OPERATING INSTRUCTIONS 6015 / RH40E Inspection and servicing

Safety filter element

Removal and installation

Replace the safety filter elements (4, Fig. 3-30:) after 1000 operating hours or 3 cleaning cycles; after one year of operation at the latest.

Never clean the safety filter element, but always renew.

 Remove main filter element (3, Fig. 3-30:) as described above.

 Withdraw safety filter element (4).

 Install the new safety filter element and a cleaned or a new main filter element.

Air-intake lines

At regular intervals:

 check intake lines for leaks and hose clamps for tightness;

 replace hoses between filter housing and engine when they were damaged.

During all works on the air-intake system ensure proper sealing to prevent unfiltered air from reaching the engine.

Fuel System

Fuel system - Safety instructions

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Secure the machine as described in the "Securing the machine" section.

Before working on the fuel system:

 shut off the engine,  keep away naked flames,  do not smoke.

Collect escaping fuel and discard without polluting the environment.

Discard used fuel filters without polluting the environment.

Avoid skin contact with diesel fuel.

Diesel fuel may cause skin injury.

Wear firm working clothing.

Wear protective gloves or use a barrier cream. Do not allow dirt to enter the fuel system. Thoroughly clean the area around a fuel component before disconnect it.

It may be necessary to relieve residual fuel pressure from the fuel system before the fuel filter is removed. Wait for one to five minutes until the fuel pressure has lowered.

Fuel pre-filter, Draining off water

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Read and observe the "Fuel system –Safety instructions" chapter.

 Open the flap of the engine compartment (1, Fig. 3-31:). The fuel filters are now accessible.

The pre-filter (1, Fig. 3-32:) works at the same time also as a water trap:

 Open valve (2) and drain off water until fuel emerges from the valve.

 Close valve (2).

For further information please refer to the "Engine, Operation and Maintenance Manual".

Fuel pre-filter, replace

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Read and observe the "Fuel system –Safety instructions" chapter.

 Unscrew pre-filter (1, Fig. 3-33:) completely.

 Pour out fuel and discard it without polluting the environment.

 Unsrew the collector (2) from the fuel pre-filter and clean it.

 Clean the contact surface at the filter head.

 Clean and check the O-Ring of the collector. Replace the ring, if it damaged. Dip the O-ring into clean diesel fuel.

 Screw the collector (2) with the O-ring by hand to the new pre-filter (1), tighten by hand.

Using a tool for tightening of the collectorcan cause irreparable damage to the collector.

 The new pre-filter can be filled with fresh and clean fuel. This helps to prevent rough running of the engine caused by excessive amounts of air in the fuel system.

 Lubricate the sealing of the primary fuel filter lightly with clean fuel and screw it onto the filter base by hand. Continue to tighten filter by a further 1/2 to 3/4 turn.

Using a tool for tightening of the filter element can cause cracking or deformation of the filter head.

 Start the engine and let it run for about one minute. Check that the fuel system has no leaks.

For further information please refer to the "Engine operating and servicing instructions".

Secondary fuel filter, replace

Read and observe the "Inspection and servicing – Safety instructions" chapter.

Read and observe the "Fuel system –Safety instructions" chapter.

 Open the flap of the engine compartment (1, Fig. 3-34:). The fuel filters are now accessible.

 Unsrew the fuel filter (3, Fig. 3-35:).

 Clean the contact surface at the filter head.

 Do not fill fuel into the new filter. This measure prevents unfiltered fuel from getting into the injection system.

 Apply a thin layer of clean diesel fuel on the seal of the new filter.

 Screw the fuel filter onto the filter base by hand. Use the rotation index marks on the filter as a guide for proper tightening. Tighten the filter according to the instructions that are on the filter.

Using a tool for tightening of the filter element can cause cracking or deformation of the filter head.

 Vent the fuel system, see "Engine, Operation and Maintenance Manual".