0580895 JOHNSON LEAD ASSY.,Ground

Table 1
Event Codes
J1939 Code and Description Description Conditions Which Generate This Code Notes
157-0 High Fuel Rail Pressure Rail pressure sensor is normal.
Sensor supply voltage is normal.
Actual rail pressure is 197 MPa or higher engine derates EGR stop. Intake throttle is 100 percent open
C3.8 Tier 4 Final Actual rail pressure is 267 MPa or higher.
Warning Level 2
633-7 Pressure Limiter Emergency Open
Rail pressure sensor is normal
Sensor supply voltage is normal.
Fuel leak is detected when rail pressure exceeds 191 MPa (27702 psi) and 1239-1 Fuel Leak code is active within 1 second of the 191 MPa (27702 psi).
Engine speed limited to 50%
Derated to 50%
EGR stop
Intake throttle is 100% open
Warning Level 3
523539-2 Pump Seizing 1
Sensor supply voltage normal
Rail Pressure sensor is normal.
Rail pressure of 230 MPa (33400 psi) or higher continues for 1 second or more at 800 rpm or above. (Threshold varies depending on engine speed.) (C3.3B Tier 4 Final and C3.8 Tier 4 Interim Engines Only)
Engine derates
EGR Stop
C3.8 Tier 4 Final / Stage IV
Rail pressure of 300 MPa ( 43500 psi) or higher continues for 1 second or more at 500 rpm or above. (Threshold varies depending on engine speed.)
Intake Throttle 100% open
Warning Level 2
523540-2 Pump Seizing 2
Sensor supply voltage normal
Rail pressure sensor is normal
Rail pressure above 197 kPa (28600 psi) or below 230 MPa (33400 psi) for 35 second or more at 800 rpm or higher. (C3.3B Tier 4 Final and C3.8 Tier 4 Interim Engines Only)
Engine derates
EGR Stop
C3.8 Tier 4 Final / Stage IV
Rail pressure above 267 kPa (38700 psi) or below 300 MPa ( 43500 psi) for 35 second or more at 800 rpm or higher.
Intake Throttle 100% open
Warning Level 2
523606-2 Pressure Relief Valve Error
Battery voltage is normal.
Starter switch signal is not activated.
During pump operating normally.
Camshaft sensor is normal.
Injection quantity is 0 mm3/st or lower.
After pressure relief valve opens, excessively higher pressure than expected.
Engine derates 50%
Speed limitation to 50% acceleration
EGR Stop
523608-2 High Pressure Delivery System too High
Battery voltage is normal.
Starter switch signal is not activated.
During pump operating normally.
Camshaft sensor is normal.
Target pressure is under 10 MPa.
Excessively operating Pressure Relief Valve error (Actual rail pressure>target rail pressure) occurring.
Engine derates 50%
Speed limitation to 50% acceleration
EGR Stop
523611-2 High Pressure Pump too High
Battery voltage is normal.
Starter switch signal is not activated.
Key switch is ON.
High-pressure errors are detected. (pressures vary based on engine speed)
Engine Stop.
Note: If 633-7 Pressure Limiter Emergency Open has occurred, replacement of the common rail manifold and high-pressure tubes are required. Refer to the Disassembly and Assembly, "Fuel Manifold (Rail) - Remove and Install". After replacing, the “Fuel Pump Calibration” must be performed in Cat ET. Refer to “Cat ET Service Features” for this calibration.
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.
Table 2
Troubleshooting Test Steps Values Results
1. Diagnostic Codes
A. Establish communication with Caterpillar Electronic Technician (Cat ET). Check for active diagnostic codes.
Diagnostic Codes
Result: Active diagnostic codes are present.
Troubleshoot the diagnostic code.
Result: Active diagnostic codes are not present.
Proceed to Test Step 2.
2. Fuel Rail Pressure
A. Check the fuel rail pressure in Cat Electronic Technician (Cat ET)
Low Idle: 39989 kPa (5800 psi) to 49642 kPa (7200 psi)
Accelerating to Hi Idle: 96526 kPa (14000 psi) to 131000 kPa (19000 psi)
Hi Idle: 96526 kPa (14000 psi) to 131000 kPa (19000 psi)
C3.8 Tier 4 Final / Stage IV (ONLY)
Low Idle: 35-60 MPa (5100-8700 psi)
Accelerating to Hi Idle: 0-100% (During acceleration) Max value 155 MPa (22500)
No-Load Max speed: 75 to 155 MPa (10900 to 22400 psi)
Result: The fuel pressure is not within specification.
Refer to Testing and Adjusting, "Air in Fuel - Test"
Result: The fuel pressure is within specification.
Proceed to Test Step 3.
3. Check the Fuel System
Refer to Systems Operation/Testing and Adjusting, "Fuel System" for additional information.
A. Visually check the fuel level in the fuel tank. Do not rely on the fuel gauge only.
B. Ensure that the vent in the fuel cap is not filled with debris.
C. Inspect the fuel system for external leaks.
D. Check that there is no air in the clear primary fuel filter. Refer to Systems Operation/Testing and Adjusting, Low-Pressure Fuel System - Test.
E. Check fuel quality. Refer to Systems Operation/Testing and Adjusting, "Fuel Quality - Test" for the proper procedure. Check the fuel tank for debris or foreign objects which may block the fuel supply.
F. Check for the proper operation of the fuel transfer pump. Replace the pre-filter if excessive contamination or if the maintenance interval is exceeded. Refer to Systems Operation/Testing and Adjusting, "Fuel System" for test information.
Fuel System
Result: The fuel system is OK.
Proceed to Test Step 4.
Result: The fuel system is not OK.
Replace the fuel filters. Clean the primary filter/water separator of debris. Refer to the Operation and Maintenance Manual for details.
4. Check the Fuel Rail Pressure Sensor
Refer to Troubleshooting, "Sensor Signal (Analog, Active) - Test" for more information.
Fuel Rail Pressure Sensor
Result: The fuel rail pressure sensor is OK.
Proceed to Test Step 5.
Result: The fuel pressure sensor is NOT working properly.
Repair: Replace the fuel rail pressure sensor and verify that the problem has been corrected.
5. Check SCV Resistance
(Does not apply to C3.8 Tier 4 Final / Stage IV)
A. Check resistance at the SCV terminals. At 20° C (68° F) the resistance should approximately be 2.1 ohms.
B. With the plug connected to the SCV, check resistance at the ECM connector to check the harness. The resistance should be approximately 2.1 ohms.
SCV Resistance
Result: The SCV resistance and the harness are OK.
Proceed to Test Step 6.
Result: The SCV resistance and/or the harness are NOT OK.
Repair: Replace the SCV and/or the engine harness.
6. Check Cat ET for Suction Control Valve Current
(Does not apply to C