Air Intake System - LEBW4969-00 PDF
Air Intake System - LEBW4969-00 PDF
Air Intake System - LEBW4969-00 PDF
G3600 • G3500
G3400 • G3300
3600 • C175 • 3500
3412E • 3400 • 3126B
C18 • C-16 • C-15 • C15
C13 • C-12 • C11 • C-10
C9 • C-9 • C7
Contents
©2005 Caterpillar®
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Foreword
This section of the Application and Installation Guide generally describes
wide-ranging requirements and options for the Air Intake System on
Caterpillar® engines listed on the cover of this section. Additional engine
systems, components and dynamics are addressed in other sections of this
Application and Installation Guide.
Engine-specific information and data are available from a variety of
sources. Refer to the Introduction section of this guide for additional
references.
Systems and components described in this guide may not be available or
applicable for every engine. Below is a listing of air intake system
components for various Caterpillar engines. Refer to the Price List for specific
options and compatibility.
G3300/G3400
z = Standard
C-10/C-12
C-15/C-16
= Optional
C11/C13
C15/C18
C27/C32
G3520C
G3500
G3600
3126B
3406E
- = Not 3412E
C175
3500
3600
Available
C-9
C7
C9
Standard Duty
Air Cleaners z z z z z
Heavy Duty Air
Cleaners - - - - - -
Precleaners - ‡ - - -
Dual Element Air
Cleaners z† - - - -
Exhaust Ejectors - - - - - - - - - -
Remote
Mounted Air - - - - - - - - - - - z - - z z
Cleaners
Service
Indicator, Trip z z z z z z
Lock Device
Service
Indicator,
Differential - - - - - - - - - - - ‡ z z - - - -
Pressure Gauge
Intake Air
Silencers - - - - - - - - - - - - - - - - -
Inlet Air Shutoff - - - - - - - - - - - ‡
z - - - -
Air Manifold
Drain Valve - - - - - - - - - - - - - - - - -
Cold Weather
Boost Control - - - - - - - - - - - - - - - - -
Valve
† Standard on select models, Optional on others.
‡ Optional on select models, Not Available on others.
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Application and Installation Guide Air Intake Systems
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Air Intake Systems Application and Installation Guide
Air Cleaners
Dirt and debris are the major The efficiency of dry-type filters is
source of engine wear. For this not affected by installation
reason, air cleaners are necessary to orientation. However, special care
remove dirt and debris from the should be used in arranging the filter
incoming air. Any moving engine housing and piping to ensure that
part may be subjected to accelerated dirt retained in the filter housing is
wear when dirt is contained in the not inadvertently dumped into the
inlet air. Since the air intake is one engine air supply during air cleaner
of the primary locations where dirt service. A vertically mounted air
may enter an engine, frequent cleaner with a bottom-mounted
replacement of air cleaners may be engine supply pipe is particularly
needed. vulnerable to this occurrence. A filter
Dirt and debris is introduced into design incorporating a secondary or
the intake air ducting through: “safety” element which remains
undisturbed during primary filter
• Residual materials from initial
change should be used. Its higher
fabrication and assembly of
initial cost is offset by its
the intake air ducts.
contribution to longer engine life.
• Filter changes.
• Leaks in the ducting system. Standard Air Cleaners
All Caterpillar engines are available
• Intake air flow. with air cleaners, consisting of high
Engine wear tests have shown that efficiency, dry paper elements,
dust particles under 1 micron packaged in low restriction, weather
(0.00004 in.) size have little effect resistant housings. They remove
on the engine. 99.5% of this dust 99.5% of AC fine dust and are
will pass out through the engine designed to minimize dust entrance
exhaust. during filter changes.
Dust particles 1 to 10 microns On most engine models, these air
(0.00004 to 0.0004 inch) in size has cleaners are engine mounted,
a measurable effect on engine life. however, on some engines the air
Inlet air dust particles larger than cleaners are supplied loose for
bearing oil film thicknesses will remote mounting. See Remote
seriously affect bearing and piston Mounted Air Cleaners later in this
ring life. section. Refer to the engine price
Well designed air cleaners are the lists for availability of air cleaner
most efficient way of assuring that options on specific engine models.
only clean air enters the engine and
harmful particles are not distributed
Heavy-Duty Air Cleaners
Heavy-duty air cleaners provide the
through the engine systems.
same protection as standard filters
but allow extension of filter change
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Application and Installation Guide Air Intake Systems
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Air Intake Systems Application and Installation Guide
The air comes into the precleaner Remote Mounted Air Cleaners
where the dirt and chaff is removed Due to air flow requirements and
from the air. With a slight vacuum, size considerations, it is impractical
the dirt is sucked directly through to mount G3520C and 3600/G3600
the muffler into the exhaust flow air cleaners on the engine. They are
and does no harm to the engine. furnished as shipped loose items,
Refer to Figure 1. and must be remote mounted and
The remaining dust in the air is plumbed by the customer. The air
then removed by the air cleaner cleaner housings may be wall, floor,
before it enters the turbo. or roof mounted with the inlet facing
With this system, consideration downward, or they can be oriented
must be made regarding the location for horizontal entry, but
of exit of the exhaust and the modifications are required to support
surroundings, as there may be the elements.
particles in the engine exhaust. Two element (double) and three
element (triple) air cleaner housings
Oil-Bath Air Cleaners are available. Unlike the dual
Oil-bath air cleaners, while element arrangement, air flow
sometimes required to meet through these elements is in parallel.
customer specifications, are not The double and triple air cleaner
recommended by Caterpillar. At best housings have optional precleaners
their efficiency is 95% as compared and soot filters, to extend element
to 99.5% for dry-type filters. Their life in severe applications. Examples
relative ease of service and of remote air cleaner housings are
insensitivity to water are advantages shown in Figure 2 and Figure 3.
easily outweighed by disadvantages,
such as:
• Lower efficiency Double Element Housing
• Low ambient temperature
limits, low oil level, high
restriction at low air flow (such
as at low idle), and installed tilt
angle may lessen efficiency
further.
• Oil carry-over, which is the oil
becoming airborne in the air
intake system whether resulting
from overfilling or increased air
flow, can seriously affect
turbocharger and engine life, Figure 2
and may actually become an
engine fuel.
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Application and Installation Guide Air Intake Systems
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Air Intake Systems Application and Installation Guide
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Application and Installation Guide Air Intake Systems
Example B
Using the same engine but with
paper air cleaner elements that offer
approximately 0.99 efficiency (e =
0.99).
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Air Intake Systems Application and Installation Guide
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Application and Installation Guide Air Intake Systems
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Air Intake Systems Application and Installation Guide
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Application and Installation Guide Air Intake Systems
Figure 4
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Air Intake Systems Application and Installation Guide
Figure 5
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Application and Installation Guide Air Intake Systems
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Air Intake Systems Application and Installation Guide
Figure 6
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Application and Installation Guide Air Intake Systems
Figure 7
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Air Intake Systems Application and Installation Guide
Figure 9
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Application and Installation Guide Air Intake Systems
Figure 10
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Air Intake Systems Application and Installation Guide
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Application and Installation Guide Air Intake Systems
Where:
Lastly, insert the previous results
x= 1000 mm (12 in.) into the duct restriction formula and
As shown above, if 90° bends are calculate.
required, long radius elbows, with a 16.1 x 1.075 x 36.72 x 3598805.2
P=
radius of 1.5 times the pipe 1525
diameter, offer lower resistance than P = 1.02 kPa or 104 mm H2O
standard elbows.
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Air Intake Systems Application and Installation Guide
53 x 0.067 x 12922
P=
5184 x 65
P = 0.147 psi or 4.07 in H2O
Total duct restriction should be
below 0.5 kPa (2 in. H2O). The duct
restriction in this example is above
the desired value, therefore this duct
configuration is unacceptable.
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Application and Installation Guide Air Intake Systems
Additional Considerations
the other end to a straight length of
Service Indicators pipe immediately upstream of the
Vacuum sensing devices designed turbocharger.
to indicate the need for air cleaner
servicing are commercially available Intake Air Silencers
and when added to the air intake A Caterpillar air intake
system, serve a vital function. There filter/silencer is available for use
are two types of sensing devices, with 3600 diesel engines. It cannot
both recommended for use. be used with G3600 gas engines
Service indicators are installed due to turbocharger orientation.
directly into the intake air ducting
and sense the pressure differential
between the air in the intake ducting
and the air outside the ducting.
It must be noted that in
installations using outside air for
combustion, engine room pressure
and outside, or atmospheric,
pressure is not always the same.
The indicator must be installed so
that it senses the air in the intake
duct on one side and the air from
where it was drawn on the other.
Figure 12
Trip Lock Device
The trip lock device indicates that The filter/silencer provides good air
the air cleaner condition is either filtration, but it should only be used
satisfactory or in need of service. in a clean engine room environment
When in need of service, it typically (filtered air). The customer is
will have a red display. This type of responsible for ensuring the engine
mechanism uses a spring-loaded room air is suitably filtered.
diaphragm to measure the pressure
differential between the clean and Unless specifically designed for
dirty side of the air cleaner. The trip such a purpose, intake air silencers
or latching type is preferred and should be remote mounted from the
available on most engine price lists. turbocharger inlet as shown in Figure
12.
Differential Pressure Gauge
The direct reading differential Air Inlet Shut Off
gauge indicates the actual pressure Air inlet shut-off is a feature
differential across the intake air specific to the diesel engine air
filter. One end of the gauge is intake system. It provides a positive
connected to the air inlet duct and means of stopping the combustion
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Air Intake Systems Application and Installation Guide
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Application and Installation Guide Air Intake Systems
of the air. This results in moisture 0°C (32°F). Admitting engine room
condensation and ice crystal air must be done without the
formation. The ice buildup reduces possibility of allowing dirt or debris
the airflow area and increases the into the air inlet system of the
pressure differential across the air engine.
cleaner. Eventually, a plateau is
Considerations for Low Pressure Gas
reached where the pressure
Take special care when designing
differential remains constant even
the air intake system for low-
though ice buildup may continue.
pressure gas engines that do not
Power loss and increased fuel have air-fuel ratio control.
consumption will result during these
periods. Carburetors used in Caterpillar gas
engines meter fuel into incoming air
Several techniques may be used to
on a volume-for-volume basis. If the
overcome air cleaner icing. One
density of either the air or the gas
solution is to heat the intake air
changes relative to the other, the air-
slightly. It is not necessary to heat
fuel ratio of the engine will change,
the air above freezing. The air
affecting emission levels and the
requires only enough heat to be detonation margin.
above the dew point. Heat can be
supplied to the air cleaner housing For example, if a G3516 Low
by ducting engine room air. Heated Emissions engine with an 11:1
air from the exhaust piping or compression ratio and 32°C (90°F)
muffler, or electrical heating tape A/C is adjusted to produce 2 g NOx
may also be used. at full load, the percent of O2 in the
exhaust must be set to 8%, which
Boost Control results in an air-fuel ratio of 14.75
A boost control valve is available on a volume-for-volume basis.
for the 3600 diesel engine family for
If the engine is adjusted when the
use in extremely cold ambient
incoming air is 10°C (50°F) and the
conditions, 0°C (32°F). The valve is
incoming gas is 21°C (70°F), then:
used to limit the air inlet manifold
pressure during low air temperature ∆T1 = 10°C - 21°C = -11°C
conditions to maintain acceptable (∆T1 = 50°F - 70°F = -20°F)
cylinder pressure. If the air temperature is later
Extreme Cold increased to 32°C (90°F) and the
Heated engine room air may be gas temperature remained constant,
required (for starting purposes only) then:
in applications at very cold ambient ∆T2 = 32°C - 21°C = 11°C
temperatures, -25°C (-13°F). This (∆T2 = 90°F - 70°F = 20°F)
assumes combustion air is being The Variation in Air Temperature
drawn from outside the engine (VAT) would then become:
building, and the engine is
V∆T = |-11°C - 11°C)| = 22°C
preconditioned with pre-heaters for
(V∆T = |-20°F - 20°F| = 40°F)
metal, water and oil temperatures of
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Air Intake Systems Application and Installation Guide
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Application and Installation Guide Air Intake Systems
Figure 14
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Air Intake Systems Application and Installation Guide
Reference Material
The following information is
provided as an additional reference
to subjects discussed in this guide.
SEBD9317
Engine News 2003/01/01.
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LEBW4969-00 ©2005 Caterpillar Printed in U.S.A.
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