Air Intake System - LEBW4969-00 PDF

APPLICATION AND INSTALLATION GUIDE
AIR INTAKE SYSTEMS
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
Air Cleaners ..................................................................... 2

Standard Air Cleaners.................................................... 2
Heavy-Duty Air Cleaners................................................ 2
Precleaners .................................................................. 3
Dual Element Air Cleaners.............................................. 3
Exhaust Ejector ............................................................ 3
Oil-Bath Air Cleaners ..................................................... 4
Remote Mounted Air Cleaners ........................................ 4
Customer Furnished Air Cleaners .................................... 5
Air Cleaner Efficiency ................................................ 5
Air Cleaner Design Requirements .................................... 6
Air Cleaner Dust Calculation........................................... 6
Combustion Air Flow Requirements..................................... 8
Air Intake Ducting............................................................. 9
General........................................................................ 9
Marine Intake Air Piping Examples .................................10
Air Inlet Adapters.........................................................12
Connections to Inlet Adapters and Turbochargers ........13
Joining Two Turbochargers...........................................15
Turbocharger Loading...................................................16
Flex Connections .........................................................17
Cleanliness During Installation .......................................17
Inlet Air Duct Insulation ................................................18
Air Intake Restriction....................................................18
Example..................................................................19
Additional Considerations .................................................21
Service Indicators ........................................................21
Trip Lock Device ......................................................21
Differential Pressure Gauge .......................................21
Intake Air Silencers ......................................................21
Air Inlet Shut Off .........................................................21
Air Manifold Drain Valve ...............................................22
Shielding.....................................................................22
Breakaway Joints ........................................................22
Cold Conditions ...........................................................22
Air Cleaner Icing ......................................................22
Boost Control ..........................................................23
Extreme Cold...........................................................23
Considerations for Low Pressure Gas .........................23
Controlling Air Temperature ......................................24
Gas-to-Air Heat Exchanger ........................................25
Reference Material ...........................................................26
Information contained in this publication may be considered confidential.

Discretion is recommended when distributing. Materials and specifications
are subject to change without notice.
CAT, CATERPILLAR, their respective logos and “Caterpillar Yellow”, as well

as corporate and product identity used herein, are trademarks of Caterpillar
and may not be used without permission.
©2005 Caterpillar®
All rights reserved.
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.
Application and Installation Guide Air Intake Systems
Air Intake Systems

A well designed air intake system provides cool, clean air for combustion
while minimizing inlet air pressure drop to the turbocharger. Normally, this
can be accomplished by using engine-mounted air cleaners, but some
applications require intake air to be brought in through ducts from outside
the engine room. There may also be requirements for special filtration and
ducting due to fumes, dust, airborne mists, ambient temperature or even
altitude. These requirements should be carefully considered because the inlet
restriction that accompanies increased filtration and ducting can cause the
engine to be derated and turbocharger life reduced. The air inlet restriction
limits shown in TMI must not be exceeded, especially for EQP certified
engines, in order to ensure regulatory compliance.
Air intake systems using ducted air from outside the engine room should be
accessible for routine maintenance and inspection. The system should also
be located away from exhaust stacks (including engine exhaust stack), vents
or processes that might vent flammable vapors, large concentrations of dirt,
chemicals, industrial waste, or any other material that would not allow for
cool, clean air. In an optimal design, nominal air temperature around the inlet
should be between 15° to 32°C (60° to 90°F). Inlet air temperatures should
not exceed 45°C (113°F) for standard ratings.
For all Caterpillar engines, efficient engine combustion is based on the
proper mass flow ratio of fuel and air. The ratio is mass-based and not
volume-based. It is always important to remember this fact when considering
the impact of installations with non-standard altitude and temperature. Also
be sure to submit a special rating request for non-standard altitude and
temperature applications so it can be evaluated by Caterpillar performance
engineering.
SECTION CONTENTS
Air Cleaners ........................ 2 • Connections

• Dust, Dirt & Debris • Insulation
• Types of Air Cleaners • Intake Air Restriction
• Customer Furnished Air Additional Considerations ....20
Cleaners • Service Indicators
Combustion Air Requirements 8 • Silencers
Air Intake Ducting................ 9
• Shutoff Valve
• General
• Cold Weather Operation
• System Design
• Low Pressure Gas Engines
• Inlet Adapters
Reference Material ..............25
• Turbocharger Loading
All rights reserved. Page 1
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
Page 2 All rights reserved.
periods. Depending on the engine configuration it that the two

air-flow rate and filter type, service elements are used in parallel.
periods may be extended six to Dual element air cleaners are also
seven times that of standard air available with a precleaning stage.
cleaners.
Depending on specific design, dual Exhaust Ejector
element air cleaners may also be In extremely dusty environments
categorized as heavy duty air where dust and other particles cause
cleaners. air cleaners to plug up quickly, an
improved precleaner has been
Precleaners designed. It is an integral part of an
Precleaners are an available option exhaust aspirated air cleaner system
on some Caterpillar engines, which, and will extend the service life of the
when added to the standard air air cleaner elements.
cleaner, can extend filter service Using a louvered body design, the
periods. precleaner has a very high separator
The precleaner imparts a swirl to efficiency. It will separate and
the air, centrifuging out a major remove over 90% of the dirt and
percentage of the dirt particles chaff from the incoming air stream.
which may be collected in a
reservoir or exhausted out on either
Example of Precleaner, Air Cleaner
a continuous or an intermittent
and Exhaust Ejector
basis.
A flow restriction of 0.25 to 1.5
kPa (1 to 6 in. H2O) is imposed by
the precleaner, but it can prolong the
life of the filter by three to seven
times. Any application in an
environment with heavy dust and
debris is recommended to use a
precleaner.
Dual Element Air Cleaners

Dual element air cleaners can be
used to provide additional protection
for the engine. This arrangement
uses two elements mounted in
series. The secondary filter remains
in place while the primary filter is
serviced.
A dual element configuration
differs from a double element
Figure 1
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.
Double Element Housing with Customer Furnished Air

3 Precleaners Cleaners
Air Cleaner Efficiency
Customer furnished air cleaner
selection should be based upon the
following air cleaner efficiency test:
A satisfactory air cleaner must
meet the International Organization
of Standardization’s requirement of
the ISO 5011 dust test.
The filter should have 99.5%
minimum efficiency as calculated
following test code with additions
Figure 3 and exceptions as follows:
• Air flow corrected to m3/min at
99.9 kPa pressure and 32.2°C
For marine and offshore (ft3/min at 29.6 in. Hg pressure
applications, where remote mounted and 90°F).
air cleaners may be located in a salt
water environment, epoxy coated • Use sonic dust feeder.
housings are available. Refer to • Dust quantity determined by
Figure 4 and Figure 5 in the next light-duty class.
section for typical marine • Filter to be dried and weighed in
arrangements for remote mounted an oven at 93°C to 107°C
air cleaners. (200°F to 225°F) before and
Dirty or improper filters can restrict after test.
intake air flow. Differential pressure • Use AC fine dust.
readings should be used to signal
needed filter changes.
AC fine dust is defined as follows:
Caution: Under no circumstances
should the engine be operated Particle Size
% Total Weight
without air cleaners. (microns)
If the air cleaner enclosure(s) are 0–5 39 ± 2
outside in the weather, a protective 6 –10 18 ± 3
shield is recommended to prevent 11 – 20 16 ± 3
rain from being pulled into the 21 – 40 18 ± 3
cleaners/precleaners.
41 – 80 9±3
99.5% filtration of the AC fine

dust has been determined to be a
practical combination of the kind of
dirt likely encountered in service, Where:

and will result in an air cleaner D = Specific dust consumption in
efficiency expected to give optimum mg/hr/cylinder
engine wear life.
V = Intake air flow in cu ft/min
Air Cleaner Design (cfm).
Requirements d= Dust concentration in mg/cu ft
Following the above procedure will (Estimated dust concentration
establish sufficient control on the for residential and offshore
filter media filtering ability of the applications is 0.001 to 0.002
tested air cleaner, but there are in mg/cu ft. Estimate
other design variables needing industrial and inland waterway
further control. applications at 0.002 to 0.05
in mg/cu ft.)
• Choose filters supplied by
manufacturers that can best e= Average air cleaner efficiency
provide quality control. (always < 1.0) (estimated
efficiency of paper elements
• Design filters to be resistant to
= 0.99, & estimated
damage at initial assembly or
efficiency of non-paper
during cleaning. If end seal and
elements = 0.95)
filter media are subject to
damage, dust leakage into the n= Number of engine cylinders
engine can result. (6, 8, 12 or 16)
Air Cleaner Dust Calculation Example A
3600/G3600 engines must not A 3606 Engine operating at 900
ingest more than 34.5 rpm in an EPG application with non-
mg/hr/cylinder of dust at rated paper elements.
power to achieve acceptable engine V = 5554 CFM
life. Air cleaners offered by d= 0.02 mg/cu ft
Caterpillar are designed to this
requirement. Customer provided air e= 0.95
cleaners must also meet this n= 6
requirement or reduced engine life
will result. Specific dust 5554 x 0.02 x (1 – 0.95) x 60
D=
consumption for various engines, air 6
cleaners, and environments can be
calculated using the following Example A equates to a dust
formula. consumption of 55.54
mg/hr/cylinder. Since the engine
V x d x (1 - e) x 60 must not ingest more than 34.5
D= mg/hr/cylinder of dust for acceptable
n
engine life, this air cleaner system is
unacceptable.
Example B
Using the same engine but with
paper air cleaner elements that offer
approximately 0.99 efficiency (e =
0.99).
5554 x 0.02 x (1 – 0.99) x 60

D=
6
Example B equates to a dust

consumption of 11.1 mg/hr/cylinder.
This air cleaner system will provide
acceptable engine life.
Combustion Air Flow Requirements

Combustion air flow requirements QR = Volumetric air flow at
will vary, depending on the specific reference conditions (m3/min),
engine model and rating. Specific air (cfm)
flow data for Caterpillar engines is SR = Density of air at reference
given in both volumetric [m3/min conditions (kg/m3), (lb/ft3).
(cfm)] and mass [kg/hr (lb/hr)] flow (Density of air = 1.292 kg/Nm3
terms, at standard reference (0.074 lb/ft3))
conditions.
Reference conditions for
To convert both mass airflow and
temperature and pressure are used
volumetric air flow from reference
to provide a basis for consistent
conditions to site conditions, use the
measure of combustion air
following formulas:
quantities. However, different parts
of the world subscribe to different TS
MR x = MS
standards, thus it is important to TR
note that the metric and English
conditions are not equivalent. TS
Caterpillar practice is to use ISO QR x = QS
TR
“normal” conditions of 0°C (32°F)
and 101.3 kPaa (14.7 psia) when
Where:
providing values in metric units and
ASME “standard” conditions of MR = Mass flow at reference
25°C (77°F) and 101.3 kPaa (14.7 conditions (kg/hr), (lb/hr).
psia) when providing values in MS = Mass flow at site conditions
English units. (kg/hr), (lb/hr).
To convert from mass airflow to QR = Air flow at reference
volumetric airflow at reference conditions (m3/min), (cfm).
conditions, use the following QS = Air flow at site conditions
formula: (m3/min), (cfm).
MR TR = Air temperature at reference
= QR
SR conditions (°K), (°R).
TS = Air temperature at site
Where: conditions (°K), (°R).
MR = Mass air flow at reference °K = °C + 273.
conditions (kg/hr), (lb/hr)
°R = °F + 460.
Air Intake Ducting

To allow for minor misalignment
General due to manufacturing tolerances,
When ducting is necessary to engine-to-enclosure relative
obtain cooler or cleaner air, the movement and isolate vibrations,
filters should remain on the engine segments of the piping should
to prevent harmful dirt from leaking consist of flexible rubber fittings.
into the engine through ducting These are designed for use on diesel
joints. When air cleaners must be engine air intake systems and are
remote-mounted it is extremely commercially available. These
important that all joints be air tight fittings include hump hose
to prevent ingestion of dirt. connectors and reducers, rubber
When designing air intake ducting, elbows and a variety of special
consideration must be given to shapes.
appropriate routing, duct support Wire-reinforced flexible hose
and system restriction, especially on should not be used. Most material
the larger engines, where overhead available is susceptible to damage
cranes are used to service the from abrasion and abuse and is very
engines. Proper support for duct difficult to seal effectively at the
work adjacent to the engine is clamping points unless special ends
critical, so that its weight is not are provided on the hose.
borne by the turbocharger or other
Inlet ducting should be designed to
engine-mounted components.
withstand a minimum vacuum of
Locate the air piping away from 12.5 kPa, (50 in. H2O) which is also
the vicinity of the exhaust piping so the structural capability of the
that the air provided to the engine is Caterpillar air cleaner filter element.
as cool as possible. Air temperature
Piping diameter should be equal to
to the air inlet should be no more
or larger than the air cleaner
than 11°C (20°F) above ambient air
inlet/outlet and the engine air inlet.
temperature. Inlet air temperature
A rough guide for pipe size selection
should not exceed 45°C (113°F) for
is to keep maximum air velocity in
standard ratings.
the piping to 10 m/s (2,000 fpm).
Avoid abrupt transitions in the Higher velocities will cause high
intake ducting to provide the noise levels and excessive flow
smoothest possible air flow path. restrictions. Refer to the Air Intake
When unavoidable, transitions Restriction section for guidance in
should be made as far upstream of determining required intake duct
the turbocharger as possible. Keep sizing.
total duct head loss (restriction)
All piping must be designed and
below 0.5 kPa (2 in. H2O) for
supported to meet any local seismic
maximum filter life. Any additional
requirements that may be in force.
restriction will reduce filter life.
The ducting should be of seamless PVC pipe, use at least schedule 40

or welded seam piping to minimize pipe and check that it meets local
the flow restriction. The ducting regulations for the area
should also be constructed of classification.
materials suitable for local If ferrous material is necessary, it
environmental conditions such as must be properly cleaned after
offshore or marine applications. fabrication and treated to prevent
Beaded pipe ends at hose joints are rust and scale from accumulating.
recommended. Sealing surfaces Stainless steel ducting should be
should be round, smooth and free of treated in the same manner. Flanged
burrs or sharp edges that can cut connections with gaskets are
the hose. The tubing should have preferred over threaded connections.
sufficient strength to withstand hose Fasteners such as rivets should not
clamping forces. Either T-bolt type be used.
or SAE type F hose clamps that Unsupported weight on clamp-type
provide a 360° seal should be used. joints should not exceed 1.3 kg (3
High quality clamps must be used. lb).
Double clamps are recommended on
connections downstream of the air Marine Intake Air Piping
cleaner. Examples
PVC piping has a number of Figure 4 shows a 3600 marine
benefits. It is light-weight, provides application configured to use a
a good seal without the chance of remote mounted air cleaner and
weld slag coming loose and will not outside air for combustion. An intake
rust. However, it is not well suited air heater may be required for cold
for high or low temperature weather operation.
environments. It can lose much of Figure 5 shows a 3600 marine
its strength when subjected to application configured to use a
temperatures of 150C (300F) or remote mounted air cleaner and
above. It can also become brittle and engine room air for combustion.
shatter at low temperatures. If using
Remote Mounted Air Cleaner with Outside Air Intake
Figure 4
Remote Mounted Air Cleaner with Engine Room Air Intake
Figure 5
shipped loose and include gaskets

Air Inlet Adapters
and mounting hardware.
Caterpillar offers various air inlet
adapters for connecting to CAUTION: Turbocharger
turbocharger air inlets. The adapters performance may be adversely
are part of the system to provide an affected if appropriate air intake
efficient transition from the engine components are not used (They are
room intake air ducting to the engine designed to provide the proper air
turbocharger. Adapters are typically
flow pattern ahead of the immediately preceding the straight

turbocharger). section of pipe should consider the
following guidelines:
Connections to Inlet Adapters and
Turbochargers • The duct between the straight
The piping connected to the pipe and elbow cannot have
turbocharger inlet should be protruding edges.
designed to ensure that air is flowing • The bend can be designed as a
in a straight, uniform direction into circular arc or with sections of
the turbocharger compressor. This is mitered pipe with rectangular or
typically achieved by installing a round flow cross sections, or as
straight section of pipe, equal in transition from round to
length to at least two or three times rectangular cross section.
pipe diameter, to the inlet. This
• An accelerated flow is expected
arrangement reduces the possibility
to occur in the bend. The flow
of premature compressor wheel
area (F) should be: F1 > 1.5 x
failure due to pulsations created by
F2, as shown in Figure 6.
air striking the compressor wheel at
an angle. Transitional ducting
Turbocharger Vertical Inlet Design Options
Figure 6
Inlet Pipe Design Joining Two Turbochargers
Figure 7
Joining Two Turbochargers selected, the steadying zone must

When ductwork feeding two be provided.
turbochargers is combined to form a The transitions used to combine
single duct, a steadying zone must multiple ducts must also follow
be provided after the dividing joint; typical design standards described in
as shown in Figure 7. The steadying this guide. Ducts should have
zone B must be a minimum of 5 smooth transitions and not cause
times the pipe diameter: disturbance in the air flow. Piping
B > 5 x Dh1 designs that use a Tee, as shown in
Figure 8, should not be used to
connect multiple ducts.
The flow area is:
F0 = 1.0 ÷ 2.0 x F1
The transitions from Sections 0-0

to 1-1 and from 1-1 to 2-2 will have
many circular or rectangular
variations due to turbocharger
hardware and installation site
design. Regardless of the transition Figure 8
Turbocharger Loading The maximum allowable

When remote-mounted air cleaners turbocharger load will vary,
are used, turbocharger loading from depending on the engine model, the
the weight of the air inlet inlet adapter and the adapter
components becomes a concern. orientation. In the example below,
The turbochargers are not designed Figure 10, the 90° inlet adapter can
to support any additional weight be rotated in 30° increments.
beyond standard factory Turbochargers for 3600/G3600
attachments. When possible, make engines are designed to withstand a
the flexible connection directly to maximum moment of 294 N•m (217
the turbocharger air inlet, as shown ft-lb). Figure 10 shows how the
in Figure 9. All duct work to that moment can be calculated.
point must be supported off-engine. Models that provide a mounting
bracket for the turbocharger inlet
adapter, such as the C15, can
support up to 11.3 kg (25 lb) of
duct weight.
Figure 9
Maximum Loads for Turbocharger Intake
Figure 10
Flex Connections minimum of 50 mm (2 in.) and a

Flexible connections are required to maximum of 200 mm (8 in.). Care
isolate engine vibration and noise must be used to prevent exhaust
from the ducting system. The piping heat from deteriorating rubber
connections should be configured for flex connections.
maximum allowable offset and
compression to prevent early failure Cleanliness During Installation
and excess forces on the The air intake ducting must be
turbocharger and air inlet cleaned of all debris. Fabricated
components. The flexible connection ducting, utilizing fasteners such as
should be as close to the engine as rivets, should not be used. The
practical and installed in such a way ducting should be made of material
to not induce stress on the ducting such that prolonged operation will
system. The flex engagement with not result in debris coming loose and
the air intake duct should be a entering the turbocharger.
An identifiable blanking plate the Technical Information Appendix

should be installed ahead of the or TMI.
turbocharger to prevent debris from In order to maximize air filter life, it
entering during initial installation of is important to keep total duct
the unit. The plate should have a restriction below 0.5 kPa (2 in.
warning tag indicating it has to be H2O). Every additional restriction
removed prior to starting the engine. caused by the air inlet system
The Caterpillar supplied shipping subtracts from air filter life.
cover can be used for this purpose. Maximum filter life is partially
Provisions should be made to dependent on the absolute pressure
inspect the ducting for cleanliness differential between the
just prior to initial start up. If the turbocharger compressor inlet and
piping is not clean, it must be atmosphere.
cleaned before the engine is started Inlet air restriction includes the
at commissioning. This may require pressure losses between the air
removal of the piping from its cleaner and the engine air inlet
installed position. connection. For remote mounted air
cleaners, the following formulas can
Inlet Air Duct Insulation
be used to calculate duct restriction.
Insulation may be needed on the
intake ducting for remote mounted
air cleaners. Insulation reduces L x S x Q2 x 3.6 x 106
P(kPa) =
turbocharger noise emitted into the D5
engine room and will minimize pre-
heating of intake air. L x S x Q2
P(in. H20) =
187 x D5
Air Intake Restriction
Excessive vacuum on the inlet side Where:
of the turbocharger (or the air inlet P = Restriction (kPa), (in. H2O)
on naturally aspirated engines) can
result in reduced engine power psi = 0.0361 x in. water column
capability and degrade engine kPa = 6.3246 x mm water column
performance. L= Total equivalent length of
Air intake restriction is also an pipe, measured in (m), (ft)
emissions critical parameter declared Q= Inlet air flow, measured in
to obtain EPA non-road certification. (m3/min), (cfm). - (found in
Therefore, the air intake system’s TMI or performance book,
total restriction (including dirty and corrected for site
filters, duct work, vents, silencers, conditions when necessary)
etc.) is limited depending on engine
D= Inside diameter of pipe,
model, rating and air configuration.
measured in (mm), (inches)
The air intake restriction limits for
Caterpillar engines can be found in
If the duct is rectangular, as Example

shown in Figure 11: Below is an example of an air
Then: intake duct restriction calculation.
2xaxb A 3412 packaged genset has an
D= inlet air flow of 36.7 m3/min (1292
a+b
cfm) with duct configuration
consisting of 3 m (10 ft) of straight
length duct along with 2 standard
elbows and a long radius elbow. The
pipe has a diameter of 152.4 mm (6
in) and the temperature of the air is
Figure 11 55°C (131°F).
S= Density of air kg/m3 (lb/ft3) First calculate the total equivalent
length of the ducting.
352.5
S(kg/m3) =
Air Temperature + 273°C 3 + 2 x (33 x 152.4) 20 x 152.4
L= +
1000 mm 1000 mm
39.6
S(lb/ft3) = L = 16.1 m
Air Temperature + 460°F
Use the following formulas to 10 + 2 x (33 x 6) 20 x 6

L= +
obtain equivalent lengths of straight 12 in. 12 in.
pipe for various elbows. L = 53 ft
Standard Elbow 33D
L=
(radius = diameter) X
Next, calculate the density of the
Long Radius Elbow 20D air.
L=
(radius = 1.5 diameter) X 352.5
S=
55 + 273°C
45° Elbow 15D S = 1.075 kg/m3
(radius = 1.5 diameter) L=
X
39.6
Square Elbow S=
66D 131 + 460°F
(radius = 1.5 diameter) L=
X S = 0.067 lb/ft3
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.
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.
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
process in the event of an to a minimum. Some users have

emergency shutdown by stopping designed a front air intake which
the flow of combustion air. This is provides a direct air inlet and an
not recommended for gas engines, internal means of achieving water
as they have the ability to positively separation.
stop the combustion process by Precleaners and prescreeners
controlling the source of ignition. incorporated into the intake cap
The air inlet shut-off feature is design are also available. They can
standard on 3600 diesel engines and be used where special conditions
available on many other Caterpillar prevail or to increase the air cleaner
diesel engines. It is normally used service life. These devices can
when an engine will be operating in remove 70% to 80% of airborne
a potentially combustible dirt.
environment. This feature can be
actuated manually or electronically, Breakaway Joints
but is for emergency use in case of A breakaway joint may be used on
engine overspeed only, not for a cab or hood to tilt away from the
normal engine shutdown. engine compartment for accessibility
and servicing of the engine. Half of
Air Manifold Drain Valve the rubber seal flange remains on
An air manifold drain valve is the engine air intake and the other
available for the 3600 diesel engine half is secured to the enclosure or
family, consisting of an automatic hood.
float valve that drains the If carefully designed and used only
condensate from the engine air upstream of the air cleaner,
manifold. This feature is breakaway joints may be used.
recommended for use in applications
Note: Never use breakaway joints
where high humidity is expected and
between the air cleaner and engine.
the possibility exists for the air inlet
manifold temperature to drop below When breakaway joints are
the atmospheric dew point. Refer to required, chose a joint designed for
Caterpillar Service Publication lifetime sealing under the most
SEBD9317, Engine News severe conditions and needing
2003/01/01 for more information on limited or no maintenance.
this subject.
Cold Conditions
Shielding Air Cleaner Icing
The air inlet should be shielded Air cleaner icing can occur in
against direct entrance of rain or saturated air environments when the
snow. The most common practice is dew point of the ambient air is near
to provide a cap or inlet hood which freezing. Small disturbances to the
incorporates a course screen to keep air such as velocity and pressure
out large objects. This cap should be changes at the air cleaner inlet
designed to keep air flow restriction reduce the moisture-holding capacity
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
gas temperature remains relatively

The density of the air would then constant at most installations and
decrease, resulting in a lower air-fuel the thermostatically controlled
ratio of 13.67. The lower air-fuel aftercooler maintains a fairly
ratio would result in reducing the constant air temperature to the
percent O2 in the exhaust to 6.5%. carburetor. Since these two
The graph in Figure 13 shows how temperatures are not subject to large
NOx changes as a function of changes, the air-fuel ratio remains
percent O2 in the exhaust. The relatively constant.
increased air temperature in our There are two primary methods of
example would increase the NOx controlling VAT, controlling the air
emissions to 8.8 g NOx /bhp-hr, temperature and using a gas-to-air
which is an increase of 440%. heat exchanger.
To maintain a 2.0 g NOx /bhp-hr Controlling Air Temperature
level, VAT must not exceed 5.5°C One method of controlling air
(10°F). supply temperature is to regulate the
engine room temperature. However,
this approach is not recommended.
It is difficult to regulate an engine
room to a temperature that is both
comfortable to work in and high
enough to provide a constant air
temperature to the engine. For
example, an installation expecting a
32°C (90°F) ambient temperature,
will need to regulate the engine
room to about 38°C (100°F) at all
times. Also, engine rooms having
large service doors that, at times,
must be left open while the engines
are running, will not maintain the air-
fuel ratio while the doors are open.
The preferred method is to use
duct work to supply a temperature
Figure 13
regulated air supply to the engine.
See Figure 14. This system uses
jacket water to heat the air to the
High pressure gas engines are not temperature set by the thermostat.
affected by these changes to the
same extent as low pressure gas
engines. This is because the supply
Ducting with Temperature Regulator
Figure 14
If one intake system is used to before entering the gas regulator.

supply temperature controlled air to The pressure drop across the heat
multiple engines, provisions must be exchanger at full load must be added
made to ensure that heated water is to the minimum gas supply pressure
sent to the heat exchanger when required by the engine. Design the
engines are running. If engine jacket heat exchanger to minimize both gas
water is used, the engine that the and air flow pressure drop while still
water is taken from must be running providing enough heat transfer so
when any of the other engines are that VAT stays within the given
operating. limits.
Gas-to-Air Heat Exchanger
If the use of duct work is not
practical for a given installation,
another option is to install a gas-to-
air heat exchanger, shown in Figure
15. If done correctly, this system
will prevent temperature changes in
the gas or the air from affecting the
air-fuel ratio.
Design the system so the gas
flows through the heat exchanger Figure 15
Reference Material
The following information is
provided as an additional reference
to subjects discussed in this guide.
SEBD9317
Engine News 2003/01/01.
LEBW4969-00 ©2005 Caterpillar Printed in U.S.A.

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APPLICATION AND INSTALLATION GUIDE

AIR INTAKE SYSTEMS

Air Cleaners ..................................................................... 2

Information contained in this publication may be considered confidential.

CAT, CATERPILLAR, their respective logos and “Caterpillar Yellow”, as well

Air Intake Systems

Air Cleaners ........................ 2 • Connections

periods. Depending on the engine configuration it that the two

Dual Element Air Cleaners

Double Element Housing with Customer Furnished Air

99.5% filtration of the AC fine

dirt likely encountered in service, Where:

5554 x 0.02 x (1 – 0.99) x 60

Example B equates to a dust

Combustion Air Flow Requirements

Air Intake Ducting

The ducting should be of seamless PVC pipe, use at least schedule 40

Remote Mounted Air Cleaner with Outside Air Intake

Remote Mounted Air Cleaner with Engine Room Air Intake

shipped loose and include gaskets

flow pattern ahead of the immediately preceding the straight

Turbocharger Vertical Inlet Design Options

Inlet Pipe Design Joining Two Turbochargers

Joining Two Turbochargers selected, the steadying zone must

The transitions from Sections 0-0

Turbocharger Loading The maximum allowable

Maximum Loads for Turbocharger Intake

Flex Connections minimum of 50 mm (2 in.) and a

An identifiable blanking plate the Technical Information Appendix

If the duct is rectangular, as Example

Use the following formulas to 10 + 2 x (33 x 6) 20 x 6

process in the event of an to a minimum. Some users have

gas temperature remains relatively

Ducting with Temperature Regulator

If one intake system is used to before entering the gas regulator.

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