Fuel SystemMaintenanceServicing the Fuel SystemDANGERUnder certain conditions, diesel fuel and fuelvapors are highly flammable and explosive. A fireor explosion from fuel can burn you and others andcan cause property damage.• Use a funnel and fill the fuel tank outdoors, inan open area, when the engine is off and is cold.Wipe up any fuel that spills.• Do not fill the fuel tank completely full. Add fuelto the fuel tank until the level is 1 inch (25 mm)below the bottom of the filler neck. This emptyspace in the tank allows the fuel to expand.• Never smoke when handling fuel, and stay awayfrom an open flame or where fuel fumes may beignited by a spark.• Store fuel in a clean, safety-approved containerand keep the cap in place.Fuel TankService Interval: Every 1,000 hours—Drain and cleanthe fuel tank.Drain and clean the fuel tank every 1000 hours.Also, drain and clean the tank if fuel system becomescontaminated or if the machine will be stored for anextended period of time. Use clean fuel to flush outthe tank.Fuel Lines and ConnectionsService Interval: Every 500 hours—Inspect the fuellines and connections.Check the fuel lines and connections every 500 hoursor yearly, whichever comes first. Inspect them fordeterioration, damage, or loose connections.Servicing the Water SeparatorService Interval: Before each use or daily—Drain thewater separatorEvery 500 hours—Replace thefuel/water separator element.Draining the Water Separator1. Place a clean container under the water separator(Figure 62).2. Open the drain plug and operate the pump to drainoff contaminates (Figure 62).Figure 621. Water separator filtercanister4. Flow check valve2. Priming pump 5. Vent plug3. Drain plug3. Close the drain plug.Replacing the Fuel Filter Element1. Place a clean container under the water separator.2. Drain some fuel by loosening the vent plug andopening the drain plug (Figure 62).3. Disconnect the water sensor (electrical connector)from the bottom of the water separator4. Clean the area where the filter element mounts tothe head.5. Remove the filter element and bowl. Remove theelement from the bowl and clean the mountingsurface.6. Clean the O-ring gland on the bowl.7. Apply a coating of clean fuel or motor oil to the newO-ring and element seal.8. Spin the bowl onto the new element and then spinthem both onto the filter head by hand only. Do notuse tools.9. Close the drain plug.48