NUMBER: 7 03–10 S.M. REF.

: Listed in Table ENGINE: EPA07/10 DD Platform DATE: July

2010

SUBJECT: LOW PRESSURE FUEL SYSTEM - PRESSURE TEST

ADDITIONS, REVISIONS, OR UPDATES

Publication Number Platform Section Title Change Page Number(s)
DDC-SVC-MAN-0084 EPA07/10 DD Platform 4.3 Low Pressure Fuel New fuel system tools Insert as section states
System – Pressure Test updated for servicing
the low pressure fuel
system.
NOTE: Page numbers are based on the most recent version of the individual publication and may be adjusted throughout the annual print cycle.
LOW PRESSURE FUEL SYSTEM - PRESSURE TEST
This procedure will allow the low pressure fuel system to be monitored using pressure gauges.
1. Place a towel or container under the fittings in the low pressure lines to catch any draining fuel.

2. Remove four 8mm plugs in each of the four lines: low pressure pump inlet (1), low pressure
pump outlet (2), high pressure pump inlet (3), and high pressure pump outlet (4). Fittings
will be reinstalled when testing is complete.
NOTICE:
If your fuel system is equipped with a banjo fitting at the low
pressure pump inlet (1), use the banjo fitting with test port
contained in W470589039100 fuel system tool update kit.

3. Insert four quick disconnect fittings (J-48706-3 - part of J-48706) into each of the four fuel
line test ports.
 NOTICE:
If chassis application prevents access, a 90° or 45° pipe fitting
(1/8" NPT Female to Male) can be used if needed for access.
The elbow must be installed on the brass Schrader valve and into
the adaptor with a thread sealant. Do not thread the pipe thread
into the fuel line on the engine.

4. Torque each fitting to 8 N·m (6 lb·ft).

5. Connect the low pressure diagnostic gauge set (J-48706).
6. Prime the fuel system.
7. Install priming port gauge (J-48876).

ENGINE EXHAUST
To avoid injury from inhaling engine exhaust, always operate
the engine in a well-ventilated area. Engine exhaust is toxic.

8. Start the engine; refer to section and compare the pressures to the tables found there.
9. Remove test equipment.
FUEL SYSTEM PRESSURES
Normal and abnormal fuel system pressure are listed in the following tables. The pressures can vary
slightly due to different chassis fuel line configurations, fuel temperatures, fuel filter condition, and fuel
viscosity.
Normal System Pressures with New Filters
Cold Engine 600 Cold Engine 1800 Warm Engine 600 Warm Engine 1800
RPM RPM RPM RPM
LPP Inlet (in. Hg -8 to-9 -14 -7.5 -13.5
LPP Outlet (PSI) 78-80 104 73-74 97
HPP Inlet (PSI) 74-76 87 70-71 83
HPP Outlet (PSI) 2.5 4.5 2-2.5 4
Priming Port (PSI) 78-80 101 72-73 94-95

Table 1 Normal Fuel System Pressures

Abnormal Fuel System Pressures
Coalescer (at or past its useful life) Final Filter (at or past its useful life)
Warm Engine 600 Warm Engine 1800 Warm Engine 600 Warm Engine 1800
RPM RPM RPM RPM
LPP Inlet (in. Hg) -8.5 -13.5 -5.5 -6
LPP Outlet (PSI) 82 122 160+ 160+
HPP Inlet (PSI) 72 90 65 66
HPP Outlet (PSI) 3 4 1-2 2
Priming Port (PSI) 75 105 160+ 160+
Restricted Fuel Feed Line to Module Restricted Fuel Return Line From Module
Warm Engine1000
Warm Engine600 RPM Warm Engine600 RPM Warm Engine1000 RPM
RPM
LPP Inlet (in. Hg) -12 -14.5 -4.5 -6.5
LPP Outlet (PSI) 69 80 75 91
HPP Inlet (PSI) 67 75 72 84
HPP Outlet (PSI) 1-2 1-2 4.5 5.5
Priming Port (PSI) 70 80 75 90
Air in System (connector at line to MCM-MCM2)
Warm Engine 600 RPM
LPP Inlet (in. Hg) -1 to -5 (oscillating) — — —
LPP Outlet (PSI) 14 — — —
HPP Inlet (PSI) 14 — — —
HPP Outlet (PSI) 1-2 — — —
Priming Port (PSI) 14 — — —

Table 2 Abnormal Fuel System Pressures

ADDITIONAL SERVICE INFORMATION
Additional service information is available in Power Service Literature.

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