W07.00-1001-06
4 Fuel heat exchanger
5 Fuel pump (KFP)
6 Fuel filter
7 Nozzle holder combination
8 Unit pump Pump-Line-Nozzle (Y6 to Y13)
10 Overflow valve
A Fuel feed/suction side
B Fuel feed
(pressure side)
C Fuel high pressure side (injection line) after unit pump Pump-Line-Nozzle
D Fuel return to unit pump Pump-Line-Nozzle
E Fuel rinsing amount (fuel short circuit)
F Fuel return flow/leak fuel
W07.15-1080-09
1 Fuel tank
1.1 Fuel strainer (800 μm)
2 Fuel prefilter (KVF 300 μm) with manual fuel pump
3.1 Assembly valve in fuel feed (opened by pressure)
3.2 Assembly valve in fuel return flow (opened by pressure)
4 Fuel heat exchanger
5 Fuel pump (KFP)
5.1 Pressure relief valve (9.0...12.0 bar)
6 Fuel filter (KF 5 μm)
6.1 Fuel filter drain valve
6.2 Permanent purging bore in the KF (0.7 mm)
7 Nozzle holder combination
8 Unit pump Pump-Line-Nozzle (Y6 to Y13)
9 Banjo union with permanent purging bore (0.7 mm)
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10 Overflow valve (up to engine end no. 092407: 2.0 bar;
as of engine end no. 092408: 2.65 bar)
10.1 Restrictor (3.1 mm) in overflow valve
11.1 Fuel feed connector (in frame)
11.2 Fuel return flow connector (in frame)
12 Restrictor (0.5 mm) in the flame starting system fuel line
B10 Fuel temperature sensor
R3 Flame glow plug
Y5 Flame starting system solenoid valve
G Manometer test
H Testing fuel return flow quantity
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Test points
I Fuel pressure downstream of fuel filter for
idle speed:
Overflow valve 2.0 bar (up to engine end no. 092407)
1.8...2.8 bar;
Overflow valve 2.65 bar (from engine end no. 092408)
2.2...3.2 bar
for limit speed: 4.5...5.5 bar
II Fuel return quantity at fuel tank
Idle speed: 0.6...1.0 rpm
Limit speed: 1.0...1.6 rpm
III Low pressure fuel circuit leaktightness
Test pressure 5.5 bar/test period 5 min: no pressure drop
IV Fuel intake pressure upstream of fuel pump for
limit speed: - 0.35...- 0.25 bar
Fuel circuit
A Fuel feed/suction side
B Fuel feed
(pressure side)
C Fuel high pressure side (injection line) after unit pump Pump-Line-Nozzle
D Fuel return after unit pump
E Fuel rinsing amount (fuel short circuit)
F Fuel return flow/leak fuel
----- Fuel passages in crankcase
Fuel lines
| Remove/install | ||
Danger! | Risk of injury caused by body parts being pinched or crushed as cab is tilted | Ensure that no one is within tilting range of cab as it is being tilted. Always tilt cab all the way to end position and secure with safety strut. | |
1 | Tilt cab | ||
| Notes on tilting the cab | ||
Danger! | Risk of explosion caused by ignition of flammable products, risk of poisoning caused by inhaling fuel vapors or swallowing fuel as well as risk of injury to skin and eyes exposed to fuel. | No fire, sparks, open flames or smoking. Wear protective clothing when handling fuel. | |
2 | Carry out visual inspection of all fuel lines, screw connections and components | Clean parts if dirty and dry. Run engine for about 2 to 3 minutes at limit speed. Replace damaged parts with new parts. In the case of leaks tighten threaded connections. | |
3.1 | Clean fuel pre-filter insert | Vehicles without Racor fuel prefilter. | |
| Clean filter element of fuel prefilter | ||
3.2 | Check and dewater fuel prefilter element | Vehicles with Racor fuel prefilter. | |
4 | Check fuel filter element, replace if necessary | ||
| Replace fuel filter | ||
5 | Open end cover at fuel tank | ||
6 | Connect STAR DIAGNOSIS and read fault memory | ||
| |||
7 | Increase set parameter of stationary speed limit to 4000 rpm with STAR DIAGNOSIS | Only on engines fitted with stationary engine speed limit. Note the previously set stationary engine speed limit value. | |
8 | Disconnect fuel lines on fuel prefilter and connect to each other | Only for an installed Racor fuel prefilter and only for the period of the checking. | |
Checking | |||
9 | Attach testing and measuring equipment to low pressure fuel circuit | ||
High pressure hose | |||
Testing unit | |||
Adapter parts | |||
| |||
10 | Check fuel pressure downstream of fuel filter | Test conditions: - Engine must be at operating temperature. - Fuel temperature in fuel tank 40°C. - Collect escaping fuel. - The fuel must be free of bubbles through during the tests. | |
| Fuel pressure downstream of fuel filter, testing hydraulics system MR (PLD) | ||
If the fuel pressure is OK it is not necessary to conduct any further tests. If the fuel pressure lies outside of tolerance range: | |||
| Measure fuel return quantity at the fuel tank. | ||
11 | Check low pressure fuel circuit for signs of leaks | ||
| Low-pressure fuel circuit leaktightness, MR (PLD) hydraulic testing | ||
Attach testers and measuring equipment to low pressure fuel circuit. | |||
High pressure hose | |||
Testing unit | |||
Adapter parts | |||
| |||
| Plug for fuel line | ||
12 | Test fuel inlet pressure upstream of fuel pump | ||
| Fuel vacuum upstream of fuel pump, MR. (PLD) hydraulic testing | ||
Attach testers and measuring equipment to low pressure fuel circuit. | |||
Testing unit | |||
Clamping device | |||
Adapter parts | |||
| |||
13 | Re-parameterize the stationary speed limit using Star Diagnosis | To the previously set (recorded) stationary engine speed limit value. | |
14 | Install in the reverse order | ||
15 | Bleed fuel system | ||
|
Fuel pipes/hoses
Number | Designation | Engine | ||
BA47.25-N-1002-01B | Banjo bolt, fuel line to fuel pump | M161.5 | Nm | 50 |
BA47.25-N-1003-01B | Banjo screw, fuel line to fuel filter housing | M161.5 | Nm | 50 |
123 589 04 21 18
Clamping device
High pressure hose
Tester
Tester
617 589 04 21 00
000 589 40 37 00
541 589 02 21 00
Adapter parts
541 589 00 91 00
Referenced documents
- ad0000w200004a Connect STAR DIAGNOSIS and read out fault memory
- ad0715w700101a Fuel pressure downstream of fuel filter, MR (PLD) hydraulic testing
- ad0715w700103a Fuel intake pressure upstream of fuel pump, MR (PLD) hydraulic testing
- ad0715w700104a Fuel return quantity at fuel tank, MR (PLD) hydraulic testing
- ad0715w700108a Low pressure fuel circuit tightness, MR (PLD) hydraulic testing
- ah6080n000301a Notes on tilting the cab
- ap4700w172001a Bleed fuel system
- ap4720w0730a Clean filter element of fuel prefilter
- ap4720w0780a Replace fuel filter
- ar0715w200001a Install test/measuring equipment in the low pressure fuel circuit
- ar0715w200001c Install the test/measuring equipment in the low pressure fuel circuit
- ar0715w200001ha Install the test/measuring equipment in the low pressure fuel circuit
- as4700z000101a 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.
- as6080z000101a Risk of injury caused by body parts being pinched or crushed as cab is tilted
- wf5850w472501a Plug for fuel line