Aftercooler/Heat Exchanger service, 480CE

[Bobby O’Neal]

Hello,
I’m looking at an ’03 with Cummins 480 CE’s. I wanted to ask what I could expect to pay for the aftercooler/heat exchanger service provided it hasn’t been done in the last 2-3 years?
Regards,
Bobby

Topic

[Philip]

Fresh water flushing with the engine on or off is dependent on where you are inserting the fresh water in the system (before or after the seawater pump) and exhaust design.

If you insert fresh water ore seawater pump then the overpressure some have mentioned only occurs if you shut the thru hull. It’s not required to shut the thru hull as the fresh water dilution is what you after, although many do shut the valve. No harm either way but if you do shut the thru hull then there is the vulnerability of forgetting to open it.

Phil

[glenn111]

“Also, do not apply the pressurized freshwater to the engine when it is not running! You can apply the freshwater if the thru hull is open to relieve the pressure.”

Is there a problem with freshwater on with engine not running, assuming hoses and hardware components are in good shape.

[Bobby O’Neal]

Thanks

H y Tom & Phillip,
Thanks for your help, it’s greatly appreciated. I’m currently searching for my next boat. Prefer Cummins engines too. I’m just thinking ahead and would definitely want fresh water flush kits on my next one.
Regards,
Bobby

[firehoser75]

Freshwater Flush

Bobby,
I have attached a photo of my freshwater flush setup. Seems the website loaded it upside down? It is basically a “garden hose” attachment that was installed in the lid of my Groco seawater strainer. The engine is a Cummins 6bta 330hp. The potential downside is that the engine must be running when flushing. Also, do not apply the pressurized freshwater to the engine when it is not running! You can apply the freshwater if the thru hull is open to relieve the pressure. A machine shop should be able to “modify” a lid for you if you cannot find a “ready made” one. Start to finish the flushing procedure doesn’t take very long, and I flush every time after a run if I am at a dock with a decent water supply.
As Philip stated, there are multiple ways to accomplish this task, but I think this method should work on most boats.
Hope this helps,
Tom

1 user thanked author for this post.

Bobby O’Neal

[Philip]

There is no such thing as a one size fits all application to fresh water flush installation as every boat is different in how the builder installed the engines, intake design, exhaust design etc.

With some research here on the website on how others have installed a fresh water flush and posting some good in focus hi def pictures of your engines as installed from all angles including exhaust we can offer some suggestions on how you could install a fresh water flush system.

In the absence of fresh water flushing plan to service coolers every 2 years max,

[Bobby O’Neal]

Fresh water flush kits

Thanks for your reply and the service info, good to know. Question about fresh water flush kits. Can they be ordered from Seaboard Marine?
Thanks,
Bobby

1 user thanked author for this post.

Brian K. Baker

[Philip]

Bobby O’Neal wrote:

Sounds like you’re saying that proper aftercooler, heat exchanger, sea water pump maintenance and fresh water flushing is the key to long engine life rather than focusing on engine hours.

100% Correct

Aftercooler – with proper servicing and fresh water flushing a 4-5 year service cycle is normal. Zincs as needed

Heat Exchanger – with fresh water flushing, service on these items are 5-8 year cycles or more. We don’t see leaks on this item like the aftercooler mostly because of low pressures and anti corrosive properties on antifreeze. Zincs as needed

Gear cooler – don’t neglect this item. Nothing to truly service except acid wash to keep cooling tubes free from scale. Zincs as needed

Sea Water Pump – impeller changes based on how silty your water is. The more silt the more often you will need to change the impeller. Also if you don’t use the boat for periods (45+ days) at a time. Keep an eye on the back side of the pump for leaks indicating a whole pump rebuild/replacement,

Filters – every 100 hours

Oil – engine/100 hrs, gear/250-500hrs

Final note is any items that spin (alternator, fresh water pump, idler pulleys, tensioner) – take the belt off, check that belt and replace if necessary. Spin all those items and rock them to see if there is any play, and grinding noise, sloppiness to bearings etc. if so, replace that item.

That’s your basic service cycle….

[Bobby O’Neal]

Marine age

Tony,
I read your “Marine Age” article, it makes sense. Sounds like you’re saying that proper aftercooler, heat exchanger, sea water pump maintenance and fresh water flushing is the key to long engine life rather than focusing on engine hours. (please correct me if I’m wrong) I’m looking for my next boat and appreciate your tips.
Regards,
Bobby

[Tony Athens]

Proper Aftercooler Service

This works for some guys:

https://www.sbmar.com/services/seawater-component-cleaning-repair/

It really all comes down to what condition the cooler is in..

Tony

[Philip]

A lot of that answer depends on exactly how it was serviced in the past. Not to scare you but I have seen mechanics silicone a leaky cooler back together just to get it sellable. The parts are a few hundred dollars for a pair of service kits and associated parts etc.

Expect labor to be a minimum of two to three days if done right, That means take the cooler off the engine, disassemble, acid clean, pressure test the core, reassemble with new o rings and lots of grease, pressure test the final assembly and install everything back on the boat. All that at whatever hourly labor rate in your area demands.

If the aftercooler is not serviceable those run $3350 each, so $6700 for twins and labor…

[Bobby O’Neal]

Aftercooler/heat exchanger maintenance

Hey Mike,
Thanks for the reply. I’ll look for info about DYI. I appreciate the tip.
Bobby

[Mike Mason]

If you can turn a wrench you can do it yourself. Learn a lot and save a bunch of $$

Lots of info on here on this topic.

Mike

[Author]

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