30 Testing and adjusting SEN00250-09

Testing fuel pressure 1

Testing tools for fuel pressure <6D107E-1 (PC200-8) as an example>

Symbol Part No. Part name

799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
Adapter
6732-81-3170
(10 × 1.0 mm Rc1/8)
2 Adapter
G 795-790-4430
(10 × 1.0 mm Rc1/8)
6215-81-9710 O-ring
3 799-401-2320 Gauge
4 795-790-5110 Screw
5 799-201-2202 Boost gauge kit
2) Install adapter G2 and nipple [1] of
See PAGE 18 for procedure of "Testing fuel hydraulic tester G1 and connect it to oil
pressure" of HB205-1M0 and HB215LC- pressure gauge [2].
1M0. Use an oil pressure gauge of 2.5 MPa
The test point is subject to machine models. {25 kg/cm2}.
Test only the fuel pressure in the low-pressure <4D107E-1 (PC160LC-7) as an example>
circuit from the feed pump through the fuel
main filter to the supply pump and in the return
circuit from the supply pump through the com-
mon rail and the injector to the fuel tank.
Since the pressure in the high-pressure cir-
cuit from the fuel supply pump through the
common rail to the injector is very high, it
cannot be measured.

1. Testing fuel low-pressure circuit pressure

1) Remove fuel pressure pickup plug (1)
from the fuel main filter fuel inlet.
<4D107E-1 (PC160-7) as an example>

<6D107E-1 (PC200-8) as an example>

107E-1 Series 15
SEN00250-09 30 Testing and adjusting

3) Run the engine at low idle and test the fuel 2) Install adapter [4] of hydraulic tester G1
low-pressure circuit pressure. between return manifold (3) and quick
If the fuel low-pressure circuit pres- coupler (4) and install hydraulic tester G1
sure is in the following range, it is nor- to the center with nipple [1].
mal. Adapter [4]: 795-790-5200
0.5 – 1.3 MPa
At Low idle
{5.1 – 13.3 kg/cm2}
0.3 – 1.1 MPa
At cranking
{3.1 – 11.3 kg/cm2}

When the engine cannot run, you

may test it by cranking the engine
with the starting motor. To protect
the starting motor, do not continu-
ously crank the engine 20 seconds
or more.

3) While running the engine at low idle, mea-

sure the fuel return circuit pressure.
If the fuel return circuit pressure is in
the following standard range, it is nor-
mal.
At Low idle and Max. 0.02 MPa
At cranking {Max. 0.19 kg/cm2}

If the engine cannot be started, you

may measure while cranking the
engine with the starting motor. Do
4) After finishing testing, remove the testing not crank the engine for more than
tools and return the removed parts. continuous 20 seconds to protect
Fuel pressure pickup plug: it, however.
10 ± 2 Nm {1 ± 0.2 kgm}
4) After finishing measurement, remove the
2. Checking fuel return circuit pressure measuring instruments and return the
(4D107E-1) removed parts.
1) Disconnect quick coupler (4) of the return
hose connected to the fuel filter of fuel
return manifold (3).

16 107E-1 Series
30 Testing and adjusting
3. Check of fuel return circuit pressure
(6D107E-1)
1) Remove fuel pressure pickup plug (2)
from the fuel return block.
2) Connect nipples [3] and [1] of hydraulic
tester G1 there and connect gauge G3.
Nipple [3]: 790-301-1181, 07002-11223
3) Run the engine at low idle and test the fuel
return circuit pressure.
If the fuel return circuit pressure is in
the following range, it is normal.
At Low idle Max. 0.02 MPa
At cranking {Max. 0.19 kg/cm2}
When the engine cannot run, you
may test it by cranking the engine
with the starting motor. To protect
the starting motor, do not continu-
ously crank the engine 20 seconds
or more.
4) After finishing testing, remove the testing
tools and return the removed parts.
Fuel pressure pickup plug:
24 ± 4 Nm {2.4 ± 0.4 kgm}
107E-1 Series
SEN00250-09
4. Measuring fuel negative-pressure circuit
pressure
The figure below shows 6D107E-1 as an
example.
1) Remove joint bolt (2) of fuel hose (1)
between the prefilter and supply pump.
2) Connect fuel hose (1) to supply pump (3)
by tool G4 instead of joint bolt (2).
When installing tool G4, fit the gaskets to
both sides of the fuel hose joint.
Tool G4:
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
3) Connect tool G5 to tool G4.
4) Run the engine and measure the circuit
negative pressure at high idle.
Circuit standard negative pressure:
Max. –50.7 kPa {–380 mmHg}
5) If the negative pressure is higher than the
standard pressure, the fuel prefilter may
be clogged. In this case, replace the fuel
prefilter and measure again.
6) After finishing measurement, remove the
measuring instruments and return the
removed parts.
Joint bolt (2):
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
17
SEN00250-09 30 Testing and adjusting

Procedure of "Testing fuel pressure" of Use oil pressure gauge of 2.5 MPa
HB205-1M0 and HB215LC-1M0 is shown {25 kg/cm2}.
below.
Testing tools for fuel pressure

Symbol Part No. Part name

799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
Adapter
795-790-4430
2 (10 × 1.0 mm Rc1/8)
G
6215-81-9710 O-ring
5 799-201-2202 Boost gauge kit
6 795-790-5110 Screw
7 799-401-2320 Gauge
3) Start the engine and test the pressure in
the fuel low-pressure circuit with the auto-
Place the machine on a level ground and deceleration OFF and the engine at low
lower the work equipment to the ground. idle.
Test only the fuel pressure in the low-pressure The pressure in the fuel low-pressure
circuit from the feed pump through the fuel circuit is normal when it is within the
main filter to the supply pump and the return following standard range.
circuit from the supply pump/common rail/
injector to fuel tank. At Low idle 0.5 to 1.3 MPa
Testing of the high-pressure circuit con- (1,050 rpm) {5.1 to 13.3 kg/cm2}
necting the supply pump, the common rail 0.3 to 1.1 MPa
At cranking
and the injector can not be performed due {3.1 to 11.3 kg/cm2}
to the extremely high pressure generated
there. If the engine cannot be started, you
may perform the measurement
1. Check of pressure in fuel low-pressure cir- while rotating the engine by the
cuit starting motor. However, do not
1) Open the side cover on the right side of crank the engine continuously for
the machine and remove fuel pressure more than 20 seconds for protec-
pickup plug (on the fuel inlet side) (1) from tion of the starting motor.
the fuel main filter head.

4) After finishing the test, remove the testing

2) Install adapter G2 and nipple [1] of tools and restore the machine.
hydraulic tester G1, and connect them to Fuel pressure pickup plug:
oil pressure gauge [2]. 10 ± 2 Nm {1 ± 0.2 kgm}

18 107E-1 Series
30 Testing and adjusting
2. Testing pressure in fuel return circuit
1) Remove joint bolt (2) of the fuel return
hose.
2) Install screw G6, and nipple [1] and hose
[2] of hydraulic tester G1 instead of joint
bolt (2), and connect them to gauge G7.
When installing screw G6, be sure to
install the seal washer.
Screw G6:
24 ± 4 Nm {2.45 ± 0.41 kgm}
The nipple and hose of digital hydrau-
lic tester G1 can also be used.
107E-1 Series
SEN00250-09
3) Start the engine and test the pressure in
the fuel return circuit at low idle.
If the pressure in the fuel return circuit
is in the following range, it is normal.
At Low idle Max. 0.02 MPa
At cranking {Max. 0.19 kg/cm2}
If the engine cannot be started, you
may perform the measurement while
rotating the engine by the starting
motor. However, do not crank the
engine continuously for more than 20
seconds for protection of the starting
motor.
4) After finishing the test, remove the testing
tools and restore the machine.
Joint bolt (2):
24 ± 4 Nm {2.45 ± 0.41 kgm}
3. Measuring fuel negative-pressure circuit
pressure
1) Open the engine hood and remove joint
bolt (2) of fuel hose (1) between the prefil-
ter and supply pump from supply pump
(3).
2) Using tool G6 instead of joint bolt (2), con-
nect fuel hose (1) to supply pump (3).
When installing tool G6, place the
gaskets to both sides of eyejoint on
the fuel hose.
Tool G6:
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
19
SEN00250-09 30 Testing and adjusting

3) Connect tool G6 to tool G5.

4) Start the engine and test the circuit nega-

tive pressure at high idle.
Circuit standard negative pressure:
Min. -50.7 kPa {-380 mmHg}
5) If the negative pressure is higher than the
criteria, the fuel prefilter may be clogged.
In this case, replace the fuel prefilter and
measure the pressure again.
6) After finishing test, remove the testing
instruments and return the removed parts.
Joint bolt (2):
19.6 to 29.4 Nm {2.0 to 3.0 kgm}

20 107E-1 Series
30 Testing and adjusting SEN00250-09

Reduced cylinder mode operation No-injection cranking 1

Reduced cylinder mode operation means to No-injection cranking means to crank the
run the engine with the fuel injectors of 1 or engine with the starting motor while all the
more cylinders disabled electrically to reduce injections are stopped electrically. The pur-
the number of effective cylinders. The pur- pose and effect of this operation are as follows.
poses and effects of this operation are as fol- Before the engine is started after it or the
lows. machine has been stored for a long period, the
1. This operation is used to find out a cylinder no-injection cranking is performed to lubricate
which does not output power normally (or, the engine parts and protect them from sei-
combustion in it is abnormal). zure.
2. When a cylinder is selected for the reduced Perform the no-injection cranking mode opera-
cylinder mode operation, if the engine speed tion with the engine mounted on the machine
and output do not change from the normal or connected to INSITE (troubleshooting kit).
operation (all-cylinder operation), that cylinder Before performing, see Testing method in the
has 1 or more defects. shop manual for the machine or INSITE (trou-
The possible defects are as follows. bleshooting kit).
Leakage through cylinder head gasket
Defective injection
Defective piston or piston ring
Defective valve mechanism
(Moving valve system)
Defect in electrical system
3. Since the common rail fuel injection system
controls the injector of each cylinder electroni-
cally, the operator can perform the reduced cyl-
inder mode operation easily with switches to
find out a defective cylinder.
Perform the reduced cylinder mode opera-
tion with the engine mounted on the
machine or connected to INSITE (trouble-
shooting kit).
Before performing, see Testing method in
the shop manu al for the machine or
INSITE (troubleshooting kit).

107E-1 Series 21
SEN00250-09 30 Testing and adjusting

Testing fuel delivery, return and leak amount 1

Testing tools for fuel delivery, return and leak
amount.

Symbol Part No. Part name

1 795-790-4700 Tester kit
6754-71-5340 Connector
3
6754-71-5350 Washer
Commercially
4 Measuring cylinder
available
H Commercially
5 Stopwatch
available
Commercially Hose
6
available (Inside diameter: 14 mm)
Commercially Hose
7 3) Crank the engine for 30 seconds and
available (Inside diameter: 8 mm)
measure the delivery with measuring cyl-
inder H4.
See PAGE 29 for procedure of "Testing fuel Adjust the route of the test hose so
discharge, return and leakage" of HB205- that it will not slacken and put its end
1M0 and HB215LC-1M0. in an oil container.
Prepare a container of 20 for fuel leakage Do not crank the engine for more than
during testing. 30 seconds to protect the starting
motor in any case other than this
1. Measuring supply pump delivery measurement.
(4D107E-1) If the supply pump delivery is in the
1) Loosen clamp (2) of discharge tube (1) of following standard range, it is normal.
the supply pump and disconnect tube (1).
At cranking speed
Min. 75 cc
(125 rpm)
At cranking speed
Min. 90 cc
(150 rpm)

2) Install test hose H6 to the nipple on the

discharge side of the supply pump.
Fix the hose with a wire etc.
Adjust the route of the test hose so
that it will not slacken and put its end
4) After finishing measurement, remove the
in an oil container.
measuring instruments and return the
removed parts.
Tube sleeve nut:
35 ± 4 Nm {3.6 ± 0.4 kgm}
Clamp mounting bolt:
24 ± 4 Nm {2.5 ± 0.4 kgm}

22 107E-1 Series
30 Testing and adjusting SEN00250-09

2. Measuring supply pump return rate

(4D107E-1)
1) Disconnect quick coupler (2) of the return
hose of supply pump (1).

5) After finishing measurement, remove the

2) Install connector H3 and cap nut [1] of tes-
ter kit H1 to quick coupler (2) of the return
hose to stop the fuel from flowing out.
Install the seal washer between con-
nector H3 and cap nut [1].
3) Install connector H3 to the supply pump
and connect test hose [2] of tester kit H1.
Adjust the route of the test hose so
that it will not slacken and put its end
in an oil container.
measuring instruments and return the
removed parts.
When measuring the leakage from
the pressure limiter after the supply
pump return rate, return the engine to
the normal condition.
When measuring the injector return
rate after the supply pump return rate,
leave the engine as it is and keep the
hose end in an oil container.
3. Measuring leakage from pressure limiter
(4D107E-1)
1) Disconnect quick coupler (4) of the return
hose of the pressure limiter from connec-
tor (5) of the pump side.

4) While running the engine at low idle, mea-

sure the returning fuel with measuring cyl-
inder H4 for 25 seconds.
If the leakage from the supply pump
is in the following standard range, it is
normal.
At low idle
Max. 400 cc
(750 rpm)

107E-1 Series 23
SEN00250-09 30 Testing and adjusting

2) Install connector H3 and cap nut [1] of tes-
ter kit H1 to the return hose to stop the fuel
from flowing out.
3) Connect test hose [2] of tester kit H1 to
the common rail side.
Adjust the route of the test hose so
that it will not slacken and put its end
in an oil container.
4. Measuring injector return rate (4D107E-1)
The injector return rate must be measured
with the pressure limiter return hose con-
nected. Accordingly, check that no fuel
leaks from the pressure limiter in advance.
1) Referring to "Measuring supply pump
return rate", set the supply pump under
the condition for measurement.
While the injector return rate is mea-
sured, the fuel flows out of the supply
pump. Accordingly, put the test hose
end on the supply pump in an oil con-
tainer.
2) Disconnect return hose (6) from the mani-
fold.
Fit the seal washer to the return hose.

4) While running the engine at low idle, mea-

sure the leakage from the pressure limiter
with measuring cylinder H4 for 1 minute.
If the leakage from the pressure lim-
iter is in the following standard range,
it is normal.
At Low idle 0 cc (No leakage)
3) Install removed joint bolt (7) and cap nut
[1] of tester kit H1 to the return hose to
prevent the fuel from flowing out.
4) Install connector H3 to the manifold and
connect test hose [3] of tester kit H1.
Set the test hose so that it will not
slack and put its end in an oil con-
tainer.

5) After finishing measurement, remove the

measuring instruments and return the
removed parts.

24 107E-1 Series
30 Testing and adjusting SEN00250-09

5) Run the engine at low idle and measure 5. Measuring supply pump delivery
the return rate from the injector in 1 minute (6D107E-1)
with measuring cylinder H4. 1) Loosen clamp (2) of discharge tube (1) of
If the return rate from the injector is in the supply pump and disconnect tube (1).
the following range, it is normal.
At Low idle Max. 120 cc
At cranking Max. 90 cc

The fuel returning from the supply

pump flows out during measurement
of the return rate from the injector.
Accordingly, keep the test hose end
on the supply pump side in an oil con-
tainer.
If the engine cannot be started, you
may measure the return rate while
rotating the engine with the start-
ing motor. Do not rotate for more
than 20 seconds continuously, 2) Install test hose H6 to the nipple on the
however, for protection of the start- discharge side of the supply pump.
ing motor. Fix the hose with a wire etc.
Adjust the route of the test hose so
that it will not slacken and put its end
in an oil container.

6) After finishing measurement, remove the

measuring tools and return the removed
parts.
Joint bolt:
19.6 – 29.4 Nm {2.0 – 3.0 kgm}
3) Crank the engine for 30 seconds and
measure the delivery with measuring cyl-
inder H4.
Adjust the route of the test hose so
that it will not slacken and put its end
in an oil container.
Do not crank the engine for more than
30 seconds to protect the starting
motor in any case other than this
measurement.
If the supply pump delivery is in the
following standard range, it is normal.
At cranking speed
Min. 75 cc
(125 rpm)
At cranking speed
Min. 90 cc
(150 rpm)

107E-1 Series 25
SEN00250-09 30 Testing and adjusting

2) Install connector H3 and cap nut [1] of tes-

ter kit H1 to the return hose to stop the fuel
from flowing out.
3) Connect test hose [2] of tester kit H1 to
the supply pump.
Adjust the route of the test hose so
that it will not slacken and put its end
in an oil container.

4) After finishing measurement, remove the

measuring instruments and return the
removed parts.
Tube sleeve nut:
35 ± 4 Nm {3.6 ± 0.4 kgm}
Clamp mounting bolt:
10 ± 2 Nm {1.0 ± 0.2 kgm}

6. Testing supply pump return rate (6D107E-1) 4) Run the engine at low idle and measure
1) Disconnect return hose (1) of the supply the return rate from the supply pump with
pump. measuring cylinder H4 25 sec or more.
If the return rate from the supply
pump is in the following range, it is
normal.
At Low idle 400 cc

When the engine cannot run, you

may test it by cranking the engine
with the starting motor. To protect
the starting motor, do not continu-
ously crank the engine 20 seconds
or more.

5) After finishing testing, remove the testing

tools and return the removed parts.

26 107E-1 Series
30 Testing and adjusting SEN00250-09

7. Measuring leakage from pressure limiter

(6D107E-1)
1) Disconnect return hose (2) of the pressure
limiter.
Keep the seal washer installed to the
connector bolt.

5) After finishing testing, remove the testing

tools and return the removed parts.
Joint bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm}

8. Testing return rate from injector (6D107E-1)

1) Disconnect return hose (4) from the cylin-
2) Install removed joint bolt (3) and cap nut
der head.
[1] of tester kit H1 to the return hose to
Fit the seal washer to the connector
prevent the fuel from flowing out.
bolt.
3) Install connector H3 to the common rail
and connect test hose [2] of tester kit H1.
Set the test hose so that it will not
slack and put its end in an oil con-
tainer.

2) Install connector H3 to the cylinder head

and connect test hose [2] of tester kit H1
and put its end in an oil container.
3) Install removed connector bolt (5) and cap
nut [1] of tester kit H1 to the return hose to
4) Run the engine at low idle and measure
prevent fuel leakage.
the leakage in 1 minute with measuring
4) Run the engine at low idle and test the
cylinder H4.
return rate from the injector with measur-
If the leakage from the pressure lim-
ing cylinder H4 1 min or more.
iter is in the following range, it is nor-
If the return rate from the injector is in
mal.
the following range, it is normal.
0 cc
At Low idle At Low idle Max. 180 cc/min.
(No leakage)
At cranking Max. 90 cc/min.

107E-1 Series 27
SEN00250-09 30 Testing and adjusting

When the engine cannot run, you

may test it by cranking the engine
with the starting motor. To protect
the starting motor, do not continu-
ously crank the engine 20 seconds
or more.

5) After finishing testing, remove the testing

tools and return the removed parts.
Joint bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm}

28 107E-1 Series
30 Testing and adjusting SEN00250-09

Procedure of "Testing fuel discharge, 2) Remove clamp (2) and then disconnect
return and leakage" of HB205-1M0 and connector (3).
HB215LC-1M0 is shown below.
Testing tools for fuel discharge, return and
leakage.

Symbol Part No. Part name

1 795-790-4700 Tester kit
6754-71-5340 Connector
2
6754-71-5350 Washer
3 6164-81-5790 Joint
4 6745-71-1130 Seal washer
H 5 07206-30812 Joint bolt
Commercially
6 Stopwatch 3) Remove fuel spray prevention caps (4) (2
available
places).
Commercially
7 Measuring cylinder 4) Remove clamps (5) (2 places), and
available
remove high-pressure pipe (6).
Commercially
8 Hose
available

Since fuel flows out during the test, prepare a

container of approximately 20 .
Place the machine on a level ground and
lower the work equipment to the ground.

1. Testing supply pump discharge

1) Open the engine hood and remove cover
(1) on the top of the counterweight.

5) Install test hose H8 to the nipple on the

discharge side of the supply pump.
Fix the hose using a band to prevent
the hose from coming off.
Arrange the route of the test hose so
that it does not sag and put its end in
a container.

107E-1 Series 29
SEN00250-09 30 Testing and adjusting

6) Crank the engine for 20 seconds and Adjust the route of the test hose so
measure the delivery by using measuring that it does not slacken and put its
cylinder H7. end in an container.
In order to protect the starter motor, it
is prohibited to continue cranking for
more than 20 seconds for any other
purpose than this measurement.
If the supply pump delivery is in the
following standard range, it is proper.
(For 30 seconds conversion)
Engine speed Discharge [Q]
125 rpm Max. 75 cc
150 rpm Max. 90 cc

Discharge [Q]:
Q = Engine speed × 0.6
4) Start the engine, measure the leak from
the pressure limiter by using the measur-
ing cylinder H7 for 1 minute while running
the engine at low idle.
Leakage from the pressure limiter is
normal when it is within the following
standard value range.
At Low idle 0 cc (No leakage)

7) After finishing the test, remove the testing

tools and restore the machine.
Tube sleeve nut:
35 ± 3.5 Nm {3.6 ± 0.4 kgm}

2. Testing leakage from pressure limiter

1) Disconnect quick coupler (7) of the pres-
sure limiter spill hose.

5) After finishing the test, remove the testing

tools and restore the machine.

2) Install connector H3 and cap nut [1] of tes-

ter kit H1 to the spill hose side to stop the
fuel from flowing out.
3) Connect test hose [2] of tester kit H1 to
the common rail side.

30 107E-1 Series
30 Testing and adjusting SEN00250-09

3. Testing fuel return rate from injector
The fuel return rate from the injector must
be measured with the pressure limiter spill
hose connected. Accordingly, check that
no fuel leaks from the pressure limiter in
advance.
1) After removing clamp (1), remove joint bolt
(check valve) (9) and disconnect spill hose
(10).
If the engine cannot be started, you
may check the machine while rotat-
ing the engine with the starting
motor. Do not rotate for more than
tw en ty secon ds continuously,
however, for protection of the start-
ing motor.

6) After finishing the test, remove the testing

tools and restore the machine.
2) Install cap nut [1] of tester kit H1 to spill Joint bolt (check valve) (9):
hose (10) to prevent outflow of fuel. 19.6 to 29.4 Nm {2.0 to 3.0 kgm}
When installing cap nut [1], be sure to
install seal washer H5.
3) Install joint H4 to the cylinder head side
with joint bolt H6.
When installing joint H4, be sure to
install seal washer H5.
Joint bolt H6:
24 ± 4 Nm {2.45 ± 0.41 kgm}
4) Install joint H4 to hose H9.

5) Start the engine and run it at low idle, and

measure the fuel return rate from the
injector for 1 minute by using measuring
cylinder H7.
If the return rate from the injector is in
the following range, it is proper.
At low idle Max. 120 cc
At cranking Max. 90 cc

107E-1 Series 31
SEN00250-09 30 Testing and adjusting

4. Testing supply pump return rate
Subtract the pressure limiter leakage and
injector return rate from overall return rate
to measure the supply pump return rate.
Therefore, check that the leakage from the
pressure limiter and return rate from the
injector are normal, and then perform the
measurement.
Since fuel may flow back when discon-
necting fuel return hose (12), drain the fuel
from the fuel tank to the lower level than
the supply pump installation position.
1) Move rubber cover (11), and disconnect
fuel return hose (12).
5) Start the engine and run it at low idle, and
measure the return rate in 25 seconds by
using measuring cylinder H7.
Supply pump return rate = (Overall
return rate) - (pressure limiter leak-
age) - (injector return rate)
When the return rate from the supply
pump is in the following range, it is
normal.
At low idle
Max. 400 cc
(750 rpm)

6) After finishing the test, remove the testing

tools and restore the machine.
2) Install cap nut [1] of tester kit H1 to fuel
return hose (12) side to prevent the fuel
from flowing out.
When installing cap nut [1], be sure to
install seal washer H4.
3) Install joint H3 to the supply pump side
with joint bolt H5.
When installing joint H3 and joint bolt
H5, be sure to install seal washer H4.
Joint bolt H5:
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
4) Install joint H3 to hose H8.

32 107E-1 Series
30 Testing and adjusting SEN00250-09

Bleeding air from fuel circuit 1

If fuel is used up or if a fuel circuit part is
removed and installed, bleed air from the fuel
circuit according to the following procedure.
When the priming pump and fuel filter is
remote mounted, bleed air by operating the
priming pump at the remote side.

1. Loosen the knob of the priming pump (1)

(remote mount side) and move it back and
forth.
<The photo shows PC160LC-7 as an example>

Continue moving the knob until it becomes

hard to move.
(If the main filter is empty, move the knob
60 – 70 times, and the air is bled.)

2. Start the engine with the starting motor.

The air in the high-pressure circuit is bled
automatically if the engine is cranked.
If the engine does not start, air may not be
bled from the low-pressure circuit. In this
case, repeat the above work.

107E-1 Series 33
SEN00250-09 30 Testing and adjusting

Testing fuel system for leakage 1

Very high pressure is generated in the high-
pressure circuit of the fuel system. If fuel
leaks while the engine is running, it is dan-
gerous since it can catch fire.
After testing the fuel system or removing
its parts, test it for fuel leakage according
to the following procedure.
Clean and degrease the engine and the parts
around it in advance so that you can test it eas-
ily for fuel leakage.
9. Inspect the fuel piping and devices for fuel
leakage.
Check mainly around the high-pressure
circuit parts coated with the color checker
for fuel leakage.
If any fuel leakage is detected, repair it
and inspect again from step 2.
If no fuel leakage is detected, check is
completed.

1. Spray color checker (developer) over the fuel

supply pump, common rail, fuel injector, and
joints of the high-pressure piping.

2. Run the engine at speed below 1,000 rpm and

stop it after its speed is stabilized.

3. Inspect the fuel piping and devices for fuel

leakage.
Check mainly around the high-pressure
circuit parts coated with the color checker
for fuel leakage.
If any fuel leakage is detected, repair it
and inspect again from step 1.

4. Run the engine at low idle.

5. Inspect the fuel piping and devices for fuel

leakage.
Check mainly around the high-pressure
circuit parts coated with the color checker
for fuel leakage.
If any fuel leakage is detected, repair it
and inspect again from step 1.

6. Run the engine at high idle.

7. Inspect the fuel piping and devices for fuel

leakage.
Check mainly around the high-pressure
circuit parts coated with the color checker
for fuel leakage.
If any fuel leakage is detected, repair it
and inspect again from step 1.

8. Run the engine at high idle and load it.

When checking while the components to
be checked are mounted on the machine,
stall the torque converter or relieve the
hydraulic pump.

34 107E-1 Series