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SERIES 60 SEA PRO 152 FUEL FILTER SYSTEM (MARINE ENGINE)

The Sea Pro 152 diesel fuel processor system is used in place of a separate spin-on primary fuel filter. See Figure 35447 . This system uses a high efficiency five-micron fuel filter element which requires replacement when the fuel level in the see-thru filter cover reaches the top of the element or after one year of service, whichever comes first. ‪

Note: The secondary fuel filter must be changed at regular hour intervals. Refer to section .

Sea Pro 152 Fuel Processor System

The Sea Pro 152 diesel fuel processor system consists of the following: ‪

  • A permanently mounted fuel processor
  • A replaceable five-micron filter element and sealing grommet assembly
  • A filter spring
  • A see-thru filter cover and O-ring seal
  • A cover-locking retainer collar/deflector
  • A cover vent cap and seal
  • An electric fuel primer pump
  • Fuel inlet and outlet valves
  • A see-thru water filter bowl and collar assembly

Replacement of Sea Pro 152 Fuel Filter Element

Replace the Sea Pro 152 filter element as follows: ‪

  1. With the engine shut down and at ambient temperature (cool to the touch), place a suitable container under the fuel processor.
  2. Turn the fuel inlet and outlet valves on the fuel processor to the closed position (perpendicular to the valves) and loosen the vent cap on the see-thru cover. See Figure 35446 .

    1. Filter Element

    7. Retainer/Deflector Collar

    2. Cover Seal

    8. Fuel Processor Assembly

    3. Spring (part of cover assembly)

    9. See-Thru Water Separator Bowl

    4. See-Thru Cover Assembly

    10. Retainer Collar

    5. Vent Cap Seal

    11. Deflector/Drain Valve Assembly

    6. Vent Cap

    12. Drain Valve Plug

    13. Water Filter Bowl and Collar Assembly

    Sea Pro 152 Fuel Processor/Filter Assembly

  3. Remove the plug from the drain valve at the base of the water-separator bowl, open the valve, and drain the fuel until it is below the level of the retainer/deflector collar on the see-thru cover. Close the drain valve and replace the plug.
  4. Using the offset wrench supplied with the Sea Pro 152 fuel processor assembly, turn the cover retainer/deflector collar counterclockwise and remove. Then remove the cover, filter spring, and cover seal ring by lifting straight up and over the filter element. Remove the element from the center stud by pulling upward and twisting slightly.

    Note: Any remaining fuel dripping from the element will be caught by the deep well in which the element sits and will drain into the processor body.

  5. Dispose of the used element in an environmentally responsible manner, according to state and/or federal (EPA) recommendations.

Installation of Sea Pro 152 Fuel Filter Element

Install the Sea Pro 152 element as follows: ‪

  1. Before installing the new filter element, ensure the sealing surface on top of the processor body is clean by wiping with a clean cloth or paper towel.
  2. Ensure a sealing grommet is included in the base of the replacement filter, then install the element onto the center stud by pushing down and twisting slightly to seat the element.
  3. Ensure the filter spring is installed at the top of the cover. If missing, the spring must be replaced to insure proper filter operation. Wipe the cover lip and cover seal clean. After ensuring the seal is properly positioned at the base of the cover, install the cover over the filter and onto the fuel processor. Install the retainer/deflector collar. Then, using the wrench supplied with the fuel processor assembly, tighten the collar securely.

    NOTICE:

    To avoid cover or vent cap damage, do not use tools to tighten the vent cap. ‪

  4. Remove the vent cap from the top of the cover by turning counterclockwise, then open the fuel inlet valve on the processor body. Do not open the outlet valve. Fill the cover to the top of the filter element with clean fuel by operating the electric primer pump. After ensuring the O-ring seal is installed on the vent cap, reinstall the cap and tighten by hand only. Open the fuel outlet valve.

    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.
  5. Start the engine. When the lubrication system reaches its normal operating pressure, increase engine speed to high idle for 2 to 3 minutes.

    NOTICE:

    To avoid possible cover or vent cap damage, do not use tools to tighten the vent cap. ‪

    NOTICE:

    Do not allow the fuel level in the see-thru cover to fall below the top of the retainer collar/deflector, since this may lead to interruption of the fuel flow and engine stalling. ‪

  6. After the air is purged and with the engine still running, slowly loosen the vent cap on the filter cover. The fuel level will start falling. When the level falls to the top of the retainer/deflector collar, tighten the vent cap securely by hand .
  7. With the engine running, check for leaks.
  8. Shut down the engine.

    Note: The see-thru filter cover will not fill completely during engine operation. It will gradually fill over time as the filter medium becomes clogged. The filter element does not require changing until the fuel level has risen to the top of the element, or after one year of service, whichever comes first.

    Note: The secondary fuel filter must be changed at regular hour intervals. Refer to section .

Removal of See-Thru Water Filter Bowl and Collar Assembly

Removal of the see-thru water filter bowl and collar assembly at the bottom of the processor body may be required for occasional cleaning. To remove and clean the bowl and collar assembly, proceed as follows: ‪

  1. Close the fuel inlet and outlet valves and loosen the vent cap on the see-thru cover.
  2. Place a suitable container under the see-thru bowl, and remove the drain valve plug. Open the drain valve, and drain the filter, processor, and bowl completely of fuel. Dispose of the fuel in an environmentally friendly manner, according to state and/or federal (EPA) recommendations.
  3. Using the offset wrench supplied with the Sea Pro 152 fuel processor assembly, turn the retainer collar clockwise (as viewed from the top) until it separates from the processor body. Pull the collar and bowl assembly down and away from the processor body. Remove and retain the O-ring seal in the groove at the top of the bowl.
  4. Clean the bowl and collar assembly in mild detergent and warm water and dry with a clean, soft cloth.
Inspection of See-Thru Water Filter Bowl and Collar Assembly

Inspect the see-thru water filter bowl and collar assembly as follows: ‪

  1. Inspect the top seal for damage. If reusable, reinstall. If damaged, replace.
  2. Inspect the bowl for damage. If reusable, reinstall the assembly. If damaged, replace the bowl as follows:
    1. Hold the bowl securely and disassemble the drain valve by turning counterclockwise.
    2. Remove the drain valve and separate the bowl and collar from the deflector. Remove and discard the bowl and the O-ring seal between the deflector and the bowl.
    3. Clean the deflector thoroughly in mild detergent and warm water to remove any residual seal material and dry with a soft cloth.

      NOTICE:

      Do not overtighten the drain valve, since this will damage the threads in the bowl, resulting in fuel leakage. ‪

    4. With the deflector facing up, place a new O-ring seal over the center opening. Position the collar-threaded side up on top of the deflector, then place the new bowl onto the O-ring seal. Screw the drain valve into the threads in the bowl, and tighten securely by hand.

Installation of See-Thru Water Filter Bowl and Collar Assembly

Install the see-thru water filter bowl and collar assembly as follows: ‪

  1. With the O-ring seal in the top groove of the bowl, position the bowl and collar assembly onto the base of the processor body and thread the retainer collar onto the processor.
  2. Using the offset wrench supplied with the fuel processor assembly, tighten the collar securely.

Priming Sea Pro 152

For efficient engine operation, the Sea Pro 152 processor system must be properly primed after the filter element is replaced and before the engine is started. ‪

NOTICE:

Failure to prime the fuel system after filter replacement may result in aerated fuel reaching the injectors. This could cause hard starting, reduced engine performance, injector damage, or all three consequences. ‪

Prime the Sea Pro 152 fuel processor system as follows: ‪

  1. Refer to section of the Series 60 Service Manual , and replace the Sea Pro filter element.
  2. With the replacement element installed, make sure the outlet valve and drain valve on the processor assembly are closed. See Figure 38645 .

    1. Priming Pump ‪

    6. Fuel Outlet Valve ‪

    2. Momentary Switch Button ‪

    7. Fuel Inlet valve ‪

    3. See-Thru Cover ‪

    8. Drain Valve ‪

    4. Vent Cap ‪

    9. See-Thru Bowl ‪

    5. Retainer Collar/Deflector ‪

    Sea Pro 152 Fuel Processor System

  3. Open or remove the vent cap on the see-thru cover assembly by turning counter-clockwise. Then open the fuel inlet valve on the fuel processor. Do not open the fuel outlet valve at this time.
  4. Press the momentary switch button on the electric priming pump until the see-thru filter cover is filled with enough fuel to cover the filter element.

    NOTICE:

    To avoid possible cover or vent cap damage, do not use tools to tighten the vent cap. ‪

  5. After ensuring the O-ring seal is installed on the vent cap, replace the vent cap on the see-thru filter cover, if previously removed. Tighten the vent cap by hand until secure.
  6. Refer to section for the exhaust caution before preceeding. Open the fuel outlet valve on the fuel processor, and start the engine.
  7. When the lubrication system reaches its normal operating pressure, increase engine speed to 1500 rpm for 2 or 3 minutes.

    NOTICE:

    Do not allow the fuel level in the see-thru cover to fall below the top of the retainer collar/deflector, since this may lead to interruption of the fuel flow and engine stalling. ‪

  8. After the air is purged and with the engine still running, slowly loosen the vent cap on the filter cover. The fuel level in the see-thru cover will start falling. When the level falls to the top of the retainer collar/deflector, tighten the vent cap quickly by hand .
  9. With the engine running, check for leaks.
  10. Shut down the engine.
  11. If the drained fuel is to be reused, return it to the fuel tank. If the fuel is not to be reused, dispose of it in an environmentally friendly manner, according to state and/or federal (EPA) recommendations.