0583489 JOHNSON POWER PACK

Illustration 1 g06471531Reference: For more information, refer to supplemental video "3500 & C175 High-Pressure Fuel Line Leaks on Engines Using the CR-C Fuel System" on Caterpillar Channel1.Note: Click or copy the following link into a web browser (a CWS login is required to access Caterpillar Channel1), or scan the following QR code using a QR enabled device.https://channel1.mediaspace.kaltura.com/media/1_nnrmcene
Illustration 2 g06482399Use this procedure to troubleshoot a high fuel flow in the high-pressure fuel system. Also, use this procedure if the following event code is active.
Table 1
J1939 Code and Description CDL Code and Description Comments
157-17
Engine Injector Metering Rail #1 Pressure : Low - least severe (1) E398(1)
Low Fuel Rail Pressure The fuel rail pressure is below an acceptable level.
The code is logged.
The check engine light will illuminate.
157-18
Engine Injector Metering Rail #1 Pressure : Low - moderate severity (2) E398(2)
Low Fuel Rail Pressure The fuel rail pressure is below an acceptable level.
The code is logged.
The check engine light will illuminate.
1440-0
Engine Fuel Flow Rate #1 : High - most severe (3) E1106(3)
High Fuel Rail Pump Flow There is excessive leakage in the high-pressure fuel system.
The code is logged.
The check engine light will illuminate.
1440-15
Engine Fuel Flow Rate #1 : High - least severe (1) E1106(1)
High Fuel Rail Pump Flow There is excessive leakage in the high-pressure fuel system.
The code is logged.
The check engine light will illuminate.
1440-16
Engine Fuel Flow Rate #1 : High - moderate severity (2) E1106(2)
High Fuel Rail Pump Flow There is excessive leakage in the high-pressure fuel system.
The code is logged.
The check engine light will illuminate.
5585-17
Engine Injector Metering Rail #1 Cranking Pressure : Low - least severe (1) E1220(1)
Low Cranking Fuel Rail Pressure The fuel rail pressure is too low while cranking.
This action can be caused by a fuel system service prior to starting the engine.
Table 2
Associated Codes
J1939 Code CDL Code Troubleshooting Procedure
95-0 E390(3) Troubleshooting, "Fuel Filter Is Restricted"
95-15 E390(1) Troubleshooting, "Fuel Filter Is Restricted"
95-16 E390(2) Troubleshooting, "Fuel Filter Is Restricted"
5578-3 289-3 Troubleshooting, "Sensor Signal (Analog, Active) - Test"
5578-4 289-4 Troubleshooting, "Sensor Signal (Analog, Active) - Test"
5580-3 460-3 Troubleshooting, "Sensor Signal (Analog, Active) - Test"
5580-4 460-4 Troubleshooting, "Sensor Signal (Analog, Active) - Test"
5580-17 E198(1) Troubleshooting, "Fuel Pressure Is Low"
5580-18 E198(2) Troubleshooting, "Fuel Pressure Is Low" Probable Causes
Diagnostic codes and event codes
Pressure relief valve leakage
High-pressure fuel pump leakage
High-pressure fuel rail leakage
Fuel control valve problemRecommended Actions
Table 3
Troubleshooting Test Step Value Result
1. Check for Codes
A. Turn the keyswitch to ON.
B. Connect Cat® Electronic Technician (ET) to the service tool connector.
C. Turn the keyswitch to ON.
D. Look for active codes that are associated with the system for the event code. Codes Result: An associated code is active.
Refer to the appropriate troubleshooting story.
Result: An E1220 or a 5585–17 code is present.
Proceed to Test Step 2.
Result: An E398, E1106, 157, or a 1440 code is present.
Proceed to Test Step 3.
2. Check the Service History.
A. An E1220 or 5585-17 code can be caused by a recent service on the fuel system. If the high-pressure system was not primed after the last service, this code will log.
B. Prime the fuel system.
C. Turn the keyswitch to ON.
D. Connect Cat ET.
E. Clear the fault E1220 or 5585-17 code.
F. Start the engine.
Code Result: An E1220 or a 5585-17 code came active after clearing.
Proceed to Test Step 4.
Result: An E1220 or a 5585-17 code did not come active.
The high-pressure fuel system was not properly primed.
Proceed to Test Step 11.
3. Perform a "Fuel System Functional Test"
A. Turn the keyswitch to OFF.
B. Remove all accumulator leak detection port plugs.
Note: Removal of accumulator plugs, when system leak is present, will allow external leak from plug hole. Take precaution to collect leaking fuel and not allow any leakage to come into contact with hot surfaces or personnel.
Note: Remove accumulator leak plugs before running a Fuel System Functional Test to prevent over pressure of double wall lines and potential contingent damage.
C. Connect Cat ET.
D. Start the engine.
E. Perform the "Fuel System Functional Test".
F. Once the test has completed, turn the keyswitch to the OFF position.
G. Wait for 2 minutes to allow the pump diagnostics to run.
H. Turn the keyswitch to ON.
I. Connect Cat ET.
J. Check for active diagnostic codes.
Test Successful
Result: The "Fuel System Functional Test" passed successfully and there are no active codes.
Repair Complete.
Result: There was a 1684 or 1077 code present after running the "Fuel System Functional Test".
A failed high-pressure fuel pump has been detected.
Release the pressure in the high-pressure rail by loosening the end plug on one of the last two fuel accumulators. Refer to Testing and Adjusting, "Fuel Rail Pressure - Release" for instructions on how to release the pressurized fuel.
Repair: Replace the high-pressure fuel pump.
Proceed to Test Step 11.
Result: The test failed for an E111F - Fuel Flow Too Low.
A failed high-pressure fuel pump has been detected.
Release the pressure in the high-pressure rail by loosening the end plug on one of the last two fuel accumulators. Refer to Testing and Adjusting, "Fuel Rail Pressure - Release" for instructions on how to release the pressurized fuel.
Repair: Replace the high-pressure fuel pump.
Proceed to Test Step 11.
Result: The test failed for an E111D - Fue