Unit2: Air Intake and Exhaust

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.

Unit References:

Air Intake and Exhaust Presentation CD-ROM

3406E Operation and Maintenance Manual SEBU6758
Turbochargers SEBV0550
Air System Specifications Handout Copy
3406B Service Manual SEBR0544
3406C Service Manual SEBR0560
Unit 2 Quiz Copy

Tooling:
8T0461 Serviceman's Tool Set or equivalent
9S9082 Turning Tool
6V4186 Pin
 Lesson 1: Air Intake and Exhaust
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 SEBV0550
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.
Unit 2 2-1-2 Engine Fundamentals
Lesson 1

Air Inlet
and
Exhaust System
Fig. 2.1.1 Introduction

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
Unit 2 2-1-3 Engine Fundamentals
Lesson 1

Fig. 2.1.3 Air 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.
Unit 2 2-1-4 Engine Fundamentals
Lesson 1

Fig. 2.1.5 Dry Element Air 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.
Unit 2 2-1-5 Engine Fundamentals
Lesson 1

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.
Unit 2 2-1-6 Engine Fundamentals
Lesson 1

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.

Unit 2 2-1-7 Engine Fundamentals
Lesson 1

Fig. 2.1.10 Turbocharger

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.

Advantages of Turbochargers
• Power
• Efficiency

Fig. 2.1.11 Advantages 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.
Unit 2 2-1-8 Engine Fundamentals
Lesson 1

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. If the
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.
Unit 2 2-1-9 Engine Fundamentals
Lesson 1

Aftercooler
• Air to Air Aftercooler
• Jacket Water Aftercooler

Fig. 2.1.13 Aftercooler

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.
Unit 2 2-1-10 Engine Fundamentals
Lesson 1

Fig. 2.1.14 Air to Air Aftercooler (ATAAC)

Air to Air Aftercooler (ATAAC)

With the air to air aftercooled system, a separate cooler core is
installed in front of the vehicle engine radiator. Ambient temperature
air is moved across the aftercooler core by the engine fan.
Pressurized air from the turbocharger is cooled by the air to air
aftercooler before entering the intake manifold. This is an extremely
effective method for cooling the turbocharged air when a large
volume of fresh cool air can be pushed through the aftercooler. For
this reason this is the configuration found most often in on-highway
truck applications.

Fig. 2.1.15 Jacket Water Aftercooler (JWAC)

Jacket Water Aftercooler (JWAC)

The jacket water aftercooler system has a coolant charged core
assembly. It uses the engine coolant in order to cool the air charge
entering the cylinders. Coolant from the water pump flows through
the aftercooler core. Pressurized air from the turbocharger is cooled
by the aftercooler before entering the intake manifold.
Unit 2 2-1-11 Engine Fundamentals
Lesson 1

SEPERATE CIRCUIT AFTERCOOLER

TURBOCHARGER
AFTERCOOLER

AUXILIARY
WATER PUMP

JACKET
AFTERCOOLER WATER JACKET WATER WATER
COOLING CIRCUIT COOLING CIRCUIT PUMP

Fig. 2.1.16 Separate Circuit Aftercooler

Separate Circuit Aftercooler (SCAC)

A separate circuit aftercooler system is similar to the jacket water
aftercooler system with minor differences. A separate cooling circuit
from the jacket water of the engine is used to cool the engine. The
jacket water acts as normal, cooling the engine head, block,
transmission oil, etc. The separate circuit aftercooler system has a
dedicated water pump, lines, and heat exchanger for the aftercooler.
This system is typically used in applications where maximum
aftercooling is required. Many marine applications utilize separate
circuit aftercoolers in conjunction with a heat exchanger that is
designed to use the keel water for cooling the circuit. Many of
Caterpillar’s large mining trucks also use this type of aftercooler.
Unit 2 2-1-12 Engine Fundamentals
Lesson 1

Inlet Manifold
From the air cleaner (turbocharger/aftercooler, if equipped) the
incoming air enters the inlet manifold. The inlet manifold directs the
air into the cylinder head.

Fig. 2.1.17 Intake Stroke

Intake Stroke
Air fills the inlet ports in the cylinder head. On the INTAKE stroke
as the piston travels down in the cylinder the intake valves open, and
air fills the volume of the cylinder.
Unit 2 2-1-13 Engine Fundamentals
Lesson 1

Fig. 2.1.18 Compression Stroke

Compression Stroke
On the COMPRESSION stroke, as the piston begins to travel up, the
intake valves close. The air that is trapped in the cylinder is
compressed. Compressing the air raises the air temperature to a point
where it will cause fuel to ignite when it is injected into the cylinder.

Fig. 2.1.19 Power Stroke

Power Stroke
When the piston nears the top of its travel, fuel is injected into the
cylinder. The fuel mixes with the hot air and combustion begins.
The energy released by the combustion forces the piston down
producing the POWER stroke.
Unit 2 2-1-14 Engine Fundamentals
Lesson 1

Fig. 2.1.20 Exhaust Stroke

Exhaust Stroke
Near the end of the POWER stroke the exhaust valves open. Any
residual pressure from combustion will rush into the exhaust
manifold. On the upward or EXHAUST stroke the gases are pushed
out of the cylinder by the piston. At the top of the stroke the exhaust
valves close and the cycle starts over.

Fig. 2.1.21 Exhaust Flow

Exhaust Flow
Exhaust gases leaving the cylinder enter the exhaust manifold and are
then routed to the turbocharger, if equipped.

The hot exhaust gases flowing out of the cylinders contain substantial
unused heat energy. The turbocharger exhaust turbine captures some
of this heat energy.
Unit 2 2-1-15 Engine Fundamentals
Lesson 1

Fig. 2.1.22 Turbocharger Operation

Turbocharger Operation
The exhaust gases flow past the blades of the turbine wheel and cause
the turbine wheel to rotate. The turbine wheel is connected by a shaft
to the compressor wheel. The exhaust gases push the turbine and
subsequently the compressor wheel to a high RPM, about 80,000 -
130,000 RPM. This causes the intake air to be compressed.

When the load on the engine increases, more fuel is injected into the
cylinders. The increased combustion generates more exhaust gases
causing the turbine and compressor wheel to turn faster. As the
compressor wheel turns faster, more air is forced into the engine.The
maximum rpm of the turbocharger is controlled by the fuel setting,
the high idle speed setting and the height above sea level.

Fig. 2.1.23 Exhaust Flow

Exhaust Flow
From the turbocharger (if equipped), the exhaust gases pass through
the exhaust pipe, the muffler, and the exhaust stack.
Unit 2 1 Engine Fundamentals
Exercise 1

Unit 2, Exercise 1.1

1. Explain the function of components and service required for diesel engine air intake and exhaust
systems.

Air Cleaners - types and maintenance. How to clean.

Turbochargers - increase air density but also increases intake air temperature.

Aftercoolers - cools air (increases density) after it leaves the turbocharger.

2. Using Handout "Turbochargers" Form (SEBV0550):

Review turbocharger structure.

Review causes of failure.

3. Using Handout “3406E Operation and Maintenance manual”(Form SEBU6758).

Review air system related maintenance intervals (p. 90-91):

Air Cleaner - check service indicator daily.

Valve Lash Adjustment - initial adjustment between 15,000 - 60,000 miles. Every PM2 after that.

Air-to-air Aftercooler - every 2 years, 33,000 US gallons of fuel, 200000 miles, or 4000 hours.
Unit 2 2 Engine Fundamentals
Lesson 1, Handout 1

CATERPILLAR ENGINE AIR SYSTEMS SPECIFICATIONS

Maximum inlet air temperature - 120°F ambient

Maximum air cleaner restriction -

New filter - 15" H2O
Used filter - use air filter service indicator
On-highway diesel engines - 25" H2O
Other diesel engines - 30" H2O
Natural gas engines - 15" H2O

Maximum aftercooler restriction -

Jacket Water Aftercooler - 3" Hg
Air-to-Air Aftercooler - 4" Hg

Maximum exhaust temperature -

Turbocharged - 1200°F (a small number of engines may be higher)
Naturally aspirated - 1300°F

Maximum exhaust restriction -

Turbocharged - 27" H2O
Naturally aspirated - 34" H2O
On-highway diesel engines - 40" H2O

Maximum inlet manifold temperatures -

Turbocharged - 325°F
Turbocharged, Jacket Water Aftercooled - 245°F
Turbocharged, Separate Circuit Aftercooled (85°F water) - 125°F
Turbocharged, Air-to-Air Aftercooled - 150°F

Conversion data -
.5 psi = 1" Hg = 1' H2O = 3.5 kpa
1 psi = 2" Hg = 2' H2O = 7 kpa
15 psi = 30" Hg = 30' H2O = 103 kpa
 Lesson 2: Remove, Inspect and Install
Lesson 2: Remove, Inspect and Install Air
Intake and Exhaust System

Objectives:
Using the Disassembly and Assembly section of the appropriate 3406
Service Manual, the student will demonstrate the ability to correctly
remove, inspect, and install air intake and exhaust system
components.

References:
3406B Service Manual SEBR0544
3406C Service Manual SEBR0560
Turbochargers SEBV0550

Introduction:
To effectively perform diagnosis, repair, and service on a diesel
engine intake and exhaust system, it is necessary to be able to
remove, inspect and install the related components.

Tooling:
8T0461 Serviceman’s Tool Set or equivalent
9S9082 Turning Tool
6V4186 Pin
Unit 2 2-2-2 Engine Fundamentals
Lesson 2

Lab Exercises
Using a lab engine or engine installed in a vehicle, show students air
and exhaust system components and explain their function.

Using the appropriate 3406 Service Manual as a guide, remove the

turbocharger from the 3406 lab engine. Remove housings from the
turbocharger and inspect components using "Turbochargers" as an
inspection guide.

Remove exhaust manifold and inspect for cracks and erosion.

Reassemble engine using 3406 Service Manual as a reference

Check and adjust intake and exhaust valves (and compression brake
if equipped) per Service Manual.