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Replacing the inline fuel filter/water separator element is essential for good engine performance and service life. A dirty or clogged filter may cause the engine to perform poorly and continued use may cause component damage. Extremely dirty conditions may require that the filter be replaced more often.

Explosion and fire hazard. Engine fuels are combustible. Perform this procedure in an open, well- ventilated area away from heaters, sparks, flames and lighted

tobacco. Always have an approved fire extinguisher within easy reach.

Perform this procedure with the engine off.

1 Tag, disconnect and plug the fuel line from the fuel tank at the inline fuel filter/water separator head.

TABLE B PROCEDURES

2 Loosen the vent plug located on the inline fuel filter/water separator head.

a head bolt b vent plug c drain plug d filter bowl e filter element

f fuel filter/water separator head

3 Place a suitable container under the filter bowl. 4 Loosen the drain plug located at the bottom of

the bowl. Completely drain the fuel from the bowl.

5 Loosen the head bolt. Rotate the filter bowl counterclockwise and remove it from the element.

6 Install the bowl onto the new inline filter element (Genie part number 62433). Tighten the drain plug.

7 Fill the element and bowl with clean diesel fuel. 8 Apply a thin layer of oil onto the element gasket. 9 Install the filter/bowl assembly onto the filter

head and tighten it securely by hand.

The filter/bowl assembly must be full of fuel when it is installed onto the filter head or the fuel system will have to be bled.

10 Tighten the head bolt to 65 in-lbs (7.3 Nm). 11 Tighten the vent plug.

12 Clean up any diesel fuel that may have spilled during the procedure.

13 Use a permanent ink marker to write the date and number of hours from the hour meter on the filter.

14 Install the fuel tank line onto the inline fuel filter/ water separator head. Tighten the hose clamp.

Inline fuel filter/water separator element -

Genie part number 62433

Bleed the fuel system:

Before bleeding the fuel system, be sure the fuel tank is full.

Deutz models:

1 Loosen the overflow valve at the injector pump.

a overflow valve

b fuel lift pump priming lever c oil filter

d filter head e fuel filter

TABLE B PROCEDURES

2 Operate the priming lever of the fuel lift pump until fuel, free from air, comes from the vent. 3 While continuing to operate the priming lever,

tighten the overflow valve.

4 Clean up any diesel fuel that might have spilled during the procedure.

5 Start the engine and inspect for leaks.

Explosion and fire hazard. If a fuel leak is discovered, keep any additional personnel from entering the area and do not operate the machine. Repair the leak immediately.

Component damage hazard. Damage to the fuel injection pump, battery and starter motor can occur if the stater motor is used excessively to eliminate air from the fuel system. Do not engage the starter motor for more than 30 seconds at a time. Wait 120 seconds between starter motor engagements.

Component damage hazard. Operate the engine at low idle speed for a minimum of two minutes immediately after air has been removed from the fuel system. This will ensure that the pump is free of air and prevent any damage to the pumps by metal to metal contact.

If the engine does not start or runs

Cummins models:

Controlled venting is provided at the injection pump. Small amounts of air introduced by changing the filters or injection pump supply line will be vented automatically. If the fuel filter is changed in accordance with instructions, no manual bleeding of the fuel system is needed.

1 Remove the engine pivot plate retaining fastener. Swing the engine pivot plate out away from the machine.

a engine pivot plate anchor hole b engine pivot plate retaining fastener

2 Locate the engine pivot plate anchor hole at the pivot end of the engine pivot plate.

3 Install the bolt that was just removed into the anchor hole to secure the engine pivot plate from moving.

Crushing hazard. Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury.

b a

TABLE B PROCEDURES

4 Loosen the fuel filter/water separator filter vent screw, located on top of the fuel filter/water separator head.

a filter head vent screw b fuel filter

c lift pump d priming lever

5 Operate the priming lever on the fuel lift pump until fuel, free from air, comes out from the vent screw.

6 While continuing to operate the priming lever, tighten the vent screw. Torque the vent screw to 80 in-lbs (9 Nm).

10 Clean up any diesel fuel that may have spilled during the procedure.

11 Start the engine and inspect for leaks.

Explosion and fire hazard. If a fuel leak is discovered, keep any additional personnel from entering the area and do not operate the machine. Repair the leak immediately.

Component damage hazard. Damage to the fuel injection pump, battery and starter motor can occur if the stater motor is used excessively to eliminate air from the fuel system. Do not engage the starter motor for more than 30 seconds at a time. Wait 120 seconds between starter motor engagements.

Component damage hazard. Operate the engine at low idle speed for a minimum of two minutes immediately after air has been removed from the fuel system. This will ensure that the pump is free of air and prevent any damage to the pumps by metal to metal contact.

If the engine does not start or runs erratically, refer to the Cummins Operation and Maintenance Manual, Cummins part number 3810205 (Genie part number 62448) for additional information on the fuel system.

TABLE B PROCEDURES

12 Remove the engine pivot plate retaining

fastener from the engine pivot plate anchor hole at the pivot end of the engine pivot plate. 13 Swing the engine pivot plate in towards the

machine.

14 Install the bolt that was just removed into the original hole to secure the engine pivot plate.

Crushing hazard. Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury.

Perkins models:

1 Remove the engine pivot plate retaining

fastener. Swing the engine pivot plate out away from the machine.

a engine pivot plate anchor hole b engine pivot plate retaining fastener

2 Locate the engine pivot plate anchor hole at the pivot end of the engine pivot plate.

3 Install the bolt that was just removed into the anchor hole to secure the engine pivot plate from moving.

Crushing hazard. Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury. 4 Loosen the fuel filter/water separator filter vent

screw, located on top of the fuel filter/water separator head.

a vent screw b fuel filter head c fuel filter b

TABLE B PROCEDURES

5 Operate the priming lever of the fuel lift pump until fuel, free from air, comes from the vent.

If the drive cam of the fuel lift pump is at the point of maximum lift, it will not be possible to operate the priming lever. In this situation, rotate the crankshaft one revolution.

a fuel lift pump

6 While continuing to operate the priming lever, tighten the vent screw.

7 Loosen the union nut on the fuel inlet pipe at the injection pump.

8 Operate the priming lever of the fuel lift pump until fuel, free from air, comes from the connection.

9 Tighten the union nut.

10 Clean up any diesel fuel that may have spilled during the procedure.

11 Start the engine and check for leaks.

Explosion and fire hazard. If a fuel leak is discovered, keep any additional personnel from entering the area and do not operate the machine. Repair the leak immediately.

Component damage hazard. Damage to the fuel injection pump, battery and starter motor can occur if the stater motor is used excessively to eliminate air from the fuel system. Do not engage the starter motor for more than 30 seconds at a time. Wait 120 seconds between starter motor engagements.

Component damage hazard. Operate the engine at low idle speed for a minimum of two minutes immediately after air has been removed from the fuel system. This will ensure that the pump is free of air and prevent any damage to the pumps by metal to metal contact.

If the engine does not start or runs erratically, refer to the Perkins User's Handbook, Perkins part number TPD 1349 (Genie part number 62447) for additional information on the fuel system.

TABLE B PROCEDURES

12 Remove the engine pivot plate retaining

fastener from the engine pivot plate anchor hole at the pivot end of the engine pivot plate. 13 Swing the engine pivot plate in towards the

machine.

14 Install the bolt that was just removed into the original hole to secure the engine pivot plate.

Crushing hazard. Failure to install the bolt into the engine pivot plate to secure it from moving could result in death or serious injury.

B-5

Replace the Air Filter

Maintaining the engine air filter in good condition is essential to good engine performance and service life. Failure to perform this procedure can lead to poor engine performance and component damage.

Perform this procedure with the engine off.

1 Open the evacuator valve located on the air cleaner cap by squeezing the sides together with your fingers.

2 Open the latches on the air cleaner cap. Remove the end cap from the air cleaner canister.

3 Remove the filter element.

4 Clean the inside of the air cleaner canister and end cap with a damp cloth.

5 Install the new filter element.

6 Replace the end cap on the canister. Be sure the evacuator valve is pointing in the down direction.