Common Faults and Handling Methods of Diesel Generator Sensors

The types of sensors can be roughly divided into three categories: pressure sensors, temperature sensors, and speed and position sensors. There are more than ten sub categories, such as oil pressure sensors, intake temperature sensors, coolant temperature sensors, fuel pressure and temperature sensors, engine speed sensors, and so on.

The sensors of the common rail diesel engine include rail pressure sensor, coolant temperature sensor, oil pressure temperature sensor, intake pressure temperature sensor, crankshaft speed sensor, camshaft speed sensor, and so on. Common faults of various sensors include damaged sensor hardware, incorrect sensor electrical characteristics, poor or damaged wiring harness connectors, and open or short circuits in the wiring harness. Today we will learn about the detection methods of sensors and wiring harnesses, as well as common faults and troubleshooting methods.

The relevant functions of each sensor in the common rail diesel engine and the response mode after failure are as follows:

1. Rail pressure sensor

Function: Provides pressure inside the common rail tube and is one of the most critical sensors in the common rail system.

System response after failure: The pressure limiting valve opens, the return oil heats up, and the system limps home.

2. Coolant temperature sensor

Function: Provides coolant temperature, which is related to the intake heating status and thermal protection function.

System response after failure: limp home

3. Oil pressure and temperature sensor

Function: Provides oil pressure and temperature parameters

System response after failure: oil pressure alarm

4. Intake pressure and temperature sensor

Function: Provides intake pressure and temperature parameters

System response after failure: diesel engine emits black and white smoke, limping home

5. Crankshaft speed sensor

Function: Provides crankshaft position signal and speed signal

System response after failure: difficult to start, smoking

6. Camshaft speed sensor

Function: Provide cylinder detection signal and speed signal

System response after failure: difficult to start, limping home

The common faults and handling methods of each sensor are as follows:

Fault type 1: Sensor hardware damage

Cause analysis: Damaged plug or damaged sensor body during installation

Solution: Replace the sensor with a new one

Fault type 2: Incorrect electrical characteristics of the sensor

Cause analysis: The sensor is damaged due to circuit reasons

Solution: Replace the sensor with a new one

Fault type three: Poor or damaged contact of wiring harness connectors

Cause analysis: Not securely inserted or damaged during operation

Solution: Re plug or replace the wiring harness

Fault type four: open circuit or short circuit in the wiring harness

Cause analysis: Worn wiring rubber or disconnected wiring harness

Solution: Protect or replace the wiring harness

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