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SERIES 60 ASSEMBLY FUEL FILTER AND WATER SEPARATOR

The fuel filter and water separator assembly facilitates the settling of water in a collection bowl. See Figure 21177 . ‪

1. Collection Bowl ‪

4. Reducer Bushing ‪

2. Spin-on Element ‪

5. Filter Head to Transfer Pump Hose ‪

3. Priming Pump ‪

6. Hose to Secondary Fuel Filter ‪

Typical Fuel Filter and Water Separator Installation

Replacement of Fuel and Water Separator Element

Use the following procedure: ‪

  1. Drain off some fuel by opening the drain valve on the collection bowl. Close the valve.
  2. Remove the element and bowl together, then remove the bowl from the element. Clean the bowl and the O-ring gland.
  3. Apply a coating of clean fuel or grease to the new O-ring and element seal. Spin the bowl onto the new element and them spin the assembly onto the filter head by hand until snug. Do not use tools to tighten.
  4. To eliminate air from the filter, operate the primer pump until the fuel purges at the filter assembly.

    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 and check for fuel leaks. Correct any leaks with the engine shut off.

Fuel Return System Check Valve

The purpose of the check valve is to reduce the risk of fuel prime loss and fuel siphoning from the head when the fuel filter is removed. See Figure 21176 . ‪

Typical Fuel Return Check Valve Locations

NOTICE:

The check valve must be included in the fuel system. If the check valve is removed for any reason or found to be defective, a new valve must be installed and the fuel system primed before start-up. The R-80 0.080 in. (2.0 mm) restricted fitting (elbow connector) which is ahead of the check valve must also be included in the fuel system. ‪

NOTICE:

Do not increase the size of the orifice in restricted fittings. Increasing restricted fittling hole size can cause injector caviation, resulting in reduced durability of injectors and other engine components, and increased engine emissions. ‪

A check valve is connected to a hose in the fuel return line coming from the rear of the cylinder head or at the cylinder head restricted fitting, depending on individual installation requirements. See Figure 21176 . ‪

Removal of PRO-CHEK Fuel System Check Valve

Remove the valve as follows: ‪

NOTICE:

The PRO-CHEK fuel system check valve is installed after the secondary filter. Any dirt or debris entering the fuel system at this point may cause severe injector damage. ‪

  1. Clean the area around the PRO-CHEK valve thoroughly to remove loose dirt or debris.
  2. Disconnect the fuel supply and return lines from the bottom of the valve and cap the hoses immediately to prevent the entrance of dirt.
  3. Disconnect the air purge line from the top elbow on the valve and cap the line to prevent the entrance of dirt.
  4. Remove the valve and bracket assembly from the engine as follows:
    1. If rear mounted, remove the two 12 mm bolts securing the valve to the rear lifter bracket.
    2. If side mounted, remove the two 10 mm bolts and spacers holding the valve to the cylinder head.
Inspection of the PRO-CHEK Fuel System Check Valve

Inspect the PRO-CHEK fuel system check valve as follows: ‪

  1. Visually inspect exterior casing of the PRO-CHEK valve for cracks, leaks, or other signs of damage.
    1. If the PRO-CHEK valve has no cracks, leaks, or other signs of damage, reuse the valve.
    2. If the PRO-CHEK valve has cracks, leaks, or other signs of damage, replace the valve.

Installation of PRO-CHEK Fuel System Check Valve

The PRO-CHEK fuel system check valve is an optional item that, when properly installed, removes air from the fuel supply line between the secondary filter and the cylinder head. No priming is required even after filter change, since any air that may get into the lines is automatically removed when it reaches the PRO-CHEK valve. ‪

Install the PRO-CHEK valve as follows: ‪

  1. Mount the PRO-CHEK valve on the side or rear of the Series 60 engine.
    1. If side-mounted, install with two 10 mm bolts and spacers. The location may be ahead of or behind the location shown. See Figure 21170 .
    2. 1. Secondary Fuel Filter ‪

      4. Air Purge Line ‪

      2. Fuel Inlet ‪

      5. Fuel Outlet ‪

      3. PRO-CHEK Valve ‪

      6. Fuel Spill Line ‪

      Typical Side-mounted PRO-CHEK Installation

    3. If rear-mounted remove the two 12 mm bolts holding the rear lifter bracket and install the PRO-CHEK valve against the bracket with two 12 mm bolts that are 5 mm (approximately 0.20 in.) longer and two spacers. See Figure 21171 .
    4. 1. Fuel Inlet ‪

      4. Air Purge Line ‪

      2. PRO-CHEK Valve ‪

      5. Fuel Spill Line ‪

      3. Engine Lifter Bracket ‪

      6. Fuel Outlet ‪

      Typical Rear-mounted PRO-CHEK Installation

  2. Disconnect the fuel supply hose assembly at the rear of the engine and reconnect it to the PRO-CHEK 3/8 in. SAE flared bottom fitting marked with the words Fuel In.
  3. Connect a separate fuel hose assembly to the 1/4 in. 18 NPTF PRO-CHEK female bottom fitting marked with the words Fuel Out . Install the other end in the fuel manifold inlet port at the rear of the engine.
  4. An R80 2.03 mm (.080 in.) restricted fitting is installed in the fuel spill (return) opening in the cylinder head. Install a tee-fitting after the R80 spill fitting. The spill hose from this tee-fitting must be routed at least 4 in. (101.6 mm) above the fuel gallery. See Figure 21170 and see Figure 21171 . Connect a 1/4 in. diameter fuel hose assembly to the elbow in the top port of the PRO-CHEK. Route this air purge hose to the spill tee fitting.
  5. Tie-wrap the PRO-CHEK inlet and outlet fuel lines to prevent chafing and/or contact with metal parts.
  6. Prime the fuel system.
  7. Refer to section for the exhaust caution before preceeding. Start the engine and check for leaks.

The PRO-CHEK valve is fully assembled and ready to install when received. If the Fuel In or Fuel Out fittings are accidentally loosened or removed for any reason, they must be reinstalled in their proper locations as follows: ‪

  • The male fitting with the long, solid pipe is installed in the fuel in port. See Figure 21172 .
  • The female fitting with the short, perforated pipe is installed in the fuel out port. See Figure 21172 .

PRO-CHEK Valve Cutaway View

NOTICE:

Fittings must remain clean when installed, since anything that gets inside the PRO-CHEK valve will be carried into the fuel manifold and may damage the injectors. ‪

NOTICE:

Do not overtighten the Fuel In or Fuel Out fittings or the top elbow, since this may damage the threads on the fittings or the PRO-CHEK body, resulting in fuel leaks. If fitting or body threads are damaged, the complete assembly must be replaced. ‪

  1. Thread the inspected, clean dry fittings into the valve body for a few turns.

    NOTICE:

    Do not use Teflon pipe sealant tape on the male pipe fittings, since this may flake off into the fuel system and damage the injectors. ‪

  2. Apply a light coating of pipe sealant with Teflon to the visible male threads.
  3. Torque the Fuel In fitting and top elbow to 14-19 Nm (10-14 lbft).
  4. Torque the Fuel Out fitting to 19-24 Nm (14-18 lbft).