Maintenance manual for sunray hfc4da1-2c china-IV diesel engines
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5. Rail pressure sensor
1) Overview
The resistance of the metal film installed on the diaphragm will change accordingly following the change of shape.
This change of shape generated by the established system pressure (approximate 1mm under 1,500bar pressure) will
change the resistance and lead to the change of voltage between two sides of 5V bridge composed of resistor units.
This voltage change range is 0~70mv (depending on the applied pressure) and is amplified to 0.5~4.5V by the
evaluation circuit.
The accurate measurement of rail pressure is of great importance to the effective working of the system. This is one of
the causes for very strict tolerance over the rail pressure sensor during the pressure measurement. Under the scope of
main working conditions, the measurement accuracy is approximately ±2% of the full scale reading.
Wiring terminals: 1. Grounding; 2. Rail pressure sensor signal; 3. +5V power supply.
2) Working Principle
It transmits one voltage signal to the ECU, depending on the fuel pressure. The rail pressure sensor must measure the
instant pressure in the fuel rail and embody sufficient accuracy and rapid response capability. The rail pressure sensor
is composed of following parts:
cIntegrated sensing unit welded onto the pressure device
d Printed circuit board (PCB) with electric evaluation circuit
sensor housing with electric connector. The fuel flows into the rail pressure sensor via one hole on the common rail
and the end of this hole is sealed by one sensor diaphragm. The fuel under high pressure reaches the sensor diaphragm
via one blind hole. One sensing unit (semiconductor unit) is arranged on this diaphragm and converts the pressure into
electric signal. This signal generated is transmitted via wire to evaluation circuit, which will amplify this signal and
transmit to the ECU.
3) Test analysis
Wiring terminals: 1 - Grounding; 2 - Rail pressure sensor signal; 3 - +5V power supply.
4) Malfunction Mode
The malfunction indicator lamp lights up if the voltage is higher or less than this limit. If the voltage is out of the
normal working voltage range, but is not out of the limit, the malfunction indicator lamp will not light up.
5) Troubleshooting
The light-up of the engine malfunction indicator lamp indicates the presence of malfunction in the engine system and
it’s necessary to diagnose with diagnosis instrument. Use JAC special diagnosis instrument to communicate with ECU
of electronic injection system and read out the malfunction data in the ECU.
6. Engine coolant temperature sensor
1) Overview
z The sensor is installed on the cylinder head, closing to the water outlet. The body is made of brass to protect the
resistor unit fabricated from negative temperature coefficient (NTC) resistor;
Rail
pressure
sensor
5V power supply
Rail sensor signal
Grounding