ISC, ISCe, QSC8.3, ISL, ISLe3, ISLe4 and QSL9 Engines – 008-041   Marine Gear Oil Cooler

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

CAUTION  Use caution when draining coolant that coolant is not spilled or drained into the bilge area. Do not pump the coolant overboard. If the coolant is not reused, it must be discarded in accordance with local environmental regulations.

NOTE: This procedure applies to marine engines
only.

• Disconnect the batteries.
  Refer to Procedure 013-009 (Battery Cables and Connections) in Section 13.
• Shut off the sea water inlet valve(s) on the vessel hull, if equipped. Refer to the OEM service manual.

NOTE: This procedure applies to QSL9 and QSC8.3 with oil cooler marine engines
only.
For the QSC engine with combination cooler, refer to Procedure 008-129 (Marine Gear Oil and Fuel Cooler Assembly) in Section 8.

NOTE: Some QSL engines are keel cooled, so
not all of the steps will apply.

• Disconnect the oil temperature and pressure sensor connectors from the OEM harness.

Shut off the sea water inlet valve on the vessel hull, if equipped.

Remove the marine gear oil cooler drain plug and drain the sea water from the marine gear oil cooler.

Disconnect the sea water inlet and outlet connections.

Use clean water to back flush all the debris from the cooler.

Make sure the debris flushed from the cooler does
not enter the water supply hoses.

Install the drain plug and sea water hose connections.

Open the sea water valve on the vessel hull, if closed.

CAUTION  Removing the sea water supply line for the shaft log seal will allow sea water to leak into the vessel, if the line is not plugged. To reduce the possibility of damage, be sure to plug the supply line and prevent sea water from leaking into the vessel.

Remove the aftercooler sea water discharge hose from the gear cooler.

Remove the marine gear cooler sea water discharge hose form the gear cooler.

Remove and plug the sea water supply line for the shaft log seal from the gear oil cooler (if equipped).

Remove the transmission oil supply and return lines; mark their locations.

Disconnect the marine gear oil pressure/temperature sensor (if equipped).

Remove the bracket to cooler mounting capscrew.

Drain the sea water system by removing the two plugs at the bottom of the marine gear oil cooler assembly.
Refer to Procedure 008-059 (Zinc Anode) in Section 8.

Disconnect the sea water inlet and outlet pipes.

Remove the capscrews mounting the gear cooler to the aftercooler.

Turn the cooler so the transmission oil supply and return lines can be removed.

Remove the transmission oil supply and return lines and mark their locations.

Disconnect the marine gear oil pressure/temperature sensor, if equipped.

Place the cooler in a vise and remove the two oil line fittings from the gear cooler, if necessary.

Mark the fitting locations prior to removal.

Place the cooler in a vise and remove the two oil line fittings from the gear cooler, if necessary.

Mark the fitting locations prior to removal.

Remove the sensors, if equipped.

Do
not tighten the vise to the extent that the cooler case can be damaged.

Plug one gear oil port and attach an air supply line to the other gear oil port with a quick disconnect fitting. Apply thread sealant to the threads to prevent leaks. Do
not allow sealant to enter the gear oil cooler.

WARNING  Troubleshooting with high pressure air presents the risk of equipment damage, personal injury, or death. Troubleshooting must be performed by trained, experienced technicians.

WARNING  Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

Attach a high-pressure air supply source (air cylinder or other suitable source) with an air pressure regulator and an inline shutoff valve to the quick disconnect fitting.

Set the regulator test pressure to 276 kPa [40 psi].

Submerge the gear oil cooler into a tank of water. Rotate the cooler to allow any trapped air to escape. Allow the cooler to remain submerged for 1 minute.

Inspect for air bubbles at the fitting braze joints.

Inspect for air bubbles at the opening at each end of the cooler.

If leaks are detected, replace the gear oil cooler.

Remove the cooler from the tank. Shut off the air supply and disconnect the air supply.

Remove the plug and test fitting.

Fabricate a test fixture to seal the sea water connections, or use connector hoses with a quick disconnect air connection to supply a regulated test pressure of 276 kPa [40 psi] to the sea water side of the gear oil cooler.

Submerge the cooler into a tank of water for 1 minute.

Inspect for air leaks at the braze joints of the end caps and any bubbles from the gear oil ports. If leaks are detected, replace the gear oil cooler.

Remove the cooler from the tank.

Shut off the air supply and disconnect the air supply.

Remove the test equipment.

WARNING  When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer’s recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury.

WARNING  Some solvents are flammable and toxic. Read the manufacturer’s instructions before using.

WARNING  Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

Drain the water from the cooler.

Flush the oil side of the cooler with clean solvent.

Use compressed air to dry the cooler.

Plug one gear oil port and sensor ports, as needed.

Attach an air supply line to the other gear oil port with a quick disconnect fitting.

Apply thread sealant to the threads to prevent leaks.

Do
not allow sealant to enter the gear oil cooler.

Attach a high-pressure air supply source, such as an air cylinder or other suitable source, with an air pressure regulator and an inline shutoff valve to the quick disconnect fitting.

Set the regulator test pressure to 276 kPa [40 psi].

Submerge the gear oil cooler into a tank of water.

Rotate the cooler to allow any trapped air to escape.

Allow the cooler to remain submerged for 1 minute.

Inspect for air bubbles at the fitting braze joints.

Inspect for air bubbles at the opening at each end of the cooler.

If leaks are detected, replace the gear oil cooler.

Remove the cooler from the tank.

Shut off the air supply and disconnect the air supply.

Remove the test fitting and install a plug. This is to keep water from contaminating the oil side of the cooler.

Fabricate a test fixture to seal the sea water connections, or use connector hoses with a quick disconnect air connection to supply a regulated test pressure of 276 kPa [40 psi] to the sea water side of the gear oil cooler.

WARNING  Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

Submerge the cooler into a tank of water for 1 minute.

Inspect for air leaks at the braze joints.

If leaks are detected, replace the gear oil cooler.

Remove the cooler from the tank.

Shut off the air supply and disconnect the air supply.

Remove the test equipment.

Drain the water from the cooler.

Flush the oil and fuel sides of the cooler with clean solvent.

Use compressed air to dry the cooler.

Coat the threads with thread sealant and install the two line fittings into the gear cooler, if removed. Be sure they are oriented in the same direction as they were removed.

Tighten the two locknuts.

Place the cooler in a vise.

Do
not tighten the vise to the extent that the cooler case could be damaged.

(1) Coat the threads with thread sealant and install the two line fittings into the gear cooler, if removed. They
must be oriented in the same direction as they were removed.

(2) Install the oil temperature sensor on the right and the oil pressure sensor on the left.

Tighten the oil temperature sensor.

Tighten the oil pressure sensor.

Install the marine gear oil cooler to the mounting bracket with two mounting capscrews. Tighten the capscrews.

Install the mounting bracket to the engine block with two mounting capscrews. Tighten the capscrews.

Install the marine gear oil cooler inlet and outlet hoses and tighten the hose clamps.

Install the aftercooler discharge hose and tighten the hose clamp.

Install the transmission oil supply and return hoses to the gear cooler.

Install the sea water supply for the shaft log seal to gear oil cooler (if equipped).

Connect the gear oil pressure/temperature sensor wiring harness connector (if equipped).

Connect the transmission oil supply and return lines to their original locations and tighten.

Install the marine gear oil cooler to the aftercooler.

Tighten the capscrews.

Connect the sea water inlet and outlet pipe.

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

• Connect the aftercooler air inlet connection and air crossover to the aftercooler.
  Refer to Procedure 010-019 (Air Crossover) in Section 10,
  and Procedure 010-131 Air Intake Connection Adapter) in Section 10.
• If the engine is sea water cooled, open the sea water valve. Refer to the OEM service manual.
• If the engine is keel cooled, fill the cooling system.
  Refer to Procedure 008-018 (Cooling System) in Section 8.
• Connect the batteries.
  Refer to Procedure 013-009 (Battery Cables and Connections) in Section 13.
• Operate the engine and check for leaks.