Yanmar 3TNV82A Troubleshooting Manual
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Yanmar 3TNV82A Troubleshooting Manual

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See also: Service Manual , Operating Manual
TROUBLESHOOTING
MANUAL
ELECTRONIC CONTROL
3TNV82A
3TNV82A-B
3TNV84
3TNV84T
3TNV84T-B
3TNV88
3TNV88-B
3TNV88-U
4TNV84
4TNV84T
4TNV84T-Z
4TNV88
4TNV88-B
4TNV88-U
4TNV94L
4TNV98
4TNV98-Z
4TNV98-E
4TNV98T
4TNV98T-Z
4TNV106
4TNV106T

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Summary of Contents for Yanmar 3TNV82A

  • Page 1 TROUBLESHOOTING MANUAL ELECTRONIC CONTROL 3TNV82A 4TNV84 3TNV82A-B 4TNV84T 3TNV84 4TNV84T-Z 3TNV84T 4TNV88 3TNV84T-B 4TNV88-B 3TNV88 4TNV88-U 3TNV88-B 4TNV94L 3TNV88-U 4TNV98 4TNV98-Z 4TNV98-E 4TNV98T 4TNV98T-Z 4TNV106 4TNV106T...

  • Page 2: Proposition 65 Warning

    California California Proposition 65 Warning Proposition 65 Warning Diesel engine exhaust and some of its Battery posts, terminals, and related accessories contain lead and lead constituents are known to the state of compounds, chemicals known to the California to cause cancer, birth state of California to cause cancer and defects, and other reproductive harm.

  • Page 3: Table Of Contents

    Section 1 TNV DI Service Manual FAILURE DIAGNOSIS Page DTCs (Diagnostic Trouble Codes) General Description....1-3 DTC Code List ................1-3 Description Items............... 1-7 Analog Input Related Failures ........... 1-8 Pulse Sensor Related Failures ..........1-60 Contact Output Related Failures ..........1-66 Contact Input Related Failures ..........
  • Page 4 FAILURE DIAGNOSIS This Page Intentionally Left Blank TNV DI Service Manual...

  • Page 5: Dtcs (Diagnostic Trouble Codes) General Description

    DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS DTCS (DIAGNOSTIC TROUBLE CODES) GENERAL DESCRIPTION DTC Code List Referenced page Error Item Clas Lamp number sifica Flashing Failure tion Patterns Area Status Overview Diagnosis P1202/4 Error (low voltage) P.1-8 Rack position sensor P.1-136 P1203/3 Error (high voltage)
  • Page 6 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description Referenced page Error Item Clas Lamp number sifica Flashing Failure tion Patterns Area Status Overview Diagnosis P0340/4 Speed Sensor Error P.1-60 P.1-164 P1340/4 Spare speed sensor Error P.1-62 P.1-167 P0219/0 Overspeed Error P.1-64 P.1-64 P1222/4...
  • Page 7 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Referenced page Error Item Clas Lamp number sifica Flashing Failure tion Patterns Area Status Overview Diagnosis P1212/4 Error (low current) P.1-114 P1213/3 Rack actuator Error (high current) P.1-116 P1211/7 Mechanical failure P.1-118 P.1-193 P1214/2 Engine...
  • Page 8 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description This Page Intentionally Left Blank TNV DI Service Manual...

  • Page 9: Description Items

    DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Description Items Code Number DTC Name DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); Check points 3 - Flashing pattern of failure indicator 1. Precondition for Error detection This column shows what parts or 2.

  • Page 10: Analog Input Related Failures

    FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description Analog Input Related Failures Rack position sensor (1) P1202/4: Failure with Rack Position Sensor (Low Voltage) P1202/4 Rack Position Sensor Error (Low Voltage) DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); Check points 3 - Flashing pattern of failure indicator 1.
  • Page 11 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis • Check the sensor voltage (AD value). tool *For details of the method and the procedure of diagnosis, see P.1-136 2) Check of •...
  • Page 12 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description (2) P1203/3: Failure with Rack Position Sensor (High Voltage) P1202/3 Failure with Rack Position Sensor (High Voltage) DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); Check points 3 - Flashing pattern of failure indicator 1.
  • Page 13 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis • Check the sensor voltage (AD value). tool *For details of the method and the procedure of diagnosis, see P.1-136 2) Check of •...
  • Page 14 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description Accelerator sensor (1) P0122/4: Accelerator Sensor Error (Low Voltage) P0122/4 Accelerator Sensor Error (Low Voltage) DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); Check points 3 - Flashing pattern of failure indicator 1.
  • Page 15 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis • Check the sensor voltage. tool *For details of the method and the procedure of diagnosis, see P.1-140 2) Check of •...
  • Page 16 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description (2) P0123/3: Accelerator Sensor Error (High Voltage) P0123/3 Accelerator Sensor Error (High Voltage) DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); Check points 3 - Flashing pattern of failure indicator 1.
  • Page 17 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis • Check the sensor voltage. tool *For details of the method and the procedure of diagnosis, see P.1-140 2) Check of •...
  • Page 18 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description (3) P0124/2: Intermittent Failure with Accelerator Sensor P0124/2 Intermittent Failure with Accelerator Sensor DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); Check points 3 - Flashing pattern of failure indicator 1.
  • Page 19 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis • Check the sensor voltage. tool *For details of the method and the procedure of diagnosis, see P.1-140 2) Check of •...
  • Page 20 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description (4) P0123/1: Accelerator Sensor Error (foot pedal-close position) P1125/1 Accelerator Sensor Error (foot pedal-close position) DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); Check points 3 - Flashing pattern of failure indicator 1.
  • Page 21 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis • Check that the foot pedal movement is correctly recognized. tool *For details of the method and the procedure of diagnosis, see P.1-144 2) Check of •...
  • Page 22 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description (5) P1126/0: Accelerator Sensor Error (foot pedal-open position) P1126/0 Accelerator Sensor Error (foot pedal-open position) DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); Check points 3 - Flashing pattern of failure indicator 1.
  • Page 23 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis • Check that the foot pedal movement is correctly recognized. tool *For details of the method and the procedure of diagnosis, see P.1-144 2) Check of •...
  • Page 24 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description Spare accelerator sensor (option) (1) P0222/4: Failure with Spare Accelerator Sensor (Low Voltage) P0222/4 Failure with Spare Accelerator Sensor (Low Voltage) DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); Check points 3 - Flashing pattern of failure indicator 1.
  • Page 25 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis • Check the sensor voltage. tool *For details of the method and the procedure of diagnosis, see P.1-148 2) Check of •...
  • Page 26 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description (2) P0223/3: Spare Accelerator Sensor Error (High Voltage) P0223/3 Spare Accelerator Sensor Error (High Voltage) DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); Check points 3 - Flashing pattern of failure indicator 1.
  • Page 27 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis • Check the sensor voltage. tool *For details of the method and the procedure of diagnosis, see P.1-148 2) Check of •...
  • Page 28 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description (3) P0224/2: Intermittent Failure with Spare Accelerator Sensor P0224/2 Intermittent Failure with Spare Accelerator Sensor DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); Check points 3 - Flashing pattern of failure indicator 1.
  • Page 29 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis • Check the sensor voltage. tool *For details of the method and the procedure of diagnosis, see P.1-148 2) Check of •...
  • Page 30 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description (4) P1225/1: Spare Accelerator Sensor Error (foot pedal-close position) Spare Accelerator Sensor Error (foot pedal-close P1225/1 position) DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); Check points 3 - Flashing pattern of failure indicator 1.
  • Page 31 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis • Check that the foot pedal movement is correctly recognized. tool *For details of the method and the procedure of diagnosis, see P.1-144 2) Check of •...
  • Page 32 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description (5) P1226/0: Spare Accelerator Sensor Error (foot pedal-open position) Spare Accelerator Sensor Error (foot pedal-open P1226/0 position) DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); Check points 3 - Flashing pattern of failure indicator 1.
  • Page 33 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis • Check that the foot pedal movement is correctly recognized. tool *For details of the method and the procedure of diagnosis, see P.1-144 2) Check of •...
  • Page 34 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description (6) P1227/8: Failure with Spare Accelerator Sensor (Pulse Communication) Failure with Spare Accelerator Sensor (Pulse P1227/8 Communication) * This DTC is output when a pulse accelerator is used. DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); Check points 3 - Flashing pattern of failure indicator 1.
  • Page 35 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis tool *For details of the method and the procedure of diagnosis, see P.1-152 2) Check of • Before beginning your work, be sure to turn off the key switch. connectors/wiring •...
  • Page 36 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description Atmospheric pressure sensor (option) (1) P2228/4: Failure with Atmospheric Pressure Sensor (Low Voltage) P2228/4 Failure with Atmospheric Pressure Sensor (Low Voltage) DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); Check points 3 - Flashing pattern of failure indicator 1.
  • Page 37 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis • Check the sensor voltage. tool *For details of the method and the procedure of diagnosis, see P.1-148 2) Check of •...
  • Page 38 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description (2) P2229/3: Failure with Atmospheric Pressure Sensor (High Voltage) P2229/3 Failure with Atmospheric Pressure Sensor (High Voltage) DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); Check points 3 - Flashing pattern of failure indicator 1.
  • Page 39 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis • Check the sensor voltage. tool *For details of the method and the procedure of diagnosis, see P.1-148 2) Check of •...
  • Page 40 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description (3) P2230/2: Intermittent Failure with Atmospheric Pressure Sensor P2230/2 Intermittent Failure with Atmospheric Pressure Sensor DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); Check points 3 - Flashing pattern of failure indicator 1.
  • Page 41 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis • Check the sensor voltage. tool *For details of the method and the procedure of diagnosis, see P.1-148 2) Check of •...
  • Page 42 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description ECU Temperature Sensor (1) P0668/4: Failure with ECU Temperature Sensor (Low Voltage) P0668/4 Failure with ECU Temperature Sensor (Low Voltage) DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); Check points 3 - Flashing pattern of failure indicator 1.
  • Page 43 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS (2) P0669/3: Failure with ECU Temperature Sensor (High Voltage) P0669/3 Failure with ECU Temperature Sensor (High Voltage) DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); Check points 3 - Flashing pattern of failure indicator 1.
  • Page 44 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description (3) P1664/2: Intermittent Failure with ECU Temperature Sensor P1664/2 Intermittent Failure WITH ECU Temperature Sensor DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); Check points 3 - Flashing pattern of failure indicator 1.
  • Page 45 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS (4) P0634/0: ECU Temperature Rise Alarm P0634/0 ECU Temperature Rise Alarm DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); Check points 3 - Flashing pattern of failure indicator 1. Key switch ON. E-ECU 2.
  • Page 46 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis • Check the ECU temperature. tool *For details of the method and the procedure of diagnosis, see P.1-154 2) Engine Inspection • Turn the key switch off to stop the engine. •...
  • Page 47 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Cooling water temperature sensor (1) P0117/4: Failure with Cooling Water Temperature Sensor (Low Voltage) Failure with Cooling Water Temperature Sensor (Low P0117/4 Voltage) DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); Check points 3 - Flashing pattern of failure indicator 1.
  • Page 48 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis • Check the sensor voltage. tool *For details of the method and the procedure of diagnosis, see P.1-156 2) Check of •...
  • Page 49 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS (2) P0118/3: Failure with Cooling Water Temperature Sensor (High Voltage) Failure with Cooling Water Temperature Sensor (High P0118/3 Voltage) DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); Check points 3 - Flashing pattern of failure indicator 1.
  • Page 50 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis • Check the sensor voltage. tool *For details of the method and the procedure of diagnosis, see P.1-156 2) Check of •...
  • Page 51 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS (3) P0119/2: Intermittent Failure with Cooling Water Temperature Sensor Intermittent Failure with Cooling Water Temperature P0119/2 Sensor DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); Check points 3 - Flashing pattern of failure indicator 1.
  • Page 52 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis • Check the sensor voltage. tool *For details of the method and the procedure of diagnosis, see P.1-156 2) Check of •...
  • Page 53 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS (4) P0217/0: Cooling Water Temperature Rise Alarm P0217/0 Cooling Water Temperature Rise Alarm DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); Check points 3 - Flashing pattern of failure indicator 1.
  • Page 54 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis • Check the cooling water temperature and the sensor voltage. tool *For details of the method and the procedure of diagnosis, see P.1-156 2) Check of •...
  • Page 55 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS SENSOR 5V (1) P0642/4: Failure with SENSOR 5V (Low Voltage) P0642/4 Failure with SENSOR 5V (Low Voltage) DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); 3 - Flashing pattern of failure indicator Check points 1.
  • Page 56 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description (2) P0643/3: Failure with SENSOR 5V (High Voltage) P0643/3 Failure with SENSOR 5V (High Voltage) DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); 3 - Flashing pattern of failure indicator Check points 1.
  • Page 57 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS (3) P1644/2: Intermittent Failure with SENSOR 5V P1644/2 Intermittent Failure with SENSOR 5V DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); 3 - Flashing pattern of failure indicator Check points 1.
  • Page 58 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description Power supply Voltage (1) P0562/1: Power Supply Voltage Error (Low Voltage) P0562/1 Power Supply Voltage Error (Low Voltage) DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); 3 - Flashing pattern of failure indicator Check points 1.
  • Page 59 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis • Check the battery voltage. tool 2) Engine Inspection • Turn the key switch off to stop the engine. •...
  • Page 60 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description (2) P0563/0: Power Supply Voltage Error (High Voltage) P0563/0 Power Supply Voltage Error (High Voltage) DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); 3 - Flashing pattern of failure indicator Check points 1.
  • Page 61 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis • Check the battery voltage. tool 2) Engine Inspection • Turn the key switch off to stop the engine. •...

  • Page 62: Pulse Sensor Related Failures

    FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description Pulse Sensor Related Failures Speed Sensor (1) P0340/4: Failure with Speed Sensor P0340/4 Speed Sensor Error DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); 3 - Flashing pattern of failure indicator Check points 1.
  • Page 63 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis • Check the engine speed. tool *For details of the method and the procedure of diagnosis, see P.1-164 2) Check of •...
  • Page 64 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description Spare speed sensor (option) (1) P1340/4: Failure with Spare Speed Sensor P1340/4 Failure with Spare Speed Sensor DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); 3 - Flashing pattern of failure indicator Check points 1.
  • Page 65 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis • Check the rotational speed of the spare speed sensor. tool *For details of the method and the procedure of diagnosis, see P.1-167 2) Check of •...
  • Page 66 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description Engine rotational speed (1) P0219/0: Over speed error P0219/0 Overspeed Error DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); 3 - Flashing pattern of failure indicator Check points 1. Engine running. Harness 2.
  • Page 67 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis tool 2) Engine Inspection • Turn the key switch off to stop the engine. • Inspect the engine and the operating machine. •...

  • Page 68: Contact Output Related Failures

    FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description Contact Output Related Failures Rack actuator Relay (1) P1222/4: Failure A with Rack Actuator Relay P1222/4 Failure A with Rack Actuator Relay DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); 3 - Flashing pattern of failure indicator Check points 1.
  • Page 69 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis • Check the output signal of the rack actuator relay. tool • Check the movement of the rack actuator relay by the active control function. *For details of the method and the procedure of diagnosis, see P.1-170 2) Check of •...
  • Page 70 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description (2) P1223/3: Failure B with Rack Actuator Relay P1223/3 Failure B with Rack Actuator Relay DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); 3 - Flashing pattern of failure indicator Check points 1.
  • Page 71 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis • Check the output signal of the rack actuator relay. tool • Check the movement of the rack actuator relay by the active control function. *For details of the method and the procedure of diagnosis, see P.1-170 2) Check of •...
  • Page 72 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description (3) P1224/2: Intermittent Failure with Rack Actuator Relay P1224/2 Intermittent Failure with Rack Actuator Relay DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); 3 - Flashing pattern of failure indicator Check points 1.
  • Page 73 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis • Check the output signal of the rack actuator relay. tool • Check the movement of the rack actuator relay by the active control function. *For details of the method and the procedure of diagnosis, see P.1-170 2) Check of •...
  • Page 74 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description Start Assist Relay (1) P1232/4: Failure A with Start Assist Relay P1232/4 Failure A with Start Assist Relay DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); 3 - Flashing pattern of failure indicator Check points 1.
  • Page 75 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis • Check the output signal of the start assist relay. tool • Check the movement of the start assist relay by the active control function. *For details of the method and the procedure of diagnosis, see P.1-174 2) Check of •...
  • Page 76 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description (2) P1233/3: Failure B with Start Assist Relay P1233/3 Failure B with Start Assist Relay DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); 3 - Flashing pattern of failure indicator Check points 1.
  • Page 77 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis • Check the output signal of the start assist relay. tool • Check the movement of the start assist relay by the active control function. *For details of the method and the procedure of diagnosis, see P.1-174 2) Check of •...
  • Page 78 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description (3) P1234/2: Intermittent Failure with Start Assist Relay P1234/2 Intermittent Failure with Start Assist Relay DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); 3 - Flashing pattern of failure indicator Check points 1.
  • Page 79 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis • Check the output signal of the start assist relay. tool • Check the movement of the start assist relay by the active control function. *For details of the method and the procedure of diagnosis, see P.1-174 2) Check of •...
  • Page 80 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description CSD solenoid valve (1) P1242/4: Failure A with CSD solenoid valve P1242/4 Failure A with CSD Solenoid Valve DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); 3 - Flashing pattern of failure indicator Check points 1.
  • Page 81 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis • Check the output signal of the CSD solenoid valve. tool • Check the movement of the CSD solenoid valve by the active control function. *For details of the method and the procedure of diagnosis, see P.1-178 2) Check of •...
  • Page 82 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description (2) P1243/3: Failure B with CSD solenoid valve P1243/3 Failure B with CSD Solenoid Valve DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); 3 - Flashing pattern of failure indicator Check points 1.
  • Page 83 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis • Check the output signal of the CSD solenoid valve. tool • Check the movement of the CSD solenoid valve by the active control function. *For details of the method and the procedure of diagnosis, see P.1-178 2) Check of •...
  • Page 84 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description (3) P1244/2: Intermittent Failure with CSD solenoid valve P1244/2 Intermittent Failure with CSD solenoid valve DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); 3 - Flashing pattern of failure indicator Check points 1.
  • Page 85 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis • Check the output signal of the CSD solenoid valve. tool • Check the movement of the CSD solenoid valve by the active control function. *For details of the method and the procedure of diagnosis, see P.1-178 2) Check of •...
  • Page 86 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description EGR valve (1) P1402/4: Failure A with EGR valve (Step Motor A-phase) P1402/4 Failure A with EGR valve (Step Motor A-Phase) DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); Check points 3 - Flashing pattern of failure indicator 1.
  • Page 87 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis • Check the output signal of the EGR step motor. tool • Check the movement of the EGR step motor by the active control function. *For details of the method and the procedure of diagnosis, see P.1-182 2) Check of •...
  • Page 88 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description (2) P1403/3: Failure B with EGR valve (Step Motor A-phase) P1403/3 Failure B with EGR valve (Step Motor A-Phase) DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); Check points 3 - Flashing pattern of failure indicator 1.
  • Page 89 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis • Check the output signal of the EGR step motor. tool • Check the movement of the EGR step motor by the active control function. *For details of the method and the procedure of diagnosis, see P.1-182 2) Check of •...
  • Page 90 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description (3) P1412/4: Failure A with EGR valve (Step Motor B-phase) P1412/4 Failure A with EGR valve (Step Motor B-Phase) DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); Check points 3 - Flashing pattern of failure indicator 1.
  • Page 91 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis • Check the output signal of the EGR step motor. tool • Check the movement of the EGR step motor by the active control function. *For details of the method and the procedure of diagnosis, see P.1-182 2) Check of •...
  • Page 92 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description (4) P1413/3: Failure B with EGR valve (Step Motor B-phase) P1413/3 Failure B with EGR valve (Step Motor B-Phase) DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); Check points 3 - Flashing pattern of failure indicator 1.
  • Page 93 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis • Check the output signal of the EGR step motor. tool • Check the movement of the EGR step motor by the active control function. *For details of the method and the procedure of diagnosis, see P.1-182 2) Check of •...
  • Page 94 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description (5) P1422/4: Failure A with EGR valve (Step Motor C-phase) P1422/4 Failure A with EGR valve (Step Motor C-Phase) DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); Check points 3 - Flashing pattern of failure indicator 1.
  • Page 95 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis • Check the output signal of the EGR step motor. tool • Check the movement of the EGR step motor by the active control function. *For details of the method and the procedure of diagnosis, see P.1-182 2) Check of •...
  • Page 96 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description (6) P1423/3: Failure B with EGR valve (Step Motor C-phase) P1423/3 Failure B with EGR valve (Step Motor C-Phase) DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); Check points 3 - Flashing pattern of failure indicator 1.
  • Page 97 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis • Check the output signal of the EGR step motor. tool • Check the movement of the EGR step motor by the active control function. *For details of the method and the procedure of diagnosis, see P.1-182 2) Check of •...
  • Page 98 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description (7) P1432/4: Failure A with EGR valve (Step Motor D-phase) P1432/4 Failure A with EGR valve (Step Motor D-Phase) DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); Check points 3 - Flashing pattern of failure indicator 1.
  • Page 99 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis • Check the output signal of the EGR step motor. tool • Check the movement of the EGR step motor by the active control function. *For details of the method and the procedure of diagnosis, see P.1-182 2) Check of •...
  • Page 100 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description (8) P1433/3: Failure B with EGR valve (Step Motor D-phase) P1433/3 Failure B with EGR valve (Step Motor D-Phase) DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); Check points 3 - Flashing pattern of failure indicator 1.
  • Page 101 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis • Check the output signal of the EGR step motor. tool • Check the movement of the EGR step motor by the active control function. *For details of the method and the procedure of diagnosis, see P.1-182 2) Check of •...

  • Page 102: Contact Input Related Failures

    FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description Contact Input Related Failures Oil Pressure Related Failures (1) P1192/4: Failure with Oil Pressure Switch P1192/4 Failure with oil pressure switch DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); 3 - Flashing pattern of failure indicator Check points 1.
  • Page 103 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis • Check that the input signal of the oil pressure switch is correctly recognized. tool *For details of the method and the procedure of diagnosis, see P.1-187 2) Check of •...
  • Page 104 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description (2) P1198/1: Abnormal Oil Pressure Descend P1198/1 Abnormal Oil Pressure Descend DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); 3 - Flashing pattern of failure indicator Check points 1. Key switch ON. Hydrostatic system 2.
  • Page 105 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis • Check that the input signal of the oil pressure switch is correctly recognized. tool *For details of the method and the procedure of diagnosis, see P.1-187 2) Engine Inspection •...
  • Page 106 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description Battery Charge Related Failures (1) P1562/4: Failure with Charge Switch P1562/4 Failure with Charge Switch DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); 3 - Flashing pattern of failure indicator Check points 1.
  • Page 107 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis • Check that the input signal of the charge switch is correctly recognized. tool *For details of the method and the procedure of diagnosis, see P.1-187 2) Check of •...
  • Page 108 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description (2) P1568/1: Charge Alarm P1568/1 Charge Alarm DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); 3 - Flashing pattern of failure indicator Check points 1. Key switch ON. alternator 2. Charge switch turns ON after engine has been started. Harness * This manual assumes that the contact input is configured as Normally Open Charge switch...
  • Page 109 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis • Check that the input signal of the charge switch is correctly recognized. tool *For details of the method and the procedure of diagnosis, see P.1-187 2) Engine Inspection •...
  • Page 110 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description Water Temperature Switch (1) P1217/0: Abnormal Water Temperature P1217/0 Abnormal Water Temperature DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); Check points 3 - Flashing pattern of failure indicator 1. Key switch ON. Engine cooling system 2.
  • Page 111 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis • Check that the input signal of the water temperature switch is correctly tool recognized. *For details of the method and the procedure of diagnosis, see P.1-187 2) Engine Inspection •...
  • Page 112 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description Air cleaner switch (1) P1101/0: Air Cleaner Clogging Alarm P1101/0 Air cleaner Clogging Alarm DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); 3 - Flashing pattern of failure indicator Check points 1.
  • Page 113 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis • Check that the input signal of the air cleaner switch is correctly recognized. tool *For details of the method and the procedure of diagnosis, see P.1-187 2) Engine Inspection •...
  • Page 114 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description Oil-Water Separator Switch (1) P1151/0: Oil-Water Separator Alarm P1151/0 Oil-water separator Alarm DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); Check points 3 - Flashing pattern of failure indicator 1. Key switch ON. Oil-Water Separator 2.
  • Page 115 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis • Check that the input signal of the oil-water separator switch is correctly tool recognized. *For details of the method and the procedure of diagnosis, see P.1-187 2) Engine Inspection •...

  • Page 116: Actuators Etc

    FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description Actuators etc. Rack actuator (1) P1212/4: Failure with Rack Actuator (Low Current) P1212/4 Failure with Rack Actuator (Low Current) DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); 3 - Flashing pattern of failure indicator Check points 1.
  • Page 117 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis • Check the movement of the rack actuator by the active control function. tool *For details of the method and the procedure of diagnosis, see P.1-193 2) Check of •...
  • Page 118 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description (2) P1212/3: Failure with Rack Actuator (High Current) P1213/3 Failure with Rack Actuator (High Current) DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); 3 - Flashing pattern of failure indicator Check points 1.
  • Page 119 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis • Check the movement of the rack actuator by the active control function. tool *For details of the method and the procedure of diagnosis, see P.1-193 2) Check of •...
  • Page 120 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description (3) P1211/7: Rack Actuator Mechanical Failure P1211/7 Rack Actuator Mechanical Failure DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); 3 - Flashing pattern of failure indicator Check points 1. Key switch ON. Rack 2.
  • Page 121 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis • Check the movement of the rack actuator by the active control function. tool *For details of the method and the procedure of diagnosis, see P.1-193 2) Check of •...
  • Page 122 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description Engine (1) P1214/2: Engine Trouble P1214/2 Engine Trouble DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); 3 - Flashing pattern of failure indicator Check points 1. Key switch ON. Harness 2.
  • Page 123 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis tool 2) Engine Inspection • Turn the key switch off to stop the engine. • Inspect the engine and the operating machine. •...

  • Page 124: E-Ecu Internal And Communication Errors

    FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description E-ECU Internal and Communication Errors E-ECU Internal Errors (1) P0601/12, P1610/12, P1611/12, P1612/12: ECU internal errors (1) P0601/12 EEPROM error (read/write error) P1610/12 Failure A with Sub-CPU P1611/12 Failure B with Sub-CPU P1612/12 Failure C with Sub-CPU DTC Detecting Conditions...
  • Page 125 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS (2) P1601/2, P0605/12, P1605/2, P1606/2, P1620/12: ECU internal errors (2) P1601/2 EEPROM error (Checksum) P0605/12 FlashROM error (Checksum A) P1605/2 FlashROM error (Checksum B) P1606/2 FlashROM error (Checksum C) P1620/12 Map format error DTC Detecting Conditions 1 - Precondition;...
  • Page 126 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description (3) P0686/4: Main relay error P0686/4 Main relay error DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); 3 - Flashing pattern of failure indicator Check points 1. Key switch OFF. Connector 2.
  • Page 127 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis • Check if a log-in to the diagnosis tool with the key switch OFF is available. tool *For details of the method and the procedure of diagnosis, see P.1-199 2) Check of •...
  • Page 128 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description CAN Communication (1) U0001/12: CAN Communication Error U0001/12 CAN Communication Error DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); 3 - Flashing pattern of failure indicator Check points 1. (1) Before and (2) after ECU start-up Other ECUs 2.
  • Page 129 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis • Check the battery voltage. tool *For details of the method and the procedure of diagnosis, see P.1-203 2) Check of •...
  • Page 130 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description Immobilizer (1) U0167/12: Immobilizer Error (CAN communication) U0167/12 Immobilizer Error (CAN communication) DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); 3 - Flashing pattern of failure indicator Check points 1. Key switch ON. Immobilizer 2.
  • Page 131 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis • Check the battery voltage. tool *For details of the method and the procedure of diagnosis, see P.1-205 2) Check of •...
  • Page 132 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description (2) U1167/8: Immobilizer Error (pulse communication) U1167/8 Immobilizer Error (pulse communication) DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); 3 - Flashing pattern of failure indicator Check points 1. Key switch ON. Immobilizer 2.
  • Page 133 DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS Diagnosis Description 1) Initial diagnosis • Check the fault indication. with the diagnosis tool *For details of the method and the procedure of diagnosis, see P.1-205 2) Check of • Before beginning your work, be sure to turn off the key switch. connectors/wiring •...
  • Page 134 FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description (3) U0426/2: Immobilizer Error (system) U0426/2 Immobilizer Error (system) DTC Detecting Conditions 1 - Precondition; 2 - Detecting condition(s); 3 - Flashing pattern of failure indicator Check points 1. Key switch ON. Immobilizer 2.

  • Page 135: Method And Procedure Of Failure Diagnosis

    Method and Procedure of Failure Diagnosis FAILURE DIAGNOSIS METHOD AND PROCEDURE OF FAILURE DIAGNOSIS Description Items Related DTC Related DTC(s) is listed. Code Number Error Name Work flow Work flow for the failure diagnosis is listed, Wiring Diagram Shows a wiring diagram that encompasses the components/parts associated with the failure. Work Description Describes how to diagnose and correct the failure.
  • Page 136 FAILURE DIAGNOSIS Method and Procedure of Failure Diagnosis E-ECU Pin Layout Diagram Harness side coupler (coupling face) ECU side coupler (coupling face) E40 E39 E38 E37 E36 E35 E34 E33 E32 E31 E31 E32 E33 E34 E35 E36 E37 E38 E39 E40 E30 E29 E28 E27 E26 E25 E24 E23 E22 E21 E21 E22 E23 E24 E25 E26 E27 E28 E29 E30 E20 E19 E18 E17 E16 E15 E14 E13 E12 E11...
  • Page 137 Method and Procedure of Failure Diagnosis FAILURE DIAGNOSIS How to use the 2G eco-checker harness Failure diagnosis for area listed in the following correspondence list includes the work measuring voltage with the 2G eco-checker harness.Therefore before the failure diagnosis, remove the E-ECU and machine’s harness, and connect the 2G eco-checker harness between the E-ECU and machine’s harness.
  • Page 138 FAILURE DIAGNOSIS Method and Procedure of Failure Diagnosis Analog Input Related Failures Rack position sensor Related DTC P1202/4 Rack Position Sensor Error (Low Voltage) P1203/3 Rack Position Sensor Error (High Voltage) Work flow *For details of the work, see after-mentioned "<Diagnosis Description>."For the operation of the diagnosis tool, see “Diagnosis tool Operation Manual”...
  • Page 139 Method and Procedure of Failure Diagnosis FAILURE DIAGNOSIS Wiring Diagram : Check points Battery ＋ − Main relay Fuse Rack Actuator E-ECU MAIN-RLY Rack position sensor GND-A Actuator side coupler (coupling face) Harness side coupler (coupling face) B17 E42 E36 E43 E28 017535-00E *For the E-ECU Pin Layout, see [E-ECU Pin Layout Diagram] (P.1-134).
  • Page 140 FAILURE DIAGNOSIS Method and Procedure of Failure Diagnosis Diagnosis Description 1. Check of the input voltage of the rack position sensor (harness + E-ECU) • Turn the key switch off, and remove the rack actuator connector from the fuel injection pump. At this time, keep the E-ECU connector being connected to E-ECU.
  • Page 141 Method and Procedure of Failure Diagnosis FAILURE DIAGNOSIS 3. Execution check of the directive rack position control: • Connect the all connectors (sensors, E-ECU). • Connect the diagnosis tool, and log in to the diagnosis tool after key switch turning-on. •...
  • Page 142 FAILURE DIAGNOSIS Method and Procedure of Failure Diagnosis Accelerator sensor Related DTC P0122/4 Accelerator Sensor Error (Low Voltage) P0123/3 Accelerator Sensor Error (High Voltage) P0124/2 Intermittent Failure with Accelerator Sensor Work flow *For details of the work, see after-mentioned "<Work Description>."For the operation of the diagnosis tool, see “Diagnosis tool Operation Manual”...
  • Page 143 Method and Procedure of Failure Diagnosis FAILURE DIAGNOSIS Wiring Diagram : Check points Accelerator sensor (standard) E-ECU SNS5 Sensor side coupler (coupling face) AVCC GND-A Harness side coupler (coupling face) Spare accelerator sensor (option) E28 E35 E38 SNS5 REAN 017537-00E *For the E-ECU Pin Layout, see [E-ECU Pin Layout Diagram] (P.1-134) .
  • Page 144 • using a circuit tester. *See above-mentioned “(REF) Total resistance value of Yanmar standard accelerator sensors”. Check the harness for correct continuity. → [3. Check of harness continuity:] Check the resistance value between the harness E35 and E28. → Go to [• Between harness E38 and E28] •...
  • Page 145 Method and Procedure of Failure Diagnosis FAILURE DIAGNOSIS 3. Check of harness continuity: • Remove the accelerator sensor and E-ECU from the harness. • Check the harness continuity using a circuit tester. Terminal Continuity Status Available OK: normal Sensor signal wire E35 [Between E-ECU and sensor connector] Unavailable NG: harness disconnection...
  • Page 146 FAILURE DIAGNOSIS Method and Procedure of Failure Diagnosis Foot pedal Related DTC P1125/1 Accelerator Sensor Error (foot pedal-close position) P1126/0 Accelerator Sensor Error (foot pedal-open position) P1225/1 Spare Accelerator Sensor Error (foot pedal-close position) P1226/0 Spare Accelerator Sensor Error (foot pedal-open position) Work flow *For details of the work, see after-mentioned "<Work Description>."For the operation of the diagnosis tool, see “Diagnosis tool Operation Manual”...
  • Page 147 Method and Procedure of Failure Diagnosis FAILURE DIAGNOSIS Wiring Diagram : Check points Accelerator sensor (standard) E-ECU SNS5 AVCC GND-A Spare accelerator sensor (option) SNS5 REAN Foot pedal APP-IP2 APP-IP7 019478-00E *For the E-ECU Pin Layout, see [E-ECU Pin Layout Diagram] (P.1-134). TNV DI Service Manual 1-145...
  • Page 148 FAILURE DIAGNOSIS Method and Procedure of Failure Diagnosis Work Description 1. Continuity check (foot pedal only): • Remove the foot pedal from the harness. • Check the foot pedal continuity with a specified pedal opening using a circuit tester. Continuity Pedal opening Status Between A and GND Between B and GND...
  • Page 149 Method and Procedure of Failure Diagnosis FAILURE DIAGNOSIS 3. Check of harness continuity: • Remove the foot pedal and E-ECU from the harness. • Check the harness continuity using a circuit tester. Terminal Continuity Status Available OK: normal Pedal signal wire (A) E14 [Between E-ECU and pedal connector] Unavailable NG: harness disconnection...
  • Page 150 FAILURE DIAGNOSIS Method and Procedure of Failure Diagnosis Spare Analog (Spare accelerator sensor, Atmospheric pressure sensor) Related DTC P0222/4 Failure with Spare Accelerator Sensor (Low Voltage) P0223/3 Spare Accelerator Sensor Error (High Voltage) P0224/2 Intermittent Failure with Spare Accelerator Sensor P2228/4 Failure with Atmospheric Pressure Sensor (Low Voltage) P2229/3...
  • Page 151 Method and Procedure of Failure Diagnosis FAILURE DIAGNOSIS Failure diagnosis flow 1. Check of sensor resistance value Sensor replacement (sensor only) 2. Check of sensor resistance value Harness 3. Harness continuity check (sensor + harness) replacement 4. Check of Replacement of E-ECU sensor output voltage (when fit to sensor) sensor...
  • Page 152 Remove the harness from the spare accelerator sensor or the atmospheric pressure sensor. • Measure the resistance between sensor terminals A and C (total resistance value) using a circuit tester. • (REF) Total resistance value of Yanmar standard spare accelerator sensor or atmospheric pressure sensor Terminal Specification Sensors A - C 5 ±...
  • Page 153 Method and Procedure of Failure Diagnosis FAILURE DIAGNOSIS 3. Check of harness continuity: Remove the accelerator sensor and E-ECU from the harness. • Check the harness continuity using a circuit tester. • Terminal Continuity Status Sensor signal wire E37 Available OK: normal [Between E-ECU and sensor connector] Unavailable...
  • Page 154 FAILURE DIAGNOSIS Method and Procedure of Failure Diagnosis Pulse accelerator Related DTC P1127/8 Failure with Spare Accelerator Sensor (Pulse Communication) Work flow *For details of the work, see after-mentioned "<Work Description>."For the operation of the diagnosis tool, see “Diagnosis tool Operation Manual” separately. Initial diagnosis with the diagnosis tool Check the failure DTC in the failure history indication...
  • Page 155 Method and Procedure of Failure Diagnosis FAILURE DIAGNOSIS Wiring Diagram : Check points E-ECU CAN Communication CANH CANL APP-IP3 Pulse accelerator signal 019483-00J *For the E-ECU Pin Layout, see [E-ECU Pin Layout Diagram] (P.1-134). Work Description 1. Harness continuity check: •...
  • Page 156 FAILURE DIAGNOSIS Method and Procedure of Failure Diagnosis ECU Temperature Sensor Related DTC P0668/4 Failure with ECU Temperature Sensor (Low Voltage) P0669/3 Failure with ECU Temperature Sensor (High Voltage) P1644/2 Intermittent Failure WITH ECU Temperature Sensor Work flow *For details of the work, see after-mentioned "<Work Description>."For the operation of the diagnosis tool, see “Diagnosis tool Operation Manual”...
  • Page 157 Method and Procedure of Failure Diagnosis FAILURE DIAGNOSIS Work Description 1. Work with the diagnosis tool: • Check of current failure indication Turn the key switch off, and turn the key switch on again. • Connect the diagnosis tool, and check if any error is detected on the current fault indication. •...
  • Page 158 FAILURE DIAGNOSIS Method and Procedure of Failure Diagnosis Cooling water temperature sensor Related DTC P0117/4 Failure with Cooling Water Temperature Sensor (Low Voltage) P0118/3 Failure with Cooling Water Temperature Sensor (High Voltage) P0119/2 Intermittent Failure with Cooling Water Temperature Sensor Work flow *For details of the work, see after-mentioned "<Work Description>."For the operation of the diagnosis tool, see “Diagnosis tool Operation Manual”...
  • Page 159 Method and Procedure of Failure Diagnosis FAILURE DIAGNOSIS View of the sensor *High-precision cooling water temperature sensor and conventional cooling water temperature sensor share similar construction. * High-precision cooling water temperature sensor and conventional cooling water temperature sensor have similar construction. M12 x 1.5 007217-00E Wiring Diagram...
  • Page 160 FAILURE DIAGNOSIS Method and Procedure of Failure Diagnosis Work Description 1. Check of the sensor resistance value (sensor only): • Remove the harness from the cooling water temperature sensor. • Measure the resistance between cooling water temperature sensor terminals A and B using a circuit tester.
  • Page 161 Method and Procedure of Failure Diagnosis FAILURE DIAGNOSIS 3. Check of harness continuity: • Remove the cooling water temperature sensor and E-ECU from the harness. • Check the harness continuity using a circuit tester. Terminal Continuity Status Sensor signal wire E16 (E25) Available OK: normal [E-ECU ñ...
  • Page 162 FAILURE DIAGNOSIS Method and Procedure of Failure Diagnosis SENSOR 5V Related DTC P0642/4 Failure with SENSOR 5V (Low Voltage) P0643/3 Failure with SENSOR 5V (High Voltage) P1644/2 Intermittent Failure with SENSOR 5V Work flow *For details of the work, see after-mentioned "<Work Description>."For the operation of the diagnosis tool, see “Diagnosis tool Operation Manual”...
  • Page 163 Method and Procedure of Failure Diagnosis FAILURE DIAGNOSIS Work Description 1. Check of the accelerator sensor: • For details, see[Accelerator sensor] (P.1-12). 2. Check of the output voltage (not fit with sensor): • Remove the harness from the accelerator sensor.At this time, keep the E-ECU connector being connected to E-ECU.
  • Page 164 FAILURE DIAGNOSIS Method and Procedure of Failure Diagnosis 4. Check of the output voltage (fit with sensor): • Connect the 2G eco-checker harness between E-ECU and machine’s harness (for details, see [How to use the 2G eco-checker harness] (P.1-135). And connect the all connectors (sensors, E-ECU). •...
  • Page 165 Method and Procedure of Failure Diagnosis FAILURE DIAGNOSIS TNV DI Service Manual 1-163...
  • Page 166 FAILURE DIAGNOSIS Method and Procedure of Failure Diagnosis Pulse Sensor Related Failures Speed Sensor Related DTC P0340/4 Speed Sensor Error Work flow *For details of the work, see after-mentioned "<Work Description>."For the operation of the diagnosis tool, see “Diagnosis tool Operation Manual” separately. Initial diagnosis with the diagnosis tool Check the failure DTC in the failure history indication...
  • Page 167 Method and Procedure of Failure Diagnosis FAILURE DIAGNOSIS Wiring Diagram : Check points Battery ＋ − Starter Fuse Sensor side coupler (coupling face) Key switch E-ECU “ON” or “START” Fuse STARTSW Speed Sensor CRK+ NRPM CRK- NRPM-GND Harness side coupler Spare speed sensor (option) (coupling face) (Alternator)
  • Page 168 • Measure the resistance between harness side E-ECU connector terminals E19 and E18 using a circuit tester. *See above-mentioned “(REF) Coil resistance of Yanmar standard speed sensors”. Replace the harness. Check the harness for correct continuity. → Go to [3. Check of harness continuity:] 3.
  • Page 169 Method and Procedure of Failure Diagnosis FAILURE DIAGNOSIS Spare speed sensor Related DTC P1340/4 Failure with Spare Speed Sensor Work flow *For details of the work, see after-mentioned "<Work Description>."For the operation of the diagnosis tool, see “Diagnosis tool Operation Manual” separately. Initial diagnosis with the diagnosis tool Check the failure DTC in the failure history indication...
  • Page 170 FAILURE DIAGNOSIS Method and Procedure of Failure Diagnosis Wiring Diagram : Check points Battery ＋ − Starter Fuse Key switch E-ECU “ON” or “START” Fuse STARTSW Speed Sensor CRK+ NRPM CRK- NRPM-GND Harness side coupler Spare speed sensor (option) (coupling face) (Alternator) P01 B18 E10 RENRPM...
  • Page 171 Method and Procedure of Failure Diagnosis FAILURE DIAGNOSIS Work Description 1. Battery voltage check: • Set the accelerator at the lowest position, and operate the engine. • Measure the battery voltage using a circuit tester. Terminal Specification Battery voltage (in the normal condition) 10 to 16 [V] •...
  • Page 172 FAILURE DIAGNOSIS Method and Procedure of Failure Diagnosis Contact Output Related Failures RACK ACTUATOR RELAY Related DTC P1222/4 Failure A with Rack Actuator Relay P1223/3 Failure B with Rack Actuator Relay P1224/2 Intermittent Failure with Rack Actuator Relay Work flow *For details of the work, see after-mentioned "<Work Description>."For the operation of the diagnosis tool, see “Diagnosis tool Operation Manual”...
  • Page 173 Method and Procedure of Failure Diagnosis FAILURE DIAGNOSIS Wiring Diagram : Check points Relay side coupler (coupling face) ＋ − Battery Rack Actuator Relay Main relay Fuse Fuse Key switch “ON” Fuse Harness side coupler E-ECU (coupling face) MAIN-RLY E07 E48 B17 IGNSW RACK-RLY Rack Actuator...
  • Page 174 FAILURE DIAGNOSIS Method and Procedure of Failure Diagnosis Work Description 1. Check of the relay coil resistance value (relay only): • Remove the rack actuator relay from the harness. • Measure the resistance between relay side terminals C and D using a circuit tester. Measurement conditions Measured value Status...
  • Page 175 Method and Procedure of Failure Diagnosis FAILURE DIAGNOSIS 3. Check of harness continuity: • Remove the rack actuator relay from the harness, and remove E-ECU from the harness. • Check the harness continuity using a circuit tester. Terminal Continuity Status Relay coil (downstream side) E33 Available OK: normal...
  • Page 176 FAILURE DIAGNOSIS Method and Procedure of Failure Diagnosis START ASSIST RELAY Related DTC P1232/4 Failure A with Start Assist Relay P1233/3 Failure B with Start Assist Relay P1234/2 Intermittent Failure with Start Assist Relay Work flow *For details of the work, see after-mentioned "<Work Description>."For the operation of the diagnosis tool, see “Diagnosis tool Operation Manual”...
  • Page 177 Method and Procedure of Failure Diagnosis FAILURE DIAGNOSIS Wiring Diagram : Check points Battery ＋ − Air heater relay Starter Fuse Fuse E-ECU AIRHT-RLY Air heater Air heater 017548-00E Harness side coupler (coupling face) 017549-00E *For the E-ECU Pin Layout, see [E-ECU Pin Layout Diagram] (P.1-134). TNV DI Service Manual 1-175...
  • Page 178 1. Check of the relay coil resistance value (relay only): • Remove the start assist relay from the harness. • Measure the resistance between relay side terminals C and D using a circuit tester. (REF) The resistance value of Yanmar standard start assist relay Terminal Specification Relay coil side C - D (40A relay) 103Ω...
  • Page 179 Method and Procedure of Failure Diagnosis FAILURE DIAGNOSIS Movement check of the relay: • Connect the 2G eco-checker harness between E-ECU and machine’s harness (for details, see [How to use the 2G eco-checker harness] (P.1-135). And connect the all connectors (start assistant relay, E- ECU).
  • Page 180 FAILURE DIAGNOSIS Method and Procedure of Failure Diagnosis CSD Solenoid Valve Coil Related DTC P1242/4 Failure A with CSD Solenoid Valve P1243/3 Failure B with CSD Solenoid Valve P1244/2 Intermittent Failure with CSD solenoid valve Work flow *For details of the work, see after-mentioned "<Work Description>."For the operation of the diagnosis tool, see “Diagnosis tool Operation Manual”...
  • Page 181 Method and Procedure of Failure Diagnosis FAILURE DIAGNOSIS Wiring Diagram : Check points Fuel injection pump E-ECU CSD solenoid valve CSD-CL Harness side coupler (coupling face) 017551-00E *For the E-ECU Pin Layout, see [E-ECU Pin Layout Diagram] (P.1-134). TNV DI Service Manual 1-179...
  • Page 182 • Remove E-ECU from the harness. • Measure the resistance between E-ECU connectors E41 and B00 using a circuit tester. *See above-mentioned “(REF) Coil resistance of Yanmar standard CSD solenoid valve”. Check the harness for correct continuity. → Go to [3. Check of harness continuity:] Check the movement of the CSD solenoid valve by a diagnosis tool.
  • Page 183 Method and Procedure of Failure Diagnosis FAILURE DIAGNOSIS Movement check of the CSD solenoid valve: • Connect the 2G eco-checker harness between E-ECU and machine’s harness (for details, see [How to use the 2G eco-checker harness] (P.1-135). And connect the all connectors (CSD solenoid valve connector, E-ECU).
  • Page 184 FAILURE DIAGNOSIS Method and Procedure of Failure Diagnosis EGR valve Related DTC P1402/4 Failure A with EGR valve (Step Motor A-Phase) P1403/3 Failure B with EGR valve (Step Motor A-Phase) P1412/4 Failure A with EGR valve (Step Motor B-Phase) P1413/3 Failure B with EGR valve (Step Motor B-Phase) P1422/4 Failure A with EGR valve (Step Motor C-Phase)
  • Page 185 Method and Procedure of Failure Diagnosis FAILURE DIAGNOSIS Failure diagnosis flow 1. Resistance check of Replace the EGR step motor coil sensor. (EGR Valve only) 2. Resistance check Replace the 3. Check the harness of EGR step motor coil harness. continuity.
  • Page 186 FAILURE DIAGNOSIS Method and Procedure of Failure Diagnosis Wiring Diagram : Check points ＋ − Battery EGR side coupler Main relay (coupling face) Fuse EGR valve E-ECU MAIN-RLY Harness side coupler (coupling face) E01 E48 E21 E11 E48 E31 STPM-D STPM-C STPM-B STPM-A...
  • Page 187 • Install the EGR valve to the harness. • Remove E-ECU from the harness. • Measure the coil resistance at the E-ECU connector using a circuit tester. *See above-mentioned “(REF) Resistance of Yanmar standard EGR step motor coil”. Step motor ECU connector terminal number...
  • Page 188 FAILURE DIAGNOSIS Method and Procedure of Failure Diagnosis 3. Check of harness continuity: • Remove the EGR valve from the harness, and remove E-ECU from the harness. • Check the harness continuity using a circuit tester. Terminal Continuity Status Motor coil (downstream side) Available OK: normal E31(E21/E11/E01)
  • Page 189 Method and Procedure of Failure Diagnosis FAILURE DIAGNOSIS Contact Input Related Failures Related DTC P1192/4 Failure with oil pressure switch P1198/1 Abnormal Oil Pressure Descend P1562/4 Failure with Charge Switch P1568/1 Charge Alarm P1217/0 Abnormal Water Temperature P1101/0 Air cleaner Clogging Alarm P1151/0 Oil-water separator Alarm Work flow...
  • Page 190 FAILURE DIAGNOSIS Method and Procedure of Failure Diagnosis Failure diagnosis flow 1. Continuity check Replacement of each (contact input switch only) contact input switch 2. Continuity check 3. Continuity check Harness (contact input switch + harness) (harness) replacement Harness replacement or 4.
  • Page 191 Method and Procedure of Failure Diagnosis FAILURE DIAGNOSIS Wiring Diagram : Check points ＋ − Battery Sub-relay Key switch E-ECU IGNSW lamp lamp lamp lamp lamp 120Ω APP-IP6 APP-IP5 APP-IP4 APP-IP3 APP-IP2 Charge Oil pressure Oil-Water Water switch switch Separator cleaner Temperature Switch...
  • Page 192 FAILURE DIAGNOSIS Method and Procedure of Failure Diagnosis Work Description 1. Continuity check (contact input switch only): • Remove the harness from each contact input switch. • Referring to the following table, check the continuity between contact input terminal and body frame using a circuit tester.
  • Page 193 Method and Procedure of Failure Diagnosis FAILURE DIAGNOSIS 3. Check of harness continuity: • Remove the contact input switch and E-ECU from the harness. • Check the harness continuity using a circuit tester. Terminal Continuity Status Switch signal wire E14 (*) Available OK: normal [Between E-ECU and switch connector]...
  • Page 194 FAILURE DIAGNOSIS Method and Procedure of Failure Diagnosis 4. Movement check of the contact input switch: • Connect the all connectors (contact input switch, E-ECU). • Connect the diagnosis tool, and log in to the diagnosis tool after key switch turning-on. •...

  • Page 195: Actuator Related Failures

    Method and Procedure of Failure Diagnosis FAILURE DIAGNOSIS Actuator Related Failures Rack actuator Related DTC P1212/4 Failure with Rack Actuator (Low Voltage) P1213/3 Failure with Rack Actuator (High Voltage) P1211/7 Rack Actuator Mechanical Failure Work flow *For details of the work, see after-mentioned "<Work Description>."For the operation of the diagnosis tool, see “Diagnosis tool Operation Manual”...
  • Page 196 FAILURE DIAGNOSIS Method and Procedure of Failure Diagnosis Wiring Diagram : Check points Battery ＋ − Rack Actuator Relay Main relay Fuse Fuse Key switch “ON” Fuse Actuator side coupler E-ECU (coupling face) MAIN-RLY Harness side coupler (coupling face) IGNSW B17 E42 E36 E43 E28 Rack Actuator...
  • Page 197 • Measure the resistance between harness side E-ECU connector terminal E42 and rack actuator relay contact downstream side E18 using a circuit tester. *See above-mentioned “(REF) Coil resistance of Yanmar standard speed sensors”. Check the harness for correct continuity. → Go to [3. Check of harness continuity:] Check the movement of the actuator by the diagnosis tool.
  • Page 198 FAILURE DIAGNOSIS Method and Procedure of Failure Diagnosis Movement check of the rack actuator: • Connect the all connectors (rack actuator, E-ECU). • Connect the diagnosis tool, and log in to the diagnosis tool after key switch turning-on. • Execute the directive rack position control with the diagnosis tool “Diagnosis Test: Active control”.At this time, set the rack position arbitrarily within the settings.

  • Page 199: Ecu Internal And Communication Errors

    Method and Procedure of Failure Diagnosis FAILURE DIAGNOSIS ECU Internal and Communication Errors ECU Internal Errors Related DTC P0601/12 EEPROM error (read/write error) P1601/2 EEPROM error (Checksum) P0605/12 Flash ROM error (Checksum A) P1605/2 Flash ROM error (Checksum B) P1606/2 Flash ROM error (Checksum C) P1610/12 Failure A with Sub-CPU...
  • Page 200 FAILURE DIAGNOSIS Method and Procedure of Failure Diagnosis Work Description 1. Work with the diagnosis tool: • Turn the key switch off, and turn the key switch on again. • Connect the diagnosis tool, and check if any error is detected on the current fault indication. Check the error history indication, confirm error occurrence situation if any error Unavailable history is indicated.
  • Page 201 Method and Procedure of Failure Diagnosis FAILURE DIAGNOSIS Main relay Related DTC P0686/4 Main relay error Work flow *For details of the work, see after-mentioned "<Work Description>."For the operation of the diagnosis tool, see “Diagnosis tool Operation Manual” separately. Initial diagnosis with the diagnosis tool Check the failure DTC in the failure history indication A.
  • Page 202 FAILURE DIAGNOSIS Method and Procedure of Failure Diagnosis Wiring Diagram : Check points Relay side coupler (coupling face) ＋ − Battery Self-hold relay Fuse Fuse E-ECU Harness side coupler (coupling face) Key switch “ON” B10 B10 E48 MAIN-RLY Fuse IGNSW 017559-00E *For the E-ECU Pin Layout, see [E-ECU Pin Layout Diagram] (P.1-134).
  • Page 203 Method and Procedure of Failure Diagnosis FAILURE DIAGNOSIS Work Description 1. Check of the relay coil resistance value (relay only): • Remove the E-ECU main relay from the harness. • Check the continuity between relay side terminals A and B using a circuit tester. Replace the E-ECU main relay.
  • Page 204 FAILURE DIAGNOSIS Method and Procedure of Failure Diagnosis 4. Check of harness continuity: • Remove the E-ECU main relay from the harness and remove the E-ECU from the harness. • Check the harness continuity using a circuit tester. Terminal Continuity Status Between relay coil (downstream side) Unavailable...
  • Page 205 Method and Procedure of Failure Diagnosis FAILURE DIAGNOSIS CAN Communication Related DTC U0001/12 CAN Communication Error Work flow *For details of the work, see after-mentioned "<Work Description>."For the operation of the diagnosis tool, see “Diagnosis tool Operation Manual” separately. Initial diagnosis with the diagnosis tool Check the failure DTC in the failure history indication A.
  • Page 206 FAILURE DIAGNOSIS Method and Procedure of Failure Diagnosis Work Description 1. Battery voltage check: • During the engine running, connect the diagnosis tool and log in to the diagnosis tool. • Check the battery voltage with the diagnosis tool “Diagnosis Test: Pulse/analog etc.”. Voltage Status Action...
  • Page 207 Method and Procedure of Failure Diagnosis FAILURE DIAGNOSIS Immobilizer Related DTC U1167/8 Immobilizer Error (pulse communication) Work flow *For details of the work, see after-mentioned "<Work Description>."For the operation of the diagnosis tool, see “Diagnosis tool Operation Manual” separately. Initial diagnosis with the diagnosis tool Check the failure DTC in the failure history indication A.
  • Page 208 FAILURE DIAGNOSIS Method and Procedure of Failure Diagnosis Wiring Diagram : Check points Immobilizer CAN Communication CANH CANL APP-IP4 Pulse communication 019615-00E * For the E-ECU Pin Layout, see [E-ECU Pin Layout Diagram] (P.1-134). Work Description 1. Harness continuity check: •...

  • Page 209: Failure Indicator Lamp Flashing Pattern

    Method and Procedure of Failure Diagnosis FAILURE DIAGNOSIS FAILURE INDICATOR LAMP FLASHING PATTERN This section provides examples that demonstrate how the failure indicator flashes in a pattern specific to the DTC that occurs. If an accelerator sensor failure is detected at power-on time, the failure indicator flashes in a pattern of 5 (five equal flashes) as shown in the fist example;...

  • Page 210: Using The Failure Indicator For Failure Diagnosis

    FAILURE DIAGNOSIS Using the Failure Indicator for Failure Diagnosis USING THE FAILURE INDICATOR FOR FAILURE DIAGNOSIS Flashing Patterns of the Failure Indicator Flashing Patterns of the Failure Indicator Error Item Flashing Referenced Patterns page number Area Status Cooling Water Temperature Failure (low voltage) P0117/4 P.1-45...
  • Page 211 Using the Failure Indicator for Failure Diagnosis FAILURE DIAGNOSIS Error Item Flashing Referenced Patterns page number Area Status P.1-66 Rack Actuator Relay Failure (low voltage) P1222/4 P.1-68 Failure (high voltage) P1223/3 Intermittent failure P1224/2 P.1-70 Spare Accelerator Sensor Failure (low voltage) P0222/4 P.1-22 Failure (high voltage)

  • Page 212: Factor Analysis

    FAILURE DIAGNOSIS Factor Analysis FACTOR ANALYSIS 2G-Type Eco-Governor Speed-Fluctuation Factor Analysis Check method Relevant DTC Remarks Engine speed Insufficient fuel supply Fuel pipe clogging Check fuel system. fluctuation Engine failure Nozzle failure etc. Check whole engine. Working machine Load fluctuation in Check whole working failure working machine...
  • Page 213 Factor Analysis FAILURE DIAGNOSIS Check method Relevant DTC Remarks Wire breakage or short- CSD solenoid valve system Intermittent on/off of circuit in CSD solenoid Check conduction of CSD. error: P1242/4, P1243/3, CSD solenoid valve valve P1244/2 Wire breakage or short- Check error occurrence, tool CSD solenoid valve system circuit in harness, or...
  • Page 214 FAILURE DIAGNOSIS Factor Analysis Check method Relevant DTC Remarks Intermittent fluctuation Wire breakage or short- Check error occurrence, tool Cooling-water temperature of cooling-water circuit in cooling-water data, and conduction with sensor system error: P0117/4, temperature sensor temperature sensor tester. P0118/3, P0119/2 signal Wire breakage or short- Check error occurrence, tool...

  • Page 215: G-Type Eco-Governor Engine Stalling/Start-Up Inability Factor Analysis

    Factor Analysis FAILURE DIAGNOSIS 2G-Type Eco-Governor Engine Stalling/Start-Up Inability Factor Analysis Check method Relevant DTC Remarks Engine stalling/start-up Engine failure Nozzle failure etc. Check whole engine. inability Working machine Excessive load on Check whole working failure working machine machine. Unstable injection due Fuel pump failure Check fuel pump.
  • Page 216 FAILURE DIAGNOSIS Factor Analysis Check method Relevant DTC Remarks Rack actuator Rack actuator system malfunction due to Check rack actuator operation Rack actuator system error: failure excessive hysteresis and hysteresis. P1212/4, P1213/3, P1211/7 etc. Wire breakage or short- Check error occurrence, tool circuit in harness, or Rack actuator system error: data, harness shaking, and...
  • Page 217 Factor Analysis FAILURE DIAGNOSIS Check method Relevant DTC Remarks Communication circuit Check error occurrence, tool CAN communication failure in controller for data, and communication CAN communication error: system failure working machine, Eco- status with measuring U0001/12 Governor, etc. instrument. Wire breakage or short- Check error occurrence, tool circuit in harness, or CAN communication error:...

  • Page 218: G-Type Eco-Governor Black Smoke Factor Analysis

    FAILURE DIAGNOSIS Factor Analysis 2G-Type Eco-Governor Black Smoke Factor Analysis Check method Relevant DTC Remarks Black-smoke emission Insufficient fuel supply Fuel pipe clogging Check fuel system. from engine Engine failure Nozzle failure etc. Check whole engine. Working machine Load fluctuation in Check whole working failure working machine...
  • Page 219 Factor Analysis FAILURE DIAGNOSIS Check method Relevant DTC Remarks Temporary failure in Controller system controller input/output Check occurrence of error. failure circuit Program or map data Check program and map data. failure Control system Unexpected strong Check presence of conductive affected by conductive noise or surge noise.

  • Page 220: Special Service Tools

    FAILURE DIAGNOSIS Special Service Tools SPECIAL SERVICE TOOLS For measuring compression pressure Yanmar Gauge Set Part No. TOL-97190080 0000849 Adapter for direct injection 2-valve cylinder head Yanmar Adapter Part No. 119802-92950 Compression Gauge Kit 0000850 Adapter for direct injection 4-valve cylinder head for 4TNV94L/98/98T Yanmar Adapter Part No.

  • Page 221: Troubleshooting By Measuring Compression Pressure

    Troubleshooting By Measuring Compression Pressure FAILURE DIAGNOSIS TROUBLESHOOTING BY For engines with 4 valve cylinder heads 4. Remove the valve cover assembly. See MEASURING COMPRESSION Removal of Valve Cover on page 6-52. Remove PRESSURE the fuel injector from the cylinder to be tested. See Removal of Fuel Injectors on page 7-35.
  • Page 222 FAILURE DIAGNOSIS Troubleshooting By Measuring Compression Pressure Figure 1-2 9. After performing the compression check remove the compression gauge and compression gauge adapter from the cylinder. For engines with 2 valve cylinder heads 10. Reinstall the fuel injector, high-pressure fuel injection lines, and reconnect the stop solenoid.
  • Page 223 Engine Model Deviation Between Cylinders Standard Limit 443 - 473 psi 340 - 370 psi 3TNV82A (3.06 - 3.26 MPa; 30 - 32 kgf/cm²) (2.35 - 2.55 MPa; 24 - 26 kgf/cm²) 3TNV84 455 - 485 psi 355 - 385 psi 4TNV84 (3.14 - 3.34 MPa;...

  • Page 224: Quick Reference Table For Troubleshooting

    FAILURE DIAGNOSIS Quick Reference Table For Troubleshooting Measured Value and Troubleshooting When the measured compression pressure is below the limit value, inspect each part by referring to the table below. Item Cause Corrective Action Clogged element Clean the element. Air Cleaner Element Broken element Replace the element.
  • Page 225 FAILURE DIAGNOSTIC LIST Failure Diagnostic List FAILURE DIAGNOSTIC LIST TNV DI Service Manual Failure Diagnostic List Engine stall Insufficient Cooling Defective start Defective rotation control Noise/vibration Lubricant Intake Exhaust Fuel Electrics/electronics Symptoms and conditions of failures after start engine output water Starter not Starter...
  • Page 226 FAILURE DIAGNOSTIC LIST Failure Diagnostic List Engine stall Insufficient Cooling Defective start Defective rotation control Noise/vibration Lubricant Intake Exhaust Fuel Electrics/electronics Symptoms and conditions of failures after start engine output water Starter not Starter Exhaust Without load At work Exhaust color At work rotate rotates...
  • Page 227 Failure Diagnostic List FAILURE DIAGNOSTIC LIST Engine stall Insufficient Cooling Defective start Defective rotation control Noise/vibration Lubricant Intake Exhaust Fuel Electrics/electronics Symptoms and conditions of failures after start engine output water Starter not Starter Exhaust Without load At work Exhaust color At work rotate rotates...
  • Page 228 FAILURE DIAGNOSTIC LIST Failure Diagnostic List Engine stall Insufficient Cooling Defective start Defective rotation control Noise/vibration Lubricant Intake Exhaust Fuel Electrics/electronics Symptoms and conditions of failures after start engine output water Starter not Starter Exhaust Without load At work Exhaust color At work rotate rotates...
  • Page 229 Failure Diagnostic List FAILURE DIAGNOSTIC LIST Engine stall Insufficient Cooling Defective start Defective rotation control Noise/vibration Lubricant Intake Exhaust Fuel Electrics/electronics Symptoms and conditions of failures after start engine output water Starter not Starter Exhaust Without load At work Exhaust color At work rotate rotates...
  • Page 230 FAILURE DIAGNOSTIC LIST Failure Diagnostic List This Page Intentionally Left Blank 1-228 TNV DI Service Manual...
  • Page 231 TNV DI Service Manual ELECTRICAL WIRING Note: The following wiring diagram is “representative” of a common installation using a Yanmar engine. The actual installation may be equipped with a variety of electrical components and wiring harnesses. Contact the machine manufacturer for specific information.
  • Page 232 WIRING DIAGRAM Electrical Wiring This Page Intentionally Left Blank 1-230 TNV DI Service Manual...
  • Page 233 Buffalo Grove, IL 60089-4508, U.S.A. TEL: 1-847-541-1900 FAX: 1-847-541-2161 http://www.yanmar.com Yanmar Europe B.V. Brugplein11, 1332 BS Almere -de Vaart, The Netherlands. TEL: 31-36-5493200 FAX: 31-36-5493209 http://www.yanmar.nl Yanmar Asia (Singapore) Corporation Pte. Ltd. 4 Tuas Lane, Singapore 638613 TEL: 65-68615077 FAX: 65-68611509 http://www.yanmar.co.jp/yasc/...
  • Page 234 0DTNV-G00600 PRINTED IN JAPAN...

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