Caterpillar AIR INTAKE SYSTEMS

APPLICATION AND INSTALLATION GUIDE
AIR INTAKE SYSTEMS

Contents
Air Intake Systems

Air Cleaners ...................................................................... 2
Standard Air Cleaners ..................................................... 2
Heavy-Duty Air Cleaners ................................................. 3
Precleaners.................................................................... 3
Dual Element Air Cleaners ............................................... 3
Exhaust Ejector .............................................................. 3
Oil-Bath Air Cleaners ...................................................... 4
Remote Mounted Air Cleaners ......................................... 4
Customer Furnished Air Cleaners ..................................... 5
Air Cleaner Efficiency ................................................. 5
Air Cleaner Design Requirements ..................................... 6
Air Cleaner Dust Calculation ............................................ 6
Combustion Air Flow Requirements...................................... 8
Air Intake Ducting .............................................................. 9
General ......................................................................... 9
Marine Intake Air Piping Examples ................................. 10
Air Inlet Adapters ......................................................... 12
Connections to Inlet Adapters and Turbochargers ........ 13
Joining Two Turbochargers ........................................... 15
Turbocharger Loading ................................................... 16
Flex Connections ......................................................... 17
Cleanliness During Installation ....................................... 17
Inlet Air Duct Insulation ................................................ 18
Air Intake Restriction .................................................... 18
Example .................................................................. 19
Additional Considerations.................................................. 20
Service Indicators......................................................... 20
Trip Lock Device ...................................................... 20
Differential Pressure Gauge ....................................... 20
Intake Air Silencers ...................................................... 20
Air Inlet Shut Off ......................................................... 20
Air Manifold Drain Valve ............................................... 21
Shielding ..................................................................... 21
Breakaway Joints......................................................... 21
Cold Conditions ........................................................... 21
Air Cleaner Icing ...................................................... 21
Boost Control .......................................................... 22
Extreme Cold ........................................................... 22
Considerations for Low Pressure Gas ......................... 22
Controlling Air Temperature....................................... 23
Gas-to-Air Heat Exchanger ........................................ 24
Reference Material ........................................................... 25
Foreword
This section of the Application and Installation Guide generally describes
wide-ranging requirements and options for the Air Intake System on
Caterpillar® engines listed on the cover of this section. Additional engine
systems, components and dynamics are addressed in other sections of this
Application and Installation Guide.
Engine-specific information and data are available from a variety of
sources. Refer to the Introduction section of this guide for additional
references.
Systems and components described in this guide may not be available
or applicable for every engine. Below is a listing of air intake system
components for various Caterpillar engines. Refer to the Price List for
specific options and compatibility.
G3300/G3400
= Standard
C-10/C-12
C-15/C-16
C11/C13
C15/C18
C27/C32
= Optional
G3520C
G3500
G3600
3126B
3406E
- = Not 3412E
C175
3500
3600
C-9
Available
C7
C9
Standard Duty
Air Cleaners
Heavy Duty Air
Cleaners - - - - - -
Precleaners - ‡ - - -
Dual Element Air
Cleaners † - - - -
Exhaust Ejectors - - - - - - - - - -
Remote
Mounted Air - - - - - - - - - - - - -
Cleaners
Service
Indicator, Trip
Lock Device
Service
Indicator,
Differential - - - - - - - - - - - ‡ - - - -
Pressure Gauge
Intake Air
Silencers - - - - - - - - - - - - - - - - -
Inlet Air Shutoff - - - - - - - - - - - ‡
- - - -
Air Manifold
Drain Valve - - - - - - - - - - - - - - - -
Cold Weather
Boost Control - - - - - - - - - - - - - - - - -
Valve
† Standard on select models, Optional on others.
‡ Optional on select models, Not Available on others.
Information contained in this publication may be considered confidential.
Discretion is recommended when distributing. Materials and specifications
are subject to change without notice.
CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow” and the

POWER EDGE trade dress, as well as corporate and product identity used
herein, are trademarks of Caterpillar and may not be used without
permission.
Air Intake Systems Application and Installation Guide
Air Intake Systems

A well designed air intake system provides cool, clean air for combustion
while minimizing inlet air pressure drop to the turbocharger. Normally, this
can be accomplished by using engine-mounted air cleaners, but some
applications require intake air to be brought in through ducts from outside
the engine room. There may also be requirements for special filtration and
ducting due to fumes, dust, airborne mists, ambient temperature or even
altitude. These requirements should be carefully considered because the inlet
restriction that accompanies increased filtration and ducting can cause the
engine to be derated and turbocharger life reduced. The air inlet restriction
limits shown in TMI must not be exceeded, especially for EPA certified
engines, in order to ensure regulatory compliance.
Air intake systems using ducted air from outside the engine room should be
accessible for routine maintenance and inspection. The system should also
be located away from exhaust stacks (including engine exhaust stack), vents
or processes that might vent flammable vapors, large concentrations of dirt,
chemicals, industrial waste, or any other material that would not allow for
cool, clean air. In an optimal design, nominal air temperature around the inlet
should be between 15° to 32°C (60° to 90°F). Inlet air temperatures should
not exceed 45°C (113°F) for standard ratings.
For all Caterpillar engines, efficient engine combustion is based on the
proper mass flow ratio of fuel and air. The ratio is mass-based and not
volume-based. It is always important to remember this fact when considering
the impact of installations with non-standard altitude and temperature. Also
be sure to submit a special rating request for non-standard altitude and
temperature applications so it can be evaluated by Caterpillar performance
engineering.
SECTION CONTENTS
Air Cleaners........................ 2 • Connections

• Dust, Dirt & Debris • Insulation
• Types of Air Cleaners • Intake Air Restriction
• Customer Furnished Air Additional Considerations .... 20
Cleaners • Service Indicators
Combustion Air Requirements 8 • Silencers
Air Intake Ducting ............... 9
• General • Shutoff Valve
• Cold Weather Operation
• System Design
• Low Pressure Gas Engines
• Inlet Adapters
• Reference Material 25
• Turbocharger Loading
©2008 Caterpillar®
All rights reserved. Page 1
Application and Installation Guide Air Intake Systems
Air Cleaners
Dirt and debris are the major source orientation. However, special care
of engine wear. For this reason, air should be used in arranging the filter
cleaners are necessary to remove dirt housing and piping to ensure that
and debris from the incoming air. Any dirt retained in the filter housing is
moving engine part may be subjected not inadvertently dumped into the
to accelerated wear when dirt is engine air supply during air cleaner
contained in the inlet air. Since the service. A vertically mounted air
air intake is one of the primary cleaner with a bottom-mounted
locations where dirt may enter an engine supply pipe is particularly
engine, frequent replacement of air vulnerable to this occurrence. A filter
cleaners may be needed. design incorporating a secondary or
Dirt and debris is introduced into “safety” element which remains
the intake air ducting through: undisturbed during primary filter
change should be used. Its higher
• Residual materials from initial
initial cost is offset by its
fabrication and assembly of
contribution to longer engine life.
the intake air ducts.
• Filter changes. Standard Air Cleaners
• Leaks in the ducting system. The standard air cleaner on most
Caterpillar engines uses a high-
• Intake air flow. efficiency, dry paper element
Engine wear tests have shown that packaged in a low restriction,
dust particles under 1 micron weather resistant housing. They
(0.00004 in.) size have little effect remove 99.5% of AC fine dust and
on the engine. 99.5% of this dust are designed to minimize dust
will pass out through the engine entrance during filter changes. Some
exhaust. newer models use a PowerCore air
Dust particles 1 to 10 microns cleaner featuring a special nanofiber
(0.00004 to 0.0004 inch) in size has element design. These cleaners
a measurable effect on engine life. achieve the filtration goals with
Inlet air dust particles larger than lower restriction to air flow than
bearing oil film thicknesses will the dry paper element design.
seriously affect bearing and piston On most engine models, these
ring life. air cleaners are engine mounted,
Well designed air cleaners are the however, on some engines the air
most efficient way of assuring that cleaners are supplied loose for
only clean air enters the engine and remote mounting. See Remote
harmful particles are not distributed Mounted Air Cleaners later in this
through the engine systems. section. Refer to the engine price
lists for availability of air cleaner
The efficiency of dry-type filters
options on specific engine models.
is not affected by installation
Page 2 All rights reserved.
A dual element configuration

Heavy-Duty Air Cleaners differs from a double element
Heavy-duty air cleaners provide the configuration it that the two
same protection as standard filters elements are used in parallel.
but allow extension of filter change
Dual element air cleaners are also
periods. Depending on the engine
available with a precleaning stage.
air-flow rate and filter type, service
periods may be extended six to Exhaust Ejector
seven times that of standard air In extremely dusty environments
cleaners. where dust and other particles cause
Depending on specific design, dual air cleaners to plug up quickly, an
element air cleaners may also be improved precleaner has been
categorized as heavy duty air designed. It is an integral part of an
cleaners. exhaust aspirated air cleaner system
and will extend the service life of the
Precleaners air cleaner elements.
Precleaners are an available option
Using a louvered body design, the
on some Caterpillar engines, which,
precleaner has a very high separator
when added to the standard air
efficiency. It will separate and
cleaner, can extend filter service
remove over 90% of the dirt and
periods.
chaff from the incoming air stream.
The precleaner imparts a swirl
Example of Precleaner, Air Cleaner
to the air, centrifuging out a major
and Exhaust Ejector
percentage of the dirt particles which
may be collected in a reservoir or
exhausted out on either a continuous
or an intermittent basis.
A flow restriction of 0.25 to
1.5 kPa (1 to 6 in. H2O) is imposed
by the precleaner, but it can prolong
the life of the filter by three to seven
times. Any application in an
environment with heavy dust and
debris is recommended to use a
precleaner.
Dual Element Air Cleaners

Dual element air cleaners can be
used to provide additional protection
for the engine. This arrangement
uses two elements mounted in
series. The secondary filter remains
in place while the primary filter is
serviced. Figure 1
The air comes into the precleaner Remote Mounted Air Cleaners
where the dirt and chaff is removed Due to air flow requirements and
from the air. With a slight vacuum, size considerations, it is impractical
the dirt is sucked directly through to mount G3520C and 3600/G3600
the muffler into the exhaust flow air cleaners on the engine. They are
and does no harm to the engine. furnished as shipped loose items,
Refer to Figure 1. and must be remote mounted and
The remaining dust in the air is plumbed by the customer. The air
then removed by the air cleaner cleaner housings may be wall, floor,
before it enters the turbo. or roof mounted with the inlet facing
With this system, consideration downward, or they can be oriented
must be made regarding the location for horizontal entry, but modifications
of exit of the exhaust and the are required to support the elements.
surroundings, as there may be Two element (double) and three
particles in the engine exhaust. element (triple) air cleaner housings
are available. Unlike the dual
Oil-Bath Air Cleaners element arrangement, air flow
Oil-bath air cleaners, while through these elements is in parallel.
sometimes required to meet The double and triple air cleaner
customer specifications, are not housings have optional precleaners
recommended by Caterpillar. and soot filters, to extend element
At best their efficiency is 95% life in severe applications. Examples
as compared to 99.5% for dry-type of remote air cleaner housings are
filters. Their relative ease of service shown in Figure 2 and Figure 3.
and insensitivity to water are
advantages easily outweighed Double Element Housing
by disadvantages, such as:
• Lower efficiency
• Low ambient temperature
limits, low oil level, high
restriction at low air flow (such
as at low idle), and installed tilt
angle may lessen efficiency
further.
• Oil carry-over, which is the oil
becoming airborne in the air
intake system whether resulting
from overfilling or increased air Figure 2
flow, can seriously affect
turbocharger and engine life,
and may actually become an
engine fuel.
Double Element Housing with Customer Furnished Air

3 Precleaners Cleaners
Air Cleaner Efficiency
Customer furnished air cleaner
selection should be based upon the
following air cleaner efficiency test:
A satisfactory air cleaner must
meet the International Organization
of Standardization’s requirement of
the ISO 5011 dust test.
The filter should have 99.5%
minimum efficiency as calculated
following test code with additions
Figure 3 and exceptions as follows:
• Air flow corrected to m3/min at
99.9 kPa pressure and 32.2°C
For marine and offshore (ft3/min at 29.6 in. Hg pressure
applications, where remote mounted and 90°F).
air cleaners may be located in a salt
water environment, epoxy coated • Use sonic dust feeder.
housings are available. Refer to • Dust quantity determined by
Figure 4 and Figure 5 in the next light-duty class.
section for typical marine arrange- • Filter to be dried and weighed in
ments for remote mounted air an oven at 93°C to 107°C
cleaners. (200°F to 225°F) before and
Dirty or improper filters can restrict after test.
intake air flow. Differential pressure • Use AC fine dust.
readings should be used to signal
needed filter changes.
AC fine dust is defined as follows:
Caution: Under no circumstances
should the engine be operated Particle Size
% Total Weight
without air cleaners. (microns)
If the air cleaner enclosure(s) are 0–5 39 ± 2
outside in the weather, a protective 6 –10 18 ± 3
shield is recommended to prevent 11 – 20 16 ± 3
rain from being pulled into the 21 – 40 18 ± 3
cleaners/precleaners.
41 – 80 9± 3
99.5% filtration of the AC fine

dust has been determined to be a
practical combination of the kind of
dirt likely encountered in service, Where:

and will result in an air cleaner D = Specific dust consumption
efficiency expected to give in mg/hr/cylinder
optimum engine wear life.
V = Intake air flow in cu ft/min
Air Cleaner Design (cfm).
Requirements d= Dust concentration in mg/cu ft
Following the above procedure will (Estimated dust concentration
establish sufficient control on the for residential and offshore
filter media filtering ability of the applications is 0.001 to
tested air cleaner, but there are 0.002 in mg/cu ft. Estimate
other design variables needing industrial and inland waterway
further control. applications at 0.002 to
0.05 in mg/cu ft.)
• Choose filters supplied by
manufacturers that can best e= Average air cleaner efficiency
provide quality control. (always < 1.0) (estimated
efficiency of paper elements
• Design filters to be resistant
= 0.99, & estimated
to damage at initial assembly
efficiency of non-paper
or during cleaning. If end seal
elements = 0.95)
and filter media are subject
to damage, dust leakage into n= Number of engine cylinders
the engine can result. (6, 8, 12 or 16)
Air Cleaner Dust Calculation Example A
3600/G3600 engines must not A 3606 Engine operating at
ingest more than 34.5 900 rpm in an EPG application
mg/hr/cylinder of dust at rated with non-paper elements.
power to achieve acceptable engine V = 5554 CFM
life. Air cleaners offered by d= 0.02 mg/cu ft
Caterpillar are designed to this
requirement. Customer provided e= 0.95
air cleaners must also meet this n= 6
requirement or reduced engine life
will result. Specific dust consumption 5554 x 0.02 x (1 – 0.95) x 60
D=
for various engines, air cleaners, and 6
environments can be calculated
using the following formula. Example A equates to a dust
consumption of 55.54 mg/hr/
V x d x (1 - e) x 60 cylinder. Since the engine must
D= not ingest more than 34.5 mg/hr/
n
cylinder of dust for acceptable
engine life, this air cleaner system
is unacceptable.
Example B
Using the same engine but with
paper air cleaner elements that offer
approximately 0.99 efficiency
(e = 0.99).
5554 x 0.02 x (1 – 0.99) x 60

D=
6
Example B equates to a dust

consumption of 11.1 mg/hr/cylinder.
This air cleaner system will provide
acceptable engine life.
Combustion Air Flow Requirements

Combustion air flow requirements QR = Volumetric air flow at
will vary, depending on the specific reference conditions (m3/min),
engine model and rating. Specific air (cfm)
flow data for Caterpillar engines is SR = Density of air at reference
given in both volumetric [m3/min conditions (kg/m3), (lb/ft3).
(cfm)] and mass [kg/hr (lb/hr)] flow (Density of air = 1.292 kg/Nm3
terms, at standard reference (0.074 lb/ft3))
conditions.
Reference conditions for
To convert both mass airflow and
temperature and pressure are used
volumetric air flow from reference
to provide a basis for consistent
conditions to site conditions, use the
measure of combustion air
following formulas:
quantities. However, different parts
of the world subscribe to different TS
MR x = MS
standards, thus it is important to TR
note that the metric and English
conditions are not equivalent. TS
Caterpillar practice is to use ISO QR x = QS
TR
8528 “normal” conditions of 25°C
(77°F) and 101.3 kPaa (14.7 psia)
Where:
when providing values in metric
units, and ASME SAE J1349 MR = Mass flow at reference
“standard” conditions of 25°C conditions (kg/hr), (lb/hr).
(77°F) and 101.3 kPaa (14.7 psia) MS = Mass flow at site conditions
when providing values in English (kg/hr), (lb/hr).
units. QR = Air flow at reference
To convert from mass airflow to conditions (m3/min), (cfm).
volumetric airflow at reference QS = Air flow at site conditions
conditions, use the following (m3/min), (cfm).
formula:
TR = Air temperature at reference
MR conditions (°K), (°R).
= QR
SR
TS = Air temperature at site
conditions (°K), (°R).
Where:
°K = °C + 273.
MR = Mass air flow at reference
conditions (kg/hr), (lb/hr) °R = °F + 460.
Air Intake Ducting

To allow for minor misalignment
General due to manufacturing tolerances,
When ducting is necessary to engine-to-enclosure relative
obtain cooler or cleaner air, the movement and isolate vibrations,
filters should remain on the engine segments of the piping should
to prevent harmful dirt from leaking consist of flexible rubber fittings.
into the engine through ducting These are designed for use on diesel
joints. When air cleaners must be engine air intake systems and are
remote-mounted it is extremely commercially available. These
important that all joints be air tight fittings include hump hose
to prevent ingestion of dirt. connectors and reducers, rubber
When designing air intake ducting, elbows and a variety of special
consideration must be given to shapes.
appropriate routing, duct support Wire-reinforced flexible hose
and system restriction, especially on should not be used. Most material
the larger engines, where overhead available is susceptible to damage
cranes are used to service the from abrasion and abuse and is very
engines. Proper support for duct difficult to seal effectively at the
work adjacent to the engine is clamping points unless special ends
critical, so that its weight is not are provided on the hose.
borne by the turbocharger or other
Inlet ducting should be designed to
engine-mounted components.
withstand a minimum vacuum of
Locate the air piping away from 12.5 kPa, (50 in. H2O), which is also
the vicinity of the exhaust piping so the structural capability of the
that the air provided to the engine is Caterpillar air cleaner filter element.
as cool as possible. Air temperature
Piping diameter should be equal to
to the air inlet should be no more
or larger than the air cleaner
than 11°C (20°F) above ambient air
inlet/outlet and the engine air inlet.
temperature. Inlet air temperature
A rough guide for pipe size selection
should not exceed 45°C (113°F)
is to keep maximum air velocity in
for standard ratings.
the piping to 10 m/s (2,000 fpm).
Avoid abrupt transitions in the Higher velocities will cause high
intake ducting to provide the noise levels and excessive flow
smoothest possible air flow path. restrictions. Refer to the Air Intake
When unavoidable, transitions Restriction section for guidance in
should be made as far upstream of determining required intake duct
the turbocharger as possible. Keep sizing.
total duct head loss (restriction)
All piping must be designed and
below 0.5 kPa (2 in. H2O) for
supported to meet any local seismic
maximum filter life. Any additional
requirements that may be in force.
restriction will reduce filter life.
The ducting should be of seamless PVC pipe, use at least schedule

or welded seam piping to minimize 40 pipe and check that it meets
the flow restriction. The ducting local regulations for the area
should also be constructed of classification.
materials suitable for local If ferrous material is necessary,
environmental conditions such as it must be properly cleaned after
offshore or marine applications. fabrication and treated to prevent
Beaded pipe ends at hose joints are rust and scale from accumulating.
recommended. Sealing surfaces Stainless steel ducting should be
should be round, smooth and free of treated in the same manner. Flanged
burrs or sharp edges that can cut connections with gaskets are
the hose. The tubing should have preferred over threaded connections.
sufficient strength to withstand hose Fasteners such as rivets should not
clamping forces. Either T-bolt type be used.
or SAE type F hose clamps that Unsupported weight on clamp-type
provide a 360° seal should be used. joints should not exceed 1.3 kg
High quality clamps must be used. (3 lb).
Double clamps are recommended on
connections downstream of the air Marine Intake Air Piping
cleaner. Examples
PVC piping has a number of Figure 4 shows a 3600 marine
benefits. It is light-weight, provides application configured to use a
a good seal without the chance of remote mounted air cleaner and
weld slag coming loose and will not outside air for combustion. An intake
rust. However, it is not well suited air heater may be required for cold
for high or low temperature weather operation.
environments. It can lose much of Figure 5 shows a 3600 marine
its strength when subjected to application configured to use a
temperatures of 150C (300F) or remote mounted air cleaner and
above. It can also become brittle and engine room air for combustion.
shatter at low temperatures. If using
Remote Mounted Air Cleaner with Outside Air Intake
Figure 4
Remote Mounted Air Cleaner with Engine Room Air Intake
Figure 5
shipped loose and include gaskets

Air Inlet Adapters
and mounting hardware.
Caterpillar offers various air inlet
adapters for connecting to CAUTION: Turbocharger
turbocharger air inlets. The adapters performance may be adversely
are part of the system to provide an affected if appropriate air intake
efficient transition from the engine components are not used (they are
room intake air ducting to the engine designed to provide the proper air
turbocharger. Adapters are typically
flow pattern ahead of the section of pipe should consider the

turbocharger). following guidelines:
Connections to Inlet Adapters and • The duct between the straight
Turbochargers pipe and elbow cannot have
The piping connected to the protruding edges.
turbocharger inlet should be • The bend can be designed as a
designed to ensure that air is flowing circular arc or with sections of
in a straight, uniform direction into mitered pipe with rectangular or
the turbocharger compressor. This round flow cross sections, or as
is typically achieved by installing a transition from round to
straight section of pipe, equal in rectangular cross section.
length to at least two or three times
• An accelerated flow is
pipe diameter, to the inlet. This
expected to occur in the bend.
arrangement reduces the possibility
The flow area (F) should be:
of premature compressor wheel
F1 > 1.5 x F2, as shown in
failure due to pulsations created by
Figure 6.
air striking the compressor wheel at
an angle. Transitional ducting
immediately preceding the straight
Turbocharger Vertical Inlet Design Options
Figure 6
Inlet Pipe Design Joining Two Turbochargers
Figure 7
Joining Two Turbochargers selected, the steadying zone must

When ductwork feeding two be provided.
turbochargers is combined to form The transitions used to combine
a single duct, a steadying zone must multiple ducts must also follow
be provided after the dividing joint; typical design standards described
as shown in Figure 7. The steadying in this guide. Ducts should have
zone B must be a minimum of smooth transitions and not cause
5 times the pipe diameter: disturbance in the air flow. Piping
B > 5 x Dh1 designs that use a Tee, as shown
in Figure 8, should not be used to
connect multiple ducts.
The flow area is:
F0 = 1.0 ÷ 2.0 x F1
The transitions from Sections 0-0

to 1-1 and from 1-1 to 2-2 will have
many circular or rectangular
variations due to turbocharger
hardware and installation site
design. Regardless of the transition Figure 8
Turbocharger Loading The maximum allowable

When remote-mounted air cleaners turbocharger load will vary,
are used, turbocharger loading from depending on the engine model,
the weight of the air inlet the inlet adapter and the adapter
components becomes a concern. orientation. In the example below,
The turbochargers are not designed Figure 10, the 90° inlet adapter can
to support any additional weight be rotated in 30° increments.
beyond standard factory Turbochargers for 3600/G3600
attachments. When possible, make engines are designed to withstand
the flexible connection directly to a maximum moment of 294 N•m
the turbocharger air inlet, as shown (217 ft-lb). Figure 10 shows how
in Figure 9. All duct work to that the moment can be calculated.
point must be supported off-engine. Models that provide a mounting
bracket for the turbocharger inlet
adapter, such as the C15, can
support up to 11.3 kg (25 lb) of
duct weight.
Figure 9
Maximum Loads for Turbocharger Intake
Figure 10
Flex Connections Cleanliness During Installation

Flexible connections are required to The air intake ducting must be
isolate engine vibration and noise from cleaned of all debris. Fabricated
the ducting system. The connections ducting, utilizing fasteners such
should be configured for maximum as rivets, should not be used. The
allowable offset and compression to ducting should be made of material
prevent early failure and excess forces such that prolonged operation will
on the turbocharger and air inlet not result in debris coming loose
components. The flexible connection and entering the turbocharger.
should be as close to the engine as
practical and installed in such a way An identifiable blanking plate
to not induce stress on the ducting should be installed ahead of the
system. The flex engagement with the turbocharger to prevent debris from
air intake duct should be a minimum entering during initial installation of
of 50 mm (2 in.) and a maximum of the unit. The plate should have a
200 mm (8 in.). Care must be used to warning tag indicating it has to be
prevent exhaust piping heat from removed prior to starting the engine.
deteriorating rubber flex connections. The Caterpillar supplied shipping
cover can be used for this purpose.
Provisions should be made to turbocharger compressor inlet and

inspect the ducting for cleanliness atmosphere.
just prior to initial start up. If the Inlet air restriction includes the
piping is not clean, it must be pressure losses between the air
cleaned before the engine is started cleaner and the engine air inlet
at commissioning. This may require connection. For remote mounted air
removal of the piping from its cleaners, the following formulas can
installed position. be used to calculate duct restriction.
Inlet Air Duct Insulation
Insulation may be needed on the L x S x Q2 x 3.6 x 106
P(kPa) =
intake ducting for remote mounted D5
air cleaners. Insulation reduces
turbocharger noise emitted into L x S x Q2
the engine room and will minimize P(in. H20) =
187 x D5
pre-heating of intake air.
Where:
Air Intake Restriction P = Restriction (kPa), (in. H2O)
Excessive vacuum on the inlet side
of the turbocharger (or the air inlet psi = 0.0361 x in. water column
on naturally aspirated engines) can kPa = 6.3246 x mm water column
result in reduced engine power L= Total equivalent length of
capability and degrade engine pipe, measured in (m), (ft)
performance.
Q= Inlet air flow, measured in
Air intake restriction is also an (m3/min), (cfm). - (found in
emissions critical parameter declared TMI or performance book,
to obtain EPA non-road certification. and corrected for site
Therefore, the air intake system’s conditions when necessary)
total restriction (including dirty filters,
D= Inside diameter of pipe,
duct work, vents, silencers, etc.) is
measured in (mm), (inches)
limited depending on engine model,
rating and air configuration. The air If the duct is rectangular, as
intake restriction limits for Caterpillar shown in Figure 11:
engines can be found in the Technical Then:
Information Appendix or TMI. 2xaxb
D=
In order to maximize air filter life, it a+b
is important to keep total duct
restriction below 0.5 kPa (2 in. H2O).
Every additional restriction caused by
the air inlet system subtracts from air
filter life. Maximum filter life is
partially dependent on the absolute Figure 11
pressure differential between the
S= Density of air kg/m3 (lb/ft3) (6 in) and the temperature of the

352.5 air is 55°C (131°F).
S(kg/m3) =
Air Temperature + 273°C First calculate the total equivalent
length of the ducting.
39.6
S(lb/ft3) = 3 + 2 x (33 x 152.4) 20 x 152.4
Air Temperature + 460°F L= +
1000 mm 1000 mm
Use the following formulas to L = 16.1 m
obtain equivalent lengths of straight
pipe for various elbows.
10 + 2 x (33 x 6) 20 x 6
Standard Elbow 33D L= +
L= 12 in. 12 in.
(radius = diameter) X
L = 53 ft
Long Radius Elbow 20D
L=
(radius = 1.5 diameter) X
Next, calculate the density of
the air.
45° Elbow 15D
(radius = 1.5 diameter) L= 352.5
X S=
55 + 273°C
S = 1.075 kg/m3
Square Elbow 66D
(radius = 1.5 diameter) L=
X
39.6
S=
131 + 460°F
Where:
S = 0.067 lb/ft3
x= 1000 mm (12 in.)
As shown above, if 90° bends are
Lastly, insert the previous results
required, long radius elbows, with
into the duct restriction formula and
a radius of 1.5 times the pipe
calculate.
diameter, offer lower resistance
than standard elbows. 16.1 x 1.075 x 36.72 x 3598805.2
P=
1525
Example P = 1.02 kPa or 104 mm H2O
Below is an example of an air
intake duct restriction calculation.
53 x 0.067 x 12922
A 3412 packaged genset has an P=
5184 x 65
inlet air flow of 36.7 m3/min
P = 0.147 psi or 4.07 in H2O
(1292 cfm) with duct configuration
consisting of 3 m (10 ft) of straight Total duct restriction should be
length duct along with 2 standard below 0.5 kPa (2 in. H2O). The duct
elbows and a long radius elbow. The restriction in this example is above
pipe has a diameter of 152.4 mm the desired value, and therefore this
duct configuration is unacceptable.
Additional Considerations
the other end to a straight length
Service Indicators of pipe immediately upstream of
Vacuum sensing devices designed the turbocharger.
to indicate the need for air cleaner
servicing are commercially available Intake Air Silencers
and when added to the air intake A Caterpillar air intake
system, serve a vital function. There filter/silencer is available for use
are two types of sensing devices, with 3600 diesel engines. It cannot
both recommended for use. be used with G3600 gas engines
Service indicators are installed due to turbocharger orientation.
directly into the intake air ducting
and sense the pressure differential
between the air in the intake ducting
and the air outside the ducting.
It must be noted that in
installations using outside air for
combustion, engine room pressure
and outside, or atmospheric,
pressure is not always the same.
The indicator must be installed so
that it senses the air in the intake
duct on one side and the air from
where it was drawn on the other.
Figure 12
Trip Lock Device
The trip lock device indicates that The filter/silencer provides good air
the air cleaner condition is either filtration, but it should only be used
satisfactory or in need of service. in a clean engine room environment
When in need of service, it typically (filtered air). The customer is
will have a red display. This type of responsible for ensuring the engine
mechanism uses a spring-loaded room air is suitably filtered.
diaphragm to measure the pressure
differential between the clean and Unless specifically designed for
dirty side of the air cleaner. The trip such a purpose, intake air silencers
or latching type is preferred and should be remote mounted from the
available on most engine price lists. turbocharger inlet as shown in
Figure 12.
Differential Pressure Gauge
The direct reading differential Air Inlet Shut Off
gauge indicates the actual pressure Air inlet shut-off is a feature
differential across the intake air specific to the diesel engine air
filter. One end of the gauge is intake system. It provides a positive
connected to the air inlet duct and means of stopping the combustion
process in the event of an to provide a cap or inlet hood which

emergency shutdown by stopping incorporates a course screen to keep
the flow of combustion air. This is out large objects. This cap should be
not recommended for gas engines, designed to keep air flow restriction
as they have the ability to positively to a minimum. Some users have
stop the combustion process by designed a front air intake which
controlling the source of ignition. provides a direct air inlet and an
The air inlet shut-off feature is internal means of achieving water
standard on 3600 diesel engines and separation.
available on many other Caterpillar Precleaners and prescreeners
diesel engines. It is normally used incorporated into the intake cap
when an engine will be operating design are also available. They can
in a potentially combustible be used where special conditions
environment. This feature can be prevail or to increase the air cleaner
actuated manually or electronically, service life. These devices can
but is for emergency use in case of remove 70% to 80% of airborne
engine overspeed only, not for dirt.
normal engine shutdown.
Breakaway Joints
Air Manifold Drain Valve A breakaway joint may be used on
An air manifold drain valve is a cab or hood to tilt away from the
available for the 3600 diesel engine engine compartment for accessibility
family, consisting of an automatic and servicing of the engine. Half of
float valve that drains the the rubber seal flange remains on
condensate from the engine air the engine air intake and the other
manifold. The C175 offers a manual half is secured to the enclosure or
ball type air manifold drain valve as hood.
an option. Otherwise, draining must If carefully designed and used only
be facilitated by removing the upstream of the air cleaner,
standard plugs from the aftercooler breakaway joints may be used.
outlet lines.This feature is
Note: Never use breakaway joints
recommended for use in applications
between the air cleaner and engine.
where high humidity is expected and
the possibility exists for the air inlet When breakaway joints are
manifold temperature to drop below required, chose a joint designed
the atmospheric dew point. Refer for lifetime sealing under the most
to Caterpillar Service Publication severe conditions and needing
SEBD9317 and SEBU8100 for more limited or no maintenance.
information on this subject.
Cold Conditions
Shielding Air Cleaner Icing
The air inlet should be shielded Air cleaner icing can occur in
against direct entrance of rain or saturated air environments when the
snow. The most common practice is dew point of the ambient air is near
freezing. Small disturbances to the drawn from outside the engine

air such as velocity and pressure building, and the engine is
changes at the air cleaner inlet preconditioned with pre-heaters for
reduce the moisture-holding capacity metal, water and oil temperatures of
of the air. This results in moisture 0°C (32°F). Admitting engine room
condensation and ice crystal air must be done without the
formation. The ice buildup reduces possibility of allowing dirt or debris
the airflow area and increases the into the air inlet system of the
pressure differential across the air engine.
cleaner. Eventually, a plateau is
Considerations for Low Pressure Gas
reached where the pressure Take special care when designing
differential remains constant even the air intake system for low-
though ice buildup may continue. pressure gas engines that do not
Power loss and increased fuel have air-fuel ratio control.
consumption will result during these
periods. Carburetors used in Caterpillar gas
engines meter fuel into incoming air
Several techniques may be used on a volume-for-volume basis. If the
to overcome air cleaner icing. One density of either the air or the gas
solution is to heat the intake air changes relative to the other, the air-
slightly. It is not necessary to heat fuel ratio of the engine will change,
the air above freezing. The air affecting emission levels and the
requires only enough heat to be detonation margin.
above the dew point. Heat can be
supplied to the air cleaner housing For example, if a G3516 Low
by ducting engine room air. Heated Emissions engine with an 11:1
air from the exhaust piping or compression ratio and 32°C (90°F)
muffler, or electrical heating tape A/C is adjusted to produce 2 g NOx
may also be used. at full load, the percent of O2 in the
exhaust must be set to 8%, which
Boost Control results in an air-fuel ratio of 14.75
A boost control valve is available on a volume-for-volume basis.
for the 3600 diesel engine family
If the engine is adjusted when the
for use in extremely cold ambient
incoming air is 10°C (50°F) and the
conditions, 0°C (32°F). The valve is
incoming gas is 21°C (70°F), then:
used to limit the air inlet manifold
pressure during low air temperature ∆T1 = 10°C - 21°C = -11°C
conditions to maintain acceptable (∆T1 = 50°F - 70°F = -20°F)
cylinder pressure. If the air temperature is later
Extreme Cold increased to 32°C (90°F) and the
Heated engine room air may be gas temperature remained constant,
required (for starting purposes only) then:
in applications at very cold ambient ∆T2 = 32°C - 21°C = 11°C
temperatures, -25°C (-13°F). This (∆T2 = 90°F - 70°F = 20°F)
assumes combustion air is being
The Variation in Air Temperature High pressure gas engines are not
(VAT) would then become: affected by these changes to the
V∆T = |-11°C - 11°C)| = 22°C same extent as low pressure gas
(V∆T = |-20°F - 20°F| = 40°F) engines. This is because the supply
gas temperature remains relatively
constant at most installations and
The density of the air would then the thermostatically controlled
decrease, resulting in a lower air-fuel aftercooler maintains a fairly
ratio of 13.67. The lower air-fuel constant air temperature to the
ratio would result in reducing the carburetor. Since these two
percent O2 in the exhaust to 6.5%. temperatures are not subject to
The graph in Figure 13 shows how large changes, the air-fuel ratio
NOx changes as a function of remains relatively constant.
percent O2 in the exhaust. The
There are two primary methods of
increased air temperature in our
controlling VAT, controlling the air
example would increase the NOx
temperature and using a gas-to-air
emissions to 8.8 g NOx /bhp-hr,
heat exchanger.
which is an increase of 440%.
Controlling Air Temperature
To maintain a 2.0 g NOx /bhp-hr
One method of controlling air
level, VAT must not exceed 5.5°C
supply temperature is to regulate the
(10°F).
engine room temperature. However,
this approach is not recommended.
It is difficult to regulate an engine
room to a temperature that is both
comfortable to work in and high
enough to provide a constant air
temperature to the engine. For
example, an installation expecting a
32°C (90°F) ambient temperature,
will need to regulate the engine
room to about 38°C (100°F) at all
times. Also, engine rooms having
large service doors that, at times,
must be left open while the engines
are running, will not maintain the air-
fuel ratio while the doors are open.
The preferred method is to use
duct work to supply a temperature
Figure 13 regulated air supply to the engine.
See Figure 14. This system uses
jacket water to heat the air to the
temperature set by the thermostat.
Ducting with Temperature Regulator
Figure 14
If one intake system is used to before entering the gas regulator.

supply temperature controlled air to The pressure drop across the heat
multiple engines, provisions must be exchanger at full load must be added
made to ensure that heated water is to the minimum gas supply pressure
sent to the heat exchanger when required by the engine. Design the
engines are running. If engine jacket heat exchanger to minimize both gas
water is used, the engine that the and air flow pressure drop while still
water is taken from must be running providing enough heat transfer so
when any of the other engines are that VAT stays within the given
operating. limits.
Gas-to-Air Heat Exchanger
If the use of duct work is not
practical for a given installation,
another option is to install a gas-to-
air heat exchanger, shown in
Figure 15. If done correctly, this
system will prevent temperature
changes in the gas or the air from
affecting the air-fuel ratio.
Design the system so the gas
flows through the heat exchanger Figure 15
Reference Material
The following information is
provided as an additional reference
to subjects discussed in this guide.
SEBD9317
Engine News 2003/01/01.
SEBU8100
C175 Series Generator Sets
LEBW4969-02 ©2008 Caterpillar Printed in U.S.A.
All rights reserved.

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APPLICATION AND INSTALLATION GUIDE

AIR INTAKE SYSTEMS

Air Intake Systems

CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow” and the

Air Intake Systems

Air Cleaners........................ 2 • Connections

A dual element configuration

Dual Element Air Cleaners

Double Element Housing with Customer Furnished Air

99.5% filtration of the AC fine

dirt likely encountered in service, Where:

5554 x 0.02 x (1 – 0.99) x 60

Example B equates to a dust

Combustion Air Flow Requirements

Air Intake Ducting

The ducting should be of seamless PVC pipe, use at least schedule

Remote Mounted Air Cleaner with Outside Air Intake

Remote Mounted Air Cleaner with Engine Room Air Intake

shipped loose and include gaskets

flow pattern ahead of the section of pipe should consider the

Turbocharger Vertical Inlet Design Options

Inlet Pipe Design Joining Two Turbochargers

Joining Two Turbochargers selected, the steadying zone must

The transitions from Sections 0-0

Turbocharger Loading The maximum allowable

Maximum Loads for Turbocharger Intake

Flex Connections Cleanliness During Installation

Provisions should be made to turbocharger compressor inlet and

S= Density of air kg/m3 (lb/ft3) (6 in) and the temperature of the

process in the event of an to provide a cap or inlet hood which

freezing. Small disturbances to the drawn from outside the engine

Ducting with Temperature Regulator

If one intake system is used to before entering the gas regulator.

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