Archive for the ‘Air Intake System’ Category
Series 60 Turbocharger Oil Lines
Oil for lubricating the turbocharger is supplied under pressure through an external oil line extending from the oil filter adaptor to the top of the center housing.
| 1. Elbow, Oil Drain Tube | 10. Connector, Oil Supply Tube |
| 2. Bolt, Mounting Bracket | 11. Tube Assembly, Turbo Oil Supply |
| 3. Bolt, Oil Drain Tube Clip | 12. Clip, Oil Supply Tube |
| 4. Tube, Turbo Oil Drain | 13. Bolt, Oil Supply Tube Clip |
| 5. Bolt, Oil Drain Tube Mounting | 14. Connector, Oil Supply Tube (to turbocharger) |
| 6. Gasket, Turbo Oil Drain Tube | 15. Gasket, Turbo Exhaust Inlet |
| 7. Nut, Turbo Mounting | 16. Clip, Oil Drain Tube |
| 8. Washer, Turbo Mounting | 17. Bracket, Oil Drain Tube Clip Mounting |
| 9. Turbocharger Assembly | 18. Nut, Oil Drain Tube Clip |
Series 60 Schematic Air Flow Diagram
The turbocharger is mounted on the exhaust outlet flange of the engine exhaust manifold. After the engine is started, the exhaust gases flow from the engine and through the turbine housing causing the turbine wheel and shaft to rotate.
The gases are discharged into the exhaust system after passing through the turbine housing.
The compressor wheel, in the compressor housing, is mounted on the opposite end of the turbine wheel shaft and rotates with the turbine wheel. The compressor wheel draws in clean air, compresses it, and delivers high pressure air through the intake manifold to the engine cylinders.
Series 60 TMF Turbocharger
Series 60 Turbocharger
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 three basic pieces; a compressor cover, a center housing rotating assembly (CHRA), and a turbine housing.
The compressor cover provides a hose connection for the compressor inlet, and a V-band connection for the compressor outlet. The compressor cover is secured to the compressor side of the CHRA, and encloses the compressor wheel.
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.
The Garrett (formerly Airesearch) family of turbochargers look similar. The model TV51 turbocharger is used on all Series 60 diesel engines through the 1989 models. The TV45 turbocharger is used on 1991 and later 11.1 liter displacement diesel engines.
Series 60 Closed Breathers
Closed breathers are required for natural gas automotive engines in 1998. The Series 60G engine uses a remote mount Racor CV4500 Crankvent breather/filter.
The Crankvent contains a coalescing filter to remove liquid from the blowby gas. The liquid that is coalesced from the blowby is drained back to the ground. The blowby gas is routed out of the rocker cover, through the filter element and returns to the inlet side of the turbo.
Replacement of the Closed Crankcase Breather
The Crankvent coalescing filter is a nonservicable component but should be changed in conjunction with oil service intervals.
Removal of Closed Crankcase Breather
Remove the closed crankcase breather as follows:
- Release latches on the side of the breather assembly and lower canister away from the assembly.
- Remove the filter from the assembly.
- Dispose of the used filter in an environmentally responsible manner.
- Clean the filter canister with a clean lint-free cloth.
Installation of the Closed Crankcase Breather Filter
Install the closed crankcase breather filter as follows:
- Insert new filter into the top of the assembly, ensuring the new filter contains the top O-ring.
- Replace the lower canister ensuring the larger O-ring is secure in the top half of the assembly.
- Secure the latches on the side of the can.
- There are two O-rings in the system. One on the filter element itself and one that seals between the lower canister and the upper body. Ensure both O-rings are secure before reassembling the crankvent.
Series 60 Intake Manifold Parts
On diesel engines, the intake charge air is routed to the individual cylinders by an intake manifold that is bolted to the cylinder head with seven bolts. The mating surface of the manifold and cylinder head is machined. The intake manifold is sealed to the cylinder head with three 2-port graphite coated gaskets. If the manifold is removed, new gaskets must be installed to maintain seal under higher boost pressure. A turbo-boost pressure sensor is mounted to the intake manifold with two bolts. An O-ring seals the boost sensor where it enters a hole in the manifold. On DDEC III/IV engines there is an air temperature sensor located on the bottom of the manifold. The intake manifold air inlet is attached to the CAC ducting and the air compressor using flexible hose and clamps.
| 1. Intake Manifold Inlet | 6. Air Temperature Sensor |
| 2. Bolt (2) | 7. Turbo Boost Sensor Bolt |
| 3. Intake Manifold Gasket | 8. Turbo Boost Sensor |
| 4. Cylinder Head | 9. O-ring |
| 5. Bolt (5) | 10. Intake Manifold |
Series 60 Air Separator System
The breather system consists of an air separator assembly mounted to the inlet side of the turbocharger, along with an oil drain tube(s), check valve(s), required breather piping and mounting hardware.
The system performs three functions:
- Collects the crankcase vapors normally emitted to atmosphere and separates particles of oil from the vapors. Any oil collected in this manner drains back to the crankcase, while the remaining fumes are mixed with the turbocharger air flow. This system virtually eliminates crankcase fumes from the engine room.
- Filters the outside air entering the turbocharger. The oil-coated filter element removes dirt and salt particles from the incoming air.
- Serves as an air silencer to reduce air induction noise.
| 1. Turbine Housing | 3. Air Separator Assembly |
| 2. Compressor Housing |
Series 60 Marine Engine Air Intake System Schematic
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.
Series 60 Air Intake System Schematic
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.
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.
