Check low-pressure fuel circuit

AR07.15-G-2000NA

Check low-pressure fuel circuit

27.08.2020

Engine

902.912 in model 405.210/230

For USA/Canada only

Engine

906.936 in model 405.210/230

For USA/Canada only

Engine

906.967 in model 405.210/230

with code M03 (Increased engine output)

For USA/Canada only

Schematic diagram of fuel circuit

1

Fuel delivery pump (KFP)

2

Fuel filter (KF)

3

Fuel prefilter (KVF)

4.1

Plug-on valve in fuel feed (from tank)

5.1

Plug-on valve in fuel return (to tank)

6

MR/PLD unit pumps

7.03

Overflow valve (4.5 bar)

9

Nozzle holder combination

11

Fuel return line – scavenging fuel of unit pumps

12

Return flow – leak fuel line

13

Fuel line KVF to KFP

14

Fuel feed line to unit pumps MR/PLD

15

Leak fuel line

16

Pressure pipe connection

17

Injection line

 Warning

Risk of accident from vehicle starting off by itself when engine running. Risk of injury (bruises and burns) resulting from working on the engine while it is being started or when it is running.

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

AS00.00-Z-0005-01A

 Danger

Risk of explosion caused by fuel igniting, risk of poisoning caused by inhaling and swallowing fuel as well as risk of injury to eyes and skin caused by contactwith fuel.

No fires, sparks, open flames or smoking. Pour fuels into suitable and appropriately marked containers only.
Wear protective clothing when handling fuel.

AS47.00-Z-0001-01A

 Warning

Risk of injury caused by body parts being pinched or crushed as cab is tilted

Ensure that no one is within the tilting range of the cab as it is being tilted. Always tilt the cab all the way to the end position and secure it with the safety strut.

AS60.80-Z-0001-01A

Topical note

Notes on tilting the cab

AH60.80-N-0003-01B

1

Start engine and bring to operating temperature

 Coolant temperature approx. 70 to 95°C.

2

Let engine run at maximum governed rpm

 Discharge approx. 2 to 3 min.

3

Turn off engine

 

Remove/install

4

Tilt cab

AR60.80-G-0010NA

5

Remove air intake pipe (exhaust gas turbocharger to air filter)

6

Perform visual inspection of all fuel lines, threaded connections, and component parts

 Replace damaged or leaking parts. Retighten screw connections if necessary.

7

Clean filter element of fuel prefilter



AP47.20-G-0730NA

8

Replace fuel filter



AP47.20-G-0780NA



Check

9

Open cap on fuel tank

10

Check fuel pressure downstream of fuel filter

AR07.15-G-2000-01NA



Conduct test

AD07.15-G-7001-01NA

 Install test and measuring equipment at low-pressure fuel circuit.

 High-pressure hose

*123589042118

 Adaptation parts

*541589009100

 Tester

*541589022100

11

Measure fuel return quantity to nozzle holder assembly

AR07.15-G-2000-01ND



Conduct test

AD07.15-G-7001-07NA

 Install test and measuring equipment at low-pressure fuel circuit.

 If the fuel return quantity is OK, no further tests need to be performed.

 Injection line to connection fitting and unit pump

*BA07.15-N-1004-01E

 Banjo bolt, fuel line to cylinder head

*BA07.15-N-1006-01E

 Retainer wrench

*904589010700

 Ring wrench

*000589070300

 Box wrench bit

*000589680300

 Adaptation parts

*541589009100

12

Measure fuel return quantity at the engine

AR07.15-G-2000-01NC



Conduct test

AD07.15-G-7001-06NA

 Install test and measuring equipment at low-pressure fuel circuit.

 Banjo bolt, fuel line to overflow valve

*BA07.15-N-1007-01E

 Connectors

*405589009100

 Adaptation parts

*541589009100

13

Check fuel intake pressure upstream of fuel delivery pump

AR07.15-G-2000-01NB



Conduct test

AD07.15-G-7001-03NA

 Install test and measuring equipment at low-pressure fuel circuit.

 Connectors

*405589009100

 Adaptation parts

*541589009100

 Tester

*617589042100

14

Check low-pressure fuel circuit in engine for leaks

AR07.15-G-2000-01NE



Conduct test

AD07.15-G-7001-08NA

 Install test and measuring equipment at low-pressure fuel circuit.

 High-pressure hose

*123589042118

 Adaptation parts

*541589009100

 Tester

*541589022100

15

Install in the reverse order

16

Start the engine and bleed the fuel system

 Run the engine for approx. 1 minute. The fuel system is bled automatically.

17

Turn off engine

18

Test vehicle power output on dynamometer



Only after all tests or measurements have been performed and any defects have been rectified:



If no improvement of fuel consumption or performance has been achieved, a fuel consumption measuring system must be connected.

 Diesel injection system with unit pumps (MR/PLD)

Number

Designation

Engine 902.912, 906.936/967

BA07.15-N-1004-01E

Injection line to connection fitting and unit pump

Nm

35

 Diesel injection system with unit pumps (MR/PLD)

Number

Designation

Engine 902.912, 906.936/967

BA07.15-N-1006-01E

Banjo bolt, fuel line to cylinder head

Nm

45

 Diesel injection system with unit pumps (MR/PLD)

Number

Designation

Engine 902.912, 906.936/967

BA07.15-N-1007-01E

Banjo bolt, fuel line to overflow valve

Nm

45