Replace fuel filter

AP47.20-D-0780E

Replace fuel filter

23.8.11



Removing

 Danger!

Risk of explosion caused by fuel igniting. Risk of injury to skin and eyes caused by fuel spraying out at high pressure

Keep all ignition sources out of hazard area.

Do not carry out any work on system when it is pressurized.

AS07.16-Z-0001-01A

 Danger!

Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel and risk of injury to eyes and skin caused by contact with fuel

No fire, sparks, open flames or smoking.
Pour fuels only into suitable and appropriately marked containers.

Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

Danger!

Risk of accident caused by vehicle starting off by itself when engine is running. Risk of injury caused by contusions and burns during starting procedure or when working near the engine as it is running

Secure vehicle to prevent it from moving by itself.
Wear closed and snug-fitting work clothes.
Do not touch hot or rotating parts.

AS00.00-Z-0005-01A

1

Remove hose clamp of fuel inlet line (9)

 To do so, pull off the fuel inlet line (9).

 Collect escaping fuel.

2

Disconnect connector of fuel outlet line (8) from fuel filter with water separator (1)

 Collect escaping fuel.

AP47.25-D-0780-01A

3

Unscrew mounting bolts (5) from preheating valve (4)

4

Move preheating valve (4) out of locking arm and pull off

 Collect escaping fuel.

5

Attach drain hose to drain fitting of drain plug (6)

 Use a drain hose with an inside diameter of Ø 4 mm.

6

Open drain plug (6).

 Drain off the water and fuel and then remove the drain plug (6).

 Collect the water/fuel mixture and dispose of it in accordance with the local environmental regulations.

7

Disconnect cable connector from water level sensor (7)

 To do so, unlock the release button of the cable connector.

8

Pull fuel filter with water separator (1) out of bracket (2)

 To do so, undo the clamp bolt (3).

9

Remove fuel filter with water separator (1)

 Push the water level sensor (7) into the fuel filter with water separator (1) and remove by turning through 90°.



Install

10

Install fuel filter with water separator (1)

 Push the water level sensor (7) against the spring force into the new fuel filter with water separator (1) and move to the installation position by turning through 90°.

 Replace sealing ring on water level sensor (7). As a result of the spring force, the water level sensor (7) must lock into place in the installation position at the bottom of the filter.

11

Insert fuel filter with water separator (1) into bracket (2)

 The fuel filter with water separator (1) must make full contact.

12

Connect cable connector to water level sensor (7)

 The locking button on the cable connector of the water level sensor (7) must engage.

13

Move fuel filter with water separator (1) into installation position

 To do so, tighten the clamp bolt (3).



*BA47.20-N-1002-02F



*BA47.20-N-1005-02F

14

Screw in drain screw (6)

Replace seal ring on drain plug (6).



*BA47.20-N-1001-02F

15

Fill fuel filter with water separator (1) with fuel

 To prevent damage, make sure that the fuel and filling tool are clean.

 Add fuel into the fuel filter with water separator (1) through the opening of the preheating valve (4).

16

Install preheating valve (4)

 To do so, tighten the mounting bolts (5).



*BA47.20-N-1003-02F

17

Connect connector of fuel outlet line (8)

Except on engine 611.980

AP47.25-D-0780-01A

 On model 638 with engine 611.980, the fuel outlet line (8) is connected after bleeding the low-pressure fuel circuit.

18

Connect fuel inlet line (9)

19

Bleed low pressure fuel circuit

Engine 611.981/983/987, 612.981

AR07.16-D-0100A

Bleed low pressure fuel circuit

Engine 611.980

AR07.16-S-0100A

20

Connect connector of fuel outlet line (8)

Only for engine 611.980

AP47.25-D-0780-01A



Checking

21

Check fuel filter with water separator (1) for leaks

 Start the engine and run in neutral.

Number

Designation

Engine
611.980/981/983/
987
with code KL5,
engine 612.981 with code KL5

Engine 612.981
in model
WD1/WD2/
WD3/WD6/
WD7/XD1/
XD2/XD3/
XD4/XD5/
XD6/XD7/
YD1/YD2/
YD3/YD4/
YD5/YD6/
YD7

Engine
647.981

BA47.20-N-1001-02F

Drain plug to filter

Nm

1.5

1.5

-

BA47.20-N-1002-02F

Clamping bolt to bracket

Nm

6

6

-

BA47.20-N-1003-02F

Mounting bolt for preheating valve

Nm

1.5

1.5

-

BA47.20-N-1005-02F

Bolt, hose clamp to fuel filter

Nm

-

-

8