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How do you troubleshoot this problem?

The Honeywell oil pressure sensor on my Rotax 912UL failed—the Dynon D180 display just showed three dashes where the oil pressure is normally indicated. The crazy part was that the failed oil pressure sensor also caused the EGT probes to read -99. Cutting the lead to the oil pressure sensor restored the EGT temps. There was some intense head scratching leading up to this which I will not recount.

Sent the D180 to Dynon; no issues with the instrument.

I replaced the previous faulty oil pressure sensor (956413/956415–the big expensive one) with the newer Honeywell version from Lockwood. Connecting the new sensor to the Dynon gives me exactly the same result—EGT probes read -99. I did the pressure purge and no oil pressure was indicated when rotating the prop.

I have experimented with all 8 possible wiring combinations of input and output wires with no joy. When the sensor is disconnected the EGT and other devices (fuel CHT OAT etc) read correctly. Though the sensor is new, my only conclusion is that it is faulty. Overtorqued and damaged?

Is there another interpretation?
  • Re: Faulty oil pressure sensor? Or something else

    by » 6 years ago


    Are there any other wires in-between the sensor and the D180? If there is check continuity on each wire and that they are not shorted to each other, ground or 12 volts. There is only one way to connect the sensor consult your documentation/schematics. The sensor is a 4 to 20 ma current output and can be checked with an appropriate meter.

  • Re: Faulty oil pressure sensor? Or something else

    by » 6 years ago


    The EGTs and the Oil Sensor likely share the same Ground.
    The EGTs are High impedance Mili-Voltage range sensors and will tolerate a few extra ohms of ground resistance.
    When the Oil sender pushes 20ma across that same poor ground it may raise the ground by a 1/10th. volt or more.
    This will push the EGTs readings off-scale.

    Find the Ground problem.
    Better yet, Separate the Grounds.

    Ancient Troubleshooting Proverb: ;)
    [quote]If it absolutely makes no sense and it appears that Magic is at play,
    It is a Ground Problem![/quote]

    Bill Hertzel
    Rotax 912is
    North Ridgeville, OH, USA
    Clicking the "Thank You" is Always Appreciated by Everyone.


  • Re: Faulty oil pressure sensor? Or something else

    by » 6 years ago


    I think this is a loose wire issue to and as Bill said a ground.

    Roger Lee
    LSRM-A & Rotax Instructor & Rotax IRC
    Tucson, AZ Ryan Airfield (KRYN)
    520-349-7056 Cell


  • Re: Faulty oil pressure sensor? Or something else

    by » 6 years ago


    Bingo. After tearing apart a lot of wire bundles I think I found the problem: the 200 ohm resistor wired inline from the sender to ground had fractured a lead. I just located a 216 ohm resistor and hopefully this will allow the repair to proceed tomorrow. Whew.

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