Troubleshooting by failure code

Failure code [CA559] Rail Press Low Error

Failure code [CA559] Rail Press Low Error 40-218

Action code Failure code Common rail pressure low error
Failure
(Engine controller system)
E02 CA559
Detail of failure There is low pressure error (1) in common rail circuit.
Action of con-
None in particular.
troller
Engine does not start at all or does not start easily.
Problem on
Exhaust gas becomes black.
machine
Engine output lowers.
Common rail pressure can be checked with monitoring function.
Related infor-
(Code: 36400 Common rail pressure)
mation
Method of reproducing failure code: Start engine.

Cause Procedure, measuring location, criteria and remarks

1 Non-fuel Check fuel remain.

2 Defective fuel tank breather Fuel tank breather may be clogged. Check it.

Fuel may be leaking to outside. Check it (Check visually while running engine at
3 Fuel leakage to outside
low idle).
Defect in low pressure circuit parts
4 Pressure drop in fuel low-pressure circuit = Fuel filter inlet pressure - Fuel filter
(Note 1)
pressure (gear pump side)
Defective injector
5 (including high pressure
piping in head)
For check of pressure in fuel low pressure circuit, see Testing and adjusting,
“Checking fuel pressure”.
Measured in fuel filter inlet side.
Cranking speed: Min. 150 rpm
Pressure in fuel Min. 0.14 MPa
During cranking
low-pressure circuit {Min. 1.4 kg/cm2}
For check of pressure in fuel low pressure circuit, see Testing and adjusting,
“Checking fuel pressure”.
Measured in fuel filter outlet side.
Pressure in fuel Min. 0.48 MPa
During cranking
low-pressure circuit {Min. 4.9 kg/cm2}
For check of pressure in fuel low pressure circuit, see Testing and adjusting,
“Checking fuel pressure”.
Measured in fuel filter inlet and outlet sides.
outlet pressure
Pressure drop in fuel Max. 0.14 MPa
During cranking
low-pressure circuit {Max. 1.4 kg/cm2}
For check of fuel suction pressure, see Testing and adjusting, “Checking fuel
pressure”.
Measured in gear pump fuel inlet side of supply pump.
Fuel suction circuit Max. 33.9 kPa
During cranking
{Max. 254 mmHg}
For check of fuel suction pressure, see Testing and adjusting, “Checking fuel
pressure”.
Measured in fuel connector side.
Fuel suction circuit
Max. 27.1 kPa
pressure During cranking
{Max. 203 mmHg}
(fuel connector side)
For check of return rate from injector, see Testing and adjusting, “Checking
fuel return rate and leakage”.
During cranking
(if engine cannot be Max. 100 cc/30 sec.
Return rate from injector started)
During low idle
Max. 300 cc/45 sec.
(if engine can be started)

40-226 GD705-5
(01)
 Troubleshooting by failure code
Failure code [CA559] Rail Press Low Error

Cause Procedure, measuring location, criteria and remarks

For check of return rate from supply pump, see Testing and adjusting,
“Checking fuel return rate and leakage”.
During cranking
6 Defective supply pump (if engine cannot be Max. 200 cc/30 sec.
Return rate from supply
started)
pump
During low idle
Max. 300 cc/30 sec.
(if engine can be started)
For check of leakage through pressure limiter, see Testing and adjusting,
“Checking fuel return rate and leakage”.
7 Defective pressure limiter
Leakage through pressure
At low idle Below 30 drops/60 sec.
limiter
8 Defective supply pump plunger Remove the supply pump head, and check that the plunger is not damaged.
There may be air in low pressure circuit. Check it according to the following pro-
cedure.
1. Remove pressure pickup plug (outlet side) of fuel main filter.
2. Operate feed pump of fuel prefilter.
3. Check pressure pickup plug for leakage of fuel and air.
9 Air in low pressure circuit
If this failure occurs during air bleeding after the fuel filter was replaced, air
may remain in the fuel circuit. Keep running the engine at low idle for about 3
minutes.
As air is bled from the fuel circuit, the engine speed will be stabilized, erasing
the failure indication.
Note 1: When low-pressure circuit equipment is detective, check the following:
1) Clogged fuel tank breather
2) Clogged check valve (3) installed cooling plate (2) on engine controller (1).
3) Leaked or clogged low-pressure fuel pipe
4) Clogging in fuel prefilter
5) Clogging in fuel main filter
Replace fuel main filter if cause of failure is not detected with checking clogging.

GD705-5 40-227
(01)