Cummins ISX11.9 CM2250 (2010-12) Fault Code: 559 (B) PID: SPN: 157 FMI: 18 Injector Metering Rail 1 Pressure- Data Valid But Below Normal Operating Range- Moderately Severe Level

Circuit Description
The pressure control loop relies on fuel pressure supplied to the high-pressure pump by the fuel pump gear pump. The ECM monitors rail fuel pressure and engine operating conditions and changes the flow command to maintain the proper rail fuel pressure. Changes to the flow command result in opening (or closing) of the fuel pump actuator to supply more (or less) fuel to the high-pressure pump.

Component Location
The high-pressure fuel pump is mounted to the gear housing on the intake side of the engine.

Conditions for Running the Diagnostics
This diagnostic runs continuously when the engine is operating.

Conditions for Setting the Fault Codes
The ECM has detected the measured fuel rail pressure is below the commanded fuel rail pressure by at least 250 bar [3625 psi] for 7 seconds.

Action Taken When the Fault Code is Active
The ECM illuminates the amber CHECK ENGINE lamp and/or the malfunction indicator lamp (MIL) immediately when the diagnostic runs and fails.
Active and stationary regeneration of the diesel particulate filter will be disabled.
The exhaust gas recirculation (EGR) valve will be closed.
Engine torque will be reduced if the engine is operated for an extended period of time with this fault active.
Conditions for Clearing the Fault Code
To validate the repair using a Diagnostic Road Test, utilize a route that incorporates both stop-and-go city driving and steady state highway driving. It may be necessary to load the unit for certain diagnostics in the ECM to run.
To validate the repair using a Chassis Dynamometer Test, utilize a routine that incorporates acceleration and motoring events, steady state highway operation, and load. This will simulate normal driving and allow the diagnostics in the ECM to run.
The fault code status displayed by INSITE? electronic service tool will change to INACTIVE immediately after the diagnostic runs and passes.
The ECM will turn off the amber CHECK ENGINE lamp after the diagnostic runs and passes.
For On-Board Diagnostic (OBD) engines, the ECM will turn off the MIL after three consecutive trips where the diagnostic runs and passes.
The “Reset All Faults” command in INSITE? electronic service tool can be used to clear active and inactive faults, as well as extinguish the MIL for OBD applications

Shop Talk
The fuel system is designed to operate on clean fuel. It has two fuel filters to maintain this cleanliness. Carelessness in handling and storage of fuel system components during the repair can subject the precision components to damaging debris. Before servicing any fuel system components (such as fuel lines, fuel pump, injectors, etc.), clean the fittings, mounting hardware, and the area around the component to be removed. Store the components in a clean environment. Keep all fuel port openings and line ends covered so that no dirt can enter. Use the following procedure in the ISB CM2250 Service Manual, Bulletin 4022254. Refer to Procedure 000-009 in Section 0.

Fault Code 559 sets when the engine is operating and measured rail fuel pressure remains at least 250 bar [3625 psi] less than commanded pressure. Once detected, Fault Code 559 will remain active until the engine is turned OFF, or until the measured rail fuel pressure matches the commanded rail fuel pressure. When a condition exists that causes Fault Code 559 to become active, it is typical for the fault code to become active when the engine is heavily loaded and to become inactive when the engine is lightly loaded.

When Fault Code 559 occurs, the fuel system has lost the ability to maintain rail fuel pressure. Causes of this fault include:

Fuel inlet restrictions
Fuel filter plugging
Air in the fuel
Fuel level is below the suction line in the fuel tank
Fuel gear pump output low
Fuel gear pump pressure regulator sticking or leaking
High-pressure pump capacity decay (high leakage to drain from the high-pressure pump)
Fuel rail pressure relief valve leaks to drain
Fuel rail pressure relief valve opens (at too low a pressure), Fault Code 3727 detects this condition
Injector fuel circuit leaks to drain
External fuel leaks.
If Fault Code 559 is inactive and there are not any existing performance complaints, it is possible the vehicle was run out of fuel, or the fault became active if the engine was not primed following fuel filter replacement. However, if the customer reports that the fault code becomes active during engine operation, the steps in this fault code diagnostic tree can be used to identify the cause and make a repair.

If the engine will not start, Fault Code 559 becomes active during cranking, and no speed sensor fault codes exist, it is likely the engine is not developing rail pressure during cranking. Possibly, the engine is not primed, the gear pump pressure is too low, or the high-pressure fuel system components have excessive leakage to drain. The procedures referenced in this troubleshooting tree also have checks for engine no-start conditions.

The steps of this fault code tree assume that the fault condition is repeatable (this does not necessarily mean that the fault code is active with the engine at idle). The troubleshooting has been designed to isolate the problem into three categories:

(1) Other more precise fault codes exist (example: electrical circuit faults).

(2) Isolate the low pressure system; determine if the low pressure system functions correctly. The system must first be primed. Then, it is important to note that checks of fuel gear pump pressure and inlet restriction involve using a special service tool that causes the flow rate to increase to a rated flow. Fuel gear pump pressure and/or inlet restriction can not be accurately measured without a method of increasing the flow (i.e. using the special service tool or operating the engine at full power).

(3) Isolate the high-pressure system; determine if the high-pressure system has high leakage.

Verify the ECM calibration is correct. Check the calibration revision history found on QuickServe? Online for applicable fixes to the calibration stored in the ECM. If necessary, calibrate the ECM. Refer to Procedure 019-032 in Section 19.

Troubleshooting inactive Fault Code 559 can be difficult. For engines with high counts of inactive Fault Code 559, or if the troubleshooting tree has been exhausted, operate the engine on a chassis dynamometer or conduct a diagnostic road test to duplicate the fault code. Be certain to have a fuel pressure gauge installed at the pressure filter outlet side during the test.

If the accuracy of the fuel rail pressure sensor is being questioned, a key ON accuracy check can be performed. When checking the fuel rail pressure sensor accuracy, make sure the high-pressure fuel rail is not pressurized. The fuel pump, high-pressure fuel lines, and fuel rail contain very high-pressure fuel. Do not loosen any fittings while the engine is operating.

Once the engine is keyed OFF, there could be a significant amount of time waiting for the fuel to depressurize to 0 bar [0 psi]. Wait at least 10 minutes after shutting down the engine to allow the pressure to decrease to a lower level.
At key ON, a depressurized rail pressure sensor should read 0 ? 43 bar [624 psi].
Air in the fuel will cause starting complications. Use the following procedure in the ISB6.7 CM2250 Service Manual, Bulletin 4022254. Refer to Procedure 006-003 in Section 6.

Intermittent ECM power supply connections can cause Fault Code 559. If the engine is operating with an active Fault Code 559 and Fault Code 449, 1911, or 2311 is not present, check the ECM power supply for intermittent connections or battery issues. Fault Code 1117 can also be active if this fault condition exits. Verify the vehicle system voltage by monitoring battery voltage in INSITE? electronic service tool data monitor or connecting a digital volt ohm meter to the batteries. This will help identify a potential system voltage issue. Refer to the OEM service manual for specified voltage range and troubleshooting procedures.

Possible Cause:
1) Fuel tank or Fuel Gauge
2) Fuel Pump failure
3) Fuel pump gear pump failure
4) Injector failure
5) Fuel pressure relief valve failure
6) Fuel pump Actuator failure
7) ECM calibration