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manual abstract
Follow the following procedure: 1. Close the fuel shutoff valve (Lever should be perpendicular to the hose) located on the side of the Fuel Pre-Filter/Water Separator Assembly. 2. Unscrew the cap ring located on the top of the filter header and remove the plastic center cap and O- ring. 3. Remove the large white volume plug located directly under the center cap in the upper cavity of the filter header. Use a small screwdriver (or similar device) to lift the plug part way out of the cavity to assist with its removal. Be careful not to damage the pre-filter screen with the tool used to remove the plug. 4. Using a pair of pliers, gently tug on the pull tabs of the pre-filter screen in an alternating pattern to gradually remove the pre-filter screen. 5. Brush off any debris and rinse in diesel fuel. 6. Re-install the pre-filter screen into the upper cavity of the filter header making sure the four pull tabs are pointing up. Putting your fingers on the pull tabs, push down evenly until the lower body of the pre-filter screen contacts the floor of the upper cavity. 7. Re-insert the large white volume plug into the upper cavity. 8. Place the O-ring onto the angled seal surface of the filter header and re-install the plastic cap. Make sure its flange rests on the O-ring. 9. Screw on the cap ring and tighten hand tight. 10. Remember to open the fuel shutoff valve (Lever in line with the hose) before starting the engine. WATER SEPARATOR ELEMENT The water separator element is a two stage filter with a special filtration/water separating media, and an expanded water reservoir providing maximum protection against water in the fuel. The recommended change interval for the water separator element is 1,000 hours. The procedure for changing the element is as follows: 1. Close the fuel shutoff valve (Lever should be perpendicular to the hose) located on the side of the Fuel Pre-Filter/Water Separator Assembly. 2. Rotate the quick change ring (located just below filter header) clockwise approximately 1/2 turn and slide it down and off of the element. 3. Grasp the element and pull down with a slight rocking motion to remove the element from the grommet post on the bottom of the filter header. COMMANDER 500 D-3 D-3 MAINTENANCE 4. Slide the new element onto the grommet post on the bottom of the filter header until the element no longer easily moves up into the filter header. Now rotate the element (may take almost 1 full turn) with a slight upward pressure until the element begins to further engage the header. With the proper orientation now established apply additional pressure to seat the element in the filter header. You should feel the element “pop” into place when properly seated. Note: The element will only go on one way. Never use excessive force when mounting the element to the header. 5. Slide the quick change ring up over the element and rotate counter clockwise until an audible click or pop is heard. If you do not hear the click you have not rotated the ring far enough and the element is not in the locked position. Another indication that the ring is in the locked position is that one set (it doesn’t matter which one) of arrows located on the outside of the ring should be located directly under the air vent valve. 6. Open the fuel shutoff valve (lever in line with the hose). 7. Open the air vent valve on the front of the filter header until fuel emerges free of air bubbles and then close the air vent valve. Note : Consult your engine operation manual for information on air -bleeding the entire fuel system. SECONDARY FUEL FILTER The Secondary Fuel Filter is a spin on cartridge type mount directly to the engine. Consult your engine operation manual for complete information on service intervals and element changing procedures. COOLING SYSTEM The cooling system of the Deutz engine needs to be checked and cleaned periodically. Consult the engine owners manual for the proper frequency and procedure. COOLING BLOWER BELT The following procedure should be followed to replace the cooling blower belt: 1. Allow the machine to cool. 2. Unfasten and slide the battery holder out from the welder. 3. Disconnect the negative battery cable. 4. Remove engine case side. 5. Loosen air cleaner hose clamp and detach hose. 6. Remove the engine end panel with air box and air cleaner attached for access to the engine. 7. Loosen the alternator mounting bolts and rotate the alternator towards the engine. 8. Remove the old cooling blower belt and install a new one. 9. Adjust the cold belt tension to 63-73 lbs. midway between any two pulleys. 10. Reinstall the air cleaner hose, engine case side and end panel. Reattach the negative battery cable. Slide in and refasten the battery holder. 11. Check the cooling blower belt tension after 100 hours of operation. (Follow steps 1,2,3,4,5,6,9 & 10) BATTERY HANDLING WARNING GASES FROM BATTERY can explode. • Keep sparks, flame and cigarettes away from battery. To prevent EXPLOSION when: • INSTALLING A NEW BA...