PSID 096 FMI 1:

This code indicates that the system is trying to achieve a rail pressure set value, but ends
up with a too low pressure.

So everything that affects the rail pressure or the reading of rail pressure can be causing
this error code, e.g.:

Low fuel feed pressure (low pressure side):

-Clogged fuel filters
-Low feed pressure
-Air in the fuel system
Faulty monitoring of the rail pressure:
-Faulty rail pressure sensor.
Low fuel delivery from FCV to high pressure fuel pumps:
-Fuel control valve (FCV) closed or partly closed or out of characteristic
External or internal fuel leakage from high pressure to low pressure side:
-Rail pressure release valve (PRV) stuck open or unwanted opening.
-An injector is stuck open or leaking internally, draining fuel from the high pressure side to
the fuel return line.
Low fuel delivery from high pressure pumps to the rail:
-Faulty high pressure pump/pumps (Last action replace the high pressure pumps)

(FCV)
 Trouble shooting:

1. Check all engine related error codes

2. Check fuel pipes for visible leakage

- Check fuel pipes for leakage; high pressure pipes, suction pipes, return pipes).

3. Check the fuel filters

4. Check the fuel feed pressure (MID 128, PID 94)

Normally the feed pressure measured in the machine is between 85-95 Psi (5.8-6.5 bar)

Please check the feed pressure also at high speed and load. There have been cases
where there has been flake shaped debris in the fuel system, causing a lower feed
pressure at high engine rpm due to that the flake is put in a blocking position at high fuel
flow. In these cases the feed pressure was normal at idle speed.

5. Check for air in the fuel system

Fit a see through hose on the return nipple in the picture to see if there are air bubbles
in the fuel system
6. Check the rail pressure sensor (MID 128, PID 164).

1. Clamp
2. Rail pressure sensor

Check the sensor:

7. Check the fuel control valve (MID 128 SID 42)
Check if the fuel control valve, FCV, is closed or partly closed or out of characteristic

This magnetically controlled proportional valve controls the fuel flow (feed) to the two high
pressure pumps. The input signal to the valve is a PWM signal which pulse width is controlled
by the engine control module. When the current through the valve is changed, this
affects the fuel flow, which results in changed rail pressure. Zero current (removed connector)
gives maximum fuel flow.
8. Leakage on high pressure side.
It must be an internal leakage (from high to low pressure side, fuel circuit internal), otherwise
you would have seen it. This can only be at PRV or Injectors. Fuel leakage increases with
temperature, which can explain that the problem appears mostly after hard work.

8a. Check the PRV valve (MID 128 PSID 97)

- Check if the Rail pressure release valve (PRV) is stuck open or has an unwanted
opening. This will cause fuel to be drained from the rail via the PRV (1) through the rubber
return hose (2) back to the fuel tank. Normally there should be no fuel coming from through
this hose. The easiest way to determine if the PRV is open is to feel if the return hose (2) is
warm. Another way is to disconnect the hose.

8b. Check the injectors (MID 128 SID 1-6)

Internal leakage in the injectors might e.g. be caused by dirt particles in the fuel that has
stuck inside the injector and does not allow the control valve to close correctly.
To check if there is a leakage please remove the hose coming from the injector return
channel at the end of the cylinder head.

If there is a high fuel flow there is probably a leakage through one of the injectors. To
determine which injector you have to remove the fuel line and plug the rail connection for
this line. Do this for one cylinder at the time and when you see a decrease in fuel flow from
the return channel in the head then you know this was the leaking injector. If an injector is
leaking please also check the fuel quality and if there is water in the fuel that could have
caused the problem.

Remove the fuel line

Fit a plug on the rail instead of the fuel line