Yanmar - TNV Troubleshooting Manual

TROUBLESHOOTING
TROUBLESHOOTING MANUAL
MANUAL
ELECTRONIC CONTROL
3TNV82A 4TNV84
3TNV82A-B 4TNV84T
3TNV84 4TNV84T-Z
3TNV84T 4TNV88
3TNV84T-B 4TNV88-B
3TNV88 4TNV88-U
3TNV88-B 4TNV94L
3TNV88-U 4TNV98
4TNV98-Z
4TNV98-E
4TNV98T
4TNV98T-Z
4TNV106
4TNV106T
0DTNV-G00600
PRINTED IN JAPAN
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
http://www.yanmar.nl
Yanmar Asia (Singapore) Corporation Pte. Ltd.

4 Tuas Lane, Singapore 638613
TEL: 65-68615077 FAX: 65-68611509
http://www.yanmar.co.jp/yasc/
California California
Proposition 65 Warning Proposition 65 Warning
Diesel engine exhaust and some of its Battery posts, terminals, and related
constituents are known to the state of accessories contain lead and lead
California to cause cancer, birth compounds, chemicals known to the
defects, and other reproductive harm. state of California to cause cancer and
reproductive harm.
Wash hands after handling.
TNV_DI_SM_A4-Troubleshooting.book 1 ページ２００７年１１月１５日　木曜日　午後５時２７分
TNV DI Service Manual

Section 1
FAILURE DIAGNOSIS
Page
DTCs (Diagnostic Trouble Codes) General Description.................. 1-3
DTC Code List ........................................................................... 1-3
Description Items....................................................................... 1-7
Analog Input Related Failures ................................................... 1-8
Pulse Sensor Related Failures ................................................ 1-60
Contact Output Related Failures ............................................. 1-66
Contact Input Related Failures .............................................. 1-100
Actuators etc.......................................................................... 1-114
E-ECU Internal and Communication Errors........................... 1-122
Method and Procedure of Failure Diagnosis ............................... 1-133
Description Items................................................................... 1-133
Analog Input Related Failures ............................................... 1-136
Pulse Sensor Related Failures .............................................. 1-164
Contact Output 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
Stalling/Start-Up Inability Factor Analysis.............................. 1-213
2G-Type Eco-Governor Black Smoke Factor Analysis.......... 1-216
Special Service Tools.................................................................. 1-218
Troubleshooting By Measuring Compression Pressure .............. 1-219
Compression Pressure Measurement Method ...................... 1-219
Quick Reference Table For Troubleshooting .............................. 1-222
TNV DI Service Manual 1-1

FAILURE DIAGNOSIS
This Page Intentionally Left Blank
1-2 TNV DI Service Manual

DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS
DTCS (DIAGNOSTIC TROUBLE CODES) GENERAL DESCRIPTION

DTC Code List
Referenced page
Clas Lamp Error Item
number
sifica DTC Flashing
tion Patterns Failure
Area Status Overview
Diagnosis
P1202/4 Error (low voltage) P.1-8
7 Rack position sensor P.1-136
P1203/3 Error (high voltage) P.1-10
P1203/3 Error (high voltage) P.1-14 P.1-140
P0124/2 5 Accelerator sensor Intermittent failure P.1-16
P1125/1 Error (foot pedal-close position) P.1-18
P.1-144
P1126/0 Error (foot pedal-open position) P.1-20
P0223/3 Error (high voltage) P.1-24 P.1-148
P0224/2 Intermittent failure P.1-26
1-8 Spare accelerator sensor
P1225/1 Error (foot pedal-close position) P.1-28
P.1-144
Analog Input Related Failures
P1226/0 Error (foot pedal-open position) P.1-30

P1227/8 Error (pulse communication) P.1-32 P.1-152
Atmospheric pressure
P0223/3 1-9 Error (high voltage) P.1-36 P.1-148
sensor
ECU Temperature
P0669/3 4-1 Error (high voltage) P.1-41 P.1-154
Sensor
ECU Temperature Rise
P0634/0 2-5 P.1-43 P.1-154
Alarm
P0117/4 Error (Low Voltage) P.1-45
Cooling water
P0118/3 4 Error (High Voltage) P.1-47 P.1-156
temperature sensor
Cooling Water
P0217/0 3-6 P.1-51 P.1-156
Temperature Rise Alarm
P0643/3 2-4 SENSOR 5V Error (High Voltage) P.1-54 P.1-160
P0562/1 Error (Low Voltage) P.1-56 P.1-56
2-3 Power supply Voltage
P0563/0 Error (High Voltage) P.1-58 P.1-58

FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description
Referenced page
number
sifica DTC Flashing
Diagnosis
P0340/4 6 Speed Sensor Error P.1-60 P.1-164
Pulse Sensors
P1340/4 1-1 Spare speed sensor Error P.1-62 P.1-167
P0219/0 9 Overspeed Error P.1-64 P.1-64
P1222/4 Error A P.1-66

P1223/3 1-7 Rack actuator Relay Error B P.1-68 P.1-170
P1232/4 Error A P.1-72
Contact Output Related Failures
P1233/3 1-5 Start Assist Relay Error B P.1-74 P.1-174

P1242/4 Error A P.1-78
P1243/3 1-4 CSD solenoid valve Error B P.1-80 P.1-178
P1402/4 Error A (Step Motor A-Phase) P.1-84
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
1-3 EGR valve P.1-182
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
P1192/4 2-1 Oil pressure switch Error P.1-100
Contact Input Related Failures
P1198/1 3-1 Oil Pressure Descend Error P.1-102

P1562/4 2-2 Charge switch Error P.1-104
P1568/1 3-2 Charge Alarm P.1-106
P1217/0 3-3 Abnormal Water Temperature P.1-108
P.1-187
P1101/0 3-4 Air cleaner Clogging Alarm P.1-110
P1151/0 3-5 Oil-water separator Alarm P.1-112

Referenced page
number
sifica DTC Flashing
Diagnosis
P1212/4 Error (low current) P.1-114
ECU inside and Communication Related Failures Actuator Errors
P1213/3 Rack actuator Error (high current) P.1-116

P1211/7 8 Mechanical failure P.1-118 P.1-193
P1214/2 Engine Error P.1-120
P0605/12 Error (Checksum A)

P1605/2 Flash ROM Error (Checksum B)
P1606/2 Error (Checksum C) P.1-122
P1620/12 Map format Error
ECU
P1601/2 4-1 Error (Checksum) P.1-197
Internal EEPROM
P0601/12 Error (read/write error)
P1610/12 Error A
P.1-123
P1611/12 Sub CPU 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 Error (CAN communication) P.1-128
U1167/8 Error (pulse communication) P.1-130
4-2 Immobilizer P.1-205
U0426/2 Error (System) P.1-132



Description Items
DTC Code Number DTC Name
DTC Detecting Conditions
1 - Precondition; 2 - Detecting condition(s);

Check points
3 - Flashing pattern of failure indicator
1. Precondition for Error detection This column shows what parts or
2. Error detecting Condition items should be checked to identify
3. Indicates the pattern in which the failure lamp flashes when the the cause of the error.
DTC is output. (For detailed information on various flashing For details, see "<Diagnosis
patterns, see Annex). Description>."
Movement at Error occurrence
Error Mode [Operation Continuation] / [Run Under Restrictions] / [Stop Immediately]:

The engine operation after detecting the error is described.
*
[Operation Continuation]:After detecting the error, the system lets the engine
continue to run without any restrictions.
[Run Under Restrictions]:The system lets the engine continue to run but restricts the
High idle speed, engine power, and/or other performance
factors as appropriate.
[Stop Immediately]: The system stops the engine immediately after detecting the
error.When any error is detected before starting the engine, the
starter will not rotate.
Run restricted? Yes/No.: If Yes, this field details how the engine run is restricted when the error has
occurred.
Recovery Yes/No.: If Yes, this field describes what conditions must be true for the error mode
Conditions to be reset.
Remarks This field describes some notes on safety precautions and so on, as appropriate.
Estimation of Failure cause/Error condition

Provides descriptive information on possible points of failure, possible direct causes (such as a disconnected sensor
wire), or possible system abnormalities that has indirectly caused the failure (such as abnormally high cooling water
temperature), as can be estimated from the output DTC.
Note: Indicates failures that might be related with the output DTC.
Diagnosis Description
Describes methods or procedures of failure diagnosis.
* After sucessful recovery by the replacement of ECU, sensor or actuator, make sure that installing
the previous parts will reproduce the same error.


Rack position sensor
(1) P1202/4: Failure with Rack Position Sensor (Low Voltage)
DTC P1202/4 Rack Position Sensor Error (Low Voltage)

Check points
1. Key switch ON. Connector
2. The sensor voltage lower limit and below [at E-ECU activation, Harness
engine running] Rack position sensor
3. Seven flashes. E-ECU
Error Mode [Run Under Restrictions]:

The engine continues to run in on-error engine control mode.
If any error is detected at E-ECU activation, it takes 1 - 10 seconds from the starter
begins to rotate until the engine starts.
Run restricted? Yes: • The High idle speed is restricted to one of the following, whichever smaller:
• 80% of the pre-error High idle speed
• 150% of the Low idle speed
• The fuel injection rate is restricted.
Recovery No.
Conditions
Remarks The High and Low idle speeds must be equal to those specified in the engine
specifications.

• The connector may not be properly connected.
• Wiring defect of the harness
• The rack position sensor's signal wires may be disconnected or short-circuited with GND.
• The SENSOR 12V wire may be disconnected or short-circuited with GND (*NOTE).
• The SENSOR GND wire may be short-circuited with POWER SUPPLY (*NOTE).
*NOTE) If the SENSOR 12V wire is short-circuited with GND or SENSOR GND wire is short-circuited with
POWER SUPPLY, the E-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 rack 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.


1) Initial diagnosis • Check the fault indication.

with the diagnosis • Check the sensor voltage (AD value).
tool
*For details of the method and the procedure of diagnosis, see P.1-136
2) Check of • Before beginning your work, be sure to turn off the key switch.
connectors/wiring • 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 • Check the input voltage of the rack position sensor (voltage of the sensor 12V
Work line).
• Check the harness for correct continuity.

(2) P1203/3: Failure with Rack Position Sensor (High Voltage)
DTC P1202/3 Failure with Rack Position Sensor (High Voltage)

Check points
2. The sensor voltage upper limit and above [at E-ECU activation, Harness rack position sensor
engine running] Rack actuator
3. Seven flashes. E-ECU
Detection at the engine start Detection at the engine running

Error Mode [Run Under Restrictions]: [Stop Immediately]:
Start the engine in on-error engine control The engine stops running.
mode.
It takes 1 to 10 seconds from the starter’s
rotation to the engine start.
Run restricted? Yes: • The High idle is restricted to one of Yes: The rack actuator relay is turned
the following, whichever smaller: OFF, and the rack position is forcibly
• 80% of the pre-error High idle speed set to the engine stop position.
• 150% of the Low idle speed
• The fuel injection rate is restricted.
Recovery No. No.
Conditions
Remarks The High and Low idle speeds must be
equal to those specified in the engine
specifications.

• The SENSOR GND wire may be disconnected.
• The rack position sensor signal wire may be short-circuited with POWER SUPPLY.
• The rack actuator wiring may be short-circuited with GND (with engine running).
• The rack position sensor may be faulty.
• Output defect of the rack position signal by a disconnection or a short circuit of the inner wiring
• The rack actuator may be faulty.
• The rack actuator inner wiring may be short-circuited with GND (with engine running).



with the diagnosis • Check the sensor voltage (AD value).
tool
3) Failure Diagnostic • Check the input voltage of the rack position sensor (voltage of the sensor 12V
Work line).

Accelerator sensor
(1) P0122/4: Accelerator Sensor Error (Low Voltage)
DTC P0122/4 Accelerator Sensor Error (Low Voltage)

Check points
1. Key switch ON. Harness
2. Sensor voltage 0.2 [V] or lower. Accelerator sensor
3. Five flashes.
Spare Accelerator Sensor Function

Unavailable Available
The engine runs at a constant rotational The engine continues to run using the
speed. spare accelerator sensor instead.
Run restricted? Yes: The target speed is set to the "on- No.
error target speed (standard value:
1500[min-1])" or “pre-error target
speed”.
Recovery Yes: This error will be automatically reset Yes: This error will be automatically reset
Conditions when a normal voltage (0.2 to when a normal voltage (0.2 to
4.6[V]) is input. 4.6[V]) is input.
Remarks

• The accelerator sensor's signal wires may be disconnected or short-circuited with GND.
• The SENSOR 5V wire may be disconnected or short-circuited with GND.
*NOTE) If the SENSOR GND wire is short-circuited with POWER SUPPLY, the E-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 accelerator sensor may be faulty.
• Sensor output defect by a disconnection of the accelerator sensor inner wiring or a sliding resistance
increase



with the diagnosis • Check the sensor voltage.
tool
connectors/wiring • 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 • Check the resistance value of the accelerator sensor.

Work • Check the harness for correct continuity.
• Check the output voltage of the accelerator sensor.

(2) P0123/3: Accelerator Sensor Error (High Voltage)
DTC P0123/3 Accelerator Sensor Error (High Voltage)

Check points
2. Sensor voltage 4.6 [V] or higher. Accelerator sensor
3. Five flashes.
Spare Accelerator Sensor Function

speed. spare accelerator sensor instead.
speed”.
Remarks

• The sensor signal wire may be short-circuited with POWER SUPPLY.
• Sensor output defect by a short circuit with power supply of the accelerator sensor inner wiring



tool


(3) P0124/2: Intermittent Failure with Accelerator Sensor
DTC P0124/2 Intermittent Failure with Accelerator Sensor

Check points
1. Engine running. Connector
2. Unconfirmed error detected 10 times. Harness
3: Does not flash. Accelerator sensor

After detecting the error, the system lets the engine continue to run without any
restrictions.
Run restricted? No.
Recovery No.
Conditions
Remarks

• Accelerator sensor signal wire may be disconnected, or short-circuited with GND or power supply.
• Sensor 5V wire may be disconnected, or short-circuited with GND or power supply.
• Sensor GND wire may be disconnected.
• Inner wiring may be disconnected or short-circuited



tool


(4) P0123/1: Accelerator Sensor Error (foot pedal-close position)
DTC P1125/1 Accelerator Sensor Error (foot pedal-close position)

Check points
2. With sensor voltage at or below 0.65[V], foot pedal Normally Foot pedal
Open switch detected being ON or foot pedal Normally Closed
Switch detected being OFF.
3. Five flashes.

The engine runs at a constant rotational speed.
Run restricted? Yes: The target speed is set to the "on-error target speed (standard value: 1500[min-1])"
or “pre-error target speed”.
Recovery No.
Conditions
Remarks

• The wiring for the foot pedal Normally Closed switch may be disconnected.
• The wiring for the foot pedal Normally Open switch may be short-circuited with GND.
• The foot pedal may be faulty.
• The foot pedal inner wiring may be disconnected or short-circuited with GND.



with the diagnosis • Check that the foot pedal movement is correctly recognized.
tool
connectors/wiring • 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 • Check the foot pedal for correct continuity.


(5) P1126/0: Accelerator Sensor Error (foot pedal-open position)
DTC P1126/0 Accelerator Sensor Error (foot pedal-open position)

Check points
2. With sensor voltage 1.1[V] and above, foot pedal Normally Open Foot pedal
switch detected being OFF or foot pedal Normally Closed
Switch detected being ON.
3. Five flashes.

The engine runs at a constant rotational speed.
Run restricted? Yes: The target speed is set to the "on-error target speed (standard value: 1500[min-1])"
or “pre-error target speed”.
Recovery No.
Conditions
Remarks

• The wiring for the foot pedal Normally Open switch may be disconnected.
• The wiring for the foot pedal Normally Closed switch may be short-circuited with GND.
• The inner wiring may be disconnected or short-circuited with GND.



tool


Spare accelerator sensor (option)

(1) P0222/4: Failure with Spare Accelerator Sensor (Low Voltage)
DTC P0222/4 Failure with Spare Accelerator Sensor (Low Voltage)

Check points
2. Sensor voltage 0.2 [V] or lower. Spare accelerator sensor
3. One flash followed by eight flashes
Error detection of main accelerator sensor

Error Mode [Run As Is]: [Run Under Restrictions]:
The engine continues to run using the The engine runs at a constant rotational
main accelerator sensor. speed.
Run restricted? No. Yes: The target speed is set to the "on-
speed”.
Remarks

• The spare accelerator sensor's signal wires may be disconnected or short-circuited with GND.
the error history.
• The spare accelerator sensor may be faulty.
• Sensor output defect by a disconnection of the spare accelerator sensor inner wiring or a sliding
resistance increase



tool
connectors/wiring • 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
3) Failure Diagnostic • Check the resistance value of the spare accelerator sensor.
• Check the output voltage of the spare accelerator sensor.

(2) P0223/3: Spare Accelerator Sensor Error (High Voltage)
DTC P0223/3 Spare Accelerator Sensor Error (High Voltage)

Check points
2. Sensor voltage 4.6 [V] or higher. Spare accelerator sensor

speed”.
Remarks

• Sensor output defect by a short circuit with power supply of the spare accelerator sensor inner wiring



tool

(3) P0224/2: Intermittent Failure with Spare Accelerator Sensor
DTC P0224/2 Intermittent Failure with Spare Accelerator Sensor

Check points
3: Does not flash. Spare accelerator sensor
Error Mode [Run As Is]:

restrictions.
Run restricted? No.
Recovery No.
Conditions
Remarks

• Spare accelerator sensor signal wire may be disconnected or short-circuited with GND or power supply.
• Spare accelerator sensor wiring may be disconnected or short-circuited.



tool

(4) P1225/1: Spare Accelerator Sensor Error (foot pedal-close position)
Spare Accelerator Sensor Error (foot pedal-close

DTC P1225/1
position)

Check points
2. With sensor voltage at or below 0.65[V], foot pedal Normally Foot pedal
Open switch detected being ON or foot pedal Normally Closed
Switch detected being OFF.

speed”.
Recovery No. No.
Conditions
Remarks

• The wiring for the foot pedal Normally Closed switch may be disconnected.
• The wiring for the foot pedal Normally Open switch may be short-circuited with GND.



tool


(5) P1226/0: Spare Accelerator Sensor Error (foot pedal-open position)
Spare Accelerator Sensor Error (foot pedal-open

DTC P1226/0
position)

Check points
2. With sensor voltage 1.1[V] and above, foot pedal Normally Open Foot pedal
switch detected being OFF or foot pedal Normally Closed
Switch detected being ON.

speed”.
Recovery No. No.
Conditions
Remarks

• The wiring for the foot pedal Normally Open switch may be disconnected.
• The wiring for the foot pedal Normally Closed switch may be short-circuited with GND.



tool


(6) P1227/8: Failure with Spare Accelerator Sensor (Pulse Communication)
Failure with Spare Accelerator Sensor (Pulse

DTC P1227/8
Communication)
* This DTC is output when a pulse accelerator is used.

Check points
2. No pulse accelerator signal input
CAN communication error detection

After detecting the error, the system lets The engine runs at a constant rotational
the engine continue to run without any speed.
restrictions.
speed”.
Recovery Yes: The error is automatically reset Yes: The error is automatically reset
Conditions when a normal data is received. when a normal data is received.
Remarks

• The pulse accelerator's signal wires may be disconnected or short-circuited with GND.
• Source circuitry fault of the pulse accelerator signal



with the diagnosis
tool *For details of the method and the procedure of diagnosis, see P.1-152
connectors/wiring • 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
3) Failure Diagnostic • Check the harness for correct continuity.

Work

Atmospheric pressure sensor (option)

(1) P2228/4: Failure with Atmospheric Pressure Sensor (Low Voltage)
DTC P2228/4 Failure with Atmospheric Pressure Sensor (Low Voltage)

Check points
2. Sensor voltage 0.2 [V] or higher. Atmospheric pressure sensor
3. One flash followed by nine flashes.

The engine continues to run with the atmospheric pressure unchanged from the pre-
error value.
Run restricted? Yes: The altitude compensation function is disabled.
Recovery No.
Conditions
Remarks

• The atmospheric pressure sensor's signal wires may be disconnected or short-circuited with GND.
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



tool
connectors/wiring • 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 • Check the resistance value of the atmospheric pressure sensor.
• Check the output voltage of the atmospheric pressure sensor.

(2) P2229/3: Failure with Atmospheric Pressure Sensor (High Voltage)
DTC P2229/3 Failure with Atmospheric Pressure Sensor (High Voltage)

Check points
2. Sensor voltage 4.8 [V] or higher. Atmospheric pressure sensor
3. One flash followed by nine flashes.

The engine continues to run with the atmospheric pressure unchanged from the pre-
error value.
Run restricted? Yes: The altitude compensation function is disabled.
Recovery No.
Conditions
Remarks

• Sensor output defect by a short circuit with power supply of the atmospheric pressure sensor inner wiring



tool
inserted.

(3) P2230/2: Intermittent Failure with Atmospheric Pressure Sensor
DTC P2230/2 Intermittent Failure with Atmospheric Pressure Sensor

Check points
3: Does not flash. Atmospheric pressure sensor

restrictions.
Run restricted? No.
Recovery No.
Conditions
Remarks

• Accelerator sensor signal wire may be disconnected, or short-circuited with GND or power supply.
• Inner wiring of atmospheric pressure sensor may be disconnected, or short circuited.



tool
inserted.

ECU Temperature Sensor

(1) P0668/4: Failure with ECU Temperature Sensor (Low Voltage)
DTC P0668/4 Failure with ECU Temperature Sensor (Low Voltage)

Check points
1. Key switch ON. E-ECU
2. Sensor voltage 1.0 [V] (at 140°C) or lower.
3. Four flashes followed by one flash.
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 Yes: This error will be automatically reset when a normal sensor voltage (1.0 to
Conditions 4.6[V]) is input.
Remarks


with the diagnosis • Check the ECU temperature.
tool


(2) P0669/3: Failure with ECU Temperature Sensor (High Voltage)
DTC P0669/3 Failure with ECU Temperature Sensor (High Voltage)

Check points
2. Sensor voltage 4.6 [V] (at -45°C) or lower.
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 Yes: This error will be automatically reset when a normal sensor voltage (0.2 to
Conditions 4.6[V]) is input.
Remarks


tool

(3) P1664/2: Intermittent Failure with ECU Temperature Sensor
DTC P1664/2 Intermittent Failure WITH ECU Temperature Sensor

Check points
1. Engine running. E-ECU
2. Unconfirmed error detected 10 times.
3: Does not flash.

restrictions.
Run restricted? No.
Recovery No.
Conditions
Remarks


tool


(4) P0634/0: ECU Temperature Rise Alarm
DTC P0634/0 ECU Temperature Rise Alarm

Check points
2. ECU internal temperature is 150 [°C] or higher.
3. Two flashes followed by five flashes.
Setting of response to ECU temperature rise error

After detecting the error, the system lets The engine continues to run under
the engine continue to run without any restrictions.
restrictions.
Run restricted? No. Yes: The system restricts the High idle
speed or engine power.
Recovery Yes: This error is automatically reset Yes: This error is automatically reset
Conditions when the normal internal when the normal internal
temperature (under 100[°C]) of ECU temperature (under 100[°C]) of ECU
is detected. is detected.
Remarks

• The ambient temperature around the ECU may be too high.


tool
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 • Check the ECU temperature sensor.

Work


Cooling water temperature sensor
(1) P0117/4: Failure with Cooling Water Temperature Sensor (Low Voltage)
Failure with Cooling Water Temperature Sensor (Low

DTC P0117/4
Voltage)

Check points
2. Sensor voltage 0.2 [V] or lower. Harness
3. Four flashes. 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]: [Run As Is]:
The engine continues to run under
restrictions.
The engine continues to run with the cooling water temperature set to the default of
30[°C].
Run restricted? Yes: The system restricts the High idle No.
Recovery No. Yes: This error will be automatically reset
Conditions when a normal sensor voltage (0.2
to 4.8[V]) is kept.
Remarks The restriction similar to one applied
against EGR errors is applied.

• The cooling water temperature sensor's signal wires may be short-circuited with GND.
• The cooling water temperature sensor's GND wire may be short-circuited with POWER SUPPLY.
• The cooling water temperature sensor may be faulty.
• Output defect of the cooling water temperature signal by the inner wiring short-circuited with GND.


tool
connectors/wiring • 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 • Check the resistance value of the cooling water temperature sensor.
• Check the output voltage of the cooling water temperature sensor.


(2) P0118/3: Failure with Cooling Water Temperature Sensor (High Voltage)
Failure with Cooling Water Temperature Sensor (High

DTC P0118/3
Voltage)

Check points
2. Sensor voltage 4.8 [V] or higher. Harness
3. Four flashes. Cooling water temperature sensor
E-ECU
In the case of a system with EGR In the case of a system without EGR
The engine continues to run under
restrictions.
The engine continues to run with the cooling water temperature set to the default of
30 [°C].
Run restricted? Yes: The system restricts the High idle No.
Recovery No. Yes: This error will be automatically reset
Conditions when a normal sensor voltage (0.2
to 4.8[V]) is kept.
Remarks The restriction similar to one applied
against EGR errors is applied.

• The cooling water temperature sensor's signal wires may be disconnected or short-circuited with
POWER SUPPLY.
• The cooling water temperature GND wire may be disconnected.
• Output defect of the cooling water temperature signal by the inner wiring disconnection


tool
inserted.


(3) P0119/2: Intermittent Failure with Cooling Water Temperature Sensor
Intermittent Failure with Cooling Water Temperature

DTC P0119/2
Sensor

Check points
3: Does not flash. High-accuracy cooling water
temperature sensor
E-ECU

restrictions.
Run restricted? No.
Recovery No.
Conditions
Remarks

• The cooling water temperature sensor's signal wires may be short-circuited with GND.
• The cooling water temperature sensor's signal wires may be disconnected or short-circuited with
POWER SUPPLY.
• GND wire of the cooling water temperature sensor may be disconnected.
• Signal wire in the sensor may be disconnected, or short circuited.
• Sensor GND wire in the sensor may be disconnected.


tool
inserted.


(4) P0217/0: Cooling Water Temperature Rise Alarm
DTC P0217/0 Cooling Water Temperature Rise Alarm

Check points
1. Key switch ON. Engine cooling water level
2. Cooling water temperature 115[°C] or higher. Engine cooling system
3. Three flashes followed by six flashes. Cooling Water Temperature
Sensor
Setting of response to cooling water temperature rise error

restrictions.
Recovery Yes: This error is automatically reset Yes: This error is automatically reset
Conditions when the normal cooling water when the normal cooling water
temperature (under 110[°C]) is temperature (under 110[°C]) is
detected. detected.
Remarks

• The engine may be overheated.
• The engine cooling water level may be too low.
• The engine cooling system may be faulty.


with the diagnosis • Check the cooling water temperature and the sensor voltage.
tool
2) Check of • Turn the key switch off to stop the engine.

connectors/wiring • Check the engine cooling system.
(“Engine”).
3) Failure Diagnostic • Check the cooling water temperature sensor system.

Work


SENSOR 5V
(1) P0642/4: Failure with SENSOR 5V (Low Voltage)
DTC P0642/4 Failure with SENSOR 5V (Low Voltage)
1 - Precondition; 2 - Detecting condition(s); 3 - Flashing pattern of failure indicator Check points

2. SENSOR 5V monitoring voltage 4.5 [V] or lower. E-ECU
3. Two flashes followed by four flashes.
Error Mode [Operation Continuation]: After detecting the error, the system lets the engine
Run restricted? No.
Recovery No.
Conditions
Remarks

• The SENSOR 5V wire may be short-circuited with GND.

with the diagnosis • Check the voltage of the Sensor 5V .
connectors/wiring • Check that the insulation of the Sensor 5V is not peeled.

Work • Check the output voltage of the E-ECU (voltage of the sensor 5V line).

(2) P0643/3: Failure with SENSOR 5V (High Voltage)
DTC P0643/3 Failure with SENSOR 5V (High Voltage)

2. SENSOR 5V monitoring voltage 5.5 [V] or higher. E-ECU
3. Two flashes followed by four flashes.
Error Mode [Run As Is]:After detecting the error, the system lets the engine continue to run
without any restrictions.
Run restricted? No.
Recovery No.
Conditions
Remarks

• The SENSOR 5V wire may be short-circuited with POWER SUPPLY.

connectors/wiring • Check that the Sensor 5V line and sensor GND line are not disconnected or the



(3) P1644/2: Intermittent Failure with SENSOR 5V
DTC P1644/2 Intermittent Failure with SENSOR 5V

1. Engine running. Harness
2. Unconfirmed error detected 10 times. E-ECU
3: Does not flash.
Run restricted? No.
Recovery No.
Conditions
Remarks

• The SENSOR 5V wire may be short-circuited with power supply or GND.

connectors/wiring • Check that the Sensor 5V line and sensor GND line are not disconnected or the


Power supply Voltage

(1) P0562/1: Power Supply Voltage Error (Low Voltage)
DTC P0562/1 Power Supply Voltage Error (Low Voltage)

1. Engine running. Battery
2. E-ECU supply voltage below 10[V] alternator
3. Two flashes followed by three flashes. Harness
Run restricted? No.
Recovery Yes: This error will be automatically reset when a normal supply voltage (10 to 16[V])
Conditions is input.
Remarks

• The battery may be deteriorated.
• The battery connection may be miswired.
• The alternator may be faulty.
• The harness may be disconnected or short-circuited.



with the diagnosis • Check the battery voltage.
tool
• Check the battery voltage using a circuit tester.
• Inspect the charging system of the engine .
(“Engine”).
3) Failure Diagnostic • Check that the battery wiring is not disconnected or the insulation of the wiring
Work is not peeled.

(2) P0563/0: Power Supply Voltage Error (High Voltage)
DTC P0563/0 Power Supply Voltage Error (High Voltage)

1. Engine running. Battery
2. E-ECU supply voltage over 16[V] alternator
3. Two flashes followed by three flashes. Harness
Run restricted? No.
Recovery Yes: This error will be automatically reset when a normal supply voltage (10 to 16[V])
Conditions is input.
Remarks

• An incompatible battery (such as a 24V battery) may be used.
• The battery connection may be miswired.
• The harness may be disconnected or short-circuited.



tool
• Check the battery voltage using a circuit tester.
(“Engine”).
3) Failure Diagnostic • Check that the battery wiring is not disconnected or the insulation of the wiring
Work is not peeled.

Pulse Sensor Related Failures

Speed Sensor
(1) P0340/4: Failure with Speed Sensor
DTC P0340/4 Speed Sensor Error

1. Key switch START, engine running. Connector
2. Speed sensor signal 0[min-1] Harness
3. Six flashes. Speed Sensor
E-ECU
Spare speed sensor setting
Error Mode [Stop Immediately]: [Run Under Restrictions]:
The engine stops running. The engine continues to run under
restrictions with the spare speed sensor
used instead.
Run restricted? Yes: The rack actuator relay is turned Yes: The system restricts the High idle
OFF, and the rack position is forcibly speed or engine power.
set to the engine stop position.
Recovery Yes: Key switch START Yes: Key switch START
Conditions
Remarks

• Engine speed defect
• Battery voltage descent at cold start etc.
• Starter system failure
• Fuel injection not available (fuel freezing)
• Engine locked (seizure, freezing)
• Battery voltage descent (over discharge, deterioration)
• Load increase driven by the operating machine
• The speed sensor's signal wires (+) and (-) may be disconnected or short-circuited with GND.
• The starter signal wire may be short-circuited with POWER SUPPLY.
• The speed sensor may be faulty.
• Output defect of the speed signal by a disconnection or a short circuit of the inner wiring



with the diagnosis • Check the engine speed.
tool
connectors/wiring • 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
3) Failure Diagnostic • Check the resistance value of the speed sensor.


Spare speed sensor (option)

(1) P1340/4: Failure with Spare Speed Sensor
DTC P1340/4 Failure with Spare Speed Sensor

2. Spare speed sensor signal below 0[min-1]. Harness
3. One flash followed by another flash. alternator
E-ECU
Main speed sensor error detection

Error Mode [Run As Is]: [Stop Immediately]:
After detecting the error, the system lets The engine stops running.
the engine continue to run without any
restrictions.
Run restricted? No. Yes: The rack actuator relay is turned
OFF, and the rack position is forcibly
set to the engine stop position.
Recovery No. Yes:Key switch START
Conditions
Remarks

• Output pulse voltage defect by low engine speed
• Output pulse defect by the battery over-charge
• The spare speed sensor's signal wires may be disconnected or short-circuited with GND.
• The alternator's terminals B and IG may be disconnected or short-circuited with GND.
• Output pulse defect by the alternator failure



with the diagnosis • Check the rotational speed of the spare speed sensor.
tool
connectors/wiring • Check that the connector of the alternator is correctly inserted.
• Check that the wiring of the alternator is not disconnected or the insulation of
3) Failure Diagnostic • Check the battery voltage.


Engine rotational speed

(1) P0219/0: Over speed error
DTC P0219/0 Overspeed Error

1. Engine running. Harness
2. Sensor signal at or above the upper limit (High idle speed +600[min-1]). Speed Sensor
3. Two flashes followed by five flashes. Rack actuator
E-ECU
Error Mode [Stop Immediately]: The engine stops running.

Run restricted? Yes: The rack actuator relay is turned OFF, and the rack position is forcibly set to the
engine stop position.
Recovery No.
Conditions
Remarks

• The rack actuator wiring may be short-circuited with GND.
• False generation of speed sensor signal pulse
• False wiring of the speed sensor
• Engine over speed loaded by the operating machine’s drive
• Control error of the fuel injection pump



with the diagnosis
tool
• Inspect the engine and the operating machine.
(“Engine”).
3) Failure Diagnostic • Check the Rack Actuator.

Work


Rack actuator Relay
(1) P1222/4: Failure A with Rack Actuator Relay
DTC P1222/4 Failure A with Rack Actuator Relay

2. Make an assessment logically as to followings.E-ECU detects the rack actuator Harness
relay turning ON during the command to turn OFF the rack actuator relay. Rack actuator Relay
3. One flash followed by seven flashes. E-ECU

Recovery No.
Conditions
Remarks

• The rack actuator relay wiring may be disconnected or short-circuited with GND.
• The rack actuator relay may be faulty.
• Inner wiring disconnection



with the diagnosis • Check the output signal of the rack actuator relay.
tool • Check the movement of the rack actuator relay by the active control function.
connectors/wiring • 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
3) Failure Diagnostic • Check the resistance value of the rack actuator relay.

(2) P1223/3: Failure B with Rack Actuator Relay
DTC P1223/3 Failure B with Rack Actuator Relay

2. Make an assessment logically as to followings.E-ECU detects the rack actuator Harness
relay turning OFF during the command to turn ON the rack actuator relay. Rack actuator Relay
3. One flash followed by seven flashes. E-ECU

Recovery No.
Conditions
Remarks

• The rack actuator relay wiring may be short-circuited with POWER SUPPLY (*NOTE).
• The rack actuator relay may be faulty.
• Inner wiring short-circuited with POWER SUPPLY (*NOTE).
*NOTE) If the rack actuator relay wire is short-circuited with POWER SUPPLY, inner circuit of E-ECU may fail
before the E-ECU's power supply line fuse 10A is blown.In this case, the ECU fails to detect/indicate
the error, and to store the error history.




(3) P1224/2: Intermittent Failure with Rack Actuator Relay
DTC P1224/2 Intermittent Failure with Rack Actuator Relay

3: Does not flash. Rack actuator Relay
E-ECU

restrictions.
Run restricted? No.
Recovery No.
Conditions
Remarks

• The rack actuator relay wiring may be disconnected or short-circuited with GND.




Start Assist Relay

(1) P1232/4: Failure A with Start Assist Relay
DTC P1232/4 Failure A with Start Assist Relay

2. Make an assessment logically as to followings.E-ECU detects the start assist Harness
relay turning ON during the command to turn OFF the start assist relay. Start Assist Relay
3. One flash followed by five flashes. E-ECU

restrictions.
Run restricted? No.
Recovery No.
Conditions
Remarks

• The start assist relay wiring may be disconnected or short-circuited with POWER SUPPLY.
• The start assist relay may be faulty.
• Disconnection of Start Assist Relay inner wiring



with the diagnosis • Check the output signal of the start assist relay.
tool • Check the movement of the start assist relay by the active control function.
connectors/wiring • 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
3) Failure Diagnostic • Check the resistance value of the start assist relay.

(2) P1233/3: Failure B with Start Assist Relay
DTC P1233/3 Failure B with Start Assist Relay

2. Make an assessment logically as to followings.E-ECU detects the start assist Harness
relay turning OFF during the command to turn ON the start assist relay. Start Assist Relay
3. One flash followed by five flashes. E-ECU

restrictions.
Run restricted? No.
Recovery No.
Conditions
Remarks

• The start assist relay wiring may be short-circuited with GND (*NOTE).
• The start assist relay may be faulty.
• Inner wiring of the start assist relaymay be short-circuited with GND (*NOTE).
*NOTE) If the start assist relay wire is short-circuited with GND, the E-ECU's power supply line fuse 10A
might be 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.




(3) P1234/2: Intermittent Failure with Start Assist Relay
DTC P1234/2 Intermittent Failure with Start Assist Relay

3: Does not flash. Start Assist Relay
E-ECU

restrictions.
Run restricted? No.
Recovery No.
Conditions
Remarks

• The start assist relay wiring may be disconnected or short-circuited with POWER SUPPLY.




CSD solenoid valve

(1) P1242/4: Failure A with CSD solenoid valve
DTC P1242/4 Failure A with CSD Solenoid Valve

2. Make an assessment logically as to followings.E-ECU detects the CSD Harness
solenoid valve turning ON signal during the command to turn OFF the CSD CSD solenoid valve
solenoid valve. E-ECU
3. One flash followed by four flashes.

restrictions.
Run restricted? No.
Recovery No.
Conditions
Remarks

• CSD solenoid valve wiring may be disconnected or short-circuited with POWER SUPPLY.
• The CSD solenoid valve may be faulty.
• Inner wiring disconnection



with the diagnosis • Check the output signal of the CSD solenoid valve.
tool • Check the movement of the CSD solenoid valve by the active control function.
connectors/wiring • 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
3) Failure Diagnostic • Check the resistance value of the CSD solenoid valve coil.

(2) P1243/3: Failure B with CSD solenoid valve
DTC P1243/3 Failure B with CSD Solenoid Valve

2. Make an assessment logically as to followings.E-ECU detects the CSD Harness
solenoid valve turning OFF signal during the command to turn ON the CSD CSD solenoid valve
solenoid valve. E-ECU
3. One flash followed by four flashes.

restrictions.
Run restricted? No.
Recovery No.
Conditions
Remarks

• The CSD solenoid valve wiring may be short-circuited with GND (*NOTE).
• The CSD solenoid valve may be faulty.
• Inner wiring short-circuited with GND (*NOTE).
*NOTE) If the CSD solenoid valve wire is short-circuited with GND, the E-ECU's power supply line fuse 10A
might be 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.




(3) P1244/2: Intermittent Failure with CSD solenoid valve
DTC P1244/2 Intermittent Failure with CSD solenoid valve

3: Does not flash. CSD solenoid valve
E-ECU

restrictions.
Run restricted? No.
Recovery No.
Conditions
Remarks

• The CSD solenoid valve wiring may be disconnected or short-circuited with POWER SUPPLY.




EGR valve
(1) P1402/4: Failure A with EGR valve (Step Motor A-phase)
DTC P1402/4 Failure A with EGR valve (Step Motor A-Phase)

Check points
2. Make an assessment logically as to followings.E-ECU detects Harness
the EGR step motor A-phase turning ON during the command to EGR valve (step motor)
turn OFF the EGR step motor A-phase. E-ECU
3. One flash followed by three flashes.
Movement setting at the EGR step motor error

restrictions.
Recovery No. No.
Conditions
Remarks

• The EGR step motor A-phase wiring may be disconnected or short-circuited with GND.
• The EGR step motor power supply line may be disconnected.
• The EGR step motor may be faulty.
• Inner wiring of the EGR step motor A-phase may be disconnected or short-circuited with GND.
• Power supply line in the EGR step motor may be disconnected.



with the diagnosis • Check the output signal of the EGR step motor.
tool • Check the movement of the EGR step motor by the active control function.
connectors/wiring • 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
3) Failure Diagnostic • Check the coil resistance of the EGR step motor.

(2) P1403/3: Failure B with EGR valve (Step Motor A-phase)
DTC P1403/3 Failure B with EGR valve (Step Motor A-Phase)

Check points
the EGR step motor A-phase turning OFF during the command EGR valve (step motor)
to turn ON the EGR step motor A-phase. E-ECU

restrictions.
Recovery No. No.
Conditions
Remarks

• The EGR step motor A-phase wiring may be short-circuited with POWER SUPPLY.
• The EGR step motor wiring may be short-circuited between phases.
• Inner wiring of the EGR step motor A-phase may be short-circuited with POWER SUPPLY.
• Inner wiring of the EGR step motor may be short-circuited between phases.




(3) P1412/4: Failure A with EGR valve (Step Motor B-phase)
DTC P1412/4 Failure A with EGR valve (Step Motor B-Phase)

Check points
the EGR step motor B-phase turning ON during the command to EGR valve (step motor)
turn OFF the EGR step motor B-phase. E-ECU

restrictions.
Recovery No. No.
Conditions
Remarks

• The EGR step motor B-phase wiring may be disconnected or short-circuited with GND.
• Inner wiring of the EGR step motor B-phase may be disconnected or short-circuited with GND.




(4) P1413/3: Failure B with EGR valve (Step Motor B-phase)
DTC P1413/3 Failure B with EGR valve (Step Motor B-Phase)

Check points
the EGR step motor B-phase turning OFF during the command EGR valve (step motor)
to turn ON the EGR step motor B-phase. E-ECU

restrictions.
Recovery No. No.
Conditions
Remarks

• The EGR step motor B-phase wiring may be short-circuited with POWER SUPPLY.
• Inner wiring of the EGR step motor B-phase may be short-circuited with POWER SUPPLY.




(5) P1422/4: Failure A with EGR valve (Step Motor C-phase)
DTC P1422/4 Failure A with EGR valve (Step Motor C-Phase)

Check points
the EGR step motor C-phase turning ON during the command EGR valve (step motor)
to turn OFF the EGR step motor C-phase. E-ECU

restrictions.
Recovery No. No.
Conditions
Remarks

• The EGR step motor C-phase wiring may be disconnected or short-circuited with GND.
• Inner wiring of the EGR step motor C-phase may be disconnected or short-circuited with GND.




(6) P1423/3: Failure B with EGR valve (Step Motor C-phase)
DTC P1423/3 Failure B with EGR valve (Step Motor C-Phase)

Check points
the EGR step motor C-phase turning OFF during the command EGR valve (step motor)
to turn ON the EGR step motor C-phase. E-ECU

restrictions.
Recovery No. No.
Conditions
Remarks

• The EGR step motor C-phase wiring may be short-circuited with POWER SUPPLY.
• Inner wiring of the EGR step motor C-phase may be short-circuited with POWER SUPPLY.




(7) P1432/4: Failure A with EGR valve (Step Motor D-phase)
DTC P1432/4 Failure A with EGR valve (Step Motor D-Phase)

Check points
2. Make an assessment logically as to followings. E-ECU detects Harness
the EGR step motor D-phase turning ON during the command EGR valve (step motor)
to turn OFF the EGR step motor C-phase. E-ECU

restrictions.
Recovery No. No.
Conditions
Remarks

• The EGR step motor D-phase wiring may be disconnected or short-circuited with GND.
• Inner wiring of the EGR step motor D-phase may be disconnected or short-circuited with GND.




(8) P1433/3: Failure B with EGR valve (Step Motor D-phase)
DTC P1433/3 Failure B with EGR valve (Step Motor D-Phase)

Check points
the EGR step motor D-phase turning OFF during the command EGR valve (step motor)
to turn ON the EGR step motor D-phase. E-ECU

restrictions.
Recovery No. No.
Conditions
Remarks

• The EGR step motor D-phase wiring may be short-circuited with POWER SUPPLY.
• Inner wiring of the EGR step motor D-phase may be short-circuited with POWER SUPPLY.





Oil Pressure Related Failures
(1) P1192/4: Failure with Oil Pressure Switch
DTC P1192/4 Failure with oil pressure switch

2. Oil pressure switch turns ON with engine stopped. Harness
* This manual assumes that the contact input is configured as Normally Open Oil pressure switch
(NO). E-ECU
3. Two flashes followed by one flash.

restrictions.
Run restricted? No.
Recovery No.
Conditions
Remarks

• The oil pressure switch wiring may be disconnected or short-circuited with POWER SUPPLY.
• The oil pressure switch may be faulty.
• Inner wiring of the oil pressure switch may be disconnected or short-circuited with POWER SUPPLY.



with the diagnosis • Check that the input signal of the oil pressure switch is correctly recognized.
tool
connectors/wiring • 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

Work

(2) P1198/1: Abnormal Oil Pressure Descend
DTC P1198/1 Abnormal Oil Pressure Descend

1. Key switch ON. Hydrostatic system
2. Oil pressure switch turns ON after engine has been started. Harness
* This manual assumes that the contact input is configured as Normally Open Oil pressure switch
(NO). E-ECU
3. Three flashes followed by one flash
Setting of response to "oil pressure low" alarm

restrictions.
Recovery No. No.
Conditions
Remarks

• The oil pressure may be too low.
• The hydraulic system may be faulty.
• The oil pressure switch wiring may be short-circuited with GND.
• The oil pressure switch may be faulty.
• Inner wiring of the oil pressure switch may be short-circuited with GND.



with the diagnosis • Check that the input signal of the oil pressure switch is correctly recognized.
tool
• Inspect the oil pressure system.
• After the inspection, turn the key switch on to check if the DTC is detected.
(“Engine”).
3) Failure Diagnostic • Check the oil pressure switch system.

Work

Battery Charge Related Failures

(1) P1562/4: Failure with Charge Switch
DTC P1562/4 Failure with Charge Switch

2. Charge switch turns OFF with engine stopped. Harness
* This manual assumes that the contact input is configured as Normally Open Charge switch
(NO). E-ECU
3. Two flashes followed by two flashes.

restrictions.
Run restricted? No.
Recovery No.
Conditions
Remarks

• The charge switch wiring may be disconnected or short-circuited with POWER SUPPLY.
• The charge switch may be faulty.
• Inner wiring of the charge switch may be disconnected or short-circuited with POWER SUPPLY.



with the diagnosis • Check that the input signal of the charge switch is correctly recognized.
tool
connectors/wiring • 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

Work

(2) P1568/1: Charge Alarm
DTC P1568/1 Charge Alarm

1. Key switch ON. alternator
2. Charge switch turns ON after engine has been started. Harness
* This manual assumes that the contact input is configured as Normally Open Charge switch
(NO). E-ECU
3. Three flashes followed by two flashes.

restrictions.
Run restricted? No.
Recovery No.
Conditions
Remarks

• The battery may not be properly charged.
• The charge switch wiring may be short-circuited with GND.
• The charge switch may be faulty.
• Inner wiring of the charge switch may be short-circuited with GND.



with the diagnosis • Check that the input signal of the charge switch is correctly recognized.
tool
• After the inspection, turn the key switch on to check if the DTC is detected.
(“Engine”).
3) Failure Diagnostic • Check the charge switch system.

Work

Water Temperature Switch

(1) P1217/0: Abnormal Water Temperature
DTC P1217/0 Abnormal Water Temperature

Check points
1. Key switch ON. Engine cooling system
2. Water temperature switch turns ON after engine has been Harness
started. Water Temperature Switch
* This manual assumes that the contact input is configured as E-ECU
Normally Open (NO).
3. Three flashes followed by three flashes.
Setting of response to water temperature error

restrictions.
Recovery No. No.
Conditions
Remarks

• The engine may be overheated.
• The engine cooling water level may be too low.
• The engine cooling system may be faulty.
• The water temperature switch wiring may be short-circuited with GND.
• The water temperature switch may be faulty.
• Inner wiring of the water temperature switch may be short-circuited with GND.



with the diagnosis • Check that the input signal of the water temperature switch is correctly
tool recognized.
• Check the engine cooling system.
(“Engine”).
3) Failure Diagnostic • Check the water temperature switch system.

Work

Air cleaner switch

(1) P1101/0: Air Cleaner Clogging Alarm
DTC P1101/0 Air cleaner Clogging Alarm

1. Key switch ON. Air Cleaner
2. Air cleaner switch turns ON after engine has been started. Harness
* This manual assumes that the contact input is configured as Normally Open Air cleaner switch
(NO). E-ECU
3. Three flashes followed by four flashes.
Setting of Response to Air Cleaner Failure

restrictions.
Recovery No. No.
Conditions
Remarks

• The air cleaner may be clogged.
• The air cleaner switch wiring may be short-circuited with GND.
• The air cleaner switch may be faulty.
• Inner wiring of the air cleaner switch may be short-circuited with GND.



with the diagnosis • Check that the input signal of the air cleaner switch is correctly recognized.
tool
• Inspect the air cleaner.
(“Engine”).
3) Failure Diagnostic • Check the air cleaner switch system.

Work

Oil-Water Separator Switch

(1) P1151/0: Oil-Water Separator Alarm
DTC P1151/0 Oil-water separator Alarm

Check points
1. Key switch ON. Oil-Water Separator
2. Oil-water separator switch turns ON after engine has been Harness
started. Oil-Water Separator Switch
* This manual assumes that the contact input is configured as E-ECU
Normally Open (NO).
3. Three flashes followed by five flashes.
Setting of response to oil-water separator failure

restrictions.
Recovery No. No.
Conditions
Remarks

• The oil-water separator may be malfunctioning.
• The oil-water separator switch wiring may be short-circuited with GND.
• The oil-water separator switch may be faulty.
• Inner wiring of the oil-water separator switch may be short-circuited with GND.



with the diagnosis • Check that the input signal of the oil-water separator switch is correctly
tool recognized.
• Inspect the oil-water separator.
(“Engine”).
3) Failure Diagnostic • Check the oil-water separator switch system.

Work

Actuators etc.
Rack actuator
(1) P1212/4: Failure with Rack Actuator (Low Current)
DTC P1212/4 Failure with Rack Actuator (Low Current)

2. Rack actuator current detected equal to or below the lower limit. Harness
3. Eight flashes. Rack actuator
E-ECU
Error Mode [Stop Immediately]:

The engine stops running.
Recovery No.
Conditions
Remarks

• The rack actuator wiring may be disconnected or short-circuited with GND.
• Disconnection of Rack Actuator inner wiring
• Inner wiring of the rack actuator may be short-circuited with GND.



with the diagnosis • Check the movement of the rack actuator by the active control function.
tool
3) Failure Diagnostic • Check the resistance value of the rack actuator solenoid.

(2) P1212/3: Failure with Rack Actuator (High Current)
DTC P1213/3 Failure with Rack Actuator (High Current)

2. Rack actuator current detected equal to or above the upper limit. Harness
3. Eight flashes. Rack actuator
E-ECU

Recovery No.
Conditions
Remarks

• The rack actuator wiring may be short-circuited with POWER SUPPLY (*NOTE).
• Inner wiring of the rack actuator short-circuited with POWER SUPPLY (*NOTE)
*NOTE) If the rack actuator wiring is short-circuited with POWER SUPPLY, the ECU's power supply line fuse
the error history.



tool

(3) P1211/7: Rack Actuator Mechanical Failure
DTC P1211/7 Rack Actuator Mechanical Failure

1. Key switch ON. Rack
2. Rack operation check at the activation
3. Eight flashes.

The engine does not start up.
Run restricted? Yes: The rack actuator relay is turned OFF, and the starter does not rotate.
Recovery No.
Conditions
Remarks

• The rack may be stuck.
• Water entered into the fuel rusts the plunger.



tool

Engine
(1) P1214/2: Engine Trouble
DTC P1214/2 Engine Trouble

2. (1) Engine stall during a rack position sensor error Rack actuator
(2) Unexpected engine speed rise is detected other than acceleration.
3. Eight flashes.

Recovery No.
Conditions
Remarks

• The rack actuator wiring may be short-circuited with POWER SUPPLY.
• Engine over speed loaded by the operating machine’s drive
• Control error of the fuel injection pump



with the diagnosis
tool
• Inspect the engine and the operating machine.
(“Engine”).
3) Failure Diagnostic • Check the Rack Actuator.

Work

E-ECU Internal and Communication Errors

E-ECU Internal Errors
(1) P0601/12, P1610/12, P1611/12, P1612/12: ECU internal errors (1)
P0601/12 EEPROM error (read/write error)

P1610/12 Failure A with Sub-CPU
DTC
P1611/12 Failure B with Sub-CPU
P1612/12 Failure C with Sub-CPU

2. E-ECU detects an error of the internal circuit.

restrictions.
Run restricted? No.
Recovery No.
Conditions
Remarks


with the diagnosis • Turn the key switch on/off to check the fault indication again.
tool


(2) P1601/2, P0605/12, P1605/2, P1606/2, P1620/12: ECU internal errors (2)
P1601/2 EEPROM error (Checksum)

P0605/12 FlashROM error (Checksum A)
DTC P1605/2 FlashROM error (Checksum B)
P1606/2 FlashROM error (Checksum C)
P1620/12 Map format error

2. E-ECU detects an error of the internal circuit.

Recovery No.
Conditions
Remarks

• ROM data error of E-ECU
• Checksum error of EEPROM initial individual information
• Checksum error of control application, map data or initial individual information in FlashROM
* Checksum A: control application, checksum B: map data, checksum C: initial individual information
• Unconformity of the map data format

with the diagnosis • Rewrite the E-ECU software.
tool • Turn the key switch on/off to check the fault indication again.

(3) P0686/4: Main relay error
DTC P0686/4 Main relay error

1. Key switch OFF. Connector
2. Power supply to ECU fails to turn OFF. Harness
3. One flash followed by six flashes. Main relay

restrictions.
Run restricted? No.
Recovery No.
Conditions
Remarks

• Downstream line of the main relay coil may be short-circuited with GND or POWER SUPPLY (*NOTE).
• The main relay contact may be faulty.
• The main relay contact may be stuck.
• Inner wiring of the main relay coil short-circuited with POWER SUPPLY (*NOTE).
*NOTE) If the downstream line 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.



with the diagnosis • Check if a log-in to the diagnosis tool with the key switch OFF is available.
tool
connectors/wiring • 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
3) Failure Diagnostic • Check the main relay contact for correct continuity.
Work • Check the resistance value of the main relay.

CAN Communication
(1) U0001/12: CAN Communication Error
DTC U0001/12 CAN Communication Error

1. (1) Before and (2) after ECU start-up Other ECUs
2. A necessary CANID cannot be received that should periodically received. Battery
3. One flash followed by two flashes. Connector
Harness
E-ECU
Accelerator sensor function

CAN communication only CAN communication plus analog input or
pulse accelerator#
speed. analog input or pulse accelerator instead.
speed”.
Recovery Yes: The error is reset when the Yes: The error is reset when the
Conditions necessary data is received. necessary data is received.
Remarks When the error is reset, then the engine
switches to CAN communication mode
and continues to run.

• Deactivation of another ECU
• Battery voltage descent
• CAN communication line (Hi, Low) may be disconnected, or short-circuited with GND or power supply.



tool
connectors/wiring • Check that the connector of the CAN communication is correctly inserted.
• Check that the wiring of the CAN communication is not disconnected or the


Immobilizer
(1) U0167/12: Immobilizer Error (CAN communication)
DTC U0167/12 Immobilizer Error (CAN communication)

1. Key switch ON. Immobilizer
2. If the immobilizer does not respond to a request of authorization start. Battery
3. Four flashes followed by two flashes Connector
Harness
E-ECU
Immobilizer pulse communication setting

Yes No
Authorization by the emergency pulse The engine does not start up.
communication
Run restricted? - Yes: The rack actuator relay is turned
(As same as the movement at the OFF, and the starter does not rotate.
immobilizer pulse communication error)
Recovery - No.
Conditions (As same as the movement at the
immobilizer pulse communication error)
Remarks

• Battery voltage descent
• CAN communication line (Hi, Low) may be disconnected, or short-circuited with GND or power supply.



tool
connectors/wiring • Check that the connector of the CAN communication is correctly inserted.
• Check that the wiring of the CAN communication is not disconnected or the


(2) U1167/8: Immobilizer Error (pulse communication)
DTC U1167/8 Immobilizer Error (pulse communication)

2. In the case of timeout detection Connector
3. Four flashes followed by two flashes Harness
E-ECU
Immobilizer CAN communication

Normal Error
Engine start is authorized. The engine does not start up.
Run restricted? No. Yes:The rack actuator relay is turned
OFF, and the starter does not rotate.
Recovery Yes: The error is automatically reset Yes: The error is automatically reset
Conditions when a normal data is received. when a normal data is received.
Remarks

• Pulse communication line may be disconnected, or short-circuited with GND or power supply.



with the diagnosis
connectors/wiring • 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

Work

(3) U0426/2: Immobilizer Error (system)
DTC U0426/2 Immobilizer Error (system)

2. (1) Authorization by CAN communication is NG. authorization key
(2) Immobilizer CAN communication is faulty, and authorization by immobilizer
pulse communication is NG.
3. Four flashes followed by two flashes

Run restricted? Yes: The rack actuator relay is turned OFF, and the starter does not rotate.
Recovery No.
Conditions
Remarks

• Unconformity of the immobilizer authorization key
1) Initial diagnosis • Check that the immobilizer authorization key is correct.

with the diagnosis
tool

Method and Procedure of Failure Diagnosis FAILURE DIAGNOSIS
METHOD AND PROCEDURE OF FAILURE DIAGNOSIS

Description Items
Related DTC
Related DTC(s) is listed.
DTC Code Number Error Name
Work flow
Work flow for the failure diagnosis is listed,
Wiring Diagram
Shows a wiring diagram that encompasses the components/parts associated with the failure.
Work Description
Describes how to diagnose and correct the failure.

FAILURE DIAGNOSIS Method and Procedure of Failure Diagnosis
E-ECU Pin Layout Diagram

Harness side coupler (coupling face) ECU side coupler (coupling face)
1 E48 E47 E40 E39 E38 E37 E36 E35 E34 E33 E32 E31 E31 E32 E33 E34 E35 E36 E37 E38 E39 E40 E47 E48 1
M L K J H G F E D C B A A B C D E F G H J K L M
017070-00X 017071-00X
No. Pin function name Code No. Pin function name Code
E01 4-A STEP MOTOR D-PHASE STPM-D E25 2-E COOLING WATER TEMPERATURE TW
(CONVENTIONAL)
E02 4-B APPLICATION OPEN OUTPUT 2 APP-OP2 E26 2-F INTAKE TEMPERATURE TAIR
E03 4-C RxD1 RxD E27 2-G EGR TEMPERATURE TEGR
E04 4-D TxD1 TxD E28 2-H SENSOR GND GND-A
E05 4-E APPLICATION OPEN INPUT 5 APP-IP5 E29 2-J BOOT MODE BOOTSW
E06 4-F APPLICATION OPEN INPUT 6 APP-IP6 E30 2-K CAN TERMINAL RESISTANCE RECAN
SWITCH-OVER
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 APS
SENSOR
E12 3-B FAILURE INDICATOR LAMP FAIL-LMP E36 1-F Rack position sensor RPS
E13 3-C APPLICATION OPEN INPUT 7 APP-IP7 E37 1-G RESERVED ANALOG REAN
E14 3-D APPLICATION OPEN INPUT 2 APP-IP2 E38 1-H SENSOR 5V AVCC
E15 3-E EMERGENCY ENGINE STOP SHUDNSW E39 1-J CANL CANL
E16 3-F COOLING WATER RET E40 1-K CANH CANH
TEMPERATURE (HIGH
ACCURACY)
E17 3-G APPLICATION OPEN INPUT 4 APP-IP4 E41 4-L CSD Solenoid Valve Coil CSD-CL
E18 3-H SPEED INPUT (-) NRPM-GND E42 4-M Rack actuator RACKSOL
E19 3-J SPEED INPUT (+) NRPM E43 3-L SENSOR 12V AVB
E20 3-K APPLICATION OPEN OUTPUT 1 APP-OP1 E44 3-M START ASSIST RELAY AIRHT-RLY
E21 2-A STEP MOTOR B-PHASE STPM-B E45 2-L POWER SUPPLY GND GND
E22 2-B SPEED MONITOR NRPM-M E46 2-M (FLY-BACK) (FB)
E23 2-C PREHEAT LAMP PREHT-LMP E47 1-L POWER GND GND-P
E24 2-D APPLICATION OPEN INPUT 1 APP-IP1 E48 1-M POWER SUPPLY 12V VB


How to use the 2G eco-checker harness
Failure diagnosis for area listed in the following correspondence list includes the work measuring voltage
with the 2G eco-checker harness.Therefore before the failure diagnosis, remove the E-ECU and machine’s
harness, and connect the 2G eco-checker harness between the E-ECU and machine’s harness.
* For details of the failure diagnosis for each area, see the followings.
* Measure the voltage using a circuit tester referring the following list.
2G Eco-checker Harness Pin layout correspondence list

Circuit tester
Area
(+) (-)
Accelerator sensor E35
E01 E02 E03 E04 E05 E06 E07 E08
Cooling water temperature sensor E16 (E25) E28
E09 E10 E11 E12 E13 E14 E15 E16
Sensor 5V E38
E17 E18 E19 E20 E21 E22 E23 E24 Rack Actuator Relay E33
Start Assist Relay E44
CSD Solenoid Valve Coil E41
E31 (A-Phase) E45
E25 E26 E27 E28 E29 E30 EGR valve E21 (B-Phase)
(step motor) E11 (C-Phase)
E31 E32 E33 E34 E35 E36
E01 (D-Phase)
E37 E38 E39 E40 -- --
(-)
E41 E42 E43 Check !

E44 E45 E46 E47 (+)
E48 -- -- V
Connect between E-ECU and Machine’s

machine’s harness. harness
Measure the voltage between

specified terminals using a
circuit tester.
E-ECU
019618-00E


Related DTC
P1202/4 Rack Position Sensor Error (Low Voltage)

DTC
P1203/3 Rack Position Sensor Error (High Voltage)
Work flow
*For details of the work, see after-mentioned "<Diagnosis Description>."For the operation of the
diagnosis tool, see “Diagnosis tool Operation Manual” separately.
Initial diagnosis with the diagnosis tool
DTC in the failure history indication Check the failure

A. Check the current
conditions.
failure display.
Current failure
exists. [Check items]:
B. Check the detected Rack position sensor voltage (AD value) - "Signal Data (SD)"
value to estimate the • SD=0 (0V) or equivalent Signal wire disconnected ?
cause of failure.
• SD=5000 (5.0V) or equivalent Sensor GND wire disconnected ?
Failure diagnosis flow
1. Input voltage check NG NG

of the rack position sensor 2. Check the harness Replace the
(harness + E-ECU) continuity. harness.
OK
OK
3. Execution of
directive rack position control NG Replace the
(use diagnosis tool) fuel injection pump.
OK Replace the
E-ECU.
017534-00E


Wiring Diagram
: Check points
Battery ＋ −
ECU
Main relay
Fuse
10A
Rack Actuator
E-ECU
A E48 VB
B E34
MAIN-RLY
D E43
BAT AVB
RPS C E36
RPS
E E28
G_S
GND-A
Actuator side coupler (coupling face) Harness side coupler (coupling face)
B17 E42 -- E36 E43 E28
E D C B A
017535-00E
*For the E-ECU Pin Layout, see [E-ECU Pin Layout Diagram] (P.1-134).

1. Check of the input voltage of the rack position sensor (harness + E-ECU)
• Turn the key switch off, and remove the rack actuator connector from the fuel injection pump. At this
time, keep the E-ECU connector being connected to E-ECU.
• Turn the key switch on to turn on the E-ECU power.
• Measure the voltage between sensor terminal E43 and E28 using a circuit tester.
Terminal Normal value

Sensor connector E43 - E28 Equivalent to the battery voltage
NG Check the harness for correct continuity. → Go to [2. Check of harness continuity:]
Check if the “Directive rack position control” is executable using the diagnosis tool
OK “Diagnosis Test: Active control”. → Go to [3. Execution check of the directive rack
position control:]
2. Check of harness continuity:
• Remove the rack actuator connector and E-ECU from the harness.
• Check the harness continuity using a circuit tester.
Terminal Continuity Status

Sensor signal wire E36 Available OK: normal
[Between E-ECU and sensor connector] Unavailable NG: harness disconnection
Sensor GND wire E28 Available OK: normal
Sensor 12V wire E43 Available OK: normal
Between E36 and other terminal/GND Unavailable OK: normal
and between E43 and other
terminal/GND 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
NG: harness short-circuited with another
Available
wiring
• Check if the harness is damaged, or if the wiring is correct.

NG
• Replace the harness.
Check if the “Directive rack position control” is executable using the diagnosis tool
OK “Diagnosis Test: Active control”. → Go to [3. Execution check of the directive rack
position control:]


3. Execution check of the directive rack position control:
• Connect the all connectors (sensors, E-ECU).
• Connect the diagnosis tool, and log in to the diagnosis tool after key switch turning-on.
• 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.

Accelerator sensor
Related DTC
P0122/4 Accelerator Sensor Error (Low Voltage)

DTC P0123/3 Accelerator Sensor Error (High Voltage)
P0124/2 Intermittent Failure with Accelerator Sensor
Work flow
*For details of the work, see after-mentioned "<Work Description>."For the operation of the
A. Check the current DTC in the failure history indication Check the failure
failure display conditions.
Current failure [Check items]:

exists. Accelerator sensor position (%) "Signal Data(SD)"
B. Check the detected • SD ≤ 200 (0.2V) Signal wire disconnected?

value to estimate the • 200 (0.2V) < SD < 4600(4.6V) Normal
cause of failure.
• 4600 (4.6V) ≤ SD GND wire disconnected?
1. Check of sensor NG
resistance value Replace the
(sensor only) sensor.
OK
2. Sensor replacement NG 3. Check the harness NG

Check of sensor resistance value Replace the
(sensor + harness) continuity. harness.
OK
OK
4. Check of the Replace the ECU

accelerator sensor output voltage NG
or
(when fit to sensor) sensor.
OK Replace the
E-ECU.
017536-00E


Wiring Diagram
: Check points
Accelerator sensor (standard)

E-ECU
SNS5 C E38
Sensor side coupler (coupling face)
AVCC
B
C A STH B E35
APS
G_S A E28
GND-A
Harness side coupler (coupling face)
E28 E35 E38
SNS5
STH
E37
REAN
G_S
017537-00E
*For the E-ECU Pin Layout, see [E-ECU Pin Layout Diagram] (P.1-134) .

Work Description
1. Check of the sensor resistance value (sensor only):
• Between accelerator sensor terminals A and C (all the resistance value)
• Remove the accelerator sensor from the harness.
• Measure the resistance between sensor terminals A and C (all the resistance value) using a circuit tester.
(REF) Total resistance value of Yanmar standard accelerator sensors
Terminal Specification
Sensor A - C 5 ± 1.5kΩ
NG Replace the accelerator sensor.

Check the resistance value between accelerator sensor terminal A and B. → Go to
OK
[• Between accelerator sensor terminals A and B]
• Between accelerator sensor terminals A and B
• Measure the resistance between accelerator sensor terminals A and B using a circuit tester.
• Check if the resistance value between accelerator sensor terminal A and B fluctuates when the
accelerator throttle is moved.
NG Replace the accelerator sensor.

Check the sensor resistance with the sensor and the harness being connected. →
OK
Go to [2. Check of the sensor resistance value (sensor + harness):]
2. Check of the sensor resistance value (sensor + harness):
• Between harness E38 and E28 (total resistance value)
• Connect accelerator sensor and harness, and remove E-ECU from the harness.
• Measure the resistance between harness side E-ECU connectors E38 and E28 (total resistance value)
using a circuit tester.
*See above-mentioned “(REF) Total resistance value of Yanmar standard accelerator sensors”.
NG Check the harness for correct continuity. → [3. Check of harness continuity:]
Check the resistance value between the harness E35 and E28. → Go to [• Between
OK
harness E38 and E28]
• 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.
NG Check the harness for correct continuity. → [3. Check of harness continuity:]
OK
[2. Check of the sensor resistance value (sensor + harness):]


• Remove the accelerator sensor and E-ECU from the harness.

Available NG: harness short-circuited with GND
terminal/GND
Available OK: normal
Between E28 and GND/E45/E47
Unavailable OK: normal
Between E28 and other terminals NG: harness short-circuited with another
Available
wiring

NG
Check the output voltage of the accelerator sensor. → Go to [4. Check of the
OK
accelerator sensor output voltage:]
4. Check of the accelerator sensor output voltage:

• Connect the 2G eco-checker harness between E-ECU and machine’s harness (for details, see [How to
use the 2G eco-checker harness] (P.1-135) And connect the all connectors (sensors, E-ECU).
• Measure the voltage between sensor signal E35 and E28 using a circuit tester.
Voltage Status Action

E35 ≤ 0.2[V] NG
• Replace the accelerator sensor.
OK Replace E-ECU.
0.2[V] < E35 < 4.6[V]
(Normal range)
4.6V ≤ E35 NG

NG
OK Replace E-ECU.

Foot pedal
Related DTC
P1125/1 Accelerator Sensor Error (foot pedal-close position)
P1126/0 Accelerator Sensor Error (foot pedal-open position)
DTC
P1225/1 Spare Accelerator Sensor Error (foot pedal-close position)
P1226/0 Spare Accelerator Sensor Error (foot pedal-open position)
Work flow

conditions.
failure display

exists.
“Foot pedal SW-NO” “Foot pedal SW-NC”
B. Check the detected • Pedal full-closed : SW-NO=OFF, SW-NC=ON=>Normal

value to estimate the • Pedal full-opened : SW-NO=ON, SW-NC=OFF=>Normal
cause of failure.
• Other than above=>Error
1. Continuity check NG
(foot pedal only) Foot pedal replacement
OK
2. Continuity check NG 3. Continuity check NG Harness

(foot pedal + harness) (harness) replacement
OK
OK
4. Movement check Replacement of E-ECU

NG
(use diagnosis tool) or
foot pedal
OK
Replacement of E-ECU
019477-00E


Wiring Diagram
: Check points
Accelerator sensor (standard)

E-ECU
SNS5 C E38
AVCC
STH
B E35
APS
G_S
A E28
GND-A
SNS5
STH
E37
REAN
G_S
Foot pedal
A E14
NO APP-IP2
E13
APP-IP7
NC B
019478-00E

Work Description
1. Continuity check (foot pedal only):
• Remove the foot pedal from the harness.
• Check the foot pedal continuity with a specified pedal opening using a circuit tester.
Continuity
Pedal opening Status
Between A and GND Between B and GND
Unavailable Available OK: normal
Unavailable Unavailable NG: Internal circuitry fault
Full close position
Available Unavailable NG: Internal circuitry fault
Available Available NG: Internal circuitry fault
Available Unavailable OK: normal
Full open position
Unavailable Available NG: Internal circuitry fault
NG Replace the foot pedal.

Check the continuity with the foot pedal and the harness being connected. → Go to
OK
[2. Continuity check (foot pedal + harness):]
2. Continuity check (foot pedal + harness):

• Connect foot pedal and harness, and remove E-ECU from the harness.
•Check the foot pedal continuity with a specified pedal opening using a circuit tester.
Continuity
Pedal opening Status
Between E-14 and GND Between E-13 and GND
Unavailable Available OK: normal
Full close position
Available Unavailable NG: Internal circuitry fault
Available Unavailable OK: normal
Full open position
Unavailable Available NG: Internal circuitry fault
Check if the foot pedal movement is correctly recognized with the diagnosis tool
OK
“Diagnosis Test”. → Go to [4. Foot pedal movement check:]


• Remove the foot pedal and E-ECU from the harness.
Pedal signal wire (A) E14 Available OK: normal

[Between E-ECU and pedal connector] Unavailable NG: harness disconnection
Pedal signal wire (B) E13 Available OK: normal

[Between E-ECU and pedal connector] Unavailable NG: harness disconnection

NG
Check if the foot pedal movement is correctly recognized with the diagnosis tool
OK
“Diagnosis Test”. → Go to [4. Foot pedal movement check:]
4. Foot pedal movement check:

• Connect the all connectors (foot pedal, E-ECU).
• With the diagnosis tool “Diagnosis Test: Pulse/Analog etc.”, operate the pedal to obtain the specified
sensor voltage watching “accelerator sensor position”, and fix it at that opening.
• With the diagnosis tool “Diagnosis Test: Digital Input etc.”, make “Foot pedal SW-NO” and “Foot pedal
SW-NC” be displayed, and check the status of ON/OFF.
Foot pedal
Sensor voltage Action
SW-NO SW-NC
OFF ON Replace the E-ECU.
0.65[V] and below • Replace the harness.
Other than above
ON OFF Replace the E-ECU.
1.1[V] and above • Replace the harness.
Other than above

Spare Analog (Spare accelerator sensor, Atmospheric pressure sensor)

Related DTC
P0222/4 Failure with Spare Accelerator Sensor (Low Voltage)

P0223/3 Spare Accelerator Sensor Error (High Voltage)
P0224/2 Intermittent Failure with Spare Accelerator Sensor
DTC
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
Work flow
*For details of the work, see after-mentioned "<Diagnosis Method, Procedure>."For the operation
of the diagnosis tool, see “Diagnosis tool Operation Manual” separately.

exists. Reserved Analog Input 1 (V) “Signal Data (SD)”
B. Check the detected • SD ≤ 200 (0.2V) => Signal wire disconnected?

value to estimate the • 200 (0.2V) < SD < 4600 (4.6V) => Normal
cause of failure.
• 4600 (4.6V) ≤ SD => GND wire disconnected?
019479-00E

1. Check of
sensor resistance value NG
Sensor replacement
(sensor only)
OK
2. Check of
sensor resistance value NG NG Harness
3. Harness continuity check
(sensor + harness) replacement
OK
OK
4. Check of Replacement of E-ECU

sensor output voltage NG
or
(when fit to sensor)
sensor
OK
Replacement of E-ECU
019480-00E
Wiring Diagram
: Check points
Spare accelerator sensor

or
Atmospheric pressure sensor
E-ECU
C E38
SNS5 AVCC
B E37
SG REAN
A E28
G_S GND-A
019481-00E

Work Description
• Between sensor terminal A and C of the spare accelerator sensor or the atmospheric pressure sensor
(total resistance value)
• Remove the harness from the spare accelerator sensor or the atmospheric pressure sensor.
• Measure the resistance between sensor terminals A and C (total resistance value) using a circuit tester.
(REF) Total resistance value of Yanmar standard spare accelerator sensor or atmospheric pressure sensor
Sensors A - C 5 ± 1.5kΩ
NG Replace the spare accelerator sensor or the atmospheric pressure sensor.

Check the resistance value between terminal A and B of the spare accelerator
OK sensor or the atmospheric pressure sensor. → Go to [• Between sensor terminal A
and B of the spare accelerator sensor or the atmospheric pressure sensor]
• Between sensor terminal A and B of the spare accelerator sensor or the atmospheric pressure sensor
• Measure the resistance between sensor terminals A and B using a circuit tester.
• Check if the resistance value between sensor terminal A and B fluctuates when the sensor opening is
changed.
NG Replace the spare accelerator sensor or the atmospheric pressure sensor.

OK
• Between harness E38 and E28 (all the resistance value)
• Connect sensor and harness, and remove E-ECU from the harness.
• Measure the resistance between harness side E-ECU connectors E38 and E28 (all the resistance value)
using a circuit tester. *Refer to above-mentioned sensor resistance values.
Check the resistance value between the harness E37 and E28. → Go to [• Between
OK
harness E37 and E28]
• Between harness E37 and E28

• Check if the resistance value between E-ECU connector E37 and E28 fluctuates when the sensor
opening is changed.
OK


• Remove the accelerator sensor and E-ECU from the harness.

Between E37 and other terminal/GND, Unavailable OK: normal
Available
wiring

NG
Check the output voltage of the spare accelerator sensor or the atmospheric
OK
pressure sensor. → Go to [4. Check of the sensor output voltage:]
4. Check of the sensor output voltage:

use the 2G eco-checker harness] (P.1-135). And connect the all connectors (sensors, E-ECU).

E37 ≤ 0.2[V] NG
• Replace the sensor.
OK
0.2[V] < E37 < 4.6[V] Replace the E-ECU.
(normal range)
4.6V ≤ E37 NG
• Replace the sensor.

NG

Pulse accelerator
Related DTC
DTC P1127/8 Failure with Spare Accelerator Sensor (Pulse Communication)
Work flow

conditions.
failure display
Current failure
exists.
[Check items] : Fault Code
NG
1. Harness continuity check Harness replacement
Check the sender unit of the

OK
pulse accelerator signal, or
replace E-ECU.
019482-00E


Wiring Diagram
: Check points
UFO E-ECU
CAN Communication E40
CANH
E39
CANL
E09
APP-IP3
Pulse accelerator signal
019483-00J
Work Description
1. Harness continuity check:
• Remove the source unit of the pulse accelerator signal and E-ECU from the harness.
Pulse accelerator signal wire E09 Available OK: normal

[Between E-ECU and source units] Unavailable NG: harness disconnection
Between E09 and other terminal/GND

NG
• Check the source unit of the pulse accelerator signal.
OK
• Replace the E-ECU.

ECU Temperature Sensor

Related DTC
P0668/4 Failure with ECU Temperature Sensor (Low Voltage)

DTC P0669/3 Failure with ECU Temperature Sensor (High Voltage)
P1644/2 Intermittent Failure WITH ECU Temperature Sensor
Work flow
Check the failure

A. Check the current DTC in the failure history indication
conditions.
failure display.
Current failure
exists.
[Check items]: ECU temperature
B. Check the detected ECU temperature is stationary at 30°C ECU may be faulty.
value to estimate the
cause of failure. ECU temperature equivalent to Normal
ambient temperature
Repeat Turn ON/OFF

the key switch.
1. Do the same steps as DTC in the failure history indication

Check the failure
in the initial diagnosis
above. conditions.
OK
Replace the
E-ECU.
017538-00E


Work Description
1. Work with the diagnosis tool:
• Check of current failure indication
• Turn the key switch off, and turn the key switch on again.
• Connect the diagnosis tool, and check if any error is detected on the current fault indication.
Check the error history indication, confirm error occurrence situation if any error
Unavailable
history is indicated.
Check the detected value using the diagnosis tool. → Go to [• Check of detected
Available
value]
• Check of detected value

• Check the value indicated in the “E-ECU Temperature” with the diagnosis tool “Diagnosis Test” function.
Indicated value Status Action

Fixed at 30°C NG Replace the E-ECU.
Ambient temperature OK Replace the E-ECU.
NG Replace E-ECU.
Turn the key switch on/off again, and perform the work [• Check of current failure
OK indication] [• Check of detected value].
Replace E-ECU.


Related DTC
P0117/4 Failure with Cooling Water Temperature Sensor (Low Voltage)
DTC P0118/3 Failure with Cooling Water Temperature Sensor (High Voltage)
P0119/2 Intermittent Failure with Cooling Water Temperature Sensor
Work flow

A. Check the current conditions.
failure display
Current failure
exists. [Check items]: Engine cooling water temperature - "Signal Data(SD)"
• SD≤200(0.2V) Short-circuited with GND?
B. Check the detected
value to estimate the • 200(0.2V)<SD<4800(4.8V) Normal
cause of failure.
• 4800(4.8V)≤SD Disconnected?
1. Check of sensor NG
resistance value Replace the sensor.
(sensor only)
2. Check of sensor NG NG
resistance value 3. Check the harness Replace the
OK
4. Check of cooling NG
water temperature sensor Replace the E-ECU
output voltage or
sensor.
OK
Replace the E-ECU.
017539-00E


View of the sensor
*High-precision cooling water temperature sensor and conventional cooling water temperature
sensor share similar construction.
59
A * High-precision cooling
water temperature sensor
and conventional cooling
19
water temperature sensor
have similar construction.
B
M12 x 1.5 007217-00E
Wiring Diagram
: Check points
High-accuracy cooling water temperature sensor

E-ECU
A E16
THW RET
B E28
G_S G_S
Harness side coupler

(coupling face)
E16 E28

A E25
THW TW
B
G_S
Harness side coupler (coupling face)
E25 E28
017540-00E

Work Description
• Remove the harness from the cooling water temperature sensor.
• Measure the resistance between cooling water temperature sensor terminals A and B using a circuit
tester.
• Check if the measured resistance value is within the normal range, referring to the following table
<Characteristics of cooling water temperature sensor>.
<Characteristics of cooling water temperature sensor>

• Relationship between cooling water temperature and sensor resistance
100
Temperature Resistance [kΩ]
(°C) High-precision Conventional
-30 25.4 28.6
-20 15.04 16.2
-10 9.16 9.56
Resistance [kΩ]
10
0 5.74 5.88
10 3.7 3.73
20 2.45 2.45
30 1.66 1.65
1 40 1.15 1.14
50 0.811 0.808
60 0.584 0.584
70 0.428 0.43
80 0.318 0.322
0.1 90 0.24 0.245
-40 0 40 80 120 -40 0 40 80 120
100 0.1836 0.189
Temperature (°C) Temperature (°C)
017541-00E 110 0.1417 0.148
High-accuracy cooling water Conventional cooling water 120 0.1108 0.117
temperature sensor temperature sensor
NG Replace the cooling water temperature sensor.

OK

• Connect the cooling water temperature sensor and the harness, and remove E-ECU from the harness.
• Measure the resistance between harness side E-ECU connector terminals E16 (E25) and E28 using a
circuit tester.
• Check if the measured resistance value is within the normal range, referring to the above table
<Characteristics of cooling water temperature sensor>.
Check the output voltage of the cooling water temperature sensor. → Go to [4.
OK
Output voltage check of the cooling water temperature sensor:]


• Remove the cooling water temperature sensor and E-ECU from the harness.

Sensor signal wire E16 (E25) Available OK: normal
[E-ECU ñ between sensor connector] Unavailable NG: harness disconnection
(between E25 and other terminal/GND) Available NG: harness short-circuited with GND
E28 ñ GND/E45/E47 Available OK: normal
Available NG: harness short-circuited with another
wiring

NG
Check the output voltage of the cooling water temperature sensor. → Go to [4.
OK
Output voltage check of the cooling water temperature sensor:]
4. Output voltage check of the cooling water temperature sensor:

• Connect the 2G eco-checker harness between E-ECU and machine’s harness (for details, see[How to
• Measure the voltage between sensor signal E16 and E28 (E35 and E28) using a circuit tester.

E16(E25) ≤ 0.2[V] NG
• Replace the cooling water temperature sensor.
OK ReplaceE-ECU.
0.2[V] < E16(E25) < 4.8V
(Normal range)
4.8V ≤ E16(E25) NG
• Replace the cooling water temperature sensor.

NG
OK ReplaceE-ECU.

SENSOR 5V
Related DTC
P0642/4 Failure with SENSOR 5V (Low Voltage)
DTC P0643/3 Failure with SENSOR 5V (High Voltage)
P1644/2 Intermittent Failure with SENSOR 5V
Work flow

failure display.
Current failure
exists. [Check items]: SENSOR 5V voltage
• SENSOR 5V voltage ≤ 4.5V Short-circuited with GND?
B. Check the detected
value to estimate the • 4.5V < SENSOR 5V voltage < 5.5V Normal
cause of failure.
• 5.5V ≤ SENSOR 5V voltage hort-circuited with
POWER SUPPLY?
1. Check the accelerator NG Replace the

sensor. sensor.
* For checking procedure, see [Accelerator sensor].

OK
2. Check of output voltage NG NG

3. Check the harness Replace the
(when not fit to sensor) continuity. harness.
OK OK
4. Check of output voltage NG Replace the

(when fit to sensor) E-ECU.
OK Replace the
E-ECU.
017542-00E


Work Description
1. Check of the accelerator sensor:
• For details, see[Accelerator sensor] (P.1-12).
2. Check of the output voltage (not fit with sensor):
• Remove the harness from the accelerator sensor.At this time, keep the E-ECU connector being
connected to E-ECU.
• Turn the key switch on to turn on the E-ECU power.
• Measure the voltage between the harness side accelerator sensor connector terminals E38 and GND
Terminal Normal value

Sensor connector E38 - GND 5V
Check the output voltage with the accelerator sensor being connected. → Go to [4.
OK
Check of the output voltage (fit with sensor):]

• Remove the harness from the accelerator sensor and E-ECU.

Between E38 and E28/E45/E47/GND Unavailable OK: normal
Between E38 and E43/E48 Unavailable OK: normal
NG: Harness short-circuited with power
Available
supply
ÅiBetween E-ECU and sensor connector Unavailable NG: harness disconnection
Between E38/E28 and other terminals Unavailable OK: normal
Available
wiring

NG
Check the output voltage with the accelerator sensor being connected. → Go to [4.
OK
Check of the output voltage (fit with sensor):]

4. Check of the output voltage (fit with sensor):


E38 ≤ 4.5[V] NG
OK Replace E-ECU.
4.5[V] < E38 < 5.5[V]
(Normal range)
5.5[V] ≤ E38 NG

NG
OK Replace E-ECU.


Pulse Sensor Related Failures

Speed Sensor
Related DTC
DTC P0340/4 Speed Sensor Error
Work flow

failure display
Current failure
exists.
B. Check the detected [Check items]: Real engine speed [value]

cause of failure. • value=0 => Disconnected? Sensor error?
1. Check of sensor NG Replace the

resistance value sensor.
(sensor only)
OK
2. Check of sensor NG 3. Check the harness

resistance value Replace the
OK
NG Replace the
4. Check the harness for harness.
misconnections.
OK Replace the
E-ECU.
017543-00E


Wiring Diagram
: Check points
Battery ＋ −
Starter
Fuse
15A B
S
Sensor side coupler
(coupling face)
Key switch
B “ON” or “START” E-ECU
E08
Fuse STARTSW
5A
Speed Sensor
A E19
CRK+
A NRPM
CRK- B E18
NRPM-GND

Spare speed sensor (option)
(coupling face)
(Alternator)
B
B19 E18
IG
L
E10
P RENRPM
017544-00E
*For the E-ECU Pin Layout, see [E-ECU Pin Layout Diagram] (P.1-134)

Work Description
• Remove the harness from the speed sensor.
• Measure the resistance between speed sensor terminals A and B using a circuit tester.
(REF) Coil resistance value of Yanmar standard speed sensor
Sensors A - B 500 ± 100Ω
NG Replace the speed sensor.

Check the resistance between sensor terminals A and B with the speed sensor and
OK the harness being connected. → Go to [2. Check of the sensor resistance value
(sensor + harness):]

• Connect the speed sensor and the harness, and remove E-ECU from the harness.
• Measure the resistance between harness side E-ECU connector terminals E19 and E18 using a circuit
tester.
*See above-mentioned “(REF) Coil resistance of Yanmar standard speed sensors”.
NG Replace the harness.

OK Check the harness for correct continuity. → Go to [3. Check of harness continuity:]

• Remove the speed sensor and E-ECU from the harness.

Sensor signal (+) wire E19 Available OK: normal
Sensor signal (-) wire E18 Available OK: normal
Between E19 and GND/E45/E47 Unavailable OK: normal
(between E18 and GND/E45/E47) Available NG: harness short-circuited with GND

NG
OK Replace E-ECU.


Spare speed sensor
Related DTC
DTC P1340/4 Failure with Spare Speed Sensor
Work flow

failure display
Current failure
exists.
B. Check the detected [Check items]:Spare speed sensor “Value”

cause of failure. • Value=0 => Disconnected? Sensor error?
NG
1. Check of battery voltage Battery replacement
or
alternator check
OK
NG Harness
2. Check of harness continuity
replacement
OK Alternator check
or
E-ECU replacement
019609-00E

Wiring Diagram
: Check points
Battery ＋ −
Starter
Fuse
15A B
Key switch
“ON” or “START” E-ECU
E08
Fuse STARTSW
5A
Speed Sensor
B E19
CRK+
NRPM
CRK- A E18
NRPM-GND

Spare speed sensor (option) (coupling face)
(Alternator)
B
P01 B18 E10
IG
L
E10
P RENRPM
019610-00E


Work Description
1. Battery voltage check:
• Set the accelerator at the lowest position, and operate the engine.
• Measure the battery voltage using a circuit tester.
Battery voltage (in the normal condition) 10 to 16 [V]
• Check the alternator.

NG
• Replace the battery.

• Remove the connector of the spare speed sensor and E-ECU from the harness.

Alternator P terminal (E10) Available OK: normal
[Between E-ECU and alternator]
Alternator IG terminal Available OK: normal
[Between Key switch and alternator]
Alternator B terminal Available OK: normal
[Between battery and alternator]
Between E10 and GND/E45/E47 Unavailable OK: normal

NG
• Check the alternator.
OK


RACK ACTUATOR RELAY
Related DTC
P1222/4 Failure A with Rack Actuator Relay
DTC P1223/3 Failure B with Rack Actuator Relay
P1224/2 Intermittent Failure with Rack Actuator Relay
Work flow

failure display.
Current failure
exists. [Check items]: Rack actuator relay
B. Check the detected • Contact status → ON Normal ?

cause of failure. • Contact status → OFF Abnormal ?
1. Check of relay NG Replace the

coil resistance relay.
(relay only)
2. Check of relay NG NG
coil resistance 3. Check the harness Replace the
(relay + harness) continuity. harness.
OK
OK
4. Movement check NG Replace the ECU

of the relay or
(use diagnosis tool) harness.
OK Replace the
E-ECU.
017545-00E


Wiring Diagram
: Check points
Relay side coupler

(coupling face)
A B C
Battery ＋ −
ECU
Rack Actuator Relay Main relay
Fuse Fuse
10A 15A
A D C B
Key switch
“ON”
Fuse
5A
E-ECU
(coupling face)
E34
MAIN-RLY
E07 E48 B17 E48

VB
E33 -- -- E07
IGNSW
E33
B17 RACK-RLY
Rack Actuator
To the upstream of the coil. 017546-00E

Work Description
1. Check of the relay coil resistance value (relay only):
• Remove the rack actuator relay from the harness.
• Measure the resistance between relay side terminals C and D using a circuit tester.
Measurement conditions
Measured value Status
Tester (+) side Tester (-) side
Terminal C Terminal D Available (*)
OK when both are normal
Terminal D Terminal C Infinity (*)
Terminal C Terminal D NG: Fault of the relay internal
Infinity (*)
Terminal D Terminal C circuitry
*As a reverse-biased diode is integrated, the above-mentioned checking method is applied, and the measured value
varies depending on a circuit tester to be used.
NG Replace the rack actuator relay.

Check the relay coil resistance with the rack actuator relay and the harness being
OK connected. → Go to [2. Check of the relay coil resistance value (relay + harness
side):]
2. Check of the relay coil resistance value (relay + harness side):

• Install the rack actuator relay to the harness.
• Remove E-ECU from the harness.
E07 E33 Available (*)
OK: normal
E33 E07 Infinity (*)
E07 E33
Infinity (*) NG: Harness error
E33 E07
Check the movement of the rack actuator relay by the diagnosis tool. → Go to [4.
OK
Movement check of the relay:]


• Remove the rack actuator relay from the harness, and remove E-ECU from the harness.

Relay coil (downstream side) E33 Available OK: normal
Relay coil (upstream side) E07 Available OK: normal
Between E33 and GND/E28/E45/E47 Unavailable OK: normal
Available
supply

NG
OK
4. Movement check of the relay:

use the 2G eco-checker harness] (P.1-135). And connect the all connectors (rack actuator relay, E-
ECU).
• Activate the rack actuator relay by the diagnosis tool “Diagnosis Test: Active control”, and measure the
voltage between terminals E33 and E45.
ON/OFF setting status Voltage Status

1.75[V] and below OK: normal
ON NG: Harness short-circuited with power supply or E-
Over 1.75[V]
ECU fault
2.5[V] and above OK: normal
OFF
Under 2.5[V] NG: Harness short-circuited with GND or E-ECU fault

NG

START ASSIST RELAY

Related DTC
P1232/4 Failure A with Start Assist Relay
DTC P1233/3 Failure B with Start Assist Relay
P1234/2 Intermittent Failure with Start Assist Relay
Work flow
failure display. conditions.
Current failure
exists. [Check items]: Air heater relay 1
1. Check of relay NG Replace the

coil resistance relay.
(relay only)
NG
2. Check of relay NG
3. Check the harness Replace the
coil resistance
OK OK
Replace the ECU

4. Movement check NG or
of the relay harness.
(use diagnosis tool)
OK Replace the
E-ECU.
017547-00E


Wiring Diagram
: Check points
Battery ＋ −
Air heater relay

Starter
Fuse Fuse S
60A 60A
E-ECU
E44
AIRHT-RLY
Air heater
Air heater
017548-00E
B02
B04
B00 E44
B14
B15
(coupling face)
017549-00E

Work Description
• Remove the start assist relay from the harness.
(REF) The resistance value of Yanmar standard start assist relay
Relay coil side C - D (40A relay) 103Ω ± 10% (at 20°C)
Relay coil side C - D (70A relay) 103Ω ± 10% (at 20°C)
Relay coil side C - D (90A relay) 80Ω (at 20°C)
NG Replace the start assist relay.

Check the relay coil resistance with the start assist relay and the harness being
OK
connected. → Go to [2. Check of relay coil resistance value (relay + harness side):]
2. Check of relay coil resistance value (relay + harness side):
• Install the start assist relay to the harness.
• Measure the resistance between E-ECU connectors E44 and B00 using a circuit tester.
*See above-mentioned “(REF) Resistance of Yanmar standard start assist relay”.
Check the movement of the start assist relay by a diagnosis tool. → Go to [4.
OK
• Remove the start assist relay from the harness, and remove E-ECU from the harness.

Relay coil (upstream side) E44 Available OK: normal
Relay coil (downstream side) B00 Available OK: normal
Available
supply

NG
OK


4. Movement check of the relay:
use the 2G eco-checker harness] (P.1-135). And connect the all connectors (start assistant relay, E-
ECU).
• Activate the start assistant relay by the diagnosis tool “Diagnosis Test: Active control”, and measure
the voltage between terminals E44 and E45.

ON
OFF NG: Harness short-circuited with power supply or E-
Over 1.75[V]
ECU fault

NG

CSD Solenoid Valve Coil

Related DTC
P1242/4 Failure A with CSD Solenoid Valve
DTC P1243/3 Failure B with CSD Solenoid Valve
P1244/2 Intermittent Failure with CSD solenoid valve
Work flow
Current failure
exists. [Check items]: CSD solenoid valve
1. Check of resistance NG Replace the

value of CSD solenoid valve coil
(solenoid valve only) relay.
2. Check of resistance NG NG
value of CSD solenoid valve coil 3. Check the harness Replace the
(solenoid valve + harness) continuity. harness.
OK
Replace the ECU

4. Movement check of NG or
CSD solenoid valve harness.
OK Replace the
E-ECU.
017550-00E


Wiring Diagram
: Check points
Fuel injection pump E-ECU
CSD solenoid valve

E41
CSD-CL

(coupling face)
E41
017551-00E

Work Description
1. Check of resistance value of the CSD solenoid valve coil (solenoid valve only):
• Remove the CSD solenoid valve connector from the harness.
• Measure the resistance between CSD solenoid valve side terminals C and D using a circuit tester.
(REF) Coil resistance of the CSD solenoid valve
CSD solenoid valve side C - D (400W) 8Ω (at 23°C)
NG Replace the solenoid valve.

Check the coil resistance of the CSD solenoid valve with the CSD solenoid valve
OK connector and the harness being connected. → Go to [2. Check of resistance value
of the CSD solenoid valve coil (solenoid valve + harness):]
2. Check of resistance value of the CSD solenoid valve coil (solenoid valve + harness):
• Connect the CSD solenoid valve and the harness.
• Measure the resistance between E-ECU connectors E41 and B00 using a circuit tester.
*See above-mentioned “(REF) Coil resistance of Yanmar standard CSD solenoid valve”.
Check the movement of the CSD solenoid valve by a diagnosis tool. → Go to [4.
OK
Movement check of the CSD solenoid valve:]

• Remove the CSD solenoid valve connector from the harness, and remove E-ECU from the harness.

CSD Solenoid Valve (upstream side) E41 Available OK: normal
Available
supply

NG
Check the movement of the CSD solenoid valve by a diagnosis tool. → Go to [4.
OK
Movement check of the CSD solenoid valve:]


4. Movement check of the CSD solenoid valve:
use the 2G eco-checker harness] (P.1-135). And connect the all connectors (CSD solenoid valve
connector, E-ECU).
• Activate the start assistant relay by the diagnosis tool “Diagnosis Test: Active control”, and measure
the voltage between terminals E41 and E45.

ON
OFF NG: Harness short-circuited with power supply or E-
Over 1.75[V]
ECU fault

NG

EGR valve
Related DTC
P1402/4 Failure A with EGR valve (Step Motor A-Phase)

P1403/3 Failure B with EGR valve (Step Motor A-Phase)
P1412/4 Failure A with EGR valve (Step Motor B-Phase)
P1413/3 Failure B with EGR valve (Step Motor B-Phase)
DTC
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)
Work flow
[Check items]: Step motor A-phase (B-phase, C-phase, D-phase)

017552-00E

1. Resistance check of Replace the

EGR step motor coil sensor.
(EGR Valve only)
OK
2. Resistance check 3. Check the harness Replace the

of EGR step motor coil
(EGR + harness) continuity. harness.
OK
Replace the
E-ECU.
Replace the ECU

4. Check of EGR movement or
harness.
Replace the
E-ECU.
017553-00E

Wiring Diagram
: Check points
Battery ＋ −
ECU
EGR side coupler
Main relay
(coupling face)
Fuse
1 2 3 10A
4 5 6
EGR valve
E-ECU
E48 VB
E34
MAIN-RLY
(coupling face)
E01 E48 E21

2 4 1 6 3 5
E11 E48 E31
E01
STPM-D
E11
STPM-C
E21
STPM-B
E31
STPM-A
017554-00E


Work Description
1. Check of the EGR step motor coil resistance (EGR only):
• Remove the EGR valve from the harness.
• Measure the resistance between EGR side coil terminals 4-5, (1-2, 5-6, 2-3) using a circuit tester.
(REF) Resistance value of Yanmar standard EGR step motor coil
Coil terminal 4 - 5 (A-Phase)
Coil terminal 1 - 2 (B-Phase)
15 ± 2Ω
Coil terminal 5 - 6 (C-Phase)
Coil terminal 2 - 3 (D-Phase)
NG Replace the EGR valve.

Check the EGR step motor coil resistance with the EGR valve and the harness
OK being connected. → Go to [2. Check of EGR step motor coil resistance (relay +
harness side):]
2. Check of EGR step motor coil resistance (relay + harness side):

• Install the EGR valve to the harness.
• Measure the coil resistance at the E-ECU connector using a circuit tester.
*See above-mentioned “(REF) Resistance of Yanmar standard EGR step motor coil”.
Step motor ECU connector terminal number

A-Phase E31-E48
B-Phase E21-E48
C-Phase E11-E48
D-Phase E01-E48
Check the movement of the EGR by the diagnosis tool. → Go to [4. Movement check
OK
of the EGR:]


• Remove the EGR valve from the harness, and remove E-ECU from the harness.

Motor coil (downstream side) Available OK: normal
E31(E21/E11/E01)
[Between E-ECU and EGR connector] Unavailable NG: harness disconnection
Motor coil (upstream side) E48 Available OK: normal

[Between E-ECU and EGR connector] Unavailable NG: harness disconnection
Between E31 (E21/E11/E01) and Unavailable OK: normal
GND/E28/E45/E47 Available NG: harness short-circuited with GND
Between E31 (E21/E11/E01) and
E43/E48 NG: Harness short-circuited with power
Available
supply

NG
Check the movement of the EGR by the diagnosis tool. → Go to [4. Movement
OK
check of the EGR:]
4. Movement check of the EGR:

use the 2G eco-checker harness] (P.1-135). And connect the all connectors (EGR valve, E-ECU).
• Activate each step motor of the EGR valve by the diagnosis tool “Diagnosis Test: Active control”, and
measure the voltage between step motor coil terminals E31-E45, (E21-E45, E11-E45, E01-E45)
respectively.

ON NG: Harness short-circuited with power supply or E-
Over 1.75[V]
ECU fault
OFF

NG


Related DTC
P1192/4 Failure with oil pressure switch

P1198/1 Abnormal Oil Pressure Descend
P1562/4 Failure with Charge Switch
DTC P1568/1 Charge Alarm
P1217/0 Abnormal Water Temperature
P1101/0 Air cleaner Clogging Alarm
P1151/0 Oil-water separator Alarm
Work flow
Current failure
exists.
[Check items] : Contact input terminal ON/OFF status
B. Check the detected “Oil pressure SW”, “Charge SW”

cause of failure. • Before engine start : ON => Normal
: OFF => Disconnected?
“Water temperature SW”, “Air cleaner SW”, “Air cleaner SW”

• Before engine start : OFF => Normal
: ON => Short-circuited with GND?
019611-00E

1. Continuity check NG Replacement of each

(contact input switch only) contact input switch
OK
2. Continuity check NG 3. Continuity check NG

Harness
(contact input switch + harness) (harness) replacement
OK OK
Harness replacement or
4. Movement check of NG
each contact input switch
contact input switch replacement
OK Replacement of E-ECU
019612-00E


Wiring Diagram
: Check points
Battery ＋ −
Sub-relay
Key switch
E-ECU
E07
IGNSW
Or
lamp lamp lamp lamp lamp
120Ω
E06
APP-IP6
E05
APP-IP5
E17
APP-IP4
E09
APP-IP3
E14
APP-IP2
Oil-Water Air Water Charge Oil pressure

Separator cleaner Temperature switch switch
Switch
019613-00E

Work Description
1. Continuity check (contact input switch only):
• Remove the harness from each contact input switch.
• Referring to the following table, check the continuity between contact input terminal and body frame
Continuity
Terminal name
Item [Between terminal and body Status
(Terminal No.)
frame]
Available OK: normal
Oil pressure switch APP-IP2 (E14)
Unavailable NG: Internal circuitry fault
Charge Switch APP-IP3 (E09)
Available NG: Internal circuitry fault
Water Temperature Unavailable OK: normal
APP-IP4 (E17)
Switch Available NG: Internal circuitry fault
Air cleaner switch APP-IP5 (E05)
Available NG: Internal circuitry fault
Oil-Water Separator Unavailable OK: normal
APP-IP6 (E06)
Switch Available NG: Internal circuitry fault
NG Replace the contact input switch.

Check the continuity with the contact input switch and the harness being connected.
OK
→ Go to [2. Continuity check (contact input switch + harness):]
2. Continuity check (contact input switch + harness):

• Connect the contact input switch and the harness, and remove E-ECU from the harness.
• Check the continuity between harness ECU connector terminal and body frame using a circuit tester.
Then, for the terminal name to be checked, refer to above-mentioned [1. Continuity check (contact
input switch only):].
Check if the movement of the contact input switch is correctly recognized with the
OK diagnosis tool “Diagnosis Test”. → Go to [4. Movement check of the contact input
switch:]


• Remove the contact input switch and E-ECU from the harness.

Switch signal wire E14 (*) Available OK: normal
[Between E-ECU and switch connector]
Between E14 (*) and E38/E43/E48 Unavailable OK: normal
(power supply line)
Available
supply
Between E14 (*) and E28/E45/E47(GND Unavailable OK: normal
line)/GND
*This table takes an oil pressure switch as an example.In the case of charge switch (E09), water temperature switch
(E17), air cleaner switch (E05), oil-water separator switch (E06), check the continuity using the same procedure.

NG
Check if the movement of the contact input switch is correctly recognized with the
OK diagnosis tool “Diagnosis Test”. → Go to [4. Movement check of the contact input
switch:]

4. Movement check of the contact input switch:

• Connect the all connectors (contact input switch, E-ECU).
• With the diagnosis tool “Diagnosis Test: Digital Input etc.”, monitor each of displayed items, check the
ON/OFF indication of the contact input switch under the specified conditions.
Check
Item ON/OFF indication Status
conditions
Before engine ON OK: normal
Oil pressure start OFF NG: Harness error or internal circuitry fault
switch During engine OFF OK: normal
running ON NG: Harness error or internal circuitry fault
Before engine ON OK: normal
Charge start OFF NG: Harness error or internal circuitry fault
Switch During engine OFF OK: normal
runnning ON NG: Harness error or internal circuitry fault
Water OFF OK: normal
Before engine
Temperature
start ON NG: Harness error or internal circuitry fault
Switch
Air cleaner Before engine OFF OK: normal
switch start ON NG: Harness error or internal circuitry fault
Oil-Water OFF OK: normal
Before engine
Separator
start ON NG: Harness error or internal circuitry fault
Switch

NG • Replace the harness.
• Replace the contact input switch.


Actuator Related Failures
Rack actuator
Related DTC
P1212/4 Failure with Rack Actuator (Low Voltage)
DTC P1213/3 Failure with Rack Actuator (High Voltage)
P1211/7 Rack Actuator Mechanical Failure
Work flow

failure display
Current failure
exists.
[Check items]: Fault Code
1. Check of rack NG Replace the

actuator coil resistance
sensor.
(actuator only)
2. Check of rack NG NG
actuator coil resistance 3. Check the harness Replace the
(actuator + harness) continuity. harness.
OK
OK
NG Replace the E-ECU

4. Check of rack actuator or
movement fuel injection pump.
OK
Replace the E-ECU.
017555-00E

Wiring Diagram
: Check points
Battery ＋ −
ECU
Rack Actuator Relay Main relay
Fuse Fuse
10A 15A
Key switch
“ON”
Fuse
5A
Actuator side coupler E-ECU
(coupling face)
E34
MAIN-RLY
E48
VB(coupling face)
E07
E D C B A IGNSW
B17 E42 -- E36 E43 E28

Rack Actuator
A
E33
RACK-RLY
B E42
RACKSOL
BAT D E43
AVB
RPS C E36 RPS
G_S E E28
GND-A
017556-00E


Work Description
1. Check of the rack actuator coil resistance (actuator only):
• Remove the harness from the rack actuator.
• Measure the resistance between rack actuator terminals A and B using a circuit tester.
(REF) Coil resistance value of Yanmar standard rack actuator
Coils A - B 1Ω ± 10%

Check the resistance between actuator terminals A and B with the rack actuator and
OK the harness being connected. → Go to [2. Check of the rack actuator coil resistance
(harness + actuator):]
2. Check of the rack actuator coil resistance (harness + actuator):

• Connect rack actuator and harness, and remove E-ECU and rack actuator from the harness.
• Measure the resistance between harness side E-ECU connector terminal E42 and rack actuator relay
contact downstream side E18 using a circuit tester.
*See above-mentioned “(REF) Coil resistance of Yanmar standard speed sensors”.
Check the movement of the actuator by the diagnosis tool. → Go to [4. Movement
OK
check of the rack actuator:]

• Remove the rack actuator and E-ECU from the harness.

Actuator coil wire (downstream side) E42 Available OK: normal
Between actuator coil (upstream) and Available OK: normal
rack actuator relay contact (downstream) Unavailable NG: harness disconnection
Between rack actuator relay contact Available OK: normal
(downstream) and main relay contact
(downstream) Unavailable NG: harness disconnection

NG

4. Movement check of the rack actuator:

• Connect the all connectors (rack actuator, E-ECU).
• 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.



ECU Internal and Communication Errors
ECU Internal Errors
Related DTC
P0601/12 EEPROM error (read/write error)
P1601/2 EEPROM error (Checksum)
P0605/12 Flash ROM error (Checksum A)
P1605/2 Flash ROM error (Checksum B)
DTC 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
Work flow

failure display
Current failure
exists.
[Check items]: Fault Code
Repeat Turn key switch

ON/OFF
1. Same work as DTC in the failure history indication Check the failure
above-mentioned initial conditions.
diagnosis
OK
Rewrite E-ECU software or replace E-ECU.

017557-00E

Work Description
1. Work with the diagnosis tool:
• Turn the key switch off, and turn the key switch on again.
• Connect the diagnosis tool, and check if any error is detected on the current fault indication.
Check the error history indication, confirm error occurrence situation if any error
Unavailable
history is indicated.
• Turn the key switch on/off again, and perform the work [1. Work with the diagnosis
tool:].
Available
• Rewrite the E-ECU software.


Main relay
Related DTC
DTC P0686/4 Main relay error
Work flow
Check the failure

A. Check the current DTC in the failure history indication
conditions.
failure display
Current failure
exists.
Key switch OFF.
[Check items]: Logging into the diagnosis tool

• Cannot log in → Normal
B. Log into the diagnosis tool. • Can log in → Main relay contact stuck?
Main relay coil downstream
short-circuited with GND?
1. Check of relay NG
contact continuity Replace the relay.
OK
2. Check of
NG
relay coil resistance Replace the relay.
(relay only)
OK
3. Check of NG
OK 4. Check the harness
relay coil resistance Replace the
OK Replace the
NG
E-ECU.
Replace the
harness.
017558-00E

Wiring Diagram
: Check points
Relay side coupler

(coupling face)
A B C
Battery ＋ −
ECU
Self-hold relay
Fuse Fuse
15A 10A
B C D A
E-ECU
(coupling face) E48 VB
Key switch
“ON”
E34
B10 B10 E48
MAIN-RLY
Fuse
5A E34 -- --
E07
IGNSW
017559-00E


Work Description
• Remove the E-ECU main relay from the harness.
• Check the continuity between relay side terminals A and B using a circuit tester.
NG Replace the E-ECU main relay.

Check the resistance of the E-ECU main relay coil. → Go to [2. Check of the relay
OK
coil resistance value (relay only):]
• Remove the E-ECU main relay from the harness.
Terminal C Terminal D Available (*)
OK when both are normal
Terminal D Terminal C Infinity (*)
Terminal C Terminal D NG: Fault of the relay internal
Infinity (*)
Terminal D Terminal C circuitry
NG Replace the E-ECU main relay.

Check the relay coil resistance with the E-ECU main relay and the harness being
OK
connected. → Go to [3. Check of relay coil resistance value (relay + harness side):]
3. Check of relay coil resistance value (relay + harness side):
• Install the E-ECU main relay to the harness.
• Measure the resistance between battery cable (+) line and harness side E-ECU connector E34.
Battery (+) line E34 Available (*)
OK: normal
E34 Battery (+) line Infinity (*)
Battery (+) line E34
Infinity (*) NG: Harness error
E34 Battery (+) line
NG Replace the harness.



• Remove the E-ECU main relay from the harness and remove the E-ECU from the harness.

Between relay coil (downstream side) Unavailable OK: normal
E34 and GND/E28/E45/E47 Available NG: harness short-circuited with GND
Between relay contact (downstream Unavailable OK: normal
side) E48 and E43/battery(+) NG: Harness short-circuited with power
Available
supply

NG
• Connect the all connectors (E-ECU main relay, E-ECU), and recheck that any
error is detected with the diagnosis tool “Fault code: Current fault indication”
OK
again.


CAN Communication
Related DTC
DTC U0001/12 CAN Communication Error
Work flow

failure display.
Current failure [Check Items]: Battery voltage

exists.
• 12[V] or equivalent ≤ battery voltage < 16[V]
B. Check the detected →CAN wiring disconnected?
cause of failure. • 10.5[V] ≤ Battery voltage <12[V] or equivalent
→ Battery voltage descent?
Another ECU deactivated?
1. Check of
NG
battery voltage Charge or replace battery.
(diagnosis tool)
OK
2. Check the harness NG

Replace the harness.
continuity.
OK
Check of other ECUs movement
or replacement of E-ECU
017560-00E

Work Description
1. Battery voltage check:
• During the engine running, connect the diagnosis tool and log in to the diagnosis tool.
• Check the battery voltage with the diagnosis tool “Diagnosis Test: Pulse/analog etc.”.

OK
Approx.12[V] ≤ battery voltage < 16[V] Check the harness for correct continuity.
(normal range)
• Charge or replace the battery.
10.5[V] ≤ battery voltage < approx.12[V] NG
• Check the movement of other E-ECUs.
• Charge or replace the battery.

NG


CAN wiring (Hi side) E40 Available OK: normal
(Between E-ECU and sensor connector) Unavailable NG: harness disconnection
CAN wiring (Low side) E39 Available OK: normal
(Between E-ECU and sensor connector) Unavailable NG: harness disconnection
Between E39/E40 and Unavailable OK: normal
GND/E28/E45/E47 Available NG: harness short-circuited with GND

NG
OK


Immobilizer
Related DTC
DTC U1167/8 Immobilizer Error (pulse communication)
Work flow

failure display
Current failure
exists.
[Check items] : Fault Code
1. Check the harness NG

Replace the harness.
continuity.
OK
Check of immobilizer
or
replacement of E-ECU
019614-00E

Wiring Diagram
: Check points
Immobilizer ECU
CAN Communication E40

CANH
E39
CANL
E17
APP-IP4
Pulse communication
019615-00E
* For the E-ECU Pin Layout, see [E-ECU Pin Layout Diagram] (P.1-134).
Work Description
1. Harness continuity check:
• Remove the immobilizer and E-ECU from the harness.

Immobilizer pulse communication Available OK: normal
line E17
[Between E-ECU and immobilizer]
Between E17 and Unavailable OK: normal
E38/E43/E48(power supply line)
Available
supply
Between E17 and Unavailable OK: normal
E28/E45/E47(GND line)/GND

NG
• Check the immobilizer.
OK


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

Lower: 5 flashes
At power-on time
2s 3s 0.5s 0.5s 3s
ON
Continuously ON
OFF
EGR valve failure

Upper: 1 flash Lower: 3 flashes
At power-on time
2s 3s 0.5s 0.5s 3s
ON
Continuously ON
017118-00E
OFF

FAILURE DIAGNOSIS Using the Failure Indicator for Failure Diagnosis
USING THE FAILURE INDICATOR FOR FAILURE DIAGNOSIS

Flashing Patterns of the Failure Indicator
Flashing Patterns of the Failure Indicator
Flashing Error Item Referenced

DTC
Patterns Area Status page number
4 Cooling Water Temperature Failure (low voltage) P0117/4 P.1-45
Sensor Failure (high voltage) P0118/3 P.1-47
5 Accelerator Sensor Failure (low voltage) P0122/4 P.1-12
Failure (high voltage) P0123/3 P.1-14
Intermittent failure P0124/2 P.1-16
Lower limit error P1125/1 P.1-18
Upper limit error P1126/0 P.1-20
6 Speed Sensor Failure (low voltage) P0340/4 P.1-60
7 Rack Position Sensor Failure (low voltage) P1202/4 P.1-8
8 Rack Actuator Failure (low voltage) P1212/4 P.1-114
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) P1413/3 P.1-90
C-phase failure (disconnection) P1422/4 P.1-92
C-phase failure (short circuit) P1423/3 P.1-94
D-phase failure (disconnection) P1432/4 P.1-96
D-phase failure (short circuit) P1433/3 P.1-98
1-4 CSD Solenoid Valve Failure (disconnection) P1242/4 P.1-78
Failure (short circuit) P1243/3 P.1-80
1-5 Start Assist Relay Failure (disconnection) P1232/4 P.1-72
Failure (short circuit) P1233/3 P.1-74
1-6 Self-Hold Relay Failure (low voltage) P0686/4 P.1-124

Using the Failure Indicator for Failure Diagnosis FAILURE DIAGNOSIS
Flashing Error Item Referenced

DTC
Patterns Area Status page number
1-7 Rack Actuator Relay Failure (low voltage) P1222/4 P.1-66
1-8 Spare Accelerator Sensor Failure (low voltage) P0222/4 P.1-22
Lower limit error P1225/1 P.1-28
Communication error P1227/8 P.1-32
1-9 Atmospheric Pressure Sensor Failure (low voltage) P2228/4 P.1-34
2-1 Oil Pressure Switch Failure (disconnection) P1192/4 P.1-100
2-2 Charge Switch Failure (disconnection) P1562/4 P.1-104
2-3 ECU Supply Voltage Lower limit error P0562/1 P.1-56
2-4 SENSOR 5V Failure (low voltage) P0642/4 P.1-53
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 P.1-110
3-5 Oil-Water Separator Mechanical failure P1151/0 P.1-112
3-6 Cooling Water Temperature Rise Error P0217/0 P.1-51
4-1 ECU Flash ROM P0605/12 P.1-123
Internal EEPROM P0601/12 P.1-122
Sub CPU CRC error P1610/12 P.1-122
Send ACK error P1611/12 P.1-122
Communication error P1612/12 P.1-122
Map format P1620/12 P.1-123
ECU Temperature Failure (low voltage) P0668/4 P.1-40
Sensor Failure (high voltage) P0669/3 P.1-41

FAILURE DIAGNOSIS Factor Analysis
FACTOR ANALYSIS
2G-Type Eco-Governor Speed-Fluctuation Factor Analysis
No. Check method Relevant DTC Remarks
Engine speed
1 Insufficient fuel supply Fuel pipe clogging Check fuel system.
fluctuation
2 Engine failure Nozzle failure etc. Check whole engine.
Working machine Load fluctuation in Check whole working

3
failure working machine machine.
Abnormal vibration of
4 working machine and Rack actuator hunting. Check vibration of fuel pump.
engine
Unstable injection due

5 Fuel pump failure Check fuel pump.
to defective rack etc.
Check error occurrence, tool

Abnormal fluctuation of ECU supply voltage system
6 Battery system failure data, and voltage with
supply voltage error: P0562/1, P0563/0
voltmeter.

Alternator system Battery charging system error:
7 data, and voltage with
failure P1562/4, P1568/1
voltmeter.
Fluctuation of electrical Check presence of failure in

8 large-load electrical
load
equipment such as air heater.
Wire breakage or short-

circuit in harness, or ECU supply voltage system
9 data, harness shaking, and
connector contact error: P0562/1, P0563/0
conduction with tester.
failure
Intermittent on/off of Wire breakage or short-

10 Check conduction of heater.
start-assisting heater circuit in heater

Wire breakage or short- Start-assisting relay error:
11 data, impact on relay, and
circuit of heater relay conduction with tester. P1232/4, P1233/3, P1234/2

circuit in harness, or Start-assisting relay error:
connector contact P1232/4, P1233/3, P1234/2
failure

Factor Analysis FAILURE DIAGNOSIS

Wire breakage or short- CSD solenoid valve system

Intermittent on/off of
13 circuit in CSD solenoid Check conduction of CSD. error: P1242/4, P1243/3,
CSD solenoid valve
valve P1244/2

Check error occurrence, tool CSD solenoid valve system
circuit in harness, or
14 data, harness shaking, and error: P1242/4, P1243/3,
connector contact
conduction with tester. P1244/2
failure
Rack actuator
Rack actuator malfunction due to Check rack actuator operation Rack actuator system error:
15
malfunction excessive hysteresis and hysteresis. P1212/4, P1213/3, P1211/7
etc.

circuit in harness, or Rack actuator system error:
failure

Intermittent on/off of Contact failure of relay Rack actuator system error:
actuator relay contact P1212/4, P1213/3, P1211/7

Wire breakage or short- Actuator relay system error:
circuit in relay coil P1222/4, P1223/3, P1224/2

circuit in harness, or Actuator relay system error:
failure
Wire breakage or short- Check error occurrence, tool

Rack position sensor Rack position sensor system
20 circuit in sensor, or data, and conduction with
signal failure error: P1202/4, P1203/3
output failure tester.

circuit in harness, or Rack position sensor system
failure
Check polarity difference

Speed sensor signal Reversed polarity of
22 between harness drawing and
failure speed sensor harness
actual harness.

Wire breakage or short- Speed sensor system error:
23 data, and conduction with
circuit in speed sensor P0340/4
tester.

24 circuit in harness, or Speed sensor system error:
data, harness shaking, and
connector contact P0340/4
failure
Intermittent fluctuation Wire breakage or short- Check error occurrence, tool Accelerator sensor system
25 of accelerator sensor circuit in accelerator data, and conduction with error: P0222/4, P0223/3,
signal sensor tester. P0224/2

Check error occurrence, tool Sensor 5V system error in
26 contact failure in data, harness shaking, and addition to above: P0642/4,
conduction with tester. P0643/3, P1644/2
connector

Intermittent fluctuation
Wire breakage or short- Check error occurrence, tool Cooling-water temperature
of cooling-water
27 circuit in cooling-water data, and conduction with sensor system error: P0117/4,
temperature sensor
temperature sensor tester. P0118/3, P0119/2
signal

Check error occurrence, tool Cooling-water temperature
28 data, and conduction with sensor system error: P0117/4,
connector contact
tester. P0118/3, P0119/2
failure
Intermittent fluctuation
Wire breakage or short- Check error occurrence, tool Atmospheric-pressure sensor
29 of atmospheric- circuit in atmospheric- data, and conduction with system error: P2228/4,
pressure sensor
pressure sensor tester. P2229/3, P2230/2
system

Check error occurrence, tool Atmospheric-pressure sensor
30 connector contact data, and conduction with system error: P2228/4,
tester. P2229/3, P2230/2
failure
Intermittent on/off of Working machine Check presence of failure in

31 contact input signal
controller failure working machine controller.
from working machine

circuit in harness, or Check tool data and
32
connector contact conduction with tester.
failure
Communication circuit Check error occurrence, tool

CAN communication failure in controller for data, and communication CAN communication error:
33
system failure working machine, Eco- status with measuring U0001/12
Governor, etc. instrument.

circuit in harness, or CAN communication error:
connector contact U0001/12
tester.
failure

Controller system Contact failure of
failure controller connector conduction with tester.
Temporary failure in
36 controller input/output Check occurrence of error.
circuit
37 Program or map data Check program and map data.

failure
Control system
Unexpected strong Check presence of conductive
38 affected by conductive
noise or surge noise.
noise
Control system
Check presence of radioactive
39 affected by radioactive
noise.
noise


2G-Type Eco-Governor Engine
Stalling/Start-Up Inability Factor Analysis
Engine stalling/start-up
inability
Working machine Excessive load on Check whole working

2

3 Fuel pump failure Check fuel pump.
to defective rack etc.

Dropped supply ECU supply voltage system
4 Battery system failure data, and voltage with
voltage voltmeter. error: P0562/1, P0563/0

Alternator system Battery charging system error:
5 failure data, and voltage with P1562/4, P1568/1
voltmeter.

circuit in harness, or ECU supply voltage system
failure
Occurs only at
Start-assisting heater Wire breakage or short-
7 Check conduction of heater. low
system failure circuit in heater
temperatures.

Wire breakage or short- Start-assisting relay error:
circuit of heater relay P1232/4, P1233/3, P1234/2

circuit in harness, or Start-assisting relay error:
failure

CSD solenoid valve
10 circuit in CSD solenoid Check conduction of CSD. error: P1242/4, P1243/3,
system failure
valve P1244/2

connector contact
failure

EGR step motor Check conduction of ECR step ECR step motor system error:
12 circuit in ECR step P1402/4, P1403/3, other
system failure motor.
motor phase errors

Check error occurrence, tool ECR step motor system error:
13 data, harness shaking, and P1402/4, P1403/3, other
connector contact
conduction with tester. phase errors
failure

Rack actuator
Rack actuator system malfunction due to Check rack actuator operation Rack actuator system error:
14
failure excessive hysteresis and hysteresis. P1212/4, P1213/3, P1211/7
etc.

failure

Actuator relay system Contact failure of relay Rack actuator system error:
16 failure contact data, impact on relay, and P1212/4, P1213/3, P1211/7
Wire breakage or short- Check error occurrence, tool Actuator relay system error:
circuit in relay coil P1222/4, P1223/3, P1224/2

circuit in harness, or Actuator relay system error:
connector contact conduction with tester. P1222/4, P1223/3, P1224/2
failure
Check polarity difference

19 Speed sensor system Reversed polarity of between harness drawing and
failure speed sensor harness
actual harness.

Wire breakage or short- Speed sensor system error:
circuit in speed sensor P0340/4
tester.

circuit in harness, or Speed sensor system error:
connector contact P0340/4
failure
Cooling-water Wire breakage or short- Check error occurrence, tool Cooling-water temperature Occurs only at
22 temperature sensor circuit in cooling-water data, and conduction with sensor system error: P0117/4, low
system failure temperature sensor tester. P0118/3, P0119/2 temperatures.

Check error occurrence, tool Cooling-water temperature
23 data, and conduction with sensor system error: P0117/4,
connector contact
tester. P0118/3, P0119/2
failure

Atmospheric-pressure
24 circuit in atmospheric- data, and conduction with system error: P2228/4,
sensor system failure

25 data, and conduction with system error: P2228/4,
connector contact
tester. P2229/3, P2230/2
failure
Invalid contact input

26 signal from working Working machine Check presence of failure in
controller failure working machine controller.
machine

circuit in harness, or Check tool data and
27
connector contact conduction with tester.
failure


Communication circuit Check error occurrence, tool

CAN communication failure in controller for data, and communication CAN communication error:
28
system failure working machine, Eco- status with measuring U0001/12
Governor, etc. instrument.

circuit in harness, or CAN communication error:
connector contact U0001/12
tester.
failure

Controller system Contact failure of
30 failure controller connector data, harness shaking, and
circuit
Program or map data

32 Check program and map data.
failure
Control system
noise
Control system
noise.
noise

2G-Type Eco-Governor Black Smoke Factor Analysis

Black-smoke emission
1 Insufficient fuel supply Fuel pipe clogging Check fuel system.
from engine
Working machine Load fluctuation in Check whole working

3

4 Fuel pump failure to defective rack etc. Check fuel pump.

5 CSD solenoid valve circuit in CSD solenoid Check conduction of CSD. error: P1242/4, P1243/3,
system failure
valve P1244/2

connector contact
failure

EGR step motor Check conduction of ECR step ECR step motor system error:
7 circuit in ECR step P1402/4, P1403/3, other
system failure motor.
motor phase errors

Check error occurrence, tool ECR step motor system error:
8 data, harness shaking, and P1402/4, P1403/3, other
connector contact
conduction with tester. phase errors
failure
Rack actuator
Rack actuator system malfunction due to Check rack actuator operation Rack actuator system error:
9 failure excessive hysteresis and hysteresis. P1212/4, P1213/3, P1211/7
etc.

failure

11 Atmospheric-pressure circuit in atmospheric- data, and conduction with system error: P2228/4,
sensor system failure

12 circuit in harness, or data, and conduction with system error: P2228/4,
connector contact
tester. P2229/3, P2230/2
failure


Controller system
failure
circuit
Program or map data

14 Check program and map data.
failure
Control system
noise
Control system
noise.
noise

FAILURE DIAGNOSIS Special Service Tools
SPECIAL SERVICE TOOLS
For measuring compression pressure

Yanmar Gauge Set Part No. TOL-97190080
0000849
Adapter for direct injection 2-valve cylinder head

Yanmar Adapter Part No. 119802-92950
130
Compression Gauge Kit
0000850
Adapter for direct injection 4-valve cylinder head for

4TNV94L/98/98T
165
000085
Adapter for direct injection 4-valve cylinder head for

4TNV106(T)
179
0000852

Troubleshooting By Measuring Compression Pressure FAILURE DIAGNOSIS
TROUBLESHOOTING BY For engines with 4 valve cylinder heads
MEASURING COMPRESSION 4. Remove the valve cover assembly. See

Removal of Valve Cover on page 6-52. Remove
PRESSURE the fuel injector from the cylinder to be tested.
Compression pressure drop is one of the major See Removal of Fuel Injectors on page 7-35.
causes of increasing blow-by gas (engine oil 5. Turn off the fuel supply valve in the fuel supply
contamination or increased engine oil consumption line. Disconnect the fuel injection pump stop
as a resultant phenomenon) or starting failure. The solenoid at the connector. This prevents the fuel
compression pressure is affected by the following injection pump from injecting fuel during
factors: compression testing.
1. Degree of clearance between the piston and 6. Before installing the compression gauge
cylinder ((Figure 1-1, (1)) 2 valve engine,
(Figure 1-2, (1)) 4 valve engine) adapter, crank
2. Degree of clearance at the intake / exhaust the engine with the stop solenoid disconnected
valve seat for a few seconds to clear the cylinder of any
3. Gas leak from the nozzle gasket or cylinder residual fuel.
head gasket 7. Install a nozzle seat at the tip end of the
The pressure will drop due to increased parts wear. compression gauge adapter. Install the
Pressure drop reduces the durability of the engine. compression gauge and the compression
gauge adapter at the cylinder to be measured.
A pressure drop may also be caused by a
scratched cylinder or piston, dust entrance from the 8. Crank the engine until the compression gauge
dirty air cleaner element or a worn or broken piston reading is stabilized.
ring. Measure the compression pressure to
(1)
determine the condition of the engine.
Compression Pressure Measurement

Method
1. Warm up the engine.
2. Stop the engine. Remove the high-pressure fuel
injection lines as an assembly from the engine.
For engines with 2 valve cylinder heads
3. Remove the fuel injector from the cylinder to be
measured. See Removal of Fuel Injectors on
page 7-35. Figure 1-1
CAUTION
Remove or install the high-pressure fuel
injection lines as an assembly whenever
possible. Disassembling the
high-pressure fuel injection lines from
the retainers or bending any of the fuel
lines will make it difficult to reinstall the
fuel lines.
0000047en

FAILURE DIAGNOSIS Troubleshooting By Measuring Compression Pressure
(1)
Figure 1-2
9. After performing the compression check
remove the compression gauge and
compression gauge adapter from the cylinder.
10. Reinstall the fuel injector, high-pressure fuel
injection lines, and reconnect the stop solenoid.
See Reassembly of Fuel Injectors on
page 7-41.
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 stop solenoid.
13. Prime the fuel system. Check for leaks. Test the
engine.

Troubleshooting By Measuring Compression Pressure FAILURE DIAGNOSIS

Standard Compression Pressure (Reference Value)
Compression Pressure
Engine Model at 250 rpm (250 min-1) Deviation Between Cylinders
Standard Limit
443 - 473 psi 340 - 370 psi
3TNV82A
(3.06 - 3.26 MPa; 30 - 32 kgf/cm²) (2.35 - 2.55 MPa; 24 - 26 kgf/cm²)
3TNV84 455 - 485 psi 355 - 385 psi
4TNV84 (3.14 - 3.34 MPa; 32 - 34 kgf/cm²) (2.45 - 2.65 MPa; 25 - 27 kgf/cm²)
3TNV84T 411 - 441 psi 340 - 370 psi
4TNV84T (2.84 3.04 MPa; 29 - 31 kgf/cm²) (2.35 - 2.55 MPa; 24 - 26 kgf/cm²) 29 - 43 psi
3TNV88 (0.2 - 0.3 MPa; 2 - 3 kgf/cm²)
4TNV88
4TNV94L
483 - 513 psi 384 - 414 psi
4TNV98
(3.33 - 3.53 MPa; 34 - 36 kgf/cm²) (2.65 - 2.85 MPa; 27 - 29 kgf/cm²)
4TNV98T
4TNV106
4TNV106T
Engine Speed and Compression Pressure (Use for Reference)
3TNV88
4TNV88
4TNV94L
4TNV98
569 psi 4TNV98T
(4 MPa)
(40 KgF/cm2) 3TNV84
4TNV106
4TNV106T
498 psi 4TNV84
(35 KgF/cm2)
427 psi
(30 KgF/cm2) (3 MPa)
356 psi
(25 KgF/cm2) 3TNV82A
3TNV84T
284 psi
4TNV84T (2 MPa)
(20 KgF/cm2)
200 250 300 350 400

Engine speed (min-1)
Figure 1-3

FAILURE DIAGNOSIS Quick Reference Table For Troubleshooting
Measured Value and Troubleshooting

When the measured compression pressure is below the limit value, inspect each part by referring to the
table below.
No. Item Cause Corrective Action

Clogged element Clean the element.
1 Air Cleaner 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.
Replace the gasket.
4 Cylinder Head Gasket Gas leak from gasket Retighten the cylinder head bolts to the specified
torque.
Intake / Exhaust Valve Sticking valve Replace the intake / exhaust valve.
5 Gas leak due to worn valve seat

Valve Seat or foreign matter trapped in Lap the valve seat.
valve
Piston
Gas leak due to scratching or
6 Piston Ring Perform honing and use an oversized part.
wear
Cylinder
QUICK REFERENCE TABLE

FOR TROUBLESHOOTING
The following table summarizes the general trouble
symptoms and their causes. If any trouble symptom
occurs, take corrective action before it becomes a
serious problem so as not to shorten the engine
service life.

Failure Diagnostic List TNV DI Service Manual FAILURE DIAGNOSTIC LIST FAILURE DIAGNOSTIC LIST
Failure Diagnostic List
Defective start Engine stall Defective rotation control Insufficient Noise/vibration Lubricant Cooling Intake Exhaust Fuel Electrics/electronics
Symptoms and conditions of failures after start engine output water
Starter not Starter Exhaust
Speed change by accelerator not available (constant speed)

rotate rotates fume Without load At work Exhaust color At work
ECU indicator lamp not on just after key-on (2 seconds)

ECU indicator lamp on just after key-on (2 seconds)
Fuel mixed with water (oil-water separator lamp on)

Engine not start (stall after serial combustion)
Engine not start (not even initial combustion)
Prescribed ECU control function not operate

ECU indicator lamp not on just after key-on
Oil pressure too low (oil pressure lamp on)
Fuse meltdown, disconnection (repeated)

Noise other than combustion from engine
Overheated (water temperature lamp on)
Battery charge defect (charge lamp on)

Knocking noise at combustion too high
Specified speed setting not available
Pressure down (air cleaner lamp on)

Action Referenced page number
Fuel filter contaminated too early

Lubricant consumption too much
Return to low speed not smooth
Engine starts later then ever
ECU indicator lamp flashing

Fuel consumption too much
Lubricant mixed with water
Water temperature too low

Combustion noise uneven
Lubricant diluted with fuel
Exhaust temperature up
Engine vibration too big
White exhaust color
Black exhaust color
Blow-by too much

Poor acceleration
Pressure up
Hunting
Hunting
Normal
White
Much
Black
None
Little
Cause
Intake/exhaust valve clearance c c c c c c

Valve clearance adjustment See "Measuring and Adjusting Valve
incorrect Clearance" (on page 6-66)
Valve seat facing See "Valve Face and Valve Seat" (on
page 6-43) for 2-valve head, and "Valve
Compression failure at valve seat c c c c c c c c c
Face and Valve Seat" (on page 6-59) for
4-valve head.
Correction or replacement of See "Removal of Intake / Exhaust Valves"
Intake/exhaust valve seizure c c c c c c c c c c c
intake/exhaust valve (on page 6-39).
Gasket replacement See "Removal of Cylinder Head" (on
Cylinder head gasket blow-out c c c
page 6-54).
Piston ring replacement See "Reassembly of Pistons" (on page 6-
Piston ring sticking or breakage c c c c c c c c c c c c
89).
Horning work and usage of over-sized See "Honing and Boring" (on page 6-88).
Wear of piston ring, piston or cylinder c c c c c c c
parts
Repair or replacement See "Inspection of Crankshaft" (on page
Seizure of crank pin metal or bearing parts c c c c c c c
6-86).
Correction of closed gap position See "Reassembly of Pistons" (on page 6-
Closed gap position fault of piston ring c c c c
89).
Engine system
Correction of assembling See "Reassembly of Pistons" (on page 6-

Reverse assembling of piston ring c c c c
89).
Wear of crank pin metal and journal c c c c c c
Measurement and replacement See "Inspection of Crankshaft" (on page
metal 6-86).
Tightening at specified torque See"Torque for Bolts and Nuts" (on page
Connecting rod bolt loose c c c
6-25).
Foreign material entered into c c c c
Disassembling and repair See "Disassembly of Engine" (on page 6-
combustion chamber 72).
Gear mesh adjustment See "Checking Timing Gear Backlash"
Gear backlash too big c
(on page 6-73).
Measurement and replacement See "Inspection of Valve Guides" (on
Wear of intake/exhaust valve guide c c c
page 6-41).
Adjustment See "Check and Adjust the Governor
Lever and Engine Speed Control (This
does not apply to the following
Governor misalignment c c c c c c
electronically controlled engines:
4TNV84T-Z, 4TNV98-E, Z, and
4TNV98T-Z.)" (on page 5-30).
Open/close timing failure of c c c c c c
Valve clearance adjustment See "Measuring and Adjusting Valve
intake/exhaust valve Clearance" (on page 6-66).
Engine vibration isolating support c c c c
Repair or replacement of faulty parts
loose, damage

FAILURE DIAGNOSTIC LIST Failure Diagnostic List










White exhaust color
Black exhaust color
Blow-by too much

Poor acceleration
Pressure up
Hunting
Hunting
Normal
White
Much
Black
None
Little
Cause
Floor cleaning See"Washing Procedure" (on page 10-

Supercharger
Floor contamination c c c
12).
Disassembling and inspection See "Waste Gate Valve Test" (on page
Operation defect of waste gate c c c
10-14).
Disassembling and inspection See "Radial Bearing" (on page 10-11).
Wear of radial metal c c c
Thermostat replacement See "Disassembly of Engine Coolant

Radiator super cooled c c c
Pump" (on page 8-10).
Thermostat replacement See "Disassembly of Engine Coolant
Cooling water system
or check for fan belt loose Pump" (on page 8-10) or "Check and
Insufficient radiator cooling c c c
Adjust Cooling Fan V-Belt" (on page 5-
22).
Water leak inspection of cooling water See "Engine Coolant System Check" (on
Insufficient cooling water quantity c c c
system page 8-8).
Repair or replacement See "Disassembly of Engine Coolant
Water jacket cracks c c c
Adjustment of belt tension See "Check and Adjust Cooling Fan V-
Fan belt elongation c c c
Belt" (on page 5-22).
Inspection or replacement See "Disassembly of Engine Coolant
Thermostat fault c c c c
Usage of correct lubricant See "Engine Oil Specifications" (on page
Incorrect lubricant c c c c c c
4-15).
Repair See "Disassembly of Oil Pump" (on page
Lubricant system leakage c c
9-10).
Lubricant system
Insufficient discharge rate of trochoid c

Inspection and repair See "Disassembly of Oil Pump" (on page
pump 9-10).
Cleaning or replacement See "Replace Engine Oil and Engine Oil
Lubricant filter clogged c c
Filter" (on page 5-20).
Cleaning, adjustment or replacement See "Disassembly of Oil Pump" (on page
Regulator valve fault c
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).

Failure Diagnostic List FAILURE DIAGNOSTIC LIST










White exhaust color
Black exhaust color
Blow-by too much

Poor acceleration
Pressure up
Hunting
Hunting
Normal
White
Much
Black
None
Little
Cause
Stopper solenoid fault c c Inspection and replacement See "Stop Solenoid" (on page 7-9).
Fuel injection pump with injection c c c c
Inspection and adjustment See "Checking and Adjusting Fuel
timing excessively advanced Injection Timing" (on page 7-30).
Fuel injection pump with injection c c c c c c
Inspection and adjustment See "Checking and Adjusting Fuel
timing excessively retarded Injection Timing" (on page 7-30).
Usage of correct fuel See "Diesel Fuel Specifications" (on page
Incorrect fuel c c c c c c c c
4-12).
Drainage of fuel filter See "Drain Fuel Filter / Water Separator"
Water entered into fuel system c c c c c c c c c
(on page 5-24).
Cleaning or replacement See "Clean Fuel Filter / Water Separator"
Fuel filter clogged c c c c c
(on page 5-34).
Bleeding See "Priming the Fuel System" (on page
Air entered into fuel system c c c c c c
4-15).
Fuel system
Fuel pipe clogged, cracked c c c Cleaning or replacement

Insufficient fuel feeding to fuel injection c c c c c
Check of fuel tank cock, fuel filter, fuel
pump pipe, fuel feed pump
Uneven injection quantity of fuel c c c c c c c c c
Inspection and adjustment See "Testing of Fuel Injectors" (on page
injection pimp 7-38).
Fuel injection quatity too much c c c c c c c
7-38).
Defective spray of fuel injection nozzle c c c c c c c c c
7-38).
Valve in priming pump pinched dust See "Fuel System Components" (on page
Priming not available c
(disassembled cleaning) 7-15).
Strainer at feed pump inlet clogged c c c Cleaning of strainer
Replacing the Pump
Operation defect of CSD valve c c c
Replacement of CSD valve
Check of fuel tank and cap, as well as
Sealing defect of fuel tank c c installation of
genuine parts
Cleaning of air filter See "Clean Air Cleaner Element" (on
Air filter clogged c c c c c c c c
page 5-31).
Intake
Engine operation at high temperature c c c c c

Consideration of matching output
or high land reduction with load
Exhaust pipe clogged c c c c c c Cleaning of exhaust pipe











White exhaust color
Black exhaust color
Blow-by too much

Poor acceleration
Pressure up
Hunting
Hunting
Normal
White
Much
Black
None
Little
Cause
Inspection and replacement of fuse For harness inspection method, see

Fuse meltdown, disconnection c c c c c
Repair or replacement of harness "Failure Diagnosis" (on page 1-1).
Starter fault c c Repair or replacement of starter See "Starter Motor" (on page 11-10).
Repair or replacement of alternator See "Removal of Alternator" (on page 12-
Alternator fault c c
12).
Repair or replacement of harness
Wiring disconnection c c c c c c c c
disconnection
Wiring short-circuit (insulator broken), Inspection, repair or replacement of
electric power load of added device too c c harnesses
big Review of added devices
Battery voltage descent c c - Inspection and charging of battery See "Check Battery" (on page 5-26).
Repair or replacement of harness For harness inspection method, see
Key switch fault, disconnection c c c
Key switch replacement "Failure Diagnosis" (on page 1-1).
Instantaneous interruption of key c c
Key switch replacement
switch
Failure, disconnection, short-circuit of c
starter relay Replacement of starter relay "Failure Diagnosis" (on page 1-1).
Electric system
Main relay fault Repair or replacement of harness For harness inspection method, see
(Error other than contact sticking that c c Replacement of main relay "Failure Diagnosis" (on page 1-1).
ECU can’t detect)
Actuator relay fault c c c
Replacement of actuator relay
(Error of contact that ECU can’t detect)
The start assist relay may be faulty. c c c c
Replacement of start assist relay
(Error of contact that ECU can’t detect)
Accelerator sensor signal error c c c c
Repair or replacement of accelerator Monitor the accelerator sensor by the
(Error at which level ECU can’t detect) sensor diagnosis tool.
Water temperature sensor signal error c c c c c
Replacement of water temperature sensor Monitor the cooling water temperature by
(Error at which level ECU can’t detect) the diagnosis tool.
Speed sensor signal error Cleaning or replacement of speed sensor Monitor the engine rotational speed by
(Cause of noise etc. that ECU can’t c c c c c c Repair or replacement of fuel injection the diagnosis tool.
detect) pump
Rack position sensor signal error c c c c c c

Repair or replacement of fuel injection Monitor the rack position sensor signal by
(Level that ECU can’t detect) pump the diagnosis tool.
Operation defect of rack actuator c c c c c c
Repair or replacement of fuel injection Check the movement of rack actuator by
(Level that ECU can’t detect) pump the diagnosis tool.
Replace the lamp.
ECU failure lamp disconnected c Repair or replace the harness.
ECU faulty (ECU self diagnosis failure) c c c c c Replace the ECU.

Failure Diagnostic List FAILURE DIAGNOSTIC LIST










White exhaust color
Black exhaust color
Blow-by too much

Poor acceleration
Pressure up
Hunting
Hunting
Normal
White
Much
Black
None
Little
Cause
Not failure Check the causes of engine stop or

ECU control function operating c c c c
Implement regular usage starter restraint by a diagnosis tool.
Disconnection/short-circuit of water Repair or replacement of harness For harness inspection method, see
Engine stop or operation limits by ECU failure diagnosis function
c c c Replacement of water temperature sensor "Failure Diagnosis" (on page 1-1).

temperature sensor
Disconnection/short-circuit of c c
accelerator sensor Replacement of accelerator sensor "Failure Diagnosis" (on page 1-1).
Speed sensor signal error c c c Repair or replacement of fuel injection "Failure Diagnosis" (on page 1-1).
pump
Rack position sensor signal error c c c c c Repair or replacement of fuel injection "Failure Diagnosis" (on page 1-1).
pump
Operation defect of rack actuator c c c Repair or replacement of fuel injection "Failure Diagnosis" (on page 1-1).
pump
Check operating machine’s driving.
Engine over speed c c
Check speed sensor signal.
CAN communication error c c c
ECU Replacement "Failure Diagnosis" (on page 1-1).
Disconnection/short-circuit of EGR c c c
valve motor Replacement of EGR valve "Failure Diagnosis" (on page 1-1).
Disconnection/short-circuit of CSD c c c
solenoid valve Replacement of CSD valve solenoid "Failure Diagnosis" (on page 1-1).
Disconnection/short-circuit of start c c c c
assist relay Relay replacement "Failure Diagnosis" (on page 1-1).
Main relay “OFF” not available c c Relay replacement
Disconnection/short-circuit of rack c c
actuator relay Relay replacement "Failure Diagnosis" (on page 1-1).
Malfunction by ECU self-diagnosis c c ECU Replacement


Electrical Wiring TNV DI Service Manual WIRING DIAGRAM

ELECTRICAL WIRING
Note: The following wiring diagram is “representative” of a common installation using a Yanmar engine. The actual installation may be equipped with a variety of electrical components and wiring harnesses. Contact the machine
manufacturer for specific information.
KEY SWITCH* 30A

FUSE*
EMERGENCY
STOP
SWITCH*
Items marked with * are

not provided by Yanmar.
0000864A

WIRING DIAGRAM Electrical Wiring

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
http://www.yanmar.nl
Yanmar Asia (Singapore) Corporation Pte. Ltd.

4 Tuas Lane, Singapore 638613
TEL: 65-68615077 FAX: 65-68611509
http://www.yanmar.co.jp/yasc/
California California
Proposition 65 Warning Proposition 65 Warning
Diesel engine exhaust and some of its Battery posts, terminals, and related
constituents are known to the state of accessories contain lead and lead
California to cause cancer, birth compounds, chemicals known to the
defects, and other reproductive harm. state of California to cause cancer and
reproductive harm.
Wash hands after handling.
TROUBLESHOOTING
TROUBLESHOOTING MANUAL
MANUAL
ELECTRONIC CONTROL
3TNV82A 4TNV84
3TNV82A-B 4TNV84T
3TNV84 4TNV84T-Z
3TNV84T 4TNV88
3TNV84T-B 4TNV88-B
3TNV88 4TNV88-U
3TNV88-B 4TNV94L
3TNV88-U 4TNV98
4TNV98-Z
4TNV98-E
4TNV98T
4TNV98T-Z
4TNV106
4TNV106T
0DTNV-G00600
PRINTED IN JAPAN

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TROUBLESHOOTING

Yanmar America Corporation

Yanmar Europe B.V.

Yanmar Asia (Singapore) Corporation Pte. Ltd.

TNV DI Service Manual

TNV DI Service Manual 1-1

This Page Intentionally Left Blank

1-2 TNV DI Service Manual

DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS

DTCS (DIAGNOSTIC TROUBLE CODES) GENERAL DESCRIPTION

P1226/0 Error (foot pedal-open position) P.1-30

TNV DI Service Manual 1-3

FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description

P1340/4 1-1 Spare speed sensor Error P.1-62 P.1-167

P0219/0 9 Overspeed Error P.1-64 P.1-64

P1222/4 Error A P.1-66

P1233/3 1-5 Start Assist Relay Error B P.1-74 P.1-174

P1198/1 3-1 Oil Pressure Descend Error P.1-102

P1151/0 3-5 Oil-water separator Alarm P.1-112

1-4 TNV DI Service Manual

DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS

P1213/3 Rack actuator Error (high current) P.1-116

P1214/2 Engine Error P.1-120

P0605/12 Error (Checksum A)

TNV DI Service Manual 1-5

FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description

This Page Intentionally Left Blank

1-6 TNV DI Service Manual

DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS

DTC Detecting Conditions

1 - Precondition; 2 - Detecting condition(s);

Movement at Error occurrence

Error Mode [Operation Continuation] / [Run Under Restrictions] / [Stop Immediately]:

Estimation of Failure cause/Error condition

TNV DI Service Manual 1-7

FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description

Analog Input Related Failures

DTC P1202/4 Rack Position Sensor Error (Low Voltage)

DTC Detecting Conditions

1 - Precondition; 2 - Detecting condition(s);

Movement at Error occurrence

Error Mode [Run Under Restrictions]:

Estimation of Failure cause/Error condition

1-8 TNV DI Service Manual

DTCs (Diagnostic Trouble Codes) General Description FAILURE DIAGNOSIS

1) Initial diagnosis • Check the fault indication.

TNV DI Service Manual 1-9

FAILURE DIAGNOSIS DTCs (Diagnostic Trouble Codes) General Description

(2) P1203/3: Failure with Rack Position Sensor (High Voltage)

DTC P1202/3 Failure with Rack Position Sensor (High Voltage)

DTC Detecting Conditions

1 - Precondition; 2 - Detecting condition(s);

Movement at Error occurrence

Detection at the engine start Detection at the engine running