PISTON-.040 OS 9L8614 - Caterpillar

Test Preparation
Remove all covers to expose the fuel system.Test Procedures
Checking Fuel Pressure
Use the following procedure in order to measure the fuel pressure that is 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, achieving an average reading and a steady needle. Keep the gauge above the measuring point.
Illustration 2 g02324296
Standard secondary fuel filter base
(1) Input fuel line from transfer pump
(2) Output fuel line to head
(3) Test port
Install the 198-4240 Digital Pressure Indicator Gp into test port (3). This port is the proper test port.
Adjust the engine speed to 1800 rpm with no load.
The fuel pressure should be 586 kPa (85 psi) nominal. Record the pressure.
If excessive pressure is found, check the conditions that are listed previously under the "High Fuel Pressure" heading.
Illustration 3 g02928276
Fuel transfer pump
(4) Outlet fuel line
(5) Inlet fuel port
(6) Pressure regulating valve
Use the following procedure to check the output of the fuel transfer pump:
Remove the fuel line (4).
Tee the 198-4240 Digital Pressure Indicator Gp into the port that contained the fitting for the fuel line (4) .
Adjust the engine speed to 600 rpm with no load.
The fuel pressure should be 690 kPa (100 psi) to 724 kPa (105 psi).
If the fuel pressure is within the specified range, proceed to Step 3.
If the pressure is less than 655 kPa (95 psi), the fuel transfer pump is weak. The pressure regulating valve (6) in the pump may be stuck or worn. Remove the pressure regulating valve, the spring, and the pin. Inspect the pressure regulating valve. If contamination is not found, and the pressure regulating valve is worn out, replace the fuel transfer pump. If dirt is found, clean the valve assembly and reinstall the valve assembly.
Check the fuel pressure again. Replace the fuel transfer pump if the fuel pressure still measures less than 655 kPa (95 psi). The fuel transfer pump is operating properly if the fuel pressure measures at least 690 kPa (100 psi) to 724 kPa (105 psi).
Once the fuel transfer pump has been confirmed as properly operating, check the fuel pressure again after the secondary fuel filter base. Refer to Step 1. If the fuel pressure is not at the nominal specification, continue to Step 3.
Illustration 4 g02928297
(7) Fuel pressure regulating valve
(8) Return line from the cylinder head (Input)
(9) Check valve
(10) Return to tank (output)
Use the following procedure to inspect the return pressure regulating valve to the fuel tank:
Return fuel pressure regulating valve (7) is located above the ECM.
Inspect return fuel pressure regulating valve (7).
The return fuel pressure regulating valve may be stuck or worn. Remove the check valve (9). Inspect the check valve. If contamination is not found, and the fuel pressure regulating valve is worn out, replace the fuel pressure regulating