Service Information System Page 1 of 8

Troubleshooting
C4.2 and C6.4 Engines for Caterpillar Built Machines
Media Number -KENR5342-01 Publication Date -2007/07/01 Date Updated -2007/07/11

i02642412

Fuel Rail Pump - Test

SMCS - 1251-038

System Operation Description:

Use this procedure to troubleshoot the electrical system if a problem is suspected with the fuel rail pump
or if any one of the diagnostic codes in Table 1 is active or easily repeated.

Table 1

Diagnostic Codes Table

Description
1779-5 Fuel Rail #1 Pressure
Valve Solenoid current below
normal
1779-6 Fuel Rail #1 Pressure
Valve Solenoid current above
normal
Conditions which Generate this
System Response
Code
The Electronic Control Module
(ECM) detects current that is below
normal. The code is logged.
The battery voltage must be above If equipped, the warning
nine volts for two seconds. light will illuminate.
The ECM detects current that is The engine may be
shutdown.
above normal.
The battery voltage must be above
nine volts for two seconds.

Note: The fuel rail pump is installed on the engine at the factory. The fuel rail pump is not a serviceable
part. When the fuel rail pump solenoid is energized fuel is pumped into the fuel rail at very high
pressure. When the fuel rail pump solenoid is de-energized, the fuel that is not sent to the fuel rail is
returned to the fuel tank.

The fuel rail pump solenoid receives an electrical supply from the ECM. Varying the timing of the
voltage to the solenoid controls the fuel delivery from the fuel rail pump.

The fuel rail pump solenoid forms part of the closed loop control system for the fuel rail pressure in
conjunction with the fuel rail pressure sensor and the ECM. The signal for the fuel rail pressure sensor is
processed by the ECM. The ECM compares the measured pressure to the desired fuel rail pressure for
the given engine operating conditions.

If the fuel rail pump solenoid fails, it is likely that the fuel will not be pumped into the high pressure fuel
rail and engine shutdown or failure to start the engine is expected. No fuel rail pressure can be observed
on the status screen of the Caterpillar Electronic Technician (ET).

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View Image

Illustration 1 g0132
A typical schematic for the fuel rail pump solenoid

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Illustration 2 g0132
A typical view of the P2 connector (harness side) pin locations.

(25) fuel rail pump solenoid signal

(26) fuel rail pump solenoid return

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Illustration 3 g0134
A typical view of the P2 connector (ECM side) pin locations.

Test Step 1. Inspect the Electrical Connectors and the Harness

Electrical shock hazard. The fuel rail pump solenoid uses 63 to 73 volts.

A. Turn the keyswitch to the OFF position.

View Image

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Illustration 4 g01325579
Typical engine ECM

(1) J1 ECM connector

(2) J2 ECM connector

B. Thoroughly inspect the harness connector P2/J2 and the solenoid connector. Refer to service
Troubleshooting, "Electrical Connectors - Inspect" for details.

C. Perform a 45 N (10 lb) pull test on the wires that are associated with the fuel rail pump solenoid.
Refer to Illustration 2.

D. Check the harness for abrasions and for pinch points from the battery to the ECM. Check the
harness for abrasions and for pinch points from the key switch to the ECM.

Expected Result:

All connectors, pins, and sockets are completely coupled and/or inserted. The harness is free of
corrosion, of abrasion, and of pinch points.

Results:

z OK - The connectors and the harness are OK. Proceed to Test Step 2.

z Not OK - There is a problem with the connectors and/or the harness.

Repair: Repair the connectors or the harness and/or replace the connectors or the harness. Ensure
that all of the seals are correctly in place and ensure that the connectors are completely
coupled.Verify that the repair has eliminated the fault.If applicable, perform a wiggle test by using
Cat ET in order to identify intermittent connections.

STOP

Test Step 2. Check for Active Diagnostic Codes

A. Connect Cat ET to the diagnostic connector.

B. Turn the keyswitch to the ON position.

C. Use Cat ET to verify if any diagnostic codes are active or recently logged. Wait at least 30
seconds for activation of the code.

Expected Result:

One or more diagnostic codes that are associated with the fuel rail pump solenoid are active or recently
logged.

z 1779-5 Fuel Rail #1 Pressure Valve Solenoid current below normal

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z 1779-6 Fuel Rail #1 Pressure Valve Solenoid current above normal

Results:

z OK - An open circuit diagnostic code -5 is active at this time. Proceed to Test Step 4.

z OK - A short circuit diagnostic code -6 is active at this time. Proceed to Test Step 3.

z Not OK - No active diagnostic codes or recently logged diagnostic codes are displayed.

Repair: The electrical problem may be intermittent. Refer to service Troubleshooting, "Electrical
Connectors - Inspect".If applicable, perform a wiggle test by using Cat ET in order to identify
intermittent connections.

STOP

Test Step 3. Disconnect the Connector for the Fuel Rail Pump Solenoid in Order to Create an
Open Circuit

A. Turn the keyswitch to the OFF position.

B. Disconnect the connector for the fuel rail pump solenoid.

C. Turn the keyswitch to the ON position.

D. Use Cat ET to run the "Fuel Pump Solenoid Test", at least two times.

Note: The"Fuel Pump Solenoid Test" must be carried out in order to activate the diagnostic codes.

E. Access the "Active Diagnostic Code" screen on Cat ET. Check for an active open circuit
diagnostic code -5 for the fuel rail pump solenoid.

F. Turn the keyswitch to the OFF position.

Expected Result:

An open circuit diagnostic code -5 is now active for the fuel rail pump solenoid.

Results:

z OK - A short circuit diagnostic code -6 was active before disconnecting the connector. An open
circuit diagnostic code -5 became active after disconnecting the connector.

Repair: There is a problem with the fuel rail pump solenoid. Replace the fuel rail pump. Refer to
the Disassembly and Assembly manual. Clear any logged diagnostic codes.

STOP

z Not OK - There is a short circuit between the connector for the fuel rail pump solenoid and the

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ECM. There may be a problem with the ECM. Leave the connector disconnected. Proceed to Test
Step 5.

Test Step 4. Create a Short at the Connector for the Fuel Rail Pump Solenoid

A. Turn the keyswitch to the OFF position.

B. Fabricate a jumper wire that is long enough to short the terminals of the connector for the fuel rail
pump solenoid. Crimp connector pins to each end of the jumper wire.

C. Disconnect the connector for the fuel rail pump solenoid.

D. Install the jumper wire between terminal 1 (fuel rail pump solenoid) and terminal 2 (solenoid
return) on the harness side of the connector.

E. Turn the keyswitch to the ON position.

F. Use Cat ET to run the "Fuel Pump Solenoid Test", at least two times.

Note: The"Fuel Pump Solenoid Test" must be carried out in order to activate the diagnostic codes.

G. Monitor the "Active Diagnostic Codes" screen on Cat ET before installing the jumper wire and
after installing the jumper wire.

H. An open circuit diagnostic code -6 should be active for the fuel rail pump solenoid.

I. Turn the keyswitch to the OFF position.

J. Remove the jumper wire.

Expected Result:

A short circuit diagnostic code -6 is active when the jumper wire is installed. An open circuit diagnostic
code -5 is active when the jumper wire is removed.

Results:

z OK - A short circuit diagnostic code -6 is active when the jumper wire is installed. An open
circuit diagnostic code -5 is active when the jumper wire is removed.

Repair: There is a problem with the fuel rail pump solenoid. Replace the fuel rail pump. Refer to
the Disassembly and Assembly manual. Clear any logged diagnostic codes.

STOP

z Not OK - The open circuit diagnostic code -5 remains active with the jumper in place. There is an
open circuit in the harness between the ECM and the connector for the fuel rail pump solenoid.
There may be a problem with the ECM. Proceed to Test Step 5.

Test Step 5. Check the Operation of the ECM

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A. Disconnect the J2/P2 ECM connector.

B. Remove the wire for the fuel rail pump solenoid from P2-25. Install a jumper wire with Deutsch
sockets on each end into P2-25.

C. Remove the wire for the fuel rail pump solenoid return from P2-26. Install a jumper wire with
Deutsch sockets on each end into P2-26.

a. Reconnect the ECM connector.

b. Turn the keyswitch to the ON position.

c. Use Cat ET to run the "Fuel Pump Solenoid Test", at least two times.

Note: The"Fuel Pump Solenoid Test" must be carried out in order to activate the diagnostic
codes.

d. Monitor the "Active Diagnostic Code" screen on Cat ET.

An open circuit diagnostic code -5 should be active for the fuel rail pump solenoid.

D. Check the operation of the ECM by creating a short at the ECM.

a. Install a wire jumper between the jumper wire for the fuel rail pump solenoid and the
jumper wire for the solenoid return.

b. Use Cat ET to run the "Fuel Pump Solenoid Test", at least two times.

Note: The"Fuel Pump Solenoid Test" must be carried out in order to activate the diagnostic
codes.

c. Monitor the "Active Diagnostic Code" screen on Cat ET.

A short circuit diagnostic code -6 should be active when the wire jumper is installed.

d. Turn the keyswitch to the OFF position.

e. Remove the wire jumpers. Reconnect all wires and connectors.

Expected Result:

An open circuit diagnostic code -5 is active when the wire from the fuel rail pump solenoid is removed
from the ECM connector. A short circuit diagnostic code -6 is active when the wire for the fuel rail
pump solenoid is connected to the solenoid return.

Results:

z OK - The ECM is operating properly. The problem is in the harness for the fuel rail pump
solenoid.

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Repair: Repair the connectors or wiring and/or replace the connectors or wiring.Verify that the
repair has eliminated the fault.If applicable, perform a wiggle test by using Cat ET in order to
identify intermittent connections.

STOP

z Not OK - One of the following conditions exists: The open circuit diagnostic code -5 is not active
when the wire for the fuel rail pump solenoid is disconnected. The short circuit diagnostic code -6
is not active when the wire jumper is installed.

Repair: Replace the ECM. Refer to service Troubleshooting, "ECM - Replace". Verify that the
problem is resolved.

STOP

Copyright 1993 - 2007 Caterpillar Inc. Tue Aug 7 14:12:00 UTC+0800 2007
All Rights Reserved.
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