I have a EC140D that began displaying the "Fuel Injection Error, Shut down Engine" message. In the service menu, it showed a PSID96-01. Changed fuel filters and cleaned rust from tank. Installed fuel rail kit. No change. Disassembled the fuel control regulator. Found small amount of rust under PWM solenoid. Overflow valve was clean. Cleaned the regulator assembly and reinstalled. Primed system and ran machine at full hydraulic, 2 pump stall for over an hour. No code or performance issues returned. Low pressure reading in monitor 82 psi. Rail pressure under full load 25,600 psi. Customer ran machine not ten minutes the following day and couldn't make it to the fuel tank. Began throwing the fuel injection error again. Low pressure at this time is 82 psi. Rail pressure under full load 21,700 psi. After consulting with the local dealer, I changed the regulator assembly. Primed the system and tested. Low pressure showed 100 psi then dropped closer to 87 psi. Rail pressure at low idle showed 22k psi when before, it was 10k psi. Machine would run for a few seconds and shut off like you hit the key, with no codes or messages. Continued this after several attempts. Finally, it gave the fuel injection error, derated, but didn't die on its own. After all of this there are no new messages or codes left in service mode. It does show some computer failure codes from the past but nothing recent. Does anyone have any suggestions before I have to hand it over to dealer for them to connect their computer to it?
Have you checked the fuel filter-head for blockages?
Yes. Verified when hoses and tank were cleaned out. With the rail pressure now twice what it was before at low idle, it seems it’s seeing an incorrect fuel/air mixture but figured it would give a related code. I’m going back out this week to verify then cleanliness of the rail and limiter.
Welcome to the forums, swing by new member introductions when you have a chance, say hi. The fact that there was rust in the tank and the PWM valve of the FCV tells you, it's gonna be expensive and never ending unless you go all in. Common rail fuel systems have 0, I mean ZERO tolerance for water. If water got to your FCV, then your injectors saw it too. I would not skip on anything. The only possibility of salvage is the high pressure pumps, since they're bumping safety pressure relief setting. If she were mine, new filters, new FCV, new injectors, and new rail kit. Your low pressure lift pump and high pressure pumps seem to be all that survived .
I will pull injectors and have them checked. The shutdown without code or warning has me concerned with ecm issue though.
Beware the testing. The injectors are cold, only check for spray pattern against pressure. They don't typically heat soak them to see the high return volume. Lots of guys have lost handfuls of hair thinking they have "good" injectors.
Thanks for the tip! I'll ask my local guy what his steps to testing are.