ROLLER-GUIDE 5411678 - Caterpillar

Table 1
Event Codes    
CDL Code and Description    Conditions which Generate this Code    System Response    
E396(1) High Fuel Rail Pressure     The fuel rail pressure is above the trip point pressure for the programmed delay time.     The code is logged.    
E396(2) High Fuel Rail Pressure    
E396(3) High Fuel Rail Pressure    Probable Causes
Diagnostic codes and event codes
Fuel rail pressure sensor
Pressure relief valve
High-pressure fuel pumpRecommended Actions
Note: The procedures have been listed in order of probability. Complete the procedures in the order of the listed test steps.
Table 2
Troubleshooting Test Steps    Values    Results    
1. Check for Codes
A. Connect Caterpillar Electronic Technician (ET) to the service tool connector. Refer to Troubleshooting, "Electronic Service Tools", if necessary.
B. Download the "Product Status Report" from the engine ECM before performing any troubleshooting or clearing diagnostic trouble codes.
C. Determine if the diagnostic trouble code that directed to this procedure is present.
D. Look for active diagnostic codes that are associated with the system for the event code that directed to this procedure.
   
E396
   
Result: An associated code is present.
Repair: Troubleshoot any associated codes before continuing with this test.
Result: An E396 code is present.
Proceed to the next step.
Result: No active codes
STOP
   
2. Check the Fuel Rail Pressure Sensor
A. With the engine shutdown, use Cat ET to check the value for the "Fuel Rail Pressure (absolute)" parameter. After the engine has been shut down for 10 minutes, the "Fuel Rail Pressure (absolute)" will be less than 5,000 kPa (725 psi) (gauge).
If the pressure is not less than
5,000 kPa (725 psi) (gauge) after 10 minutes, vent the pressure from the fuel system. Refer to Systems Operation/Testing and Adjusting, "Fuel Rail Pressure - Release" for information.
   
Rail
pressure
   
Result: The sensor reports that the pressure that is in the fuel rail is less than
5,000 kPa (725 psi) (gauge) after venting the fuel system, the fuel rail pressure sensor and the electrical circuit are OK.
Repair: Proceed to the next step.
Result: The sensor reports that the pressure that is in the fuel rail does not fall to less than
5,000 kPa (725 psi) (gauge) after venting the fuel system, there may be a problem with the fuel rail pressure sensor or the electrical circuit for the sensor.
Repair: Perform the necessary repairs. Refer to Troubleshooting, "Sensor Signal (Analog, Active) - Test" for information that is related to testing the circuit.
If the problem is not resolved, proceed to the next step.
   
Illustration 1 g02913361
Locations of the test points at the high-pressure fuel pump (1) Valve block for the pressure regulating valve (2) Pump head assembly
Table 3
Troubleshooting Test Steps    Values    Results    
3. Check the Pressure Relief Valve
An excessive fuel pressure in the low-pressure fuel system will cause the pressure relief valve in the high-pressure fuel pump to bypass fuel. The bypass damages the pressure relief valve. Perform the following procedure in order to check for this condition and/or a damaged valve:
A. While the engine is at normal operating temperature, run the engine at high engine idle.
B. Use