷头对准任何人。 Never connect or disconnect a hose or line containing pressure; it may whip as air escapes.禁止连接或切断软管或连续加压。这可能漏气。 Never remove a device or pipe plug unless you are certain all system pressure has been depleted.禁止拆除装置或管塞除非所有气压耗尽。 Park the vehicle on a level surface, apply the parking brakes, and always chock the wheels asDepleting vehicle air system pressure may cause the vehicle to roll.在光滑的路面停车时，使用制动系统会随着消耗气压而引起车轮打滑。 If work is being performed on the vehicles air braking system, or any auxiliary pressurised airsystems, and if it is necessary to drain the air pressure from reservoirs, etc., keep clear of brakeActuator push rods and levers since they may move as system pressure drops. Be aware that ifthe vehicle is equipped with an air dryer system, it can also contain air pressure along with itspurge reservoir, if tted, even after pressure has been drained from the other reservoirs.如果制动系统或者辅助系统正常工作和必须实施排压工作等等，请保持制动器易推动连杆和杠杆因为他们会随系统排压而运动。 When working under or around the vehicle, and particularly when working in the engineCompartment, the engine should be shut off and the ignition key removed. Where circumstancesrequire that the engine is running, EXTREME CAUTION should be taken to prevent personalinjury resulting from contact with moving, rotating, leaking, heated or electrically chargedcomponents. Additionally, it is advisable to place a clear sign on or near the steering wheeladvising that there is work in progress on the vehicle.在车辆下面或者周围工作时，尤其在发动机箱工作时，应该关闭发动机和点火键。这样才能保证发动机正常运转。采取谨慎措施预防由于运转,泄露或者充电造成人身伤害。另外，应该在转向轮附近放置一个警示牌。 Examine all pipework for signs of kinks, dents, abrasion, drying out or overheating. Be aware thatkinks in pipework may result in air pressure being trapped in the pipework and associatedequipment. Replacement hardware, tubing, hose, fittings, etc. must be of equivalent size, typeand strength as original equipment and be designed specically for such applications andsystems. Check the attachment of all pipework; it should be supported so that it cannot abrade orbe subjected to excessive heat.检查所有管路的问题，压痕，锈蚀及干燥和过热。注意问题管路可能导致管路气压和辅助设备失效。硬件，管路，软管，配件等必须与原始配件或指定的配件尺寸，类型和强度一致。检查所有管路配件。因此它不能磨损或者过热。repaired. Do not attempt repairs requiring machining or welding unless specically stated andapproved by the vehicle or component manufacturer.维修。未经制造商同意或无特别规定不允许修理机械。 Never attempt to install, remove, disassemble or assemble a device until you have read andthoroughly understood the recommended procedures. Some units contain powerful springs andinjury can result if not properly dismantled. Use only the correct tools and observe all precautions pertaining to use of those tools. Before removing any device note its position and the connectionsof all pipework so that the replacement/serviced device can be properly installed. Ensure thatadequate support or assistance is provided for the removal/installation of heavy items. 未阅读和理解程序说明，禁止安装，删除，拆卸或组装装置。一些零部件含有强力弹簧如不正确拆卸可能造成人身伤害。正确使用工具，认真阅读预防措施。在拆除装置之前，标明其位置和连接的管路，以便更换和有效装置能够正确安装。确保有充分的支持或者提供主要零部件安装拆卸的协助工作。 Use only genuine Knorr-Bremse replacement parts, components and kits.仅能使用克诺尔的备件，零件和管件。 Prior to returning the vehicle to service, make certain all components and systems are leak free and restored to their proper operating condition.在返回维修服务前，确保所有零部件和系统无泄漏和恢复其正常工作状态。Page 3 of 14Note: This publication is subject to alteration without notice. A printed copy of this document may not be the latest revision. Please check our website www.Knorr-BremseCVS.com for the latest update or contact your local Knorr-Bremse representative.KNORR-BREMSE SystemefrNutzfahrzeuge GmbH . MoosacherStrae 80 . 80809Munich . Germany . Tel: +4989 3547-0 . Fax: +49893547-2767 . www.Knorr-B . www.Knorr-BremseCVS.comCopyright 2007 Knorr-Bremse AG all rights reserved, including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as for copying and transferring.Y037387: EN: 000: MAX1: Released:Webmaster: 2008/02/27-19:18:24 Y037387- EN-00 0C o m m e r c i a l V e h i c l e S y s t e m s 继续运行/检测结束整改活动检查进气系统检查干燥器/卸荷阀检查排气管路检查干燥器/排气看下图结果是否正常结果是否正常检查进气管路结果是否正常结果是否正常结果是否正常检查空气悬架系统（详见调查1）启动/开始Page 4 of 14Note: This publication is subject to alteration without notice. A printed copy of this document may not be the latest revision. Please check our website www.Knorr-BremseCVS.com for the latest update or contact your local Knorr-Bremse representative.KNORR-BREMSE SystemefrNutzfahrzeuge GmbH . MoosacherStrae 80 . 80809Munich . Germany . Tel: +4989 3547-0 . Fax: +49893547-2767 . www.Knorr-B . www.Knorr-BremseCVS.comCopyright 2007 Knorr-Bremse AG all rights reserved, including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as for copying and transferring.Y037387: EN: 000: MAX1: Released:Webmaster: 2008/02/27-19:18:24 Y037387- EN-00 0C o m m e r c i a l V e h i c l e S y s t e m s 看下图结束结束联系车辆代理商结果是否正常做实验检查进入干燥器的空气温度结果是否正常检查阀门结果是否正常继续运行/检测清理车辆底部的干燥器/阀门检查储气罐继续服务结果是否正常检查车辆服务记录检查干燥器/排气结果是否正常Page 5 of 14Note: This publication is subject to alteration without notice. A printed copy of this document may not be the latest revision. Please check our website www.Knorr-BremseCVS.com for the latest update or contact your local Knorr-Bremse representative.KNORR-BREMSE SystemefrNutzfahrzeuge GmbH . MoosacherStrae 80 . 80809Munich . Germany . Tel: +4989 3547-0 . Fax: +49893547-2767 . www.Knorr-B . www.Knorr-BremseCVS.comCopyright 2007 Knorr-Bremse AG all rights reserved, including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as for copying and transferring.Y037387: EN: 000: MAX1: Released:Webmaster: 2008/02/27-19:18:24 Y037387- EN-00 0C o m m e r c i a l V e h i c l e S y s t e m s 结束结束装新空压机继续运行/检测清理车辆底部的干燥器/阀门联系车辆代理商是否在三包期间结果是否正常做实验Page 6 of 14Note: This publication is subject to alteration without notice. A printed copy of this document may not be the latest revision. Please check our website www.Knorr-BremseCVS.com for the latest update or contact your local Knorr-Bremse representative.KNORR-BREMSE SystemefrNutzfahrzeuge GmbH . MoosacherStrae 80 . 80809Munich . Germany . Tel: +4989 3547-0 . Fax: +49893547-2767 . www.Knorr-B . www.Knorr-BremseCVS.comCopyright 2007 Knorr-Bremse AG all rights reserved, including industrial property rights applications. Knorr-Bremse AG retains any power of disposal, such as for copying and transferring.Y037387: EN: 000: MAX1: Released:Webmaster: 2008/02/27-19:18:24 Y037387- EN-00 0C o m m e r c i a l V e h i c l e S y s t e m s How to establish if an oil carry over problem is caused by the air compressor如何确定空压机能引起排油问题？The following investigations should be carried out in conjunction with the Faultfinding Charts. You may find it helpful to record the results of your investigation on the Check List at the end of this document (see page 13).下列调查应该结合失效模式图表。你将会发现它有助于记录文件末尾的调查结果。Investigation 1 Air System Leakage调查1.空气系统泄露Check for leakage in the air brake and suspension systems, initially by carrying out a checkfor any audible leaks, both with brakes applied and released. If none are found, charge thesystem to cut-out pressure, switch off the engine and note the readings of the cab pressuregauges after one minute. Leave the vehicle to stand for 30 minutes and note any drop inth