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SERIES 60 AIR INTAKE SYSTEM OVERVIEW

The air intake system consists of the following components: ‪

  • Air cleaner or air silencer
  • Gas mixer (Series 60 gas engine)
  • Turbocharger
  • Charge air cooler
  • Throttle actuator (Series 60 gas engine)
  • Intake manifold
  • Air dryer

The turbocharger supplies air under pressure to the CAC and then to the intake manifold. The air enters the turbocharger after passing through the air cleaner or air silencer. Power to drive the turbocharger is extracted from energy in the engine exhaust gas. The expanding exhaust gases turn a single stage turbocharger wheel, which drives an impeller, thus pressurizing intake air. This charge air is then cooled by an air-to-air or air-to-water (marine engine) intake manifold before flowing into the cylinders for improved combustion efficiency. See Figure 20416 . ‪

Air Intake System Schematic (Series 60 Diesel Engine)

On vehicle and industrial engines, charge air cooler (CAC) is mounted ahead of the engine coolant radiator. The pressurized intake charge is routed from the discharge side of the turbocharger, through the CAC to the intake manifold, which directs the air to ports in the cylinder head, through two intake valves per cylinder, and into the cylinder. At the beginning of the compression stroke, each cylinder is filled with clean air. ‪

On heat exchanger-cooled pleasure craft marine engines, the raw water-cooled charge air cooler/air intake manifold is mounted on the intake side of the engine. The pressurized intake charge is routed from the discharge side of the turbocharger, through the CAC/intake manifold, which directs the air to the ports in the cylinder head. See Figure 36035 . ‪

Air Intake System Schematic Heat Exchanger-Cooled Marine Engine

On keel-cooled commercial marine engines, the charge air cooler (CAC) is mounted at the front of the engine. The pressurized intake charge is routed from the discharge side of the turbocharger, through the CAC to the intake manifold, which directs the air to ports in the cylinder head, through two intake valves per cylinder, and into the cylinder. At the beginning of the compression stroke, each cylinder is filled with clean air. See Figure 36034 . ‪

Air Intake System Schematic Keel-Cooled Marine Engine

Repair and replacement procedures for the individual components of the air intake system are contained in this section. ‪

Air System for Series 60G Engine (Low Pressure Natural Gas)

The air system components on the Series 60G engine with low pressure fuel system are similar to the diesel engine air system except for the addition of a gas mixer and throttle, see Figure 27855 . The turbocharger for this engine is similar to the diesel turbocharger. The features are described in more detail in the turbocharger section. Refer to section . ‪

Air Intake System Schematic Series 60G (Low Pressure)

On genset engines, which have the low pressure fuel system, air is drawn into the gas mixer ahead of the turbocharger. A precisely controlled flow of natural gas is mixed with the air and flows into the turbocharger where it is compressed before flowing through the charge air cooler. This combustible air fuel mix then passes through the throttle and into the intake manifold. The throttle controls the flow of air-fuel mixture to the intake manifold there by providing control over the power output of the engine. ‪

Air System for Series 60G (High Pressure)

The air system components on the Series 60G engine with high pressure fuel system are similar to the diesel engine air system except for the addition of a gas mixer and throttle, See Figure 35339 . The turbocharger for this engine is also different and features a turbine bypass (wastegate) and compressor recirculation valve. These features are described in more detail in the turbocharger section. Refer to section . ‪

Air Intake System Schematic 60G (High Pressure)

In this system, air leaving the charge air cooler enters the mixer assembly and is mixed with a precisely controlled flow of natural gas. This combustible air fuel mixture then passes through the throttle and into the intake manifold. The throttle controls the flow of air-fuel mixture to the intake manifold there by providing control over the power output of the engine. ‪