C13 and C15 On-highway Engines Caterpillar


Fuel System Pressure - Test

Usage:

C15 B5R
System Operation Description:

Use this procedure in order to troubleshoot the listed codes.

Table 1
Diagnostic Trouble Codes for ARD Low Fuel Pressure 
J1939 Code  Description  Conditions Which Cause the Code 
4077-17  Aftertreatment #1 Fuel Pressure #2 : Low - Least Severity (2)  The ARD pilot fuel pressure is less than a desired value after the ignition of the system and the DPF inlet temperature has increased in order to regenerate the system. 
4077-18  Aftertreatment #1 Fuel Pressure #2 : Low - Moderate Severity (2)  The ARD pilot fuel pressure is less than 50 PSI during ignition. The ARD pilot fuel pressure is less than 50 PSI while attempting to increase DPF temperature after ignition of the ARD system has occurred. 
Follow the troubleshooting procedure in order to identify the root cause of the problem. 

Illustration 1, Illustration , 2 and Illustration 3 show an overview of the troubleshooting procedure. Follow the steps in order.



Illustration 1g02079414


Illustration 2g02151373


Illustration 3g02079573

The fuel system provides the engine and the Aftertreatment Regeneration Device (ARD) with pressurized fuel. This procedure verifies that the fuel system can provide adequate fuel pressure for the cylinder head and for the ARD.

Fuel System Pressures

The typical fuel pressure of the engine at operating temperature can vary. The cylinder head runs at approximately 620 kPa (90 psi). For a (S/N: Lee) engine the pilot fuel pressure should be () 1551 kPa (225 psi) to 1724 kPa (250 psi) (read in Cat ET) when the ARD Fuel Pressure Command Control Percentage is above 50 percent. For an (S/N: SDP) engine the pilot fuel pressure should be 1586 kPa (230 psi) to 1758 kPa (255 psi) (read in Cat ET) when the ARD Fuel Pressure Command Control Percentage is above 50 percent.

Use this procedure if the engine starts. If the engine will not start, refer to Troubleshooting, "Engine Cranks But Does Not Start" before you use this procedure.

Test Step 1. Check for Diagnostic Codes

  1. Establish communication between the Caterpillar Electronic Technician (ET) and the engine ECM.

    Note: The communications adapter must be communicating on both data links in order to perform this procedure. Refer to Troubleshooting, "Electronic Service Tools" for additional information, if necessary.

  2. Look for the following codes:

    • 4077-17 Aftertreatment #1 Fuel Pressure #2 : Low - Least Severe (1)

    • 4077-18 Aftertreatment #1 Fuel Pressure #2 : Low - Moderate Severity (2)

Expected Result:

A 4077-17 or 4077-18 code is present.

Results:

  • A 4077-17 or 4077-18 code is present. - Proceed to Test Step 2.

Test Step 2. Determine the Last Primary Fuel Filter Maintenance

Determine the number of engine hours that have elapsed since the filter has been replaced.

Results:

  • The primary fuel filter has been installed for less than 300 engine operating hours. - Proceed to Test Step 3.

  • The primary fuel filter has been installed for more than 300 engine operating hours. -

    Repair: Replace the primary fuel filter.

    Proceed to Test Step 3.

Test Step 3. Inspect the Fuel Enable Valve

Note: The fuel system must be flushed and the connector filters must be replaced after completing this test step. Flush the fuel system and remove the connector filters, exactly as instructed in the Special Instruction, REHS3848, "Procedure to Flush the Fuel System for the Aftertreatment Regeneration Device (ARD)". Torque specifications can be found in Specifications under Fuel Control Manifold.



Illustration 4g02008337
Typical fuel filter base
(1) Fuel enable valve
(2) 1050 kPa (150 psi) regulator
(3) 690 kPa (100 psi) regulator
(4) 520 kPa (75 psi) regulator
(5) Fuel filter base
(6) Purge air screw regulator

  1. Remove the fuel enable valve.


    Illustration 5g02008354
    (7) Correct location for the inner O-ring seal
    (8) Example of an incorrect location for the inner O-ring seal

  2. Inspect the inner O-ring seal. Determine if the inner O-ring seal is in the correct location.


    Illustration 6g01600013
    Outer O-ring seals on the fuel enable valve

  3. Verify that all four of the outer O-ring seals are present. Verify that all four of the outer O-ring seals are not damaged.

Results:

  • The inner O-ring seal is not in the correct location. The valve has failed. -

    Repair: Replace the fuel enable valve.

    Proceed to Test Step 13 in order to test the operation of the ARD.

  • One or more of the outer O-rings seals are damaged or missing. -

    Repair: Replace seals that are damaged or missing. Install the fuel enable valve.

    Proceed to Test Step 13 in order to test the operation of the ARD.

  • No problems with the fuel enable valve are observed. - Install the original fuel enable valve. Proceed to Test Step 4.

Test Step 4. Assembly Instructions for the Required Test Apparatus

In order to proceed to the next step, an apparatus will need to be assembled, and the apparatus will need to be installed.

Note: This test is the only approved procedure for the ARD fuel pressure test.

Refer to table 2 for the required materials in order to assemble the apparatus. Refer to Illustration 7 for the orientation of the apparatus.

Table 2
Parts List for Test Apparatus 
Part Number  Description  Quantity 
122-6869  Hydraulic Hose  52 in. 
124-1897  Permanent Coupling 
124-1956  Permanent Coupling 
8L-6005  Pipe Tee 
3B-7722  Reducing Bushing 
6V-4144  Quick Connect Coupler 
5P-7090  Ball Valve 
6V-3966  Fitting As 
8T-0855  Pressure Gauge 
1U-5809  Grommet 
3N-6938  Sight Gauge 
9S-8927  Plug 


Illustration 7g02108576

Note: Use teflon tape on all male pipe threads. Ensure that you start the tape at the second thread.

  1. Assemble the test apparatus.

    1. Cut two 660 mm (26 inch) lengths of 122-6869 Hydraulic Hose.

    2. Crimp one 124-1956 Permanent Coupling onto each hose.

    3. Crimp one 124-1897 Permanent Coupling onto the other end of each hose.

    4. Connect the 3N-6938 Sight Gauge onto the male pipe thread of the 5P-7090 Ball Valve. Connect the 5P-7090 Ball Valve onto the male pipe thread of the 8L-6005 Pipe Tee.

    5. Connect one hose to the Sight Gauge. Connect the other hose to the opposing side of the Pipe Tee.

    6. Connect the 3B-7722 Reducing Bushing to the Pipe Tee. Connect the 6V-3966 Fitting As to the Reducing Bushing.

    7. Connect the 8T-0855 Pressure Gauge to the 6V-4144 Quick Connect Coupler.

    8. Install the 1U-5809 Grommet around the 8T-0855 Pressure Gauge in order to protect the gauge.

Results:

  • The apparatus is assembled. - Proceed to Test Step 5.

Test Step 5. Installation Instructions for the Required Test Apparatus

  1. Disconnect the fuel supply line from the outlet of the fuel transfer pump.

  2. Connect the hose that is attached to the Pipe Tee to the outlet of the fuel transfer pump.

  3. Place the other hose end of the test apparatus into an approved container for fuel.

  4. Crank the engine for 20 seconds in order to remove debris from the hose.

  5. Disconnect the fuel supply line from the inlet to the secondary fuel filter base.

  6. Remove the hose end from the container and connect to the inlet of the secondary fuel filter base.

  7. Connect the gauge in order to complete the apparatus.

Results:

  • The apparatus is assembled and the apparatus is installed. - Proceed to Test Step 6.

Test Step 6. Measure the Quantity of Air in the Fuel

Note: The fuel sight gauge must be installed at the outlet of the fuel transfer pump. Do not install the gauge at the primary fuel filter outlet.

  1. Run the engine at 1800 rpm for 20 seconds and perform the following tasks:

    • Record the fuel pressure that is measured at the gauge.

    • Check for air in the fuel. Refer to Illustration 8.


Illustration 8g01391837

Results:

  • The amount of air in the system is acceptable. - Proceed to Test Step 8.

  • There is an unacceptable amount of air in the fuel system. - Proceed to Test Step 7.

  • The measured fuel pressure is less than 75 psi and the amount of air in the system is acceptable. - Proceed to Test Step 9.

Test Step 7. Determine the Cause of Air in the System

  1. Run the engine at low idle. Inspect the following components for leaks:

  • Fuel lines between the fuel tank and the inlet to the primary fuel

  • Primary fuel filter base

  • Fuel lines between the primary fuel filter and the inlet to the transfer pump

Results:

  • The location of the air entry into the fuel system is determined. -

    Repair: Make the necessary repairs to the system. Run the engine again in order to verify that the amount of air in the fuel system is acceptable.

    If the amount of air in the system is acceptable, proceed to Test Step 8.

Test Step 8. Verify that the Air Purge Screw is Tight

Verify that the air purge screw is tight.

Ensure that the seal has not been damaged.

Results:

  • The air purge screw was loose. -

    Repair: Tighten the air purge screw.

    Proceed to Test Step 9.

  • The seal for the air purge screw was damaged. -

    Repair: Replace the seal for the air purge screw.

    Proceed to Test Step 9.

  • The purge air screw was tight. - Proceed to Test Step 9.

Test Step 9. Measure the Pressure between the Cylinder Head and the Secondary Fuel Filter Base.

  1. DO NOT remove the previously installed test apparatus. Install a pressure gauge between the secondary fuel filter base and the inlet of the cylinder head.

  2. Run the engine at low idle and high idle. Record the fuel pressures. The specifications are listed in table 3.

    Table 3
    Engine Speed  C13  C15 
    High Idle  586 kPa (85 psi)
    to 689 kPa (100 psi) 
    620 kPa (90 psi)
    to 723 kPa (105 psi) 
    Low Idle  482 kPa (70 psi)
    to 551 kPa (80 psi) 
    482 kPa (70 psi)
    to 586 kPa (85 psi) 

Results:

  • The low idle pressure was low and the high idle pressure was low. - Proceed to Test Step 11.

  • The low idle pressure was low and the high idle pressure was within specifications. - Proceed to Test Step 10.

  • The low idle pressure is high. - Proceed to Test Step 10.

  • The low idle pressure is within specifications and the high idle pressure is high. - Proceed to Test Step 10.

  • The 75 psi regulator and the 100 psi regulator have both been replaced. The pressure is still low. - Proceed to Test Step 12.

  • The pressures are normal. - Proceed to Test Step 12.

Test Step 10. Replace the 75 psi Regulator

    Note: If the 75 psi regulator has already been replaced Proceed to Test Step 11.

    Note: The fuel system must be flushed and the connector filters must be replaced after completing this test step. Flush the fuel system and remove the connector filters, exactly as instructed in the Special Instruction, REHS3848, "Procedure to Flush the Fuel System for the Aftertreatment Regeneration Device (ARD)". Torque specifications can be found in Specifications under Fuel Control Manifold.

  1. Replace the 75 psi regulator. Ensure that the regulator is torqued to specifications. If the regulator is not torqued to specifications, the regulator will not operate properly. The torque specifications can be found in Specifications under filter base.

Results:

  • The regulator was replaced. - Proceed to Test Step 9.

Test Step 11. Replace the 100 psi Regulator

Note: If the 100 psi regulator has already been replaced Proceed to Test Step 10.

Note: The fuel system must be flushed and the connector filters must be replaced after completing this test step. Flush the fuel system and remove the connector filters, exactly as instructed in the Special Instruction, REHS3848, "Procedure to Flush the Fuel System for the Aftertreatment Regeneration Device (ARD)". Torque specifications can be found in Specifications under Fuel Control Manifold.

Replace the 100 psi regulator. Ensure that the regulator is torqued to specifications. If the regulator is not torqued to specifications, the regulator will not operate properly. The torque specifications can be found in Specifications under filter base.

Results:

  • The regulator was replaced. - Proceed to Test Step 9.

Test Step 12. Check the Transfer Pump

  1. Run the engine at 1800 rpm.

  2. Perform the following, in the shortest time that is possible.

    1. Rapidly close the valve for the test apparatus.

    2. Measure the pressure at the gauge for the test apparatus.

    3. Rapidly open the valve.

Results:

  • The pressure is below 1965 kPa (285 psi). -

    Repair: Replace the transfer pump. The fuel system must be flushed and the connector filters must be replaced after the transfer pump has been replaced. Flush the fuel system and remove the connector filters, exactly as instructed in the Special Instruction, REHS3848, "Procedure to Flush the Fuel System for the Aftertreatment Regeneration Device (ARD)". Torque specifications can be found in Specifications under Fuel Control Manifold.

    Proceed to Test Step 13.

  • The pressure is above 1965 kPa (285 psi). - Proceed to Test Step 13.

Test Step 13. Perform the Fuel Pressure Test (ARD ON)

Note: The ARD Ignition Test is used to troubleshoot performance problems for the ARD. The test operates the ARD for approximately 5 minutes. The test determines if the ARD can generate heat. If certain diagnostic trouble codes are active, the test will not start. Record the active codes. Then, clear the active codes in order to run this test.

Table 4
Specifications for the Fuel Pressure 
C13  1585 kPa (230 psi) to 1758 kPa (255 psi) 
C15  1620 kPa (235 psi) to 1792 kPa (260 psi) 

  1. Clear all codes.

  2. Start the ARD Ignition Test by selecting the following menus on Cat ET:

    Note: The CRS Ignition Test is the ARD Ignition Test.

    • Diagnostics

    • Diagnostic Tests

    • CRS Ignition Test

  3. Record the fuel pressure that is measured at the gauge on the test apparatus.


Illustration 9g02009213
(9) Location of the connector filters on C15 applications
(10) Location of the connector filters on certain C13 applications


Illustration 10g02009253
(11) Control valve for main fuel
(12) Control valve for pilot fuel

Results:

  • The measured pressure meets specifications. There is no 4077-17 or 4077-18 code. -

    Repair: Perform a manual regeneration and return the engine to service.

    STOP

  • The measured pressure does not meet specifications or there is a 4077-17 or 4077-18 code. - Proceed to Test Step 14.

Test Step 14. Replace the 150 psi Regulator

Note: The fuel system must be flushed and the connector filters must be replaced after completing this test step. Flush the fuel system and remove the connector filters, exactly as instructed in the Special Instruction, REHS3848, "Procedure to Flush the Fuel System for the Aftertreatment Regeneration Device (ARD)". Torque specifications can be found in Specifications under Fuel Control Manifold.

Replace the 150 psi regulator. Ensure that the regulator is torqued to specifications. If the regulator is not torqued to specifications, the regulator will not operate properly. The torque specifications can be found in Specifications under filter base.

Results:

  • The regulator was replaced. - Proceed to Test Step 15.

Test Step 15. Perform the Fuel Pressure Test (ARD ON)

  1. Clear all codes.

  2. Start the ARD Ignition Test.

  3. Record the fuel pressure that is measured at the gauge on the test apparatus.

Results:

  • The measured pressure meets specifications. There is no 4077-17 or 4077-18 code. -

    Repair: Perform a manual regeneration and return the engine to service.

    STOP

  • The measured pressure does not meet specifications or there is a 4077-17 or 4077-18 code. - Proceed to Test Step 16.

Test Step 16. Replace the Fuel Enable Valve

Note: The fuel system must be flushed and the connector filters must be replaced after completing this test step. Flush the fuel system and remove the connector filters, exactly as instructed in the Special Instruction, REHS3848, "Procedure to Flush the Fuel System for the Aftertreatment Regeneration Device (ARD)". Torque specifications can be found in Specifications under Fuel Control Manifold.

  1. Replace the fuel enable valve. Ensure that the enable valve is torqued to specifications. If, the fuel enable valve is not torqued to specifications the valve will not operate properly. The torque specifications can be found in Specifications under filter base.

Results:

  • The fuel enable valve was replaced. - Proceed to Test Step 17.

Test Step 17. Perform the Fuel Pressure Test (ARD ON)

  1. Clear all codes.

  2. Start the ARD Ignition Test.

  3. Record the fuel pressure that is measured at the gauge on the test apparatus.

Results:

  • The measured pressure meets specifications. There is no 4077-17 or 4077-18 code. -

    Repair: Perform a manual regeneration and return the engine to service.

    STOP

  • The measured pressure does not meet specifications or there is a 4077-17 or 4077-18 code. - Proceed to Test Step 18.

Test Step 18. Replace the Pilot Control Valve

Replace the control valve for the pilot fuel. The fuel system must be flushed and the connector filters must be replaced after the control valve has been replaced. Flush the fuel system and remove the connector filters, exactly as instructed in the Special Instruction, REHS3848, "Procedure to Flush the Fuel System for the Aftertreatment Regeneration Device (ARD)". Torque specifications can be found in Specifications under Fuel Control Manifold.

Results:

  • The pilot control valve was replaced. - Proceed to Step 19.

Test Step 19. Perform the Fuel Pressure Test (ARD ON)

  1. Clear all codes.

  2. Start the ARD Ignition Test.

  3. Record the fuel pressure that is measured at the gauge on the test apparatus.

Results:

  • The measured pressure meets specifications. There is no 4077-17 or 4077-18 code. -

    Repair: Perform a manual regeneration and return the engine to service.

    STOP

  • The measured pressure does not meet specifications or there is a 4077-17code or a 4077-18 code. -

    Repair: Perform a manual regeneration with a datalog and contact your Technical Communicator.

    STOP

Caterpillar Information System:

CX31-P600 Petroleum Transmission Torque Converter Housing - Integral Pump Drive, Retarder
797F and 797F XQ Off-Highway Truck/Tractor Braking System Parking Brake Release Pressure - Test
CX31-P600 Petroleum Transmission Drive Plate - Flywheel) (C9 - C13 Engines
2009/11/18 Changes To Caterpillar Incident Reporting Field Use Form And DSN Incident Report Entry Screens {1000, 7000}
797F and 797F XQ Off-Highway Truck/Tractor Braking System Brake Accumulator System Recovery - Test
797F and 797F XQ Off-Highway Truck/Tractor Braking System Relief Valve (Main) - Test and Adjust
CX31-P600 Petroleum Transmission Drive Plate - Flywheel) (C15 - C18 Engines
C13 Industrial Engines Camshaft
349F and 352F Excavators Hydraulic System Pump Control (Negative Flow) - Adjust
797F and 797F XQ Off-Highway Trucks Torque Converter Sump Oil Level - Check
325D and 329D Excavators Hydraulic System Swing Bearing Movement - Measure
CX31-P600 Petroleum Transmission Coupling Fastener - Flywheel) (C9 - C13 Engines
C32 Petroleum Generator Sets Sound Information
C32 Petroleum Generator Sets Declaration of Conformity
3508, 3512 and 3516 Generator Set Engines Aftercooler - Remove and Install
G3512 Generator Set Engines Power Supply
G3512E and G3520E Generator Set Engines Circuit Breaker
C18 Marine Engines Sensors and Electrical Connectors
G3512E and G3520E Generator Set Engines Engine Speed/Timing Sensor
2009/10/15 New Software is Now Used for the Product Link PL121SR and PL321SR Systems {7606, 7620}
C15 and C18 Petroleum Generator Sets Space Heater - Test
3508B, 3512B, and 3516B High Displacement Generator Sets Rotating Rectifier - Inspect/Test
C175-16 Marine Engines Fuel System Primary Filter - Clean/Inspect/Replace
770 and 772 Off-Highway Truck Parking
Back to top
The names Caterpillar, John Deere, JD, JCB, Hyundai or any other original equipment manufacturers are registered trademarks of the respective original equipment manufacturers. All names, descriptions, numbers and symbols are used for reference purposes only.
CH-Part.com is in no way associated with any of the manufacturers we have listed. All manufacturer's names and descriptions are for reference only.