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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 regulating valve in the fuel transfer pump
Pinched fuel return line
Plugged screen in return elbow in cylinder headChecking Fuel Pressure
Refer to Special Instruction, SEHS8907, "Using The 1U-5470 Engine Pressure Group".
Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. Clean up fuel spills immediately.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products.Dispose of all fluids according to local regulations and mandates.
Use the following procedure to measure the fuel pressure after the secondary filter:Note: Fuel pressure readings near the fuel supply manifold have pressure spikes. The pressure spikes are caused by excess fuel that is returning to the fuel system from the injectors. Excessive needle movement at the gauge may be present. Connect the gauge with a section of suitable hose. The air in the hose absorbs the spikes. This gives an average reading and a steady needle. Keep the gauge above the measuring point.
Illustration 1 g01124050
(1) PortInstall the 1U-5470 Engine Pressure Group into port (1).During both normal operating conditions and load conditions, the fuel pressure should register the following range:
455 kPa to 579 kPa (66 psi to 84 psi)At low idle, the fuel pressure at the fuel filter inlet should be at the following amount:
400 kPa to 434 kPa (58 psi to 62 psi)The fuel pressure to the fuel gallery should be the same amount, if you subtract the change in pressure across the filter.With a new filter, the pressure drop across the fuel filter typically registers the following amount:
35 kPa (5 psi)As deposits collect on a fuel filter, the pressure differential will increase. The engine may misfire or the engine may shutdown if the fuel pressure in the fuel gallery decreases to approximately 69 kPa (10 psi).The fuel pressure regulator valve is mounted at the fuel return port at the rear of the fuel gallery in the cylinder head. The fuel pressure regulating valve maintains fuel pressure at low engine rpm. The regulating valve also contains a check valve that is spring loaded. The check valve that is spring loaded prevents the fuel from draining from the fuel gallery back to the fuel tank after engine shutdown.Unit Injector Hydraulic Pump (Test)
Injection Actuation Pressure (Test)
The test for injection actuation pressure is used to check for the following conditions:
The unit injector hydraulic pump is producing maximum pressure.
The pump pressure regulator is working properly.
The unit injector hydraulic pump is worn.
System leaksThe Caterpillar Electronic Technician (ET) is used to perform this test.Test for Hydraulic Pump Dead Head
The test for the hydraulic pump dead head is used to verify that the following conditions exist:
The injection actuation pressure circuit is working.
The unit injector hydraulic pump is working properly.
Illustration 2 g01799394
(2) High-pressure line
Table 1
Required Tools
Part Number Part Name Quantity
125-2580 HEUI Engine Tool Arrangement 1 To check the pressure for the unit injector hydraulic pump, remove the pump outlet line (2) from the pump. Install the appropriate gauge from the 125-2580 HEUI Engine Tool Arrangement. The gauge to use should have a range that would include 34 MPa (4950 psi).Note: Be sure to install a cap or plug the fitting that goes into the high-pressure oil gallery.Crank the engine for approximately 3 seconds to get the maximum pressure.If the recorded pressure is less than 26.5 MPa (3850 psi), the pump should be replaced.If the recorded pressure is equal to or greater than 26.5 MPa (3850 psi), the pump is operating properly.