Yanmar Industrial Engines TNV Series 0DTN4G00200 Trouble Shooting Manual EN PDF

Description

Yanmar Industrial Engines TNV Series 0DTN4G00200 Trouble Shooting Manual EN PDF

FILE DETAILS:

Yanmar Industrial Engines TNV Series 0DTN4G00200 Trouble Shooting Manual EN PDF

Language : English
Pages : 402
Downloadable : Yes
File Type : PDF
Size: 2.63 MB

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Yanmar Industrial Engines TNV Series 0DTN4G00200 Trouble Shooting Manual EN PDF

1. DTC (Diagnostic Trouble Codes) General Description 1
DTC code list 1
Description 6
Sensor related 7
Crank speed sensor 7
P0336: Crank signal malfunction 7
P0337: No crank signal 9
Cam speed sensor 11
P0341: Cam signal malfunction 11
P0342: No cam signal 13
P1341: Angle offset failure 15
P0008: No signal on both crank and cam speed sensor 17
Accelerator sensor 18
P0123: Accelerator sensor 1 (Excessive sensor output) 18
P0122: Accelerator sensor 1 (Insufficient sensor output) 20
P0223: Accelerator sensor 2 (Excessive sensor output) 22
P0222: Accelerator sensor 2 (Insufficient sensor output) 24
P1646: Dual accelerator sensor (closed position) failure 26
P1647: Dual accelerator sensor (open position) failure 28
P0228: Accelerator sensor 3 (Excessive sensor output) 30
P0227: Accelerator sensor 3 (Insufficient sensor output) 32
P1227: Pulse sensor failure (Pulse communication) 34
P1126: Accelerator sensor 3 failure (Foot pedal in open position) 35
P1125: Accelerator sensor 3 failure (Foot pedal in closed position) 37
Intake throttle opening sensor 38
P02E9: Intake throttle opening sensor fault (High voltage) 38
P02E8: Intake throttle opening sensor fault (Low voltage) 40
EGR low pressure side sensor 42
P0238: EGR low pressure side sensor fault (High voltage) 42
P0237: EGR low pressure side sensor fault (Low voltage) 44
P0236: EGR low pressure side sensor (Abnormal learning value) 46
EGR high pressure side sensor 48
P0473: EGR high pressure side sensor fault (High voltage) 48
P0472: EGR high pressure side sensor fault (Low voltage) 50
P0471: EGR high pressure side sensor (Abnormal learning value) 52
Cooling water temperature sensor 54
P0118: Cooling water temperature sensor fault (High voltage) 54
P0117: Cooling water temperature sensor fault (Low voltage) 56
P0217: Cooling water temperature sensor temperature abnormal high (Overheat) 58
New air temperature sensor 60
P0113: New air temperature sensor fault (High voltage) 60
P0112: New air temperature sensor fault (Low voltage) 62
Fuel temperature sensor 64
P0183: Fuel temperature sensor fault (High voltage) 64
P0182: Fuel temperature sensor fault (Low voltage) 66
P0168: Fuel temperature sensor temperature abnormal high 68
TNV Troubleshooting Manual
Rail pressure sensor 70
P0193: Rail pressure sensor fault (High voltage) 70
P0192: Rail pressure sensor fault (Low voltage) 72
DPF differential pressure sensor 74
P2455: DPF differential pressure sensor fault (High voltage) 74
P2454: DPF differential pressure sensor fault (Low voltage) 76
P2452: DPF differential pressure sensor differential pressure abnormal high 78
P2453: DPF differential pressure sensor (Abnormal learning value) 80
DPF high pressure side sensor 82
P1455: DPF high pressure side sensor fault (High voltage) 82
P1454: DPF high pressure side sensor fault (Low voltage) 84
DPF inlet temperature sensor 86
P1428: DPF inlet temperature sensor fault (High voltage) 86
P1427: DPF inlet temperature sensor fault (Low voltage) 88
P1436: DPF inlet temperature sensor temperature abnormal high 90
DPF intermediate temperature sensor 91
P1434: DPF intermediate temperature sensor fault (High voltage) 91
P1435: DPF intermediate temperature sensor fault (Low voltage) 93
P0420: DPF intermediate temperature sensor temperature abnormal low temperature 95
P1426: DPF intermediate temperature sensor temperature abnormal high
(post-injection failure) 96
Atmospheric pressure sensor 97
P2229: Atmospheric pressure sensor fault (High voltage) 97
P2228: Atmospheric pressure sensor fault (Low voltage) 98
P1231: Atmospheric pressure sensor characteristic fault 99
EGR gas temperature sensor 101
P041D: EGR gas temperature sensor fault (High voltage) 101
P041C: EGR gas temperature sensor fault (Low voltage) 103
Intake manifold temperature sensor 105
P040D: Intake manifold temperature sensor fault (High voltage) 105
P040C: Intake manifold temperature sensor fault (Low voltage) 107
Exhaust manifold temperature sensor 109
P0546: Exhaust manifold temperature sensor fault (High voltage) 109
P0545: Exhaust manifold temperature sensor fault (Low voltage) 111
Contact output related 113
Main relay 113
P068B: Main relay contact stuck 113
P068A: Main relay early opening 115
Startup assist relay 117
P0543: Startup assist relay interrupted 117
P0541: Startup assist relay GND interrupted 119
CRS (common rail system) related 121
Injector 1 121
P0204 (4TNV), P0203 (3TNV): Injector 1 open circuit (Inherent location of the injector) 121
P0271 (4TNV), P0268 (3TNV): Injector 1 coil short circuit 123
P1271 (4TNV), P1262 (3TNV): Injector 1 short circuit 125
Injector 2 127
P0202: Injector 2 open circuit (Inherent location of the injector) 127
P0265: Injector 2 coil short circuit 129
P1265: Injector 2 short circuit 131
TNV Troubleshooting Manual
Injector 3 133
P0201: Injector 3 open circuit (Inherent location of the injector) 133
P0262: Injector 3 coil short circuit 135
P1262: Injector 3 short circuit 137
Injector 4 139
P0203: Injector 4 open circuit (Inherent location of the injector) 139
P0268: Injector 4 coil short circuit 141
P1268: Injector 4 short circuit 143
Injector (common) 145
P0611: Injector drive IC error 145
P1146: Injector drive circuit (Bank1) short circuit 146
P1149: Injector drive circuit (Bank2) short circuit 148
P1648: IQA corrected injection amount for injector 1 error 150
P1649: IQA corrected injection amount for injector 2 error 151
P1650: IQA corrected injection amount for injector 3 error 152
P1651: IQA corrected injection amount for injector 4 error 153
SCV (MPROP) 154
P1641: High-pressure pump drive circuit (Low side VB short-circuit) 154
P1643: High-pressure pump drive circuit (Low side GND short-circuit) 155
P0629: High-pressure pump drive circuit (High side VB short-circuit) 157
P1642: High-pressure pump drive circuit (High side GND short-circuit) 159
P0627: High-pressure pump drive circuit (Open circuit) 160
P062A: High-pressure pump drive circuit (Drive current (high level)) 161
P1645: High-pressure pump drive circuit (Pump overload error) 163
Abnormal rail pressure 165
P0088: Actual rail pressure rise error 165
P0094: Rail pressure deviation error during the actual rail pressure drop 167
P0093: Rail pressure deviation error during the actual rail pressure rise 169
PLV (Common rail pressure limit valve) 171
P000F: PLV open valve 171
P1666: Rail pressure fault (The times of PLV valve opening error) 173
P1667: Rail pressure fault (The time of PLV valve opening error) 175
P1668: Rail pressure fault (The actual rail pressure is too high during PRV limp home) 177
P1665: Rail pressure fault (Controlled rail pressure error after PLV valve opening) 179
Rail pressure control 181
P1669: Rail pressure fault (Injector B/F temperature error during PLV4 limp home) 181
P1670: Rail pressure fault (Operation time error during RPS limp home) 183
Actuator 184
Intake throttle drive circuit 184
P0660: No-load of throttle valve drive H bridge circuit 184
P1658: Power short circuit of throttle valve drive H bridge output 1 185
P1659: GND short circuit of throttle valve drive H bridge output 1 186
P1660: Overload on the drive H bridge circuit of throttle valve 187
P1661: VB Power short circuit of throttle valve drive H bridge output 2 188
P1662: GND short circuit of throttle valve drive H bridge output 2 189
EGR 190
P0404: EGR over-voltage fault 190
P1404: EGR under-voltage fault 191
P1409: EGR feedback malfunction 192
TNV Troubleshooting Manual
U0401: EGR ECM data fault 193
P0403: Open circuit between the EGR motor coils 194
P1405: Short circuit between the EGR motor coils 195
P0488: EGR position sensor malfunction 196
P148A: EGR stuck open valve malfunction 197
P049D: EGR initialization malfunction 198
U1401: EGR target value out of range 199
P1410: EGR high temperature thermistor malfunction 200
P1411: EGR low temperature thermistor malfunction 201
Exhaust throttle 202
P1438: Exhaust throttle (Voltage fault) 202
P1439: Exhaust throttle (Motor fault) 203
P1440: Exhaust throttle (Sensor system fault) 204
P1441: Exhaust throttle (MPU fault) 205
P1442: Exhaust throttle (PCB fault) 206
P1443: Exhaust throttle (CAN fault) 207
Communication related 208
CAN1 208
U010B: CAN1 (for EGR): Reception time out 208
U1107: Exhaust throttle (CAN message from the exhaust throttle time out) 209
CAN2 210
U0292: TSC1 (CAN message) reception time out (SA1) 210
U1301: TSC1 (CAN message) reception time out (SA2) 212
U1292: Y_ECR1 (CAN message) reception time out 214
U1293: Y_EC (CAN message) reception time out 216
U1294: Y_RSS (CAN message) reception time out 218
U1296: VH (CAN message) reception time out 220
U1298: Y_ECM3 (CAN message) reception time out 222
U0168: VI (CAN message) reception time out 224
U3002: VI (CAN message) reception data fault 226
U1300: Y_ETCP1 (CAN message) reception time out 228
U1302: EBC1 (CAN message) reception time out 230
U1303: Y_DPFIF (CAN message) reception time out 232
ECU related 234
EEPROM 234
P0601: EEPROM memory deletion error 234
P160E: EEPROM memory read error 235
P160F: EEPROM memory writing error 236
ECU internal fault 237
P1613: CY146 SPI communication fault 237
P1608: Excessive voltage of supply 1 238
P1617: Insufficient voltage of supply 1 239
P1609: Sensor supply voltage error 1 240
P1618: Sensor supply voltage error 2 241
P1619: Sensor supply voltage error 3 242
P1626: Actuator drive circuit 1 short to ground 243
P1633: Actuator drive circuit 2 short to ground 244
P1467: Actuator drive circuit 3 short to ground 245
P1469: AD converter fault 1 246
TNV Troubleshooting Manual
P1470: AD converter fault 2 247
P1471: External monitoring IC and CPU fault 1 248
P1472: External monitoring IC and CPU fault 2 249
P1473: ROM fault 250
P1474: Shutoff path fault 1 251
P1475: Shutoff path fault 2 252
P1476: Shutoff path fault 3 253
P1477: Shutoff path fault 4 254
P1478: Shutoff path fault 5 255
P1479: Shutoff path fault 6 256
P1480: Shutoff path fault 7 257
P1481: Shutoff path fault 8 258
P1482: Shutoff path fault 9 259
P1483: Shutoff path fault 10 260
P1484: Recognition error of engine speed 261
Contact input related 262
Air cleaner switch 262
P1101: Air cleaner clogged alarm 262
Oil/water separator switch 264
P1151: Oil/water separator alarm 264
Charge switch 266
P1562: Charge switch open circuit 266
P1568: Charge alarm 268
Oil pressure switch 270
P1192: Oil pressure switch open circuit 270
P1198: Low oil pressure fault alarm 272
Post treatment control 274
DPF 274
P2463: Overaccumulation (Method C) 274
P1463: Overaccumulation (Method P) 275
P2458: Regeneration defect (Stationary regeneration failure) 276
P2459: Regeneration defect (Stationary regeneration not performed) 277
DPF OP interface 278
P242F: Ash cleaning request 1 278
P1420: Ash cleaning request 2 279
P1421: Stationary regeneration standby 280
P1424: Backup mode 281
P1425: Reset regeneration prohibition 282
P1445: Recovery regeneration failure 283
P1446: Recovery regeneration prohibition 284
Others 285
Overspeed 285
P0219: Overspeed 285
TNV Troubleshooting Manual
2. Method and Procedure of Failure Diagnosis 286
Description 286
E-ECU pin layout diagram 287
How to use the Tier 4 checker harness 289
Sensor related 290
Crank speed sensor 290
Cam speed sensor 293
Accelerator sensor 297
Intake throttle position sensor 301
EGR low pressure side sensor 304
EGR high pressure side sensor 307
Cooling water temperature sensor 310
New air temperature sensor 314
Fuel temperature sensor 318
Rail pressure sensor 322
DPF differential pressure sensor 325
DPF inlet temperature sensor 329
DPF intermediate temperature sensor 333
EGR gas temperature sensor 337
Intake manifold temperature sensor 341
Exhaust manifold temperature sensor 345
Contact output related 349
Main relay 349
Startup assist relay (Glow relay) 353
Contact input related 357
Contact input related 1 357
Contact input related 2 361
CRS (common rail system) related 364
Injector 364
Injector open circuit and coil short circuit 364
Injector short circuit 368
High-pressure pump (MPROP) 370
Actuator 373
Intake throttle drive circuit 373
EGR valve 378
EGR valve 382
Communication related 384
CAN1 384
CAN2
ECU related 390
Others 393
Overspeed 393

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