6/20/23, 3:44 PM SIS 2.

2003/04/29 Fuel System Pressure - Test (SENR9528-03)

SMCS - 1250, 1256 i01911798

PIP
NOTICE
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202 1066
Keep all parts clean from contaminants.

20: 3 / 6 080
Contaminants may cause rapid wear and shortened component

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life.

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SEN :31- 0
4
NOTICE
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023 8
Care must be taken to ensure that fluids are contained during

Cat
performance of inspection, maintenance, testing, adjusting, and
repair of the product. Be prepared to collect the fluid with

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suitable containers before opening any compartment or

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disassembling any component containing fluids.

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Refer to Special Publication, NENG2500, "Dealer Service Tool
Catalog" for tools and supplies suitable to collect and contain
fluids on Cat products. nc.
Dispose of all fluids according to local regulations and
mandates.

Low Fuel Pressure

Low fuel pressure can cause low power. Low fuel pressure can also cause cavitation of the fuel
which can damage the fuel injectors.

The following conditions can cause low fuel pressure:

Plugged fuel filters

Debris in the check valves for the fuel priming pump

Sticking or worn fuel pressure relief valve in the fuel transfer pump

Severe wear on return fuel pressure regulating valve in the fuel filter base or adapter assembly

Worn gears in the fuel transfer pump

Pinched fuel lines or undersized fuel lines

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Old fuel lines that have a reduced interior diameter that was caused by swelling

Fuel lines with deteriorating interior surfaces

Pinched fuel line fittings or undersized fuel line fittings

Debris in the fuel tank, fuel lines, or fuel system components that may create restrictions

High Fuel Pressure

Excessive fuel pressure can cause fuel filter gaskets to rupture. The following conditions can cause
high fuel pressure:

Plugged orifices in the fuel pressure regulating valve

Stuck fuel pressure relief valve in the fuel transfer pump

Pinched fuel return line

Checking Fuel Pressure

Table 1
Required Toolings
Tool Part Number Part Name Quantity
1U-5470 Engine Pressure Group
A or or 1
198-4240 Digital Pressure Indicator

Illustration 1 g00293196
1U-5470 Engine Pressure Group

Reference: Special Instruction, SEHS8907 , "Using the 1U-5470 Engine Pressure Group"

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Reference: Operation Manual, NEHS0818 , "Using the 198-4240 Digital Pressure Indicator"

Fuel System Identification

Refer to the following illustrations in order to identify the fuel system for your application. Locate the
pressure testing ports in order to measure the different fuel system pressures.

Illustration 2 g00996187
Fuel filter base that is mounted directly to the fuel manifold
Typical example
(1) Test location for unfiltered fuel pressure
(2) Test location for filtered fuel pressure

Illustration 3 g00996311
Applications with a fuel adapter
Typical example
(1) Test location for unfiltered fuel pressure
(2) Test location for filtered fuel pressure

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Applications with a Quick Connect Coupler

Some applications may be equipped with a quick connect coupler. Refer to these illustrations for the
location and the purpose of the fuel pressure tap.

Illustration 4 g00996062
Fuel filter base that is mounted directly to the fuel manifold
Typical example
(1) Test location for unfiltered fuel pressure
(2) Test location for filtered fuel pressure

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Illustration 5 g00996149
Applications with a fuel adapter
Typical example
(1) Test location for unfiltered fuel pressure
(2) Test location for filtered fuel pressure

Measuring Unfiltered Fuel Pressure

Fuel leaked or spilled onto hot surfaces or electrical

components can cause a fire. Clean up fuel spills immediately.

A high pressure fuel line must be disconnected. To avoid

personal injury or fire from fuel spray, the engine must be
stopped before the fuel line is disconnected.

Use the following procedure to measure the unfiltered fuel pressure:

1. Refer to "Fuel System Identification" in order to identify the correct location for measuring the
unfiltered fuel pressure. Install Tooling (A) into pressure test location (1) in order to measure the
unfiltered fuel pressure.
Note: A fuel sensor may be installed in one of the ports that are indicated in the illustrations. If a
fuel sensor is installed in the port, install a tee fitting into the port. Install the sensor and Tooling
(A) onto this tee prior to operating the engine. Ensure that the tee and all fuel fittings are
securely tightened. Failure to tighten all fittings could result in serious fuel leaks.

Clean any residual fuel from the engine components.

2. Start the engine.

3. Record the pressure reading that is on Tooling (A) for engine speeds of 1800 rpm and 2100
rpm. The test should be performed with no load on the engine.

4. Stop the engine and remove Tooling (A) from the fuel system.

Measuring Filtered Fuel Pressure

Fuel leaked or spilled onto hot surfaces or electrical

components can cause a fire. Clean up fuel spills immediately.

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A high pressure fuel line must be disconnected. To avoid

personal injury or fire from fuel spray, the engine must be
stopped before the fuel line is disconnected.

1. Refer to "Fuel System Identification" in order to identify the correct location for measuring the
filtered fuel pressure. Install Tooling (A) into pressure test location (2) in order to measure the
filtered fuel pressure.
Note: A fuel sensor may be installed in one of the ports that are indicated in the illustrations. If a
fuel sensor is installed in the port, install a tee fitting into the port. Install the sensor and Tooling
(A) onto this tee prior to operating the engine. Ensure that the tee and all fuel fittings are
securely tightened. Failure to tighten all fittings could result in serious fuel leaks.

Clean any residual fuel from the engine components.

2. Start the engine.

3. Record the pressure reading that is on Tooling (A) for engine speeds of 600 rpm and 1800 rpm.
The test should be performed with no load on the engine.
Note: Excessive needle movement at the gauge may be present. Fuel pressure readings near
the fuel supply manifold will be affected by pressure spikes. The pressure spikes are caused by
excess fuel that is returning to the fuel system from the injectors. If the gauge is connected with
a suitable length of hose, the air in the hose will absorb the spikes. This will give you an average
reading and a steady needle. Ensure that the gauge is elevated above the pressure measuring
port during the test.

4. Stop the engine and remove Tooling (A) from the fuel system.

Fuel Filter Differential Pressure

Calculate the fuel filter's differential pressure by subtracting the filtered fuel pressure from the
unfiltered fuel pressure. For best results, use the pressures that have been measured at an engine
speed of 1800 rpm.

Typically, the differential pressure for a new fuel filter will not exceed the 35 kPa (5.0 psi).

As abrasive particles collect in the fuel filter, the pressure differential across the filter will increase.
When a filter becomes plugged, the pressure differential may increase as much as 69 kPa (10.0 psi)
before a significant power loss is detected by the operator. Low filtered fuel pressure will cause
cavitation of the fuel and internal damage to the unit injectors. The pressure differential across the
fuel filter should not exceed 69 kPa (10.0 psi).

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If a high differential pressure exists, replace the fuel filter. Refer to Testing and Adjusting, "Fuel
System - Prime" for information on priming the fuel system after you replace the fuel filter.

Fuel Pressure Relief Valve

Illustration 6 g00996532
Fuel transfer pump
Typical example
(3) Fuel pressure relief valve
The fuel pressure relief valve (3) is an internal component that is located in the fuel transfer pump.
The relief valve is used to regulate the maximum pressure for the fuel system. Refer to Illustration 6
in order to locate the pressure relief valve.

The maximum unfiltered fuel pressure at an engine speed of 2100 rpm ... 715 kPa to 785 kPa
(103.7 psi to 113.9 psi)

The fuel pressure relief valve is not a serviceable component. If the operation of the fuel pressure
relief valve is suspect, replace the fuel transfer pump.

Fuel Pressure Regulating Valve

The pressure regulator valve is used in order to maintain an optimum operating pressure within the
low pressure fuel system. If the filtered fuel pressure is low, the pressure regulator valve may be
worn or stuck in the open position.

There are two types of fuel pressure regulating valves that are available for this engine. The integral
pressure regulator valve has been replaced with the new pressure regulator assembly that is self-
contained.

Integral Pressure Regulator Valve

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Illustration 7 g00996544
Location of the fuel pressure regulator valve
Typical example
(4) Fuel pressure regulator valve
The integral pressure regulator valve (4) is an internal component that is located in the fuel filter
base or in the fuel adapter. The pressure regulator valve is used in order to maintain an optimum
operating pressure within the low pressure fuel system. Refer to Illustration 7 in order to locate the
pressure regulator valve.

The filtered fuel pressure at an engine speed of 600 rpm ... 450 kPa to 600 kPa (65.3 psi to 87.0 psi)

If the filtered fuel pressure is not within specifications, remove the fuel pressure regulator valve and
the valve spring. Inspect the components for wear or damage. If there is visible signs of wear or
damage to the valve, replace the valve. Check the spring for distortion. Refer to Specifications, "Fuel
Lines" for information that relates to the specifications for the spring. If necessary, replace the spring.
Retest the filtered fuel pressure after the replacement of any components.

Pressure Regulator Assembly that is Self-Contained

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Illustration 8 g00996664
Location of the pressure regulator assembly
Typical example
(5) Pressure regulator assembly
This pressure regulator assembly (5) is a serviceable component. The pressure regulator valve is
located in the fuel filter base or in the fuel adapter. This regulator valve is used in order to maintain
an optimum operating pressure within the low pressure fuel system. Refer to Illustration 8 in order to
locate the pressure regulator assembly that is self-contained.

The filtered fuel pressure at an engine speed of 600 rpm ... 450 kPa to 600 kPa (65.3 psi to 87.0 psi)

This type of fuel pressure regulator valve is a serviceable component. If the operation of the fuel
pressure regulator valve is suspect, replace the pressure regulator assembly.

PIP-10666080
2023/06/20
20:43:45-05:00
i01374182
© 2023 Caterpillar Inc.

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