Yanmar 3TNV88C 3TNV86CT 4TNV88C 4TNV86CT 4TNV98C 4TNV98CT TROUBLESHOOTING MANUAL – PDF DOWNLOAD

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Yanmar 3TNV88C 3TNV86CT 4TNV88C 4TNV86CT 4TNV98C 4TNV98CT TROUBLESHOOTING MANUAL – PDF DOWNLOAD

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Yanmar 3TNV88C 3TNV86CT 4TNV88C 4TNV86CT 4TNV98C 4TNV98CT TROUBLESHOOTING MANUAL – PDF DOWNLOAD

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Pages : 476
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Yanmar 3TNV88C 3TNV86CT 4TNV88C 4TNV86CT 4TNV98C 4TNV98CT TROUBLESHOOTING MANUAL – PDF DOWNLOAD

1. DTC (Diagnostic Trouble Codes) General Description …………… 1
DTC code list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Additional requirements for EU Stage V (less than 56kW) regulations . . . . . . 6
Power restrictions due to inducement when NCD abnormality occurs . . . . . . . . . 6
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Sensor related . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Crankshaft speed sensor . . . . . .. . . . . . . . .. . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . .. . . . . . . . . 9
P0336: Crankshaft signal errar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
P0337: No signal fram crankshaft ……………………………………………………………… 11
Camshaft speed sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
P0341: Camshaft signal errar …………………………………………………………………… 13
P0342: No signal fram camshaft ………………………………………………………………… 15
P1341: Angle offset errar ………………………………………………………………………… 17
P0008: Crankshaft/camshaft speed sensor non-input (simultaneous) ……………………… 19
Accelerator sensor . . .. . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . 20
P0123: Accelerator sensor 1 errar (voltage high) ……………………………………………… 20
P0122: Accelerator sensor 1 errar (voltage low) ……………………………………………… 22
P0223: Accelerator sensor 2 errar (voltage high) ……………………………………………… 24
P0222: Accelerator sensor 2 errar (voltage low) ……………………………………………… 26
P1646: Dual accelerator sensor errar (closed position) ……………………………………… 28
P1647: Dual accelerator sensor errar (open position) ………………………………………… 30
P0228: Accelerator sensor 3 errar (voltage high) ……………………………………………… 32
P0227: Accelerator sensor 3 errar (voltage low) ……………………………………………… 34
P1227: Pulse accelerator sensor errar (pulse communication) ……………………………… 36
P1126: Accelerator sensor 3 errar (foot pedal in open position) …………………………… 37
P1125: Accelerator sensor 3 errar (foot pedal in closed position) …………………………… 39
lntake throttle position sensor ………………………………………………………… 40
P02E9: lntake thrattle position sensor errar (voltage high) …………………………………… 40
P02E8: lntake thrattle position sensor errar (voltage low) …………………………………… 42
EGR low pressure side pressure sensor . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . .. . . . . . . . .. . . . . . 44
P0238: EGR low pressure side pressure sensor errar (excessive sensor output) ………… 44
P0237: EGR low pressure side pressure sensor errar (insufficient sensor output) ………… 46
P0236: EGR low pressure side pressure sensor errar (abnormal learning value) ………… 48
P1673: EGR low pressure side pressure sensor errar (detected value errar) ……………… 50
EGR high pressure side pressure sensor…………………………………………… 52
P0473: EGR high pressure side pressure sensor errar (excessive sensor output) ……… 52
P0472: EGR high pressure side pressure sensor errar (insufficient sensor output) ……… 54
P0471: EGR high pressure side pressure sensor errar (abnormal learning value) ………… 56
P1679: EGR high pressure side pressure sensor errar ( detected value errar) …………… 58
Engine coolant temperature sensor . . . . . . . . .. . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . .. . . . . . . . . 60
P0118: Engine coolant temperature sensor errar (excessive sensor output) ……………… 60
P0117: Engine coolant temperature sensor errar (insufficient sensor output) ……………… 62
P1674: Engine coolant temperature sensor errar (detected value errar) …………………… 64
P0217: Engine coolant temperature high ( overheat) ………………………………………… 66
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Ambient air temperature sensor . . . . . .. . . . . . . . .. . . . . .. . . . . . . . .. . . . . . . . .. . . . . .. . . . . . . . .. . . . . . . . . 68
P0113: Ambient air temperature sensor errar (voltage high) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
P0112: Ambient air temperature sensor errar (voltage low)………………………………… 70
Fuel temperature sensor . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . .. . . . . . . . .. . . . . . . . .. . . . . .. . . 72
P0183: Fuel temperature sensor errar (voltage high) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
P0182: Fuel temperature sensor errar (voltage low)………………………………………… 7 4
P0168: Fuel temperature high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Rail pressure sensor . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . .. . . . . . . . .. . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . . 78
P0193: Rail pressure sensor errar (voltage high) … … … … … … … … … … … … … … … … … 78
P0192: Rail pressure sensor errar (voltage low) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
DPF differential pressure sensor……………………………………………………… 82
P2455: DPF differential pressure sensor errar (excessive sensor output)………………… 82
P2454: DPF differential pressure sensor errar (insufficient sensor output) . . . . . . . . . . . . . . . . . . 84
P2452: DPF differential pressure sensor abnormal rise in differential pressure . . . . . . . . . . . . 86
P2453: DPF differential pressure sensor errar (abnormal learning value)………………… 88
DPF substrate/DPF differential pressure sensor…………………………………… 90
P226D: DPF substrate/DPF differential pressure sensor errar
(DPF substrate removal/DPF differential pressure sensor detected value errar)………… 90
DPF high pressure side pressure sensor . . .. . . . . .. . . . . . . . .. . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . . 92
P1455: DPF high pressure side pressure sensor errar ( excessive sensor output) . . . . . . . . . 92
P1454: DPF high pressure side pressure sensor errar (insufficient sensor output)……… 94
P167C: DPF high pressure side pressure sensor errar (detected value errar)…………… 96
DPF inlet temperature sensor . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . .. . . . . . . . .. . . . . .. . . . . . . . .. . . 98
P1428: DPF inlet temperature sensor errar ( excessive sensor output) . . . . . . . . . . . . . . . . . . . . . . . . 98
P1427: DPF inlet temperature sensor errar (insufficient sensor output) ………………… 100
P167E: DPF inlet temperature sensor errar ( detected value errar) ………………………… 102
P1436: DPF inlet temperature sensor abnormal temperature (abnormally high) ………… 104
DPF intermediate temperature sensor . . .. . . . . . . . .. . . . . . . . .. . . . . .. . . . . . . . .. . . . . . . . .. . . . . . 105
P1434: DPF intermediate temperature sensor errar ( excessive sensor output) ………… 105
P1435: DPF intermediate temperature sensor errar (insufficient sensor output) ………… 107
P167 A: DPF intermediate temperature sensor errar (detected value errar) ……………… 109
P0420: DPF intermediate temperature sensor abnormal temperature (abnormally low) 111
Atmospheric pressure sensor . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . .. . . . . . . . .. . . . . .. . . . . . . . . 112
P2229: Atmospheric pressure sensor errar (excessive sensor output) …………………… 112
P2228: Atmospheric pressure sensor errar (insufficient sensor output) …………………… 113
P1231: Atmospheric pressure sensor errar (characteristic errar) ………………………… 114
EGR gas temperature sensor . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . .. . . . . . . . .. . . . . . . . .. . . . . . 116
P041 D: EGR gas temperature sensor errar ( excessive sensor output) …………………… 116
P041 C: EGR gas temperature sensor errar (insufficient sensor output) ………………… 118
P1675: EGR gas temperature sensor errar (detected value errar) ………………………… 120
lntake manifold temperature sensor ……………………………………………… 122
P040D: 1 ntake manifold temperature sensor errar ( excessive sensor output) . . . . . . . . . . . . . . . 122
P040C: lntake manifold temperature sensor errar (insufficient sensor output) …………… 124
P1676: lntake manifold temperature sensor errar ( detected value errar) ………………… 126
Exhaust manifold temperature sensor . . . . . .. . . . . .. . . . . . . . .. . . . . .. . . . . . . . .. . . . . . . . .. . . . . . 128
P0546: Exhaust manifold temperature sensor errar (excessive sensor output) ………… 128
P0545: Exhaust manifold temperature sensor errar (insufficient sensor output) ………… 130
P1677: Exhaust manifold temperature sensor errar ( detected value errar) ……………… 132
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CONTENTS
Contact output related . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Main relay . . .. . . . . . . . .. . . . . . . . .. . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . .. . . . . . . . .. . . 134
P068B: Main relay contact sticking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
P068A: Main relay early opening……………………………………………………………… 136
Starting aid relay . . . . . .. . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . . 138
P0543: Starting aid relay disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
P0541: Starting aid relay GND short circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
CRS (common rail system) related …………………………………………… 142
lnjector (No. 1 cylinder) ……………………………………………………………… 142
P0201: lnjector (No. 1 cylinder) disconnection (injector-specific) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
P0262: lnjector (No. 1 cylinder) coil short circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
P1262: lnjector (No. 1 cylinder) short circuit … … … … … … … … … … … … … … … … … … … 146
lnjector (No. 2 cylinder) ……………………………………………………………… 148
P0202: lnjector (No. 2 cylinder) disconnection (injector-specific) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
P0265: lnjector (No. 2 cylinder) coil short circuit … … … … … … … … … … … … … … … … … 150
P1265: lnjector (No. 2 cylinder) short circuit ………………………………………………… 152
lnjector (No. 3 cylinder) ……………………………………………………………… 154
P0203: lnjector (No. 3 cylinder) disconnection (injector-specific) … … … … … … … … … … 154
P0268: lnjector (No. 3 cylinder) coil short circuit … … … … … … … … … … … … … … … … … 156
P1268: lnjector (No. 3 cylinder) short circuit ………………………………………………… 158
lnjector (No. 4 cylinder) . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . .. . . . . . . . .. . . . . . . . .. . . . . .. . . . . . . . . 160
P0204: lnjector (No. 4 cylinder) disconnection (injector-specific) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
P0271: lnjector (No. 4 cylinder) coil short circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
P1271: lnjector (No. 4 cylinder) short circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
AII injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
P0611: lnjector drive IC errar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
P1146: lnjector drive circuit (Bank 1) short circuit…………………………………………… 167
P1149: lnjector drive circuit (Bank 2) short circuit…………………………………………… 169
P1648: lnjector (No. 1 cylinder) correction value errar……………………………………… 171
P1649: lnjector (No. 2 cylinder) correction value errar……………………………………… 172
P1650: lnjector (No. 3 cylinder) correction value errar……………………………………… 173
P1651: lnjector (No. 4 cylinder) correction value errar……………………………………… 174
SCV (MPROP) . . .. . . . . . . . .. . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . 175
P1641: SCV (MPROP) L side VB short circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
P1643: SCV (MPROP) L side GND short circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
P0629: SCV (MPROP) H side VB short circuit … … … … … … … … … … … … … … … … … … 178
P1642: SCV (MPROP) H side GND short circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
P0627: SCV (MPROP) disconnection…… …… …… …… ……… …… …… …… ……… …… 181
P062A: SCV (MPROP) drive current (high levei) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
P1645: SCV (MPROP) pump overload errar ………………………………………………… 184
Rail pressure error . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . .. . . . . . . . .. . . . . .. . . . . . . . .. . . . . . . . . 186
P0088: Rail pressure too high … … … … … … … … … … … … … … … … … … … … … … … … … 186
P0094: Rail pressure deviation errar (low rail pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
P0093: Rail pressure deviation errar (high rail pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
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CONTENTS
PLV (Common rail pressure limit valve) ………………………………………… 192
P000F: PL V o pen valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
P1666: Rail pressure fault (The times of PLV valve opening errar) ……………………… 194
P1667: Rail pressure fault (The time of PLV valve opening errar) ………………………… 196
P1668: Rail pressure fault (The actual rail pressure is too high during PRV limp home) 198
P1665: Rail pressure fault (Contralled rail pressure errar after PLV valve opening) …… 200
Rail pressure control . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . 202
P1669: Rail pressure fault (lnjector B/F temperature errar during PLV4 limp home) …… 202
P1670: Rail pressure fault (Operation time errar during RPS limp home) ………………… 204
Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
lntake throttle drive circuit . . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . .. . . . . . . . .. . . . . . . . .. . . . . . 205
P0660: No-load of thrattle valve drive H bridge circuit ……………………………………… 205
P1658: Power short circuit of thrattle valve drive H bridge output 1 ……………………… 206
P1659: GND short circuit of thrattle valve drive H bridge output 1 ………………………… 207
P1660: Overload on the drive H bridge circuit of thrattle valve …………………………… 208
P1661: VB Power short circuit of thrattle valve drive H bridge output 2 …………………… 209
P1662: GND short circuit of thrattle valve drive H bridge output 2 ………………………… 21 O
P02E4: Thrattle valve sticking (sticking open) ……………………………………………… 211
P02E5: Thrattle valve sticking (sticking closed) ……………………………………………… 213
EGR ……………………………………………………………………………………… 215
P0404: EGR overvoltage errar ………………………………………………………………… 215
P1404: EGR lowvoltage errar ………………………………………………………………… 217
P1409: EGR feedback errar …………………………………………………………………… 219
U0401: EGR ECM data errar …………………………………………………………………… 220
P0403: Disconnection in EGR motor coils …………………………………………………… 222
P1405: Short circuit in EGR motor coils ……………………………………………………… 223
P0488: EGR position sensor errar …………………………………………………………… 224
P148A: EGR valve sticking errar ……………………………………………………………… 225
P049D: EGR initialization errar ………………………………………………………………… 226
U 1401: EGR target value out of range ………………………………………………………… 227
P141 O: EGR high temperature thermistor errar ……………………………………………… 228
P1411: EGR low temperature thermistor errar ……………………………………………… 229
Exhaust throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
P1438: Exhaust thrattle (voltage fault) ………………………………………………………… 230
P1439: Exhaust thrattle (motor fault) ………………………………………………………… 231
P1440: Exhaust thrattle (sensor system fault) ……………………………………………… 232
P1441: Exhaust thrattle (MPU fault) …………………………………………………………… 233
P1442: Exhaust thrattle (PCB fault) …………………………………………………………… 234
P1443: Exhaust thrattle (CAN fault) …………………………………………………………… 235
Communication related . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
CAN 1 …………………………………………………………………………………… 236
U010B: CAN 1 (for EGR): Reception timeout fram the EGR valve ………………………… 236
U1107: CAN 1 (for exhaust thrattle): Reception time out …………………………………… 238
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CAN 2 …………………………………………………………………………………… 239
U0292: TSC 1 (SA 1) reception timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
U1301: TSC1 (SA2) reception timeout ……………………………………………………… 241
U1292: Y ECR1 reception timeout … … … … … … … … … … … … … … … … … … … … … … … 243
U1293: Y_EC reception timeout ……………………………………………………………… 245
U1294: Y_RSS reception timeout …………………………………………………………… 247
U0168: VI reception timeout…………………………………………………………………… 249
U3002: VI reception data errar………………………………………………………………… 250
U1300: Y ETCP1 reception time out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
U 1302: EBC 1 reception timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
U1303: Y DPFIF reception timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
U0167: lmmobilizer errar (CAN communication) … … … … … … … … … … … … … … … … … 257
U0426: lmmobilizer errar (system) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
ECU related . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
EEPROM ………………………………………………………………………………… 259
P0601: EEPROM memory deletion errar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
P160E: EEPROM memory reading errar … … … … … … … … … … … … … … … … … … … … 260
P160F: EEPROM memory writing errar……………………………………………………… 261
ECU internai fault….. .. . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . . 262
P1613: CY146 SPI communication fault …………………………………………………… 262
P1608: Excessive voltage of supply 1 … … … … … … … … … … … … … … … … … … … … … 263
P1617: lnsufficientvoltage ofsupply 1 ……………………………………………………… 264
P1609: Sensor supply voltage errar 1………………………………………………………… 265
P1618: Sensor supply voltage errar 2………………………………………………………… 266
P1619: Sensor supply voltage errar 3………………………………………………………… 267
P1626: Actuator drive circuit 1 short to graund . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
P1633: Actuator drive circuit 2 short to graund . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
P1467: Actuator drive circuit 3 short to graund . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
P1469: AD converter fault 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
P14 70: AD converter fault 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
P1471: Externa! monitoring IC and CPU fault 1 273
P1472: Externa! monitoring IC and CPU fault 2 … … … … … … … … … … … … … … … … … 274
P1473: ROM fault ……………………………………………………………………………… 275
P1474: Shutoff path fault 1
P1475: Shutoff path fault 2
P1476: Shutoff path fault 3
P1477: Shutoff path fault 4
P1478: Shutoff path fault 5
P1479: Shutoff path fault 6
P1480: Shutoff path fault 7
P1481: Shutoff path fault 8
P1482: Shutoff path fault 9
P1483: Shutoff path fault 1 O…………………………………………………………………… 285
P1484: Recognition errar of engine speed…………………………………………………… 286
TNV Troubleshooting Manual V
Contact output related 287
Breather heater (Optional parts for 4TNV86CT and 4TNV98CT) ……………… 287
P053A: Breather heater disconnection ……………………………………………………… 287
P053B: Breather heater short circuit (GND) ………………………………………………… 288
P053C: Breather heater short circuit (VB) …………………………………………………… 289
Contact input related . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
Air cleaner switch …………………………………………………………………… 290
P1101: Air cleaner clogged alarm ……………………………………………………………… 290
Water separator switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
P1151: Water separator alarm ………………………………………………………………… 292
Charge switch ………………………………………………………………………… 294
P1562: Charge switch disconnection ………………………………………………………… 294
P1568: Charge alarm …………………………………………………………………………… 296
Oil pressure switch . . .. . . . . . . . .. . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . .. . . . . . . . .. . . . . . . . . 298
P1192: Oil pressure switch disconnection …………………………………………………… 298
P1198: Low oil pressure alarm ………………………………………………………………… 300
After treatment control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
DPF ……………………………………………………………………………………… 302
P2463: Excessive PM accumulation (method C) …………………………………………… 302
P1463: Excessive PM accumulation (method P) …………………………………………… 303
P2458: Regeneration failure (stationary regeneration failure) ……………………………… 304
P2459: Regeneration failure (stationary regeneration not performed) …………………… 305
P1426: DPF intermediate temperature sensor temperature rise errar
(post-injection failure) …………………………………………………………………………… 306
DPF OP interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
P242F: Ash cleaning request 1 ………………………………………………………………… 307
P1420: Ash cleaning request 2 ………………………………………………………………… 308
P1421: Stationary regeneration standby ……………………………………………………… 309
P1424: Backup mode …………………………………………………………………………… 310
P1425: Reset regeneration is inhibited ……………………………………………………… 311
P1445: Regeneration failure (recovery regeneration failure) ……………………………… 312
P1446: Recovery regeneration is inhibited …………………………………………………… 313
Others ……………………………………………………………………………… 314
Overspeed ……………………………………………………………………………… 314
P0219: Overspeed ……………………………………………………………………………… 314
2. Method and Procedure of Failure Diagnosis …………………… 315
Description ………………………………………………………………………… 315
ECU pin layout diagram . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . .. . . . . . . . .. . . . . .. . . . . . . . . 316
How to use the Tier 4 checker harness . . . . . . . . . . . .. . . . . .. . . . . . . . .. . . . . .. . . . . . . . .. . . . . . . . . 318
Sensor related …………………………………………………………………… 319
Crankshaft speed sensor . . .. . . . . . . . .. . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . .. . . . . . . . .. . . . . . . . . 319
Camshaft speed sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
Accelerator sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
lntake throttle position sensor……………………………………………………… 328
EGR low pressure side pressure sensor . . .. . . . . .. . . . . . . . .. . . . . .. . . . . . . . .. . . . . . . . .. . . . . . 331
EGR high pressure side pressure sensor………………………………………… 339
Engine coolant temperature sensor . . . . . . . . .. . . . . . . . .. . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . 342
TNV Troubleshooting Manual
CONTENTS
Ambient air temperature sensor . . .. . . . . . . . .. . . . . . . . .. . . . . .. . . . . . . . .. . . . . . . . .. . . . . .. . . . . . . . . 351
Fuel temperature sensor . . . . . .. . . . . .. . . . . . . . .. . . . . . . . .. . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . 355
Rail pressure sensor . . . . . . . . .. . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . . 359
DPF differential pressure sensor…………………………………………………… 362
DPF inlet temperature sensor . . . . . . . . .. . . . . .. . . . . . . . .. . . . . . . . .. . . . . .. . . . . . . . .. . . . . . . . .. . . . . . 365
DPF intermediate temperature sensor …………………………………………… 369
EGR gas temperature sensor . . . . . . . . .. . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . .. . . . . . 373
lntake manifold temperature sensor . . . . . .. . . . . . . . .. . . . . .. . . . . . . . .. . . . . . . . .. . . . . .. . . . . . . . . 382
Exhaust manifold temperature sensor …………………………………………… 391
Contact output related 400
Main relay . . .. . . . . . . . .. . . . . . . . .. . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . .. . . . . . . . .. . . 400
Starting aid relay (Glow relay) . . . . . . . . .. . . . . .. . . . . . . . .. . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . 404
Breather heater (Optional parts for 4TNV86CT and 4TNV98CT) ……………… 408
Contact input related …………………………………………………………… 412
Contact input related 1 ……………………………………………………………… 412
Contact input related 2 ……………………………………………………………… 415
Post treatment related …………………………………………………………… 418
DPF OP interface ……………………………………………………………………… 418
Ash cleaning request …………………………………………………………………………… 418
Stationary regeneration standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
Recovery regeneration is inhibited . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
Backup mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
DPF ……………………………………………………………………………………… 422
Excessive PM accumulation…………………………………………………………………… 422
Regeneration failure 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
Regeneration failure 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
CRS (common rail system) related …………………………………………… 431
lnjector ………………………………………………………………………………… 431
Disconnection ofthe injector and coil short circuit ………………………………………… 431
lnjector short circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436
High-pressure pump (MPROP) ……………………………………………………… 438
Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440
lntake throttle drive circuit . . . . . . . . .. . . . . . . . .. . . . . .. . . . . . . . .. . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . . 440
lntake throttle ………………………………………………………………………… 444
EGR valve . . .. . . . . . . . .. . . . . . . . .. . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . .. . . . . . . . .. . . 450
EGR valve . . .. . . . . . . . .. . . . . . . . .. . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . . . . .. . . . . .. . . . . . . . .. . . 454
Communication related ………………………………………………………… 455
CAN 1 …………………………………………………………………………………… 455
CAN 2 …………………………………………………………………………………… 458
ECU related ………………………………………………………………………… 461
Others ……………………………………………………………………………… 463
Overspeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463

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