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GB/T 3821-2015 English PDF

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GB/T 3821-2015: Small and medium power internal combustion engines -- Cleanliness limits and measurements
Status: Valid

GB/T 3821: Historical versions

Standard ID	USD	BUY PDF	Lead-Days	Standard Title (Description)	Status
GB/T 3821-2015	98	Add to Cart	1 days	Small and medium power internal combustion engines -- Cleanliness limits and measurements	Valid
GB/T 3821-2005	439	Add to Cart	4 days	Small and medium power internal combustion engine -- Cleanliness measurement	Obsolete
GB/T 3821-1983	199	Add to Cart	2 days	Determination of cleanliness for small and medium power internal combustion engines	Obsolete

Similar standards

GB/T 14097 GB/T 23341.1 GB/T 23341.2 GB/T 8243.6 GB/T 9485

Basic data

Standard ID: GB/T 3821-2015 (GB/T3821-2015)
Description (Translated English): Small and medium power internal combustion engines -- Cleanliness limits and measurements
Sector / Industry: National Standard (Recommended)
Classification of Chinese Standard: J91
Classification of International Standard: 27.020
Word Count Estimation: 17,175
Date of Issue: 2015-12-10
Date of Implementation: 2016-07-01
Older Standard (superseded by this standard): GB/T 3821-2005
Quoted Standard: GB 1922-2006; GB/T 5330; GB/T 23338; ??JB/T 6002; JB/T 7661
Regulation (derived from): National Standard Announcement 2015 No.38
Issuing agency(ies): General Administration of Quality Supervision, Inspection and Quarantine of the People's Republic of China, Standardization Administration of the People's Republic of China
Summary: This standard specifies the medium power internal combustion engine (hereinafter referred to as internal combustion engine) cleanliness limits, measurement items and parts, measurement conditions, measurement method. This standard applies to internal combustion engines and machine parts.

GB/T 3821-2015: Small and medium power internal combustion engines -- Cleanliness limits and measurements

---This is a DRAFT version for illustration, not a final translation. Full copy of true-PDF in English version (including equations, symbols, images, flow-chart, tables, and figures etc.) will be manually/carefully translated upon your order.
Small and medium power internal combustion engines.Cleanliness limits and measurements ICS 27.020 J91 National Standards of People's Republic of China Replace GB/T 3821-2005 Small and medium power internal combustion engine cleanliness limit and determination method Released on December 10,.2015 2016-07-01 implementation General Administration of Quality Supervision, Inspection and Quarantine of the People's Republic of China China National Standardization Administration issued

Foreword

This standard was drafted in accordance with the rules given in GB/T 1.1-2009. This standard replaces GB/T 3821-2005 "Measurement method for cleanliness of medium and small power internal combustion engines", compared with GB/T 3821-2005 The technical changes are as follows. --- Increased demagnetization requirements for parts prior to cleanliness inspection (see 7.1.7); --- Increased cleanliness quality and particle limit requirements (see Chapters 3, 4). This standard was proposed by the China Machinery Industry Federation. This standard is under the jurisdiction of the National Internal Combustion Engine Standardization Technical Committee (SAC/TC177). This standard was drafted. Weichai Power Co., Ltd., Shanghai Internal Combustion Engine Research Institute, Guangxi Yuchai Machinery Co., Ltd., Changchai Co., Ltd., Kunming Yunnei Power Co., Ltd., Weichai Kaidong Power Machinery Co., Ltd., Ningbo Xuelong Group Fan Co., Ltd. The main drafters of this standard. Wang Jianping, Ji Weibin, Luo Zhijian, Dai Weilin, Yan Dehui, Yang Chunliang, Tao Shouping, Chen Nianhong, Guo Hua, Li Jianghu, Chen Lanlan, Yang Junjie, Meng Hongxia. The previous versions of the standards replaced by this standard are. ---GB/T 3821-1983, GB/T 3821-2005. Small and medium power internal combustion engine cleanliness limit and determination method

1 Scope

This standard specifies the limits of cleanliness of small and medium-sized internal combustion engines (hereinafter referred to as internal combustion engines), measurement items and locations, measurement conditions, and determination. method. This standard applies to the whole machine and parts of internal combustion engines.

2 Normative references

The following documents are indispensable for the application of this document. For dated references, only dated versions apply to this article. Pieces. For undated references, the latest edition (including all amendments) applies to this document. GB 1922-2006 Solvent oil for paints and cleaning GB/T 5330 industrial wire braided square hole screen GB/T 23338 internal combustion engine charge air cooler technical conditions JB/T 6002 turbocharger cleanliness limit and method of determination JB/T 7661 diesel engine oil pump nozzle product cleanliness limit and determination method

3 Cleanliness weight limit

3.1 Machine cleanliness 3.1.1 The cleanliness of the internal combustion engine is expressed in terms of each impurity mass W, and the limit is calculated according to formula (1). W = aK1K2Peb G (1) In the formula. W --- Cleanliness limits for internal combustion engines in milligrams (mg); a --- empirical constant, 13.6mg/kW; K1---total displacement correction coefficient, the value is shown in Table 1; K2---speed correction coefficient, the value is shown in Table 2; Peb---calibrated power in kilowatts (kW); G --- compensation amount, the unit is milligram (mg), the value is shown in Table 3. Table 1 Total displacement Vb/L K1 ≤0.5 1.0 >0.5~5 1.1 >5~100 1.2 Total displacement Vb/L K1 >100~150 1.3 >150 1.4 Table 2 Calibration speed neb/(r/min) K2 ≤600 1.3 >600~1000 1.2 >1000~2000 1.1 Calibration speed neb/(r/min) K2 >2000~3000 1.0 >3000 0.9 table 3 Calibration power Peb/kW G/mg ≤3.68 50 (two strokes) 80 (four strokes) >3.68~7.35 150 >7.35~14.7.200 Calibration power Peb/kW G/mg >14.7~29.4 400~aPeb >29.4~73.5 0 >73.5 500~0.5aPeb 3.1.2 The cleanliness of the whole engine of the internal combustion engine is calculated according to formula (2). W =4.66iSD (2) In the formula. W --- Cleanliness limits for internal combustion engines in milligrams (mg); i --- number of cylinders; S --- piston travel of the internal combustion engine in centimeters (cm); D --- Cylinder diameter of the internal combustion engine in centimeters (cm). 3.2 Assembly cleanliness 3.2.1 Carburetor assembly The cleanliness of the carburetor assembly is expressed in terms of each impurity mass WH (mg), and the limit is calculated according to formula (3). WH=a KV G (3) In the formula. a --- empirical constant, 10mg; K---volume correction factor, the unit is milligrams per cubic centimeter (mg/cm3), the values are shown in Table 4; V --- carburetor volume, in cubic centimeters (cm3), measured by volumetric method; G --- compensation amount, the unit is milligram (mg), the value is shown in Table 5. Table 4 Carburetor volume V/cm3 K/(mg/cm3) ≤50 0.00 >50 0.05 table 5 Carburetor use G/mg General small gasoline engine with 4.00 Motorcycle, boat machine 7.00 Note. The compensation amount of various matching carburetor is based on low value. 3.2.2 oil pump assembly The cleanliness of the oil pump assembly is expressed in terms of each mass of WJ (mg). When the oil pump displacement q ≤ 0.005L, the limit is 20mg; When the oil pump displacement q >0.005L, the limit is calculated according to formula (4). WJ=a bKq (4) In the formula. a --- empirical constant, 10mg; b --- empirical constant, 2 × 103 mg/L; K---Material correction coefficient, the value is shown in Table 6; q --- Oil pump displacement in liters (L). See Appendix A for the calculation formula of the oil pump displacement. Table 6 Pump material K Cast iron 1.0 Cast aluminum Casting 0.9 Die casting 0.6 Note. For the oil pump installed inside the internal combustion engine, the limit of the external surface cleanliness of the assembly is determined by the OEM and the accessory factory. 3.2.3 Turbocharger The cleanliness limits for turbochargers are specified in JB/T 6002. 3.2.4 oil pump nozzle The cleanliness limit of the diesel oil pump nozzle is specified in JB/T 7661. 3.2.5 Oil filter assembly 3.2.5.1 Wire-wound, blade-type, paper, linoleum filter oil filter assembly cleanliness is expressed in WR1 (mg) per mass, limit Equation (5) calculation. WR1=aKQ (5) In the formula. a --- empirical constant, the unit is milligrams per liter (mg · min/L), the values are shown in Table 7; K---material correction coefficient, the value is shown in Table 8; Q ---rated flow in liters per minute (L/min). Table 7 Filter rated flow Q/(L/min) a/(mg · min/L) < 14 4.4 ≥14 3.0 Table 8 Filter material K Cast iron 1.0 Cast aluminum 0.9 3.2.5.2 Centrifugal oil filter assembly cleanliness, expressed in WR2 (mg) per mass, see Table 9 for limits. Table 9 Rotor inner diameter d/mm WR2/mg Cast iron filter seat cast aluminum filter seat ≤100 120 108 >100 150 135 3.2.6 Air compressor assembly The cleanliness of the air compressor assembly is expressed in WK (mg) per mass, and the limit is calculated according to formula (6). WK=a(K1K2K3 b) (6) In the formula. a --- empirical constant, 50mg; K1--- total displacement correction coefficient, the value is shown in Table 10; K2---Material correction coefficient, the values are shown in Table 11; K3---Crankshaft end transmission mode correction factor, the value is shown in Table 12; b --- The number of drive pairs on the drive shaft. Table 10 Air compressor total displacement Vk/L K1 ≤0.10 4 >0.10~0.15 5 Air compressor total displacement Vk/L K1 >0.15~0.20 6 >0.20 7 Table 11 Crankcase material K2 Cast iron 1.0 Cast aluminum 0.9 Table 12 Crankshaft end drive mode K3 Belt drive 1.0 gear drive 1.1 (excluding gears) 1.2 (including gears) 3.2.7 oil cooler assembly The cleanliness of the oil cooler assembly is expressed in WL (mg) per impurity, and the limit is calculated according to equation (7). WL=a bF0 (7) In the formula. a --- empirical constant, the unit is milligram (mg), the value is shown in Table 13; b --- empirical constant, the unit is milligrams per square meter (mg/m2), the values are shown in Table 13; F0---oil side heat transfer area in square meters (m2). Table 13 Type a/mg b/(mg/m2) Plate fin type 7 10 Shell and tube type 43 76 3.2.8 Charge air cooler assembly The charge air cooler is specified in GB/T 23338. 3.3 Main parts cleanliness limits The cleanliness limits for major parts are specified in Table 14. The cleanliness limits for other parts of the internal combustion engine that do not have specified limits are subject to the supply agreement. The standard is executed. Table 14 Serial number name (piece) limit/mg 1 cylinder head 0.48iD 2 body 1.62D 3 crankshaft 0.14iD 4 camshaft 3.5i 5 rocker shaft 6i 6 rocker seat 12 7 rocker 7 8 oil filter seat 22 9 gear 12 Table 14 (continued) Serial number name (piece) limit/mg 10 gear chamber cover 12 11 cylinder liner 10 12 valve tappet 12 13 valve stem 17 14 high pressure oil pipe 2.5l 15 cylinder head cover 14i 16 piston 14 17 piston ring 5 18 link 35 19 main bearing bush and connecting rod bearing bush 4 20 diesel filter 6 21 fuel filter 6 22 oil sump 0.06iD 23 intake pipe (including manifold) 0.06iD 24 exhaust pipe 0.12iD Note. D is the cylinder bore of the internal combustion engine, the unit is millimeter (mm); i is the number of cylinders of the internal combustion engine; l is the length of the high pressure fuel pipe, the unit is meter (m).

4 Cleanliness particle limits

The cleanliness particle limit of the internal combustion engine, the parts before the filter shall not exceed 800μm, and the parts after the filter (including the filter) shall not be larger than 600 μm.

5 Determination conditions

5.1 Measuring instruments and cleaning fluids 5.1.1 Filter elements 5.1.1.1 Filter The micropore filter has a difference of not more than 0.4 mg twice. The specifications are as follows. a) 4.5μm microporous membrane, when the cleanliness requirement of the parts is not more than 5mg, filter the sample for testing; b) 5μm microporous membrane filter, when the component cleanliness requirement is greater than 5mg, filter the sample for testing. 5.1.1.2 Filter The filter size is 430 mesh, the material is stainless steel wire, and meets the requirements of GB/T 5330. 5.1.1.3 Vacuum pump and membrane filtration device Vacuum pump (vacuum degree 80kPa), filter membrane filter device consists of funnel, funnel seat, metal frame, rubber stopper, suction filter bottle, its connection form see picture 1. Description. 1---funnel; 2---filter membrane; 3---Funnel seat; 4---rubber plug; 5--- suction filter bottle; 6---metal frame; 7---connecting pipe; 8---Connected to the vacuum pump. Figure 1 Schematic diagram of filter membrane filtration device 5.1.2 Cleaning fluid 5.1.2.1 The cleaning solution should be cleaned before use. The cleanliness of 400mL cleaning solution is not more than 1mg. 5.1.2.2 No. 2 solvent oil (oxygen-free hydrocarbon cleaning agent) specified in GB 1922-2006. 5.1.2.3 90% industrial ethanol. 5.1.3 Appliances and devices 5.1.3.1 Disassembly equipment and tools Special equipment such as cranes and flip racks, as well as general disassembly equipment and tools. 5.1.3.2 Cleaning equipment and tools Cleaning equipment and tools include. a) Nylon round brushes, flat brushes, etc. of various sizes, all brushes should be white and cleaned in the cleaning solution before use, cleaning The diameter of the round brush of the hole should be larger than the diameter of the hole to be cleaned; b) cleaning bottles and syringes, etc.; c) containers of different sizes of basins and buckets with lids; d) magnet; e) a flat, toothless tweezers; f) The whole machine and heavier parts and assemblies shall be equipped with special cleaning equipment that can be rotated; g) Pressure washer (pressure is.200kPa~250kPa), as shown in Figure 2. Description. 1 --- air compressor; 2, 5--- connecting pipe; 3 --- air filter; 4 --- pressure gauge; 6 --- spray gun; 7 ---Liquid tank. Figure 2 Schematic diagram of the pressure washer All cleaning devices are covered with a cover when they are not in use unless they are placed separately in a closed room. 5.1.3.3 Drying equipment Oven, dryer. 5.1.3.4 Analytical equipment The instrument and equipment for inspection and analysis shall meet the requirements for metrological verification and shall be within the validity period. Analytical equipment includes. a) Analytical balance with an accuracy of 10-4g; b) scale microscope with a magnification greater than 40 times; c) 40 cm x 40 cm square glass or microscope carrier glass piece. 5.2 Working environment 5.2.1 Cleanliness inspection should be set up with a special inspection room. The room is divided into operation rooms such as disintegration, cleaning, filtration, drying, weighing and analysis. The recommended layout is shown in Figure 3. Description. 1---disintegration and large-size cleaning room; 2---small cleaning room; 3---filter room; 4---drying, weighing, and analysis; 5---sample display room. Figure 3 Cleanliness inspection room floor plan (recommended) 5.2.2 The cleanliness inspection room shall have good dustproof measures, and the indoor dust reduction amount shall not exceed 40 mg/m2 (the sampling part is for each work). Platform level). See Appendix B for the method of measuring indoor dustfall. 5.2.3 The test chamber should be dry and ventilated, and the room temperature should be kept at 15 °C ~ 30 °C. 5.2.4 There must be strict fire prevention measures in the cleaning room.

6 Measurement items and parts

6.1 Machine The measurement items and parts of the whole machine shall comply with the provisions of Table 15; the items and parts of the whole machine disassembly test are shown in Appendix C. Table 15 Serial number part 1 inner surface of oil sump (including magnetic screw surface) 2 Oil strainer assembly all parts surface (except the outer surface of the assembly) 3 oil fine filter assembly all parts surface (except the outer surface of the assembly) 4 oil oil (including oil pan, oil, fine filter and oil cooler, etc.) 6.2 Parts and components (assembly) 6.2.1 Parts The measurement location of the part shall comply with the requirements of Table 16. Table 16 Serial number part 1 All internal surfaces of the cylinder head (except water passages and screw holes), including air passages, oil passages and combustion chambers 2 All internal surfaces of the body (except waterways and screw holes), including air passages and oil passages 3 All surfaces of the crankshaft (except flanges) and oil passages

4 camshaft all surfaces and oil passages

5 rocker shaft all surfaces and oil passages

6 rocker seat all surfaces and oil passages

7 rocker arm all surfaces, oil passages and threaded holes

8 oil filter seat inner surface

9 gears all surfaces

10 gear chamber cover all inner surfaces 11 Cylinder liner bore surface 12 valve tappet all surfaces 13 valve stem all surfaces 14 high pressure tubing all internal surfaces 15 cylinder head cover inner surface Table 16 (continued) Serial number part 16 piston all surfaces and tunnels 17 piston ring all surfaces 18 links all surfaces and tunnels 19 All surfaces of the main bearing bush and connecting rod bearing 20 diesel filter inner surface 21 fuel filter inner surface 22 oil pan inner surface 23 intake pipe (including manifold) inner surface 24 exhaust pipe inner surface 6.2.2 Parts (Assembly) The measurement site after disassembly of the assembly shall comply with the requirements of Table 17. Table 17 Serial number part 1 Fuel gross filter and fine filter assembly all parts surface (except for the outer surface of the assembly) 2 carburetor assembly all parts surface (except the outer surface of the assembly) 3 All parts of the fuel injection pump assembly (except for the outer surface of the assembly) 4 oil pump assembly all parts surface (except the outer surface of the assembly) 5 Injector assembly all parts surface (except for the outer surface of the assembly) 6 Oil strainer and fine filter assembly all parts surface (except the outer surface of the assembly)

7 Air compressor assembly crankcase inner surface and oil passage

8 oil radiator (cooler) contact with lubricating oil surface and oil passage

9 oil filter assembly assembly all surface

10 oil gauge assembly outer surface 11 supercharger inlet pipe assembly inner surface Note. Pressure fittings and non-removable connectors are not disassembled.

7 Determination method

7.1 Inspection preparation 7.1.1 Staff should wear clean overalls, caps and shoes and wash hands. 7.1.2 Clean the non-inspected parts of the parts. 7.1.3 Clean all sampling tools, brackets and containers. 7.1.4 Filter the cleaning solution with a 4.5μm or 5μm filter. 7.1.5 The filter screen is placed in the cleaning solution for 10 minutes and then taken out. After the cleaning solution is volatilized, it is placed in an oven at 105 °C ± 5 °C. After 60 min, it was taken out in a dry box and cooled for 30 min, and then weighed for use. 7.1.6 Put the filter into the weighing bottle with tweezers, put the half-open cover into the oven that has been heated at 90 °C ± 5 °C, take it out after 60 min, and place it in the dry After cooling for 30 minutes in the dry box, weigh it for use. (If necessary, use multiple filters to dry and weigh together, but each weighing bottle should not exceed 3 sheets, the filter membranes are required to be staggered from each other), and the difference between the weighing of the filter and the drying of the filter is not more than 0.4 mg. 7.1.7 The parts to be inspected shall be demagnetized before cleaning. The residual magnetism of the fuel system parts shall not exceed 5×10-4T, and the remanence of other parts The amount is not more than 1.5×10-3T. 7.2 Operation steps 7.2.1 Parts and components (assembly) 7.2.1.1 The measurement of the cleanliness of parts and components (assembly) includes sampling, disassembly, cleaning, filtration, drying, analysis, etc. The sequence is shown in Figure 4. Figure 4 Cleanliness inspection work program diagram 7.2.1.2 Sampling. According to the sampling method specified by the enterprise. 7.2.1.3 Disintegration. Disassemble the assembly that requires disintegration as specified in Chapter 6. Avoid scratching and bumping parts during the disintegration process. Collecting and processing foreign matter obtained in the process of disintegration that is not within the cleanliness assessment range (damaged paper pad and metal scraps scraped off by spring washers, etc.). After the parts to be inspected are numbered, they are placed on special equipment for cleaning. 7.2.1.4 Cleaning. According to the shape and size of the parts and assemblies, use a syringe, nylon brush and solvent oil (usually 50kPa). Flush the surface to be tested. For deep holes, conduits, and inner surfaces of castings, use 100 mL to 150 kPa of pressurized solvent oil. 7.2.1.5 Clean all the metal impurities in the non-through holes, remove them all (such as magnets to remove iron filings, etc.) and count the impurities. 7.2.1.6 When flushing with various appliances, the cleaning s......

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