Unit 2

Air Intake and Exhaust Systems

Unit Objectives:

The student will be able to:

1. Identify air intake and exhaust system components in an

engine installation.
2. Remove, inspect, and install air and exhaust system
components on a Caterpillar 3406B or 3406C engine.
Lesson 1: Identify Air Intake and
Exhaust Systems

Objectives:

The student will be able to explain the operation of the air intake and
exhaust system and identify related components.

References:

Air Intake and Exhaust Presentation CD-ROM

3406E Operation and Maintenance Manual SEBU6758
Turbochargers SEBVOSSO
Air System Specifications Handout Copy

Introduction:

Efficient diesel engine operation requires that the proper amount of

air can enter the combustion chamber and the exhaust gases can exit
with minimal restriction. Both inlet air and exhaust gas temperatures
are also critical for maximum engine performance and life.
 Air Inlet
and
Exhaust System
ig.2.1.1Introduction
F

Introduction
This first system we will discuss is the Air Inlet and Exhaust system.

Fig. 2.1.2 Air System Components.

Air System Components

The Air Inlet and Exhaust System contains the following components :

• Air cleaner
• Turbocharger
• Aftercooler
• Cylinder head, valves, and pistons
• Exhaust manifold
 Fig. 2.1.3Air Cleaner

Air Cleaner
Air is drawn into the engine through the air cleaner. The air cleaner
houses a filter element which removes foreign material from the air
before it enters the engine. There are several different types of air
cleaners currently available on Caterpillar engines. Always refer to
the operation and maintenance manual of the engine for the most
accurate maintenance procedures.

Fig.2.1.4 Typical Service Indicator

Engine air cleaners should be serviced on a regular basis. Many air

cleaners are equipped with a service indicator. The indicator
monitors the amount of restriction through the air cleaners. The
service indicator is the most accurate method to use to determine
when the air cleaners are in need of service. Engine air cleaner
elements should be serviced, cleaned or replaced, when either the
yellow diaphragm enters the red zone or the red piston locks into the
visible position.
Fig. 2.1.5 Dry Element Af r Cleaner

Dry element air cleaners are by far the most common type of air
cleaners used on Caterpillar engines. Dry element air cleaners are
typically composed of a pleated paper filter media that is used to
remove the dirt from the incoming air.

This type of air filter requires replacement or cleaning when the

service indicator is tripped.

Fig. 2.1.6 Dry Element Cleaning

Dry element air cleaners can usually be cleaned with filtered. dry air
with a maximum pressure of 207 kPa (30 psi). The element should
be cleaned from the clean side out, holding the tip of the air nozzle
parallel to the pleats of the air cleaner.
Fig. 2.1.7 AIRSEP® Filters
Another type of air cleaner that is found on Caterpillar engines, most
commonly in high performance marine applications, is the AIRSEP®.
The AIRSEP elements are a pleated fiber filter media that is
impregnated with a special petroleum based fluid. This allows the
AIRSEP elements to flow a high volume of air with little restriction,
but still clean the air before it enters the engine. These elements are
reusable, but the elements require a special maintenance procedure.
The AIRSEP filters must be cleaned using the 102-9720 Cleaning Kit.
Follow the guidelines in the operation and maintenance manual.
•
Fig.2.1.8 Simple Cap Precleaner

Precleaner
Many engines are also equipped with a precleaner. The precleaner is
located before the inlet to the main air cleaner. The purpose of the
precleaner is to collect much of the dirt before the air cleaner. This
increases the service life of the air cleaner.

The simplest type of precleaner is a simple mesh cap at the top of the
air filter housing inlet.

Fig. 2.1.9 Dust collection bowl

Another type of precleaner that is used on Caterpillar equipment is a

spirally vaned drum. The vanes cause the incoming air to spin.
Because the dirt that is drawn in is heavier than the air, the dirt is
forced to the outside due to the spinning action. The dirt then falls
into a collection bowl.

Precleaners should be inspected and emptied on a daily basis.

Fig. 2.1.10Turbocharger

Turbocharger
Many diesel engines are equipped with a turbocharger in order to
improve the performance and the efficiency of the engine. The
turbocharger receives clean air flow from the air cleaner. The
rotation of the turbocharger compressor wheel draws air in,
compresses it and delivers it under pressure to the cylinders.

Advantag es of Turbochargers
• Power
• Efficiency

Fig. 2.1.11Advantages of Turbochargers

Advantages of Turbochargers
Turbocharging has several important advantages:

1. Power - Compressed air has more oxygen per volume. With more
oxygen in the cylinder, more fuel can be injected for a higher
energy output.

2. Efficiency - Turbocharging allows a more efficient combustion for

improved emissions and fuel consumption.
Fig. 2.1.12 Turbocharger Operation

Turbocharger Operation

When the turbocharger compresses the intake air, the temperature of

the air is increased. Hot air has less density, thus less oxygen. Ifthe
hot compressed air is delivered to the engine, some of the efficiency
gained by compression will be lost. This is where the aftercooler
comes into play. The aftercooler lowers the temperature of the air
before its enters the cylinders.
 Aftercooler
• Air to Air Aftercooler
• Jacket Water Aftercooler

Fig.2.1.13Aftercooler

Aftercoolers
Aftercoolers are used in conjunction with turbochargers in order to
lower the temperature of the air coming from the turbocharger before
the air enters the cylinders. This causes the air to be more dense,
therefore contain more oxygen in a given volume. This increase in
oxygen in the cylinders translates into greater power and efficiency
from the engine.

There are different types of aftercoolers that are used on Caterpillar

engines: All aftercoolers serve the same purpose however, remove
heat from inlet air providing cooler and more dense air to the
cylinder.