01/31/2012 Air Inlet and Exhaust System (SENR1018-19)

SMCS - 1050 i04767614

PC
Air cleaner
P-0
202 0E
5
Turbocharger

02: 6 / 0 2FF
Aftercooler

1 8/ 0 F
5
SEN :36+ 1
Inlet manifold (passages inside the cylinder block)

© 2 R101 08:00
Cylinder head

Valves
026 8
Valve system components
Cat
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illa
Exhaust manifold

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Illustration 1 g02851416
Air inlet and exhaust system
(1) Exhaust manifold
(2) Inlet manifold and aftercooler
(3) Engine cylinder
(4) Air inlet
(5) Turbocharger compressor wheel
(6) Turbocharger turbine wheel
(7) Exhaust outlet
Clean inlet air from the air cleaner is pulled through air inlet (4) of the turbocharger by the turning
of compressor wheel (5). The compressor wheel causes a compression of the air. The air then
flows to the aftercooler, and then to inlet manifold (2) of the engine. When the inlet valves open,
the air flows into engine cylinders (3). The air is mixed with the fuel for combustion. When the
exhaust valves open, the exhaust gases go out of the engine cylinders and into exhaust manifold
(1). From the exhaust manifold, the exhaust gases flow through the blades of turbine wheel (6)
causing the turbine wheel and compressor wheel to turn. The exhaust gases then flow out of
exhaust outlet (7) of the turbocharger.

Aftercooler

Illustration 2 g00678359
Aftercooler (typical example)
(1) Air inlet pipe
(2) Aftercooler
(3) Water inlet pipe
(4) Water outlet pipe
The aftercooler (2) cools the air that comes from the turbocharger before the air goes into the
inlet manifold. The aftercooler is located toward the rear of the engine between the cylinder
heads. Coolant from the water pump flows through water inlet pipe (3) into the aftercooler. The
water then flows through the aftercooler core assembly through a different water outlet pipe (4)
into the rear of the cylinder block. Inlet air from the compressor side of the turbocharger flows
into the aftercooler through air inlet pipe (1). The air passes through the core assembly and
lowers the temperature of the air to approximately 93 °C (200 °F). The cooler air goes out of the
bottom of the aftercooler and into the inlet manifold. Cooler air is denser air. Dense air will help
the engine burn the fuel more efficiently. This denser air gives the engine more power.

Turbocharger

Illustration 3 g00678403
Turbocharger (typical example)
(1) Air inlet pipe
(2) Turbocharger
(3) Turbocharger support manifold
The turbocharger (2) is mounted to the turbocharger support manifold (3). All of the exhaust
gases go from the turbocharger support manifold through the turbocharger.

Illustration 4 g00678415
Turbocharger (typical example)
(4) Air inlet
(5) Compressor wheel
(6) Turbine wheel
(7) Exhaust outlet
(8) Compressor housing
(9) Oil inlet port
(10) Thrust collar
(11) Thrust bearing
(12) Turbine housing
(13) Spacer
(14) Air outlet
(15) Oil outlet port
(16) Bearing
(17) Lubrication passage
(18) Bearing
(19) Exhaust inlet

The exhaust gases enter the turbocharger and the blades of the turbocharger turbine wheel (6)
are turned. Because the turbocharger turbine wheel is connected by a shaft to the turbocharger
compressor wheel (5), the turbine wheel and the compressor wheel turn at high speeds. The
rotation of the compressor wheel pulls clean air through the compressor housing air inlet (4). The
action of the compressor wheel blades causes a compression of the inlet air. This compression
allows a larger amount of air to enter the engine. With more air in the engine, the engine is able
to burn more fuel. The overall effect is an increase in power.

When the load on the engine increases or when a greater engine speed is desired, additional
fuel is injected into the cylinders. The added fuel creates more exhaust gases, which cause the
turbine wheel and the compressor wheel to turn faster. Additional air is forced into the engine as
the compressor wheel turns faster. The increased flow of air allows the engine to produce more
power. The engine produces more power because the engine is able to burn additional fuel with
greater efficiency.

The maximum rpm of the turbocharger is controlled by the following items:

Fuel setting

High idle rpm setting

Height above sea level

NOTICE
If the high idle rpm or the engine rating is higher than given in
the Technical Marketing Information (TMI) for the height above
sea level at which the engine is operated, there can be damage
to engine or to turbocharger parts. Damage will result when
 increased heat and/or friction due to the higher engine output
goes beyond the engine cooling and lubrication system's
abilities.

The bearings (16) and (18) in the turbocharger use engine oil under pressure for lubrication. The
oil comes in through the oil inlet port (9). The oil flows through the passages in the center section
for the lubrication of the bearings. The oil flows out of the oil outlet port (15) to the engine
lubrication system.

Valve System Components

The crankshaft gear drives the camshaft gear. The camshaft gear is in time with the crankshaft
gear. The timing provides the correct relationship between the piston and the valve movement.

The camshaft has two lobes for each cylinder. One lobe controls the exhaust valves. The other
lobe controls the inlet valves.
Illustration 5 g00327369
Valve system components (typical example)
(1) Inlet valve bridge
(2) Inlet rocker arm
(3) Valve pushrod
(4) Rotocoil
(5) Valve spring
(6) Valve guide
(7) Inlet valves
(8) Lifter
(9) Camshaft
Illustration 6 g00542342

Valve system components (typical example)

The camshaft lobes (9) turn and the lifters (8) move up and down. This movement causes the
pushrods (3) to move. The pushrods move the rocker arms (2) and (10) up and down. The
rocker arms move the inlet valve bridge (1) and the exhaust valve bridge (11) up and down. The
bridges are attached to the cylinder head by dowels. These bridges allow one rocker arm to
either open or either close two valves at the same time. There are two inlet valves and two
exhaust valves for each cylinder.

Rotocoils (4) cause the valves to turn while the engine is running. Valve rotation provides a
longer service life. Valve rotation also minimizes carbon deposits on the valves.

The valve springs (5) cause the valves to close when the lifters move down.

PCP-00E52FFF
2026/08/01
02:15:22+08:00
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