Hi everyone. I am working on a 2012 Cat 321D excavator. It has the cat 6.4 motor. This machine has a high fuel rail pressure code and alarm. I have replaced a lot of parts on this machine to try and get the problem fixed. New ECM, new injection pump, filters, all rubber fuel lines, relief valve, pressure sensor. Still not fixed. Scanned the rail pressure. Actual and desired run maybe 50 psi difference in fluctuation. At idle the rail pressure is around 5100 psi. That seems okay. What am I missing? Does anyone have an idea what's going on?
What does it do when the engine is loaded.? Do you have access to ET to run a datalogger.? Is the Code/alarm on permanently.? Can you post a machine Serial Number and the Diagnostic Code/Event that you have popping up please.
serial # is MPG00894 code - E00096 high fuel rail pressure I can run data logger. I have not taken it to work yet. It will only run 1 min before the alarm goes off and the code appears.
The code and the alarm run all the time until the key is turned off.
Once I got a code of incorrect voltage of fuel rail sensor. Don't remember the code number. Can not get the code to come back up. How can it be a voltage issue if we get a good reading from the rail sensor?
Event code E96 does not refer to fuel rail pressure. This Event Code E96 refers to the low pressure fuel system, and the message appears if the pressure exceeds 650 kPa for 8 seconds. It is very likely that you need to check the fuel pressure sensor №5 in the fuel filter.
And here are the possible reasons for this malfunction. Probable Cause Fuel pressure regulating valve Pressure relief valve Fuel lines Recommended Actions Fuel Pressure Regulating Valve An improperly operating fuel pressure regulating valve may cause high fuel pressure. If a problem is suspected, inspect the return fuel pressure regulating valve. Clean any contamination or debris that may keep the regulating valve from operating properly. If debris is present, find the source of the contamination. Replace the return fuel pressure regulating valve if the valve is worn or damaged. Pressure Relief Valve Inspect the pressure relief valve that is in the body of fuel transfer pump. Check for damage to the spring or to the valve assembly. Fuel Lines Inspect the fuel lines for damage. A restricted return fuel line can increase fuel pressure.
Thanks for the replies. The fuel filter pressure sensor is new. It could still be bad. The relief valve on the rail is new. New fuel pump. All new fuel hoses. What is the spec for the rail pressure at idle and wide open throttle? How is it throwing an error when the actual and the desired fuel pressure is within 50 psi?
I think you may be confusing the HP fuel system (rail) and the low pressure fuel supply. The E096 is created on the low pressure side. See the comments by @Deimos above. The low pressure fuel supply should be operating around approximately 72.5psi. Are you using OEM fuel filters.?
The E096 sets if the registered fuel pressure is above 94psi for at least 8 seconds.
Ok, we may be onto the problem now! I am reading 109psi on my low pressure. See attached pic not the best.
I am ordering a new pressure sensor/ regulator update kit that mounts to the top of the filter housing. As well as new filters. Will see if that fixes it. thanks for the comments.
Put the new kit on. Did not fix the problem. It made my diff pressure go to 15 psi instead of 109 psi. Still shows the same code and the alarm comes on. Thinking maybe a software glitch? Any thoughts?
I'm sorry that makes no sense. The photo you posted earlier showed the differential pressure as 18.63psi and the absolute pressure as 109.40psi. It is the absolute pressure value that triggers the E096 Event, not the differential pressure. What is the absolute pressure reading now.? I know you said you replaced fuel filters, but to repeat my question from earlier, are you using genuine OEM filters or aftermarket.?
15psi absolute . brand new cat oem filters. getting codes E00198 E00390
E0198 - Low Fuel Pressure. Absolute fuel pressure has dropped below 22psi. Is the E0390 a dash 1, 2, or 3 Event.?
E00198 count 2 E00390 count 1 thanks for the reply
I wasn't looking for the counts but the severity level. E0390 is a plugged fuel filter event. The number after the dash (e.g. E390(2) or maybe E390-2) indicates the level of severity of the Event with -1 being the least severe and -3 being the most severe.