Subject: This AEB is for the following applications:

QSK60-M/-D(M) Cooling Automotive Industrial G-Drive Marine

System
Date Created: 08/30/2005 File Name : 0.08.00 MAB No.

Revision Date: 08/07/2009 Cooling System 0.08.00-08/30/2005

Expire Date: 12/08/2012

Engine Family : High Horsepower

Engine Model : QSK60-M/D(M)
Document Owner : Olmedo Farfan Page 1 of 28

Purpose
The purpose of this document is to provide a description of the cooling system
features and installation instructions unique to the marine QSK60-M and QSK60-
D(M) engine.

Introduction
This MAB represents one chapter within the QSK60 Marine Technical Package
MAB 0.00.00 – 09/26/2003. It should be used to support installation design
during the introduction of the QSK60-M and QSK60-D(M) engine. This report
includes a description of the cooling system as released with this engine and the
associated options particular to this engine family.

Cummins Confidential
 Table of Content
Discussion ............................................................................................................ 2
1.0 Heat Exchanged Engines ............................................................................... 3
1.1 Central Cooling Recommendations ............................................................. 5
1.2 Sea Water Pump ......................................................................................... 7
1.3 LTA Pump ................................................................................................... 8
1.4 Jacket Water Pump ..................................................................................... 9
1.5 Expansion Tank........................................................................................... 9
1.6 Heat Exchanger Selection in CSL ............................................................. 10
2.0 Keel Cooled Engines .................................................................................... 11
2.1 LTA Pump ................................................................................................. 14
2.2 Expansion Tank Design and Size (Customer Supplied) ............................ 15
2.3 Engine Coolant Vents ................................................................................ 15
2.4 Keel Cooler Engine Selection in CSL ........................................................ 16
3.0 Radiator Cooled System ............................................................................... 17
3.1 Fan Drive ................................................................................................... 18
3.2 Radiator Cooled Engine Selection in CSL ................................................. 19
3.3 Installation Considerations for the Radiator cooled System ...................... 19
4.0 Additional Options ......................................................................................... 21
4.1 Fuel Cooler ................................................................................................ 21
4.2 Marine Gear Oil Cooler ............................................................................. 22
5.0 Attachments .................................................................................................. 24
5.1 QSK60 Cooler Performance ...................................................................... 24
5.2 QSK60 KC & HX Cooling Schematic......................................................... 24
5.3 QSK60 Coolant Flow System Diagram ..................................................... 24

Discussion

The QSK60 cooling system is a two-pump, two-loop design similar to the

industrial version. The engine uses two cooling loops consisting of a main
engine loop (or Jacket Water) loop and a Low Temperature Aftercooling (LTA)
loop. The main engine loop controls the jacket water circuit and runs at higher
temperatures. This circuit is sometimes referred to as the high-temperature
circuit. The low-temperature aftercooling loop runs at lower temperatures and is
sometimes referred to as the low-temperature circuit.

The QSK60 engine comes in three main configurations: Keel Cooled, Heat
Exchanged, and Radiator Cooled. Table 1 presents a comparison of these three
cooling systems.

Page 2 of 28
 Table 1 - QSK60 MCRS Cooling System Comparison

Type of System Description

2-pump-2-loop system. Individual
keel coolers needed for LTA and
Keel Cooled jacket water. Single thermostat
with hot bypass to reduce flow by
50%.
2-pump-2-loop system. Jacket
Heat Exchanged water and LTA contained in single
heat exchanger.
Coolant connections, full flow
coolant, and fan drive arrangement
ONLY. This option does not
Radiator Cooled include a radiator. Radiator is
customer supplied. This type of
cooling system is available no
auxiliary engines only.

1.0 Heat Exchanged Engines

The QSK60 heat exchanger is a titanium plate type cooler that is mounted on the
front of the engine as shown in Figure 1. It features a total of 74 titanium plates
of 0.5 mm of thickness each. The jacket water and LTA circuits are both located
in the same heat exchanger and divided by a pair of blanking plates.
Figure 1 – QSK60 Heat Exchanged Engine

Titanium plate type

heat exchanger

Page 3 of 28
Figure 2 shows a schematic of the cooling system for a QSK60 Heat Exchanger
cooled engine. The full file is attached in PDF format at the end of this document
for better resolution.

Figure 2 - QSK60 HX Cooling System Schematic

Figure 3 shows the coolant flow diagram of the QSK60 heat exchanged version.
For more details of this diagram refer to the attached “Coolant Flow Diagram”
document at the end of this bulletin.

Page 4 of 28
 Figure 3 - QSK60 with Heat Exchanger Coolant Flow Diagram

1.1 Central Cooling Recommendations

A central cooling system is a system that can be used to cool several engines
and other marine components such as gears coolers, auxiliary engines, etc.
Typical engines that work in vessels with central cooling system are heat
exchanged engines. One important parameter that needs to be sized for central
cooling system is the sea water flow through the engine heat exchanger. Use
Figure 4 and Figure 5 to determine the minimum seawater flow along with the
following procedure:

a. Perform a study of all heat loads included in the circuit (make sure to
include all other sources of heat such as gear coolers, auxiliary engines,
etc.)
b. Provide a 20% margin to the value calculated in (a). This safety factor is
required due to fouling in the heat exchanger plates. (Fouling forms on the
plates with time under normal operating conditions.)
c. Match the total heat value to the rated engine rpm curve shown in Figures
4 & 5 an obtain the seawater flow for both the JW and LTA circuit
d. Compare the two seawater flow numbers obtained in (c) and select the
greater value of the two
e. Multiply by 2 the value obtained in (d) to account for total seawater flow
required by the engine

Page 5 of 28
This process works fine as a quick estimate of the total sea water flow needed
from the centralized system; however, a careful study of all heat loads has to be
done by the designer.

Figure 4 and Figure 5 show the heat rejection performance plots of the JW and
LTA coolers as a function of the sea water flow.

Figure 4 - Jacket Water Cooler Performance Curve

Figure 5 - LTA Cooler Performance Curve

Page 6 of 28
The sea water pressure drop curve can be used to derive total system
restrictions necessary for sizing the complete sea water pipe system. For this
reason, the pressure drop curve across of the engine’s heat exchanger is
presented below in Figure 6.
Figure 6 - QSK60 Seawater Pressure Drop across the Heat Exchanger

1.2 Sea Water Pump

The QSK60 seawater pump (option SW 6030) is equipped with a bronze impeller
and is self-priming. This pump is mounted off the front of the gear housing. This
pump can flow water at a rate of 500 gallons per minute at rated engine speed.
Figure 6 shows the location of this pump. Table 2 describes the sea water
connections.
Table 2 - Sea Water Pump Connections

Option Connection Type Dimension

Sea water inlet /
SI 6001
Flexible rubber (Mercer type)
3" ANSI B16.5 150#
Sea water outlet /
SO 6001
Flexible rubber (Mercer type)

Page 7 of 28
For further information see MAB 0.08.17-7/16/2001, Sea Water Pump
Performance, as well as MAB 0.08.17-11/04/2002, KV Gilkes Sea Water Pump.

Figure 7 -Sea Water Pump

Sea water pump

1.3 LTA Pump

The LTA pump (option TB 6800) is mounted off the rear of the gear housing as
shown in Figure 8. The location of the LTA pump is different between the heat
exchanger and keel cooled engine. For heat exchanger engines the LTA pump
is located at the back of the gear housing; whereas, for keel cooled engines, the
pump is LTA pump is mounted on the front of the gear cover on the port side of
the engine.
Figure 8 - LTA Pump

LTA pump located

at the read of the
gear housing –
heat exchanged
engines

Page 8 of 28
1.4 Jacket Water Pump

The jacket water pump (option WP6012) is mounted off the rear of the gear
housing on the starboard side of the engine as shown in Figure 9. This pump
can deliver a maximum 585 gal/min at 1900 rpm with 5 psi restriction.

Figure 9 - Jacket Water Pump

JW pump

1.5 Expansion Tank

The expansion tank is assembled loosely from the plate pack of the heat
exchanger assembly and is mounted on vibration isolators as shown in Figure
10. The tank is designed to reduce turbulence within the tank through the use of
baffles. The tank is option number HX 6129 and includes the heat exchanger
and plumbing.

During engine operation, small quantities of coolant from both LTA and Jacket
Water circuits will mix in the expansion tank because both circuits use the same
tank. This tank does not need to be removed for the disassembly of the plate
pack but it does need to be removed in order to remove the entire heat
exchanger assembly.

Page 9 of 28
 Figure 10 - Expansion Tank Location

Expansion tank Mechanical

level
sensor

The expansion tank comes with a mechanical coolant level sensor that is
mounted on the side right of the expansion tank. The coolant level sensor is
mounted on the side of the tank so that under normal conditions it is always
submerged in coolant and it does not trigger false alarms. This includes times
such as cold start ups when engine coolant is at its smallest volume.

1.6 Heat Exchanger Selection in CSL

When specifying a QSK60 heat exchanger cooled engine, the following steps will
be required:

1. Start with PRIC 2710. This price specification is keel cooled by default.
2. Select option HX6130. This automatically selects the dependent TH and
TB options. This option includes the engine mounted expansion tank.
3. Select option SW6030. This option selects the sea water pump without
any flexible connections.
4. Select options SI6001 & SO6001. These options provide the connections
needed for the sea water inlet and outlet.
5. Select WI6028 & WO6083. These options provide the plumbing for the
water inlet and outlet of the heat exchanger.

Page 10 of 28
2.0 Keel Cooled Engines

The QSK60 keel cooled (KC) configuration is a two pump two loop system, jacket
water (JW) and low temperature aftercooler (LTA). The system requires two
independent coolers, one for the JW circuit and a second for the LTA circuit. The
keel cooled engines include a bypass coolant tube located at the port side of the
H-tube in order to reduce coolant flow to the levels defined on the data sheets.
Figure 10 shows the location of the H-tube and the bypass tube.

Figure 11 - Keel Cooled Jacket Water Bypass

H-tube

Bypass Tube

To JW water
pump inlet Orifice plate

Jacket Water
Outlet

The bypass tube bypasses jacket water around the keel cooler and directs it
straight back to the inlet of the water pump. An orifice plate restricts flow through
the bypass tube so that there is still adequate cooling flow through the keel
cooler.

Figure 11 shows a schematic of the cooling system for a QSK60 Keel Cooled
engine. The full file is attached in PDF format at the end of this document.

Page 11 of 28
 Figure 12 - QSK60 KC Cooling System Schematic

Figure 12 shows the coolant flow diagram of the QSK60 keel cooled version.
For more details of this diagram refer to the attached “Coolant Flow Diagram”
document at the end of this bulletin.

Figure 13 - QSK60 Keeled Cooled Coolant System Diagram

Page 12 of 28
Figures 14 and Figure 15 show the locations of the Jacket Water inlet and outlet
connections. Figure 16 shows the locations of the LTA inlet and outlet
connection points. Both, the JW and LTA connections (WI6026 & WO6067)
include a flexible mercer type connection at each flange.

Figure 14 - Jacket Water Inlet Connection

Flexible Mercer (Rubber

Type) Connection

Main Cooling Pump Inlet

(5” ANSI B16.5 150#)

Figure 15 - Jacket Water Outlet Connection

Main Cooling Pump Outlet

(5” ANSI B16.5 150#)

Flexible Mercer (Rubber

Type) Connection

Page 13 of 28
 Figure 16 - LTA Inlet & Outlet Connections

LTA Cooling Pump Outlet

(2.5” ANSI B16.5 150#)

Flexible Mercer
(Rubber Type) Connection

LTA Cooling Pump Inlet

(2.5” ANSI B16.5 150#)

2.1 LTA Pump

The QSK60 keel cooled engine incorporates a LTA pump (Option TB 6799)
which is driven off the front of the gear housing. This pump is different than the
one on heat exchanged engines. On heat exchanged engines the LTA pump is a
small pump mounted on the back of the gear housing; whereas, on keel cooled
engines, the LTA pump is a larger pump and mounted on the front of the gear
housing as shown in Figure 17.

Figure 17 - Keel cooled LTA pump

LTA Pump

Page 14 of 28
2.2 Expansion Tank Design and Size (Customer Supplied)

Keel cooled engines require a customer supplied remote mounted expansion

tank. Both circuit, LTA and Jacket Water, may be plumbed to the same
expansion tank. The size of the expansion tank must comply with the
instructions indicated in the Commercial Marine Installation Direction bulletin.

The design of any customer supplied expansion tank must include the following
features:

• Sight glass that shows the level in the tank

• A fill cap with a maximum pressure of 15 psi must be provided
• A coolant level sensor to activate an alarm when the level in the tank is
low
• The expansion tank will need a 1/4" NPT boss to install the ECM coolant
level sensor. The sensor and extension harness will be shipped loose.
• The ECM coolant level sensor should be at a level that will be submerged
under normal operating conditions including when the coolant is cold and
therefore at its smallest volume.

2.3 Engine Coolant Vents

The engine vent system provides a continuous flow of water through the
expansion tank as method of removing air and gases from the engine coolant.
The highest points in the engine coolant circuit are the best locations. All
Cummins engines have venting provisions and the QSK60 is not the exception.
The QSK60 engine incorporates five vent connections: 1 in the H-tube, 2 in the
LTA tubes, 2 at the thermostat housing, and two possible at rear for nose down
installations. Marine hoses and fittings are not provided. Figure 18 & 19 show
the locations and recommendations for venting the QSK60 engine.

Page 15 of 28
 Figure 18 - Vent Connections

H-tube – Vent LTA outlet - Vent

or Pet Cock
(Optional)

LTA Bypass – Vent or Pet LTA Inlet -

Cock (Optional) Vent

Figure 19 - Thermostat Housing Vent Connections

LTA Vent Connection Jacket Water Vent Connection

2.4 Keel Cooler Engine Selection in CSL

When specifying a QSK60 keel cooled engine, the following steps will be
required:

1. Start CSL with PRIC 2710. This price specification is keel cooled by
default.
2. Select option WP6012. This option will add the coolant pump and its
dependents.

Page 16 of 28
 3. Select option WI6026 and WO6067. These options add the inlet and
outlet connections for both the jacket water and LTA circuit including the
flexible rubber connections.

3.0 Radiator Cooled System

The QSK60 MCRS engine comes with a one radiator cooled arrangement similar
to the QSK38/50. This option (RA6004) is a no content option that drives the
selection of coolant connections specifically designed for radiator cooled
applications. This option does not include a radiator; instead, it is intended for
customer supplied radiator.

Table 3 shows a description of the major coolant connections that are available
for a radiator cooled system.
Table 3 - Radiator Cooled Options

Option Description
RA 6004 a) No content option that indicates cooling system will use
a customer supplied radiator.
b) It also allows for selection of fan drive and appropriate
water outlet/inlet connections
FA 6199 Fan drive and tensioner (fan is not included)
Jacket water hose bead connection - 127 mm [5 in]
WI 6045
LTA hose bead connection - 76.2 mm [3 in]
Two Jacket water hose bead connections - 76.2 mm [3 in]
WO 6109
One LTA hose bead connection - 76.2 mm [3 in]

The QSK60 radiator cooled version comes with two jacket water and one LTA
outlet connections included in option WO 6109. This option is a three 76.2 mm
[3 in] hose bead type connections oriented straight up as shown in Figure 20.
Option WI6045 provides both the JW and the LTA inlet connections. The JW
connection is a 127 mm [5 in] hose bead connection. The LTA inlet is a 76.2 mm
[5in] hose bead connection.

Page 17 of 28
 Figure 20 - QSK60 Radiator Fan Drive – RA6004

LTA outlet

JW inlet

LTA inlet JW inlet

3.1 Fan Drive

The QSK60 offers one option for fan drive arrangement, FA6199. The selection
of this fan drive is not mandatory when RA 6004 is selected. Instead, it is
optional. The selection of RA6004 will not force the selection of FA 6199.

The fan drive option comes installed from factory and includes the fan pulley, the
idler pulley, a crankshaft pulley, a belt, and an automatic belt tensioner (fan is not
included). This arrangement is shown in Figure 21. The drive ratio is 0.5:1 with
a 701 mm [27.6 in] fan center.

Page 18 of 28
 Figure 21 - QSK60 Radiator Fan Drive – FA6199

JW outlet LTA outlet

LTA inlet

JW inlet

3.2 Radiator Cooled Engine Selection in CSL

When specifying a QSK60 radiator cooled engine, the following steps will be
required:

1. Start in CSL with PRIC 4600

2. Select RA 6004. This automatically selects the dependent TH and TB
options.
3. Select FA 6199 (if needed – not required). This drives selection of the
appropriate dependent DA option.
4. Select water inlet option WI 6045
5. Select water outlet option WO 6109

3.3 Installation Considerations

The following recommendations are intended to achieve a quality installation

when working with radiator cooled applications:

• Number of radiators - The radiator cooled system will need two radiators,
one for jacket water and one for LTA Coolant. LTA and jacket water must be
plumbed to the same top tank. If a common tank cannot be utilized, then a
balance tube must be connected between the two tanks.

Page 19 of 28
• Expansion tank - The expansion tank must have provision for showing the
level in the tank, a fill cap, and a sensor to activate alarm when the level in
the tank is low.
• ECM coolant sensor - The expansion tank will need a 1/4" NPT boss to
install the ECM coolant level sensor. The sensor and extension harness will
be shipped loose. The ECM coolant level sensor should be at a level that will
be submerged under normal operating conditions including when the coolant
is cold and therefore at its smallest volume.
• Customer supplied items - The fan and radiators will need to be customer
supplied.
• Remote radiator - If a remote radiator is used then the engine should be
specified as a keel cooled engine. In that case, it is important to note that the
bypass tube normally installed on a keel cooled engine must be blanked off to
eliminate any cooling water flow through the bypass tube. To blank off the
bypass tube, the three-bolt flange must be disassembled and the orifice plate
(Figure 11) replaced with a blank. This will prevent jacket water from flowing
through the bypass tube, and force all of the flow through the radiator to
ensure adequate cooling. The following table is the cooling flow data for the
radiator cooling system when the bypass tube is blanked off and when the
system is at maximum friction head.
Table 4 - Coolant Flow for Radiator Cooled Applications

Engine RPM Cooling Water Flow (GPM)

1900 515
1800 480
1500 380

• LTA requirements - Two design constraints must be given to the radiator

supplier for the LTA circuit, an emissions constraint and a durability
constraint.

o The constraint for emission compliance is 49°C [120°F] coolant return

temperature to the engine at 35°C [95°F] ambient temperature.
o The durability constraint is 68°C [155°F] coolant return temperature to
the engine at 50°C [122°F] ambient temperature.

It is not practical to design a radiator to meet the emissions constrain only. This
is because high ambient temperatures may make it impossible to provide the
coolant return temperature required. Therefore a durability constraint is given.
Typically, radiator suppliers will design for both constraints.

Page 20 of 28
4.0 Additional Options
4.1 Fuel Cooler

The QSK60 is available with a fuel cooler option number FS 6036. The fuel
cooler is plumbed into the return fuel circuit and cools the fuel returning from the
fuel pump to the vessel’s fuel tank. The fuel cooler is mounted on the engine just
aft of the LTA pump as shown on Figure 22. The fuel cooler is cooled by LTA
coolant.
Maximum fuel supply to pump temperature is below value specified in
Cummins Performance Data Sheet.

The fuel cooler must be used when the vessel’s fuel system arrangement is such
that, because of the QSK 60’s heat load, the temperature of the fuel at the inlet to
the fuel pump exceeds 160 degrees F (71 degrees C).
The QSK 60 heat load regarding return fuel is specified on the engine data sheet.
Using the fuel cooler will increase fuel return line static pressure by 3” Hg (.10
atm). For the performance data of the fuel cooler refer to Figure 23. For more
details refer to the attached “QSK60 Cooled Performance” document at the end
of this bulletin.

Figure 22 - Fuel Cooler

Fuel Cooler

Page 21 of 28
 Figure 23 - Fuel Cooler Performance

Fuel Heat Transfer Performance

5.00
80
4.50

Fuel Side Pressure Drop (in Hg

70
Heat Rejection (kBtu/hr)

4.00
60
3.50
50 2100 RPM 2000 RPM 1900 RPM

at 60F)
1800 RPM 1500 RPM 1400 RPM 3.00
40 1000 RPM 800 RPM Fuel side pressure drop (in Hg)
2.50
30

20 2.00
DP curve
10 1.50

0 1.00
3.5 4.5 5.5 6.5
Fuel Flow in GPM

4.2 Marine Gear Oil Cooler

The marine gear oil cooler is an available option on the propulsion engine and is
mounted between the flywheel housing and air cleaner assembly (see Figure
24). The cooler is part of the LTA circuit and is option number OC 6005. The
marine gear oil connections to the cooler are customer supplied. The gear oil
connections on the gear oil cooler are both 1 5/8” – 12 UN male flare fittings.
The cooling water fittings on the gear oil cooler are both female 7/8” – 14 UNF
fittings. For gear oil cooler performance see Figure 25. Refer to the Attachment
section for a larger view of the marine gear oil cooler performance curves.

Page 22 of 28
 Figure 24 - Gear Oil Cooler – OC6005

Gear Oil Inlet

Gear Oil Outlet (1 5/8” – 12UN)
(1 5/8” – 12UN)

Figure 25 - Gear Oil Cooler Performance

Gear Oil Heat Transfer Performance

Max. coolant inlet temp. = 135 deg. F
50% glycol / 50% water, SAE30 Gear Oil, Max Oil Temp 185F
3.50 35

3.00 30

Gear Oil Pressure

2.50
Heat Rejection

25
(kBtu/min)

Drop (psi)
2.00
20
1.50
15
1.00 DP curve

0.50 10

0.00 5
35 40 45 50 55 60
Gear Oil Flow (GPM)
2100 RPM 2000 RPM 1900 RPM
1800 RPM 1500 RPM 1400 RPM
1000 RPM 800 RPM Gear Oil Pressure Drop

Page 23 of 28
5.0 Attachments
5.1 QSK60 Cooler Performance

5.2 QSK60 KC & HX Cooling Schematic

5.3 QSK60 Coolant Flow System Diagram

Change Log

Revising Author’s
Date Change Page
Name
08/30/2005 MAB initially created by Paul Slotsema
11/15/2005 No change in content/Uploaded to web site. Diana DeJesus Cobb
05/03/2007 No change in content/Extended expiration Diana DeJesus Cobb
date
05/11/2007 Added coolant level sensor boss details Scott Rath
05/27/2008 No content changes/Extended expiration date Diana DeJesus Cobb
05/26/2009 No content changes/Extended expiration date Courtney Shaw
6/18/2009 Update all MAB with new information and All Olmedo Farfan
graphics
6/19/2009 Publish to the web Courtney Shaw
7/10/2009 Updated Central Cooling Information & sea 5-8 Olmedo Farfan
water pressure drop curve
07/16/2009 Published to the web Courtney Shaw
8/5/2009 Updated Radiator cooled section 17-19 Olmedo Farfan
08/05/2009 No content changes/Corrected page number Courtney Shaw
block
08/07/2009 Updated Radiator cooled section 20 Olmedo Farfan
08/11/2009 Published to the web Courtney Shaw
08/09/2010 No content change/Updated links/Extended Courtney Shaw
expiration date
12/08/2010 Extended expiration date Courtney Shaw
12/08/2011 Extended expiration date Courtney Shaw

Distribution of this document is intended for Cummins personnel and distributors. The information contained in this
document is only considered valid while published on the Marine Website. Copies and archived documents are not
considered current.

Page 24 of 28
QSK60 Heat Exchanged Cooling System

Cummins Confidential Page 25 of 28

Cummins Confidential Page 26 of 28
QSK60 Keel Cooled Cooling System

Cummins Confidential Page 27 of 28

Cummins Confidential Page 28 of 28