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MAINTENANCE
D-3
FUEL FILTERS
When working on the fuel system
• Keep naked lights away, do not
smoke !
• Do not spill fuel !
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The BIG RED™ 600 is equipped with a Fuel Pre-
Filter/Water Separator Assembly located before the
lift pump and a Secondary Fuel Filter located after
the lift pump and before the fuel injectors. The Fuel
Pre-Filter/Water Separator is mounted to the engine
block just below the lift pump. The Secondary Fuel
Filter is mounted directly to the engine just above the
oil filter.
FUEL PRE-FILTER/WATER SEPARATOR
ASSEMBLY
The pre-filter is a 150 micron screen designed to pro-
tect against gross fuel contamination of the water sep-
arator element and the Secondary Fuel Filter. If the
pre-filter becomes plugged it may be removed,
inspected, cleaned and reinstalled. In general this only
needs to be done with each water separator element
change (about every 1,000 hrs.) However if at any
time excessive fuel contamination is suspected or a
sudden fall-off in engine performance is detected the
pre-filter screen should be inspected and cleaned.
Follow the following procedure:
1. Close the fuel shutoff valve (Lever should be per-
pendicular to the hose) located on the side of the
Fuel Pre-Filter/Water Separator Assembly.
2. Unscrew the cap ring located on the top of the filter
header and remove the plastic center cap and O-
ring.
3. Remove the large white volume plug located
directly under the center cap in the upper cavity of
the filter header. Use a small screw driver (or simi-
lar device) to lift the plug part way out of the cavity
to assist with its removal.
Be careful not to damage the pre-filter screen
with the tool used to remove the plug.
4. Using a pair of pliers, gently tug on the pull tabs of
the pre-filter screen in an alternating pattern to
gradually remove the pre-filter screen.
5. Brush off any debris and rinse in diesel fuel.
6. Re-install the pre-filter screen into the upper cavity
of the filter header making sure the four pull tabs
are pointing up. Putting your fingers on the pull
tabs, push down evenly until the lower body of the
pre-filter screen contacts the floor of the upper cav-
ity.
7. Re-insert the large white volume plug into the
upper cavity.
8. Place the O-ring onto the angled seal surface of
the filter header and re-install the plastic cap. Make
sure its flange rests on the O-ring.
9. Screw on the cap ring and tighten hand tight.
10. Remember to open the fuel shutoff valve (Lever in
line with the hose) before starting the engine.
WATER SEPARATOR ELEMENT
The water separator element is a two stage filter with
a special filtration/water separating media, and an
expanded water reservoir providing maximum protec-
tion against water in the fuel. The recommended
change interval for the water separator element is
1,000 hours. The procedure for changing the element
is as follows:
1. Close the fuel shutoff valve (Lever should be per-
pendicular to the hose) located on the side of the
Fuel Pre-Filter/Water Separator Assembly.
2. Rotate the quick change ring (located just below fil-
ter header) clockwise approximately 1/2 turn and
slide it down and off of the element.
3. Grasp the element and pull down with a slight rock-
ing motion to remove the element from the grom-
met post on the bottom of the filter header.
4. Slide the new element onto the grommet post on
the bottom of the filter header until the element no
longer easily moves up into the filter header. Now
rotate the element (may take almost 1 full turn) with
a slight upward pressure until the element begins to
further engage the header. With the proper orienta-
tion now established apply additional pressure to
seat the element in the filter header. You should
feel the element “pop” into place when properly
seated.
Note: The element will only go on one way.
Never use excessive force when mounting the
element to the header.
BIG RED™ 600
WARNING