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2024/11/05 Air Inlet and Exhaust System (SENR9830-61)

SMCS - 1050 i10352415

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Illustration 1 g06471531
Reference: For more information, refer to the supplemental video C9 Engines Air Inlet
and Exhaust System on Caterpillar Channel1.

Note: Click or copy the following link into a web browser, or scan the following QR code
using a QR enabled device. A CWS login is required to access Caterpillar Channel1.

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Illustration 2 g07840640

System Operation

Illustration 3 g07840644

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(1) Exhaust manifold

(2) Air inlet heater
(3) Aftercooler core
(4) Exhaust valve
(5) Inlet valve
(6) Air inlet
(7) Exhaust outlet
(8) Compressor side of turbocharger
(9) Turbine side of turbocharger
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 components of the air inlet and
exhaust system are the following components:

Air cleaner

Turbocharger

Aftercooler

Cylinder head

Valves and valve system components

Piston and cylinder

Exhaust manifold

Inlet air is pulled through the air cleaner into air inlet (6) by turbocharger compressor
wheel (8). The air is compressed and heated to about 150 °C (300 °F) before the air is
forced to the aftercooler (3). As the air flows through the aftercooler the temperature of
the compressed air lowers to about 43 °C (110 °F). Cooling of the inlet air increases
combustion efficiency. Increased combustion efficiency helps achieve the following
benefits:

Lower fuel consumption

Increased horsepower output

From the aftercooler, air is forced into the inlet manifold. Air flow from the inlet chambers
into the cylinders is controlled by inlet valves (5). There are two inlet valves and two
exhaust valves (4) for each cylinder. The inlet valves open when the piston moves down
on the intake stroke. When the inlet valves open, cooled compressed air from the inlet
port is pulled into the cylinder. The inlet valves close and the piston begins to move up
on the compression stroke. The air in the cylinder is compressed. When the piston is
near the top of the compression stroke, fuel is injected into the cylinder. The fuel mixes
with the air and combustion starts. During the power stroke, the combustion force
pushes the piston downward. The exhaust valves open and the exhaust gases are
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pushed through the exhaust port into exhaust manifold (1) as the piston rises on the
exhaust stroke. After the exhaust stroke, the exhaust valves close and the cycle starts
again. The complete cycle consists of four strokes:

Inlet

Compression

Power

Exhaust

Exhaust gases from exhaust manifold (1) enter the turbine side of the turbocharger in
order to turn turbocharger turbine wheel (9). The turbine wheel is connected to the shaft
that drives the compressor wheel. Exhaust gases from the turbocharger pass through
exhaust outlet (7), a muffler, and an exhaust stack.

The air inlet heater (2) is controlled by the ECM. The air inlet heater aids in engine start-
up and reducing white smoke during engine start-up.

Turbocharger

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Illustration 4 g07840646
Cross section of turbocharger
(10) Compressor wheel housing
(11) Oil inlet port
(12) Bearing
(13) Turbine wheel housing
(14) Turbine wheel
(15) Air inlet
(16) Exhaust outlet
(17) Compressor wheel
(18) Bearing
(19) Oil outlet port
(20) Exhaust inlet
The turbocharger is installed on the center section of the exhaust manifold. All the
exhaust gases from the engine go through the turbocharger. The compressor side of the
turbocharger is connected to the aftercooler by pipe.

The exhaust gases enter turbine housing (13) through exhaust inlet (20). The exhaust
gases then push the blades of turbine wheel (14). The turbine wheel is connected by a
shaft to compressor wheel (14).

Clean air from the air cleaners is pulled through compressor housing air inlet (15) by the
rotation of compressor wheel (17). The action of the compressor wheel blades causes a
compression of the inlet air. This compressor allows the engine to burn more fuel. When
the engine burns more fuel the engine produces more power.

When the load on the engine increases, more fuel is injected into the cylinders. The
combustion of this additional fuel produces more exhaust gases. The additional exhaust
gases cause the turbine and the compressor wheels of the turbocharger to turn faster.
As the compressor wheel turns faster, more air is forced into the cylinders. The
increased flow of air gives the engine more power by allowing the engine to burn the
additional fuel with greater efficiency.

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Illustration 5 g07840652
Turbocharger with wastegate
(21) Canister
(22) Actuating lever
(23) Line (boost pressure)
The operation of the wastegate is controlled by the boost pressure. At high boost
pressures, the wastegate opens in order to decrease boost pressure. At low boost
pressure, the wastegate closes in order to increase boost pressure.

When the engine is operating under conditions of low boost, a spring pushes on a
diaphragm in canister (21). This action moves actuating lever (22) in order to close the
valve of the wastegate. Closing the valve of the wastegate allows the turbocharger to
operate at maximum performance.

As the boost pressure through line (23) increases against the diaphragm in canister (21),
the valve of the wastegate is opened. When the valve of the wastegate is opened, the
rpm of the turbocharger is limited by bypassing a portion of the exhaust gases. The
exhaust gases are routed through the wastegate which bypasses the turbine wheel of
the turbocharger.

Note: The turbocharger with a wastegate is preset at the factory and no adjustment can
be made.

Bearings (12) and (18) for the turbocharger use engine oil under pressure for lubrication
and cooling. The oil comes in through oil inlet port (11). 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 (19) in the bottom of
the center section. The oil then goes back to the engine oil pan.

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Valve System Components

Illustration 6 g07840657
(24) Rocker arm
(25) Pushrod
(26) Valve bridge
(27) Valve spring
(28) Valve
(29) Lifter
The valve system components control the flow of inlet air into the cylinders during engine
operation. The valve system components also control the flow of exhaust gases out of
the cylinders during engine operation.

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
movement and the valve movement.

The camshaft has two camshaft lobes for each cylinder. The lobes operate the inlet and
exhaust valves. As the camshaft turns, lobes on the camshaft cause lifters (29) to move
pushrods (25) up and down. Upward movement of the pushrods against rocker arms
(24) results in downward movement (opening) of valves (28).

Each cylinder has two inlet valves and two exhaust valves. The valve bridge (26)
actuates the valves at the same time by movement of the pushrod and rocker arm. Valve
springs (27) close the valves when the lifters move down.

Air Inlet Heater (If Equipped)

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The engines are equipped with an electric heater that is located behind the air inlet
elbow. The electric heater has two functions:

Aid in starting

Aid in white smoke cleanup during start-up

Under the proper conditions, the ECM turns on the electric heater.

The system can deliver heat for 30 seconds prior to start-up and during cranking of the
engine. After the engine has started, the system can deliver heat constantly for seven
minutes, or the system can cycle the heat for 13 minutes. During the heating cycle, the
heat is on for ten seconds and the heat is off for ten seconds.

If the air inlet heater malfunctions, the engine will still start and the engine will still run.
There may be a concern regarding the amount of white smoke that is present. Also,
there may be a concern regarding the need for an alternative starting aid.

System Components
The system of the air inlet heater consists of the following basic components:

Relay of the air inlet heater

Heater element

Coolant temperature sensor

Inlet manifold temperature sensor

ECM

Indicator lamp

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Illustration 7 g07840658
(30) Relay for air inlet heater

Illustration 8 g07840661
Location of components
(31) Air inlet heater
(32) Stud for the ground strap

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The relay of the air inlet heater (31) turns the heater ON and OFF in response to signals
from the ECM.

The air inlet heater (31) is located between the cover of the air inlet and the air inlet
elbow. The heater element has a stud (32) for the ground strap that must be connected
to the engine.

The operation of the air inlet heater is determined by five different conditions:

Power up cycle

The air inlet heater and the lamp are turned ON for 2 seconds after the ECM is first
powered up. This will happen regardless of temperatures and engine speed.

Mode of preheat

This check is for low altitude conditions. When the sum of the coolant temperature plus
the inlet air temperature is less than 25° C (77° F), the ECM will turn on the heater and
the lamp for 30 seconds. The ECM will turn off the heater and the lamp after 30 seconds
if the engine speed remains at 0 regardless of temperature.

This check is for high altitude conditions. When the sum of the coolant temperature plus
the inlet air temperature is less than 53° C (127° F), the ECM will turn on the heater and
the lamp for 30 seconds. The ECM will turn off the heater and the lamp after 30 seconds
if the engine speed remains at 0 regardless of temperature.

Mode of cranking

The air inlet heater and the lamp will remain on continuously when engine speed is
detected. The air inlet heater and the lamp will remain on when the sum of the coolant
temperature plus the air inlet temperature is less than 25 °C (77°F) for low altitude
conditions and less than 7 63° C (145° F) for high altitude conditions.

Running of the engine

When the engine achieves low idle the air inlet heater and the lamp will remain on for an
additional 7 minutes when the sum of the air temperature plus the coolant temperature is
less than 35° C (95° F) for low altitude conditions or when the sum of the air temperature
plus the coolant temperature is less than 63° C (145° F) for high altitude conditions.

Post heat cycle

The sum of the air temperature and the coolant temperature is less than 35 °C (95°F) in
low altitude conditions or 63 °C (145 °F) in high altitude conditions. The air inlet heater

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and the lamp are cycled on and off for an additional 13 minutes. The cycle is 10 seconds
on and 10 seconds off.

After the engine has started the inlet air temperature and the coolant temperature will
determine the state of the heater. The cycle has two strategies.

The two strategies are continuous and intermittent.

1. During the continuous strategy, the heater remains activated for seven minutes after
the engine is started. If the same conditions exist, the ECM will activate the
intermittent strategy.

2. During the intermittent strategy, the heater is cycled for a maximum of 13 minutes.
During this cycle, the heater is turned on for ten seconds and the heater is turned off
for ten seconds. After the 13 minute time limit, the heater is shut off.

When one of the temperature sensors fails, the system will operate in the following
manner:

Coolant temperature sensor

When the coolant temperature sensor has an open circuit or a short circuit, the coolant
temperature sensor has failed. During this condition, the heater will be activated when
the inlet air temperature is less than 10° C (50° F).

Inlet air temperature sensor

When the inlet air temperature sensor has an open circuit or a short circuit, the inlet air
temperature sensor has failed. During this condition, the heater will be activated when
the coolant temperature is less than 40° C (104° F).

Under the proper condition, the heater will be reactivated. When the sum of the coolant
temperature and the inlet air temperature has dropped below 25° C (77° F), the heater
will be reactivated. This condition could exist after a warm engine has cooled and the
operator attempts to start the engine.

When the sum of the coolant temperature and the inlet air temperature does not attain
35 °C (95°F), the heater will be activated. The heater can be activated no longer than 20
minutes (maximum). The ECM will turn off the heater after the 20 minute time limit.

For additional information on the air inlet heater, refer to Troubleshooting, "Air Inlet
Heater Circuit - Test".

Ether Starting Aid (If Equipped)

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The ECM controls all operations of the air inlet heater and for the ether starting aid. The
ether starting aid will decrease the demand on the electric starter during cold weather
starting. If the engine is equipped with the ether starting aid the engine will still have the
air inlet heater. The ether starting aid will operate at ambient temperatures lower than
−9 °C (15 °F). The air inlet heater will operate when the ambient temperature is higher
than −9 °C (15 °F). The ECM activates the relay. The relay closes and the valve injects
the ether. Once the desired engine speed is met the valve is deactivated and the flow of
ether is stopped.

PSP-000AD5AD
2025/06/16
07:30:34+07:00
i01705373
© 2025 Caterpillar Inc.

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