14483 Rev - (RK61776 Davco Replacement Kit)

All products manufactured or distributed by Racor are subject to the following, and only the following, LIMITED EXPRESS WARRANTIES, and no others: For a period of one (1) year from and after the date of purchase of a new Racor product, Racor warrants and guarantees only to the original purchaser-user that such a product shall be free from defects of materials and workmanship in the manufacturing process. The warranty period for pumps and motors is specifically limited to ninety (90) days from date of purchase. A product claimed to be defective must be returned to the place of purchase. Racor, at its sole option, shall replace the defective product with a comparable new product or repair the defective product. This express warranty shall be inapplicable to any product not properly installed and properly used by the purchaser-user or to any product damaged or impaired by external forces.

THIS IS THE EXTENT OF WARRANTIES AVAILABLE ON THIS PRODUCT. RACOR SHALL HAVE NO LIABILITY WHATSOEVER FOR CONSEQUENTIAL DAMAGES FLOWING FROM THE USE OF ANY DEFECTIVE PRODUCT OR BY REASON OF THE FAILURE OF ANY PRODUCT. RACOR SPECIFICALLY DISAVOWS ALL OTHER WARRANTIES, EXPRESS OR IMPLIED INCLUDING, WITHOUT LIMITATION, ALL WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE (EXCEPT FOR THOSE WHICH APPLY TO PRODUCT OR PART THEREOF THAT IS USED OR BOUGHT FOR USE PRIMARILY FOR PERSONAL, FAMILY, OR HOUSEHOLD PURPOSES), WARRANTIES OF DESCRIPTION, WARRANTIES OF MERCHANTABILITY, TRADE USAGE OR WARRANTIES OR TRADE USAGE.

Warning! Failure or improper selection or improper use of the products and/or systems described herein or related items can cause death, personal injury and property damage. This document and other information from Parker Hannifin Corporation, its subsidiaries and authorized distributors provide product and/or system options for further investigation by users having technical expertise. It is important that you analyze all aspects of your application and review the information concerning the product or system in the current product catalog. Due to the variety of operating conditions and applications for these products or systems, the user, through its own analysis and testing, is solely responsible for making the final selection of the products and systems and assuring that all performance, safety and warning requirements of the applications are met. The products described herein, including with limitation, product features, specifications, designs, availability and pricing, are subject to change by Parker Hannifin Corporation and its subsidiaries at any time without notice.

The following statement is required pursuant to proposition 65, applicable in the State of California: ‘This product may contain a chemical known to the State of California to cause cancer or reproductive toxicity’.

RK61776 Davco Replacement KitInstallation Instructions

Read all instructions before beginning installation.

Improper installation could cause personal injury or property damage.

Instruction Part Number 14483 Rev - (October 2016) Questions? 800-344-3286, parker.com/racor, [email protected]

This kit does not include the Racor GreenMAX Fuel Filter/Water Separator Assembly required to make this conversion. Please purchase from your local Racor distributor. See part numbers below.

First Fit Description

4400R02 Includes Hand Primer Pump and 2 Micron Filter



4400R1202 Includes 12 VDC Bowl Heater, Hand Primer Pump, and 2 Micron Filter


4400R1210-01Includes 12 VDC Bowl Heater, Hand Primer Pump, 10 Micron Filter,

and Return Fuel Heat Blender




4400R2410-01 Includes 24 VDC Bowl Heater, Hand Primer Pump, 10 Micron Filter, and a Return Fuel Heat Blender


6600R02 Includes 2 Micron Filter



6600R1202 Includes 12 VDC Bowl Heater and 2 Micron Filter


6600R1210-01 Includes 12 VDC Bowl Heater, 10 Micron Filter, and a Return Fuel Heat Blender




6600R2410-01 Includes 24 VDC Bowl Heater, 10 Micron Filter, and a Return Fuel Heat Blender


Service Replacement Filters

R61691S 2 Micron Replacement Filter For All Models

R61691T 10 Micron Replacement Filter For All Models

R61691P 30 Micron Replacement Filter For All Models

4400R02 Shown Here (with optional equipment)

THIS IS A UNIVERSAL RETROFIT KIT. NOT ALL PARTS IN THIS KIT WILL BE USED IN EVERY APPLICATION.

RK6165804 Return Fuel Heat

Blender (optional)

Hand Primer Pump

RK55726 Water-In-Fuel (WIF) Sensor

(optional)

Fuel Tank

Sample Retrofit Installation

Cold Fuel, From Tank

Warm, Clean Fuel, Back To Engine

Hot Fuel, Return-To-Tank

Hot Fuel, Return-

From-Engine

Blended Fuel Cycles Through Multi-Stage Aquabloc Filtration

H1

H2RK6165804

Return Fuel Heat Blender (optional)

Specifications:• Fuel Ports: 7/8˝-14 UNF (SAE J1926)• Return Fuel Heat Fittings: 8 SAE 45o Flare (3/4˝-16)• Max. Flow Rate: 150 GPH (568 LPH)• Clean Pressure Drop (@150 GPH): 0.5 PSI (0.03 bar)• Max. Allowable Pressure:

30 PSI (2.07 bar)• Bowl Capacity: 10.1 oz (300 ml)• Ambient Temp. Range:

-22o to +212oF (-30o to +100oC), Max. Fuel Temp: 158oF (70oC)

• Suction-side installations only• Fuel compatibility: diesel fuel per ASTM D975 and

biodiesel blends up to B20 per ASTM D7467• Do not use on gasoline applications• Properties of biodiesel vary greatly and can have an

impact on water separation performance

4400 TOP VIEW

Vent Plug

Hand Actuated Primer Pump

OUTOUT

IN IN

Plug any unused fuel ports.

6600 TOP VIEW

Fill Port

OUTOUT

IN IN

Plug any unused fuel ports.

Installation instructions for the GreenMAX assembly are included with each unit. Please

read and follow those instructions as well.

Study Current Installation • Mounting Hardware: Save mounting

hardware as you remove the current installation, if it’s in good condition, otherwise, have new parts on hand.

• Inlet/Outlet Port Locations: Take picture of current installation. Mark all inlet ports, outlet ports, and fuel lines with tape or labels.

• Return Fuel Hose: Mark return fuel hose, if equipped.

• Water-In-Fuel (WIF) Sensor: Mark WIF connector with tape or labels, if equipped.

• Bowl Heater: Mark bowl heater connector with tape or labels, if equipped.

Remove Current Fuel Filter Assembly

1. Drain current fuel filter assembly per the manufacturer’s recommendations.

2. Remove all fuel lines and connectors.

3. Remove current filter assembly from application.

Mount and Install New GreenMAX Filter Assembly

1. Using existing mounting holes, install GreenMAX assembly to your application.

2. Identify fittings on Inlet and Outlet fuel lines.

3. Select mating Inlet/Outlet fitting from kit and install in filter assembly mounting head.

4. Install port plugs that came in box with GreenMAX into unused Inlet and Outlet ports.

5. Identify fittings on Inlet and Outlet return fuel lines, if equipped.

6. Install return lines directly to selected mating Inlet and Outlet fittings from kit and install.

7. Identify engine return-to-tank fuel port on the GreenMAX.

8. Disconnect return-to-tank fuel line from engine.

9. Install 32492 fitting on return-to-tank port (H2) on GreenMAX.

10. Match fuel line size of return-to-tank fuel line with fuel lines provided: RS7077-01 for 5/8˝ ID hose or RS7077-02 for 1/2˝ ID hose.

11. Select fitting below to use with 5/8˝ or 1/2˝ fuel line.

Item P/N Description Qty

33841 Fitting, NG12 90o Voss 2

33840 Fitting, NG12 Straight Voss 2

32956 Fitting, SV 246 NG12, Straight 2

32955 Fitting, SV 246 NG12, Elbow 2

12. Put hose clamp on end of fuel line selected.

13. Press fitting into fuel line.

14. Tighten clamp.

15. Connect to return-to-tank port fitting on engine.

16. Install 32492 fitting onto return-from-engine (H1) port of GreenMAX return fuel valve.

17. Safely route fuel line between engine return-to-tank port (H2)and return-from-engine port (H1).

18. Cut fuel line to length.

19. Install hose clamp and fitting from step 5.

20. Connect to return-from-engine port (H1).

21. Install 32492 fitting on return- to-tank port (H2) on GreenMAX.

22. Install hose clamp and fitting from step 5.

23. Connect fuel line to return-to-tank port (H2).

24. Safely route fuel line between return-to-tank port (H2) and tank.

25. Start engine and check for leaks. Correct as necessary with engine off.

Additional Notes • Bowl Heater: Select heater

harness that mates with existing chassis harness or use harness provided with kit.

• Bowl Wrench: Store bowl wrench for future filter changes.

• Follow instructions included in GreenMAX packaging to prime and check fuel system before starting.

• For WIF applications, select from two harnesses available.

• Replace fuel filter every 10,000 miles, 500 engine hours, annually, or at first indication of power loss, whichever occurs first. Always keep extra replacement fuel filters on-hand as one full tank of excessively dirty fuel can clog a filter quickly.

61841 Brass Fitting (1 per kit)

7/8”-14 UNF (SAE J1926-3) to 11/16”-20 UNF (SAE J246)

50016 Hose Clamp (4 per kit)

Fits Hose I.D. 3/8” to 5/8”

68301 Brass Fitting (2 per kit)

45o Elbow, 7/8”-14 UNF to 7/8”-14 UNF

61660 Fitting (2 per kit)

7/8”-14 SAE #10 ORM to 7/8”14 SAE #10 Flare

61840 Fitting (2 per kit)7/8”-14 UNF (SAE J512) to 11/16”-20 UNF (SAE J246)

(1/2” Compression)


SV 246, NG 12, 90o (5/8” hose barb)


SV 246, NG 12, Straight (5/8” hose barb)

RS7077-01 Hose (6 feet per kit)

1/2” I.D.

RS7077-02 Hose (6 feet per kit)

5/8” I.D.

32956 Plastic Straight Fitting (2 per kit)

SV 246 NG 12 (1/2” Hose Barb)

32955 Plastic Elbow Fitting (2 per kit)

SV 246 NG 12 (1/2” Hose Barb)

33822 Steel Adaptor (2 per kit)

7/8”-14 UNF to SV 246 NG 12

32492 Adaptor (2 per kit)

Female 3/4”-16 UNF to NG 12

RK55726 WIF Assembly (1 per kit)

PFRK61730 Bowl Wrench (1 per kit)

32257 Heater Jumper Harness (1 per kit)

22716 Heater Assembly/ Connector (1 per kit)

61770 WIF Jumper (1 per kit)

Note: Pictures have NO SCALE

Parts List

Typical Navistar WIF Harness Typical Freightliner WIF Harness

Documents

14483 Rev - (RK61776 Davco Replacement Kit)