Testing and  Adjusting

Section

Note: The fuel test valve is located on the front  of

the fuel filter base.

2.  Insert the other end of the clear test line of Tooling

(A) into a suitable container.

Fuel System

3.  Crank the engine for 20  seconds. Open the

shut-off valve to check for air in fuel.

i04112210

4.  Run engine at low idle. Open the shut-off valve

Fuel System - Inspect

to check for air in fuel.

5.  Run engine at high idle. Open the shut-off valve

to check for air in fuel.

A problem with the components that  send fuel to

the engine can cause low fuel pressure. This  can

decrease engine performance.

6.  If there is no air in fuel, no repair is required. If

there is air in fuel, proceed to “Alternative  Fuel

Supply to Fuel Filter Base”.

1.  Check the fuel level in the fuel tank. Ensure that

the vent in the fuel cap is not filled with dirt.

Alternative Fuel Supply to  Fuel

Filter Base

2.  Check all fuel lines for fuel leakage. The fuel lines

must be free from restrictions and faulty bends.

Verify that the fuel return line is not collapsed.

1.  Disconnect the supply line from the fuel filter base.

2.  Fabricate a fuel test line. Use a male 90 degree

fuel line connection and install a clear plastic line

long enough to reach an alternative fuel source.

3.  Install a new fuel filter.

4.  Cut the old filter open with a suitable filter cutter.

Inspect the filter  for excess contamination.

Determine the source of the contamination. Make

the necessary repairs.

3.  Connect the test fuel line between the fuel filter

base inlet and alternative fuel source.

4.  Prime the fuel system. Refer to Systems Operation

Testing and Adjusting, “Fuel System - Prime” for

the correct procedure.

5.  Service the primary fuel filter (if equipped).

6.  Operate the hand priming pump (if equipped).

If excessive resistance is felt,  inspect the fuel

pressure regulating valve. If uneven resistance

is felt, test for air in the  fuel. Refer to Systems

Operation, Testing and Adjusting, “Air in Fuel  -

Test” for more information.

5.  Crank the engine for a maximum 20 seconds.

Open the shut-off valve to check for aeration.

6.  If there is no air in fuel, repair the restriction or

leak between the fuel filter base and the fuel tank.

If there is air in fuel, proceed to “Alternative Fuel

to Fuel Pump Test”.

7.  Remove any air that may be in the fuel system.

Refer to Systems  Operation, Testing and

Adjusting, “Fuel System - Prime”.

Alternative Fuel to Fuel Pump Test

i04876619

1.  Remove fuel pump supply line.

Air in Fuel - Test

2.  Fabricate a test fuel line. Use spare  fuel line.

Ensure that sleeve seals are in good shape. Cut

the line in half. Use  test fuel line section that

supplies the fuel pump. Install clear plastic line

in place of removed section. Secure plastic line

with a clamp.

Table 1

Required Tools

Tool

A

Part Number

27610379

27610386

Part Description

Fuel Pressure Gauge

Fuel Test Coupler

Qty

1

3.  Connect the test fuel line between the fuel pump

inlet and an alternative fuel source.

B

1

4.  Prime the fuel system. Refer to Systems Operation

Testing and Adjusting, “Fuel System - Prime” for

the correct procedure.

1.  Connect Tooling (A) and (B) to the fuel test valve.

This document is printed from SPI². Not for RESALE

KENR8772

53

Testing and  Adjusting Section

5.  Crank engine for maximum of 20 seconds. Check

for signs of aeration in the clear test line.

6.  If there is air in fuel, remove the test set-up from

the fuel pump inlet. Repair or  replace the fuel

filter base. Test for air in fuel at the inlet manifold

test valve. If there is no  air in fuel, proceed to

“Combustion Leaks to Fuel Test”

Combustion Leaks to Fuel Test

1.  Remove the valve mechanism cover.  Refer

to Disassembly and Assembly for  the correct

procedure.

2.  Check that all the bolts that secure the clamps for

the electronic unit injectors are tightened to the

correct torque.

3.  Remove all the electronic unit injectors. Refer

to Disassembly and Assembly for  the correct

procedure. Replace  injector O-rings and

combustion washers. Install the electronic unit

injectors. Refer to Disassembly and Assembly for

the correct procedure.

g02316083

Illustration 45

Typical example

3.  Position piston No. 1 at the top center position on

the compression stroke. Observe cylinder 6 rocker

arms in overlap as the vibration damper timing

mark approaches the TDC mark (1) on the front

cover. Refer to illustration 45. Cylinder 6 exhaust

valve will be closing (coming up) and  the inlet

valve will be starting to open (going down).

Note: An electronic unit injector with carbon build-up

typically indicates a loose electronic unit injector.

4.  Repeat steps 1 to 6 to check for air in fuel.

i04112554

Finding Top Center Position

for No. 1 Piston

Note: If the vibration damper is removed, ensure that

the vibration damper is correctly installed. Refer to

Disassembly and Assembly for the correct procedure.

i04112215

Fuel Quality - Test

1.  Remove the valve mechanism cover. Refer to

Disassembly and Assembly, “Valve Mechanism

Cover - Remove and  Install” for the correct

procedure.

Ensure that all adjustments and repairs are performed

by authorized personnel that have had the correct

training.

2.  Turn the crankshaft in the normal direction  of

engine rotation to remove backlash.

Use the following procedure to test  for problems

regarding fuel quality:

1.  Determine if water and/or contaminants  are

present in the fuel. Check the water separator (if

equipped). If a water separator is  not present,

proceed to Step 2. Drain the water separator, if

necessary. A full fuel tank minimizes the potential

for overnight condensation.

Note: A water separator can appear to be full of fuel

when the water separator is actually full of water.

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54

KENR8772

Testing and  Adjusting Section

2.  Determine if contaminants are present in the

fuel. Remove a sample of fuel from the  bottom

of the fuel tank. Visually inspect the fuel sample

for contaminants. The color of  the fuel is not

necessarily an indication of fuel quality. However,

fuel that is black, brown, or similar to sludge can

be an indication of the growth of bacteria  or oil

contamination. In cold temperatures, cloudy fuel

indicates that the fuel may  not be suitable for

operating conditions.

•  The fuel tank is empty or the fuel tank has been

partially drained.

•  The low-pressure fuel lines are disconnected.

•  A leak exists in the low-pressure fuel system.

•  The fuel filter has been replaced.

If you inspect the engine in operation, always use

the proper inspection procedure in order to  avoid

a fluid penetration hazard. Refer to Operation and

Maintenance Manual, “General hazard Information”.

Refer to Operation and Maintenance Manual,

“Fluid Recommendations” for more information.

3.  If fuel quality is still suspected  as a possible

cause to problems regarding engine performance,

disconnect the fuel inlet line. Temporarily operate

the engine from a separate source of  fuel that

is known to be good. This  will determine if the

problem is caused by fuel quality. If fuel quality

is determined to  be the problem, drain the

fuel system and replace the fuel filters.  Engine

performance can be affected by  the following

characteristics:

•  Cetane number of the fuel

•  Air in the fuel

•  Other fuel characteristics

i04198691

Fuel System - Prime

NOTICE

Care must be taken to ensure that fluids are contained

during performance of inspection, maintenance, test-

ing, adjusting, and repair of the product. Be prepared

to  collect  the  fluid  with  suitable containers  before

opening any compartment or disassembling any com-

ponent containing fluids.

g02837626

Illustration 46

Typical example

Priming with leak off Tool

Dispose of all fluids according to local regulations and

mandates.

In order to purge air from the fuel system a  tool is

required. Use a PCL Air  Technology Single Clip

on Connector CO2H03 or similar. Install a suitable

length of clear hose onto connector (A).

NOTICE

Do not  crank the engine continuously  for more than

30 seconds. Allow  the starting motor  to cool for two

minutes before cranking the engine again.

Ensure that all adjustments and repairs are performed

by authorized personnel that have had the correct

training.

If air enters the fuel system, the air must be purged

from the fuel system  before the engine can be

started. Air can enter  the fuel system when the

following events occur:

This document is printed from SPI². Not for RESALE

KENR8772

55

Testing and  Adjusting Section

2.  Insert the other end of the clear test line of Tooling

(A) into a suitable container if necessary.

3.  Crank the engine for 20 seconds. Measure the fuel

pressure with shut-off valve closed. The minimum

fuel pressure should be 138 kPa (20 psi).

4.  Run engine at low idle. Measure fuel pressure with

shut-off valve closed. The fuel pressure should be

between 275 to 515 kPa (40 to 75 psi).

5.  Run engine at high idle. Measure fuel pressure

with shut-off valve closed.  The fuel pressure

should be between 275 to 515 kPa (40 to 75 psi).

g02948436

Illustration 47

6.  If fuel pressure is in specification, no repair  is

required. If the fuel pressure is below specification,

proceed to “Fuel Filter Base Pressure Test”.

Typical example

1.  Remove the dust cap (3) and install tool (B) onto

schrader valve (2). Put  the clear hose into a

suitable container.

Fuel Filter Base Pressure Test

1.  Connect Tooling (A) and (B) to the fuel test valve.

2.  Depress the priming pump (1) in order to release

the air from the system.

Note: The fuel test valve is located on the front  of

the fuel filter base.

3.  When fuel free from air comes from the schrader

valve, stop depressing the priming pump. Remove

the tool and install the dust cap.

2.  Crank engine for 20 seconds.  Measure fuel

pressure with shut-off valve closed. The minimum

fuel pressure should be 138 kPa (20 psi).

4.  Depress the priming pump for a short time in order

to pressurize the system. Check the low-pressure

system for leaks.

3.  If fuel pressure is in specification, replace the

secondary filter and clean the primary filter. Refer

to Operation and Maintenance Manual  for the

correct procedures. If fuel  pressure is below

specification, proceed to “Fuel Inlet Restriction

Test”.

5.  Priming the fuel filter from empty should  take

approximately 3 minutes.  The time will be

dependent on the location of the fuel tank.

6.  Remove any container and clean any split fuel

from the engine. The system is now primed and

the engine ready to start. Operate  the starting

motor and start the engine.

Fuel Inlet Restriction Test

1.  Check for fuel inlet restriction from the primary

filter that is located in the fuel filter base.

i04208674

2.  Remove the cap from the filter base.

Fuel System Pressure - Test

3.  Connect Tooling (C) and test line to filter base.

4.  Route test line from engine compartment to the

operators enclosure of the application.

Table 2

Required Tools

5.  Connect a suitable vacuum gauge to the test line.

Tool

A

Part Number

27610379

27610386

Part Description

Fuel Pressure Gauge

Fuel Test Coupler

Qty

1

Note: The vacuum gauge should  be capable of

measuring up to 101.6 kPa (14.7 psi).

B

1

6.  Measure the high-idle fuel inlet restriction. The

maximum pressure should be 20 kPa (3 psi).

Fuel Inlet Restriction

Adapter

C

27610392

1

7.  If fuel inlet restriction is in specification, proceed to

“Fuel Pump Operation Test”. If fuel inlet restriction

is out of specification, proceed to “Alternate Fuel

Supply to Fuel Filter Base Test”.

1.  Connect Tooling (A) to the fuel test valve.

Note: The fuel test valve is located on the front  of

the fuel filter base.

This document is printed from SPI². Not for RESALE

56

KENR8772

Testing and  Adjusting Section

Fuel Pump Operation Test

1.  Connect Tooling (A) to fuel test valve in the inlet

manifold.

2.  Open the shut-off valve.

Note: A closed shut-off valve during the test will yield

incorrect values.

3.  Disconnect fuel pump supply line from the fuel

filter base.

4.  Connect test hose to fuel supply and secure with

clamp. A cone adapter (included with  vacuum

pump kit) may also be used. The adapter fits on

the end of the fuel supply line.

5.  Insert vacuum pump nozzle into the fuel supply

line. Ensure the integrity of the seal during the test.

6.  Crank the engine for a maximum of 20 seconds.

g03063996

Illustration 48

Typical example

7.  If vacuum reading is  greater than 41 kPa

(12 inch mercury), the pump is operating correctly.

Proceed to “Alternate Fuel Supply to Fuel Filter

Base Test”.

3.  Connect the test fuel line at the fuel filter base inlet

at position (X) and an alternative fuel source.

4.  Connect Tooling (A) to the inlet manifold fuel test

valve.

8.  If vacuum reading  is less than  41 kPa

(12 inch mercury), replace the fuel pump. Refer

to Disassembly and Assembly for  the correct

procedure. Repeat steps  3 to 6 to test  fuel

pressure again at inlet manifold test valve.

5.  Crank the engine for a maximum 20 seconds.

6.  Measure fuel pressure with the shut-off valve

closed. The pressure  should be between

275 to 515 kPa (40 to 75 psi).

Alternate Fuel Supply to Fuel Filter

Base Test

7.  If fuel pressure is below specification, replace

the fuel filter base. Refer  to Disassembly and

Assembly for the correct procedure. Repeat steps

3 to 5 to test fuel pressure again at inlet manifold

test valve. If fuel pressure is in specification, and

there is no air in fuel, repair the restriction or leak

between the fuel filter base and the fuel tank.

1.  Disconnect the supply line from the fuel filter base.

2.  Make a test fuel line. Use a male 90 degree fuel

line connection and install a clear plastic line long

enough to reach an alternative fuel source.

i04198651

Gear Group (Front) - Time

1.  Ensure that number one piston is in the top center

position. Refer to Systems Operation, Testing and

Adjusting, “Finding Top Center Position for No. 1

Piston” for the correct procedure.

2.  Install the camshaft gear onto the camshaft. Refer

to Disassembly and Assembly, “Camshaft Gear -

Remove and Install” for the correct procedure.

3.  Install the lower idler gear. Refer to Disassembly

and Assembly for the correct procedure.

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KENR8772

57

Testing and  Adjusting Section

4.  Install the upper idler gear. Refer to Disassembly

and Assembly for the correct procedure.

5.  Install the gear for the high-pressure pump. Refer

to Disassembly and Assembly for  the correct

procedure.

6.  Make sure that the timing marks on the gears are

in alignment. If the timing marks are not aligned,

refer to Disassembly and Assembly, “Gear Group

(Front) - Remove and Install”.

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KENR8772

Testing and  Adjusting Section

Air Inlet  and Exhaust

System

5.  If the breather tube is  made of plastic, use

low-pressure air to check for a blockage in  the

breather tube. If a blockage is inside the cover,

remove the cover. Refer to  Disassembly and

Assembly, “Crankcase Breather - Remove and

Install” for the correct procedure. When possible,

remove the blockage from the cover. If necessary,

replace the cover.

i04112660

Air Inlet and Exhaust System

- Inspect

i04041486

Turbocharger - Inspect

A general visual inspection should be made to the air

inlet and exhaust system. Make sure that there are

no signs of leaks in the system.

There will be a reduction in the performance of the

engine if there is a restriction in the air inlet system or

the exhaust system.

Hot  engine  components can  cause  injury  from

burns.  Before  performing  maintenance   on  the

engine, allow the  engine and the  components to

cool.

Hot  engine  components can  cause  injury  from

burns.  Before  performing  maintenance   on  the

engine, allow the  engine and the  components to

cool.

Personal injury can result from rotating and mov-

ing parts.

Stay clear of all rotating and moving parts.

Making contact with a  running engine can cause

burns from  hot parts and  can cause  injury from

rotating parts.

Never attempt  adjustments while the  machine is

moving or the engine is running unless otherwise

specified.

When working on an engine that is running, avoid

contact with hot parts and rotating parts.

The machine  must be parked  on a  level surface

and the engine stopped.

1.  Inspect the engine air cleaner inlet and ducting

in order to ensure that the  passageway is not

blocked or collapsed.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause  rapid wear and  shortened

component life.

2.  Inspect the engine air cleaner element. Replace

a dirty engine air cleaner element with  a clean

engine air cleaner element.

NOTICE

3.  Check for dirt tracks on the clean  side of the

engine air cleaner element.  If dirt tracks are

observed, contaminants are flowing  past the

engine air cleaner element and/or the seal for the

engine air cleaner element.

Care must be taken to ensure that fluids are contained

during performance of inspection, maintenance, test-

ing, adjusting and repair of the product. Be prepared to

collect the fluid with suitable containers before open-

ing any  compartment or  disassembling any  compo-

nent containing fluids.

4.  If you experience excessive crankcase pressure,

remove the valve mechanism cover.  Refer to

Disassembly and Assembly, “Valve Mechanism

Cover - Remove and  Install” for the correct

procedure. Inspect the  inside of the valve

mechanism cover for debris. Ensure that all of the

debris is removed.

Dispose of all fluids according to local regulations and

mandates.

This document is printed from SPI². Not for RESALE