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Page 1 of 33
This AEB supersedes AEB
21.38 dated Jul, 2001.
DOCUMENT OVERVIEW
In order to obtain Cummins concurrence with an installation:
The vehicle cooling system must meet the Engine Out Coolant to Ambient specification for the vocation,
weight and location in which the vehicle will operate:
For 10 liter and larger engines: specifications are on the Engine Data Sheet or in AEB 90.25
For engines below 10 liters: specifications are on the Engine Data Sheet or in AEB 90.24
Refer to Figure 4 of these recommendations for guidance in locating the appropriate cooling standard.
The engine cooling system must meet the required Intake Manifold to Ambient specification on the
Engine Data Sheet when tested with the ram air speed on the Engine Data Sheet.
The engine cooling system must meet the required Maximum Allowable Pressure Drop from Turbo Air
Outlet to Intake Manifold specification on the Engine Data Sheet when tested with the test procedure in
these recommendations.
Vehicle cooling system testing must be done using the test procedure at the end of these
recommendations.
For a Firetruck or Emergency Vehicle, the cooling system must meet the special requirements for these
vehicles.
Transit busses and vehicles used in dirty environments must use heat exchangers with a maximum of 810 fins/inch and non-louvered fins for acceptable life before fouling and cleanability after fouling.
The charge air cooling system must have piping, hoses and clamps which meet the requirements
outlined in AEB 21.14 Installation Recommendations - Charge Air Cooling System.
The vehicle must use the fan controls in the engine ECM or controls which fully engage the engine
cooling fan at or below the Fan-On Temperatures in these recommendations.
Radiator shutters must open in response to both engine coolant and engine intake manifold air
temperatures, and be fully open at or below the shutter opening temperatures on the Engine Data
Sheet.
Winterfronts must have a minimum open area of at least the value on the Engine Data Sheet. The open
area must be in front of the charge air cooler and the fan hub if viscous-type fan clutches are used.
Installations with automatic transmissions with retarders must have the thermostat bypass flow plumbed
into the transmission cooler inlet.
The installation must include a high coolant temperature alarm set to engage at the Coolant Alarm
Activation Temperature on the Engine Data Sheet. The Warning light operated by electronically
controlled engines meets this requirement.
If the vehicle will be used in cold ambient regions, optional equipment must be offered to improve
vehicle heating by reducing airflow through the radiator, such as a winterfront, shutters or on-off fan
drive.
The fan installation must not exceed the allowable spacing and overhung moment limits for the fan hub.
Cummins Confidential
AEB 21.38
Page 2 of 33
Introduction
The cooling system heat transfer components are the radiator, charge air cooler, fan and shroud along with
recirculation baffles and usually a fan clutch with controls. Vehicles which operate in cold weather often also use
a winterfront or shutters over the cooling system. Vehicles with automatic transmissions incorporate a
transmission cooler, often with special coolant plumbing.
The heat transfer components of the cooling system control coolant, intake manifold air and transmission oil
temperatures within desirable ranges during vehicle operation in moderate and cold ambient temperatures, and
maintain them below specified maximum levels under hot ambient conditions.
These recommendations outline Cummins requirements and design guidelines for these heat transfer related
cooling system components and the vehicle charge air cooling system. These recommendations cover design
aspects related to the performance of these components, but not component durability, which is the
responsibility of the vehicle manufacturer.
Virtually all Cummins requirements for the vehicle heat transfer system are performance-based, rather than
design-based, meaning that a certain cooling performance level is required of the complete system rather than
specific design aspects, such as a required radiator or fan size. The design guidelines in this document are
intended to aid the vehicle designer in developing an efficient heat transfer system which will meet Cummins
requirements with minimum size and cost.
The components of the cooling system related to the filling, venting and deaeration of the cooling system are
covered in the Automotive and Bus Installation Recommendations - Cooling System Fill and Deaeration.
The major steps in design of the vehicle heat transfer system; defining engine heat rejection and coolant flow;
defining cooling system performance requirements, choosing heat exchangers and choosing fan drives are
covered below.
AEB 21.38
Page 3 of 33
(line number) Cooling System
Governed Speed
Peak Power
Peak Torque
1600
Engine
1200
Coolant
Heat
Compressor
Turbo
Compressor
AEB 21.38
Page 4 of 33
Radiator Coolant Flow: (line 19) This is the coolant flow to the vehicle radiator, measured with the standard
radiator restriction shown in Figure 2. Radiators with lower restriction than this standard curve will receive
greater coolant flow, those with higher restriction will receive less. On installations with automatic transmissions,
the transmission cooler restriction should be added to the radiator restriction when comparing the installation to
the standard curve.
Charge Air Flow: (line 15) This is the flow of engine charge air which must be cooled by the charge air cooler.
Turbo Compressor Outlet Temperature: (line 21) This is the temperature of the charge air as it leaves the
engine turbo-compressor and travels to the charge air cooler. This temperature on the Engine Data Sheet is
measured in an engine test cell with a turbo-compressor inlet temperature of 77 F (25 C). The turbocompressor outlet temperature will be considerably higher than this value during a vehicle cooling test, when the
turbo-compressor inlet temperatures are typically 110-140 F (43-60 C).
Ram Air Speed and Coolant Type: (lines 5 and 6) This is the airspeed over the test vehicle during the cooling
test and the coolant to be used in the system during the testing. The ram air speed listed on the Engine Data
Sheet is only used for certain applications and vehicle weights, as outlined in the Cooling System Performance
Requirements section below. A 50-50 water-ethylene glycol coolant mixture is used for cooling tests since this is
what is commonly used in service.
Maximum Coolant Temperature - Engine Out: (line 3) This is the maximum coolant temperature the engine can
tolerate in service. The Engine Out Coolant to Ambient Specifications for the specific applications are designed
to prevent this coolant temperature from being exceeded during real world operation.
Engine Out Coolant to Ambient Specifications: (lines 7 and 8) These are the amounts that the engine outlet
coolant temperature can be higher than ambient temperature with the engine at full power output during the
cooling test. These are also commonly termed top tank differential or TTD specifications.
Intake Manifold to Ambient Specification: (line 9) This is the amount that the intake manifold air temperature can
be above the ambient temperature with the engine at full power output during the cooling test. This is commonly
termed intake manifold temperature differential specification or IMTD.
Maximum Allowable Pressure Drop from Turbo Air Outlet to Intake Manifold: (line 10) This is the maximum
allowable restriction of the complete charge air cooling system, measured during the cooling test with the engine
at full power output. This restriction includes the charge air piping, hoses and cooler.
The heat rejection required from the vehicle charge air cooler is not listed on the engine data sheet, because it
varies considerably with the turbo-compressor inlet temperature. If the charge air cooler heat rejection is needed
for cooling system design calculations, it can be estimated using the calculations shown in Figure 3.
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AEB 21.38
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Cummins Confidential
AEB 21.38
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Data Sheet Conditions
(77 F ambient)
77 F
130 F
TCOD TCOH
IMTS
TCOD is the Turbo Compressor Outlet Temperature listed on the Engine Data Sheet.
TCOH
is
the
Turbo
Compressor
Outlet
Temperature
at
high
ambient
cooling
test
130 F is assumed for the turbo compressor inlet temperature since Cummins allows 30 F heating of
the intake air in the vehicle intake system prior to the turbocharger on many engine models.
IMTS is the Intake Manifold Temperature target for the cooling test.
The turbo compressor outlet temperature will rise as the turbo compressor inlet temperature rises, but it
is not a one-for-one relationship. The turbo compressor outlet temperature and required intake manifold
temperature during the cooling test are:
TCOH = TCOD + (1.4 x ( 130 F - 77 F ))
IMTS = IMTD + 100 F
Where the IMTD is the Intake Manifold to Ambient specification on the Engine Data Sheet.
The required heat rejection by the charge air cooler to meet the engine IMTD specification under the cooling
test conditions is:
CAC Heat Rejection (Btu/min) = 0.241 Btu/lb F x Charge Air Flow (lb/min) x (TCOH - IMTS) (F)
This calculation method can be used at any ambient temperature with appropriate changes to the TCOH
formula above. Cummins recommends that a chassis dyno cooling test be run with an ambient temperature
of
90-110
F.
Figure 3. Calculation Method for CAC Heat Rejection for Cooling Test Conditions
Cummins Confidential
AEB 21.38
Page 7 of 33
AEB 21.38
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The Limiting Ambient Temperature is the maximum ambient temperature at which the vehicle can operate
before the engine coolant temperature reaches its maximum limit. Since the Engine Outlet Coolant to Ambient
(Top Tank Differential) specification is the temperature difference between the engine coolant temperature and
ambient, LAT and TTD specs are related:
Maximum Coolant Temperature Limit = Limiting Ambient Temperature + Top Tank Differential
For Example, if a heavy-duty engine had a 220 F maximum coolant temperature limit, and a cooling system
was to be designed to operate in a maximum ambient temperature of 115 F (LAT = 115 F), the Top Tank
Differential requirement would be:
220 F = 115 F + TTD
or
or
TTD = 104 C - 46 C = 58 C
So during a cooling test, the cooling system would have to meet a Top Tank Differential of 105 F to operate
successfully in this environment. The ram air speed for the cooling test would be chosen based on the vehicle
weight as outlined in AEB 90.25.
It should be noted that the LAT specifications outlined in AEB 90.25 are the LAT values to be used in chassis
dyno cooling system sizing, which are slightly lower than the maximum ambient temperatures which a vehicle
will encounter in the specified areas of the world.
AEB 90.24 Midrange Engine Cooling Requirements outlines the performance requirements for cooling systems
for midrange engines (below 10 liter displacement) for vehicles manufactured in North America and used
worldwide. Since midrange engines are applied in a wide variety of applications, these applications are grouped
into three categories for cooling system sizing based on duty cycle.
A number of midrange applications, such as on-highway trucks and school busses below 35,000 lb (16 tonnes)
GVW, use the less stringent cooling system performance requirements outlined in AEB 90.24 rather than those
listed on the Engine Data Sheet. These light duty midrange applications can use smaller, less costly cooling
systems due to their lighter duty cycle and consequently lower demands on the vehicle cooling system.
Firetrucks and Emergency vehicles also have unique cooling requirements, generally less stringent than typical
on-highway truck or bus requirements. These less stringent requirements result from generally higher power-toweight ratios for these vehicles, and less severe operating conditions. The unique cooling requirements for
these applications are listed on the Engine Data Sheets for Firetrucks and Emergency Vehicles.
Pumper firetrucks also have unique cooling requirements to control temperatures during their stationary
pumping mode. These firetrucks are required to maintain the engine outlet coolant temperature and engine
intake manifold air temperature below the limits on the Engine Data Sheet during pumping mode (see Figure 1).
Pumping mode cooling performance is typically checked during the standard pumping mode test. These cooling
requirements must be met in addition to the standard on-road cooling requirements.
AEB 21.38
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transfer cores would occur with perfectly square cores, the closer the cores are to square, the greater the
potential for good fan matching.
Since the maximum fan diameter is usually known early in the cooling system design process, this fan diameter
should be used as a guideline for the minimum desired dimension of the radiator core.
Since the fan airflow must pass through both the charge air cooler and radiator cores, greater system efficiency
results from smoothing the transition between these cores. This can be done by matching the size and shape of
these two cores as closely as possible. Since the charge air cooler core area is often smaller than the radiator
core, care must be taken in designing the charge air cooler so that the tanks do not cover the radiator core area,
resulting in undesirable airflow blockage.
Another important design consideration for the heat transfer cores is the heat exchanger fin and tube
arrangement. Generally, the higher the fin density and the greater the louvering of the fins, the greater the
performance capability of the core within a given frontal area. However, high density, louvered fins and/or
staggered tubes will quickly plug with debris if the vehicle operates in a dirty environment, and will be difficult
and expensive for the vehicle operator to clean.
Cummins recommends that heat transfer cores with high fin density (12 fins/inch or more) louvered-type fins
should only be used in clean on-highway applications. Vehicles which operate in dirty environments, such as
street sweepers and some logging and agricultural applications, must use lower fin density non-louvered fins
and in-line rather than staggered radiator tubes.
Experience has shown that urban transit busses often experience short service life with higher fin density
radiators using louvered fins. Since these cooling systems require fan operation much of the time, the cooling
system tends to collect large amounts of street debris. Although this improves cleanliness of the cities in which
they are operating, the cooling systems must be designed to have a reasonable service life in this environment,
and be easily cleanable once they become fouled.
Cummins requires that urban transit busses and other vehicles which operate in dirty environments use heat
exchanger cores with no greater than 8-10 fins/inch, with non-louvered fins. Heat exchanger manufacturers
have developed fins which use ripples or bumps for fin turbulation rather than louvers, which makes these fins
much less prone to fouling and much easier to clean once fouled.
Vehicles which operate in dirty environments can also encounter problems with debris collecting between the
radiator and charge air cooler cores, where it is not easily cleaned out without removing the charge air cooler.
This problem results from debris being pulled through the gap between the two cores, and debris which passes
through the less dense charge air cooler being trapped in the higher density radiator fins.
This problem can be lessened by using a side-by-side radiator-charge air cooler layout rather than front-to-back,
installing a seal between the radiator and charge air cooler cores, or matching the fin density of the two cores so
that debris will pass through both.
AEB 21.38
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Cummins Confidential
AEB 21.38
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The airflow through the heat transfer cores can also be improved by maximizing the fan sweep over the cores,
by matching the fan diameter with the dimensions of the heat transfer cores. The air flows smoothest between
the heat transfer cores and the fan when the fan sweeps the greatest proportion of the core areas. This occurs
when the fan diameter is equal to slightly smaller than the minimum core dimension. However, fan performance
degrades significantly if the fan diameter exceeds the core dimensions, due to the airflow blockage of the
radiator and charge air cooler tanks (see Figure 7).
The fan airflow can also be disrupted by obstructions in front of or behind the fan, particularly near the fan
perimeter where the airflow velocity is highest. Since some airflow interruption by engine accessories or pulleys
is often unavoidable, the impact of these obstructions on fan performance can be reduced by maximizing the
clearance between the fan and any obstruction. Obstructions close to the fan also increase fan noise and can
contribute to shorter fan life by increasing fan vibration levels.
Good design practice is to include a minimum of 2 inches (50 mm) clearance from the front of the fan to the heat
transfer core, with 4 inches (100 mm) much better. Minimum clearance from the back of the fan to any
obstructions should be 3/4 inch (20 mm) or greater.
The fan shroud improves system efficiency by channelling the air between the heat transfer cores and the fan,
and minimizing air recirculation at the tips of the fan blades. The best shroud designs allow for a smooth
transition from the rectangular heat transfer cores to the round fan with minimal restriction. Good and bad fan
shroud designs are shown in Figure 8.
The amount of the fan depth which protrudes into the fan shroud is termed the fan immersion in the shroud. This
immersion, and the clearance from the fan blade tips to the shroud, are the key parameters which affect the air
pumping efficiency of the fan and shroud. The optimum fan immersion in the shroud varies with fan and cooling
system design, so is often determined experimentally.
Good design practice is to immerse about 1/2 of the fan depth into the shroud for both blower and sucker-type
fans. These immersion recommendations are different than those used in the past since the optimum fan
immersion has changed due to the additional airflow restriction caused by the charge air cooler. These general
rules do not apply to every installation, so the optimum fan immersion should be determined through testing.
Fan performance improves as the clearance from fan blade tips to the shroud is reduced. For best fan
performance, the tip clearance should not exceed 2.5% of the fan diameter. The minimum tip clearance to the
shroud is usually limited by the clearance necessary to prevent the fan blades from contacting the shroud when
the vehicle is running on a rough road.
Tip clearance can often be reduced to less than 1% of fan diameter when engine-mounted shrouds are used,
which further improves fan performance. Figure 9 shows fan immersion guidelines for sucker and blower type
fans.
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AEB 21.38
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Cummins Confidential
AEB 21.38
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Airflow through the cooling system can also be improved by minimizing airflow resistance in front of the heat
exchangers and behind the fan. Grille open area should be maximized, and grille elements designed for low air
resistance. Restriction behind the fan can be reduced by easing the egress of air from the engine compartment
through maximizing exit area around the engine and using hood vents to allow air to escape.
Recirculation Baffles
When a sucker-type cooling fan is running, it pulls air through the heat exchangers and pushes the airflow
behind it into the engine compartment. This action creates a low pressure, or suction at the front of the heat
exchangers and a high pressure in the engine compartment.
The pressurized air in the engine compartment will escape in any direction possible, and can easily be sucked
into the low pressure region in front of the heat exchangers. Since the engine compartment air has already
passed through the heat exchangers and been heated, the recirculation of this hot air into the heat exchangers
degrades vehicle cooling performance.
This recirculation can be reduced by installing rubber baffles or seals between the sides of the heat exchanger
package and the vehicle hood or engine compartment. These seals must completely isolate the region in front of
the heat exchangers from the engine compartment to be effective.
Care must be taken in designing these seals so that they do not block any part of the heat transfer cores of
either the radiator or charge air cooler, are tall enough to seal the gap intended, will not blow open due to
pressure from the engine compartment, and remain stiff enough to be an effective seal at engine compartment
temperatures (typically 190-210 F, 88 - 99 C).
The hot, pressurized air in the engine compartment can also be pulled into the vehicle air intake system if this
system is not well sealed from the engine compartment. This ingestion of hot air into the vehicle air intake is the
most common reason a vehicle intake system fails to meet the intake temperature limits. If the vehicle has a
frontal air system, baffles for the intake system can often be incorporated into the cooling system recirculation
baffles.
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Cooling systems with blower-type fans also benefit from recirculation baffles, which must be designed to prevent
recirculation from the heat exchanger outlet to the fan inlet.
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The parameters for cooling system testing for all applications are listed on the Engine Data Sheet or the
appropriate AEB as listed in Figure 4. These parameters are explained below. A detailed cooling system
instrumentation and test procedure is included at the end of this document.
Four key parameters are controlled during cooling system testing: Engine speed, throttle position, ambient
temperature and ram air speed. The engine speeds to be used for cooling system testing are listed in the
Cooling System section of the Engine Data Sheet (see Figure 1). The ram air speed appropriate for the
application being designed is the value on the Engine Data Sheet or in the appropriate AEB as outlined in
Figure 4.
Cooling system testing is done at wide open throttle, with a stable ambient temperature between 90 - 110 F
(32-43 C) when testing on a chassis dyno, and 70-120 F (21-49 C) when testing on-road. Experience has
shown that cooling systems must be qualified within these ambient temperature ranges in order to provide
acceptable performance at high ambient temperatures. Cummins will not accept cooling system test results run
at ambient temperatures outside these ranges.
Four key engine parameters are measured during the cooling test: Engine coolant outlet temperature, intake
manifold air temperature, charge air system pressure drop and the rate of engine fuel consumption.
Engine coolant outlet temperature, intake manifold air temperature and charge air system pressure drop are
compared to the requirements for the application. The rate of engine fuel consumption provides an indication of
the engine power output during the cooling test.
If the engine fuel consumption rate is significantly different than the Nominal Fuel Consumption value on the
Engine Data Sheet (Fig 1 line 22), the cooling test results can be corrected to represent an engine running at
the nominal fuel rate. The correction procedure is outlined in the data reduction section of the cooling test
procedure at the end of these recommendations.
The cooling test is done at the two engine speeds listed on the Engine Data Sheet (lines 7 and 8 in Figure 1) if
the vehicle uses a manual transmission. With an automatic transmission, the lower of the two speeds often
cannot be attained because the transmission will downshift above this speed. Since the lower speed cannot be
attained during real operation, this test rpm is replaced by a higher speed, close to the downshift point of the
transmission. More detail on test procedures for automatic transmissions is available in AEB 95.04 Automatic
Transmission Cooling.
The measured engine coolant temperature, intake manifold temperature and charge air system pressure drop
are compared to the specifications appropriate to the application to determine if the cooling system meets
Cummins requirements. Detailed cooling test data reduction procedures are included in the test procedure at
the end of these recommendations.
Automatic Transmissions
Automatic transmissions reject heat to the transmission oil during operation, therefore requiring cooling. The
transmission oil cooler is typically an oil-to-coolant heat exchanger mounted between the radiator outlet and
engine inlet (see Figure 10). This cooler location provides the advantages of full flow at the coolest point in the
system, and simple plumbing. The cooler is sized to meet the transmission oil cooling requirements defined by
the transmission manufacturer.
A disadvantage of locating the transmission cooler in this location is that the cooler only receives coolant flow
when the engine thermostat opens. This problem can be solved by plumbing the engine thermostat bypass
coolant into the transmission cooler inlet, as shown in Figure 10. This plumbing arrangement provides
continuous coolant flow through the transmission cooler regardless of engine thermostat position.
All Cummins engine models offer options for plumbing the thermostat bypass flow remotely from the engine,
which typically involves blocking the internal bypass flow path and providing a port for external plumbing. The
additional coolant flow during closed thermostat conditions improves transmission cooling during situations
when the transmission requires cooling and the engine does not.
The most severe transmission cooling situations occur when a transmission retarder (braking device) is
engaged. Retarders reject large amounts of heat into the transmission oil very quickly, requiring significant
transmission oil cooling. Since retarders are most often used to enhance braking on downgrades, when the
engine thermostat is often closed, the remote bypass coolant flow is critical to cooling retarder-equipped
transmissions.
For this reason, Cummins requires that the thermostat bypass flow be plumbed to the transmission cooler inlet
on transmissions with retarders. This is necessary to control transmission oil temperatures during retarder
Cummins Confidential
AEB 21.38
Page 16 of 33
operation with the thermostat closed. Cummins does not require the thermostat bypass flow to be plumbed to
the transmission cooler inlet on transmissions without retarders, however this plumbing arrangement does
enhance transmission cooling.
Automatic transmission-equipped vehicles with fixed fan drives (no fan clutch), such as some transit busses and
cement mixers, are a special case. The fixed fan drive causes the fan to run continuously, which reduces
coolant temperatures in moderate load and ambient conditions, causing the engine thermostat to close.
Therefore, these vehicles can operate with a closed or nearly closed thermostat, and little transmission cooling
flow, a large amount of their running time. Plumbing the thermostat bypass flow to the transmission cooler inlet
is recommended on vehicles with automatic transmissions and fixed (continuously running) fan drives to
enhance transmission cooling.
The remote bypass plumbing option on the B-series and ISB engines provides lower coolant flow than other
engine models, which can be insufficient to properly cool the high heat rejection of some retarders. If additional
flow is needed for retarder cooling, this can be achieved by adding coolant from another engine port to the
remote bypass flow as shown schematically in Figure 11. The additional flow can be obtained from any of the
coolant ports on the top of the cylinder head or rear of the cylinder block.
Testing has shown that this plumbing arrangement provides sufficient coolant flow to cool Allisons medium
capacity retarders on vehicles up to 35,000 lb (16 tons) GCW. It is not approved for use on high capacity
retarders or on heavier vehicles.
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AEB 21.38
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Vehicles in which cooling air is forced through the cooling system when the vehicle is in motion, such as onhighway trucks, only engage the cooling fan during the unusual situations when the cooling system must reject
large amounts of heat with little ram air.
Vehicles in which the cooling system does not see ram air when the vehicle is in motion, such as rear-engine
busses, engage the cooling fan much more often since it is the only source of cooling airflow. These vehicles
often use different fan drive mechanisms, such as hydraulic drives, which can provide some fan speed at all
times.
Most fan control mechanisms provide zero or low fan speeds when the engine temperature is low, then turn the
fan on when the coolant temperature reaches a threshold value. On engines over 10 liter displacement, the fan
is typically engaged with a pneumatic clutch controlled by the engine ECM or coolant temperature sensor.
On engines below 10 liter displacement, viscous-type fan clutches, which sense the air temperature exiting the
radiator rather than coolant temperature, are often used. These engines also employ both pneumatic and
electromagnetic fan clutches controlled by the engine ECM or coolant temperature sensor.
For all types of fan clutches, the fan control system must bring the fan up to maximum speed before the engine
coolant temperature rises too high. It is desirable to engage the fan below the maximum allowable coolant
temperature of the engine, to allow the cooling system to respond and keep the coolant temperature from
reaching the maximum. The Fan-On temperature for each engine model is listed on the Engine Data Sheet.
For optimum vehicle performance, the fan should not engage at an engine coolant outlet temperature more than
10 F (5 C) below the Fan - On Coolant Temperature on the Engine Data Sheet. A fan clutch which engages
the fan at too low a coolant temperature causes excessive fan running time with consequent increases in noise
and parasitic power loss.
Cummins requires that the fan control system engage the cooling fan at or below the Fan-On Coolant
Temperature on the Engine Data Sheet. Engine electronic control modules (ECMs) provide a signal to engage
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AEB 21.38
Page 18 of 33
the cooling fan at the recommended temperature, and also engage the fan based on intake manifold air
temperature, refrigerant pressure and to assist downhill engine braking.
Newer engine models provide more sophisticated fan controls for new generation fan clutches with multiple
operating modes or variable fan speeds. Consult the Engine Electronic Subsystem information for details on
these controls.
Since viscous-type fan clutches engage in response to a rise in air temperature behind the radiator, rather than
directly sensing a rise in engine coolant temperature, their performance must be tested on a chassis dyno to
determine the engine coolant temperature at which the fan engages. The procedure to do this is included in the
cooling system test procedure at the end of this document.
If the vehicle is equipped with radiator shutters, these must also be opened to provide cooling airflow when
either the engine coolant or intake manifold air temperatures rise. The engine coolant and intake manifold air
temperatures at which the shutters should open are also listed on the Engine Data Sheet.
Cummins requires that shutter controls open the shutters at or below the engine coolant and intake manifold air
temperatures on the Engine Data Sheet.
Fan and shutter control requirements for all Cummins heavy-duty, midrange and alternative fuel engines are
summarized in the tables in Figure 12. The required fan control signal is provided by the engine ECM for all
engine models, but shutter controls must be provided by the vehicle manufacturer. All engine models provide
ports in the engine coolant jacket and intake manifold for installation of shutter controls, except the alternative
fueled engines, which require the intake manifold air shutter controls to be located in the pipe returning charge
air to the engine.
The recommended location for the coolant-temperature sensing fan control is sensing the engine outlet coolant
temperature. This can typically be done by locating the sensor in the coolant manifold which feeds the engine
thermostat, in the thermostat housing or piping between engine coolant outlet and the radiator. If the fan or
shutter control is located where it senses engine coolant inlet temperature rather than outlet temperature, the
sensor setting should be reduced 10 F (5 C) below the recommended setting.
Fan and Shutter Controls for Heavy-Duty Engines over 10 liter Displacement
Application
Fan On Temperatures
Shutter Opening Temperatures
Vehicle with Ram Air
Coolant = 205 F (96 C)
Coolant = 185 F (85 C)
Intake Manifold Air = 150 F (65 C)
Vehicle with No Ram Air
Coolant = 200 F (96 C)
Coolant = 185 F (85 C)
Intake Manifold Air = 160 F (71 C) Intake Manifold Air = 150 F (65 C)
Fan and Shutter Controls for Medium-Duty Engines under 10 liter Displacement
Application
Fan On Temperatures
Shutter Opening Temperatures
Vehicle with Ram Air
Coolant = 200 F (96 C)
Coolant = 185 F (85 C)
Intake Manifold Air = 150 F (65 C)
Vehicle with No Ram Air
Coolant = 200 F (96 C)
Coolant = 185 F (85 C)
Intake Manifold Air = 160 F (71 C) Intake Manifold Air = 150 F (65 C)
Fan and Shutter Controls for Alternative Fuel Engines
Application
Fan On Temperatures
Shutter Opening Temperatures
All Vehicles without Shutters
Coolant = 200 F (96 C)
N/A
Intake Manifold Air = 130 F (54 C)
All Vehicles with Shutters
Coolant = 200 F (93 C)
Coolant = 185 F (85 C)
Intake Manifold Air = 130 F (54 C) Intake Manifold Air = 120 F (49 C)
Figure 12. Fan and Shutter Control Recommendations
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Figure 13.
Winterfront
CAC Tubes
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3. Engine Inlet Coolant Temperature (or Bottom Tank Temperature) - Install between the radiator outlet and
engine water inlet connection, as close to the engine as possible. This measurement is only needed if
engine heat rejection measurements are desired during the cooling test. When testing a vehicle with an
automatic transmission ( with a transmission oil to engine coolant heat exchanger) and calculating coolant
heat rejection , it is important to understand if the heat load from the automatic transmission is included in
the calculation. The placement of the thermocouple in the lower cooling system pipe (radiator outlet to
engine water pump inlet) will determine if the heat load from the transmission is included in the heat
rejection calculation.
If the thermocouple is located in the lower radiator pipe between the coolant returning from the transmission
heat exchanger and the water pump inlet, then the heat load from the transmission WILL BE included in the
calculation. If the thermocouple is located in the lower radiator pipe between the radiator outlet and the
coolant returning from the transmission heat exchanger, the heat load WILL NOT included in the
calculation. The heat rejection will be the engine only.
4. Engine Intake Manifold Air Temperature - Install in the engine intake manifold or elbow attached to the
manifold to read the temperature of the air as it enters the manifold. Avoid locating this measurement further
into the manifold as the air is heated by the hot intake manifold metal as it travels through the manifold.
Figure B shows an example of a good location.
5. Engine Compartment Temperature - Install this to measure the temperature of the air exiting the fan blades.
This is commonly attached to the engine lifting bracket at the front of the engine. This measurement needs
to be located away from the exhaust manifold to avoid false heating.
6. Recirculation Temperatures (4 corners of cooling package) - When a sucker fan is running, it sucks air
through the heat exchangers and pushes this air back through the engine compartment. This pressurizes
the engine compartment, causing the air to exit in any direction it can. The hot engine compartment air will
curl around the sides of the heat exchanger package and enter the front if allowed to do so. This
recirculation of hot air degrades cooling performance. These four thermocouples should be located to
intercept any flow of hot air from the engine compartment. These should be located in the four corners of the
heat exchanger package, in any open paths to the engine compartment or gaps between recirculation
baffles.
7. Engine Oil Temperature - The most expedient way to measure this is by wrapping a thermocouple around
the oil dipstick with the sensing tip protruding about 1 inch beyond the end of the stick. An alternative is
installing the thermocouple into a port on the side of the oil pan below the oil level, but this requires draining
and refilling the oil pan.
8. Air Entering Intake System - Install this thermocouple to the inlet grate of the vehicle intake system. This
reading will aid in interpretation of the intake heating reading taken at the turbocompressor inlet.
9. Air at Turbocompressor Inlet - Install into the intake elbow attached to the turbocharger inlet or as close to
the turbocharger inlet as possible.
10. Fuel Supply Temperature - Install the thermocouple into the fuel supply line as close to the engine as
possible. This temperature assists in controlling the fuel supply to the engine on a chassis dyno, but is
optional for road testing.
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15. Drive Axle Temperatures, Dyno Temperatures, other cell monitoring (optional) - When testing in a
dynamometer cell, other temperatures are often monitored to protect mechanical hardware.
16. In-cab ventilation duct temperature - In the outlet of a ventilation duct in the cab to monitor the cooling
performance of the air conditioner.
Installing Pressure Taps
These pressures are commonly read using pressure transducers, differential pressure transducers and
manometers when testing in a dynamometer cell, and with gauges and manometers when testing on-road.
1. Coolant Pressure (Block Pressure) - Measure coolant pressure anywhere on the engine block between the
water pump discharge and thermostat inlet, avoiding the water pump inlet. This pressure gives an indication
of whether the water pump is pumping coolant.
2. Engine Oil Pressure - Measure oil pressure in the oil rifle or oil cooler inlet, whichever is most convenient.
This measurement is intended to indicate if a loss in oil pressure occurs so the test can be aborted.
3. Turbo Compressor Outlet Pressure - Install into the turbo compressor outlet elbow, using the tap opposite
the one used for the temperature measurement. Do not install the temperature and pressure
measurements into a common tee. This pressure measurement indicates whether the engine
turbocharger is acting correctly.
4. Intake Restriction (optional) - Measure this with a tap in the intake elbow at the turbo- compressor inlet or
immediately upstream. Do not install the temperature and pressure measurements into a common tee.
This measurement will be generally less than 15 inches of water, so a manometer is often used.
5. Exhaust Restriction (optional) - Measure this through a tap in the exhaust pipe at least one pipe diameter
downstream of the turbocharger. The exhaust pyrometer port is often used for this measurement. This
reading will be in the 30-50 inches of water range, so a manometer is often used.
6. Charge Air System Pressure Drop - Measure this with pressure taps in the turbo-compressor outlet elbow
and engine intake manifold. It is acceptable to tee this pressure reading with the turbo compressor outlet
pressure reading described above. The pressure reading at the intake manifold should be taken using a
different port than that used for the intake manifold temperature reading. Do not install the temperature
and pressure measurements into a common tee. A manometer plumbed to read the differential pressure,
or a differential pressure transducer, is used to read this pressure. This pressure differential will be in the
range of 0-5 in Hg, 0-70 in H20 (0 - 20 kPa).
Other Measurements
Engine speed and ram air speed must be measured when testing on a chassis dyno. Engine speed and road
speed must be measured when testing on-road. If automatic transmissions are being tested, and a transmission
cooling evaluation is desired, driveline speed must be measured and transmission cooling system pressure drop
may also be needed.
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12. As the temperatures in the cooling system begin to stabilize, record all the data channels at one minute
intervals. Stabilization is achieved when the engine outlet coolant temperature does not change more than 1
F (0.5 C) in 5 minutes.
13. Once the test is complete at the first test point, adjust the dynamometer loading to bring the engine speed to
the second test point and repeat steps 8-12 above.
14. If intake and exhaust restriction measurements are also being taken, these must be done at the engine
speed which produces the highest intake and exhaust airflow as listed on the Engine Data Sheet. If this
speed is different than that used for the cooling system testing, adjust the dynamometer loading to obtain
the desired engine speed while maintaining the engine at full power and take the readings.
Testing Vehicles with Automatic Transmissions
Many automatic transmissions will downshift as the engine is pulled down to the low speed cooling checkpoint,
preventing this rpm from being attained. Since this low speed checkpoint cannot be tested, this test rpm is
modified to a point just above the point at which the transmission will downshift. See AEB 95.04 Automatic
Transmission Cooling for details on how to determine the low speed checkpoint.
All engine cooling tests with automatic transmissions are done with the transmission in lockup mode (if the
transmission model has lockup). The only testing done with the torque converter slipping are transmission
cooling tests.
The performance of the transmission cooler is sometimes tested in addition to the engine cooling test. This
generally requires measuring the transmission oil sump and outlet temperature, and the pressure drop of the
transmission cooler and lines. Refer to the transmission manufacturer for details on transmission cooling
requirements and test procedures.
Measuring Viscous Fan Clutch Engagement Temperature
Since viscous fan clutches sense the air temperature exiting the heat exchangers rather than the engine coolant
temperature, testing is required to determine whether the fan engages at an engine coolant temperature which
meets our recommendations.
1. Adjust the dynamometer cell ambient temperature to 70- 90 F (21 - 32 C).
2. Run the engine at idle speed until the coolant temperature reaches 180-185 F (82 - 85 C). It is also
acceptable to begin this test with the engine at room temperature.
3. Adjust the ram air speed over the vehicle to the value on the Engine Data Sheet for the engine being tested.
4. Raise the engine speed and load rapidly to the Peak Power condition listed on the Engine Data Sheet.
5. Listen for the fan engagement and record the engine coolant outlet temperature at which it engages.
6. Allow the fan to cycle on and off a number of times and record the engine coolant outlet temperature when
the fan engages and disengages.
7. Repeat steps 2 - 6 to check repeatability.
The viscous fan clutch should engage the fan at a coolant outlet temperature no higher than the Fan - On
Coolant Temperature on the Engine Data Sheet. For optimum vehicle performance, the fan should not engage
at an engine coolant outlet temperature more than 10 F (5 C) below the Fan - On Coolant Temperature on the
Engine Data Sheet. A fan clutch which engages the fan at too low a coolant temperature causes excessive fan
running time with consequent increases in noise and parasitic power loss.
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Maximum Allowable Pressure Drop from Turbo Air Outlet to Intake Manifold ______________
Nominal Fuel Consumption _____________ = FRspec
Calculations:
Measured Engine Outlet Coolant to Ambient = ECOT- Tamb = ______ - ______ = ______ = TTDtest
Measured Intake Manifold to Ambient = IMT - Tamb = _______ - _______ = _______
If the engine fuel consumption measured during the test (FRtest) is significantly different than the Nominal Fuel
Consumption on the Engine Data Sheet (FRspec), then the measured Engine Outlet Coolant to Ambient
(TTDtest) can be projected to reflect the result if the engine was running at the nominal fuel rate:
Adjusted Engine Coolant Outlet to Ambient = TTDtest x
= ______ x = _______
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Record the Engine Data Sheet specifications at the low speed checkpoint:
Engine Out Coolant to Ambient ______________
Nominal Fuel Consumption _____________ = FRspec
Calculations:
Measured Engine Outlet Coolant to Ambient = ECOT- Tamb = ______ - ______ = ______ = TTDtest
If the engine fuel consumption measured during the test (FRtest) is significantly different than the Nominal Fuel
Consumption on the Engine Data Sheet (FRspec), then the measured Engine Outlet Coolant to Ambient
(TTDtest) can be projected to reflect the result if the engine was running at the nominal fuel rate:
Adjusted Engine Coolant Outlet to Ambient = TTDtest x
= ______ x = _______
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Maximum Allowable Pressure Drop from Turbo Air Outlet to Intake Manifold ______________
Calculations:
Measured Engine Outlet Coolant to Ambient = ECOT- Tamb = ______ - ______ = ______ = TTDtest
Measured Intake Manifold to Ambient = IMT - Tamb = _______ - _______ = _______ = IMTDtest
If the average altitude at which the cooling test is run is above 1000 feet (305 m), then the cooling test results
can be adjusted for the effects of altitude on the cooling system. The corrections are:
Adjusted Engine Outlet Coolant to Ambient = TTDtest -
x 2.5 F = ______
x 1 F = _________
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Record the Engine Data Sheet specifications at the low speed checkpoint:
Engine Out Coolant to Ambient ______________
Calculations:
Measured Engine Outlet Coolant to Ambient = ECOT- Tamb = ______ - ______ = ______ = TTDtest
If the average altitude at which the cooling test is run is above 1000 feet (305 m), then the cooling test results
can be adjusted for the effects of altitude on the cooling system. The corrections are:
Adjusted Engine Outlet Coolant to Ambient = TTDtest -
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Change Log
Date
Author
Mar, 2006
R McCoy
Jul, 2001
R McCoy
Apr, 2001
R McCoy
Mar, 2001
R McCoy
Feb, 2001
R McCoy
23
Oct, 2000
R McCoy
19
Nov, 1999
R McCoy
Description
Page(s)
Cummins Confidential
1
32-33
18
13/14