6/11/2016

3412GeneratorSet4BZ00001UP(SEBP278548)Documentation

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Welcome:apache03
Product:GENERATORSET
Model:3412CGENERATORSET4BZ
Configuration:3412GeneratorSet4BZ00001UP

SystemsOperation
3412GeneratorSetEngines
MediaNumberRENR138806

PublicationDate01/08/2015

DateUpdated26/08/2015
i02493521

AirInletandExhaustSystem
SMCS1050

TwinTurbochargerArrangement

Illustration1

g01246591

Airinletsystemandexhaustsystem
(1)Exhaustmanifold
(2)Aftercooler
(3)Enginecylinder
(4)Airinlet
(5)Turbochargercompressorwheel
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(6)Turbochargerturbinewheel
(7)Exhaustoutlet

Theenginecomponentsoftheairinletsystemandexhaustsystemcontrolthequalityofairthatisavailablefor
combustion.Thesecomponentsalsocontroltheamountofairthatisavailableforcombustion.Anaircleaner,a
turbochargerandanexhaustmanifoldareoneachsideoftheengine.Acommonaftercoolerislocatedbetween
thecylinderheadsandtowardtherearoftheengine.Theinletmanifoldisaseriesofpassagesinsidethe
cylinderblock.Thesepassagesconnecttheaftercoolertotheinletportsinthecylinderheads.Asinglecamshaft
islocatedinthecylinderblock.Thecamshaftcontrolsthemovementofthevalvesystemcomponents.
Bothsidesoftheenginehavethesameairflow.Turbochargercompressorwheel(5)pullsinletairthroughthe
aircleanerandintoairinlet(4).Theairiscompressedandheatedbeforetheairisforcedtotheaftercooler(2).
Theaftercooler(2)lowersthetemperatureofthecompressedair.Thecooledcompressedairpassesthroughthe
inletmanifold.Theairfillstheinletportsinthecylinderheads.Airflowfromtheinletportintothecylinderis
controlledbytheinletvalves.Thecombustionefficiencyincreasesbecauseofthecoolerinletair.Thishelpsto
provideloweredfuelconsumptionandincreasedhorsepoweroutput.
Eachcylinderhastwoinletvalvesandtwoexhaustvalvesinthecylinderhead.Theinletvalvesopenwhenthe
pistonmovesdownwardontheinletstroke.Whentheinletvalvesopen,cooledcompressedairfromtheinlet
chamberwithintheinletmanifoldispulledintothecylinder.Thepistonbeginstomoveuponthecompression
strokewhentheinletvalvesclose.Theairinthecylinderiscompressedandthefuelisinjectedintothecylinder
whenthepistonisnearthetopofthecompressionstroke.Combustionbeginswhenthefuelmixeswiththeair.
Theforceofcombustionpushesthepistondownwardonthepowerstroke.Theexhaustvalvesopenandthe
exhaustgasesarepushedthroughtheexhaustportintoexhaustmanifold(1).Afterthepistonmakestheexhaust
stroke,theexhaustvalvescloseandthecyclebeginsagain.
Exhaustgasesfromtheexhaustmanifold(1)flowintotheturbinesideoftheturbocharger.Thiscauses
turbochargerturbinewheel(6)toturn.Theturbinewheelisconnectedtotheshaftthatdrivesthecompressor
wheel.Exhaustgasesfromtheturbochargerpassthroughtheexhaustoutlet(7).

SeriesTurbochargerArrangement

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Illustration2

g01246597

Airinletsystemandexhaustsystem
(1)Exhaustmanifold
(2)Aftercooler
(3)Highpressureturbochargerairinlet
(4)Highpressureturbochargercompressorwheel
(5)Highpressureturbochargerturbinewheel
(6)Highpressureturbochargerexhaustoutlet
(7)Lowpressureturbochargerairinlet
(8)Lowpressureturbochargercompressorwheel
(9)Lowpressureturbochargerturbinewheel
(10)Lowpressureturbochargerexhaustoutlet

Theenginecomponentsoftheairinletandexhaustsystemcontrolthequalityofairandtheamountofairthatis
availableforcombustion.Thereisanaircleaner,twoturbochargerandanexhaustmanifoldoneachsideofthe
engine.Acommonaftercoolerislocatedbetweenthecylinderheadsandtowardtherearoftheengine.Theinlet
manifoldisaseriesofpassagesinsidethecylinderblock.Thesepassagesconnecttheaftercoolertotheinlet
portsinthecylinderheads.Asinglecamshaftislocatedinthecylinderblock.Thecamshaftcontrolsthe
movementofthevalvesystemcomponents.
Bothsidesoftheenginehavethesameairflow.Airispulledthroughthelowpressureturbochargerairinlet(7).
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Theairiscompressedandheatedbythecompressorwheel(8)ofthelowpressureturbocharger.Thecompressed
airisthendirectedthroughpipeassembly.Theairflowstothehighpressureturbochargerairinlet(3)ofthe
highpressureturbocharger.Thehighpressureturbochargercompressorwheel(4)continuestocompresstheair.
Theairisforcedintotheaftercooler(2).Theaftercooler(2)lowersthetemperatureofthecompressedair.The
cooledcompressedairpassesthroughtheinletmanifold.Theairfillstheinletportsinthecylinderheads.Air
flowfromtheinletportintothecylinderiscontrolledbytheinletvalves.Thecombustionefficiencyincreases
becauseofthecoolerinletair.Thishelpstoprovideloweredfuelconsumptionandincreasedhorsepoweroutput.
Eachcylinderhastwoinletvalvesandtwoexhaustvalvesinthecylinderhead.Theinletvalvesopenwhenthe
pistonmovesdownwardontheinletstroke.Whentheinletvalvesopen,cooledcompressedairfromtheinlet
chamberwithintheinletmanifoldispulledintothecylinder.Thepistonbeginstomoveuponthecompression
strokewhentheinletvalvesclose.Theairinthecylinderiscompressedandthefuelisinjectedintothecylinder
whenthepistonisnearthetopofthecompressionstroke.Combustionbeginswhenthefuelmixeswiththeair.
Theforceofcombustionpushesthepistondownwardonthepowerstroke.Theexhaustvalvesopenandthe
exhaustgasesarepushedthroughtheexhaustportintoexhaustmanifold(1).Afterthepistonmakestheexhaust
stroke,theexhaustvalvescloseandthecyclebeginsagain.
Exhaustgasesfromtheexhaustmanifold(1)flowintotheturbinesideofthehighpressureturbocharger.This
causesturbochargerturbinewheel(5)toturn.Thecompressedgasesfromthehighpressureturbochargerenter
theturbinesideofthelowpressureturbochargerturbinewheel(9).Theturbinewheelsareconnectedtothe
shaftsthatdrivethecompressorwheels.Exhaustgasesfromthelowpressureturbochargerpassthroughthelow
pressureturbochargerexhaustoutlet(10).

Aftercooler

Illustration3

g01246603

Aftercooler
(1)Aftercooler
(2)Pipe

Theaftercooler(1)coolstheairthatcomesfromtheturbochargers.Theairthenflowsintotheinletmanifold.
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Theaftercoolerislocatedtowardtherearoftheenginebetweenthecylinderheads.Coolantfromthewater
pumpflowsintotheaftercoolerandthroughthecoreassembly.Thecoolantflowsoutoftheaftercoolerthrough
adifferentpipe.Thecoolantthenflowsintotherearofthecylinderblock.
Theinletairfromthecompressorsideoftheturbochargersflowsintotheaftercoolerthroughapipe(2)oneach
sideoftheaftercoolerhousing.Thislowersthetemperatureoftheairtoapproximately93C(200F).The
coolerairflowsoutofthebottomoftheaftercoolerandintotheinletmanifold.Thedenseairgoesintothe
combustionchambers.Thishelpstoprovideloweredfuelconsumptionandincreasedhorsepoweroutput.

Turbocharger

Illustration4

g01246605

Turbocharger
(1)Lowpressureturbocharger
(2)Highpressureturbocharger
(3)Exhaustpipe

Therearetwoturbochargers(1)and(2)thatareinstalledoneachsideoftheengine.Thefirstturbocharger(high
pressure),oneachside,isconnectedtotheexhaustmanifold.Exhaustgasesfromtheturbinesideofthefirst
turbochargerareroutedtotheturbinesideofthesecondturbocharger(lowpressure).Theexhaustflowsthrough
theexhaustpipe(3).Thecompressorsideofthefirstturbochargerisconnectedtothecompressorsideofthe
secondturbochargerbypipeassembly.Thecompressedairisthenforcedintotheaftercoolerhousing.

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Illustration5

3412GeneratorSet4BZ00001UP(SEBP278548)Documentation

g01246608

Turbocharger
(4)Exhaustinlet
(5)Bearing
(6)Lubricationpassage
(7)Bearing
(8)Oiloutletport
(9)Airoutlet
(10)Spacer
(11)Airinlet
(12)Compressorwheel
(13)Compressorhousing
(14)Oilinletport
(15)Thrustcollar
(16)Thrustbearing
(17)Turbinehousing
(18)Turbinewheel

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(19)Exhaustoutlet

Theexhaustgasesgothroughthebladesoftheturbinewheel(18).Thiscausestheturbinewheelandthe
compressorwheel(12)toturn.Theactionofthecompressorwheelbladescausesacompressionoftheinletair.
Whentheloadontheengineincreasesorwhenagreaterenginespeedisdesired,additionalfuelisinjectedinto
thecylinders.Thiscreatesmoreexhaustgases,whichcausestheturbinewheelandthecompressorwheeltoturn
faster.Additionalairisforcedintotheengineasthecompressorwheelturnsfaster.Theincreasedflowofair
providesmorepowertotheengine.Theenginegetsmorepowerbecausetheengineisabletoburnadditional
fuelwithgreaterefficiency.
Themaximumrpmoftheturbochargeriscontrolledbytheelectronicfuelsystemcircuit.Theprogrammingof
theavailablefuelamountisdoneinthepersonalitymodule.Thisisdoneatthefactoryforaspecificengine
application.

NOTICE
Ifthehighidlerpmortheengineratingishigherthangiveninthe
TechnicalMarketingInformation(TMI)fortheheightabovesealevel
atwhichtheengineisoperated,therecanbedamagetoengineorto
turbochargerparts.Damagewillresultwhenincreasedheatand/or
frictionduetothehigherengineoutputgoesbeyondtheenginecooling
andlubricationsystem'sabilities.

Thebearings(5)and(7)intheturbochargeruseengineoilthatisunderpressureforlubrication.Thelubrication
oilforthebearingsflowsthroughanoilinletport(14)andintothelubricationpassage(6)inthecentersection
forlubricationofthebearings.Theoilexitstheturbochargerthroughanoiloutletport(8)inthebottomofthe
centersection.Thisoilthenreturnstotheenginelubricationsystem.
Thefuelrackadjustmentisdoneatthefactoryforaspecificengineapplication.Thegovernorhousingissealed.
Thefollowingchangesareprevented:
changesintheadjustmentoftheracksetting
changesinthehighidlespeedsetting

ValveSystemComponents
Thevalvesystemcomponentscontroltheflowofinletairintothecylindersduringengineoperation.Thevalve
systemcomponentscontroltheflowofexhaustgasesoutofthecylindersduringengineoperation.
Thecrankshaftgeardrivesthecamshaftgear.Thecamshaftgearisintimewiththecrankshaftgear.Thetiming
providesthecorrectrelationshipbetweenthepistonandthevalvemovement.
Thecamshafthastwolobesforeachcylinder.Onelobecontrolstheexhaustvalves.Theotherlobecontrolsthe
inletvalves.

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Illustration6

3412GeneratorSet4BZ00001UP(SEBP278548)Documentation

g01246609

Valvesystemcomponents
(1)Inletvalvebridge
(2)Rockerarm
(3)Pushrod
(4)Rotocoil
(5)Valvespring
(6)Valveguide
(7)Inletvalve
(8)Lifter
(9)Camshaft

Thecamshaft(9)turnsandthelifter(8)movesupanddown.Thismovementmakesthepushrod(3)movethe
rockerarm(2)upanddown.Therockerarmmovestheinletvalvebridge(1)andtheexhaustbridge(11)upand
down.Thebridgeisattachedtothecylinderheadbyadowel.Thebridgeallowsonerockerarmtoeitheropen
orclosetwovalvesatthesametime.Therearetwoinletvalvesandtwoexhaustvalvesforeachcylinder.
Rotocoil(4)causesthevalvetoturnwhiletheengineisrunning.Valverotationprovidesalongerservicelife.
Valverotationalsominimizescarbondepositsonthevalve.
Thevalvespring(5)causesthevalvetoclosewhentheliftermovesdown.

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Illustration7

3412GeneratorSet4BZ00001UP(SEBP278548)Documentation

g00332964

Valvesystemcomponents
(1)Inletvalvebridge
(2)Inletrockerarm
(7)Inletvalves
(10)Exhaustrockerarm
(11)Exhaustbridge
(12)Exhaustvalves
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