Shutdown SIS

Previous Screen

Product: NO EQUIPMENT SELECTED

Model: NO EQUIPMENT SELECTED
Configuration: NO EQUIPMENT SELECTED

Systems Operation
C27 and C32 Engines for Caterpillar Built Machines
Media Number -SENR9937-02 Publication Date -01/04/2006 Date Updated -01/05/2006

i02130828

Air Inlet and Exhaust System

SMCS - 1050
Illustration 1 g01107004
Basic air inlet and exhaust system

(1) Inlet valves

(2) Exhaust valves

(3) Inlet manifold

(4) Exhaust manifold

(5) Aftercooler

(6) Air inlet

(7) Exhaust outlet

(8) Compressor

(9) Turbine

The components of the air inlet and exhaust system control the quality of air and the amount of air that is available
for combustion. The air inlet and exhaust system consists of the following components:

z Air cleaner

z Turbocharger

z Aftercooler

z Cylinder head

z Valves and valve system components

z Piston and cylinder

z Inlet manifold

z Exhaust manifold

Note: The following description of the operation of the air inlet and exhaust system assumes that the engine is
developing boost pressure.

Inlet air passes through the air cleaner into the air inlet (6) of the turbocharger compressor (8). A turbocharger is
used in order to increase the flow of air into the engine. This increase in air flow pressurizes the combustion air
supply for the engine. The pressure that is placed on the inlet air allows a larger volume of air to be compressed
into the cylinder. This compressing of the inlet air is referred to as engine boost.

The compressing of air causes the air temperature to rise to about 204 °C (400 °F). As the air flows through
aftercooler (5) the temperature of the compressed air is cooled to about 46 °C (115 °F). The aftercooler utilizes a
heat exchanger in order to cool the inlet air. Cooling the inlet air causes the air to become more dense.
Compressing and cooling the inlet air increases the combustion efficiency of the engine. This also increases the
engine's horsepower output.

From the aftercooler, air enters the inlet manifold (3). Air flow from the inlet manifold to the cylinders is
controlled by inlet valves (1). There are two inlet valves and two exhaust valves (2) for each cylinder. The inlet
valves open at the top center position of the piston. When the inlet valves open, cooled compressed air enters the
cylinder through the inlet ports. The inlet valves close as the piston reaches the bottom center position. This is
called the inlet stroke of the engine. As the piston begins to travel back to the top center position on the
compression stroke, the air in the cylinder is compressed to a very high temperature. When the piston is near the
end of the compression stroke, fuel is injected into the cylinder and mixes with the compressed air. This causes
combustion to start in the cylinder. Once combustion starts, the combustion force pushes the piston toward the
bottom center position. This is called the power stroke. The exhaust valves open when the piston moves toward
the bottom center position and the exhaust gases are pushed through the exhaust port into exhaust manifold (4) as
the piston travels toward top center on the exhaust stroke. The exhaust valves close and the cycle starts again. The
complete cycle consists of four strokes:

z Inlet

z Compression

z Power

z Exhaust

The exhaust gases from the cylinder are forced into exhaust manifold (4). The flow of exhaust gases from the
exhaust manifold enter the turbine side of the turbocharger. The flow of the exhaust gas and the heat of the
exhaust gas causes the turbine wheel in the turbocharger's turbine (9) to spin. The turbine wheel is connected to a
shaft that drives the compressor wheel. Exhaust gases from the turbine wheel then exit the turbocharger (7) .

Turbocharger

Illustration 2 g01107005

Water cooled turbocharger

(1) Compressor inlet

(2) Compressor housing

(3) Compressor wheel

(4) Shaft bearing

(5) Oil Inlet port

(6) Shaft bearing

(7) Turbine wheel

(8) Turbine outlet

(9) Turbine inlet

(10) Oil outlet port

All of the air that enters the engine passes through the turbocharger's compressor. All of the exhaust gases from
the engine pass through the turbocharger's turbine.

The exhaust gases enter through turbine inlet (9). The flow of the exhaust gas pushes on the blades of the turbine
wheel (7) and exits through the turbine outlet (8). The turbine wheel is connected by a shaft to compressor wheel
(3) .

As the compressor wheel rotates, a vacuum is created in the turbocharger's compressor housing (2). Air is pulled
through the air filters into the compressor housing through the compressor inlet (1). Impeller vanes are
manufactured into the compressor wheel. The vanes are used to compress the incoming air. The compressed air is
directed to the turbocharger's compressor outlet into the inlet piping. The air is then directed toward the inlet side
of the engine. Boost pressure is created as the flow that is developed by the compressor wheel exceeds the needs
of the engine. This results in a positive inlet manifold pressure that exceeds atmospheric pressure. The increased
pressure allows the engine to burn more fuel during fuel combustion. Through optimum fuel efficiency, this
strategy allows the engine to produce more power and lower emission levels.

When the throttle is opened, more fuel is injected into the cylinders. The combustion of this additional fuel
produces an increased flow of exhaust and greater exhaust temperature. The additional flow and the increased
temperature of the exhaust causes the turbine and the compressor wheels of the turbocharger to turn faster. As the
compressor wheel turns faster, air flow into the engine's air inlet system creates an increase in the pressure that is
in the inlet manifold. This increased air pressure allows the engine to burn additional fuel with greater efficiency.

The turbocharger's shaft bearings (4) and (6) use pressurized oil from the engine for lubrication and for cooling.
The oil comes in through oil inlet port (5). The oil then goes through passages in the center section in order to
lubricate the bearings. This oil also cools the bearings. Oil from the turbocharger goes out through oil outlet port
(10) in the bottom of the center section. The oil then flows back to the engine oil pan.

Valve System Components

Illustration 3 g01062836
Valve system components

(1) Rocker arm

(2) Valve adjustment screw

(3) Rocker arm shaft

(4) Camshaft follower

(5) Camshaft

(6) Valve bridge

(7) Valve rotator

(8) Valve spring

(9) Valve

(10) Valve seat

The valve train controls the flow of inlet air into the cylinders and the flow of exhaust gases out of the cylinders
during engine operation. Specifically machined lobes on the camshaft (5) control the following aspects of valve
function:

z Height of valve lift

z Timing of valve lift

 z Duration of valve lift

The crankshaft gear drives the camshaft gear through an idler gear. The camshaft must be timed to the crankshaft
in order to get the correct relation between the piston position and the valve position.

The camshaft has three camshaft lobes for each cylinder. One camshaft lobe operates the inlet valves. One
camshaft lobe operates the exhaust valves. There is also one camshaft lobe that operates the unit injector.
Camshaft followers (4) roll against the surface of the camshaft lobes. The followers are used in order to transfer
the lift that is machined into the camshaft lobe to the rocker arm (1) .

The camshaft lobes lift the camshaft follower of the rocker arm which actuates the valves (9). As the camshaft
lobe lifts the follower, the rocker arm pivots at the rocker shaft (3). This applies the lifting action to the valve
bridge (6). The valve bridge is used to transfer the lift from the rocker arm to the valves. The valve adjustment
screw (2) is used in order to adjust the valve lash.

Each cylinder has two inlet valves and two exhaust valves. Valve springs (8) are used to hold the valves in the
closed position when lift is not being transfered from the camshaft lobe. The springs provide the force on the
valve in order to ensure that the valves will close at high rpm and under high boost pressures.

Valve rotators (7) cause the valves to rotate while the engine is running. The rotation of the valves prevents the
valves from burning by constantly changing the contact area of the valve face and the valve seat (10). This
rotation gives the valves longer service life.

Copyright 1993 - 2007 Caterpillar Inc. Fri Jul 6 14:59:22 EST 2007
All Rights Reserved.
Private Network For SIS Licensees.