Archive for the ‘Air Intake System’ Category
Series 60 Electronic Unit Injector Terminal Installation
Series 60 Electronic Unit Injector Terminal Installation
Series 60G Throttle Actuator
The throttle actuator is used to control the amount of air and fuel mixture to the engine. A butterfly valve within the body is positioned by an electric actuator that is controlled by DDEC III/IV.
Listed in Table are the throttle control diagnostic codes:
| Description | Condition | PID | FMI | Information |
| Throttle Plate Position | HIGH Voltage | P51 | 3 | Indicates that the Throttle Plate Position Sensor input to the ECM has exceeded 95% (normally >4.75 volts) of the sensor supply voltage. This diagnostic is typically an open sensor return circuit or sensor signal circuit is shorted to the sensor +5 volt supply. |
| Throttle Plate Position | LOW Voltage | P51 | 4 | Indicates that the Throttle Plate Position Sensor input to the ECM has dropped below 5% (normally < 0.25 volts) of the sensor supply voltage. This diagnostic condition is typically detected when there is:- An open sensor signal circuit- An open sensor +5 volt supply circuit- The sensor signal is shorted to the sensor return circuit or to ground. |
| Throttle Plate Position | HIGH Position | P51 | 0 | Indicates that the Throttle Plate Position Sensor input to the ECM has indicated that the throttle plate has exceeded the recommended operating range. |
| Throttle Plate Position | LOWPosition | P51 | 1 | Indicates that the Throttle Plate Position Sensor input to the ECM has indicated that the throttle plate has dropped below the recommended operating range. |
Series 60G Charge Air Cooler Parts
| 1. Coupling Hose Clamp | 4. Flexible Coupling |
| 2. Charge Air Cooler Outlet Duct | 5. Turbocharger |
| 3. Charge Air Cooler | 6. Charge Air Cooler Inlet Duct |
| | 7. V-Band Clamp |
Series 60 Keel Cooled Charge Air Cooler Parts
| 1. Raw Water Pump | 4. Charge Air Cooler Inlet |
| 2. Charge Air Cooler Outlet Pipe | 5. Air Intake Manifold |
| 3. Charge Air Cooler |
Series 60 Charge Air Cooler Parts
| 1. Coupling Hose Clamp | 4. Charge Air Cooler |
| 2. Charge Air Cooler Outlet Duct | 5. Turbocharger |
| 3. Charge Air Cooler Inlet Duct | 6. Coupling Hose Clamp |
Series 60 Heat Exchanger Charge Air Cooler Parts
Cooling is accomplished by incoming air flowing past the tubes and fins of the charge air cooler. The compressed intake charge flowing inside the CAC core transfers the heat to the tubes and fins where it is picked up by the incoming outside air (vehicle and industrial engines) or raw water (marine engines).
| 1. Hose | 8. Gasket |
| 2. Elbow | 9. CAC Matrix |
| 3. Gasket | 10. Housing Lower |
| 4. Sleeve | 11. Sensor |
| 5. Seal Ring | 12. Seal Ring |
| 6. Bolt | 13. Air Temperature Sensor |
| 7. Housing Upper | 14. Bracket |
| | 15. Bolt |
Series 60 Charge Air Cooler
On vehicle and industrial engines, a CAC (charge air cooler) is normally mounted ahead of the cooling system radiator. On keel-cooled marine engines the charge air cooler is incorporated into the keel cooler tank. On heat exchanger-cooled engines, the charge air cooler is part of the intake manifold. The compressed air leaving the turbocharger is directed through the CAC before it goes to the air inlet side of the intake manifold.
The CAC is used to reduce the temperature of the compressed air leaving the turbocharger before it reaches the intake manifold. This permits a more dense charge of air to be delivered to the engine.
Series 60 Recirculation Valve
The Series 60G automotive GT42 turbocharger requires a boost recirculation valve to reduce air system pressure pulsations and turbocharger surging during engine throttling operations. The recirculation valve is remote-mounted by the OEM and routes air from the high-pressure boost side back to the air inlet side during deceleration. The recirculation valve is a large solenoid valve that is triggered to open by DDEC through a digital output pin of the ECM.
| 1. Recirculation Valve Body | 3. 2-pin Connector |
| 2. 12V Coil | 4. Bracket |
Replacement of the Recirculation Valve for Series 60G Automotive Engine
The recirculation valve isa non-serviceable component and should be replaced as a unit. No adjustment is required.
Removal of the Recirculation Valve for Series 60G Automotive Engine
Remove the recurculation valve as follows:
Disconnect the inlet and outlet hoses from the valve.
Disconnect the two-pin electrical connector.
Remove the two bolts that attach the recirculation valve to the mounting surface.
Note: The valve has a mounting bracket attached to its body. Do not remove the bolts in the valve body to gain access to the valve. Removal of these bolts can expose the valve diaphragm and cause permanent damage.
If replacing the unit, remove the inlet and outlet fittings from the valve.
Installation of the Recirculation Valve for Series 60G Automotive Engine
Install the recirculation valve as follows:
Position the valve on the mounting surface and secure it in place with the two mounting bolts.
Note: Ensure the arrow on the base of the valve corresponds with the flow of air from the turbo outlet side to the turbo inlet side.
Connect the inlet and outlet hoses to the valve fittings.
Connect the two-pin electrical connector.
Check for any leaks in the system.
Series 60 K33 Turbocharger Assembly
The turbocharger is designed to increase the overall power and efficiency of the engine. Power to drive the turbocharger is extracted from the energy in the engine exhaust gas.
A turbocharger can be broken down into 3 basic pieces; a compressor cover, a center housing rotating assembly (CHRA), and a turbine housing.
The compressor cover is an aluminum alloy casting that encloses the compressor wheel and provides a V-band connection for the compressor outlet, and a hose connection for the compressor inlet. The compressor cover is secured to the compressor side of the CHRA.
The CHRA contains a turbine wheel and shaft assembly, piston ring(s), thrust spacer, compressor wheel, and wheel retaining nut. This rotating assembly is supported on two pressure-lubricated bearings that are retained in the center housing by snap rings. Internal oil passages are drilled in the center housing to provide lubrication to the turbine wheel shaft bearings, thrust washer, thrust collar, and thrust spacer.
The turbine housing is a heat-resistant steel alloy casting that encloses the turbine wheel and provides a flanged engine exhaust gas inlet and an axially located turbocharger exhaust gas outlet. The turbine housing is secured to the turbine end of the center housing.
All Series 60G, 60 Hz Genset engines use a model K33 turbocharger, manufactured by 3K turbosystems.
| 1. Compressor Inlet | 4. Turbine Housing |
| 2. Compressor Housing | 5. V-Band Clamp |
| 3. Turbine Housing Bolt | 6. Compressor Outlet Adapter |
Series 60 Turbocharger Oil Flow Diagram
| 1. Compressor Wheel | 6. Shaft |
| 2. Thrust Bearing | 7. Turbine Wheel |
| 3. Backplate | 8. Shaft Bearings |
| 4. Oil Inlet | 9. Oil Outlet |
| 5. Center Housing |