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Yanmar 3TNV82A, Troubleshooting Manual

The Yanmar 3TNV82A Troubleshooting Manual is a comprehensive guide designed to assist users in resolving issues with their Yanmar 3TNV82A engine. This valuable resource provides step-by-step instructions and detailed information to diagnose and fix any problems that may arise. Download this manual for free on our website manualshive.com today!

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FAILURE DIAGNOSTIC LIST

TNV DI Service Manual

1-227

Failure Diagnostic List

Engine sto

p or operation limits 

by ECU f

ailure d

iagnosis fu

nction

ECU control function operating

c

c

c

c

Not failure
Implement regular usage

Check the causes of engine stop or 
starter restraint by a diagnosis tool.

Disconnection/short-circuit of water 
temperature sensor

c

c

c

Repair or replacement of harness
Replacement of water temperature sensor

For harness inspection method, see 
"Failure Diagnosis" (on page 1-1).

Disconnection/short-circuit of 
accelerator sensor

c

c

Repair or replacement of harness
Replacement of accelerator sensor

For harness inspection method, see 
"Failure Diagnosis" (on page 1-1).

Speed sensor signal error

c

c

c

Repair or replacement of harness
Repair or replacement of fuel injection 
pump

For harness inspection method, see 
"Failure Diagnosis" (on page 1-1).

Rack position sensor signal error

c

c

c

c

c

Repair or replacement of harness
Repair or replacement of fuel injection 
pump

For harness inspection method, see 
"Failure Diagnosis" (on page 1-1).

Operation defect of rack actuator

c

c

c

Repair or replacement of harness
Repair or replacement of fuel injection 
pump

For harness inspection method, see 
"Failure Diagnosis" (on page 1-1).

Engine over speed

c

c

Check operating machine’s driving.
Check speed sensor signal.

CAN communication error

c

c

c

Repair or replacement of harness
ECU Replacement

For harness inspection method, see 
"Failure Diagnosis" (on page 1-1).

Disconnection/short-circuit of EGR 
valve motor

c

c

c

Repair or replacement of harness
Replacement of EGR valve

For harness inspection method, see 
"Failure Diagnosis" (on page 1-1).

Disconnection/short-circuit of CSD 
solenoid valve

c

c

c

Repair or replacement of harness
Replacement of CSD valve solenoid

For harness inspection method, see 
"Failure Diagnosis" (on page 1-1).

Disconnection/short-circuit of start 
assist relay

c

c

c

c

Repair or replacement of harness
Relay replacement

For harness inspection method, see 
"Failure Diagnosis" (on page 1-1).

Main relay “OFF” not available

c

c

Relay replacement

Disconnection/short-circuit of rack 
actuator relay

c

c

Repair or replacement of harness
Relay replacement

For harness inspection method, see 
"Failure Diagnosis" (on page 1-1).

Malfunction by ECU self-diagnosis

c

c

ECU Replacement

Symptoms and conditions of failures

Cause

Defective start

Engine stall 

after start

Defective rotation control

Insufficient 

engine output

Noise/vibration

Lubricant

Cooling 

water

Intake

Exhaust

Fuel

Electrics/electronics

Action

Referenced page number

Starter not 

rotate

Starter
rotates

Exhaust 

fume

Speed change 

by accelerator n

o

t available (constant sp

eed)

Without load

At work

Exhaust color

Knocking noise at combustion to

o high

Combu

s

tion noise

 uneven

Noise other t

han combustion from engine

Engine vibration

 too big

Lubricant consumption too much

Lubricant dilu

ted with fuel

Lubricant mixe

d wit

h water

Oil pre

s

sure to

o low

 (oil pressure lamp

 on)

Overheated (water temperat

ure lamp on)

Water 

temperature too low

Pressure dow

n (air cleaner lamp on)

Pr

essur

e

 up

At work

Blow-by too much

Exhaust

 temperatu

re up

Fu

el consumption too much

Fu

el mixed with water (oil-water separator 

lamp on

)

Fu

el filter contaminated too e

arly

Battery charg

e defect (charge

 lamp o

n)

ECU indica

tor lamp flashing

ECU indica

tor lamp not on just after key-on 

(2 seco

nds)

Prescribed ECU control fun

c

tion not op

erate

Fu

se meltdow

n, disconnection 

(repe

ated)

ECU indica

tor lamp not on just after key-on

ECU indica

tor lamp on just

 after key-on (2 se

conds)

Engine not start (not even initial comb

ustion)

Engine not start (stall after serial combustion)

Engine starts la

ter then e

v

er

None

Little

Much

Specified speed setti

ng not available

Poor acceleration

Retu

rn to low speed not 

smooth

Hunt

ing

Hunt

ing

Nor

m

al

White

Blac

k

White exh

aust color

Black exhaust color

TNV_DI_SM_A4-Troubleshooting.book  227 ページ  ２００７年１１月１５日　木曜日　午後５時２７分

Summary of Contents for 3TNV82A

Page 1: ...C CONTROL TROUBLESHOOTING MANUAL TROUBLESHOOTING MANUAL 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 ...

Page 2: ...cancer and reproductive harm Wash hands after handling Head Office Yanmar Co Ltd 1 32 Chayamachi Kita ku Osaka 530 8311 Japan http www yanmar co jp Yanmar America Corporation 951 Corporate Grove Drive 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 h...

Page 3: ...Related Failures 1 170 Contact Input Related Failures 1 187 Actuator Related Failures 1 193 ECU Internal and Communication Errors 1 197 FAILURE INDICATOR LAMP FLASHING PATTERN 1 207 Using the Failure Indicator for Failure Diagnosis 1 208 Flashing Patterns of the Failure Indicator 1 208 Factor Analysis 1 210 2G Type Eco Governor Speed Fluctuation Factor Analysis 1 210 2G Type Eco Governor Engine St...

Page 4: ...FAILURE DIAGNOSIS 1 2 TNV DI Service Manual This Page Intentionally Left Blank TNV_DI_SM_A4 Troubleshooting book 2 ページ ２００７年１１月１５日 木曜日 午後５時２７分 ...

Page 5: ...1 Error foot pedal close position P 1 28 P 1 144 P1226 0 Error foot pedal open position P 1 30 P1227 8 Error pulse communication P 1 32 P 1 152 P0222 4 1 9 Atmospheric pressure sensor Error low voltage P 1 34 P 1 148 P0223 3 Error high voltage P 1 36 P0224 2 Intermittent failure P 1 38 P0668 4 4 1 ECU Temperature Sensor Error low voltage P 1 40 P 1 154 P0669 3 Error high voltage P 1 41 P1644 2 Int...

Page 6: ...p Motor A Phase P 1 84 P 1 182 P1403 3 Error B Step Motor A Phase P 1 86 P1412 4 Error A Step Motor B Phase P 1 88 P1413 3 Error B Step Motor B Phase P 1 90 P1422 4 Error A Step Motor C Phase P 1 92 P1423 3 Error B Step Motor C Phase P 1 94 P1432 4 Error A Step Motor D Phase P 1 96 P1433 3 Error B Step Motor D Phase P 1 98 Contact Input Related Failures P1192 4 2 1 Oil pressure switch Error P 1 10...

Page 7: ...ksum B P1606 2 Error Checksum C P1620 12 Map format Error P1601 2 EEPROM Error Checksum P0601 12 Error read write error P 1 123 P1610 12 Sub CPU Error A P1611 12 Error B P1612 12 Error C P0686 4 1 6 Main relay Error P 1 124 P 1 199 U0001 12 1 2 CAN Communication Error P 1 126 P 1 203 U0167 12 4 2 Immobilizer Error CAN communication P 1 128 P 1 205 U1167 8 Error pulse communication P 1 130 U0426 2 ...

Page 8: ...FAILURE DIAGNOSIS 1 6 TNV DI Service Manual DTCs Diagnostic Trouble Codes General Description This Page Intentionally Left Blank TNV_DI_SM_A4 Troubleshooting book 6 ページ ２００７年１１月１５日 木曜日 午後５時２７分 ...

Page 9: ... the failure lamp flashes when the DTC is output For detailed information on various flashing patterns see Annex This column shows what parts or items should be checked to identify the cause of the error For details see Diagnosis Description Error Mode Operation Continuation Run Under Restrictions Stop Immediately The engine operation after detecting the error is described Operation Continuation A...

Page 10: ...ck position sensor may be faulty Output defect of the rack position signal by a disconnection or a short circuit of the inner wiring The E ECU internal circuitry may be faulty DTC P1202 4 Rack Position Sensor Error Low Voltage 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Key switch ON 2 The sensor voltage lower limit and below at E ECU activation en...

Page 11: ...Before beginning your work be sure to turn off the key switch Check that the connector of the rack actuator is correctly inserted Check that the wiring of the rack actuator is not disconnected or the insulation of the wiring is not peeled 3 Failure Diagnostic Work Check the input voltage of the rack position sensor voltage of the sensor 12V line Check the harness for correct continuity For details...

Page 12: ...Rack Position Sensor High Voltage 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Key switch ON 2 The sensor voltage upper limit and above at E ECU activation engine running 3 Seven flashes Connector Harness rack position sensor Rack actuator E ECU Detection at the engine start Detection at the engine running Error Mode Run Under Restrictions Start the...

Page 13: ...Before beginning your work be sure to turn off the key switch Check that the connector of the rack actuator is correctly inserted Check that the wiring of the rack actuator is not disconnected or the insulation of the wiring is not peeled 3 Failure Diagnostic Work Check the input voltage of the rack position sensor voltage of the sensor 12V line Check the harness for correct continuity For details...

Page 14: ...y Sensor output defect by a disconnection of the accelerator sensor inner wiring or a sliding resistance increase The E ECU internal circuitry may be faulty DTC P0122 4 Accelerator Sensor Error Low Voltage 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Key switch ON 2 Sensor voltage 0 2 V or lower 3 Five flashes Harness Accelerator sensor Spare Accele...

Page 15: ...r work be sure to turn off the key switch Check that the connector of the accelerator sensor is correctly inserted Check that the wiring of the accelerator sensor is not disconnected or the insulation of the wiring is not peeled 3 Failure Diagnostic Work Check the resistance value of the accelerator sensor Check the harness for correct continuity Check the output voltage of the accelerator sensor ...

Page 16: ...sor Error High Voltage 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Key switch ON 2 Sensor voltage 4 6 V or higher 3 Five flashes Harness Accelerator sensor Spare Accelerator Sensor Function Unavailable Available Error Mode Run Under Restrictions The engine runs at a constant rotational speed Stop Immediately The engine continues to run using the sp...

Page 17: ...r work be sure to turn off the key switch Check that the connector of the accelerator sensor is correctly inserted Check that the wiring of the accelerator sensor is not disconnected or the insulation of the wiring is not peeled 3 Failure Diagnostic Work Check the resistance value of the accelerator sensor Check the harness for correct continuity Check the output voltage of the accelerator sensor ...

Page 18: ... circuited with GND or power supply Sensor GND wire may be disconnected The accelerator sensor may be faulty Inner wiring may be disconnected or short circuited DTC P0124 2 Intermittent Failure with Accelerator Sensor 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Engine running 2 Unconfirmed error detected 10 times 3 Does not flash Connector Harness ...

Page 19: ...r work be sure to turn off the key switch Check that the connector of the accelerator sensor is correctly inserted Check that the wiring of the accelerator sensor is not disconnected or the insulation of the wiring is not peeled 3 Failure Diagnostic Work Check the resistance value of the accelerator sensor Check the harness for correct continuity Check the output voltage of the accelerator sensor ...

Page 20: ...ay be disconnected or short circuited with GND The E ECU internal circuitry may be faulty DTC P1125 1 Accelerator Sensor Error foot pedal close position 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Key switch ON 2 With sensor voltage at or below 0 65 V foot pedal Normally Open switch detected being ON or foot pedal Normally Closed Switch detected be...

Page 21: ...1 144 2 Check of connectors wiring Before beginning your work be sure to turn off the key switch Check that the connector of the foot pedal is correctly inserted Check that the wiring of the foot pedal is not disconnected or the insulation of the wiring is not peeled 3 Failure Diagnostic Work Check the foot pedal for correct continuity Check the harness for correct continuity For details of the me...

Page 22: ...e disconnected or short circuited with GND The E ECU internal circuitry may be faulty DTC P1126 0 Accelerator Sensor Error foot pedal open position 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Key switch ON 2 With sensor voltage 1 1 V and above foot pedal Normally Open switch detected being OFF or foot pedal Normally Closed Switch detected being ON ...

Page 23: ...1 144 2 Check of connectors wiring Before beginning your work be sure to turn off the key switch Check that the connector of the foot pedal is correctly inserted Check that the wiring of the foot pedal is not disconnected or the insulation of the wiring is not peeled 3 Failure Diagnostic Work Check the foot pedal for correct continuity Check the harness for correct continuity For details of the me...

Page 24: ... Sensor output defect by a disconnection of the spare accelerator sensor inner wiring or a sliding resistance increase The E ECU internal circuitry may be faulty DTC P0222 4 Failure with Spare Accelerator Sensor Low Voltage 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Key switch ON 2 Sensor voltage 0 2 V or lower 3 One flash followed by eight flashe...

Page 25: ...re to turn off the key switch Check that the connector of the spare accelerator sensor is correctly inserted Check that the wiring of the spare accelerator sensor is not disconnected or the insulation of the wiring is not peeled 3 Failure Diagnostic Work Check the resistance value of the spare accelerator sensor Check the harness for correct continuity Check the output voltage of the spare acceler...

Page 26: ...nsor Error High Voltage 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Key switch ON 2 Sensor voltage 4 6 V or higher 3 One flash followed by eight flashes Harness Spare accelerator sensor Error detection of main accelerator sensor Unavailable Available Error Mode Run As Is The engine continues to run using the main accelerator sensor Run Under Restri...

Page 27: ...re to turn off the key switch Check that the connector of the spare accelerator sensor is correctly inserted Check that the wiring of the spare accelerator sensor is not disconnected or the insulation of the wiring is not peeled 3 Failure Diagnostic Work Check the resistance value of the spare accelerator sensor Check the harness for correct continuity Check the output voltage of the spare acceler...

Page 28: ...ited with GND or power supply Sensor GND wire may be disconnected The spare accelerator sensor may be faulty Spare accelerator sensor wiring may be disconnected or short circuited DTC P0224 2 Intermittent Failure with Spare Accelerator Sensor 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Engine running 2 Unconfirmed error detected 10 times 3 Does not...

Page 29: ...re to turn off the key switch Check that the connector of the spare accelerator sensor is correctly inserted Check that the wiring of the spare accelerator sensor is not disconnected or the insulation of the wiring is not peeled 3 Failure Diagnostic Work Check the resistance value of the spare accelerator sensor Check the harness for correct continuity Check the output voltage of the spare acceler...

Page 30: ...y DTC P1225 1 Spare Accelerator Sensor Error foot pedal close position 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Key switch ON 2 With sensor voltage at or below 0 65 V foot pedal Normally Open switch detected being ON or foot pedal Normally Closed Switch detected being OFF 3 One flash followed by eight flashes Harness Foot pedal Error detection o...

Page 31: ...1 144 2 Check of connectors wiring Before beginning your work be sure to turn off the key switch Check that the connector of the foot pedal is correctly inserted Check that the wiring of the foot pedal is not disconnected or the insulation of the wiring is not peeled 3 Failure Diagnostic Work Check the foot pedal for correct continuity Check the harness for correct continuity For details of the me...

Page 32: ...ty DTC P1226 0 Spare Accelerator Sensor Error foot pedal open position 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Key switch ON 2 With sensor voltage 1 1 V and above foot pedal Normally Open switch detected being OFF or foot pedal Normally Closed Switch detected being ON 3 One flash followed by eight flashes Harness Foot pedal Error detection of m...

Page 33: ...1 144 2 Check of connectors wiring Before beginning your work be sure to turn off the key switch Check that the connector of the foot pedal is correctly inserted Check that the wiring of the foot pedal is not disconnected or the insulation of the wiring is not peeled 3 Failure Diagnostic Work Check the foot pedal for correct continuity Check the harness for correct continuity For details of the me...

Page 34: ...tion 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Key switch ON 2 No pulse accelerator signal input 3 One flash followed by eight flashes Harness CAN communication error detection Unavailable Available Error Mode Run As Is After detecting the error the system lets the engine continue to run without any restrictions Run Under Restrictions The engine ...

Page 35: ... wiring Before beginning your work be sure to turn off the key switch Check that a source unit of the pulse accelerator signal and ECU are correctly connected Check that the wiring of the pulse accelerator signal is not disconnected or the insulation of the wiring is not peeled 3 Failure Diagnostic Work Check the harness for correct continuity For details of the method and the procedure of diagnos...

Page 36: ...0A might be blown With this fuse blown the E ECU may fail to detect indicate the error and to store the error history The atmospheric pressure sensor may be faulty Sensor output defect by a disconnection of the atmospheric pressure sensor inner wiring or a sliding resistance increase The E ECU internal circuitry may be faulty DTC P2228 4 Failure with Atmospheric Pressure Sensor Low Voltage 1 Preco...

Page 37: ...turn off the key switch Check that the connector of the atmospheric pressure sensor is correctly inserted Check that the wiring of the atmospheric pressure sensor is not disconnected or the insulation of the wiring is not peeled 3 Failure Diagnostic Work Check the resistance value of the atmospheric pressure sensor Check the harness for correct continuity Check the output voltage of the atmospheri...

Page 38: ...ct by a short circuit with power supply of the atmospheric pressure sensor inner wiring The E ECU internal circuitry may be faulty DTC P2229 3 Failure with Atmospheric Pressure Sensor High Voltage 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Key switch ON 2 Sensor voltage 4 8 V or higher 3 One flash followed by nine flashes Harness Atmospheric press...

Page 39: ...turn off the key switch Check that the connector of the atmospheric pressure sensor is correctly inserted Check that the wiring of the atmospheric pressure sensor is not disconnected or the insulation of the wiring is not peeled 3 Failure Diagnostic Work Check the resistance value of the atmospheric pressure sensor Check the harness for correct continuity Check the output voltage of the atmospheri...

Page 40: ...D or power supply Sensor GND wire may be disconnected The atmospheric pressure sensor may be faulty Inner wiring of atmospheric pressure sensor may be disconnected or short circuited DTC P2230 2 Intermittent Failure with Atmospheric Pressure Sensor 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Engine running 2 Unconfirmed error detected 10 times 3 Do...

Page 41: ...turn off the key switch Check that the connector of the atmospheric pressure sensor is correctly inserted Check that the wiring of the atmospheric pressure sensor is not disconnected or the insulation of the wiring is not peeled 3 Failure Diagnostic Work Check the resistance value of the atmospheric pressure sensor Check the harness for correct continuity Check the output voltage of the atmospheri...

Page 42: ...rn of failure indicator Check points 1 Key switch ON 2 Sensor voltage 1 0 V at 140 C or lower 3 Four flashes followed by one flash E ECU Error Mode Operation Continuation No obstacles to control the engine The engine continues to run with the ECU temperature set to the default of 30 C Run restricted No Recovery Conditions Yes This error will be automatically reset when a normal sensor voltage 1 0 ...

Page 43: ...ure indicator Check points 1 Key switch ON 2 Sensor voltage 4 6 V at 45 C or lower 3 Four flashes followed by one flash E ECU Error Mode Operation Continuation No obstacles to control the engine The engine continues to run with the ECU temperature set to the default of 30 C Run restricted No Recovery Conditions Yes This error will be automatically reset when a normal sensor voltage 0 2 to 4 6 V is...

Page 44: ... Sensor 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Engine running 2 Unconfirmed error detected 10 times 3 Does not flash E ECU Error Mode Run As Is After detecting the error the system lets the engine continue to run without any restrictions Run restricted No Recovery Conditions No Remarks 1 Initial diagnosis with the diagnosis tool Check the faul...

Page 45: ...is 150 C or higher 3 Two flashes followed by five flashes E ECU Setting of response to ECU temperature rise error Unavailable Available Error Mode Run As Is After detecting the error the system lets the engine continue to run without any restrictions Run Under Restrictions The engine continues to run under restrictions Run restricted No Yes The system restricts the High idle speed or engine power ...

Page 46: ... diagnosis see P 1 154 2 Engine Inspection Turn the key switch off to stop the engine Inspect around the E ECU After a little turn the key switch on to check if the DTC is detected For description and procedure of engine inspection see the Service manual section Engine 3 Failure Diagnostic Work Check the ECU temperature sensor For details of the method and the procedure of diagnosis see P 1 154 TN...

Page 47: ...internal circuitry may be faulty DTC P0117 4 Failure with Cooling Water Temperature Sensor Low Voltage 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Key switch ON 2 Sensor voltage 0 2 V or lower 3 Four flashes Connector Harness Cooling water temperature sensor E ECU In the case of a system with EGR In the case of a system without EGR Error Mode Run U...

Page 48: ...he key switch Check that the connector of the cooling water temperature sensor is correctly inserted Check that the wiring of the cooling water temperature sensor is not disconnected or the insulation of the wiring is not peeled 3 Failure Diagnostic Work Check the resistance value of the cooling water temperature sensor Check the harness for correct continuity Check the output voltage of the cooli...

Page 49: ... faulty DTC P0118 3 Failure with Cooling Water Temperature Sensor High Voltage 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Key switch ON 2 Sensor voltage 4 8 V or higher 3 Four flashes Connector Harness Cooling water temperature sensor E ECU In the case of a system with EGR In the case of a system without EGR Error Mode Run Under Restrictions The e...

Page 50: ...he key switch Check that the connector of the cooling water temperature sensor is correctly inserted Check that the wiring of the cooling water temperature sensor is not disconnected or the insulation of the wiring is not peeled 3 Failure Diagnostic Work Check the resistance value of the cooling water temperature sensor Check the harness for correct continuity Check the output voltage of the cooli...

Page 51: ...ing water temperature sensor may be disconnected The cooling water temperature sensor may be faulty Signal wire in the sensor may be disconnected or short circuited Sensor GND wire in the sensor may be disconnected DTC P0119 2 Intermittent Failure with Cooling Water Temperature Sensor 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Engine running 2 Unc...

Page 52: ...he key switch Check that the connector of the cooling water temperature sensor is correctly inserted Check that the wiring of the cooling water temperature sensor is not disconnected or the insulation of the wiring is not peeled 3 Failure Diagnostic Work Check the resistance value of the cooling water temperature sensor Check the harness for correct continuity Check the output voltage of the cooli...

Page 53: ...ure 115 C or higher 3 Three flashes followed by six flashes Engine cooling water level Engine cooling system Cooling Water Temperature Sensor Setting of response to cooling water temperature rise error Unavailable Available Error Mode Run As Is After detecting the error the system lets the engine continue to run without any restrictions Run Under Restrictions The engine continues to run under rest...

Page 54: ...e of diagnosis see P 1 156 2 Check of connectors wiring Turn the key switch off to stop the engine Check the engine cooling system After a little turn the key switch on to check if the DTC is detected For description and procedure of engine inspection see the Service manual Engine 3 Failure Diagnostic Work Check the cooling water temperature sensor system For details of the method and the procedur...

Page 55: ... followed by four flashes Harness E ECU Error Mode Operation Continuation After detecting the error the system lets the engine continue to run without any restrictions Run restricted No Recovery Conditions No Remarks 1 Initial diagnosis with the diagnosis tool Check the fault indication Check the voltage of the Sensor 5V For details of the method and the procedure of diagnosis see P 1 160 2 Check ...

Page 56: ...ollowed by four flashes Harness E ECU Error Mode Run As Is After detecting the error the system lets the engine continue to run without any restrictions Run restricted No Recovery Conditions No Remarks 1 Initial diagnosis with the diagnosis tool Check the fault indication Check the voltage of the Sensor 5V For details of the method and the procedure of diagnosis see P 1 160 2 Check of connectors w...

Page 57: ...ash Harness E ECU Error Mode Operation Continuation After detecting the error the system lets the engine continue to run without any restrictions Run restricted No Recovery Conditions No Remarks 1 Initial diagnosis with the diagnosis tool Check the fault indication Check the voltage of the Sensor 5V For details of the method and the procedure of diagnosis see P 1 160 2 Check of connectors wiring B...

Page 58: ... internal circuitry may be faulty DTC P0562 1 Power Supply Voltage Error Low Voltage 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Engine running 2 E ECU supply voltage below 10 V 3 Two flashes followed by three flashes Battery alternator Harness Error Mode Operation Continuation After detecting the error the system lets the engine continue to run wi...

Page 59: ...h off to stop the engine Check the battery voltage using a circuit tester Inspect the charging system of the engine After a little turn the key switch on to check if the DTC is detected For description and procedure of engine inspection see the Service manual Engine 3 Failure Diagnostic Work Check that the battery wiring is not disconnected or the insulation of the wiring is not peeled TNV_DI_SM_A...

Page 60: ...ECU internal circuitry may be faulty DTC P0563 0 Power Supply Voltage Error High Voltage 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Engine running 2 E ECU supply voltage over 16 V 3 Two flashes followed by three flashes Battery alternator Harness Error Mode Operation Continuation After detecting the error the system lets the engine continue to run...

Page 61: ...h off to stop the engine Check the battery voltage using a circuit tester Inspect the charging system of the engine After a little turn the key switch on to check if the DTC is detected For description and procedure of engine inspection see the Service manual Engine 3 Failure Diagnostic Work Check that the battery wiring is not disconnected or the insulation of the wiring is not peeled TNV_DI_SM_A...

Page 62: ...R SUPPLY The speed sensor may be faulty Output defect of the speed signal by a disconnection or a short circuit of the inner wiring The E ECU internal circuitry may be faulty DTC P0340 4 Speed Sensor Error 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Key switch START engine running 2 Speed sensor signal 0 min 1 3 Six flashes Connector Harness Speed ...

Page 63: ...ctors wiring Before beginning your work be sure to turn off the key switch Check that the connector of the speed sensor is correctly inserted Check that the wiring of the speed sensor is not disconnected or the insulation of the wiring is not peeled 3 Failure Diagnostic Work Check the resistance value of the speed sensor Check the harness for correct continuity For details of the method and the pr...

Page 64: ... pulse defect by the alternator failure The E ECU internal circuitry may be faulty DTC P1340 4 Failure with Spare Speed Sensor 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Engine running 2 Spare speed sensor signal below 0 min 1 3 One flash followed by another flash Connector Harness alternator E ECU Main speed sensor error detection Unavailable Ava...

Page 65: ...see P 1 167 2 Check of connectors wiring Before beginning your work be sure to turn off the key switch Check that the connector of the alternator is correctly inserted Check that the wiring of the alternator is not disconnected or the insulation of the wiring is not peeled 3 Failure Diagnostic Work Check the battery voltage Check the harness for correct continuity For details of the method and the...

Page 66: ...f the fuel injection pump The rack actuator wiring may be short circuited with GND The E ECU internal circuitry may be faulty DTC P0219 0 Overspeed Error 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Engine running 2 Sensor signal at or above the upper limit High idle speed 600 min 1 3 Two flashes followed by five flashes Harness Speed Sensor Rack ac...

Page 67: ...he key switch off to stop the engine Inspect the engine and the operating machine After a little turn the key switch on to check if the DTC is detected For description and procedure of engine inspection see the Service manual Engine 3 Failure Diagnostic Work Check the Rack Actuator For details of the method and the procedure of diagnosis see P 1 167 TNV_DI_SM_A4 Troubleshooting book 65 ページ ２００７年１１...

Page 68: ...on The E ECU internal circuitry may be faulty DTC P1222 4 Failure A with Rack Actuator Relay 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Key switch ON 2 Make an assessment logically as to followings E ECU detects the rack actuator relay turning ON during the command to turn OFF the rack actuator relay 3 One flash followed by seven flashes Connector...

Page 69: ... of diagnosis see P 1 170 2 Check of connectors wiring Before beginning your work be sure to turn off the key switch Check that the connector of the rack actuator relay is correctly inserted Check that the wiring of the rack actuator relay is not disconnected or the insulation of the wiring is not peeled 3 Failure Diagnostic Work Check the resistance value of the rack actuator relay Check the harn...

Page 70: ...wn In this case the ECU fails to detect indicate the error and to store the error history The E ECU internal circuitry may be faulty DTC P1223 3 Failure B with Rack Actuator Relay 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Key switch ON 2 Make an assessment logically as to followings E ECU detects the rack actuator relay turning OFF during the com...

Page 71: ... of diagnosis see P 1 170 2 Check of connectors wiring Before beginning your work be sure to turn off the key switch Check that the connector of the rack actuator relay is correctly inserted Check that the wiring of the rack actuator relay is not disconnected or the insulation of the wiring is not peeled 3 Failure Diagnostic Work Check the resistance value of the rack actuator relay Check the harn...

Page 72: ...cted or short circuited with GND The E ECU internal circuitry may be faulty DTC P1224 2 Intermittent Failure with Rack Actuator Relay 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Engine running 2 Unconfirmed error detected 10 times 3 Does not flash Connector Harness Rack actuator Relay E ECU Error Mode Run As Is After detecting the error the system ...

Page 73: ... of diagnosis see P 1 170 2 Check of connectors wiring Before beginning your work be sure to turn off the key switch Check that the connector of the rack actuator relay is correctly inserted Check that the wiring of the rack actuator relay is not disconnected or the insulation of the wiring is not peeled 3 Failure Diagnostic Work Check the resistance value of the rack actuator relay Check the harn...

Page 74: ...sist Relay inner wiring The E ECU internal circuitry may be faulty DTC P1232 4 Failure A with Start Assist Relay 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Key switch ON 2 Make an assessment logically as to followings E ECU detects the start assist relay turning ON during the command to turn OFF the start assist relay 3 One flash followed by five ...

Page 75: ...e of diagnosis see P 1 174 2 Check of connectors wiring Before beginning your work be sure to turn off the key switch Check that the connector of the start assist relay is correctly inserted Check that the wiring of the start assist relay is not disconnected or the insulation of the wiring is not peeled 3 Failure Diagnostic Work Check the resistance value of the start assist relay Check the harnes...

Page 76: ... blown Also the E ECU internal circuitry may be faulty In this case the E ECU may fail to detect indicate the error and to store the error history The E ECU internal circuitry may be faulty DTC P1233 3 Failure B with Start Assist Relay 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Key switch ON 2 Make an assessment logically as to followings E ECU de...

Page 77: ...e of diagnosis see P 1 174 2 Check of connectors wiring Before beginning your work be sure to turn off the key switch Check that the connector of the start assist relay is correctly inserted Check that the wiring of the start assist relay is not disconnected or the insulation of the wiring is not peeled 3 Failure Diagnostic Work Check the resistance value of the start assist relay Check the harnes...

Page 78: ...or short circuited with POWER SUPPLY The E ECU internal circuitry may be faulty DTC P1234 2 Intermittent Failure with Start Assist Relay 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Engine running 2 Unconfirmed error detected 10 times 3 Does not flash Connector Harness Start Assist Relay E ECU Error Mode Run As Is After detecting the error the syste...

Page 79: ...e of diagnosis see P 1 174 2 Check of connectors wiring Before beginning your work be sure to turn off the key switch Check that the connector of the start assist relay is correctly inserted Check that the wiring of the start assist relay is not disconnected or the insulation of the wiring is not peeled 3 Failure Diagnostic Work Check the resistance value of the start assist relay Check the harnes...

Page 80: ...nection The E ECU internal circuitry may be faulty DTC P1242 4 Failure A with CSD Solenoid Valve 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Key switch ON 2 Make an assessment logically as to followings E ECU detects the CSD solenoid valve turning ON signal during the command to turn OFF the CSD solenoid valve 3 One flash followed by four flashes C...

Page 81: ...f diagnosis see P 1 178 2 Check of connectors wiring Before beginning your work be sure to turn off the key switch Check that the connector of the CSD solenoid valve is correctly inserted Check that the wiring of the CSD solenoid valve is not disconnected or the insulation of the wiring is not peeled 3 Failure Diagnostic Work Check the resistance value of the CSD solenoid valve coil Check the harn...

Page 82: ...U internal circuitry may be faulty In this case the E ECU may fail to detect indicate the error and to store the error history The E ECU internal circuitry may be faulty DTC P1243 3 Failure B with CSD Solenoid Valve 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Key switch ON 2 Make an assessment logically as to followings E ECU detects the CSD soleno...

Page 83: ...f diagnosis see P 1 178 2 Check of connectors wiring Before beginning your work be sure to turn off the key switch Check that the connector of the CSD solenoid valve is correctly inserted Check that the wiring of the CSD solenoid valve is not disconnected or the insulation of the wiring is not peeled 3 Failure Diagnostic Work Check the resistance value of the CSD solenoid valve coil Check the harn...

Page 84: ...or short circuited with POWER SUPPLY The E ECU internal circuitry may be faulty DTC P1244 2 Intermittent Failure with CSD solenoid valve 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Engine running 2 Unconfirmed error detected 10 times 3 Does not flash Connector Harness CSD solenoid valve E ECU Error Mode Run As Is After detecting the error the syste...

Page 85: ...f diagnosis see P 1 178 2 Check of connectors wiring Before beginning your work be sure to turn off the key switch Check that the connector of the CSD solenoid valve is correctly inserted Check that the wiring of the CSD solenoid valve is not disconnected or the insulation of the wiring is not peeled 3 Failure Diagnostic Work Check the resistance value of the CSD solenoid valve coil Check the harn...

Page 86: ...nternal circuitry may be faulty DTC P1402 4 Failure A with EGR valve Step Motor A Phase 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Key switch ON 2 Make an assessment logically as to followings E ECU detects the EGR step motor A phase turning ON during the command to turn OFF the EGR step motor A phase 3 One flash followed by three flashes Connecto...

Page 87: ...ure of diagnosis see P 1 182 2 Check of connectors wiring Before beginning your work be sure to turn off the key switch Check that the connector of the EGR step motor is correctly inserted Check that the wiring of the EGR step motor is not disconnected or the insulation of the wiring is not peeled 3 Failure Diagnostic Work Check the coil resistance of the EGR step motor Check the harness for corre...

Page 88: ...ernal circuitry may be faulty DTC P1403 3 Failure B with EGR valve Step Motor A Phase 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Key switch ON 2 Make an assessment logically as to followings E ECU detects the EGR step motor A phase turning OFF during the command to turn ON the EGR step motor A phase 3 One flash followed by three flashes Connector ...

Page 89: ...ure of diagnosis see P 1 182 2 Check of connectors wiring Before beginning your work be sure to turn off the key switch Check that the connector of the EGR step motor is correctly inserted Check that the wiring of the EGR step motor is not disconnected or the insulation of the wiring is not peeled 3 Failure Diagnostic Work Check the coil resistance of the EGR step motor Check the harness for corre...

Page 90: ...al circuitry may be faulty DTC P1412 4 Failure A with EGR valve Step Motor B Phase 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Key switch ON 2 Make an assessment logically as to followings E ECU detects the EGR step motor B phase turning ON during the command to turn OFF the EGR step motor B phase 3 One flash followed by three flashes Connector Har...

Page 91: ...ure of diagnosis see P 1 182 2 Check of connectors wiring Before beginning your work be sure to turn off the key switch Check that the connector of the EGR step motor is correctly inserted Check that the wiring of the EGR step motor is not disconnected or the insulation of the wiring is not peeled 3 Failure Diagnostic Work Check the coil resistance of the EGR step motor Check the harness for corre...

Page 92: ...ernal circuitry may be faulty DTC P1413 3 Failure B with EGR valve Step Motor B Phase 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Key switch ON 2 Make an assessment logically as to followings E ECU detects the EGR step motor B phase turning OFF during the command to turn ON the EGR step motor B phase 3 One flash followed by three flashes Connector ...

Page 93: ...ure of diagnosis see P 1 182 2 Check of connectors wiring Before beginning your work be sure to turn off the key switch Check that the connector of the EGR step motor is correctly inserted Check that the wiring of the EGR step motor is not disconnected or the insulation of the wiring is not peeled 3 Failure Diagnostic Work Check the coil resistance of the EGR step motor Check the harness for corre...

Page 94: ...al circuitry may be faulty DTC P1422 4 Failure A with EGR valve Step Motor C Phase 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Key switch ON 2 Make an assessment logically as to followings E ECU detects the EGR step motor C phase turning ON during the command to turn OFF the EGR step motor C phase 3 One flash followed by three flashes Connector Har...

Page 95: ...ure of diagnosis see P 1 182 2 Check of connectors wiring Before beginning your work be sure to turn off the key switch Check that the connector of the EGR step motor is correctly inserted Check that the wiring of the EGR step motor is not disconnected or the insulation of the wiring is not peeled 3 Failure Diagnostic Work Check the coil resistance of the EGR step motor Check the harness for corre...

Page 96: ...ernal circuitry may be faulty DTC P1423 3 Failure B with EGR valve Step Motor C Phase 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Key switch ON 2 Make an assessment logically as to followings E ECU detects the EGR step motor C phase turning OFF during the command to turn ON the EGR step motor C phase 3 One flash followed by three flashes Connector ...

Page 97: ...ure of diagnosis see P 1 182 2 Check of connectors wiring Before beginning your work be sure to turn off the key switch Check that the connector of the EGR step motor is correctly inserted Check that the wiring of the EGR step motor is not disconnected or the insulation of the wiring is not peeled 3 Failure Diagnostic Work Check the coil resistance of the EGR step motor Check the harness for corre...

Page 98: ...al circuitry may be faulty DTC P1432 4 Failure A with EGR valve Step Motor D Phase 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Key switch ON 2 Make an assessment logically as to followings E ECU detects the EGR step motor D phase turning ON during the command to turn OFF the EGR step motor C phase 3 One flash followed by three flashes Connector Har...

Page 99: ...ure of diagnosis see P 1 182 2 Check of connectors wiring Before beginning your work be sure to turn off the key switch Check that the connector of the EGR step motor is correctly inserted Check that the wiring of the EGR step motor is not disconnected or the insulation of the wiring is not peeled 3 Failure Diagnostic Work Check the coil resistance of the EGR step motor Check the harness for corre...

Page 100: ...ernal circuitry may be faulty DTC P1433 3 Failure B with EGR valve Step Motor D Phase 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Key switch ON 2 Make an assessment logically as to followings E ECU detects the EGR step motor D phase turning OFF during the command to turn ON the EGR step motor D phase 3 One flash followed by three flashes Connector ...

Page 101: ...ure of diagnosis see P 1 182 2 Check of connectors wiring Before beginning your work be sure to turn off the key switch Check that the connector of the EGR step motor is correctly inserted Check that the wiring of the EGR step motor is not disconnected or the insulation of the wiring is not peeled 3 Failure Diagnostic Work Check the coil resistance of the EGR step motor Check the harness for corre...

Page 102: ...the oil pressure switch may be disconnected or short circuited with POWER SUPPLY The E ECU internal circuitry may be faulty DTC P1192 4 Failure with oil pressure switch 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Key switch ON 2 Oil pressure switch turns ON with engine stopped This manual assumes that the contact input is configured as Normally Ope...

Page 103: ...ure of diagnosis see P 1 187 2 Check of connectors wiring Before beginning your work be sure to turn off the key switch Check that the connector of the oil pressure switch is correctly inserted Check that the wiring of the oil pressure switch is not disconnected or the insulation of the wiring is not peeled 3 Failure Diagnostic Work Check the harness for correct continuity For details of the metho...

Page 104: ...re Descend 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Key switch ON 2 Oil pressure switch turns ON after engine has been started This manual assumes that the contact input is configured as Normally Open NO 3 Three flashes followed by one flash Hydrostatic system Harness Oil pressure switch E ECU Setting of response to oil pressure low alarm Unavai...

Page 105: ...d and the procedure of diagnosis see P 1 187 2 Engine Inspection Turn the key switch off to stop the engine Inspect the oil pressure system After the inspection turn the key switch on to check if the DTC is detected For description and procedure of engine inspection see the Service manual Engine 3 Failure Diagnostic Work Check the oil pressure switch system For details of the method and the proced...

Page 106: ...itch may be disconnected or short circuited with POWER SUPPLY The E ECU internal circuitry may be faulty DTC P1562 4 Failure with Charge Switch 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Key switch ON 2 Charge switch turns OFF with engine stopped This manual assumes that the contact input is configured as Normally Open NO 3 Two flashes followed by...

Page 107: ...cedure of diagnosis see P 1 187 2 Check of connectors wiring Before beginning your work be sure to turn off the key switch Check that the connector of the charge switch is correctly inserted Check that the wiring of the charge switch is not disconnected or the insulation of the wiring is not peeled 3 Failure Diagnostic Work Check the harness for correct continuity For details of the method and the...

Page 108: ...be short circuited with GND The E ECU internal circuitry may be faulty DTC P1568 1 Charge Alarm 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Key switch ON 2 Charge switch turns ON after engine has been started This manual assumes that the contact input is configured as Normally Open NO 3 Three flashes followed by two flashes alternator Harness Charg...

Page 109: ... the procedure of diagnosis see P 1 187 2 Engine Inspection Turn the key switch off to stop the engine Inspect the charging system of the engine After the inspection turn the key switch on to check if the DTC is detected For description and procedure of engine inspection see the Service manual Engine 3 Failure Diagnostic Work Check the charge switch system For details of the method and the procedu...

Page 110: ...lty DTC P1217 0 Abnormal Water Temperature 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Key switch ON 2 Water temperature switch turns ON after engine has been started This manual assumes that the contact input is configured as Normally Open NO 3 Three flashes followed by three flashes Engine cooling system Harness Water Temperature Switch E ECU Set...

Page 111: ...thod and the procedure of diagnosis see P 1 187 2 Engine Inspection Turn the key switch off to stop the engine Check the engine cooling system After a little turn the key switch on to check if the DTC is detected For description and procedure of engine inspection see the Service manual Engine 3 Failure Diagnostic Work Check the water temperature switch system For details of the method and the proc...

Page 112: ...m 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Key switch ON 2 Air cleaner switch turns ON after engine has been started This manual assumes that the contact input is configured as Normally Open NO 3 Three flashes followed by four flashes Air Cleaner Harness Air cleaner switch E ECU Setting of Response to Air Cleaner Failure Unavailable Available Er...

Page 113: ...e method and the procedure of diagnosis see P 1 187 2 Engine Inspection Turn the key switch off to stop the engine Inspect the air cleaner After a little turn the key switch on to check if the DTC is detected For description and procedure of engine inspection see the Service manual Engine 3 Failure Diagnostic Work Check the air cleaner switch system For details of the method and the procedure of d...

Page 114: ...or Alarm 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Key switch ON 2 Oil water separator switch turns ON after engine has been started This manual assumes that the contact input is configured as Normally Open NO 3 Three flashes followed by five flashes Oil Water Separator Harness Oil Water Separator Switch E ECU Setting of response to oil water sep...

Page 115: ...thod and the procedure of diagnosis see P 1 187 2 Engine Inspection Turn the key switch off to stop the engine Inspect the oil water separator After a little turn the key switch on to check if the DTC is detected For description and procedure of engine inspection see the Service manual Engine 3 Failure Diagnostic Work Check the oil water separator switch system For details of the method and the pr...

Page 116: ...tor inner wiring Inner wiring of the rack actuator may be short circuited with GND The E ECU internal circuitry may be faulty DTC P1212 4 Failure with Rack Actuator Low Current 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Key switch ON 2 Rack actuator current detected equal to or below the lower limit 3 Eight flashes Connector Harness Rack actuator ...

Page 117: ...3 2 Check of connectors wiring Before beginning your work be sure to turn off the key switch Check that the connector of the rack actuator is correctly inserted Check that the wiring of the rack actuator is not disconnected or the insulation of the wiring is not peeled 3 Failure Diagnostic Work Check the resistance value of the rack actuator solenoid Check the harness for correct continuity For de...

Page 118: ... SUPPLY the ECU s power supply line fuse 10A might be blown With this fuse blown the E ECU may fail to detect indicate the error and to store the error history The E ECU internal circuitry may be faulty DTC P1213 3 Failure with Rack Actuator High Current 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Key switch ON 2 Rack actuator current detected equa...

Page 119: ...3 2 Check of connectors wiring Before beginning your work be sure to turn off the key switch Check that the connector of the rack actuator is correctly inserted Check that the wiring of the rack actuator is not disconnected or the insulation of the wiring is not peeled 3 Failure Diagnostic Work Check the resistance value of the rack actuator solenoid Check the harness for correct continuity For de...

Page 120: ...e fuel rusts the plunger DTC P1211 7 Rack Actuator Mechanical Failure 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Key switch ON 2 Rack operation check at the activation 3 Eight flashes Rack Error Mode Stop Immediately The engine does not start up Run restricted Yes The rack actuator relay is turned OFF and the starter does not rotate Recovery Condi...

Page 121: ...3 2 Check of connectors wiring Before beginning your work be sure to turn off the key switch Check that the connector of the rack actuator is correctly inserted Check that the wiring of the rack actuator is not disconnected or the insulation of the wiring is not peeled 3 Failure Diagnostic Work Check the resistance value of the rack actuator solenoid Check the harness for correct continuity For de...

Page 122: ... of the fuel injection pump The rack actuator wiring may be short circuited with GND DTC P1214 2 Engine Trouble 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Key switch ON 2 1 Engine stall during a rack position sensor error 2 Unexpected engine speed rise is detected other than acceleration 3 Eight flashes Harness Rack actuator Error Mode Stop Immedi...

Page 123: ...he key switch off to stop the engine Inspect the engine and the operating machine After a little turn the key switch on to check if the DTC is detected For description and procedure of engine inspection see the Service manual Engine 3 Failure Diagnostic Work Check the Rack Actuator For details of the method and the procedure of diagnosis see P 1 193 TNV_DI_SM_A4 Troubleshooting book 121 ページ ２００７年１...

Page 124: ...with Sub CPU P1612 12 Failure C with Sub CPU 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Key switch ON 2 E ECU detects an error of the internal circuit 3 Four flashes followed by one flash E ECU Error Mode Run As Is After detecting the error the system lets the engine continue to run without any restrictions Run restricted No Recovery Conditions No...

Page 125: ... FlashROM error Checksum A P1605 2 FlashROM error Checksum B P1606 2 FlashROM error Checksum C P1620 12 Map format error 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Key switch ON 2 E ECU detects an error of the internal circuit 3 Four flashes followed by one flash E ECU Error Mode Stop Immediately The engine does not start up Run restricted Yes The...

Page 126: ...ne of the main relay coil is short circuited with POWER SUPPLY the E ECU s power supply line fuse 10A may be blown or the inner circuit of E ECU may fail In this case the E ECU may fail to detect indicate the error and to store the error history The E ECU internal circuitry may be faulty DTC P0686 4 Main relay error 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Che...

Page 127: ...ctors wiring Before beginning your work be sure to turn off the key switch Check that the main relay is inserted to the harness connector correctly Check that the wiring of the main relay is not disconnected or the insulation of the wiring is not peeled 3 Failure Diagnostic Work Check the main relay contact for correct continuity Check the resistance value of the main relay Check the harness for c...

Page 128: ...t up 2 A necessary CANID cannot be received that should periodically received 3 One flash followed by two flashes Other ECUs Battery Connector Harness E ECU Accelerator sensor function CAN communication only CAN communication plus analog input or pulse accelerator Error Mode Run Under Restrictions The engine runs at a constant rotational speed Run As Is The engine continues to run using the analog...

Page 129: ...f connectors wiring Before beginning your work be sure to turn off the key switch Check that the connector of the CAN communication is correctly inserted Check that the wiring of the CAN communication is not disconnected or the insulation of the wiring is not peeled 3 Failure Diagnostic Work Check the battery voltage Check the harness for correct continuity For details of the method and the proced...

Page 130: ...dition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Key switch ON 2 If the immobilizer does not respond to a request of authorization start 3 Four flashes followed by two flashes Immobilizer Battery Connector Harness E ECU Immobilizer pulse communication setting Yes No Error Mode Run As Is Authorization by the emergency pulse communication Stop Immediately The eng...

Page 131: ...f connectors wiring Before beginning your work be sure to turn off the key switch Check that the connector of the CAN communication is correctly inserted Check that the wiring of the CAN communication is not disconnected or the insulation of the wiring is not peeled 3 Failure Diagnostic Work Check the battery voltage Check the harness for correct continuity For details of the method and the proced...

Page 132: ...munication 1 Precondition 2 Detecting condition s 3 Flashing pattern of failure indicator Check points 1 Key switch ON 2 In the case of timeout detection 3 Four flashes followed by two flashes Immobilizer Connector Harness E ECU Immobilizer CAN communication Normal Error Error Mode Run As Is Engine start is authorized Stop Immediately The engine does not start up Run restricted No Yes The rack act...

Page 133: ... Before beginning your work be sure to turn off the key switch Check that the wiring for the immobilizer pulse communication and E ECU are correctly connected Check that the wiring for the immobilizer pulse communication is not disconnected or the insulation of the wiring is not peeled 3 Failure Diagnostic Work Check the harness for correct continuity For details of the method and the procedure of...

Page 134: ...ilure indicator Check points 1 Key switch ON 2 1 Authorization by CAN communication is NG 2 Immobilizer CAN communication is faulty and authorization by immobilizer pulse communication is NG 3 Four flashes followed by two flashes Immobilizer authorization key Error Mode Stop Immediately The engine does not start up Run restricted Yes The rack actuator relay is turned OFF and the starter does not r...

Page 135: ...ated DTC Related DTC s is listed 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 DTC Code Number Error Name TNV_DI_SM_A4 Troubleshooting book 133 ページ ２００７年１１月１５日 木曜日 午後５時２７分 ...

Page 136: ...SISTANCE SWITCH OVER RECAN E07 4 G Key switch IGNSW E31 1 A STEP MOTOR A PHASE STPM A E08 4 H ENGINE START RECOGNITION STARTSW E32 1 B LOAD FACTOR MONITOR 1 LOAD M E09 4 J APPLICATION OPEN INPUT 3 APP IP3 E33 1 C RACK ACTUATOR RELAY RACK RLY E10 4 K Spare speed sensor RENRPM E34 1 D Main relay MAIN RLY E11 3 A STEP MOTOR C PHASE STPM C E35 1 E ACCELERATOR POSITION SENSOR APS E12 3 B FAILURE INDICA...

Page 137: ...ing the following list E20 E18 E19 E09 E10 E11 E12 E13 E14 E15 E16 E08 E05 E06 E02 E03 E01 E04 E07 E17 E21 E22 E23 E24 E28 E30 E25 E26 E27 E29 E31 E32 E33 E34 E35 E36 E37 E38 E39 E40 E41 E42 E43 E44 E45 E46 E47 E48 2G Eco checker Harness V Check E ECU Machine s harness Connect between E ECU and machine s harness Pin layout correspondence list Accelerator sensor E35 Cooling water temperature sensor...

Page 138: ...ace the harness OK OK OK NG NG NG 1 Input voltage check of the rack position sensor harness E ECU 2 Check the harness continuity 3 Execution of directive rack position control use diagnosis tool A Check the current failure display B Check the detected value to estimate the cause of failure DTC in the failure history indication Check the failure conditions Current failure exists Initial diagnosis w...

Page 139: ...t Diagram P 1 134 Check points 017535 00E RPS E36 RPS E ECU BAT G_S GND A E28 10A E43 E48 AVB ECU VB MAIN RLY E34 C E D B A B17 E42 E36 E43 E28 E D C A B Rack position sensor Battery Fuse Rack Actuator Main relay Harness side coupler coupling face Actuator side coupler coupling face TNV_DI_SM_A4 Troubleshooting book 137 ページ ２００７年１１月１５日 木曜日 午後５時２７分 ...

Page 140: ...to 3 Execution check of the directive rack position control Terminal Continuity Status Sensor signal wire E36 Between E ECU and sensor connector Available OK normal Unavailable NG harness disconnection Sensor GND wire E28 Between E ECU and sensor connector Available OK normal Unavailable NG harness disconnection Sensor 12V wire E43 Between E ECU and sensor connector Available OK normal Unavailable...

Page 141: ...o 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 an allowable setting range After the execution check if the rack actuator moved to the set rack position NG Replace the fuel injection pump OK Replace the E ECU TNV_DI_SM_A4 Troubleshooting book 139 ...

Page 142: ...e harness Replace the sensor 1 Check of sensor resistance value sensor only 2 Sensor replacement Check of sensor resistance value sensor harness 3 Check the harness continuity 4 Check of the accelerator sensor output voltage when fit to sensor A Check the current failure display Check the failure conditions B Check the detected value to estimate the cause of failure Current failure exists Initial ...

Page 143: ... Pin Layout Diagram P 1 134 Check points 017537 00E SNS5 STH G_S AVCC APS GND A E38 C B A E35 E28 SNS5 STH G_S REAN E37 E ECU E28 E35 E38 C B A Accelerator sensor standard Spare accelerator sensor option Harness side coupler coupling face Sensor side coupler coupling face TNV_DI_SM_A4 Troubleshooting book 141 ページ ２００７年１１月１５日 木曜日 午後５時２７分 ...

Page 144: ...stance value using a circuit tester See above mentioned REF Total resistance value of Yanmar standard accelerator sensors Between harness E38 and E28 Measure the resistance between E ECU connectors E35 and E28 using a circuit tester Check if the resistance value between E ECU connectors E35 and E28 fluctuates when the accelerator throttle is moved Terminal Specification Sensor A C 5 1 5kΩ NG Repla...

Page 145: ...5V wire E38 Between E ECU and sensor connector Available OK normal Unavailable NG harness disconnection Between E35 and other terminal GND and between E38 and other terminal GND Unavailable OK normal Available NG harness short circuited with GND Between E28 and GND E45 E47 Available OK normal Unavailable NG harness disconnection Between E28 and other terminals Unavailable OK normal Available NG ha...

Page 146: ... 019477 00E Replacement of E ECU Replacement of E ECU or foot pedal Harness replacement Foot pedal replacement 1 Continuity check foot pedal only OK OK OK NG NG NG NG 2 Continuity check foot pedal harness A Check the current failure display Check the failure conditions B Check the detected value to estimate the cause of failure Current failure exists Initial diagnosis with the diagnosis tool Failu...

Page 147: ... Pin Layout see E ECU Pin Layout Diagram P 1 134 Check points 019478 00E APP IP2 APP IP7 E14 E13 Foot pedal NO NC SNS5 STH G_S AVCC APS GND A E38 C B B A A E35 E28 Accelerator sensor standard SNS5 STH G_S REAN E37 Spare accelerator sensor option E ECU TNV_DI_SM_A4 Troubleshooting book 145 ページ ２００７年１１月１５日 木曜日 午後５時２７分 ...

Page 148: ...ircuitry fault Unavailable Available NG Internal circuitry fault Available Available NG Internal circuitry fault NG Replace the foot pedal OK Check the continuity with the foot pedal and the harness being connected Go to 2 Continuity check foot pedal harness Pedal opening Continuity Status Between E 14 and GND Between E 13 and GND Full close position Unavailable Available OK normal Unavailable Una...

Page 149: ...tatus Pedal signal wire A E14 Between E ECU and pedal connector Available OK normal Unavailable NG harness disconnection Pedal signal wire B E13 Between E ECU and pedal connector Available OK normal Unavailable NG harness disconnection Between E14 and other terminal GND and between E13 and other terminal GND Unavailable OK normal Available NG harness short circuited with GND NG Check if the harnes...

Page 150: ...re with Spare Accelerator Sensor P2228 4 Failure with Atmospheric Pressure Sensor Low Voltage P2229 3 Failure with Atmospheric Pressure Sensor High Voltage P2230 2 Intermittent Failure with Atmospheric Pressure Sensor Check the failure conditions Initial diagnosis with the diagnosis tool Reserved Analog Input 1 V Signal Data SD SD 200 0 2V Signal wire disconnected 200 0 2V SD 4600 4 6V Normal 4600...

Page 151: ...ment Sensor replacement 1 Check of sensor resistance value sensor only OK OK OK NG NG NG NG 2 Check of sensor resistance value sensor harness Failure diagnosis flow OK 3 Harness continuity check 4 Check of sensor output voltage when fit to sensor Check points 019481 00E SNS5 SG G_S AVCC REAN GND A E38 C B A E37 E28 Spare accelerator sensor or Atmospheric pressure sensor E ECU TNV_DI_SM_A4 Troubles...

Page 152: ...lue using a circuit tester Refer to above mentioned sensor resistance values Between harness E37 and E28 Measure the resistance between E ECU connectors E37 and E28 using a circuit tester Check if the resistance value between E ECU connector E37 and E28 fluctuates when the sensor opening is changed Terminal Specification Sensors A C 5 1 5kΩ NG Replace the spare accelerator sensor or the atmospheri...

Page 153: ...etween E ECU and sensor connector Available OK normal Unavailable NG harness disconnection Between E37 and other terminal GND and between E38 and other terminal GND Unavailable OK normal Available NG harness short circuited with GND Between E28 and GND E45 E47 Available OK normal Unavailable NG harness disconnection Between E28 and other terminals Unavailable OK normal Available NG harness short c...

Page 154: ... P1127 8 Failure with Spare Accelerator Sensor Pulse Communication 019482 00E Check the sender unit of the pulse accelerator signal or replace E ECU Harness replacement 1 Harness continuity check OK NG Check the failure conditions Initial diagnosis with the diagnosis tool Failure diagnosis flow Check items Fault Code A Check the current failure display Current failure exists DTC in the failure his...

Page 155: ... 00J CANH CANL APP IP3 E40 CAN Communication Pulse accelerator signal E39 E09 UFO E ECU Terminal Continuity Status Pulse accelerator signal wire E09 Between E ECU and source units Available OK normal Unavailable NG harness disconnection Between E09 and other terminal GND Unavailable OK normal Available NG harness short circuited with GND NG Check if the harness is damaged or if the wiring is corre...

Page 156: ...ensor 017538 00E OK A Check the current failure display Check the failure conditions B Check the detected value to estimate the cause of failure Current failure exists Initial diagnosis with the diagnosis tool Check items ECU temperature ECU temperature is stationary at 30 C ECU temperature equivalent to ambient temperature Normal 1 Do the same steps as in the initial diagnosis above Failure diagn...

Page 157: ... Temperature with the diagnosis tool Diagnosis Test function Unavailable Check the error history indication confirm error occurrence situation if any error history is indicated Available Check the detected value using the diagnosis tool Go to Check of detected value Indicated value Status Action Fixed at 30 C NG Replace the E ECU Ambient temperature OK Replace the E ECU NG Replace E ECU OK Turn th...

Page 158: ...Replace the E ECU or sensor Replace the E ECU Replace the harness Replace the sensor 1 Check of sensor resistance value sensor only OK 2 Check of sensor resistance value sensor harness 3 Check the harness continuity 4 Check of cooling water temperature sensor output voltage A Check the current failure display Check the failure conditions B Check the detected value to estimate the cause of failure ...

Page 159: ...in Layout Diagram P 1 134 M12 x 1 5 59 19 007217 00E High precision cooling watertemperaturesensor and conventional cooling watertemperaturesensor have similar construction A B Check points THW G_S RET G_S E16 A B E28 E ECU THW G_S TW E25 A B E16 E28 E25 E28 017540 00E High accuracy cooling water temperature sensor Cooling water temperature sensor Harness side coupler coupling face Harness side co...

Page 160: ...ured resistance value is within the normal range referring to the above table Characteristics of cooling water temperature sensor 40 0 40 80 120 0 1 1 10 100 40 0 40 80 120 017541 00E Temperature C Temperature C Resistance kΩ Temperature C Resistance kΩ High precision Conventional 30 25 4 28 6 20 15 04 16 2 10 9 16 9 56 0 5 74 5 88 10 3 7 3 73 20 2 45 2 45 30 1 66 1 65 40 1 15 1 14 50 0 811 0 808 ...

Page 161: ...normal Unavailable NG harness disconnection Between E16 and other terminal GND between E25 and other terminal GND Unavailable OK normal Available NG harness short circuited with GND E28 ñ GND E45 E47 Available OK normal Unavailable NG harness disconnection Between E28 and other terminals Unavailable OK normal Available NG harness short circuited with another wiring NG Check if the harness is damag...

Page 162: ...ons B Check the detected value to estimate the cause of failure Current failure exists Initial diagnosis with the diagnosis tool Check items SENSOR 5V voltage SENSOR 5V voltage 4 5V Short circuited with GND 4 5V SENSOR 5V voltage 5 5V Normal 5 5V SENSOR 5V voltage hort circuited with POWER SUPPLY Replace the E ECU Replace the E ECU Replace the harness Replace the sensor 1 Check the accelerator sen...

Page 163: ...f harness continuity OK Check the output voltage with the accelerator sensor being connected Go to 4 Check of the output voltage fit with sensor Terminal Continuity Status Between E38 and E28 E45 E47 GND Unavailable OK normal Available NG harness short circuited with GND Between E38 and E43 E48 Unavailable OK normal Available NG Harness short circuited with power supply Sensor GND wire E28 ÅiBetwe...

Page 164: ...nect the all connectors sensors E ECU Measure the voltage between sensor signal E38 and E28 using a circuit tester Voltage Status Action E38 4 5 V NG Replace the harness Replace the accelerator sensor 4 5 V E38 5 5 V OK Normal range Replace E ECU 5 5 V E38 NG Replace the harness Replace the accelerator sensor NG Check if the harness is damaged or if the wiring is correct Replace the harness OK Rep...

Page 165: ...FAILURE DIAGNOSIS TNV DI Service Manual 1 163 Method and Procedure of Failure Diagnosis TNV_DI_SM_A4 Troubleshooting book 163 ページ ２００７年１１月１５日 木曜日 午後５時２７分 ...

Page 166: ...ess Replace the harness Replace the sensor 4 Check the harness for misconnections A Check the current failure display Check the failure conditions B Check the detected value to estimate the cause of failure Current failure exists Initial diagnosis with the diagnosis tool Failure diagnosis flow Check items Real engine speed value value 0 Disconnected Sensor error 3 Check the harness continuity DTC ...

Page 167: ... 1 134 Check points E ECU RENRPM E10 B L IG B S ON or START 15A P 5A CRK CRK A B NRPM GND E18 NRPM E19 STARTSW E08 B19 E18 A B 017544 00E Spare speed sensor option Alternator Battery Starter Key switch Fuse Speed Sensor Harness side coupler coupling face Sensor side coupler coupling face Fuse TNV_DI_SM_A4 Troubleshooting book 165 ページ ２００７年１１月１５日 木曜日 午後５時２７分 ...

Page 168: ...he harness continuity using a circuit tester Terminal Specification Sensors A B 500 100Ω NG Replace the speed sensor OK Check the resistance between sensor terminals A and B with the speed sensor and the harness being connected Go to 2 Check of the sensor resistance value sensor harness NG Replace the harness OK Check the harness for correct continuity Go to 3 Check of harness continuity Terminal ...

Page 169: ... check or E ECU replacement Harness replacement Battery replacement or alternator check 1 Check of battery voltage NG NG Initial diagnosis with the diagnosis tool Failure diagnosis flow Check items Spare speed sensor Value Value 0 Disconnected Sensor error OK OK 2 Check of harness continuity A Check the current failure display Check the failure conditions B Check the detected value to estimate the...

Page 170: ... Layout Diagram P 1 134 Check points E ECU Spare speed sensor option Alternator RENRPM E10 Battery B S Starter Key switch ON or START Fuse 15A Fuse 5A CRK CRK B A Speed Sensor NRPM GND E18 NRPM E19 STARTSW E08 B L IG P P01 B18 E10 Harness side coupler coupling face 019610 00E TNV_DI_SM_A4 Troubleshooting book 168 ページ ２００７年１１月１５日 木曜日 午後５時２７分 ...

Page 171: ...heck the harness for correct continuity Go to 2 Check of harness continuity Terminal Continuity Status Alternator P terminal E10 Between E ECU and alternator Available OK normal Unavailable NG harness disconnection Alternator IG terminal Between Key switch and alternator Available OK normal Unavailable NG harness disconnection Alternator B terminal Between battery and alternator Available OK norma...

Page 172: ... OK NG NG NG NG Replace the E ECU Replace the ECU or harness Replace the harness Replace the relay 1 Check of relay coil resistance relay only 2 Check of relay coil resistance relay harness 3 Check the harness continuity 4 Movement check of the relay use diagnosis tool Failure diagnosis flow Check items Rack actuator relay Contact status ON Normal Contact status OFF Abnormal A Check the current fa...

Page 173: ...ACK RLY E33 ECU 10A 5A 15A IGNSW VB E07 E48 E34 MAIN RLY ON A D C B B C D A B17 E07 E48 B17 E33 Rack Actuator To the upstream of the coil Main relay Rack Actuator Relay Battery Fuse Fuse Fuse Key switch Relay side coupler coupling face Harness side coupler coupling face TNV_DI_SM_A4 Troubleshooting book 171 ページ ２００７年１１月１５日 木曜日 午後５時２７分 ...

Page 174: ...hod is applied and the measured value varies depending on a circuit tester to be used Measurement conditions Measured value Status Tester side Tester side Terminal C Terminal D Available OK when both are normal Terminal D Terminal C Infinity Terminal C Terminal D Infinity NG Fault of the relay internal circuitry Terminal D Terminal C NG Replace the rack actuator relay OK Check the relay coil resis...

Page 175: ...r connector Available OK normal Unavailable NG harness disconnection Relay coil upstream side E07 Between E ECU and sensor connector Available OK normal Unavailable NG harness disconnection Between E33 and GND E28 E45 E47 Unavailable OK normal Available NG harness short circuited with GND Between E33 and E43 E48 Unavailable OK normal Available NG Harness short circuited with power supply NG Check ...

Page 176: ... Check the current failure display B Check the detected value to estimate the cause of failure Current failure exists Initial diagnosis with the diagnosis tool Check items Air heater relay 1 Contact status ON Normal Contact status OFF Abnormal Replace the E ECU Replace the ECU or harness Replace the harness Replace the relay 3 Check the harness continuity Failure diagnosis flow Check the failure c...

Page 177: ... E ECU Pin Layout see E ECU Pin Layout Diagram P 1 134 Check points 017548 00E E ECU AIRHT RLY E44 B S 60A 60A Battery Air heater Air heater relay Starter Fuse Fuse Air heater 017549 00E B00 B02 E44 B14 B04 B15 Harness side coupler coupling face TNV_DI_SM_A4 Troubleshooting book 175 ページ ２００７年１１月１５日 木曜日 午後５時２７分 ...

Page 178: ...C 103Ω 10 at 20 C 80Ω at 20 C NG Replace the start assist relay OK Check the relay coil resistance with the start assist relay and the harness being connected Go to 2 Check of relay coil resistance value relay harness side NG Check the harness for correct continuity Go to 3 Check of harness continuity OK Check the movement of the start assist relay by a diagnosis tool Go to 4 Movement check of the...

Page 179: ... after key switch turning on Activate the start assistant relay by the diagnosis tool Diagnosis Test Active control and measure the voltage between terminals E44 and E45 ON OFF setting status Voltage Status ON 2 5 V and above OK normal Under 2 5 V NG Harness short circuited with GND or E ECU fault OFF 1 75 V and below OK normal Over 1 75 V NG Harness short circuited with power supply or E ECU faul...

Page 180: ...B Check the detected value to estimate the cause of failure Current failure exists Initial diagnosis with the diagnosis tool Check items CSD solenoid valve Contact status ON Normal Contact status OFF Abnormal Replace the E ECU Replace the ECU or harness Replace the harness Replace the relay Failure diagnosis flow Check the failure conditions 1 Check of resistance value of CSD solenoid valve coil s...

Page 181: ...ure Diagnosis Wiring Diagram For the E ECU Pin Layout see E ECU Pin Layout Diagram P 1 134 Check points 017551 00E E41 E ECU CSD CL E41 CSD solenoid valve Fuel injection pump Harness side coupler coupling face TNV_DI_SM_A4 Troubleshooting book 179 ページ ２００７年１１月１５日 木曜日 午後５時２７分 ...

Page 182: ... solenoid valve side C D 400W 8Ω at 23 C NG Replace the solenoid valve OK Check the coil resistance of the CSD solenoid valve with the CSD solenoid valve connector and the harness being connected Go to 2 Check of resistance value of the CSD solenoid valve coil solenoid valve harness NG Check the harness for correct continuity Go to 3 Check of harness continuity OK Check the movement of the CSD sol...

Page 183: ...nosis tool after key switch turning on Activate the start assistant relay by the diagnosis tool Diagnosis Test Active control and measure the voltage between terminals E41 and E45 ON OFF setting status Voltage Status ON 2 5 V and above OK normal Under 2 5 V NG Harness short circuited with GND or E ECU fault OFF 1 75 V and below OK normal Over 1 75 V NG Harness short circuited with power supply or ...

Page 184: ...ilure B with EGR valve Step Motor B Phase P1422 4 Failure A with EGR valve Step Motor C Phase P1423 3 Failure B with EGR valve Step Motor C Phase P1432 4 Failure A with EGR valve Step Motor D Phase P1433 3 Failure B with EGR valve Step Motor D Phase 017552 00E A Check the current failure display Check the failure conditions B Check the detected value to estimate the cause of failure Initial diagno...

Page 185: ...ness Replace the harness Replace the sensor OK OK Failure diagnosis flow 3 Check the harness continuity 1 Resistance check of EGR step motor coil EGR Valve only 2 Resistance check of EGR step motor coil EGR harness 4 Check of EGR movement use diagnosis tool Replace the E ECU TNV_DI_SM_A4 Troubleshooting book 183 ページ ２００７年１１月１５日 木曜日 午後５時２７分 ...

Page 186: ...in Layout Diagram P 1 134 Check points E01 E48 E21 E11 E48 E31 STPM B E21 E ECU STPM A E31 10A E11 E48 STPM C VB MAIN RLY E34 STPM D E01 017554 00E EGR side coupler coupling face Battery Fuse EGR valve Main relay 1 2 3 6 5 4 2 6 3 4 1 5 ECU Harness side coupler coupling face TNV_DI_SM_A4 Troubleshooting book 184 ページ ２００７年１１月１５日 木曜日 午後５時２７分 ...

Page 187: ...uit tester See above mentioned REF Resistance of Yanmar standard EGR step motor coil Terminal Specification Coil terminal 4 5 A Phase Coil terminal 1 2 B Phase Coil terminal 5 6 C Phase Coil terminal 2 3 D Phase 15 2Ω NG Replace the EGR valve OK Check the EGR step motor coil resistance with the EGR valve and the harness being connected Go to 2 Check of EGR step motor coil resistance relay harness ...

Page 188: ... Between E ECU and EGR connector Available OK normal Unavailable NG harness disconnection Motor coil upstream side E48 Between E ECU and EGR connector Available OK normal Unavailable NG harness disconnection Between E31 E21 E11 E01 and GND E28 E45 E47 Unavailable OK normal Available NG harness short circuited with GND Between E31 E21 E11 E01 and E43 E48 Unavailable OK normal Available NG Harness s...

Page 189: ... 0 Abnormal Water Temperature P1101 0 Air cleaner Clogging Alarm P1151 0 Oil water separator Alarm 019611 00E Initial diagnosis with the diagnosis tool Check items Contact input terminal ON OFF status Before engine start ON Normal OFF Disconnected Oil pressure SW Charge SW Before engine start OFF Normal ON Short circuited with GND Water temperature SW Air cleaner SW Air cleaner SW A Check the curr...

Page 190: ...nput switch replacement Harness replacement Replacement of each contact input switch OK OK OK OK NG NG NG NG Failure diagnosis flow 3 Continuity check harness 1 Continuity check contact input switch only 2 Continuity check contact input switch harness 4 Movement check of contact input switch TNV_DI_SM_A4 Troubleshooting book 188 ページ ２００７年１１月１５日 木曜日 午後５時２７分 ...

Page 191: ... Layout Diagram P 1 134 Check points 019613 00E APP IP3 E09 E ECU APP IP2 E14 Battery E05 E07 APP IP5 Sub relay IGNSW APP IP6 E06 Key switch Oil pressure switch Charge switch Air cleaner Oil Water Separator 120Ω Or lamp lamp lamp lamp Water Temperature Switch E17 APP IP4 lamp TNV_DI_SM_A4 Troubleshooting book 189 ページ ２００７年１１月１５日 木曜日 午後５時２７分 ...

Page 192: ...pressure switch APP IP2 E14 Available OK normal Unavailable NG Internal circuitry fault Charge Switch APP IP3 E09 Unavailable OK normal Available NG Internal circuitry fault Water Temperature Switch APP IP4 E17 Unavailable OK normal Available NG Internal circuitry fault Air cleaner switch APP IP5 E05 Unavailable OK normal Available NG Internal circuitry fault Oil Water Separator Switch APP IP6 E06...

Page 193: ...tatus Switch signal wire E14 Between E ECU and switch connector Available OK normal Unavailable NG harness disconnection Between E14 and E38 E43 E48 power supply line Unavailable OK normal Available NG Harness short circuited with power supply Between E14 and E28 E45 E47 GND line GND Unavailable OK normal Available NG harness short circuited with GND NG Check if the harness is damaged or if the wi...

Page 194: ...ry fault During engine running OFF OK normal ON NG Harness error or internal circuitry fault Charge Switch Before engine start ON OK normal OFF NG Harness error or internal circuitry fault During engine runnning OFF OK normal ON NG Harness error or internal circuitry fault Water Temperature Switch Before engine start OFF OK normal ON NG Harness error or internal circuitry fault Air cleaner switch ...

Page 195: ...tuator Mechanical Failure 017555 00E OK OK OK NG NG NG NG Replace the sensor 3 Check the harness continuity Failure diagnosis flow A Check the current failure display Check the failure conditions Current failure exists Initial diagnosis with the diagnosis tool Replace the harness Replace the E ECU or fuel injection pump Replace the E ECU Check items Fault Code 1 Check of rack actuator coil resista...

Page 196: ...N E ECU RPS BAT G_S RACKSOL RACK RLY E33 E42 E28 E36 E43 GND A RPS AVB 10A 5A 15A IGNSW VB E07 E48 E34 MAIN RLY C E D B A B17 E42 E36 E43 E28 E D C A B Key switch Rack position sensor Rack Actuator ECU Main relay Rack Actuator Relay Battery Fuse Fuse Fuse Harness side coupler coupling face Actuator side coupler coupling face TNV_DI_SM_A4 Troubleshooting book 194 ページ ２００７年１１月１５日 木曜日 午後５時２７分 ...

Page 197: ...it tester Terminal Specification Coils A B 1Ω 10 NG Replace the fuel injection pump OK Check the resistance between actuator terminals A and B with the rack actuator and the harness being connected Go to 2 Check of the rack actuator coil resistance harness actuator NG Check the harness for correct continuity Go to 3 Check of harness continuity OK Check the movement of the actuator by the diagnosis...

Page 198: ...o 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 After the execution check if the rack actuator moved to the set rack position NG Replace the fuel injection pump OK Replace the E ECU TNV_DI_SM_A4 Troubleshooting book 196 ページ ２００７年１１月１５...

Page 199: ...r Checksum B P1606 2 Flash ROM error Checksum C P1610 12 Failure A with Sub CPU P1611 12 Failure B with Sub CPU P1612 12 Failure C with Sub CPU P1620 12 Map format error OK 017557 00E Rewrite E ECU software or replace E ECU 1 Same work as above mentioned initial diagnosis A Check the current failure display Check the failure conditions Current failure exists Initial diagnosis with the diagnosis to...

Page 200: ...e diagnosis tool and check if any error is detected on the current fault indication Unavailable Check the error history indication confirm error occurrence situation if any error history is indicated Available Turn the key switch on off again and perform the work 1 Work with the diagnosis tool Rewrite the E ECU software Replace the E ECU TNV_DI_SM_A4 Troubleshooting book 198 ページ ２００７年１１月１５日 木曜日 午後...

Page 201: ...nuity 3 Check of relay coil resistance relay harness 4 Check the harness continuity A Check the current failure display Check the failure conditions B Log into the diagnosis tool Current failure exists Initial diagnosis with the diagnosis tool Failure diagnosis flow Check items Logging into the diagnosis tool Main relay coil downstream short circuited with GND Replace the relay Replace the harness...

Page 202: ...e E ECU Pin Layout Diagram P 1 134 Check points 017559 00E B10 B10 E48 E34 B C D A E ECU 10A E48 VB VB MAIN RLY E34 ON 15A IGNSW E07 5A D C A B Battery Fuse ECU Self hold relay Key switch Fuse Fuse Relay side coupler coupling face Harness side coupler coupling face TNV_DI_SM_A4 Troubleshooting book 200 ページ ２００７年１１月１５日 木曜日 午後５時２７分 ...

Page 203: ... integrated the above mentioned checking method is applied and the measured value varies depending on a circuit tester to be used NG Replace the E ECU main relay OK Check the resistance of the E ECU main relay coil Go to 2 Check of the relay coil resistance value relay only Measurement conditions Measured value Status Tester side Tester side Terminal C Terminal D Available OK when both are normal ...

Page 204: ...45 E47 Unavailable OK normal Available NG harness short circuited with GND Between relay contact downstream side E48 and E43 battery Unavailable OK normal Available NG Harness short circuited with power supply NG Check if the harness is damaged or if the wiring is correct Replace the harness OK Connect the all connectors E ECU main relay E ECU and recheck that any error is detected with the diagno...

Page 205: ...lace battery Replace the harness 1 Check of battery voltage diagnosis tool 2 Check the harness continuity A Check the current failure display Check the failure conditions B Check the detected value to estimate the cause of failure Current failure exists Initial diagnosis with the diagnosis tool Failure diagnosis flow Check Items Battery voltage 12 V or equivalent battery voltage 16 V 10 5 V Batter...

Page 206: ...ttery Check the movement of other E ECUs NG Charge or replace the battery Check the movement of other E ECUs OK Check the harness for correct continuity Go to 2 Check of harness continuity Terminal Continuity Status CAN wiring Hi side E40 Between E ECU and sensor connector Available OK normal Unavailable NG harness disconnection CAN wiring Low side E39 Between E ECU and sensor connector Available ...

Page 207: ...ual separately DTC U1167 8 Immobilizer Error pulse communication 019614 00E Check of immobilizer or replacement of E ECU Replace the harness OK NG 1 Check the harness continuity Initial diagnosis with the diagnosis tool Failure diagnosis flow Check items Fault Code A Check the current failure display Check the failure conditions Current failure exists DTC in the failure history indication TNV_DI_S...

Page 208: ...er CAN Communication Terminal Continuity Status Immobilizer pulse communication line E17 Between E ECU and immobilizer Available OK normal Unavailable NG harness disconnection Between E17 and E38 E43 E48 power supply line Unavailable OK normal Available NG Harness short circuited with power supply Between E17 and E28 E45 E47 GND line GND Unavailable OK normal Available NG harness short circuited w...

Page 209: ...r on time it flashes in a pattern of 13 i e one long flash followed by 3 short flashes as shown in the second example When two or more failures occur at the same time the failure indicator indicates all the failures one by one in the ascending order of the number of flashes Also the failure indicator is always lit for 2 s after power on whether or not any failure exists 017118 00E 2s 3s 0 5s 3s 2s...

Page 210: ...12 4 P 1 114 Failure high voltage P1213 3 P 1 116 Mechanical failure P1211 7 P 1 118 9 Engine Overspeed P0219 0 P 1 64 1 1 Spare Speed Sensor Failure low voltage P1340 4 P 1 62 1 2 CAN Communication U0001 12 P 1 126 1 3 EGR Step Motor A phase failure disconnection P1402 4 P 1 100 A phase failure short circuit P1403 3 P 1 86 B phase failure disconnection P1412 4 P 1 88 B phase failure short circuit...

Page 211: ...mit error P0563 0 P 1 58 2 4 SENSOR 5V Failure low voltage P0642 4 P 1 53 Failure high voltage P0643 3 P 1 54 Intermittent failure P1644 2 P 1 55 2 5 ECU Internal Temperature Rise Error P0634 0 P 1 43 3 1 Oil Pressure Lower limit error P1198 1 P 1 102 3 2 Battery Charge Lower limit error P1568 1 P 1 106 3 3 Cooling Water Temperature Error P1217 0 P 1 108 3 4 Air Cleaner Mechanical failure P1101 0 ...

Page 212: ...lure Check error occurrence tool data and voltage with voltmeter Battery charging system error P1562 4 P1568 1 8 Fluctuation of electrical load Check presence of failure in large load electrical equipment such as air heater 9 Wire breakage or short circuit in harness or connector contact failure Check error occurrence tool data harness shaking and conduction with tester ECU supply voltage system e...

Page 213: ...ness shaking and conduction with tester Actuator relay system error P1222 4 P1223 3 P1224 2 20 Rack position sensor signal failure Wire breakage or short circuit in sensor or output failure Check error occurrence tool data and conduction with tester Rack position sensor system error P1202 4 P1203 3 21 Wire breakage or short circuit in harness or connector contact failure Check error occurrence too...

Page 214: ...t signal from working machine Working machine controller failure Check presence of failure in working machine controller 32 Wire breakage or short circuit in harness or connector contact failure Check tool data and conduction with tester 33 CAN communication system failure Communication circuit failure in controller for working machine Eco Governor etc Check error occurrence tool data and communic...

Page 215: ...ly at low temperatures 8 Wire breakage or short circuit of heater relay Check error occurrence tool data impact on relay and conduction with tester Start assisting relay error P1232 4 P1233 3 P1234 2 9 Wire breakage or short circuit in harness or connector contact failure Check error occurrence tool data harness shaking and conduction with tester Start assisting relay error P1232 4 P1233 3 P1234 2...

Page 216: ... system error P0340 4 21 Wire breakage or short circuit in harness or connector contact failure Check error occurrence tool data harness shaking and conduction with tester Speed sensor system error P0340 4 22 Cooling water temperature sensor system failure Wire breakage or short circuit in cooling water temperature sensor Check error occurrence tool data and conduction with tester Cooling water te...

Page 217: ...ester CAN communication error U0001 12 30 Controller system failure Contact failure of controller connector Check error occurrence tool data harness shaking and conduction with tester 31 Temporary failure in controller input output circuit Check occurrence of error 32 Program or map data failure Check program and map data 33 Unexpected strong noise or surge Control system affected by conductive no...

Page 218: ...r ECR step motor system error P1402 4 P1403 3 other phase errors 8 Wire breakage or short circuit in harness or connector contact failure Check error occurrence tool data harness shaking and conduction with tester ECR step motor system error P1402 4 P1403 3 other phase errors 9 Rack actuator system failure Rack actuator malfunction due to excessive hysteresis etc Check rack actuator operation and ...

Page 219: ...error 14 Program or map data failure Check program and map data 15 Unexpected strong noise or surge Control system affected by conductive noise Check presence of conductive noise 16 Control system affected by radioactive noise Check presence of radioactive noise No Check method Relevant DTC Remarks TNV_DI_SM_A4 Troubleshooting book 217 ページ ２００７年１１月１５日 木曜日 午後５時２７分 ...

Page 220: ... direct injection 2 valve cylinder head Yanmar Adapter Part No 119802 92950 Adapter for direct injection 4 valve cylinder head for 4TNV94L 98 98T Yanmar Adapter Part No 129906 92950 Adapter for direct injection 4 valve cylinder head for 4TNV106 T Yanmar Adapter Part No 123907 92950 0000849 0 3 1 0000850 5 6 1 000085 9 7 1 0000852 TNV_DI_SM_A4 Troubleshooting book 218 ページ ２００７年１１月１５日 木曜日 午後５時２７分 ...

Page 221: ...njector from the cylinder to be measured See Removal of Fuel Injectors on page 7 35 For engines with 4 valve cylinder heads 4 Remove the valve cover assembly See Removal of Valve Cover on page 6 52 Remove the fuel injector from the cylinder to be tested See Removal of Fuel Injectors on page 7 35 5 Turn off the fuel supply valve in the fuel supply line Disconnect the fuel injection pump stop soleno...

Page 222: ...reconnect the stop solenoid See Reassembly of Fuel Injectors on page 7 41 For engines with 4 valve cylinder heads 11 Install the fuel valves See Installation of the Fuel Injectors on page 7 42 See Inspection of Valve Guides on page 6 57 Then install the valve covers and injection high pressure lines Then connect the stop solenoid 12 Turn on the fuel supply valve and reconnect the injection pump st...

Page 223: ...3TNV84 4TNV84 455 485 psi 3 14 3 34 MPa 32 34 kgf cm 355 385 psi 2 45 2 65 MPa 25 27 kgf cm 3TNV84T 4TNV84T 411 441 psi 2 84 3 04 MPa 29 31 kgf cm 340 370 psi 2 35 2 55 MPa 24 26 kgf cm 3TNV88 4TNV88 4TNV94L 4TNV98 4TNV98T 4TNV106 4TNV106T 483 513 psi 3 33 3 53 MPa 34 36 kgf cm 384 414 psi 2 65 2 85 MPa 27 29 kgf cm 200 250 300 350 400 Engine speed min 1 3TNV84 4TNV84 3TNV82A 3TNV84T 4TNV84T 569 p...

Page 224: ... 1 Air Cleaner Element Clogged element Clean the element Broken element Replace the element Defect at element seal portion 2 Valve Clearance Excessive or no clearance Adjust the valve clearance 3 Valve Timing Incorrect valve clearance Adjust the valve clearance 4 Cylinder Head Gasket Gas leak from gasket Replace the gasket Retighten the cylinder head bolts to the specified torque 5 Intake Exhaust ...

Page 225: ... facing See Valve Face and Valve Seat on page 6 43 for 2 valve head and Valve Face and Valve Seat on page 6 59 for 4 valve head Intake exhaust valve seizure c c c c c c c c c c c Correction or replacement of intake exhaust valve See Removal of Intake Exhaust Valves on page 6 39 Cylinder head gasket blow out c c c Gasket replacement See Removal of Cylinder Head on page 6 54 Piston ring sticking or ...

Page 226: ...sassembly of Oil Pump on page 9 10 Insufficient lubricant quantity c c Replenishment of correct lubricant See Adding Engine Oil on page 4 17 Excess filling into crankcase c c c Engine oil check See Adding Engine Oil on page 4 17 Symptoms and conditions of failures Cause Defective start Engine stall after start Defective rotation control Insufficient engine output Noise vibration Lubricant Cooling ...

Page 227: ...fect of fuel tank c c Check of fuel tank and cap as well as installation of genuine parts Intake Air filter clogged c c c c c c c c Cleaning of air filter See Clean Air Cleaner Element on page 5 31 Engine operation at high temperature or high land c c c c c Consideration of matching output reduction with load Exhaust pipe clogged c c c c c c Cleaning of exhaust pipe Symptoms and conditions of fail...

Page 228: ... c c c c c Cleaning or replacement of speed sensor Repair or replacement of fuel injection pump Monitor the engine rotational speed by the diagnosis tool Rack position sensor signal error Level that ECU can t detect c c c c c c Repair or replacement of fuel injection pump Monitor the rack position sensor signal by the diagnosis tool Operation defect of rack actuator Level that ECU can t detect c c...

Page 229: ...ction short circuit of start assist relay c c c c Repair or replacement of harness Relay replacement For harness inspection method see Failure Diagnosis on page 1 1 Main relay OFF not available c c Relay replacement Disconnection short circuit of rack actuator relay c c Repair or replacement of harness Relay replacement For harness inspection method see Failure Diagnosis on page 1 1 Malfunction by...

Page 230: ...FAILURE DIAGNOSTIC LIST 1 228 TNV DI Service Manual Failure Diagnostic List This Page Intentionally Left Blank TNV_DI_SM_A4 Troubleshooting book 228 ページ ２００７年１１月１５日 木曜日 午後５時２７分 ...

Page 231: ...ommon 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 0000864A KEY SWITCH 30A FUSE EMERGENCY STOP SWITCH Items marked with are not provided by Yanmar TNV_DI_SM_A4 Troubleshooting book 229 ページ ２００７年１１月１５日 木曜日 午後５時２７分 ...

Page 232: ...WIRING DIAGRAM 1 230 TNV DI Service Manual Electrical Wiring This Page Intentionally Left Blank TNV_DI_SM_A4 Troubleshooting book 230 ページ ２００７年１１月１５日 木曜日 午後５時２７分 ...

Page 233: ...cancer and reproductive harm Wash hands after handling Head Office Yanmar Co Ltd 1 32 Chayamachi Kita ku Osaka 530 8311 Japan http www yanmar co jp Yanmar America Corporation 951 Corporate Grove Drive 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 h...

Page 234: ...C CONTROL TROUBLESHOOTING MANUAL TROUBLESHOOTING MANUAL 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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