Fuel System Pressure - Test: Testing and Adjusting

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Product: EXCAVATOR
Model: 330D L EXCAVATOR RAS
Configuration: 330D L & 330D N Hydraulic Excavator RAS00001-UP
(MACHINE) POWERED BY C-9 Engine
Testing and Adjusting

C9 Engine for Caterpillar Built Machines
Media Number -SENR9830-16 Publication Date -01/11/2009 Date Updated -30/11/2009

i02241979
Fuel System Pressure - Test

SMCS - 1250-081; 1256-081
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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 (if equipped)
 Sticking or worn fuel pressure regulating valve in the fuel transfer pump
 Severe wear on return fuel pressure regulating valve at the rear of the cylinder head
 Worn gears in the fuel transfer pump
 Pinched fuel lines or undersized fuel lines
 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 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 regulating valve in the fuel transfer pump
 Pinched fuel return line
Checking Fuel Pressure

Illustration 1 g00293196
1U-5470 Engine Pressure Group
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.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
NOTICE
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, "Caterpillar Tools and Shop

Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar 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 2 g01130021
(1) Plug
Install 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 to 579 kPa (66 to 84 psi)
At low idle, the fuel pressure at the fuel filter's inlet should be at the following amount:
 400 to 434 kPa (58 to 63 psi)
The fuel pressure to the fuel gallery should be the same amount, if you subtract the change in
pressure (delta P) 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. Engine misfire may
occur 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 in order 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 leaks
The electronic service tool is used to perform this test.
Dead Head Test for the Unit Injector Hydraulic Pump
The unit injector hydraulic pump dead head test is used to verify that the following conditions
exist:
 The injection actuation pressure circuit is working.
 The unit injector hydraulic pump is working properly.
See the Troubleshooting Manual for additional information on performing the troubleshooting
tests for the Injection Actuation System and the dead head test for the Unit Injector Hydraulic
1 1 0
Pump.
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Previous Screen

Testing and Adjusting

Fuel System Pressure - Test

Low Fuel Pressure

 Plugged fuel filters

High Fuel Pressure

 Plugged orifices in the fuel pressure regulating valve

Checking Fuel Pressure

Fuel leaked or spilled onto hot surfaces or electrical components can

Contaminants may cause rapid wear and shortened component life.

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop

Dispose of all fluids according to local regulations and mandates.

Install the 1U-5470 Engine Pressure Group into port (1) .

 455 to 579 kPa (66 to 84 psi)

 400 to 434 kPa (58 to 63 psi)

Unit Injector Hydraulic Pump (Test)

 The unit injector hydraulic pump is producing maximum pressure.

The electronic service tool is used to perform this test.

Dead Head Test for the Unit Injector Hydraulic Pump

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