TD2200 Common Rail Note-In TD2200 Common …its.forcemotors.com/sap/its/homepages/its/circular2015/Circular4... · Note– In TD2650 CRDI common railassembledwith ECUcontrolrailsensor&

To,

All Dealer’s & Field Service Team

Sub – Common rail care guidelines on Traveller TD2650 CRDI & Traveller TD3250 CRDI.

We have supplied 300 T1 BS-IV vehicles & 50 nos. Traveller 26 BS-IV vehicles . The performance feedback reported is highly encouraging . All

these vehicles engines are assembled with advanced electronically fuel control system to meet the pollution norms IOBD -II. The engine

fitted with advanced common rail with pressure control valve. For healthy running of the system we are enclosing herewith guidelines of

common rail system. The common rail diesel pressure inside the rail is 1400 bars for better air fuel mixture. Following picture shows details

differentiation between TD2200 Rail & TD2650 CRDI common rails.

Pressure control valve

(PCV) which is ECU

controlled.

Common rail sensor

ECU controlled.

Circular 4Whl-230 Date -02.08.2016

Note- In TD2200 Common rail assembled with ECU control rail sensor & pressure control valve

TD2200 Common Rail

Note – In TD2650 CRDI common rail assembled with ECU control rail sensor & mechanical pressure relief Valve.

We are enclosing herewith important Do’s & Don’t on common rail & Common rail error codes.

Please note that this is private and confidential document of Force Motors Ltd. Unauthorized use of this document is not permitted. The Service

Circulars are circulated to only Authorized Dealers, Service Centers and Service Engineers of Force Motors Ltd.

TD2650 CRDI Common rail

Pressure regulating

valve (PRV) which is

mechanical control.

Common rail sensor

ECU controlled.

SN Error Code Description Reason for error latch in the System Lamp ‘ON’

1 P0191 Rail Pressure-Governor Deviation

is Too High or Too Low”

Drift in RPS sensor ‘MIL’ ON after 3rd

Driving Cycle

P0192 Fuel Rail Pressure Sensor Circuit

Low

1-Hraness short to ground.

2-Harness issue, Sensor issue

‘MIL’ ON

Immediately

P0193 Fuel Rail Pressure Sensor Circuit

High

1.Connector not connected / loose connection

2. Wiring Harness problem

3. Sensor problem

‘MIL ‘ ON

Immediately

2 P0087 Maximum Positive Deviation of

Rail Pressure Exceeded

1- Fuel shortage in fuel tank or Fuel filter / strainer choke.

2- Fuel leakage in the high Pressure circuit / at PRV

3- Leakage in the high pressure pump.

4-Injector nozzle stuck in open position or worn injector.

5- High pressure pump damage.

6-Fuel restriction in line.

7-Damage the pump.

‘MIL ‘ ON

Immediately

P0088 Maximum Negative Rail Pressure

Deviation with Metering Unit on

1- Pump metering unit is stuck in open position.

2-Metering unit & rail pressure sensor loose connection.

‘MIL ‘ ON

Immediately


Deviation with Metering Unit on

lower limit is exceeded

2-Metering unit & rail pressure sensor loose connection.

3-Incorrect size of fuel pipe.

4-Chock fuel return line.

Immediately

3 P228A Maximum Rail Pressure Exceeded

(second stage)

1- PRV stuck in closed / half open position

2- Fuel Metering unit is stuck in partial position.

‘MIL ‘ ON

Immediately

P228C Minimum Rail Pressure Exceeded 1-Fuel shortage in fuel tank or Fuel filter / strainer choke.

2-Fuel leakage in the high pressure circuit.

3-Leakage in the high pressure pump.

4-Injector nozzle stuck in open position.

5-Worn high pressure pump.

6-Fuel restriction in suction line.

7-Damage the line.

MIL ‘ ON

Immediately

P228D Maximum Rail Pressure Exceeded 1-Pump meter unit stuck in open position.

2- Metering unit / Rail Pressure sensor Connector loose

3-Incorrect or small size fuel return lines

4-Choke fuel return lines

MIL ‘ ON

Immediately

P228E Set point of Metering unit in Idle

mode not plausible

1. Injector nozzle stuck in open position / worn Injector.

2. Leakage in the high pressure pump / PRV

3. Filter / strainer choke

MIL ‘ ON

Immediately

SN Error

Code

Description Reason for error latch in the System Lamp ‘ON’

4 P0251 Metering Unit Circuit Open /

Over

Temperature

1. Connector loose / not connected / fuse blown

2. Wiring Harness problem

3. Valve problem.

MIL ‘ ON

Immediately

5 P0253 Metering Unit Circuit Low 1-Signal short to ground.

2-Wiring harness issue.

3- Valve issue

MIL ‘ ON

Immediately

6 P0254 Metering Unit Circuit High 1-Signal short to battery.

2-Wiring harness issue.

3-Valve problem

MIL ‘ ON

Immediately

7 P106A Software Reset Visibility in

DSM_0

ECU reset due to over voltage “MIL‘ & “EDC”

Lamp OFF

Once the any one above error code latched in the ECU, PRV will open to release the pressure. (Error P000F Pressure Relief Valve is Open ) is

also displaying to understand the user. ( MIL lamp is ON).


A- Consequences of the common rail error code in the system-� When you connect the diagnostic tester always two error will displayed in the system any one from above list & error P00F (Pressure Relief

Valve is Open ).

� ECU has in build counter & it counting the no of times PRV (pressure release valve ) is ‘open’ & time of engine is running with PRV ‘open’.

� For common rail safety feature PRV count is set in the ECU(Max Count 49/ Time 299 minutes ) .

once the above PRV count /time cross , the error P018F (Pressure Relief Valve reached Maximum allowed opening Count or Time) will be

latched in the system

� To clear the error P018F Bosch recommended to replace the common rail as the PRV is in build part of common rail.

Note – As the pressure relief valve is part of common rail for Safety of common rail BOSCH recommended to replace the common

rail when it cross the maximum limit. (Max Count 49/ Time 299 minutes ) .




Error code related metering unit reported &

consequential due to metering unit error

P00F will latch.

Error pressure relief valve opened latched.

P00FPressure relief valve is open

Following are the few screen shots of Common rail error codes

The error code related common rail should be

cleared immediately

Stage-1

Stage-2



1- The common rail related error code not

resolved immediately.

2- Error P000F of pressure relief valve

stored in the system.

3-Error P018F of pressure relief valve

reached max allowed count / time will latch

In the system.

1

2

3

If common rail related error code (any from Sr No 1 to 7)

not cleared at 1st stage , the error P018F latched in the

stage -2

Stage-2


Freeze Frame

Freeze Frame information needs to capture

whenever the error code observed .

ENV Conditions

Env condition details also needs to capture.



Note – In each & every error code the Freeze Frame & ENV Conditions should be capture.

SN Reason for error code Precaution to be taken

1 Vehicle run with low fuel in the Tank & Adulterated Fuel 1-Vehicle should maintain the minimum fuel level is 15 liters.

Adulterated fuel should be replace immediately.

2- Water separator water should be drained immediately

2 Discharge battery & Loose connection at Battery 1-Battery should be intact & fully charged.

2 –Battery connection should be intact.

3 Hot plugging-

Do not open the rail/ High pressure Pump connection

with ignition ‘ON’

All sensor & ECU connection to be opened after switch ‘OFF’

ignition. Time delay should be 60 sec.

4 Leakage in the fuel system. No leakages in the fuel system from Tank to Rail.

Leakage should be removed immediately

5 Fuel filter damaged / Adulterated Fuel Fuel filter element should be replaced at interval as per service

schedule day wise/ Km wise

B-Precaution to be taken to avoid the error codes.

C. Action to be taken on Common rail related error codes-


C. Action to be taken on Common rail related error codes-

�After connecting the diagnostic tester when any of above main error code from (SN 1 to7) noticed it should be immediately clear from

the system. This will default clear the error code of P000F (Pressure Relief Valve is Open).

�Refer the error code troubleshooting guide for error code diagnosis.

�Due to above main errors remains Latched for long time the error P018F (Pressure Relief Valve reached Maximum allowed opening

Count or Time). The pressure relief valve function live parameter can be seen though diagnostic tester.

The Detail procedure is enclosed to view Common rail Pressure relief valve Count/ Time



Select the pressure relief valve count/ time

Pressure relief valve Count/ time can

be seen.

1

2

3

Please note down vehicle PRV count & time on the

vehicle.


�Please note down vehicle PRV count & time on the vehicle. If the count & time cross the set limit the Common

rail needs to replace.

�Please ensure that after replacing common rail the PRV count & time needs to reset. The count & time reset

process is enclosed in the next slide.




Pressure relief valve count increased

1 1- Select the Adjust ECU Parameter

2- Adjust PRV Count to Zero.

.

2



3- Adjust PRV time to Zero

3




After adjustment PRV count / Time the message

PRV count / time successfully changed noticed at

bottom


As the common rail is very important part in the fuel system , plant has taken following corrective action

S

N

Corrective action at Plant Photographs of protective Cap on Common rail

sensor

1 Common rail Pressure relief valve count & time recording on each & every

chassis.

2 During engine mounting on vehicle the protective cap fitted on common

rail pressure sensor connector to avoid the damages.

3 All plant Engineers, Supervisor & technician are educated on the above

guidelines.



Please conduct a OJT at all dealerships under your command area & proper training is given on this aspect.

In case of MIL lamp blinking is observed , the vehicle should be attended at nearest authorized service centers on Top priority basis.

Regards,

V.N.Bellary

CC- Service Training Center/ Warranty Dept/ Export Dept

With the copy of the circular we advise you the similar care to be taken during working on the engine at the time of servicing.

Documents

TD2200 Common Rail Note-In TD2200 Common …its.forcemotors.com/sap/its/homepages/its/circular2015/Circular4... · Note– In TD2650 CRDI common railassembledwith ECUcontrolrailsensor&