WARNING

Do not use alcohol or gasoline as a fuel blending agent. They can be unstable under
certain conditions and be hazardous or explosive when mixed with diesel fuel.

WARNING
Ether or ether starting aids must never be used with the manifold preheater type
starting aid, or an explosion can result. Follow installation, storage and operating
instructions furnished with each aid. Do not use the ether aids during operation of the
engine; serious damage can result from uncontrolled high cylinder pressures.

CAUTION
Do not use ether with glow plug starting aids as engine damage can occur.

CAUTION
Anti-leak antifreezes are not recommended for use in Cummins® Engines. Although
these antifreezes are chemically compatible with DCA water treatment, the anti-leak
agents can clog the coolant filters, oil coolers and radiators making them ineffective.

CAUTION
Do not operate the external type heaters with the engine running.

CAUTION
Circuit breakers and fuses are slow to act in extreme low temperatures, therefore,
electrical accessories must have adequate size wiring and equipment.

CAUTION
Use Teflon type hose.

CAUTION
Do not use flame type preheaters in air intake manifolds with aftercoolers; the flame can
damage the o-ring seals.

CAUTION
 Allow the battery to rejuvenate and the starter to cool for 2 minutes after 30 second
maximum cranking, if no start is obtained.

CAUTION
Due to the initially high cranking speeds from these type cranking motors, always
prelube the engine and/or turbocharger in temperatures below -12°C [10°F] .

Service Bulletin Number Date

3379009 14-FEB-2008
Design Application Market Application
All All

Service Bulletin

Operation of Diesel Engines in Cold

Climates
Satisfactory performance of a diesel engine in cold and arctic climates requires
modification to the engine support systems, operating practices, and maintenance
procedures. Everyone involved with equipment in these climates must address the fact
that cold climates will have an effect on the starting, performance and reliability of the
equipment as well as the engine. The reliability of the engine and equipment will be
seriously impaired if not properly prepared for the environment in which it is operating.

To winterize equipment there are three objectives:

1. Reasonable starting characteristics followed by practical and dependable warm-up

of engine and equipment
2. A unit or installation needs to be as independent as possible from other external
influences
3. Modifications which maintain satisfactory engine operating temperatures with a
minimum increase in maintenance of the equipment and accessories.
As the operating climate becomes colder, an increasing amount of equipment modification
is required for satisfactory performance. The engines must be capable of operating in all
climate extremes with satisfactory performance and durability. Some cold climate
problems are listed below. While this list contains problems resulting from cold
temperatures, it must be stressed that additional problems can occur.

Engine Idle

It is not recommended that the engine be operated at an idle no load condition for
prolonged periods (above 15 minutes) of time. Operating engines at idle (650 to 1000 rpm)
in cold ambient temperatures wastes fuel, accelerates wear, and can result in serious
engine damage. Under these low temperature conditions, incomplete combustion will
occur, allowing deposits of unburned tars and carbon to build-up on the valve guide and
valves and eventually cause valve sticking. At low idle (650 to 700 rpm) there will be
insufficient coolant flow and coolant temperature at the cab heater to maintain adequate
cab heat. In low ambient temperatures, if radiant and convection heat losses are not
prevented, the engine will not consume an adequate amount of fuel to maintain coolant
and combustion temperatures. Sufficient support systems are recommended to preclude
the necessity to idle engines for prolonged periods.

It is recognized that regardless of recommendations, operators will idle engines for

prolonged periods, especially if the driver is sleeping in the cab compartment of the
chassis. If the operator insists on prolonged idling, it is recommended that the engine be
idled at an rpm which is adequate to maintain coolant temperatures above 60°C [140°F]. In
minus 18°C [0°F], the engine will need to be idled above 1200 rpm. For this type of
operation, a full on-off type fan and winter front must be used. The thermostat, thermostat
seal and the deaerating system must not allow coolant leakage through the radiator core
with the thermostat in the closed position.

Electrical Systems

The normal source of energy used to crank an engine is a battery. As the battery
temperature decreases, the battery's capacity to produce power is lowered and its ability to
recover power is slower. The engine's cranking load increases as the ambient temperature
decreases, compounding the battery power loss problem.

Engine manufacturers normally recommend battery and electrical system capacity for
specific engine families to provide an adequate start at minus 18°C [0°F]. For satisfactory
operation in colder ambients, the batteries need to be heated to restore their original
cranking capacity, or more batteries need to be added. Inadequate battery capacity results
in low cranking speed. Cranking speed continues to slow down during the cranking cycle
and can progress to the point where the engine will not start.

The wire size, length and connections of the starter circuit determine the ability of the
battery to freely transmit power to the starter. Undersized wire acts as a restriction to flow
of electrical power. Loose or corroded wires and connections can consume up to 50
percent more of the available battery power before it gets to the starter.

An electric starter simply receives electrical energy and converts it to mechanical energy.
The peak efficiency of the starter occurs at engine cranking speeds of between 100 to 150
rpm. At lower speeds the efficiency drops off and current flow increases. If the starter is
allowed to stall, and the engine will not start, 100 percent of the electrical energy turns to
heat and will burn up the starter and wiring. If cranking speeds are continuously low, either
more energy (battery capacity), higher starter torque, or less cranking load is required.

Fuels

The free flow of diesel fuel depends on its temperature, pour and cloud points. The
phenomenon of fuel thickening in cold environments is referred to as waxing. The
temperature at which this wax forms varies with the base stock of fuel. If the engine is
operating below the cloud point of the fuel, the wax crystals circulated with the fuel will clog
screens, filters, or restrict the fuel lines at the sharp bends, fittings etc. Pour point
depressants only reduce the size of the wax crystals in the fuel, they do not alter the
temperature at which the wax crystals form. The only known method to prevent wax
formation in fuels is to use a lower cloud point fuel or maintain the temperature of the fuel
above the cloud point. This can be accomplished by using fuel heaters whether the engine
is running or is not running.

When fuel heaters are used, they must be selected to maintain fuel temperatures above
the cloud point but below the point at which the lubricating quality of the fuel decreases.
Selected fuel heaters or filters for any given engine must not impose a restriction to the
fuel system that exceeds 100 mm Hg [4 in Hg] when measured at the fuel pump inlet.

Blending fuels (such as Number 1 fuel with Number 2 fuel) while reducing the wax point
also reduces the BTU content of the fuel, increasing fuel consumption. Blending also
reduces the lubricating quality of the fuel which reduces the life of the fuel system
components.

WARNING

Do not use alcohol or gasoline as a fuel blending agent. They can be

unstable under certain conditions and be hazardous or explosive when
mixed with diesel fuel.

Lubricating Oils

Two physical properties, viscosity and pour point, are vital to the lubrication of the engine
during cold start up. Viscosity is the most important. The lubricating oil must pour freely
from its containers and it must circulate freely throughout the engine. Although it is
possible to start an engine when the oil has solidified in the crankcase, doing so can result
in catastrophic engine shutdown due to lack of lubrication. There are cold climate
operation lubricating oils with a sufficiently low pour point available that will remain in a
liquid state at the minimum expected temperatures.

The viscosity of the oil controls engine friction and oil circulation. Oil viscosity influences
the following performance factors.
 1. Starting and warm up
2. Power output
3. Fuel consumption
4. Engine cooling
5. Starting wear
6. Oil consumption
7. Engine cooling
8. Engine noise

The first five performance factors are improved by using a low viscosity oil, while the last
three factors are improved with a high viscosity oil.

Lubricating oil viscosity is one of the most critical factors in engine startability. If the
viscosity is too high, the resistance to cranking ability is too high for the engine to reach an
acceptable cranking speed.

It is necessary to heat the engine lubricant before starting the engine if the lubricant that is
used does not have the proper pour point or viscosity. Heating the lubricant will decrease
its viscosity, therefore, increasing lubrication and reducing friction during cranking. All
filters must be located within the confines of the engine compartment so the heat of the
engine can be used to prevent gelling of the lubricants.

Air Intake Systems

There are two aspects of intake air which must be taken into consideration when
winterizing a vehicle. These considerations are air density and temperature.

Air Density

Air density increases as ambient temperature decreases. The net result in a turbocharged
engine is that the peak cylinder pressure increases. An increase of cylinder pressure can
contribute to the following types of problems.

1. Blocks cracking
2. Blown head gaskets
3. Excessive crankshaft bearing loading
4. Camshaft break down when hydraulic engine brakes are used
5. Loosening or breaking of head bolts
6. Piston ring beat in
7. Cracked pistons

Air Temperature

There is a direct correlation between intake air temperature and combustion temperature.
One of the end results of a diesel engine with cold intake temperatures is that combustion
temperatures will be reduced. At reduced combustion temperature, the low ends of the
diesel fuel do not burn. These unburned heavy ends of the fuel will deposit a tar-like
varnish substance on the valve guides and valve stems and cause them to stick in the
open position. When the open valves and pistons meet, a break down occurs. Cold intake
air temperatures will also result in detonation (uncontrolled combustion) and piston burning.
Below 0°C [32°F], it is recommended that intake air come from inside the engine enclosure.
This will provide warm air to the intake and reduce engine heat loss. If the air cleaner is
not located within the engine compartment enclosure, then ducting must be routed from
the engine compartment to the air cleaner inlet. Adequate sealing of the engine
compartment is necessary. Side curtains alone are not always satisfactory. If there are
openings around the radiator cowl and underneath the engine, these areas must also be
sealed. Depending on ambient temperature and engine compartment size, heat the air
within the engine compartment to maintain combustion temperatures. An aftercooled
engine will perform well in these conditions, as the cooler element which normally cools
heated air down to near the level of the coolant temperature, will warm cold intake air up to
near the coolant temperature. It is extremely beneficial to provide a temperature controlled
on-off type fan so the radiant and convection heat within the engine compartment is not
dissipated by air flow.

Cooling System

CAUTION

Do not use ether with glow plug starting aids as engine damage can
occur.

Coolant within a diesel engine is primarily used as a heat transfer media and is subject to
freezing in cold and Arctic climates. The lowest freezing temperature that can be provided
for the coolant is obtained by using a solution of approximately 60 percent ethylene glycol
and 40 percent water. This mixture will turn to slush at about -50°C [-60°F] . It is necessary
to heat the coolant or use a starting aid (ether) in climates of -1° to 10°C [30° to 50°F] and
colder to get a successful start. In climates colder than -23°C [-10°F] it is recommended
that coolant heaters be used in conjunction with ether starting aids.

There are three basic types of coolant heaters available in the marketplace. The heaters
selected must maintain the coolant temperature to a minimum of 50°C [120°F] in any
temperature encountered.

• Immersion Heaters
o Immersion heaters have a heating element immersed within the confines of
the engine coolant passage. Heat is transferred to the cylinder liners and
block via the coolant. Due to space limitations, the wattage is limited to 2500
watts each or less. An external electrical source is required to operate the
heaters.
• Tank Type Heaters
o Tank type heaters function on the convection principal. That is, a volume of
coolant is heated within a small tank and then the heated coolant is
circulated through the engine via the hose connections (similar to a
percolator coffee pot). There are heaters available from 1000 to 4000 watts.
An external electrical source is required for this type of heat. There are also
 tank type heaters with recirculating pumps which continuously circulate the
heated coolant through the engine systems.
• Fuel Burning Coolant Heaters
o Fuel burning coolant heaters are designed to burn liquid/vapor type fuels and
some will operate on a mixture of fuels. The most common fuel burning
heaters normally use diesel fuel, propane or gasoline. These are furnace gun
type heaters where fuel is ignited via an igniter and the fuel is then sprayed
on a transfer media such as a porous ceramic disc. This flame then heats the
coolant via coils contained within the heater and transferred to the engine
either by convection or by recirculating pumps incorporated into the heaters.
These types of heaters are available in sizes from 6000 to 82000 BTU.
Exhaust gases from these heaters can be used to heat engine compartments
and accessories such as batteries.

Coolant Flow

The minimum amount of coolant that has to be heated for maximum efficiency of the
heaters is the volume of coolant in the block and accessories in the coolant bypass system.
To achieve this condition, the thermostats and thermostat seals must not allow coolant to
flow through the radiator when the thermostat is closed. To check for coolant leakage past
the thermostat seal and/or thermostat:

1. Remove the engine outlet hose at the thermostat housing. Hold the hose in the air
above the radiator baffle level, and run engine against the governor. If water comes
out of the water outlet connection, the thermostat and/or seal is leaking. 97 percent
of the time, it is the seal or debris keeping the thermostat open.
2. If the coolant does not reach thermostat opening temperature, changing the
thermostat will not correct the problem.

The second critical area for cold operating engines is coolant flow through the radiator
core when the thermostat is in the closed position. A properly functioning deaeration
system must be incorporated and there must be no reverse flow of coolant through either
the fill line or the radiator. The deaeration baffle must not leak and must not have vent
holes. To check for this condition:

1. Drain cooling system

2. Remove make up (fill line) at water pump and plug the end
3. Fill area above baffle with coolant. If water leaks through the drain cock of radiator,
remove tank and repair. Coolant can be leaking through core vent tube which can
have to be extended in expansion area.

Radiator Shutters

When they are closed, radiator shutters prevent air flow across the radiator core as well as
the engine. Air flow across the engine can extend warm-up time and prevent the coolant
from reaching minimum operating temperatures in extremely cold ambient temperatures.

The two most commonly used terms associated with the preparation of equipment for low
temperature operation are Winterization and Arctic Specifications.
Winterization of the engine and/or components so starting and operation are possible in
the lowest temperature to be encountered requires:

1. Use of correct materials. (Some materials get brittle and fail at low temperatures.)
2. Proper lubrication, low temperature lubricating oils.
3. Protection from the low temperature air. The metal temperature does not change as
a result of air flow, but the rate of heat dissipation is significantly increased by the
flow of cold air over the exposed surfaces.
4. Fuel of proper grade for lowest operating temperature.
5. Heating to be provided to increase engine block and component temperature to a
minimum of -23°C [-10°F] for ether aided starting in lower temperatures.
6. Proper external heating source available.
7. Electrical equipment capable of operating in lowest expected temperature.

Arctic Specifications refer to the design material and specifications of components

necessary for satisfactory engine operation in extremely low temperatures to -54°C [-
65°F] . Contact Cummins Inc. or the equipment manufacturer to obtain the special items
required. The Arctic Specifications listed on the following pages are only general
guidelines.

Fan Drive

A temperature controlled fan drive can be used to reduce cold air circulation at the engine
to help conserve compartment heat. These devices function by completely or partially
disconnecting the fan from it's drive source at a specified temperature. Several types of fan
drives are commonly available: viscous, thermatic, and thermo-modulating.

Equipment Preparation

The amount of modification varies as the temperature changes. Therefore, the following
tabulation of recommended equipment is grouped into three temperature ranges. When
equipment heaters are required as recommended in this bulletin, it is suggested that all
system heaters (coolant, oil and intake air) be used. The following recommendations apply
to all engine models, except as noted.

Winterize 0°C to -23°C [32°F to -10°F]

• Use Ethylene Glycol antifreeze to protect to -29°C [-20°F]

• Use multi viscosity oils meeting API, CC/CD specifications. See Bulletin 3379002.
• Fuel to have maximum cloud and pour points 6°C [10°F] lower than ambient
temperature in which engine operates.

Thermostat

• Radiator Shutters
• System to provide a recommended 150 rpm cranking speed at -23°C [-10°F] V6-
378 and V8-555 require 180 rpm.
• Starting aid: ether or manifold flame heater.
• Provide for warmed intake air from engine compartment in temperatures below -
12°C [10°F]
• Shorten breather tube to at least 12 inches above oil pan flange on highway
applications for operations below -18°C [0°F] .

When Using Air Starters

• Provide alcohol injector in air compressor system.

Coolant Heaters

• Oil Heaters

Winterize -23°C to -32°C to [-10°F to -25°F]

• Use ethylene glycol antifreeze 50 percent, water 50 percent.

• Use multi viscosity oil meeting CC/CD specifications. See Bulletin 3379002.
• Fuel to have maximum cloud and pour points 6°C [10°F] (lower than ambient
temperature in which engine operates.

Thermostat

• Radiator shutters sealed around edge and adjusted to close tight or shutters plus
radiator cover.
• Winterized heavy duty 24 volt cranking system to provide a recommended 150 rpm
cranking speed at -32°C [-25°F] after preheat. V6-378 and V8-555 require 180 rpm.
• Starting aid: ether or manifold flame heater.
• Provide for heated intake air using intercooler manifold, engine compartment
enclosures with air cleaner intake air drawn from engine compartment.
• Dry type air cleaner.
• Shorten breather tube to at least 30 cm [12 in] above oil pan flange.

When Using Air Starters

• Provide alcohol injector in air compressor system.

Coolant Heaters

• Oil Heaters Oil heaters - If proper viscosity oil is not used.

• Off/On type fan.
• Oil pan shield for on-highway units.

Battery Warmer

• Heavy duty arctic type batteries.

• Battery cables size per Table 10,
• All filters to be mounted in the engine compartment. Before exposing the equipment
to the low temperature, change all filters, drain the systems and flush thoroughly
with arctic fuels and lubricants.
• Insulate all coolant, fuel, and oil lines exposed to the elements.

Arctic Specifications -32°C to -54°C [-25°F to -65°F]

• Use ethylene glycol antifreeze 60 percent, water 40 percent mixture.
• Use Arctic oils meeting CC/CD specifications. See Bulletin 3379002.
• Fuel to have maximum cloud and pour points 6°C [10°F] lower than ambient
temperature in which engine operates.

Thermostat

• Tight winter front cover for radiator in front of shutters.

• Winterized heavy duty 24 volt cranking system to provide a recommended 150 rpm
cranking speed at -32°C [-25°F] after preheat. V6-378 and V8-555 require 180 rpm.
• Starting aid: ether or manifold flame heater.
• Provide for heated intake air using intercooler manifold, engine compartment
enclosures with air cleaner intake air drawn from the engine compartment.
• Dry type air cleaner. Install in engine compartment.
• Shorten breather tube to at least 30 cm [12 in] above oil pan flange.

When Using Air Starters

• Provide alcohol injector in air compressor system.

Coolant Heaters

• Oil heaters - If proper viscosity oil is not used.

• Off/On type fan.
• Insulated cover for lower part of the engine compartment including oil pan shields.

Battery Warmer

• Heavy duty arctic type batteries.

• Battery cables size per Table 10. Hold circuit wiring short as possible.
• All filters to be mounted in the engine compartment. Before exposing the equipment
tot he low temperature, change all filters, drain the systems and flush thoroughly
with arctic fuels and lubricants. Replace the filter a second time after the flushing
operation.
• Repack fan hub and water pump with arctic grease.
• Winterize mechanical controls and instruments:
o tachometer
o tachometer cable
o starting aid control cable
o pressure gauges
o temperature gauges
• All regular lubricants for cables to be removed and left dry or replaced with arctic
type lubricants.
• Provide auxiliary engine compartment space heat sufficient to bring engine
temperature to -32°C [-25°F].
• -54°C [-65°F] electrical equipment and wiring.
• Use -54°C [-65°F] hose.
• Use -54°C [-65°F] rubber in the filter and dipstick expanders.
• Use -54°C [-65°F] belts.
 • Extend fuel supply tank vent to a warm area such as to the engine compartment to
prevent pulling frost into the tank.
• Insulate all coolant, fuel and oil lines exposed to the elements. Insulate or cover
with heat strip tape all coolant, fuel and oil lines exposed to the elements.

CAUTION

Anti-leak antifreezes are not recommended for use in Cummins®

Engines. Although these antifreezes are chemically compatible with
DCA water treatment, the anti-leak agents can clog the coolant filters,
oil coolers and radiators making them ineffective.

Maintenance

The accessory equipment used for low temperature operation and starting require
maintenance on a regular schedule like other components on the engine. As an example,
don't delay checking the performance of the manifold flame heater until the engine is to be
started.

Poorly or unscheduled maintenance always results in loss of productive time. Normal

maintenance practices must be followed on all components. Maintenance suggestions for
all engines are:

Winterize 0°C to -23°C [32°F to -10°F]

• Keep fuel tanks full to reduce moisture condensation. Drain sediment daily. Keep
fuel tanks full to reduce moisture condensation. Drain sediment daily.
• Adhere to a lubricating oil change schedule necessary to maintain clean oil.
• Daily check of preheater coil and electrical systems.
• Weekly check of cold weather support systems.

Winterize -23°C to -32°C [-10°F to -25°F]

• Keep fuel tanks full to reduce moisture condensation. Drain sediment daily.
• Adhere to oil change schedule necessary to maintain clean oil. Check level every
two hours.
• Daily check of preheater coil and electrical systems.
• Weekly check of cold weather support systems.
• Weekly check of temperature controls, thermostat and shutters.

Arctic Specifications -32°C to -54°C [-25°F to -65°F]

• Keep fuel tanks full to reduce moisture condensation. Drain sediment daily.
• Adhere to oil change schedule necessary to maintain clean oil. Check level every
two hours.
• Daily check of preheater coil and electrical systems.
 • Weekly check of cold weather support systems.
• Weekly check of temperature controls, thermostat, winter front, space heaters
starters and starter electrical system.

NOTE: All Temperature Categories: In areas of blowing snow it will be necessary to

remove air cleaner element and remove packed snow if air cleaner inlet is located
outside of engine compartment.

Accessory Equipment

Coolant Heaters

Electric or fuel fired coolant heaters are an excellent starting aid. Warm coolant creates a
more satisfactory starting condition by reducing cylinder to piston friction, where most cold
weather cranking drag occurs. Also, more complete combustion occurs when the
combustion chamber is warmed.

Electric Coolant Heaters

There are two types of electric coolant heaters. Direct immersion and external tank. Figure
1 shows a typical direct immersion type coolant heater. Figure 2 shows a typical external
tank type heater.

Tank Type Heaters

Some tank type coolant heaters are of the external type, mounted horizontally. The Kim
Hot Start models have an exclusive flapper type reinforced neoprene check valve. The
valve forces the heated coolant to move in only one (outlet) direction, and also stops a
bypass to normal coolant circulation while the engine is running.

Figure 2 illustrates a tank type external type coolant heater that can be applied to all
engines. Connect the heater inlet to the lowest point of coolant (water pump or lower
radiator tank) and the heater outlet to a point on the engine block higher than the heater
inlet to obtain the best thermo-syphon water flow.

CAUTION

Do not operate the external type heaters with the engine running.

CAUTION

Circuit breakers and fuses are slow to act in extreme low temperatures,
therefore, electrical accessories must have adequate size wiring and
equipment.
NOTE: Some tank type coolant heater assemblies include a check valve and
thermostat. An oil pressure switch for automatic cut-off of heating element must be
used with all heater assemblies. An appropriate pressure switch and relay assembly
is included with the 460 volt or 3 phase supply system.

Figure 1. Immersion heater for H, NH and NT engine.

Figure 2. External type heater on an engine.

Figure 3. Heater outlet to cylinder block.

These heaters are versatile in that they can be used for space heating of the engine
compartment, battery box or cab in addition to coolant housing.

Table 1: Immersion Type Coolant Heaters

Fleetguard® Part
Engine Model Wattage/Voltage
Number

C & J 160, 175, 190 1000/115, 251904

1000/230 251905

C & J 180 1000/115, 1000/230 259200, 259201

H, NH & NT Series with side 1000/115, 1000/230, 251900, 251901,

plate 1500/115, 1500/230 251902, 251903

N, NH & NT Full Flow Cooling-

1500/115, 1500/230 259360, 259361
high mount oil cooler

H, NH, & NT Full-Flow Cooling-

1500/115, 1500/230 259362, 259363
low mount oil cooler

NH 250 small bore 1500/115, 1500/230 259206, 259207

NTA 370, 420 1500/115, 1500/230 208833, 208834

KT-6 1500/115, 1500/230 254890, 259210

V-6 378 Cubic Inches V-8 504, 1000/115, 1000/230, 259204, 259205,
470, 555 Cubic Inches 1500/115 255257

V-6 195, 200, 215, 280 V-8 235, 1000/115, 1000/230, 259202, 259203,
265, 300, 350, 370, 430 1500/115 251906

V-903 1500/230 251907

L-10 1500/120 3309188

1500/240 3309189
Replacement Elements Available through Fleetguard®.

Table 2: Tank Type Coolant Heaters without Electrical Junction Box, Thermostat
and Check Valve

Heater Fleetguard® Part Number Voltage Wattage

259268 115 750

259269 115 1000

259270 115 1000

259271 230 1000

259272 230 1000

259273 115 1500

259274 115 1500

259275 230 1500

259276 230 1500

259277 460 1500

259278 115 2000

259279 115 2000

259280 230 2000

259281 230 2000

259282 460 2000

259283 115 2250

259284 115 2250

259285 230 2500

Table 2: Tank Type Coolant Heaters without Electrical Junction Box, Thermostat
and Check Valve

Heater Fleetguard® Part Number Voltage Wattage

259286 230 2500

259287 460 2500

259288 230 4000

259289 460 4000

Table 3: Thermostat for Heaters Listed in Table 2

Fleetguard® Part Number Temperature

259290 27° to 38° C [80° to 100° F]

259292 38° to 49° C [100° to 120° F]

259293 49° to 60° C [120° to 140° F]

259294* 49° to 60° C [120° to 140° F]

259295 60° to 71° C [140° to 160° F]

259296* 27° to 38° C [80° to 100° F]

259368* 60° to 71° C [140° to 160° F]

*Explosion Proof
Table 4: Tank Type Coolant Heater with Electrical Junction Box,
Thermostat and Check Valve
Cummins® Part Wiring Diagram Low Oil
Voltage Wattage
Number Number Pressure Switch
212021 120 1000 1 196074
212022 240 1000 2 196074
213730 120 1500 1 196074
212023 120 2500 1 196074
212024 240 2500 2 196074
Table 4: Tank Type Coolant Heater with Electrical Junction Box,
Thermostat and Check Valve
Cummins® Part Wiring Diagram Low Oil
Voltage Wattage
Number Number Pressure Switch
217243 480 2500 3
212026 240 4000 2 196074
217244 480 4000 3
240 (3-
217245 3750 4
phase)

Table 5: Suggested Connection Points for External Coolant Heaters

Engine Series Engine to Heater Heater to Engine

Make a pipe connection into

J (401), C (464) 3/4 inch in lower radiator pipe
65473 water heater cover.

1-1/2 inch plug at the rear of water

H (672), NH
3/4 inch in lower radiator pipe header or make connection into
(743), NH (855)
3003094.

V8-265 (785), V- Bottom plug (1 inch NPT) of rear

3/4 inch in lower radiator pipe
903, VT-903 left blank head.

V6 (352) (378) V8 Water jacket left side special

3/4 inch in lower radiator pipe
(470) (504) (555) cover.

K6 Lower radiator pipe Oil cooler.

Dual heaters (one on each side of

KV2300 &
block) unless Recirculating Pump
KV3067
is used

V12-1710 Lower radiator pipe Engine block.

Use a minimum hose size Number 16. For increased coolant flow and greater heater
efficiency, use Number 20 hose.

CAUTION

Use Teflon type hose.

Table 6: Suggested Wattage for Water and Oil Heaters
Heavy Duty
Heavy Duty
Medium Duty Heavy Duty Diesels
Temperature Diesels (Large
Diesels (Small Diesels (In-Line (Industrial and
Range V-8's-
V-Cummins®) 6-Cummins®) Off-Highway
Cummins®)
Engines)
(2) 2000/115
750 or 1000 watt 1000 watt coolant 1000 watt coolant coolant tank
immersion 1000 immersion 1500 immersion 2000 type or (1)
0°C to -18°C watt coolant tank watt coolant tank watt coolant tank 4000/23 coolant
[32°F to 0°F] type 150 watt oil type 150 watt oil type 150 watt oil tank type 300
immersion, ether immersion, ether immersion, ether watt oil
kit kit kit immersion, ether
kit
1000 watt coolant 1500 watt coolant 1500 watt coolant (2) 2000 watt or
immersion 1000 immersion 2000 immersion 2500 (1) 4000 watt
-18°C to -32°C watt coolant tank watt coolant tank watt coolant tank coolant tank
[0°F to -25°F] type 150 watt oil type 300 watt oil type 300 watt oil type 300 watt oil
immersion, ether immersion, ether immersion, ether immersion, ether
kit kit kit kit
1500 watt coolant 2250 watt or (2) 2000 watt or
4000 watt coolant
immersion 1500 2500 watt coolant (1) 4000 watt
-32°C to -51°C tank type 300
watt coolant tank tank type 300 coolant tank
[-25°F to - watt oil
type 300 watt oil watt oil type 300 watt oil
60°F] immersion, ether
immersion, ether immersion, ether immersion, ether
kit
kit kit kit

Fuses for Coolant Heaters

115 Volts

20 ampere fuse - maximum wattage 2250

25 ampere fuse - maximum wattage 2875
30 ampere fuse - maximum wattage 3450

230 Volts

20 ampere fuse - maximum wattage 4600

25 ampere fuse - maximum wattage 5750
30 ampere fuse - maximum wattage 6900
 Figure 4. Wiring diagram for tank type coolant heater.

Battery Box Heating - All Applications

Battery heating can be accomplished with hot fresh air from such sources as the cab, fuel
fired cab heater, hot exhaust air and hot liquid from the engine coolant system.

Electric Battery Heaters

Heat resistor strips can be mounted to the side of the battery box. Arrange the elements to
distribute heat around the batteries, avoiding hot spots. This strip heater is available as
Cummins® Part Number 143519, rated at 120 volts, 285 watts. This is obtained from
Cummins Inc., Columbus, Indiana, U.S.A. 47201. A typical battery warmer pad is available
as Fleetguard® Part Number 259262, rated at 150 volts, 200 watts. This part is obtained
from Fleetguard® Division, Cummins Inc. Cookville, Tennessee, 38501. See Figure 5.
Battery temperature must not exceed 58°C [125°F]. Use external electrical power as
available; this type load on the batteries would soon drain them. In all types of heaters, an
automatic thermostat control must be provided to prevent overheating of the battery.

Figure 5. Electric battery warmer.

Hot Fresh Air Heating

 Figure 6. Heated battery box.

Pipes lead from a cab or from a fuel fed cab heater to lower end of the box and discharge
on the top of the opposite end. It is advisable to provide 25.4 mm to 50.8 mm [1 in to 2 in]
clearance on each side of the battery for circulation. Further aid to heating can be provided
by mounting the battery off the floor of the box through use of a corrugated or perforated
support to permit circulation of warm air on all sides of the battery. Insulate the box.

Lubricating Oil Heaters

Lubricating oil heating is generally accomplished with immersion type electrically powered
heaters. Typical shielded type lubricating oil heaters are shown in Figure 7. All models
have stainless steel sheath elements, inserted into separate aluminum wells.

NOTE: Installation instructions for mounting and wiring accompany each unit.

Table 7: Oil Immersion Heater Applications

Oil Immersion Length of
Hole Oil System
Heaters Part Wattage Voltage Heating
Diameter Capacity
Number Element
194 mm [7-5/8 25 mm [1 7.6 to 15 liters
251920 150 115
in] in] [2 to 4 Gal]
194 mm [7-5/8 12.7 mm 7.6 to 15 liters
256855 150 115
in] [1/2 in] [2 to 4 Gal]
133 mm [5-1/4 12.7 mm 7.6 to 15 liters
259254* 150 115
in] [1/2 in] [2 to 4 Gal]
Table 7: Oil Immersion Heater Applications
Oil Immersion Length of
Hole Oil System
Heaters Part Wattage Voltage Heating
Diameter Capacity
Number Element
133 mm [5-1/4 12.7 mm 7.6 to 15 liters
259255* 150 230
in] [1/2 in] [2 to 4 Gal]
194 mm [7-5/8 25 mm [1 15 to 30 liters [4
251921 200 230
in] in] to 8 Gal]
133 mm [5-1/4 12.7 mm 15 to 30 liters [4
259256* 300 115
in] [1/2 in] to 8 Gal]
133 mm [5-1/4 12.7 mm 15 to 30 liters [4
259257* 300 230
in] [1/2 in] to 8 Gal]
216 mm [8-1/2 12.7 mm 30 to 45 liters
259258* 450 115
in] [1/2 in] [8-12 Gal]
216 mm [8-1/2 12.7 mm 30 to 45 liters
259259* 450 230
in] [1/2 in] [8-12 Gal]

*These heaters come with an adapter for brazing into a one (1) inch hole.

Optional Thermostat Part Number Fits the Following Oil Immersion Heaters:

259261** 259254, 259256, 259258

3009521 259255, 259257, 259259

**Thermostat recommended in moderate temperature areas if wattage exceeds 10

watts/quart of oil in the lubricating system.
 Figure 7. Shielded type lubricating oil heaters.

Engine Intake Air Heater

Engine intake air heating can be accomplished by pulling air from around the exhaust pipe
(Figure 8), out of the engine compartment (Figure's 9 and 10) or through an aftercooler. It
is always desirable and necessary under constant operation in ambient temperatures
below -32°C [-25°F] to preheat the air especially at lighter loads to provide conditions
leading to complete combustion. Normally, air pulled from the enclosed engine
compartment will be preheated sufficiently for operation to approximately -32°C [-25°F]. At
lower temperatures, build a compartment. (Figure 8) around the exhaust stack and pull air
through the jackets to the air cleaner. Regardless of the type of arrangement used to pull
air from the engine compartment and/or exhaust jacket, provision must be made to pull
outside air into the engine intake for operation at higher temperatures. This
recommendation applies to all engine models.
 Figure 8. Utilizing exhaust heat to warm intake air.

Figure 9. Exterior mounted air cleaner with flip valve.

 Figure 10. Utilizing engine heat to warm intake air.

Figure 11. Typical space heater for engine compartment enclosure.

NOTE: In heavy snow and ambients below -12°C [10°F], use the intake design shown
in Figure 9 and 10 to pull air from under the hood to prevent plugging of the air filter.

Engine Compartment Heaters

When the temperature drops below -32°C [-25°F], it is desirable to add heat to the engine
compartment in addition to the coolant, batteries and lubricating oil, to bring the engine
temperature up to a minimum of -32°C [-25°F] so satisfactory starting is realized. A typical
space heater, applicable to all engine models, is shown in Figure 11.

Starting Aids, Ether Type - All Engine Models

Electric Kit Part Number 3303779 (450-950 CID)

Includes all necessary components for installation. Order starting fluid cylinder, valve
assembly and atomizer separately. Measured starting fluid charge achieved by electric
dash-mounted push button. See figure 12.

Manual Kit 3303780 (250-450 CID) 3303781 (450-950 CID)

Figure 12, Electric Kit

Figure 13, Manual Kit
FOR BEST RESULTS, install atomizers in the most central location of the intake manifold.
If this is not possible, select a location that is closest to combustion. Air horn installations
require that orifice is aimed into or against the flow of air - achieving maximum mixing and
saturation for more effective starting.

The location or ejection direction of the orifice in PUNCH MARKED (arrow) on the
atomizer fitting to assists in the proper positioning of the atomizer within the manifold,
blower box or air horn.

NOTE: On turbocharged engines, the atomizer must be installed on the pressure

side of the turbocharger.
Fleetguard® Part Number Valve Assemblies

3303310 1.5cc Valve (Manual) (up to 250 CID)

259365 3cc Valve (Manual) (250 - 450 CID)

259366 6cc Valve (Manual) (450 - 950 CID)

259367 6cc Valve (Electric) (450 - 950 CID)

3304015 12cc Valve (Manual) (950 - 1900 CID)

3304016 12cc Valve (Electric) 950 - 1900 CID)

Order starting fluid can separately, Fleetguard® Part Number 259345

WARNING

Ether or ether starting aids must never be used with the manifold
preheater type starting aid, or an explosion can result. Follow
installation, storage and operating instructions furnished with each aid.
Do not use the ether aids during operation of the engine; serious
damage can result from uncontrolled high cylinder pressures.

Manifold Preheaters

CAUTION

Do not use flame type preheaters in air intake manifolds with

aftercoolers; the flame can damage the o-ring seals.

At -23°C [-10°F] and below, and using a 24 volt cranking circuit, more heat is provided by
the glow plug through the use of two resistors in the circuit as shown in Figure 14. This
prevents a reduction in the flow of current from the battery to the glow plug, which would
normally result from the load imposed by the cranking motor.

Glow Plug Preheater Operation

Make ready to start the engine by checking fuel supply, coolant level, transmission or
power take-off in neutral, and make sure all hands are clear of engine. Close glow plug
switch. (Red indicator light will illuminate.) After 20 to 30 seconds (necessary for the glow
plug to heat), operate the prime pump and maintain 241 kPa [35 psi] fuel pressure while
cranking the engine. It is necessary to use slightly higher nozzle pressure in temperatures
below -34°C [-30°F] as the fuel is thicker. If in doubt, try the nozzle before attempting a
start. The engine will generally turn a few revolutions prior to starting.

CAUTION

Allow the battery to rejuvenate and the starter to cool for 2 minutes
after 30 second maximum cranking, if no start is obtained.

Maintenance of the preheater is very important, check the glow plug and nozzle frequently.
In remote areas it is advisable to carry an extra glow plug.

Figure 14. Wiring diagram glow plug preheater - 24 volt system.

Table 9: Starting Air Recommendations

 Minimum Temperature for Minimum Cranking
Engine Model
Unaided Start Degrees Speed rpm

C (464), J (401) -1°C [30°F] 150

CS (464) 4°C [40°F] 150

CT (464) -1°C [30°F] 150

HS (672) 0°C [32°F] 150

NH (855) -1°C [30°F] 150

N (927) 0°C [32°F] 150

NH (743) -6°C [20°F] 150

H (672) -6°C [20°F] 150

NHS 4°C [40°F] 150

NT (743) 0°C [32°F] 150

NT (855) Small Cam 4°C [40°F] 150

NT (855) 400 10°C [50°F] 150

NTA 370, 420 10°C [ 50°F] 150

NT (855) Big Cam I 2°C [35°F] (4°C [40°F] Auto) 150

NT (855) 400, 475 10°C [50°F] 150

KT-1150 -1°C [30°F] 150

KT-1150-600 4°C [40°F] 150

V8 (352, 378, 470, 504,

10°C [50°F] 180
555) Small Cam

V8 (352, 378, 470, 504,

-1°C [30°F] 180
555) Big Cam
Table 9: Starting Air Recommendations

Minimum Temperature for Minimum Cranking

Engine Model
Unaided Start Degrees Speed rpm

V-VT 903 -1°C [30°F] 150

V 1710 4°C [40°F] 150

KV 2300 4°C [40°F] 150

KV 3067 4°C [40°F] 150

NT Big Cam II 4°C [40°F] 150

VT 12 (1486) 4°C [40°F] 150

VT 12 (1486) 0°C [32°F] 150

VT 8 (950) 4°C [40°F] 150

V6 (588) -1°C [30°F] 150

V6 (352, 378) 10°C [50°F] 150

V6 (352, 378) 10°C [50°F] 150

L-10 -1°C [30°F] 150

 Figure 15. Manifold preheat - flow-plug type.

1. Fuel in
2. Priming pump
3. Pressure gauge
4. 12 Volt batteries
5. The following systems do not require a glow plug resistor.
a. 12 volt glow plug connected to a 12 volt battery
b. 6 volt standard glow plug connected to a 6 volt battery.
6. Glow plug off on switch
7. Instrument panel
8. Glow plug indicator light
9. Glow plug
10. Intake manifold
11. Fuel nozzle

Insulation Materials
 Figure 16. Radiator cover with variable opening.

The engine compartment requires consideration because the walls and panels must be
sealed and insulated so no interference is created with engine components. It must be fire
safe and permit sufficient air entrance so the engine intake air restriction is under 38 cm
[15 in] water with a clean air filter. The air feed to the compartment must be in an area of
clean air and as far away from engine air intake ducting as possible. The insulation
material must be oil impervious to provide fire proof protection. Suitable materials are
available in strips or sheets for this application. Use approximately 25.40 to 38.10 mm [1 to
1 1/2 in] thickness insulation mounted securely by straps so it can not fall on the engine or
into the fan. Gypsum, glass foam or mineral wool will furnish sufficient insulation protection.

Fan Drive
 Figure 17. Thermatic fan drives.

A temperature controlled fan drive will reduce air circulation at the engine and help
conserve compartment heat. These devices function by disconnecting the fan from it's
drive source at a specified temperature. Several types of drives are available. The thermo-
modulating drive is air operated and provides gradual engagement depending on coolant
temperature. The Viscous drive utilizes a fluid coupling and will vary fan speed between 40
percent and 90 percent of it's drive source speed.

NOTE: At low idle and in cold ambient temperatures the viscous fan drive can stay
engaged due to the viscosity of the fluid.

Radiator Covers

A winter front cover (Figure 16) which is more air tight than shutters is used to seal off the
engine compartment and radiator at -32°C [-25°F] or lower temperatures. Winter front
covers are available from most automotive supply stores. Kysor and Cadillac, Radiator
Shutter Manufacturers, can supply special front covers. Generally these are custom made
to fit the application and must be air tight. The cover opening is adjusted manually
depending on the ambient temperature and operation of the shutters providing control of
air to the radiator.

Oil Pan Covers

Water-proof covered insulation or a heavy canvas blanket, can be suspended under the
engine or the cover can be a metal plate. These parts are available from any canvas or
sheet metal shop and must be custom fit to the vehicle.

Electrical Equipment

Cranking Motor

The cranking motor must be of heavy duty construction to withstand the longer cranking
periods at higher amperage loads and not overheat; use 24 volts or 32 volts. All starters
must have the positive pinion engagement feature and must be winterized for lowest
expected temperatures.

Cranking Motor Cables

Use starting system cable size and length as specified in Table 10. If a frame ground is
used, scrape paint and grease from the point of cable connection and tighten securely to
provide good electrical connection.

Table 10: Cable

Sizes (Total
Length
Allowable in
Cranking Motor
Circuit - AWG
Gauge)

Number
Maximum Two
Maximum Number Number 0000 or
Circuit Voltage Voltage Number
Resistance 00 000 Two
Drop 00
Number 0

Up to 3.6 3.6 to 4.8 4.8 to 6 m 6 to 7.6

0.12V/100
12-VDC 0.0012 Ohm m [up to m [12 to [16 to 20 m [20 to
amps
12 ft] 16 ft] ft] 25 ft]

12-VDC High Up to 2 2 to 2.7 2.7 to 3.6 3.6 to 4.2

0.075V/100 0.00075
Output Starting m [up to m [7 to 9 m [9 to 12 m [12 to
amps Ohm
Motor 7 ft] ft] ft] 14 ft]

24-VDC to 32- 0.2V/100 Up to 6 6 to 8.2 8.2 to 10.6 to

0.002 Ohm
VDC amps m [up to m [20 to 10.6 m 13.7 m
Table 10: Cable
Sizes (Total
Length
Allowable in
Cranking Motor
Circuit - AWG
Gauge)

Number
Maximum Two
Maximum Number Number 0000 or
Circuit Voltage Voltage Number
Resistance 00 000 Two
Drop 00
Number 0
20 ft] 27 ft] [27 to 35 [35 to 45
ft] ft]

NOTE: Two strands of Number 0 cable can be used in place of one Number 0000
cable provided all connections are carefully made, so current in each parallel cable
will be equal.

NOTE: The cross sectional circular mil area of Number 0000 cable is double that of
Number 0 cable.

As a final check, measure the voltage drop and ampere flow in the system while cranking
the engine for circuit resistance.

Table 11: Wire Sizes

AWG Gauge
Circuit Description
Size

See Table
Battery - Starter cables
Number 10

Glow plug preheater single 10

Glow plug preheater dual 6

Battery charging generator/alternator output leads (total length of output

leads to be under 4.8 m [16 ft]); See sheet 3 of diagram 194076.

Sensing lead battery voltage-regulator (alternator only) 10

All control circuit wiring, including generator/alternator field lead, in

14
diagram 194076.
Table 11: Wire Sizes

AWG Gauge
Circuit Description
Size

As required by
Accessory lead
load

Batteries

Heavy duty construction with ample reserve power must be specified for all batteries used
under low temperature starting conditions.

SAE J573h Battery Ratings

Cold Cranking Ampere Rating (CCA); the requirements for this standard are that the
battery be cold soaked until the center of the cell reaches -18°C [0°F] and then discharged
for 30 seconds at the rate which will provide at least 1.2 volts for each cell at the end of
this time. This discharge rate is the cold cranking amperes. See Table 12. Use 1,280
specific gravity electrolyte (Federal specifications O-S-801) in all 6TN and 8TN batteries
used in low temperatures.

Minimum Battery Capacity for Cummins® Engines

Table 12:
Minimum
Battery
Capacity for
Cummins®
Engines
Winter
Climate -
18°C [0°F]
Minimum
Engine
Temperature

12-VDC 24-VDC 30-VDC 32-VDC

Cold Cold Cold Cold

Cranking Cranking Cranking Cranking
Engine Engine Reserve Reserve
Amperes Amperes Amperes Amperes
Series Displacement Capacity Capacity
-18°C -18°C -18°C -18°C
[0°F] [0°F] [0°F] [0°F]

V6 352 1800 640 900

Table 12:
Minimum
Battery
Capacity for
Cummins®
Engines
Winter
Climate -
18°C [0°F]
Minimum
Engine
Temperature

12-VDC 24-VDC 30-VDC 32-VDC

V6 378 1280 480 640 240

V8 470 1800 640 900

V8 504 1280 480 640 240

V8 555 1280 480 640 240

J 401 1720 640 800 320 645

C 464 1800 640 900 320 645

V6 588 1720 640 800 320 730

V8 785 1800 640 900 320 800 780

NH 743 1800 640 900 320 800 780

NH 855 1800 640 900 320 800 780

NH 927 1800 640 900 320 800 780

V8 903 1800 640 900 320 800 780

K6 1150 900 320 800 780

V12 1486 1600 640 1460

V12 1710 1800 640 1600 1560

Table 12:
Minimum
Battery
Capacity for
Cummins®
Engines
Winter
Climate -
18°C [0°F]
Minimum
Engine
Temperature

12-VDC 24-VDC 30-VDC 32-VDC

L 2477 1600 1560

K12 2300 1800 640 1600 1560

K16 3067 1800 640 1600 1560

L10 611 1800 640 900 320 800 780

Table 12:
Minimum
Battery
Capacity for
Cummins®
Engines Mild
Climate 0°C
[32°F] and
Above
Engine
Temperature

12-VDC 24-VDC 30-VDC 32-VDC

Cold Cold Cold Cold

Cranking Cranking Cranking Cranking
Engine Engine Reserve Reserve
Amperes Amperes Amperes Amperes
Series Displacement Capacity Capacity
-18°C -18°C -18°C -18°C
[0°F] [0°F] [0°F] [0°F]

V6 352 1280 480 640 240

V6 378 1280 480 640 240

Table 12:
Minimum
Battery
Capacity for
Cummins®
Engines Mild
Climate 0°C
[32°F] and
Above
Engine
Temperature

12-VDC 24-VDC 30-VDC 32-VDC

V8 470 1280 480 640 240

V8 504 1280 480 640 240

V8 555 1280 480 640 240

J 401 1290 480 645 240 475 455

C 464 1280 480 640 240 475 455

V6 588 1290 480 645 240 475 475

V8 785 1280 640 240 645 520

NH 743 1280 640 240 645 520

NH 855 1280 640 540 645 520

NH 927 1280 640 240 645 520

V8 903 1280 640 240 645 520

K6 1150 640 240 645 520

V12 1486 900 320 900 950

V12 1710 1280 480 1290 1040

L 2477 1460
Table 12:
Minimum
Battery
Capacity for
Cummins®
Engines Mild
Climate 0°C
[32°F] and
Above
Engine
Temperature

12-VDC 24-VDC 30-VDC 32-VDC

K12 2300 1280 480 1290

K16 3067 1800 640

L10 611

*Dual Motor
Application -
CCA Motor is
1/2 of figure
shown

**For each
battery (2-12
Volt batteries
in series)
CCA ratings
are based on
-18°C [0°F]

Hydraulic or Air Cranking Motors

Hydraulic or air cranking motors can be used where the oil or air reservoirs and pressures
are available.

CAUTION

Due to the initially high cranking speeds from these type cranking
motors, always prelube the engine and/or turbocharger in temperatures
below -12°C [10°F] .
Fuel Warmers

Warming diesel fuel just prior to filtration is an excellent method of preventing fuel filter
plugging. If cold fuel is warmed sufficiently, the wax crystals will dissolve in the fuel; the
dissolving requires warming to a temperature of approximately 10 to 20°C [20 to 40°F]
above the fuel's cloud point.

In order for a fuel warmer to reliably prevent fuel filter plugging due to wax, it must be
capable of supplying enough heat to the fuel at the maximum fuel flow ( not fuel
consumption) rate to raise the fuel temperature from the lowest expected fuel temperature
(probably the lowest expected ambient temperature) of 11 to 22°C [20 to 40°F] above the
fuel's cloud point. See Table 13 for Fleetguard® Part Numbers and Fuel Warmer
performance data. See Table 14 for maximum fuel flow at rated engine power and
recommended fuel warmer part number.

Do not overheat the fuel. The maximum fuel temperature is 70°C [158°F]. Alterations or
heating devices must be reversible or have some means to turn them off during warm
weather operation.

A fuel warmer will not help if the fuel is below the pour point and can not be pumped to
the warmer. Therefore, in extremely cold conditions, fuel must be cut with a light distillate
diesel fuel or treated with a pour point depressant to reduce the pour point or heat the fuel
to allow it to flow.

When using fuel warmers that use engine coolant as a source of heat, some form of
coolant heating during shutdown will allow the heater to become effective much more
quickly after start-up. See Figure 18. Fuel warmers must be checked for leaks. Since the
fuel warmer is on the suction side of the fuel pump, and the cooling system is pressurized,
any small leak will allow coolant to enter the fuel system.

Table 13: Fuel

Warmer
Performance Data

Fleetguard® Fleetguard®
Fuel Warmer Part
Part Number Part Number
Number
3305782 3305162

9.46
1.89 Litres/min 5.68 Litres/min 15 Litres/min [4.0
Fuel Flow Rate Litres/min
[0.5 gal/min] [1.5 gal/min] gal/min]
[2.5 gal/min]

Outlet Fuel
Inlet Temperature
Temperature

-40°C [-40°F] 28°C [83°F] 3°C [37°F] -13°C [9°F] 31°C [88°F]
Table 13: Fuel
Warmer
Performance Data

Fleetguard® Fleetguard®
Fuel Warmer Part
Part Number Part Number
Number
3305782 3305162

-29°C [-20°F] 35°C [0°F] 13°C [55°F] -3°C [26°F] 32°C [90°F]

-18°C [0°F] 42°C [108°F] 21°C [70°F] 6°C [43°F] 33°C [92°F]

Figure 18 Fleetguard® fuel warmer

Table 14: Maximum Fuel Flow at Rated Engine Power

Engine Model Gallons/Minute Litres/Minute Fleetguard® Fuel Warmer
VT-555 1.2 4.54 3305782
NH-230 0.76 2.88 3305782
NTC-230 0.77 2.91 3305782
Table 14: Maximum Fuel Flow at Rated Engine Power
Engine Model Gallons/Minute Litres/Minute Fleetguard® Fuel Warmer
NTC-250 (Small Cam) 0.89 3.37 3305782
NTC-250 (Big Cam) 0.64 2.42 3305782
NTC-290 (Small Cam) 1.17 4.43 3305782
NTC-290 (Big Cam) 0.78 2.95 3305782
NTC-300 (Big Cam II) 0.80 3.03 3305782
NTC-350 (Small Cam) 1.40 5.30 3305782
NTC-350 (Big Cam) 0.95 4.60 3305782
NTC-350 (Big Cam) 0.90 3.41 3305782
NTA-400 (Small Cam) 1.90 7.19 3305782
NTA-400 (Big Cam) 1.10 4.16 3305782
NTC-400 (Big Cam) 1.10 4.16 3305782
VT-903 1.29 4.88 3305782
KT-450 1.23 4.66 3305782
V-1710 1.34 5.07 3305782
VT-1710 2.02 7.65 3305782
VTA-1710 2.64 9.99 3305782
KT-1150 1.41 5.34 3305782
KTA-1150 1.55 5.87 3305782
KT-2300 2.25 8.52 3305162
KTA-2300 3.15 11.92 3305162
KTA-3067 4.08 15.44 3305162

Fuel/Water Separator
 Figure 19. Injector protector (fuel/water separator).

Condensation in the fuel must be removed for dependable diesel engine performance.
Keeping the fuel tanks full and draining condensate daily, will help reduce moisture in the
tanks. There are also inline fuel filters available which will separate water from the fuel.

The Fleetguard® FS-1201 (Part Number 256546) injector protector is a remote mounted
fuel filter/water separator. It has a replaceable element. It must be installed on the suction
side of the fuel pump in series with or in place of the existing fuel filter as shown in Figure
20.
 Figure 20. Installation location for the fuel/water separator.

Dual Stage Systems: Fleetguard® recommends installation in place of the primary fuel
filter. The fuel filter/water separator also can be installed downstream of the primary fuel
filter.

Fuel/Water Separator (Spin-on)

A spin-on fuel/water separator filter is available that will directly replace the standard spin-
on fuel filter. See Figure 21. It has a self-venting valve which allows water to be drained
without breaking the fuel system vacuum. This filter has a longer overall length and
requires a remote mounting in some applications.

On highway applications, use Fleetguard® Superfilter FS-1212. For remote mounting, use
Fleetguard® spin-on head Number 1427845 and bracket Number 2565355. Table 15 gives
a size comparison between the FS-1212 and the filters it will replace.
 Figure 21. Fleetguard® superfilter.

Table 15: Filter Comparison

Approximate Dimensions
Fleetguard® Part Number Cummins® Part Number Length Diameter
FF-104 138627 137 mm [5.39 in] 97 mm [3.81 in]
FF-105 154709 175 mm [6.89 in] 97 mm [3.81 in]
FF-105C 202893 203 mm [8 in] 97 mm [3.81 in]
FF-105D 156172 191 mm [7.50 in] 97 mm [3.81 in]
FF-213 3300901 220 mm [8.68 in] 97 mm [3.81 in]
FS-1212 3308638 245 mm [9.66 in] 97 mm [3.81 in]

For industrial applications, use Fleetguard® Superfilter FS-1216. For remote mountings,
use Fleetguard® spin-on head Number 33023675. The following chart (Table 16.) gives a
size comparison between the FS-1216 and the filter it will replace.

Table 16: Filter Comparison

Approximate Dimensions
Part Number Cummins® Part Number Length Diameter
Table 16: Filter Comparison
Approximate Dimensions
FF-202 299202 297.69 mm [11.72 in] 129.3 mm [5.09 in]
FS-1216 3309437 320 mm [12.58 in] 129.3 mm [5.09 in]

Personnel Protection

The wind chill chart, Table 17, is included in this bulletin to emphasize the protection
required for the operator working under low temperature conditions. They must be
protected adequately to correctly perform the task of starting and operating the equipment.
Wind chill affects the human more than metals since it is actually a measure of
evaporation. The sensation to the skin is a lower temperature as given on the chart. As an
example, assume an ambient temperature of -32°C [-25°F] with a 48.27 km [30 mile]/hour
wind, the equivalent chill temperature is -61°C [-77°F] or it is equivalent to -61°C [-77°F]
with no wind velocity. Temperature in this range will freeze exposed human flesh in less
than one minute. Metal would remain at -32°C [-25°F].

Table 17:
Wind Chill
Rate

Temperatur
e

Wind - - - - - -
30 25 20 15 10 5 0 -5 -40 -45
Velocity mph 10 15 20 25 30 35

- - - - - - - - -
10 20 14 8 2 -4 -62 -68
10 15 21 27 33 39 45 50 56

- - - - - - - - - -
15 13 7 0 -6 -75 -81
12 18 25 31 38 44 50 57 63 69

- - - - - - - - - - -
20 9 2 -5 -85 -92
12 19 25 32 39 45 52 59 66 72 79

- - - - - - - - - - -
25 5 -2 -9 -93 -99
17 24 30 37 44 51 58 65 72 78 86

- - - - - - - - - - - - -
30 3 -5 -98
12 20 27 33 41 48 55 63 70 77 83 91 104

- - - - - - - - - - - - - -
35 0 -7
14 22 29 36 44 51 58 66 73 81 87 95 102 109
Table 17:
Wind Chill
Rate

Temperatur
e

- - - - - - - - - - - - - -
40 -1 -9
16 24 31 38 46 53 61 69 76 84 91 98 105 112

NOTE: Temperature and wind velocity related in terms of wind chill showing
equivalent temperature under still conditions. (Values are approximate and do not
allow for varying humidity.)

Highway Operation

The following equipment or equivalent protection must be provided for highway

applications operating in arctic climates. See Pages 1, 2 and 3.

1. Provide for warm intake air in ambients below -12°C [10°F].

2. Use cover over radiator such as winter front.
3. Shield oil pan and lower engine compartment from air blast created by velocity of
vehicles.
4. Use thermatic controlled fan.
5. Heat lubricating oil when engine is not operating.
6. Heat coolant when engine is not operating.
7. Use -57°C [-70°F] Arctic Fuel or provide heat to fuel tanks.
8. Exposed lines must be insulated.
9. Filters, pumps or reservoirs outside engine compartment must be insulated to
protect against ambients and air velocity.
10. Provide separate heater directed to operator's feet to maintain driver and cab
temperatures.
11. Warm the batteries.
12. Use alcohol vaporizer to protect compressed air system.
13. If engine is exposed behind the cab, a cover must be provided to enclose the
engine in the compartment.

Last Modified: 15-Feb-2008

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