008-999 Cooling System - Overview

General Information

The primary function of

the cooling system is to
remove heat energy,
created by the
combustion process,
from the engine. The
excess heat energy that
is not removed by the
cooling system is
carried away by exhaust
gases and radiation into
the atmosphere.

The accompanying
chart illustrates the
Conventional
Aftercooling coolant
flow through the
engine.

For more details,

refer to the coolant
flowcharts in
Procedure Refer to
Procedure 200-003.

A. Pump
B. Engine cylinder
head
C. Thermostat
housing
D. Radiator
E. Oil cooler
F. Aftercooler.
 The accompanying
chart illustrates the
Low Temperature
Aftercooling coolant
flow through the
engine.

For more details,

refer to the coolant
flowcharts in
Procedure Refer to
Procedure 200-003.

A. Water pump
B. Base engine
C. Engine
thermostat
D. Engine radiator
E. Low
temperature
aftercooling
thermostat
F. Low
temperature
aftercooling
radiator
G. Aftercooler.

The Cummins Inc. K19 engine requires a minimum pressure cap rating of 48 kPa [7 psi].
This provides a positive head pressure at the water pump inlet.

The Water Pump is a centrifugal type pump. It can have either the cast iron, or the
phenolic resin impeller. The cast iron impeller has been the standard for production
beginning August, 2001.

On aftercooled engines, the water pump impeller maintains 172 kPa [25 psi] block
pressure. At 2100 rpm, the water flow is 830 liters per minute [220 U.S. gallons per
minute]. The block pressure is measured at the number six rocker lever housing.

On non-aftercooled engines, the water pump impeller maintains 241 kPa [35 psi] block
pressure. At 2100 rpm, the water flow is 757 liters per minute [220 U.S. gallons per
minute]. The block pressure is measured at the number six rocker lever housing.

The water pump is gear driven by a splined drive shaft. The shaft connects the pump to
the water pump drive. Drive shafts are available in two sizes. One is a 11/16-inch
diameter shaft for use with a water pump containing a phenolic impeller. The second is a
3/8-inch diameter for the use with a water pump containing a cast iron impeller.

CAUTION

The use of the wrong drive shaft can result in failure of the splines or the impellers.
The water pump contains two antifriction bearings that are ball type. The bearings are
lubricated with pressurized oil supplied from the engine.

The water pump contains an oil seal and a water seal. The cavity between these seals is
vented. The vent prevents contamination of the lubricating or coolant in case of a seal
leak. Oil and coolant seeping from the vent will not harm the operation. Check the vent
for any obstruction at each scheduled maintenance interval.

CAUTION

DO not touch the sealing surfaces of the seal and seat. The oil from your fingers can
cause the seal to fail. If necessary, clean the sealing surfaces with a solvent that does
not have an oil base.

The water pump contains a one-piece or unitized water seal. The seal and the seat are
fastened together. This helps prevent failures caused from dirt or oil contacting the seal
faces during installation.

CAUTION

The water pump seal must be installed to the correct dimension from the water pump
body. Correct installation will result in proper spring tension. Incorrect spring tension
will cause the seal to fail. One drop of Loctite® 290, Part Number 3823682 (50 mL),
3824039 (10 mL) or equivalent, must be applied at the joint between the seat and the
shaft. More than one drop of fluid can get on the sealing faces and cause the seal to
fail.

Fan Hubs are available in three types:

1. Belt driven assembly with one of two types of spring loaded idler or an idler with a
shock absorber.
2. Gear driven assembly
3. Clutch driven assembly

NOTE: For installation and operation of the clutch driven assembly, reference
Bulletin 3387082, K-1150 Fan Clutch Operation and Installation. For rebuild
instructions for the clutch driven assembly, reference Bulletin 3387063, K-1150 Fan
Clutch Rebuild.

Belt Driven Fan Hub equipped engines have the fan belt tensioned by the spring loaded
idler assembly and does not require adjustment.

CAUTION

To prevent accidents, always release the spring tension before replacing the fan belt.

When the pivot arm cap is aligned properly with the spring, tension is a minimum of 54
n•m [40 ft-lb].
A grease nipple is on some pivot arms. The pivot arm must be greased at each schedule
maintenance interval. Do not grease the pivot arm that does not have a grease fitting. If
there is no grease fitting then the bushings work without grease.

Either a turnbuckle, an enclosed spring, or a shock absorber is used to limit the travel of
the idler pulley. Check the shock absorber for fluid leakage and loss of vibration
absorption at each scheduled maintenance interval.

Fan hubs are available in various drive ratios and fan center locations. When replacing
the fan hub, always check the part number to be sure the replacement is compatible.

All of the belt driven fan supports contain antifriction bearings that are tapered roller type.
Bearing end clearance is controlled by the use of an inner and outer bearing spacer. It is
a good service practice to tag the bearings for location when removing them. Always
replace both the bearing and bearing race if either piece requires replacement.

The idler pulley contains two antifriction bearings that are tapered roller type. The bearing
end clearance is set properly by matching select components in the kit.

CAUTION

Always replace the complete bearing kit when any one piece requires replacement.
Failure to do this will result in premature equipment failure.

The kit includes a retaining ring, an inner spacer, two bearings, and two bearing races.

CAUTION

Never use too much grease on the bearings. Too much grease will cause an
overheating due to the agitation of the grease. Excessive agitation of grease will result
in failure.

The following is the proper method of applying water pump type grease. Do not use
lithium base grease for fan hub bearings.

1. Pack both bearings with grease.

2. Fill the cavity between the bearings 2/3-full with grease.
3. Fill the cavity above the front bearing 2/3-full with grease.

Gear Driven Fan Hubs support assemblies are available in various drive ratios. When
replacing either the fan support assembly, or the gear and shaft assembly, check the part
numbers to be sure the replacement part is compatible.

WARNING
To reduce the possibility of personal injury or damage to equipment, never remove the
gear from the shaft. Damage to the press can result due to the high press fit or weld
between the gear and the shaft.
The fan hub support contains two antifriction bearings that are tapered roller type. The
fan hub bearings are pressure lubricated by the engine lubrication system. The bearing
end clearance is set properly by matching select components in the bearing kit. Always
replace the entire kit if any of the parts require replacement. This kit includes two
bearings, two bearing races, two retaining rings, and inner spacer. It is a good service
practice to tag the bearings for location when removing.

The fan is isolated from gear train vibration by a rubber divider in the fan hub. The hub
support assembly does not have to be removed from the engine to replace the fan hub. A
retainer is installed on the hub. The retainer will prevent the fan from separating from the
engine id the rubber member fails. On some models, this retainer is already cast on the
inner part of the hub and can not be removed.

WARNING
Never attempt to rotate the engine by pulling or prying on the fan. This practice can
result in serious personal injury and damage to the fan. Use only the proper engine
barring techniques to manually rotate the engine.

Engine Fans must be inspected for missing balance weights at each regular
maintenance interval. Do not attempt to repair broken or bent fans, or fans with missing
balance weights.

Most equipment that has a Cummins® engine uses a radiator and fan. The radiator and
fan transfer heat from the cooling water to the atmosphere. The fan selection process
must conclude that the fan, the fan mounting arrangement, and the fan drive system are
designed and matched for compatibility.

Upon request Cummins® Customer Engineering Department will assist in determining

the proper selection. Reference any fan changes other than the direct replacement of a
fan with precisely the same Cummins® part number first to a Cummins® Authorized
Repair Location for assistance.

Examples that require approval are:

1. Using an approved fan from one engine model on a different engine model.
2. Using an approved fan on an engine with a different fan mounting arrangement.
3. Using an approved fan on an engine with a different fan drive arrangement.
4. Converting an engine from one market model to another. An example is the
conversion of a G-drive engine to a power unit application.
5. Converting an engine model to a different model. An example is converting a KT19
to a KTA19 model.

This list is not inclusive. Always contact Application Engineering for assistance.

At times an existing fan can yield ONLY marginal cooling capability when being
considered for a new application.

CAUTION

Never repitch (bend) the blades to obtain additional air delivery. Bending the blades or
 spider creates stress in the material used for the construction of the fan. Repitching
(bending) will cause fan failure. The proper diameter fan must be selected. Never
modify an existing fan.

The following
publications, available
through a Cummins®
Authorized Repair
Location, provide
cooling system
installation
recommendations and
specifications approved
by Cummins Inc.

z Operation of
Diesel Engines in
Cold Climates,
Bulletin 3379009.
z Generator Drive
and Generator Set
Installation
Recommendations
(Cooling System),
Bulletin 3382395.
z Coolant
Requirements and
Maintenance,
Bulletin 3666132.

NOTE: Refer to
Procedure 205-002
(Service Literature
Ordering Location) in
section L for literature
ordering information.

Last Modified: 01-Mar-2010

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