9/30/22, 2:45 PM SIS 2.

2021/07/13 Fuel Rail Pressure Problem (UENR0668-58)

SMCS - 1252, 127A i08526243

Use this procedure to troubleshoot abnormal fuel rail pressure or use this procedure if any of the following diagnostic trouble codes are
active. Refer to Troubleshooting, "Diagnostic Trouble Codes" for information about the codes.

Diagnostic Trouble Codes for Fuel Rail Pressure Problem

J1939 CDL Code Description

Comments
Code Code (Code descriptions may vary)

No other 157-XX or 1797-XX codes are active.

3509-XX or 262-XX codes are not active.
3510-XX or 2131-XX codes are not active.
E396 Engine Injector Metering Rail #1 Pressure:
157-16 No codes for the high-pressure fuel pump or the injectors are active.
(2) High - moderate severity (2)
The fuel rail pressure is above an acceptable level.
The code is logged.
Engine power is derated.
No other 157-XX or 1797-XX codes are active.
3509-XX or 262-XX codes are not active.
3510-XX or 2131-XX codes are not active.
E398 Engine Injector Metering Rail #1 Pressure:
157-18 No codes for the high-pressure fuel pump or the injectors are active.
(2) Low - moderate severity (2)
The fuel rail pressure is below an acceptable level.
The code is logged.
Engine power is derated.
3509-XX or 262-XX codes are not active.
3510-XX or 2131-XX codes are not active.
E499 Engine Fuel Leakage 1: High - most severe There is a probable fuel leak from the high-pressure fuel system. The
1239-0
(3) (3) amount of leakage is a calculated parameter.
The code is logged.
The engine will shut down.
3509-XX or 262-XX codes are not active.
3510-XX or 2131-XX codes are not active.
E1264 High Pressure Common Rail Fuel Pressure
5571-0 The pressure limiting valve in the fuel rail is open. This code is a calculated
(2) Relief Valve : Active
parameter.
The code is logged.

Table 1

Probable Causes
Diagnostic codes

Electrical connectors

Fuel filters

Fuel rail pressure sensor

High fuel rail pressure

Transfer Pump Inlet Regulator (TPIR)

Transfer Pump Inlet Regulator (TPIR) return

Return fuel lines

Low fuel rail pressure

Transfer Pump Inlet Regulator (TPIR)

Transfer Pump Inlet Regulator (TPIR) Return

Electric Fuel Lift Pump (EFLP)

Return fuel lines

Recommended Actions

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Contact with high pressure fuel may cause fluid penetration and
burn hazards. High pressure fuel spray may cause a fire hazard.
Failure to follow these inspection, maintenance and service
instructions may cause personal injury or death.

Troubleshooting Test Steps Values Results

1. Diagnostic Codes

A. Connect the electronic service tool to the diagnostic connector. Refer

Result: A code other than the codes in Table 1 is present.
to Troubleshooting, "Electronic Service Tools", if necessary.
Repair: Troubleshoot the code. Refer to the applicable
B. Download the Warranty Report and the Product Status Report with
Diagnostic troubleshooting procedure.
Histograms before performing any troubleshooting or clearing any
codes
diagnostic codes.
Result: One of the codes in Table 1 is present.
Note: The downloaded information will be required by the Dealer
Proceed to Test Step 2.
Solutions Network (DSN) if troubleshooting assistance is needed.

C. Determine if a diagnostic is active or recently logged.

2. Create an Electronic Service Tool Snapshot

A. Select "Snapshot Viewer" on the electronic service tool, using

menus: Information -> Snapshot -> Viewer
Result: The electronic service tool snapshot was
successfully saved.
B. Select the event code and then click "View Graph".
Proceed to Test Step 3.
C. Select the following parameter and then click OK. Diagnostic
Codes
Result: The electronic service tool snapshot was not
· Engine Speed
successfully saved.
D. Select Save to "File to save" a Snapshot File (*.xml). This file will
Contact the DSN for guidance.
contain all the data in the snapshot and not only the data shown on the
graph.

Note: The downloaded information will be required by the Dealer

Solutions Network (DSN) if troubleshooting assistance is needed.

Result: There are suspect connectors.

3. Electrical Connectors Repair: Use the electronic service tool to perform the
"Wiggle Test".
A. Check for the correct installation of the ECM J1/P1 and the J2/P2
Connectors
connectors. Check for correct installation of the connector on the Fuel Repair or replace connectors that are suspect.
Rail Pressure Sensor and on the Suction Control Valve for the High-
Pressure Fuel Pump. Result: There are no suspect connectors.

Proceed to Test Step 4.

4. Fuel Filters Result: The filters have been replaced and the fault is
eliminated.
A. Replace the in-line fuel filter that is upstream of the electric fuel lift
pump. Refer to the Operation and Maintenance Manual for further Return the unit to service.
information. Fuel filters
Result: The filters have been replaced and the fault is still
B. Replace the primary fuel filter and the secondary fuel filters. Refer to present.
the Operation and Maintenance Manual for further information.
Proceed to Test Step 5.
C. If equipped, check the Fuel Tank Breather and replace if necessary.

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Result: The "Fuel Rail Pressure (absolute)" is more than

5,000 kPa (725 psi).

Repair: Test the fuel rail pressure sensor. Refer to

Troubleshooting, "Sensor Signal (analog, Active) - Test".

Use the electronic service tool to perform the "Fuel Rail

Pressure Test". If the test fails, replace the fuel rail
5. Fuel Rail Pressure Sensor pressure sensor. Refer to Disassembly and Assembly,
"Fuel Pressure Sensor - Remove and Install".
Pressure
A. Make sure that the engine has been shut down for at least 10
sensor
minutes. Use the electronic service tool to check the status of the "Fuel Confirm that the fault has been eliminated.
Rail Pressure".
Result: The "Fuel Rail Pressure (absolute)" is less than
5,000 kPa (725 psi).

For a high fuel rail pressure symptom, proceed to Test

Step 6.

For a low fuel rail pressure symptom, proceed to Test Step

11.

Result: Fuel rail pressure is normal after performing the

"High Pressure Fuel Pump Calibration".

Return the unit to service.

6. High Fuel Rail Pressure
Fuel
Result: Fuel rail pressure is still high after performing the
A. Use the electronic service tool to perform the "High Pressure Fuel system
"High Pressure Fuel Pump Calibration".
Pump Calibration".
Repair: Run the engine for a minimum of 30 minutes.

Proceed to Test Step 7.

Table 2

Illustration 1 g03750256
Transfer Pump Inlet Regulator (TPIR) components
(1) Transfer Pump Inlet Regulator (TPIR)
(2) TPIR return port

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Illustration 2 g02355128
Minimum TPIR flow rate in a 12 VDC system

Illustration 3 g02355130
Minimum TPIR flow rate in a 24 VDC system

Troubleshooting Test Steps Values Results

7. Transfer Pump Inlet Regulator (TPIR) Flow Test

Note: When performing the following fuel system tests, the Electric Fuel Lift Pump (EFLP) will only operate
for 2 minutes unless the engine is running. If necessary, cycle the keyswitch to reactivate the pump.

Refer to Illustration 1.
Result: The fuel flow is
A. Disconnect the TPIR return line from the drain port on the TPIR. Install a suitable blanking cap on the
greater than the minimum
open port in the TPIR return line.
limit.
B. Connect a temporary drain line to the drain port on the TPIR.
Proceed to Test Step 9.
TPIR
C. Place the end of the temporary drain line into a suitable calibrated container. flow rate
Result: The fuel flow is
less than the minimum
D. With the isolator switch in the ON position but the engine not running, use a suitable multimeter to
limit.
measure the input voltage to the EFLP. Record the reading.
Proceed to Test Step 8.
E. With the isolator switch in the ON position but the engine not running, measure the fuel flow from the
temporary drain line.

F. Refer to Illustration 2 or 3 for the minimum acceptable flow rate.

G. Remove the temporary drain line from the drain port on the TPIR. Connect the TPIR return line to the
TPIR.

Table 3

Illustration 4 g02527498
Minimum EFLP flow rate in a 12 VDC system

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Illustration 5 g02527518
Minimum EFLP flow rate in a 24 VDC system

Troubleshooting Test Steps Values Results

8. EFLP Flow Test at the Primary Fuel Filter Inlet

A. Make sure the keyswitch is in the OFF position.

B. Disconnect the fuel inlet connection from the primary fuel filter head.
Result: The fuel flow is below the minimum value for the
C. Install a suitable blank on the fuel inlet port on the primary fuel filter recorded voltage.
head.
Repair: Replace the EFLP. Refer to Disassembly and
D. Place the open end of the fuel inlet line in a suitable calibrated EFLP Assembly, "Fuel Priming Pump - Remove and Install".
container. flow
Result: The fuel flow is above the minimum value for the
E. With the keyswitch in the ON position, measure the input voltage at the recorded voltage.
EFLP. Record the result.
Proceed to Test Step 9.
F. With the keyswitch in the ON position, measure the flow from the fuel
inlet line. Record the result.

G. Check the recorded voltage and fuel flow on the graph in Illustration 4
or 5.

Result: The TPIR return line is blocked or kinked.

Repair: Clear the TPIR return line or replace the line

Confirm that the fault is eliminated.

9. Transfer Pump Inlet Regulator (TPIR) Return Test
TPIR
Result: The EFLP is not operating correctly.
A. Make sure that the TPIR return line is not blocked or kinked. return
line
Repair: Refer to Troubleshooting, "Fuel Transfer Pump -
B. Check that the Electric Fuel Lift Pump (EFLP) is operating correctly.
Test".

Result: The TPIR return line and the EFLP are OK.

Proceed to Test Step 10.

Result: The TPIR return line or the fuel lines between the
EFLP and the TPIR are blocked or kinked.

10. Check the Return Fuel Lines Repair: Clear or replace the blocked line.

A. Make sure that the TPIR return line is not blocked or kinked. Result: The TPIR return line and the fuel lines between
Return
the EFLP and the TPIR are clear.
lines
B. If the TPIR return line is clear, confirm that the Electric Fuel Lift Pump
(EFLP) is operating. Make sure that fuel lines between the EFLP and the Repair: Replace the EFLP.
TPIR are not blocked or kinked.
If the fault is still present, contact the DSN and provide the
Warranty Report, PSR and Snapshot Data as saved in
steps 1 and 2.

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Result: There is a leak from the high-pressure fuel

system.

Repair: Rectify any fuel leaks.

Result: The fuel contains solidified wax.

Repair: Replace the fuel with fuel of the correct

specification for the ambient conditions.
11. Low Fuel Rail Pressure
Result: There are fuel supply lines that are restricted or
not correctly installed.
A. Visually check the fuel tank for fuel.
Repair: Install the fuel lines correctly. Replace any
Note: The fuel gauge may be faulty.
damaged or restricted fuel lines.
B. Inspect the high-pressure fuel system for leaks.
Result: The EFLP is not operating correctly.
C. Use the electronic service tool to perform the "High Pressure Fuel
Repair: Investigate the fault with the EFLP. Refer to
Pump Calibration".
Troubleshooting, "Fuel Transfer Pump - Test".
D. If the temperature is below 0 °C (32 °F), check for solidified fuel (wax).
Result: There is air in the fuel system.
E. Check the primary filter/water separator for water in the fuel.
Repair: Prime the fuel system. Refer to Systems
Operation, Testing, and Adjusting, "Fuel System - Prime".
F. Check for fuel supply lines that are restricted or not correctly installed.
Low-
pressure Result: The diesel fuel is contaminated.
G. Replace the in-line fuel filter that is installed upstream of the Electric
fuel
Fuel Lift Pump (EFLP).
system Repair: Drain the fuel tank and the fuel system.
H. Check that the EFLP is operating correctly.
Replace the primary fuel filter and the secondary fuel
filters. Refer to the Operation and Maintenance Manual for
I. Replace the primary fuel filter and the secondary fuel filters. Refer to
further information.
the Operation and Maintenance Manual for further information.
Fill and prime the fuel system with fuel of the correct
J. Check for air in the fuel system and that the fuel system is primed.
specification. Refer to Systems Operation, Testing, and
Adjusting, "Fuel System - Prime".
K. Check the diesel fuel for contamination. Refer to Systems Operation,
Testing, and Adjusting, "Fuel Quality - Test".
Result: "Fuel Rail Pressure Relief Valve Test" fails.
L. Use the electronic service tool to perform the "Fuel Rail Pressure
Repair: Replace the Fuel Rail Pressure Relief Valve.
Relief Valve Test".
Refer to Disassembly & Assembly, "Relief Valve (Fuel) -
Remove and Install".
Note: This test will identify excessive leakage through the Pressure
Limiting Valve (PLV) in the fuel rail.
Result: "Fuel Rail Pressure Relief Valve Test" passes.

Repair: The Fuel Rail Pressure Relief Valve is operating

correctly and should not be replaced.

Result:The low-pressure fuel system is OK.

Before performing the following fuel system tests, the

engine must be run for a minimum of 30 minutes.

Proceed to Test Step 12.

Table 4

Illustration 6 g03750256
Transfer Pump Inlet Regulator (TPIR) components
(1) Transfer Pump Inlet Regulator (TPIR)
(2) TPIR return port

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Illustration 7 g02355128
Minimum TPIR flow rate in a 12 VDC system

Illustration 8 g02355130
Minimum TPIR flow rate in a 24 VDC system

Troubleshooting Test Steps Values Results

12. Transfer Pump Inlet Regulator (TPIR) Flow Test

Note: When performing the following fuel system tests, the Electric Fuel Lift Pump (EFLP) will only
operate for 2 minutes unless the engine is running. If necessary, cycle the keyswitch to reactivate the
pump.

Refer to Illustration 6.
Result: The fuel flow is
A. Disconnect the TPIR return line from the drain port on the TPIR. Install a suitable blanking cap on the
greater than the minimum
open port in the TPIR return line.
limit.
B. Connect a temporary drain line to the drain port on the TPIR.
TPIR Proceed to Test Step 14.
flow rate
C. Place the end of the temporary drain line into a suitable calibrated container.
Result: The fuel flow is less
than the minimum limit.
D. With the isolator switch in the ON position but the engine not running, use a suitable multimeter to
measure the input voltage to the EFLP. Record the reading.
Proceed to Test Step 13.
E. With the isolator switch in the ON position but the engine not running, measure the fuel flow from the
temporary drain line.

F. Refer to Illustration 7 or 8 for the minimum acceptable flow rate.

G. Remove the temporary drain line from the drain port on the TPIR. Connect the TPIR return line to the
TPIR.

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Result: The TPIR return line

is blocked or kinked.

Repair: Clear the TPIR

return line or replace the line

Confirm that the fault is

eliminated.
13. Transfer Pump Inlet Regulator (TPIR) Return Test
TPIR
Result: The EFLP is not
A. Make sure that the TPIR return line is not blocked or kinked. return
operating correctly.
line
B. Check that the Electric Fuel Lift Pump (EFLP) is operating correctly.
Repair: Refer to
Troubleshooting, "Fuel
Transfer Pump - Test".

Result: The TPIR return line

and the EFLP are OK.

Proceed to Test Step 14.

Table 5

Illustration 9 g02527498
Minimum EFLP flow rate in a 12 VDC system

Illustration 10 g02527518
Minimum EFLP flow rate in a 24 VDC system

Troubleshooting Test Steps Values Results

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14. EFLP Flow Test at the Primary Fuel Filter Inlet

A. Make sure the keyswitch is in the OFF position.

Result: The fuel flow is below the minimum value for
B. Disconnect the fuel inlet connection from the primary fuel filter head. the recorded voltage.

C. Install a suitable blank on the fuel inlet port on the primary fuel filter head. Repair: Replace the EFLP. Refer to Disassembly
and Assembly, "Fuel Priming Pump - Remove and
EFLP
D. Place the open end of the fuel inlet line in a suitable calibrated container. Install".
flow
E. With the keyswitch in the ON position, measure the input voltage at the Result: The fuel flow is above the minimum value for
EFLP. Record the result. the recorded voltage.

F. With the keyswitch in the ON position, measure the flow from the fuel inlet Proceed to Test Step 15.
line. Record the result.

G. Check the recorded voltage and fuel flow on the graph in Illustration 9 or 10.

Result: The TPIR return line or the fuel lines

between the EFLP and the TPIR are blocked or
kinked.
15. Check the Return Fuel Lines
Repair: Clear or replace the blocked line.
A. Make sure that the TPIR return line is not blocked or kinked.
Return Result: The TPIR return line and the fuel lines
lines between the EFLP and the TPIR are clear.
B. If the TPIR return line is clear, confirm that the Electric Fuel Lift Pump (EFLP)
is operating. Make sure that fuel lines between the EFLP and the TPIR are not
Repair: Replace the EFLP.
blocked or kinked.
If the fault is still present, contact the DSN and
provide the Warranty Report, PSR and Snapshot
Data as saved in steps 1 and 2.

Table 6

PPI-000740CA
2022/09/30
18:44:18-04:00
i08526243
© 2022 Caterpillar Inc.
Caterpillar:
Confidential Green

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