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SERIES 60 FUEL COOLER (HEAT EXCHANGER-COOLED MARINE ENGINE)

The Series 60 heat exchanger-cooled marine engine uses a tube-and-shell style fuel cooler mounted with connector hoses and clamps on the inlet side of the raw water pump. See Figure 36002 . The fuel cooler is a brazed assembly and cannot be disassembled. It should be removed and inspected for plugging and damage once a year and replaced every four years, regardless of apparent condition. Replace sooner if severe plugging or damage is indicated. ‪

1. Engine Block ‪

4. Bolt ‪

2. Mounting Plate ‪

5. Fuel Cooler ‪

3. Washer ‪

Fuel Cooler Location

NOTICE:

Failure to inspect the fuel cooler for plugging or replace it when required may lead to restricted coolant flow and high fuel temperatures, which could result in loss of power and inefficient engine operation. ‪

Removal of the Fuel Cooler

Remove the fuel cooler as follows: ‪

  1. With the engine at ambient temperature, place a suitable container under the heat exchanger and drain the raw water from the heat exchanger tank. Discard the raw water.
  2. Close the shutoff valves located on the fuel inlet and outlet lines attached to the fuel cooler. Mark the lines for easy reinstallation.
  3. With a suitable container placed under the fuel cooler to catch any dripping, carefully remove the lines from the fuel cooler fittings. Cap the lines to prevent any contamination of the fuel.
  4. Loosen the hose clamps holding the fuel cooler to the raw water pump inlet elbow.
  5. Loosen the hose clamps holding the fuel cooler to the raw water supply line.
  6. With the cooler properly supported, remove the fuel cooler from the bracket holding it to the block, slide it off the connector hoses, and carefully pull it away from the engine.
Inspection of the Fuel Cooler

Inspect the fuel cooler as follows: ‪

  1. Inspect the cooler shell for dents, fuel or water leaks, and fuel inlet or outlet fitting damage. A fuel cooler showing obvious signs of damage should not be reused.
  2. If no obvious signs of damage, inspect the cooler tubes for plugging. If tubes are not plugged, proceed to step . If tubes are plugged, remove plugging as follows:
    1. Circulate a cleaning solvent such as Powercool 2001 On-Line Cleaner, or equivalent, through the tubes. Carefully rod out the tubes with a bore brush, and flush out any loosened material with clean, fresh water.

      EYE INJURY

      To avoid injury from flying debris when using compressed air, wear adequate eye protection (face shield or safety goggles) and do not exceed 40 psi (276 kPa) air pressure.

    2. Drain all water from the fuel cooler and blow dry with compressed air.
  3. Pressure check fuel cooler as follows:
    1. Block water outlet with hose, end cap, and clamps.
    2. Block water inlet with hose, end cap modified with pressure valve, and clamps.
    3. Fill cooler tubes with clean fuel.

      EYE INJURY

      To avoid injury from flying debris when using compressed air, wear adequate eye protection (face shield or safety goggles) and do not exceed 40 psi (276 kPa) air pressure.

    4. Apply 207 kPa (30 lbin2 ) air pressure to pressure valve on water inlet.
    5. If pressure leak down or no bubbles in the fuel occur, replace fuel cooler.
    6. If no pressure leakdown or no bubbles occur in the fuel, reuse fuel cooler.

Installation of the Fuel Cooler

Install the fuel cooler as follows: ‪

  1. Attach the fuel cooler securely to the mounting bracket on the block, ensuring the cooler inlet and outlet openings are properly oriented.
  2. Slide the connector hoses from the raw water pump inlet elbow and the raw water supply line onto the cooler openings and tighten the hose clamps.
  3. Install fuel inlet and outlet lines to the cooler.

    PERSONAL INJURY

    Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

    • Always start and operate an engine in a well ventilated area.
    • If operating an engine in an enclosed area, vent the exhaust to the outside.
    • Do not modify or tamper with the exhaust system or emission control system.
  4. Prime the raw water pump and prime the fuel system. Start the engine and check for raw water or fuel leaks.