6AYE Trouble Shooting Manual - Unlocked (OCR)

YANMAA
Introd uction
This manual is a troubleshooting manual for 6AYEM-common rail engines.

This electronic-controlled engine is controlled by YANMAR "Engine Control SystemNC10",
which consists of various control/diagnostic functions to secure safe operation.
Therefore if unfortunately anything unusual happens to the engine, you need to follow the
appropriate diagnosis and its disposal noted in this manual.
This manual includes information about engines, VC10 system, and marine gearlYANMAR
YXH-240-7 (optional). Read carefully before troubleshooting. Make sure you understand
well before diagnosis and disposal.
You will need YANMAR Smart Assist DirectlSA-D as a tool for trouble diagnosis and
disposal.
Please also read and understand the manual of SA-D as well.
Please note that some contents and illustrations included in this manual may differ from the
actual items due to revisions and improvements.
When the marine gear is besides YANMAR YXH-240-7, please refer to the manual of the
certain marine gear.
Please review and comply with the applicable laws and regulations of the international
export control regimes at the territory or country where the product and manual are
intended to be imported and used.
TROUBLESHOOTING MODEL 6A YEM-GT, 6A YEM-ET, 6AYEM-ST

MANUAL CODE ODAYE-ENOO10
All r~ights r~eserved, Copyright YANMAII CO., LTD.

CONTENTS
1. OVERALL SySTEM............................................................ 1
1.1 Engine Control SystemIVC1 0 ................................................................. .
1.2 Position of Engine's Sensor and Switch ...... ... ...... ...... ... ...... ... ...... ...... ... ... 3
1.3 Wiring Diagram.................................................................................... 5
1.4 List of Fuses and Location ..................................................................... 21
1.5 System Diagram ................................................................................. 22
2. PREPARING FOR FAILURE DIAGNOSIS .............................. 25

3. OTROUBLESHOOTING OF ENGINE .................................... 26
3.1 DTC Code List .................................................................................... 26
3.2 Analog Sensor .................................................................................... 29
3.3 Crank/Cam Sensor .............................................................................. 62
3.4 Relay (Contact Output) ........................................................................... 68
3.5 Switch (Contact input) ........................................................................... 76
3.6 Common Rail System ........................................................................... 96
3.7 Engine Error .................................................................................... 118
3.8 ECU ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 146
3.9 No DTC Code Indication: Case 1 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 163
3.10 No DTC Code Indication: Case 2 ... ...... ... ...... ... ...... ... ...... ... ...... ...... ... ... 165
3.11 No DTC Code Indication: Case 3 ......................................................... 167
3.12 No DTC Code Indication: Case 4 ... ...... ... ...... ... ...... ... ...... ... ...... ...... ... ... 169
3.13 No DTC Code Indication: Case 5 ......................................................... 171
4. HELP OF TROUBLE SHOOTING ....................................... 173

4.1 Confirmation Way of DTC Code...... ... ...... ... ...... ... ...... ...... ... ...... ... ...... ... 173
4.2 Measurement Using SA-D
(DTC Code, Sensor Output Voltage) 175
4.3 ECU Connector Pin Arrangement ......................................................... 176
4.4 ECU Failure Flow Chart ..................................................................... 178
5. TROUBLESHOOTING OF VC1 0 ....................................... 180

5.1 DTC Code List ................................................................................. 180
5.2 Analog Input .................................................................................... 182
5.3 Switch Input .................................................................................... 188
5.4 Battery............................................................................................. 196
5.5 Marine Gear .................................................................................... 198
5.6 Calibration ....................................................................................... 206
5.7 CAN Communication ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 208
5.8 ECU ...... ... ...... ... ... ...... ...... ... ...... ... ...... ... ...... ... ...... ...... ... ...... ... ... ...... 218
5.9 Options.......................................................................................... 221
5.10 Optional Calibration... ... ...... ...... ... ...... ... ...... ... ...... ... ...... ... ...... ...... ... ... 229
5.11 Pin Arrangement .............................................................................. 235
1. OVERALL SYSTEM - 1
1. OVERALL SYSTEM
1.1 Engine Control SystemNC10

As you can see below, the 6AYE common rail engine is controlled by YANMAR's original engine control system
"VC10".
VC10
------------------------------------------,
I
Monitor Switch Backup Remote control I
panel Buzzer panel panel head I
o
I
I
~III
1iI~=;;;dJe
I I~ I
I
I
I
Display Helm ECU Drive ECU

2 - 1. OVERALL SYSTEM
1.2 Position of Engine's Sensor and Switch

Injector
Fuel pressure/temperature sensor Metering unit Rail pressure sensor

02ENOO
Lubricating oil pressure sensor

069554-01ENOO
Crank sensor
1. OVERALL SYSTEM 5
1.3 Wiring Diagram
1.3.1 Engine wiring diagram
BOOOAfRB(5) BOOO/R(S)
NOTE HARNESS,WIRE ENG
1.Wire diameter 148661-77010(REV.3)
i
Description Acceptable wire diameter
I~
HARNESS.ALTERNATOR
0.85mm' 10.85mm' ,0.75(flmm' ,AWG18 148661-77060
1.25mm i 1.25(f)mm' ,1.5mm' ,AWG16 HARNESS,STARTER
2mm 2 12(f)mm' ,AWG14 148661-77070
5mm 2 15mm' ,AWGlO
I CI
! Starter b
IBk
'--------"1
I B021/WR(O.85)
lS02()/RY(085) I B110/RB(5)
~ACCrelay li'r-----·"" ------.. I Joint connector

~llg
~DJ g
Termination resister r---ETgj/§IZo:ssY- -{S} 1 al .~
E147AfGB(0.85) ,~~~O~Q~ , E150/WG(0.85)
GO '::;
I E146AJYB(O.85) OJ -<
1
29 BUP POWER 'i
'~" SOOO/B(1.25)
1 BATTERY· S010/B(0.85) ai
CANG J1939H E146/YB(0.85) J I L ___ _
CANO J1939L E147/GB(O 85) ,TWIST I I Starter
,
................... , .............................................. ' ............•
Relay
,----
1 \' 1
~ INJECTOR 1 H E249/LW(1.25) 1 •
24 SUB THROTTLE SELECT E111IWL(0.85)
E162/G(O.85)
~ .------<1>-----1
1-" IINJ1j INJECTOR 1 L E273/LB(1.25) 1
2 19
25 SUB THROTTLE LAMP 6 273
~
11 lANA; OG SUB TH SENSOR P E192/P(O.85) ~ INJECTOR 2 H E250/LW(1.25) i 250
I Exterior system 12 lANAI OG SUB TH SENSOR S E' 78/Lg(0.85)
II~J2j INJECTOR 2 L E274/LB(1.25) 1 •
27 1
13 ANAl OG SUB TH SENSOR' E157/Gr(0.85)
Starter ai . INJECTOR 3 H E251/LW(1.25) 251
interlock Ii' ~IN~JE~C~T~0~R~3~L~________,~SH~IIIE~LD~I----
__~~+4~+-~E2~7~5/~L~B(~1~.2~5)~275
30 MAIN POWER B030/W(1.25) relay ~ r,~
20 TERMINAL 15 E169/vVL(0.85) P020/Y(0.85) [L
il:N~JECT~ORt~.
4Ht===2~E=t1t1ttE~225!L~W(11. 2;U5)225
21
22
START SW
STOPSW
E163/yR(0.85)
E182!BrW(O.85)
i E163AJYR(0 85) ~
o
~
OJ
f..'NJECTOR 4 L ,SHII E201/LB(1.25) 201
~ INJECTOR 5 H E227/LW(1.25) 1227

19 SAFETY STOP SW E136/LW(0.85) ,'88/BR(0.85)
E119/WR(0.85) ~ ~ ~ INJECTOR 5 L ,SHIELD,- E203/LB(1.25) 1
23 OVER RIDE SW E181!LG(O.85)
E160N(0.85)
oo_w E226!LW(1.25) 1
203
11~~~t :~~:~~~:::
18 E·STOP SW
1 2 226
,SHII i E202/LB(1.2S) 202
Deutsch Priming
pump E258/LW(1.25)
I~~;;~t:~:~ ~:~:::~~ ~~:~ ~
HDP24-24-31 PE 15 NEUTRALSW E114/VV(0.85) IB !
ANALOG MAIN TH SENSOR P E166/RY(0.85) ,SHII E283!LB(1.25) 258
283
9 ANALOG MAIN TH SENSOR S E179/GY(0.85)
E169BIWL 0.85: Crank ,CRANK SPEED SENSOR S E266/L(0.85)
10 ANALOG MAIN TH SENSOR G E180/BY(0.85) R
31 CAN POWER
CAN1 J1939 H
B021/WR(0.85)
E171/Y(O.85) P020A/Y(0.851
G030AiBL(O.85)
16
,
sensor i CRANK SPEED SENSOR G
CAM SPEED SENSOR P
I SHIELDI E265/G(0.85)
E209!P(0.85)
5 CAN1 J1939l E195/G(O.85)
~ Cam CAM SPEED SENSOR S E280/0(0.85)
2 MAIN GND G010/BW(1.25) Surge
G020/B·(1.25) sensor CAM SPEED SENSOR G E278/Gr(0.85) i 278
3 CAN GN[ protection diode
~
E239!GL(0.8S) !
I Water iC;()()LA'~TTEMPSE,~SORS
: 239
i temp sensor! COOLANT TEMP SENSOR G E242/BL(0.85) 1242
_ FUEL T/P(FILTER OUT)SENSOR P E231!RB(0.85) 1
231
Fuel PIT FUEL T!P(FILTER OUT)SENSOR SP E235/GB(O.85) i 235
filter FUEL T/P(FILTER OUT)SENSOR TP E213/LB(0.85) 1
out
~I!
213
sensor f--'F..:U..:E:::L.:.T..:/P.:.(F.:.I:cLT-=E::.R.:.O:.:U:.:T.:.)S:cE:.N..:S:::O::.R::.G=-______________E~2,:"0,,:,6!:."B,,(0,:,.8,,,5,,-)-1206
= CHARGEAIRT/PSENSORP E207IR(0.851. 1
: 207
Charge CHARGE AIR TIP SENSOR SP E286/GR(O.85) 1
286
air PIT CHARGE AIR TIP SENSOR TP E237/LR(0.85) 1
237
sensor CHARGE AIR TIP SENSOR G E290/BR(0.85) I
Coolant La La : 290
level filter ~,---~ LUBE OIL PRESS SENSOR P E233/RG(O.85) 1
temp Lube oil 233
SW SW SW LUBE OIL PRESS SENSOR S E216/G(O.85) 1
press 216
I
,sensor! LUBE OIL PRESS SENSOR G E219IBL(O.85) 219 i
mm
12 LD
~ ~
fT Rail
press
sensor
1 RAIL PRESS SENSOR P
RAIL PRESS SENSOR S
RAIL PRESS SENSOR G
E211/RY(0.85)
E236/GY(0.8S)
E260IBY(0.85)
!
1211
236
: 260
*w~
ro ro
~~ ~
~ ~
~
w E127AfR(0.85~ OJ ~
E127B/R{O.85)
-
~
~
I
W 4!1
2'1
~ C)j
fJil
I- GOOO/B(5)
Z WI
::'i
o
o
~I
II
u ui
ECU
1.3.2 Wiring diagram
Type 2
Note: For details on Type 2, refer to following pages in this chapter.
Type 2 (1/4)
---------------1
I I
I I
r------------------ ___ J I
Type 2 (3/4)
STATION I
I
D:soiayAssy,780
Type 2 (2/4)
Type 2 (4/4)
I 164000.10010 :
I Drive ECU I
L_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
073S60-00ENOO
Type2 (1/4)
---------------------------------------------------1
Portable Controller Option 164000-24800 I
119578-66722 I
CABLE, CANA I
CONNECTOR, T NMEA
(2)CAN Me F "
119578-66600
CABLE, NMEA
:
:@CONTROL HEAD 3
\r~.·l. ·. ~~~~RlpOWE~ii~L~~.·l. ~[J~f~if(it. ~L===================.'j':~~. .~. .~;----I

L =====----------------&f------tt-!
·.'D·
..
164000-42300 mmmmmm\s:! g~~ powE9t~~~ !w:M~02!8i:[JTIBljiW'["

!
(DeAN M6P F 15 I 51
Control Head, :6 i6:
V+ 1 02 R
SCGT CANH28;L
CAN ~ 1~Dij;3jjl~B===+=J- 164000-41200
164000-42310 Control Head, 164000-21361
D1A Gr
Shield
Control Head, CAN 2LV HARNESS, WIRE CANCH S
SCG 16400-41210
Control Head,
CANIS
:164000-36710 i
Buzzer,
Alarm
RS-485
164000-21380 I
164000-29000 I HARNESS, WIRE DISP S I
ADAPTER, TERMINAL I
'1'ENGINE (3'NEXT STATION
~"'~='-=----t0~~;:{wffir:ii-~M~01j..gW{.,-______________
iii ~ MQ2A(\i
+--++-+____~M~O~1~"WV}f-r :DENGINE
POWER
E-STOP ~8--M~O~3~'L~Yi2=;::============+=+t=+===~i~8'3 BUPACTIVE

POWER !\M10023"'r70 E.STOP
~ BUP:~l~~ ~ _ ~~_ ~i_ ~~~--(~il ~~~~g~

rMDlN-tlj E-STOP to GND
I
lsi SYS-ON~M06A(BY- II06A
~ ~
i BY,6 CANGND
I CAN GND MO? R 7 START
' '7, START ~MQ~mW ,8 GND
@TERMINAL lMQlJYi~ GND GND fM M09ArvvS-;'- l- M1' ~-CAN POWER
M10 (y~ CAN ~~~~~ ~ M10A L , rv111A Gf-tQ J1939H
J1939H rn\M1~~~ J1939L
LL=t..._J1_9_39_L=2,
J1939H ~ ~
i~(~C~ ~ M11A G , - - - - - - - "
M12B IB 5 8 ' ............... ...... . .... . .......... ......
•
SA
M12A(B :H ~~~~i~
164000-51 700
Display Assy, 780
i 068284-00ENOO
00
~ ~ ~I
0
~==~ (tJ~~~~r;n(3 8 (f)
~
"0
~~~~~~~6~~a~
,I;uO'-lOZZm-U;;o
~ '-I );! (!)
tv
~~
::! ,...........
J"J1='!J9J'f"'' ' ,,t:<,,""',"l"H"l=l !;:!
~t oz tv --"-
________ OJG)I-<'i~i~i;;oI~I-<lrl ~
"-"
o
,------
<
m
~
lW
en
r-
r-
~
"1 oo
-<
00
o l' --I
> Z
L..
g;~~cDcgj©
~z~~~ 9
m
IOrI;;U Z ~
clo;~!t~~~~=~~ >·~o
5~~
@JC10
B'2:"7~2R~ :;::tg§DT~~~~':!lt--------
-- - -- ------------- ·.. ·~~l!j2~~;~,c.n mC~g
E5B}""~o,
E57!L rj
COIL~.
BRAKE COIL +
BA:~~~ 1~~~:;111tt+
.
------------------------------------ BRAKE
L ______________ _
r
··c
__~!3UZZER
SYS=ON-~ 801 f~I\jL
BUZZER '.-j E54tB
~~;i;;r2 ~gig;ii:r I I I ['[urn

(rVPANEl
.-----~ STARTiSTOPSW E01iYR
-- tv POWER
~ _ _ ';: SYS-~~l6~ iii I I I
~'-n E-STOP
0"> CHECK I
GND M08CfBW
@CONTROLHEAD 2
.-- E08JG R ~-~~--SEL-ECT-S~V----
»0)
""U~
Z.!>-
NTWSW
SYNCRO SW
O TROLLING SW
m0
, E551LY I " SELECT LED
, 0 +-_-"Eot56i1j/LLVWV' f'? NTW LED
(lJW +-_--"EQ6<J1 11L1LB3,:-..! SYNCRO LED
___________ EQlID_~: i~lt~~~~ED
:z:CI
-~
·······f···············+·j········+·++··
M04C/WL
E60lWR POWER (SELF)
E631LO BATTERY
E02/BrW NEUTRAL LED
---------E-03/BrS- TILT UP SW
············E':r8W TILT DOWN SW
E23JLq ANALOG POWER
ANALOG SIG
ANALOG GND
c·· CAN2 H
CAN2 L
I··· SHIELD
POWERGND
®CONTROL HEAD 1
---t---t---t-I
II~
»0)
;;02) o~
zo
me;:>
(lJN <-0tid::
0
(IJ~ 00110
' ()1 ~'< '?
IO '?a;-~
,
mO Ncno
'<.!>-
s:: , 0
m
""U
@OIOOE
~
U
M09BtWBr
I CAt~ ~2)y~~
a
-:--1(1)
~< I CAN'
(1)
'10l!..::..!Wl rv l..... IIE)

mL.L.()G)(fJo(fJ(fJ(Dm""Ol m
» . . . . ->.»z,..,»-<-<c' 0 Z
A!~:n;.lzo»zc,nc,n-o~~ Q
:i~~C5 ~~~~f)~~ ~
~ 0 ~
AI m
52 0 ~
~==~ (fJ~~~;:;~C5
~8~~~~~bb~d~
O~I;ao,..,ozz~""O;;o
en mmm :r: ~
'" l"'i'1Qi'-' 555 ~ ~
ZZZ
"'''''''
ffi g
( /)0
[I HII~I CD CD CD
~~~
(/)
-m
I
~
I~~~~~ ~ g
~111~~I~~~ o
Type2 (3/4) --!.

~_ _ _ _ _ _~--",0",B,,"!U=
PA",N~IE='iL
··fT BUP POWER !fl1J
GlENGINE ®BUP
Y,y01.lu (.W" ...................... Y,"0.1,i.(,W"llljJ1 BUP POWER 1BUP POWER "l1i
1J I y.,O~.1.,lv
(W,S,,,r..................................................................................................................................................................................................................................................................... 1
AB~~~g;r,~~ ~~~~g~~~r~~~~J~003~2~~~~2 ~r2-~Y~0~2~Y~R~~~~~~~~~~~~~~~~~~~~~~~~~~~I l

r
164000-30011 1
o
;
~ BUP START
l ~~~ ~6~ivE Y04 I L Y0<1 L
BUP START
BS~~~~~~ ~ ~gl ~Y
I BUP START
!
__
"PANEL ASSY,BACK UP ~ S TH LAMP ~ S TH LAMP I S TH LAMP Ps
'7 7 ' '7
S
k--t~ SST~HGS~g
8TH POWER ~g~ ~
Y06 V
6
~g¥ (~ j~ ~ i~ ~I~D
Y08 B 8 S TH POVIIER Iis TH POWER' iii i l~ ~~~ r1~~'8tY~0~6]P~~~~~~~~~~~~~~~~~~~~i~===lF¥tl~
~gi $~
,
~ 11 BUP SHIFT F
.....................................................:L..,2,.....B...U
....p....S
....H
...I.FT
........R ,
~76 YOg Y 11 BUP SHIFT F i BUP SHIFT F 111 Y10 WB
Y10 0 12 BUPSHIFTR LBUP8HI

FT I11
R 1"24617.9"86°1 I~=,RELAlii:;:~;lr,O)'::":,'.~.1,".B'"'HY,wB,, ........................... 1 I i ~
164000-22950 Power "" ~

HARNESS, EXT BU SLD tF+ 1Y11A(WY @J,"
164000·22960 5M ~~
164000·22970 10M (7)DIODE
164000·22980 20M ~Jj ! ES3 (Y
T________ ~ ~~:~~: ~-HE63A {WY
@DIODE 2, En'; (VII

~~:~~: lliE64A (WL
164000-21420 1
1 HARNESS, WIRE DRIVE F
164000-22900
HARNESS, EXT SLD
164000·22910 3M
164000·22920 5M
164000·22930 10M
164000-22990 15M
164000·22940 20M
164000-223xO I
I {\tv I (V' CDENGINE @NEXTSTATIOJ\
I HARNESS,EXT HD I
;j)ENGINEAY 0ECU BO> llENGINEAY
BATTERY. 1 M13 (B M13 (B BATTERY.
Y22 BY
M12 B .1J Main GN~e-
CAN GND 3
~ Main GND
2J CAN GND
~SA
SAl
c---
I M10(L M10(L M10(L
I
m~~t
J1939H J1939H
ii\J~ -~- SA I SHIELD USB ! I M12G ISH

J1939L
w
N
N
>-
J1939L
M12D is iSG Y06(P Y06(W Y06(W
i;~l:~~~~: i ;~J :~~!~:~~

c---
Sub Throttle Pow
1124617.91850 1 @RELAYSTARTI12v II M12F (B SF 08(Gr Y08(Gr Y08(Gr
Sub Throttle Pos
Sub Throttle Ret
~ Start! M07(YR
~
iI
i
;
M02A Br
E-Stop E-Stop M02 V M02 V E-Stop
ENGINE
Y171WR Y17(R Y171R
itt~ ~~~~
To Terminal (15A(Y (15A
Y15A
StartSIG
1124617.91850
BA ' Stop BUP Stop
@RELAYSYSOlllmrMO'(WL
i i Y04 'LY Y04 (L ! ! Y04fL
~~:.: ,Lamp I s~bufh1r;~~
BUPActive
Y05A G Y05A G Y05A(G
Sub Th Lamp
'k!c I : c ______
M05 WY M05 Y M05 Y
!Y18(WY SYS·ON SYS·ON SYS·ON
From Y01 (WBr Y01 (Br i Y01 (Br
I i
lli ~ BUP Power
BU~ ~~::~
BUP Power
~,;lain Power Main Main Power
i i i
1124617.91860 1 @)RELAYCAN(24V @hc"" u,,,,·~
~~ 1 ~24y Y?O (WR
II i I I Y20 WB J CAN Power 24V CAN Power 24V 31 Y20 W Y20 \AI
CAN Power 24V
i' "
i
U!i :
I
I
I
@SHIFTACT
A09A Br 330 Q A09 (B i
M10A (L l J1939H
330 Q 3 J1939L
4 GND
@RESISTORx2·B
SF
1
M12C B ~ Shield
@TROLLINGACT
~1\og ~ J J1939H
M08C BW l ~1~g9L
so. M12E (B ~ Shield
OOENOO
10 1. OVERALL SYSTEM
Ty pe 2 (4/4)
C-Type Trolling Option
1164000-254xO 1
HARNESS, EXT C-TR @THERMO SENSOR
:Lj Oil Temp t
@TROLLING (j)ECU BOX 2 I Oil Temp-

I I I
! Ii I I EO? (RY Oil Temp + Oil Temp +L EO?, R @SPEED SENSOR
Shaft Speed + ~ EO
Oil Temp - Oil Temp-
,
EO' (e
Shaft Speed + E~~2 ~Jn Shaft Speed + Marine
E66 YR Shaft Speed - Shaft Speed- 4 E66, '-' l2--J Shaft Speed -
Direct Valve t Direct Valve -f
~
1
E84(Gr E84
Direct Valve - Direct Valve -
i !
E61 L PWrv1+ PWM+
~ E61 W
@SOLENOIDVALVE
E66 Yj,-,
Gear
II
1
i i
PWM· PWM· !
E84 (B __ ~ g:~:~! 0::~: ~
~PB
l PA
~"c: T @P·VALVE
~~~~~ -r-j PWM +
~PWM-
3'
164000-253xO .1 I
HARNESS, EXT CL I
@CLUTCH (DECU BOX @SHIFTF ®SHIFTCCW
B02iW I
E63A(WY I~HI F+ E63B (G
E63B G~ SHIFT F+ SOL b r:rl 802 fW P(?)SHIFTb
E64A(WL
~~II~+~: ~ A08E
E64S{Y lri_ QD2--LQ-
i~~: ~~D
A08E (B SHIFT F- COM c
IB I L G02[G
b"DSHIFTGND
E54(RW
E24 LW ! ~!!
I ~!~
Press +
Press Signal Oil
SHIFT F-
p~~:~~~~; ~ EO
fl- B021R
(W ! I E64B Y
@SHIFTR
~ SHIFT R'
T
®SHIFTCW
-,---------j 801 fR
I
SQ1(i< p(j)SHIFTa
IOil Press- Oil Press - ~
A08F B 2 SHIFT R- gg~~ ~ G01 (8 G01 (8
,AC b@SHIFTGND
~AB I
AA
177514-65600 I I
HARNESS, FNRSHIFT I
I
I
C±)PRESS SENSOR
:g22: ~~-In D.iI Pres~ +

@ACC
EOS (R
E:
E51 IB
:WR
~ ~~::: ~~\\:~ ~ G03A fBr 2: Ol! Press Signal
~OilPress-
0~C..+
EC
IY
WG
i~~~
E' IWB
:~:~~;~;~,
E49A WB 9 ~gg:
@DISPLAY
~,;l04A1WL
M08B/BW +1SYS-ON
~GND
fi
M10B/L
M11BfG
~.
Jj
BB
'"
::J
Q
N
0
W
C£f-~
§ ~
11 2 31415 6
~
"OJ ~~
W
1819 o H2 3415n6 7 Sng 0 1 23 4
+ + "-
.,.~
N
W
5~6 7 8~9BO
~I?i"
[31'
102 3
'"
~~
W
~
m
'"W
co'I1 2 31415 6
::JI
g
fi; n~l I ~g~k ~I
<DO--
;z~ ~~~~
ml
~I
1819 o H2n3 4 5n6~; S 901 n345
~~
~Po
W
U'
~~
::JI
t? 'Con"
fl;
12 3
<C
W ~
1516 7 8 19 no 1 2n3~4 5 6mS 9~021 n3 4 526
U ro
a~
ul
!!
N~
rn
W ~ o..E c c ~~ WI
® 1] Q}E~
Uj
~ m
Uj
c c
~~ (~I a. a.
OJ- ~~$ uJ~ w ::J::J
::J
~ ~6~ ~
ill 00 ill
a.
UU
WW
~
if) 15
I & is
I
I
164000-10010 I
I
I Drive ECU I
I_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ - - - - _ _ _ _ _ _1I 068287-00ENOO
Type 3
Type 3 (1/3) Type 3 (2/3) Type 3 (3/3)
073861-00ENOO
Type3 (1/3)
---------------------------------,
Portable Controller Option i 119578-66722

iCONNECTOR T NMEA'
1
@CAN Me F
1164000-24800
1CABLE, CAN A
l-----------------------------------------.-9)CAN------------,
-----------------------------~
.
GTERMINAL
;mTERMNAIFLM9~~DWLl
IJ~r~o I~r;~ I\~i~ ~ ~~r I~r;t ~~~~~ :
M10F
I~g~~l~ M11F G ,~'
t B,,,
j~
I
D1A (GI" i
! 119578-66731
11"E:I3rv1It-JA~'rv1t-Jrv1E:A
\II~~
f=
119578-66600
CABLE, NMEA
I
.----------.
;tr ~I~?>~~
"'CONTeROI HEAD M"H
~ 1::~~i\1 VI
; 164000-10300
6400042300 : Controller Assy,; ~
antral Head, ' Hand : (T)CA" M6P I C 164000-24810 : I 1 1200:
Control Head, ; 164000-21361 ;I ~
SCGT Ii~[tR ~£'i ""'" !
4000-4231
antral Head,
Sh;"~
CABLE, CAN B CAN 2LV
16400-41210 ,
, Control Head,
, HARNESS, WIRE CANCH S
~ ~ ;J ~ ,--- ----- --
I
: 164000-51040
~
SCG
---
----- -----
-- ----- ---- ----- ----- ----- ----- ----- ----- ----- ---- ----- ----- ----- ----- ----
L
CANIS
__________
,------ - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
--'
! II ~~J ~ E)
---------------------
I Display Assy,
: VC10-2
I
-- ----- ----- ---
TII~!~~~~~il !~ il~~
----
~~~
: 164000-36710 STATION
I Buzzer, Alarm
: RS-485 lil!II!!111 I,~iilZ' =~~~uu~~ ~~ J
I
I
~ ~~ ~ ! I i
I164000-21380
rh "/""/"
>-
~ ~~~
~
(j)(j)
0
Z
~
:1
JIll 164000-22900
l~fll11lr 3~ SLD 5M
TERMINALf-lAI3t-JE:~~,\I\III3E:[)I~F'~11 § I
1164000-29000 10M
I "jj:'
15M
!ADAPTER, 20M
@m'''~ Ij:~li~
Ib!lij:~i~rp
(1)FNGINF
EETOPtoOli[
Q)NExr STAr
I:l~t!
Icml\~ M12B
I"TilI~~· I'~flt @CAN B @lCAN jJ'-1Qfll!Nll:__ II I I I III J III I I
IIII
'
W if"
;::~'
i~OWER I: CAN
",',
. " ..
:1:]~Xi~~
SB SA S8
1 'TCAK"iilI '-'
c,
1164000-215001
IHARNESS,
I
I
!
,IHELMEPS
I
I
i :;~ ~
~ ~~~~ ~ ~~
1212
~
'-----
"
164000-51 700
Display Assy, 780
I~
@SYSONRE~
SVS-ON
POWER 2
II
----- ----- ----- ----- ----- ---- GND 3
SYS-ON SIG
I
I
Ii CA-1A(1E6910-82500) I 0)STARTRELAY IIM14FfWI
~ STAR::!t!~~
,
+
~
~I
~i
gi
,~
f~ ! ! ~,I~i~ I i ~
~
~
2
~
~
j
~I
wI
,~~
, , ',",14 "",1
~5~
~, ,~
,0 '"100
~ !~~~O
~ ~ ~ 3w $555 ~~~~
f-I...J
~~~~~
~
~
I
zz5
'0 ~! ~, ,88 ~~88
~~~
(j)(f)(f)(j)
~ lim 21 0 :3 §§~~ ti~~ii

L.l.iZ::JU ~ ;];]8
~ i~iii ~i~11
j li164000-37010 !~ ~~~g
~
~ g~ ~ ~
i!I[1I]
a
~
PANEL, SWlTCHI "
164000-10000
-
--,
lJ
IServicel
Helm ECU Tool
068289-00ENOO
14- 1. OVERALL SYSTEM
Type3 (3/3) 164000-30011

[PANt::LA§§Y, [3Ac:: f(LJP
@BIUPANEL
IY," (W8
122B
(w
IJ1ZA\I",
:""''''''.u="
A03A (LY~A03BIBW
[Y04AllY
me
[AO'colvv
MO:} (LV
~'1'23
I I
'
~
8 ~§ §~ :~:~
15 ~
~~§
u o..00 u
ii
164000-25200
HARNESS, EXT R!
!
gillg
® 11213%rsT @
~~~ ;
164000-25210 1M
~ 4jn11t~r===========~~~f4DLAM~P~~;";2'T§O§LA;MP~~~=~=~~®~RaES~'S~TO=:Rx~'~'B1Elif==~~~AFrER
164000-25220 3M >::
164000-25230 5M ii L01 WBr 1 BUPPower niL01A(VVBr l01A(WBr~101B(Br r?DLAMP+~'
~ ~~~~ci:JL02A(G L02 G (-~
2 SubThLamp - RUN LAMP
: (red)
! 164000-223xO HARNESS,EXT HD I
I ")ENG!NEAY ("POl'ROX
M13IB ME IR 0leNGINEA',_ - - - - - - - ,
v22 BY bJ BATTERY
OB GB
BATTERY
MainGND
I M12 B
CIINGND
ii ! i
SA I
~
........ ,
JA
H,Y
LA
............ ( ..... .
I .
I
II ,,,;G iB
-, I
I
ISH i I
M10 (L
11.111 G !j::~~) i
:,~;~~ ~:~ i~ , - ~ ~i I
M10 " ,11939H
J19391
i SG II I---~
q
11.1120 (8 Y05 (p Y05(VI
~::
Sub Throtlle Pow 110j Y06 (W Sub Throttle Pow
!is;;
~ SF SubThrotllePos Sub ThrotilePos
M12F (8 Y~S
, Sub ThroHie Rei Sub Thro11le Rei
,
I
@ReLAYSTART!12V)
12451701850
(,""" ( :~!\f1;;(YL
[Qt;
M02A (B, !E·st"" E-Stop
M02 IV M02 (V
E-stop
ENGINE
II I IR
!~~";'~SIG'
"----~----..';"j Y1' Y17 'R
! ~~,;~:;t'"
'" (WR
iBUP S'~p '~F£~ BUP
,q
.BA , I! j
I M04 ii I Y04 ,L I I
~~;:
(WI Y04 !LY Y041L
@RELAYSYSon(12V) !i ! ! ! ~~bAct"' BUPActive

3ubThLamp I
ii
;~
MOS (VV'{ MOS (V MOS (y
I SYS·ON SYS-ON SYS-ON
124617-91850
Y'8IWY
Y01 (WB, YOI (Br
~,~~ ~"w' BUP Power
Y01 'B, BUP Pm.ver
VVL ! V21 (R
Mail' Power Main Power
I
Y20 (W
, v20 (W
~ Y20 (WB
J CAN Po.",24V I CAN p,,~, 24V
'~1
CAN Power 24v; Y20 (\MI< CAN Power 24V L
CAN GND
@RElAYCAN(24V)
124617-91860 : ~ Moe (WR, MWA
OJ J1939H
't§: ,119391
IfF
I
GND
Shiela
,
164000-254xO I
EO? iR
. . . . . . . . . . . . . . . . ..
1OilT;'~p
l@rROLL!NGCIEeUBax' HARNESS, EXT C-TR I ~---.J"='''.L,®~SP~EED';;:;SEN2s00'''--R~~---i
1 --r----I--II-----------r=-II~III~m===T1rr~~~~===t==~1~~1t~E0771~~;~I~~ilnr,~mp'~~~a~,""~np1';~IEO~?'I~R~:::::~~~r~r~~H==::~:~::--~I
F:~ Ij l~lf:~f Im ~ '@D;~;;;V;";
@P·VALVE 7 PWlA'
8 P\I\I/vl-
I"h~A (\~N @CLUTCH

c _ _ _ _
GlEeu BOX
_ _ _ _
0.'
,,1
PVVM-
!164000-253xO HARNESS,EXT CL!

8
_
PB
~rt1PWM'
c ____________
@SH!FTF """1FT
II
CCW
E62A (Br
~ __________ _
nM '00'
MGarine
ear
E638 (G ~Jj I : ~-1.-~ ~ @SHIFTb

E64B ~_2J SHiFT F- cor~ ~ L-----~-'!_c=--_\~--O @SHIFTGND
E06lR I~~~: ~,,,,~ ,AC ~AB 121 SHIFT R- caM C (j)SHIFT GND
j;,~;;: [AA 1177514-65600 I
1;~~~: ®ACC HARNESS, FNR SHIFT

I ~~~::~'" RC," (R 0lPRess. seNSOR
:~:ON ~
iii
M04AM> ,: j 01 p:;;; 'I
2' GND
~
M10B'L~
@DISPLAY
M118:G ~; ~i~~~~
G'iiJ
i'12J1i
068291-00ENOO
1. OVERALL SYSTEM - - 15
Type 4
Type 4 (3/4)
Type 4 (2/4)
Type 4 (1/4)
1······~~~It~--4-~~
I
I
I
I
I
I I
-------------------- -----------------------------------------------
:==~ ====~~~~~~~
1;c:;"'::!~~L _________~
___~,~~~,
Type 4 (4/4)
074057 -OOENOO
- --- :- =- --- --- -::: --- ---

Type4 (1/4)
1 ;\ IfI ~ 164000-22900
[164060-30210
i
i
PANEL ASSY,
NO CL
il' ~ HARNESS, EXT SLD
164000-29000
ADAPTER,TERMINAL
1
v
:
164000-21390
HARNESS, WIRE DISP LAY
I ~ I! ~,~,~,~, ~
Ie;; '" (V'
1~1~~~:ll§~~ 1~~
1~!~~6:ll§~~ 16~
~J) f'(;PO~RT;"f>:IC'ENG3If:'I INE~':~@I>JE)(:r. s.:Q\1 Q,N, ~ ~ci~ ~
1
1
nENGINE ®NEXTSTATION (1)ENGINE i@PORTNEXTST nENGINE ®NEXTSTATION (1)ENGINE ®NEXTSTATION

Ll{:1~
M01~\'/t-",========================~M~01'\A I POWER Ll{:'~
"'V'~\'/t-"':::==r"::-..-:+~:r!~4i~:::::+§j==~M01~'(~W~=PO"-~"'IE"-R----,-'2.=PO"V-'IE"'R~11LIV10LCN i~01JI~N
0", "0< 0",
POWER MO)N M01 (Wli POWER POWERP (W8jf POWERP lV10LCNlf POWER POWER Ii m
,M2lli IE-STOP) GND E-STOP 12 E-STOP ESTOP P 12 12 E-STOP piE-STOP 12 E-STOP E-STOP ~HM"i1,0*2,*(BS-_ _ _ _ _---!BMO:',!2't(~B7 E-STOP E-STOP if M02A
BUP ACTIVE W~~~l;:::====M!~~f!~ BUP ACTIVE BUP ACTIVE P ! f"r103 M03 (L t3 BUP ACTIVE P I POW SW ! f"r103 I MO: POW SW BUP ACTIVE f"3f- MQ3.JW -~%i~~43 BSyUSP_AOCNTIVE POW SW t~l-~§lf\0J~~t
~~~:g~ 14)NY Is ~~~:g~ ~~~:g~ ~ I M05 Moe (W' ~ ~~~:g~ ~! SYS-ON I M05 (W MO SYS-ON ~~~:g~ ~ ~~~ ~ M05 IYh(- SYS-ON SYS-ON ~ MOSA (WY
CASNTGARND
~R
f* ~TAARNGTND
I-f- ;:-
CA!!TGANRDT Pp '''07 ""7
"'V,
~ CSTANARGTNpD P START/STOP
I-f-
CA~H~~~ M06A BY
M07 R M07
g~~~KND
START/STOP
C~qART
GND Ill' M06 (G
~ M07(R
M06 (G'1l CAN GND
M07(Rrt START
CI;;t~~~ i~'
M06 (BY
STARTISTOPSW:-r M07A(YR
T ; : - ! .. ,,"
CANPO~~~ i M09(WBr M09WBrrn- g~~POWER CANPOW~~~ i M091 WBr MO~~~~~J, rn- g~~POWERP CANPO~~~ ~~~1B~Br M09, g~~POWER CANP~~~~~ ~~~?~r .GA ~~98(~~ g~POWER CANPO~~~~ ~~~~~~r
J1939" i Mi01 ,-----, M' I.ir J1939H J1939HP i M' ,------ ~------:;;.- -- ~-, ","v,,, I.ir J1939"P J1939H i M10A M1 Ji939H J1939H tm--~W--*"V.- 1 1 ~~\-Q~t~ J1939" J1939"i1o'f-MHlJY-------
~~iic~ !IJV~
SB
-'U2{811t21~~1:~q,I!O~~l[~~~-..si.fi~~~1IJC~~~fOJ12jI=M"2=B"'-----S~
SA ~-. c: SB
. - 1- -- --
SA
M12BI ~~i~~~Pp 0
J193 L
S"IELD
IM12B(B .01 J1939L
S"'ELD SHiELD O:2rM12Ak~~
J1939L'11' , L C',
~(B(t2 S~IE'LD
11 J1939L J1039L~
S"iELD~~
,®LARGE DISPLAY 1 @DIODEP
1 M04B (WHll SYS-ON p tD----o,. I
164000-21710
2 M04A ~ SYS-ON ~ HARNESS, WIRE PANEL
3
J1939LP ~I M11B(G
J1939HP 6 M04i'(R
SYS-ON 71 MD8A (BW
GND IIl~JI M""UO,'A'"" ",,"He,'r'········ ;
10
11
©DIODE S
IGN-ON 11.5J1,M"~'1,4,1",,A\,',(R".......... ,................... , M04D ~ SYS-ON tD---" I

16
M04A{t<12I SYS-ON f£J"
J1939L S ;~Hr~~1!,'1*D'*(G"---
_ _+-,
J1939H S '9+-'M"'-''-'0"D-''L~_ _+---h
o
1
2
,164000-51700 3
1 Display Assy, ~::::::::::::::::::::::~
' 780
RS-48S" 141~M~2D)lQ.:'
1Y==h
RS-48SL Is
6
7
8
9
1
11
1
1
1
1,
1
1
1
1
2
21
2
2
'@)LARG~~~~~~AY 2
164000-22900 i 1~1~6~40=0~0~-3021 0
164000-22200 SYS-ON 1 f-'M,"O",4"E-I'
(FR'-----+++--+-+-_ _--" HARNESS, EXT SLD : PANEL ASSY,
,164000-36710 RS-485H ~ M20 IY 1("AOOO-22910 3M
: NO CL
! 164000-29000 ! HARNESS, EXT :Buzzer, Alarm RS-485L 41 M: , (G
15400022920 511.1
IA[)AF'T~R,T~Rrv1INALj 164000-21710 1("AOOO-22930 10M

3M I
5M 1 RS-485 GND ~ M08E (BW HARNESS, WIRE PANEL
15400022990
154000-22940
15M
20M
1
CDENGINE IillEXTSTATION 16400022240 20M Cj)ENGINE ,----------~ @STBDENGINEI0NC)\lOII\IIUN 'CDENGINE ®NEXTSTATI(2N CDENGINE '®NEXTSTATIO
POWER M01 W M01 11 POWER POWER S M01 (W 1 POWER S POWER M01 W POWER POWERlf M01 0N MO'0N , POWER POWER If~
~ IE-sTOP )GND E-STOP !~'W4M~02~~====MM~'0~2~
N(:1:~1 E-STOP E-STOP S !~W4m~;::::::==========t:=t=t:=====t======~~~23 E-STOP S E-STOP !~t'!4M'~002Id~V===t::;::l-i===~2~A~~1 E-STOP ... M02 1BN
E-STOPr,,'.2 M02 INB ...
2 E-STOP E qOp ~~
BUP ACTIVE 1"'03 "03 LY BUP ACTIVE SUP ACTiVE S BUP ACTIVE S POW SVV i ~M"\A 'WI POW SW BUP ACTIVE 3 "03 3 BUP ACTIVE PO-\~'SW"',·3---'
;, 1"',03A(LY
1 v
S.!S~~~ SYS-o~fT i4' . ~. ;.•.~. C.W.\_,.~.L

VI IVI IVI
SYS-ON M04 WL 104 (WL 4 SYS-ON SYS-ON S 4 SYS ON S '"0" ,'"" 4 SYS ON M04 R M04 R 4 SYS-ON SYS-ON 4...5 A
.. ........
SYS-ON :WY 5 SYS-ON SYS-ONS :) SYS~ONS_CH~_C~ i IViUtl 5 CHECK SYSONFsJ~.r)Q§--(y- MQ§JY._ 5 SYS-ON CHECKtn.~06(BY
CAN GND 6 CAN GND CAN GND S 6 CAN GND S ,';;~~, ',.'07 'YO 6 CAN GND CAN GNDf'i- M06 (G MOG G, CAN GND CAN GND 16, M"
.. ',O.7.,O....[Y..R..
!C'Tf\DT~~::'~ ! ""v. ,'"' f\ 07{R ~ ~
'VD A
STARTr-?-MQZJR START
ST~6 7 ~~~T STA~~~ ~ ~~~TS GN~m M08 B TARTIST06~g~
. '" '"I
!""J>""",,vr 7 START/STOP GA M08 B 8 GND M08(BW
CAN POWER WBr ~ CANPOWER CANPOWERS vBr ~CANPOWERS CANPO~~~ iM09 VBr g~~POWER CANPOWE~~_ ~09 Br M09 Br_~__
CAN POWER CANPOWERr-g-iM09(WBr
J1 0 39H <--------, J19'l9H J19'l9H S , - - - - - - - - - i f--------, J1939H S J1939" J1939H J1939~~ ~~~ ~ 1 ~~~o ~ 10 J1939H J1 0 39H n--o~
2'Ai~' ',L~ :~: ~;'2A(B' :~ J1939L~~I;lg
J1939L
S"'ELD ,,, -'A
J1939L
S"'ELD
J1939LS
~ CD;~~~~~;TSr. _________S~
, ...............................•...................................... ,
_________________________
J1939LS J1939L
t,S~:_····_······_·····_·····_'_"'_'·'_C"_I1:'_J-':;CHIIE~E'L~[)D_~S_-_+j---"SflHII!OELl[D~1""'_c·················~~112;;I112Jcl~i~,~1 ".'.'."
J1939L J1939Li'1
"1'!.S~HiII'EClL~D_.l_---'S.fiH~IE'LILD~,l""I'2'srl'
, ........ M12(B '1 J1939L
·SA····L'2_S_"'_EL_D_~_ _S_"_IE_L_D--'~
~I~ Ih ~
il r~~~~~
'~I p~ i~wu
~
I [
..J74053-00ENOO
Type4 (2/4)
164000-30210
PANEL ASSY,NO CL I Service Tool
164000-51 040
, ; Display Assy, VC10-2
1
, "
164000-22900 1
, 0
HARNESS, EXT SLD °
f- ~ z
164000·22910
164000·22920
164000-22930
3M
5M
10M
1
,
1
,
~
~~
®!1!2!3!4!5M
a.
OJ °
~~
~) :1121314 U
5 6 7 8 [9 [10[11[12[
1164000-21570
;~
164000·22990 15M
ClQ
~iI~~
1 I
,
164000·22940 20M
~I~ HARNESS, HELM BOX B
1
(D ENGINE I ® NEXT STATION "'I~
M01('IV M01('lVh POWER POWER 1 M01 (W POWR, M011W
~A02(~ ~1Q2j~h E·STOP M02A(V F.Ston M021V
E·STOP 2 M03A (lY
~1Q:l('IV ~1Q:l('lVi3 BUPACTIVE BUP'dive E211lY
POW SW 3 M04 (Wl
~AD:4(r:< !\A04(r:<fi SYS·ON SYSON M041Wl
SYS·O N 4 M05A (WY
~1Q~CV: ~A05l'{is SYS-ON
M06(G M061G fi CAN GND A~H~~~ ~ MOB (BY 1 CAN GND MOS BY
f7
M07 (R
MOB (B GA
•
M07 (R
MOS (8 fi START
GND
C .
START/STOP SIN
GND ~
7 M07A YR
MOB BW
M09 WBr
1 Start
GND
M07B YR
MOS BW
M09 fBr M09 (Br ~ CAN POWER CAN Power M09 NVBr
M10 (l
M11fW
-
~
--- -
c-,
M10 (L ro J1939H
M11 IW:n J1939l
CAN POWER ~
~~~~~~ ~
M10 Y
M11 G
J1939H
J1939l
M10Y
M111G
~~ , ~SAM12 (8 :12 SHIELD SH~ELD l-~-_-? M12 B Shield M12 'B
SB
,
1
,
1
Ic;,6.~1,6.(1~(3~1?~~?~g9)ml
,
@~SYS.ON RElAY (W
M01C
~ : ~ M04B(Wl
i'"M04C (Wl
I[Q:~
M08A(BW
,[2
i'"M08E (BW
R01 (C
l@
!CA-1A (1 E691 0-82500) I

(24)START RELAY
Mn4CIWl
~ I~ M07B (YR
M08EIBW
) [3
~: . [4 E611YG
1
~ClJ
010
0",
~N
~~ :;:::;:w
LUI::;:;:
>
G~
NO)
0",
,,!
~
~I,
~
!E!~
(25JDIODE 1
fn:=31
;;0
!h ~I ~
~
W
'
[1J2J3J4J5J 6 7)8: 1 'c." ~ N
c_S2,
NM
z 5;C::C,9C\...C\...:':::: 0 0 N N MM
ww
'"
a. ~~(fj~~frl
OOZu)u)I
a W
11 [2[3[4[5[6 IsI91101111
W W
11321331341 !41 5 16 1819110[' 1[12[13[14[15[161

if) MCLqWWU
p :r:~
~ U~ ~ ~
Ii
t::: ~
!'i U!
Ii;
W
, ! 112 14151s1 [8 @ @
~ )1
--
164000-37010 I
I 164000-1 0000 I
I
PANEL, SWITCH I ! I
~
I Helm ECU I
I
--
--- -- --- -- ---
074054-00ENOO
Type4 (3/4) 164000-22950

HARNESS, EXT BU SLD ---------------------------------------------------~
;~~~~:~~~i~ 1~~ I
,
164000-30120 1
PANEL ASSY.BUP NO CL 1&1000-22980 20M I

1
®B/U P A N E L L - - - - - - - - - - - - ' ( D - ENGINE i (§)BUP

',. . . . . . . . .=-:. • • • •,.'• . '• • • •;.'• . '• • • • • i91'; 1~··1··T···B··CU···p·······················t··0::[1···, Y01 (IN Y01 (W'~=B·U····p·····p···O····W·····E···R········· '···B····U····p····p····O···W·c···E···R··· 0::1' y01(\V~r
jt----------o--
V ...................II
I
~+12
.........
3
BU STARTP I!,Y·;0:2,' (,R" ............................................. ;Y,:0:2',(CR. I 2
BUP STOP Yy 0
043 BLrI Y03 Br 3
BUP START
BUP STOP
BUP START 2 I,Y',:0:21 (:Y,.,R..........................................................................
BUP STOP 3 I_Y-"0"'3=V-----------_+--~
1
~-----+'--_H4 '"~T'''C' Y04 L 4 BUPACTIVE BUPACTIVE 4I_Y-"0,E4UhLY'----------~

~ 5 S T~~~~~ iI-Y'-'O"'s..\"G"'r_ _ _ _ _--'-""-""'--I YOS Gr
5 S TH LAMP SUB TH LAMP 5
YOS GrIN
"----------j~
.c,-l=l---j 8 S TH POWERSI-Y
±
'-'0"'-6l"V-------'-"'''-''--I Y06 V 8
6
7
S TH POWER S TH POWER 8
6
7
Y06fP
r ~_ _---j 9 S TH SIG9I-Y '-'0'-'-Y.cIG
"---------'-"-'--'-"-j Y07 G 9 S TH SIG S TH SIG 9
Y07 LQ
"-=:J----j10 S TH GNDiOI-Y'-'O""-S-"B'--------"'''''-'''-j Y08 B 10 Y08{Gr
STHGND STHRET 10
11 BUP SHIFT F1iI-Y '-'0C'9"'(Y'-------c'-"'Ci'-j Y09 Y 11 BUP SHIFT F 11
12 BUP SHIFT Ri2I-Y '--1"'0-'-O"'--_ _ _ _ _ _-'-'-''-'-''-j 12 Y10(O
BUP SHIFT R 12
~------~J----------'
z 6
°u
~ Hj~ ~
~ 12131415161
AFTER RUN LAMP (red)
@LAMP , @RESISTORx1-B
I~I L01A(WBr 680n !-"'LO,-,1--,(W=B__
rl___+__+_+_+++_jo
~~I i
1 .~ K}-l-'_-,L",02"",G,--===_ _ _..
/_, 164000-25700
164000-21570 HARNESS, EXT HD A
HARNESS, HELM BOX B 164000-25710 3M
164000-25720 SM
164000-25730 8M
Power M01 (W 164000-25740 10M
E-Stop M02 (V
BUP Active E21 (LY ,CD
.••.....E...N....G....I.N....E....A....Y........ T ............ ®= E......
C ......
U B...O
....X. I CD ENGI NE AY
M04(WL
~
SYSON BATTERY _ O::f-!"'M-"13=W'-'2--'_ _ _~~~="'M!l1"-3DW""2yl1 BATTERY-
--'_ _+-+_-l_--++--------_-------___j--+-_+++_+_l_------"'Y2"'2'-'I-"B-'-Y--!~ Main GND Main GND ~ Y22 G GB GS Y22 G il Main GND
--~==~~-=~--------++_-~-----~-------~-_+----~-+-+--H--------4-~l~-------+-+-++-~l-------~~~M~2~~~2~
CAN GND M06 BY ~~D~~2B mM" ~2B~~GND
Start M07B YR
GND
CAN Power
M08 BW
M09 WBr 14 ~" rs ~~I", ~!~;
NINI
41
ii
----"-'-'='''-~=-'-'---------___j-++_-~-----+_-----~-~-_+----~-+-+--H--------4-+_-~----+_-l_-__+_+++-------"''''11'''0-'-(Y'__i--;;--
J1939H M10 Y J1939H J1939H :--S- M10{L -, ~i~i M10fL -6-jJ1939H
----"-"="--""'-'-=-------___j-++_-~-----+_-----~-~-_+----I---+-+--H--------4-+_-~----+_-l_-__+_+++-------"·
J1939L M11 G 11,111 ~ --~--
",-,--,-,(G I J 1 9 3 9 LJ1"39L
" ,i 7--- M11 W
' SA M11W12
I Y32 W --!--1 J1939L .
-'-~_c~ "'('_'~'_'~_ _!~- ~- - ~~::~~ ~::~ ~~ ~ ~~::~~ ~::~ ~~ ~ f- -~-I-~-"L"';'-':'-'~ "-L"-;--+,_--i___-+._Y'-'3"'3.\.W"-'-13C"--j _~_-I ~~::~~ ~::~ ~~ ~
Shield M12 B
,-j_ _ _
,-j--+----"'Y~"'~'-'6"B-'-~-jh101 ~i-_~ y~~~v~: -~g1 Analog Main TH G
11?~f317=~1~fi9
Analog Main TH G Analog Main TH G Y06 W6 I I
1 L.-+++++_----'Y"'0,,7"'(Lji9-j12 ~~~ ~~~~~:: :~: ~lIbb~~o~~ ~ow ~I_Y..0,,7--'\..N;'-7--+---i---__+-c:'YY=00-=-87l:'(WW.'c87'--1~ ~~~ ~~~~~:: :~:
® RELAY START CONV (12V) YOS Gr ro e os ~ YOS W8 U I ~.,i
L.-++++_+_----=="-!131 Sub Throttle Ret Sub Throttle Ret fgl-"==--t!--+---+--'-"=-"'-1~ Sub Throttle Ret
~[1
~ ~
Start:I M07B (YR
Y31 (IN 14 Y31 (W11 ' Y31 (W11
~ 'P~~~~~:2018~~:B(WWt=:~t~==~=======~========~==t==~~--~ ,-----'-"-'--'--'-'-1"'151 Neutral Neutral ~
~
~156: Neutral
~
~~ ~I-'Y-"16'l(Y---L--+-+-+_
-'" ENGINE
+ ................ I········ +································+111
"00,,,12
1 + .......................•'."... vo.<.",.L''. :181 E-Stop E-Stop
117
M02 (W1
~
M02 (W1 181 E-Stop
Start c........ t t·····················································........... t································
Y17WVR
Y15A(Y
~ To Terminal To Terminal
I9 Y17(W10!!
Y15A(W9
Y17(W10~.
Y15A(W9011 To Terminal
1124617-91850 1 : ........................................! I················ t························ ! ........ +................................ t·····················································........... + ........................! ................................+ I································ + + ++11 ! ................. y;"'CCO'3;'; (:V,',!21 ~~~ ~;~p :~prts~~~ Y03 (W3 Y03 (W3 ~ ~~~ ;;~p
L~J--fil
~
@ RELAY SYS-ON CONY (12V)
SYS-ON
. GND 2.
I: M041WL
~~~~~~W
Y04 LY
Y05A G
~ BUP Active
Sub Th Lamp Sub Th Lamp 125
123
BUPActive ~ 1-"==_+_-+_--__+-'Y-"0"-41'W.":4'-j~ BU P Ac,ve
Y04 W4
YOSA W5 _ -----' 1 Y05A fW5 ~ Sub Th Lamp
23!
~2J Main Power 3 , 1 - " ' - " " - ' - " - ' - - - + - - - - - - - - - - - - - + _ - + - - 4
~ ~ _ _ _ _ _ _1 261
SYS-ON 127 1-""""'''--_+_--+-----'"M~0''-5.l.Y'-I27j SYS-ON
MOS Y
L~~From RSYS-ON ~ :I-Y-'-1>C8"IV'-'V-'-Y_ _ _+-_~~=~--~==~-+_-+--_+----l___+----L. Y01 WBr ~ ~ Y01 Br I 28i
i ' , Y18A(WY ~I-Y'-1...8..,B-'-(B..,Y--.-+-~---+----+--I--------------.... BUP Power BU.P Power ~~_~ 1-""'--''''--_+_--~----'-YO'C1'--'-''B'-Ir291 BUP Power
1124617-91860 1 ~ Y21 WL
' - - - - - + - - + - - - - - - - - - + - - ! - - - - - - + - - - - - - - I - + - I - - - ! - - + - ' - = - ' - ' ' - ' - ' ' - 1 : 3 0 1 Main Power Main Power [30 1-"'-'--''-'--_-!,_ _~----c:'Y'''2-'-1-''R'-j-~-~J Main Power
Y21 R
I
,
@RELAYCAN (24V) @ RESISTORx2-C I
c::::::::J--ii!CAN P 24V ~i'I-:Y-'-'2"'0";(W"-'Bf_ _ _+-------------+_-+-------l___+--------------+--_~------+_-----+++_+_l_-Y'-'2-"0.\.(,W=B--!'3'l111 CAN Power24V CAN Power 24V r::HI_Y-,,2",,0,-,(\W'-'-_-t'_ _- ,_ _ _-'-Y,o,20-'-)(C'.\W'-j-~-~] CAN Power 24V
Twin Disc
L==~=h--I ;:~rGND ______I--_ _ _ _ _ _ _ _ _ _ _ _- t _ 4_ _ _ _ _ _+-+_-------------~--4
-2-;f'A,,1_._2"'C.l(B CCJ
~~
'3! P 3 ,I_Y-'-1'-"9,,(W'-'----~
ower 6:
fj)TERMINAL
L'~51 CAN Power 5 '1_'...10",9"" (~\W"'B"-r_ _ _ __.-=;;_;_;;;;_===-==c_-~ ~ ~

, ' + A09A (Br ~f':A"'0"'9"'B"'(B'---<I'-_ _+-_____- t _ - t -_ _ _ _ _ _ _ _ _ _ _ _-+__---' ~ ~
@ RELAY BUP ACTIVE (24V) ~~ ti) l4

~ !~i3
,.., '@RESISTORx2-B i:s) (5
1L Main GND 2,I-Y -'-'2"'2-"C"B"-Y'---_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _+-_ _ _ _ _ _l _ _ _ + - - - - - - - - - - - - _ . . J
BUPAc,ve. [. .•. •1.•. •. •: Y04A LY
~~~
Vi" i>~E
~ lil
31f'A"'O'-'1"C"W'-'-_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _-" Y31 W 1'8< Neutral >'8}-------------------------------~
Powerii! '--__+-Y'-'3'.',2.\.R>eY
'-{9 Analog Main TH P ~>'9
'o--i--5- BUPActive 5~I-E='2'-'1"'(=-LY'--------.-=.-.--.=-----c=~=----------+---' L_ _+_-,y",3",3"G"'Y'_I'3 Al1alog Mail1TH S 11}---------------------------------j
h24617-91860 1 tA03~(LYf;;:~:i~03B(B\~J '----+-Y-'1~-"~"-"!'-'~-{,~~~~0;~a:~:~~ ~ ~::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::=::::::::::::::::::~, ______ _

074055-00ENOO
1. OVERALL SYSTEM 19
Type4 (4/4)
i -- - -- - -- - -- - -- - -- - -- - -- - -- - -- - -- - -- - -- - -- - -- - -- - -- - -- - -- - -- - -- - -- - -- - -- - -- - -- - -- - -- - -- - -- - -- - -- - -- - -- - -- - -- - cDE~;N-E-=-Y- --,
® ECU BOX ,1,"J~c::'E,-,Nc:G,,-1N"E=-:A-'-Y'---__~ __ _
I 11 BATTERY _ ~ M13 W2 M13 W2 BATTERY- hi
164000-30210 Y22 BY 21 Main GND Main GND !-Y-"2"2'-'I"'G_________________G=B_"G,..B'-------'Y-'2"-2,,G"-j~ Main GND
PANEL ASSY,NO CL M12 B jj Shield CAN GND M12 B M12 B ~ CAN GND
4i [4 tA~I~1 41
-----------------------"'''''-'c'-Is-l M10(y
J1939H
_______________________M=11,-"OG'-j -y-j J1939L
SI
J1939H fIf-""M-"1o"-,)(I"'Lc----j--
J1939L [f_
M11 {W I
__-_--
___- -----,"
~------------
~>" Ii ~+1______-'-M"-1"'0_'{=-jL fl J1939H
--"'-+----+
M11 W -Y--i J1939L
(j) ENGINE ® NEXT STATION
I_-_~_- ~~~ f:~~
Y32 fRY ----1
Y33 GY _~_j Analog Ma~n TH P Analog Main TH P Y32 fW12 a-j Analog Main TH P
--------~~~~~~~{W~B~~ POWER POWER i fl~,,,,,10,,,1_,{,,W,:-______________ rl----------~='--I_i:;1 Analog Main TH S Analog Ma.in TH S ~ Y33 W13 ~ Analog Main TH S
I 2 :~M,",O",2",A'l(V"-:-:-______________ rlrl----------Y"'~"~-"'6B"c;'-1~ Analog Main TH G
--------~M=0~3-'W"--I~ E-STOP
E-STOP
Analog Main TH G ~6: ~~4 I Y~~~V~: ~ Analog Main TH G
--------~M':V04='R~~ BU P ACTIVE POW SW I 3 ,~',",10",3",A'l(=-LY':-------------- ---------+-+-+----------cY-':O=7"-L"--19~ Sub Throttle Pow Sub Throttle Pow !11 !-:':':"-':'":"---+----------t-------!-------'-Y'C07':-':'W':'7C1~ Sub Throttle Pow
i 4 :~M,",04?('c'W:=L:-:-_____________
~~~:~ ~ ~~~ ~~~~!~: :~~
--------~M"'O':'5-"Y":-1~ SYS-ON SYS-ON ---------+-+-+----------:':''C-''='Y~ Sub Throttle Pos
CHECK I 5' M05A (WY ________-+-+-+-_________Y"'oo>s-'CG""r-i-.gj Sub Throttle Ret Sub Throttle Po: I Y08 W8
--------~M=O"'6-'G~~ SYS-ON
------"'\""1Q"'7J'C'F!-i~ CAN GND
CAN GND I 6 '~M,",O",6"(,,,BY,-:::-______________ subThrortleRe'~!Y31{W11 ! ! 'i41
STARTfSTOP SIN ; 7 ~ __ MQZPdYR_ Y31(W ~ ij
~A08(~ -fi START G N 0 !8iiV1Q~(B\V
~ Neutral Neutral ,,-;; I '" Y31 (W11 Neutral
iV1Q~(Br -%i ~~~ POWER CAN POWER 19',"A09(\V~r ~ ~' ~

1
iV1 Q(L1cj J1939H J1939H iTOi iV11QCV: M02 (V -:;oi E-Stop E-Stop M02 (W1 I M02 (W1 ~ E-Stop ENGINE
'~A\i(f~ ~ ~~~~~~ J1939L iTT,'\A 11(c;
SHIELD !T2iiV1 12(B Y17 (WR oii To Terminal
~
To Terminal
[i]
I ~;~i~v:~
I:
Y17(W10
~
~ Tonninal
________++-+-H______-'Y-'-1"'5A'-'-'Y-i21l StartSIG Start SIG Y15A (W9 1211 Start SIG
________-+-+-+-H________'_Y"'03=V-i~ BUP Stop
,
Y03fW3 __+-________
!22!-'-'==
BUP Stop ~
-+-______!--____-'Y,,03"-'-"W'-3'-j~ BUP Stop
231
BUPActive !24!-'-'==__+-________-+-______!--____-'Y,,04=W""4'-j~ BUP Active
Y04fW4 !
---------+-+-+-H-------'Y,,04=L'-'Y-i241 BUP Active
________++-+-H______-'-Y"'05~A~G'-j~ SubThLamp SubTh Lamp i25i-'-'~~~+----------+-------!------'Y~0~5A~IV'-V5'-j~SUbThLamp
~
Y05AfW5
_ _ _ _ _ _ ---.J
271 SYS-ON !271~J2j'L---t=~=-===+=='-------~MI()O~5D('Y'-j~j!

1
M05(Y •........................
SYS-ON
281 28 Y01 (Br
!
Y01 (Br 2s1
-_::::::::::::::~::~::t::~~::::::::::~Y~~i~1~{~~w~B~~}~1 3~!
BU: Power
Main Power
BUP Power
Main Power !30!-"'-'-""----~-----------'--------------'-Y'o2-'-1"-R'-j~_~J ~~~ :~::
Y21 {R
I
,
I
________-+-+-+-H______-'-Y2"O'-"(-",VW",B'-j:li] CAN Power 24V CAN Power 24V l21!31 !_Y,..2",0-,-
(\W'"----T L_' _________ ---jJ____________-'-Y2"O'j'(",IW'-ji:TIJ CAN Power 24V
Twin Disc
164000-25700
@TERJAINi\,L HARNESS, EXT HD A
1\ (1 16<1000-25710 3M
~~, ~~
16<1000-25720 5M
164000-25730 8M
164000-25740 10M
,--____________________-,-_®~2_=B:c!U'_'_PA_=N_=E"'L'__, (j) ENGI NE
~ ~
----~--_._-_!-i:i BUP POWER iTI Y-"O",1'-'{"W':-______________-"YO"-1,,(-"'W-i:f1 BUP POWER
I~I-2
, i BUP START ~ Y02 (R Y02 (R ~ BUP START
"---+____
Y31 (IN ~7)i Neutral ~\~
:~ BUP STOP 13 ' Y03 (Br Y03 (Br : 3 i BUP STOP -'Y,-,32"-'.':R"Y-{9 Analog Main Tf-l P g } _ - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - l
:
: : 4 BUP ACTIVE i 4: Y04 (L Y04 (L '4 I BUP ACTIVE "--__-+____ Y-"3"'3'-l{"G"-Y-t10 Analog Main TH S 101}_-------------------------------------------------------------------------;:
S TH LAMP 15 ' Y05 (Gr YOS (Gr : 5 i S TH LAMP "-------+-----Y-"3,.,4U{"'-BY'-{1.~AnaIOg Main T" G ~.11}--------------------------------------------------------------------------j
161 ~
Y17 A WR 1?) Key ON (24V) \121---------------------------------------------------------------------------",
m 171
S TH POWER !8i'1'Q~(\I '1'Q~(\I,~ S TH POWER
S TH SIG 19','1'OY(C; '1'QUC3I91 S TH SIG
S TH G N 0 iTOl'1'Q~(B '1'Q~(~hol S TH GN 0
BUP SHIFT F iTf,'1'09('1' 9
'1'0 ['1"111 BUP SHIFT F
BUP SHIFT R !i2:Y10 (0 Y10 {O :12; BUP SHIFT R
1164000~30120 164000-22950
! PANEL ASSY,BUP NO CL HARNESS, EXT BU SLD
164000-22960 5M
164000-22970 10M
164000-22980 20M
074056-00ENOO
1.4 List of Fuses and Location

Engine side
Drawing Name plate (seal) Fuse type Capacity Phenomenon when fuse is blown
Engine stop
30 A ECU 30A Cannot start the starter
No engine state indication
Fuse box Blade fuse VC10 Power OFF
15 A SYS 15 A
(Can use backup panel)
10 AACC 10 A Customer's instrument board and alarm panel are not showing
10 A BUP 10 A Cannot use the backup panel
ST C 80 A 80A Cannot start the starter
MIDI fuse
Relay box ALT B 150 A 150 A "Charging system error" (P1568) appears while running
- Blade fuse 10 A -
Fuse box Relay box
I"i5AI I"3iiAl
~~ FUSE
I"i"OAI I"i"OAI
I STC80A I "
~~
~
~~ IAlTB150AI /'
~~
148661.1)7711
1
~~
ve10 side
Drawing Name on marker tube Fuse type Capacity Phenomenon when fuse is blown
VC10 Power OFF
SYS FS FUSE 15 A Mini blade fuse 15 A
(Can use backup panel)
DC/DC
Drive ECU converter ECU box (option)
K: 9~ IR~~~Y I
o
"FUSE 15A"
indicated on a marker tube
0'73931-01ENOO
1.5 System Diagram

Connector 1 Engine ECU Connector 2
<? ¢
173 BAT 24V 1 INJECTOR 1 H 249
149 BAT 24V 2 Injector #1
125 BAT 24V 3 INJECTOR 1 L 273
101 BAT24V 4 INJECTOR 2 H 250
126 BAT24V 5
Stop SW on ENG Injector #2
VC10 system - - - - - - - - INJECTOR 2 L 274
INJECTOR 3 H 251
169 TERMINAL 15 Injector #3
StartSW INJECTOR 3 L 275
163 START SW
Stop SW INJECTOR 4 H 225
182 STOP SW Injector #4
INJECTOR 4 L 201
Emergency Stop SW
160 EMERGENCY STOP SW INJECTOR 6 H 226
(N/C or N/O)
Injector #6
INJECTOR 6 L 202
f-i---1>-::-..,.--<> o-..,.-..,.--:::-:-:----ii--t-H 111 SUB THROTTLE SELECT SW INJECTOR 5 H 227
Injector #5
INJECTOR 5 L 203
'---~~-------~-+~162SUBTHROTTLELAMP
r-+--'---+-+---i 192 ANALOG SUB TH SENSOR P

;c:-t-j--t-H-I178 ANALOG SUB TH SENSOR S
'--t--!--t-+-1157 ANALOG SUB TH SENSOR G
CANO <J1939> FUEL METERING Unit P 258
,To SA-D,LOP, VC10 Metering unit
1---<-':::=::;;;;"j-j-+-I-I146 CANO J1939 H FUEL METERING UNIT G 283
I, f-----<l--+--I-+-1147 CANO J1939 L
COOLANT TEMP SENSOR S 239
, Coolant temp sensor
ICAN Power COOLANT TEMP SENSOR G 242
,,_________
<1----'----,
J
r lJ OOIP-t---!-+-1119 STARTER INTERLOCK RELAY
'------+-1188 STARTER INTERLOCK RELAY

LUBE OIL PRESS SENSOR P 233
LUBE OIL PRESS SENSOR S 216 Lube oil press sensor
LUBE OIL PRESS SENSOR G 219
H----j150Af------if---l
RAIL PRESS SENSOR P 211
RAIL PRESS SENSOR S 236
RAIL PRESS SENSOR G 260
' - - - - - - - - i 138 CHARGE SIGNAL
FUEL TlP(FILTER OUT) SENSOR P 231 f-t----'::::I-
(Filter out)
FUEL TlP(FILTER OUT) SENSOR SP 2351--+---1 Fuel press
FUEL TlP(FILTER OUT) SENSOR ST 213 Itemp sensor
FUEL TlP(FILTER OUT) SENSOR G 2061~=~

Accessory Relay
CHARGE AIR TIP SENSOR P 207 ~!==:;!

rlIn1fIf'-t----t----------l150Accessory RELAY H
' - - ' = = - - - - - - - - - - - - - 1 193 Accessory RELAY L

CHARGE AIR TIP SENSOR SP 286 f-t---I Charge air press
. - - - - - - - - - - - - i 1 2 7 S W POWER Item p sensor
LOtem SW CHARGE AIR TIP SENSOR ST 237
"'---0 O - - - - - - - - i 158 LUBE OIL TEMP SW CHARGE AIR TiP SENSOR G 290 it!:===--.J
Coolant level SW
+---C>. 0 - - - - - - - 1 1 5 9 COOLANT LEVEL SW
LO filter SW CRANK SPEED SENSOR S 266 "'-0-=::1-
L - - - c r 0 - - - - - - - I 1 3 7 LUBE OIL FILTER SW
CRANK SPEED SENSOR G 265
103 GND 1
- 24V CAM SPEED SENSOR P 209
128 GND 2
CAM SPEED SENSOR S 280 Cam sensor
T Ba;: .-~~----I175GND3
CAM SPEED SENSOR G 278
105 GND4
ECU GND 152 GND 5
106415 - OOENOO
Power HelmECU Starter Relay
o 0
B9/B10 Power
B1/B2 GND Starter ON B 1 1 I - - - - - 4 -
~STARTSTOCPr_S-W--------~
q Ai Start/Stop
Lamp
SELSW
Check eng. indicator lanp B3
A8 Station select
SYNC lamp
NTRALSW
Synch ro lam p B6
A9 Neutral
Buzzer
Buzzer B4
Ai0 Trol NTRL lamp
Neutral SW lamp B5
Ai1 Synchro NEUTRAL lamp
Neutral lamp B13

TROL lamp
,.--------1 A28 Sensor 5V
Trol lamp B14
Throttle sensor 1-+-----------1 A23 Throttle SEL lamp
'------~ A34 Sensor GND Station selected lamp B12
Back up panel GND
CAN1-H A321---------------------. . CANi-H

A2i Back up signal CAN1-L A33 CAN1-L
I
(CAN1 Terminal adapter) A31 -----...1
CAN2(Local)-H A151----------------------I~ CAN2(Local)-H

CAN2(Local)-L A16 CAN2(Local)-L
CAN(Local)Terminal adapter A14
24- 1. OVERALL SYSTEM
Drive ECU
'"F------IB24 Battery (12/24V)
__-------1B25 Battery (12/24V)
o - l - - - e - - - - - - i B26 Battery (12/24V)
~----------------------------~B10GND
GND
~----------------------------4B11
L-----------------iB17GND
r--------1B7 NMEACAN 12V
NMEACable //------1B6 NMEACAN_GND
---------~---------j B12 NMEA CAN-H
'------jB13 NMEACAN-L
J1939 Communication Line B18 J1939 CAN-H
B19 J1939 CAN-L
1VB Backup mode SW

o o--::::c-------jA21 Backup mode SW input (SW input active high)
o-----lA20 Emergency stop SW (SW input active Low)
Emergency stop SW
1----------~A6 House battery input
House battery
f - - - - - - - - - - - i B 2 1 House Battery GND
. - - - - - - - - j A 3 4 Tank level sensor 1 (analog input resistive)
Level sensor . - - - - - - i A 3 3 Tank level sensor 2 (analog input resistive)
.--+-+-------1B1 Accesory sensor 5V

;:;:'::;;---IA8 Outside seawater temperature (analog input thermistor)
'------.-+--4I>----IB15 Accesory common GND

Shift valve (F)
'-------IC3 Shift_Forward+ (source output)
e_J • 01'-----IC4 Shift_Reverse+ (source output)

'--------IC20 Shift- (GND)
Gear oil press sensor i-----+---1A24 Gear oil presuure sensor (semiconductor analog input 0-5V)
.-----+-4II>-IB20 Gear/Engine common sensor 5V

Engine oil press sensor i----+----1A23 Engine oil presuure sensor Signal (analog input 0-5V)
'------4I...----IB9 Gear/Engine common GND
Alternatorf-----jA5 Charge 1 input (12/24V) (0-32Vrange)
.----IB8 Sensor5V
Sensor A17 Rudder angle position (0-5V)
B22 GND
106416 - OOENOO
2. PREPARING FOR FAILURE DIAGNOSIS - 25
2. PREPARING FOR FAILURE DIAGNOSIS
When there is something wrong with the engine, it is important to understand the situation, diagnose its cause, and
fix the error.
1.ln order to figure out the probable cause at occurrence, gather information for failure diagnosis.
1- Check the accurate symptoms of the failure.
2- Check the conditions before and after the failure.
3- Check the error code (DTC code).
4- Check the engine model and serial number.
5- Check the ECU model and serial number.
6- Check the configuration of VC1 0 engine control system. (Configurations differ depending on the options
applied.)
7- Check the history of the engine (Operating hours, repair, inspection, and maintenance service histories).
8- Check the history for the same error. If there is any, check its solution.
2. For failure diagnosis, you will need a special service tool: SA-D (SMARTASSIST-Direct).
Make sure you have the newest version of the software installed.
3. Prepare a tester to check the electric system.
26 - 3. OTROUBLESHOOTING OF ENGINE
3. OTROUBLESHOOTING OF ENGINE
3.1 DTC Code List

DTC code DTC description
DTC SPN FMI Content Reference
P0118 110 3 COOLANT TEMP SENSOR H RANGE
3.2.1
P0117 110 4 COOLANT TEMP SENSOR L RANGE
P0183 174 3 FUEL TEMP SENSOR H RANGE
3.2.2
P0182 174 4 FUEL TEMP SENSOR L RANGE
P018D 94 3 FUEL PRESS SENSOR H RANGE
3.2.3
P018C 94 4 FUEL PRESS SENSOR L RANGE
P1015 105 3 CHARGE AIR TEMP SENSOR H RANGE
3.2.4
P1016 105 4 CHARGE AIR TEMP SENSOR L RANGE
P0238 102 3 BOOST PRESS SENSOR H RANGE
3.2.5
P0237 102 4 BOOST PRESS SENSOR L RANGE
P0523 100 3 LUBE OIL PRESS SENSOR H RANGE
3.2.6
P0522 523552 4 LUBE OIL PRESS SENSOR L RANGE
P0193 157 3 RAIL PRESS SENSOR H RANGE
3.2.7
P0192 157 4 RAIL PRESS SENSOR L RANGE
P0123 91 3 MAIN THROTTLE SENSOR1 H RANGE
3.2.8
P0122 91 4 MAIN THROTTLE SENSOR1 L RANGE
P0228 29 3 SUB THROTTLE SENSOR H RANGE
3.2.9
P0227 29 4 SUB THROTTLE SENSOR L RANGE
U1305 459726 19 CAN THROTTLE SIGNAL ERROR Y-PM1
U1307 523633 19 SUB CAN THROTTLE SIGNAL Y-PM1
U0593 522596 19 CAN THROTTLE SIGNAL ERROR TSC1
U059C 523632 19 SUB CAN THROTTLE SIGNAL TSC1
3.2.10
U1304 459726 9 CAN COMMUNICATION ERROR Y-PM1
U1306 523633 9 SUB CAN THROTTLE COMMUNICATION Y-PM1
U0292 522596 9 CAN COMMUNICATION ERROR TSC1
U029B 523632 9 SUB CAN THROTTLE COMMUNICATION TSC1
P1341 522401 7 CAM SENSOR SIGNAL ANGLE OFFSET
P0341 522401 2 CAM SENSOR IRREGULAR SIGNAL 3.3.1
P0342 522401 5 CAM SENSOR NO SIGNAL
P0336 522400 2 CRANK SENSOR IRREGULAR SIGNAL
3.3.2
P0337 522400 5 CRANK SENSOR NO SIGNAL
P1004 523016 5 ACCESSORY RELAY OPEN CIRCUIT 3.4.1
P0817 677 5 START INTERLOCK RELAY OPEN CIRCUIT 3.4.2
P068A 1485 2 MAIN RELAY EARLY OPEN
3.4.3
P068B 1485 7 MAIN RELAY STUCK
P2530 522308 7 START SWITCH STUCK 3.5.1
P1005 522778 7 STOP SWITCH STUCK 3.5.2
P1568 167 1 CHARGING SYSTEM ERROR 3.5.3
P2560 111 1 COOLANT LEVEL LOW 3.5.4
3. OTROUBLESHOOTING OF ENGINE - 27

P1008 3359 0 LUBE OIL FILTER CLOGGING 3.5.5
P1019 175 0 LUBE OIL TEMP HIGH 3.5.6
POOOF 157 16 PLV OPEN 3.6.1
P1666 523469 0 PLV OPEN EXCEED SPECIFIED TIMES
3.6.2
P1667 523470 0 PLV OPEN EXCEED SPECIFIED HOURS
P0088 157 0 RAIL PRESS TOO HIGH
3.6.3
P1668 523489 0 PLV ERROR
P0094 157 18 RAIL PRESS DEVIATION ERROR L
3.6.4
P0093 157 15 RAIL PRESS DEVIATION ERROR H
P0627 633 5 FUEL PUMP OPEN CIRCUIT
P1645 522572 11 FUEL PUMP OVER LOAD
P0629 633 3 FUEL PUMP SHORT CIRCUIT VB-H
3.6.5
P1642 633 6 FUEL PUMP SHORT CIRCUIT GND-H
P1641 522571 3 FUEL PUMP SHORT CIRCUIT VB-L
P1643 522571 6 FUEL PUMP SHORT CIRCUIT GND-L
P1146 2797 6 INJECTOR BANK1 SHORT CIRCUIT
P0201 651 5 INJECTOR1 OPEN CIRCUIT
P1262 651 3 INJECTOR1 SHORT CIRCUIT
P0262 651 6 INJECTOR1 COIL SHORT CIRCUIT
3.6.6
P0217 110 0 COOLANT TEMP TOO HIGH 3.7.1
P0234 102 0 BOOST PRESS TOO HIGH 3.7.2
P1017 105 0 CHARGE AIR TEMP TOO HIGH
3.7.3
P1018 105 1 CHARGE AIR TEMP TOO LOW
P1014 100 0 LUBE OIL PRESS TOO HIGH 3.7.4
P1022 100 18 LUBE OIL PRESS TOO LOW 1
3.7.5
P1012 94 0 FUEL PRESS TOO HIGH 3.7.6
P1021 94 18 FUEL PRESS TOO LOW 1
3.7.7

P0168 174 0 FUEL TEMP TOO HIGH 3.7.8
P160C 158 0 BATTERY VOLTAGE TOO HIGH
3.7.9
P0560 158 1 BATTERY VOLTAGE TOO LOW
P0219 190 0 ENGINE OVER SPEED 3.7.10
P160F 522578 12 EEPROM ERROR MEMORY WRITE 3.8.1
P0601 630 12 EEPROM ERROR MEMORY DELETION 3.8.2
P160E 522576 12 EEPROM ERROR MEMORY READ 3.8.3
P1469 523473 12 ECU ERROR AD CONVERTER 1
3.8.4
P1613 522585 12 ECU ERROR CY146 SPI COMMUNICATION 3.8.5
P1473 523477 12 ECU ERROR ROM 3.8.6
P0611 523492 12 INJECTOR DRIVER1 IC ERROR
3.8.7
P1471 523475 12 ECU ERROR EXT MONITOR IC & CPU 1
3.8.8
P1474 523478 12 ECU ERROR SHUTOFF PATH 1
3.8.9
P1626 522744 4 ACTUATOR DRIVE1 SHORT CIRCUIT
P1633 522994 4 ACTUATOR DRIVE2 SHORT CIRCUIT 3.8.10
P1608 522588 12 SUPPLY VOLTAGE H RANGE
3.8.11
P1617 522589 12 SUPPLY VOLTAGE L RANGE
P1609 522590 12 SENSOR SUPPLY VOLTAGE1 ERROR
P1618 522591 12 SENSOR SUPPLY VOLTAGE2 ERROR 3.8.12
P1484 523488 0 ECU ERROR ENGINE SPEED RECOGNITION 3.8.13
3.2 Analog Sensor
3.2.1 COOLANT TEMP SENSOR

DTC SPN FMI Error detail
P0118 110 3 COOLANT TEMP SENSOR H RANGE
P0117 110 4 COOLANT TEMP SENSOR L RANGE
Sensor characteristics Wiring diagram

[0] 100000 Coolant temp sensor ECU
E239
~Sig o---QSig
E242 Com
il'!l
10000
~com VB 5V GND
i ").
1000
Sensor side connector harness
100 "i'
10 ! !! ! ! !! ! !
-40 -20 0 20 40 60 80 100 120 140
rOC]
069757 -0 °
,)J-I 0 0
DTC detect condition

DTC SPN FMI 1 - Detection, 2 - Judgment, 3 - Time to detect, 4 - Monitor panel
1. Not cranking
2. Output voltage: 4.8 V or higher
P0118 110 3
3.0.5 seconds
4. Displays "CHECK ENGINE"
1. Not cranking
2. Output voltage: 0.2 V or lower
P0117 110 4
3.0.5 seconds
Behavior at failure
Inside the engine ECU while operating: 70°C
Fail mode
Stopping: -15°C
Limited operation N/A
Fail release Automatically resumes 2 seconds after detecting 0.2 to 4.8 V sensor voltage
Remarks During the failure, the cooling water temperature is indicated "-"
Detail of trouble
• P0118: Open circuit of engine harness (Sig, Com)
Short circuit of engine harness (Sig - SSV, Sig - VB)
• P0117: Short circuit of engine harness (Sig - Com, Sig - GND)
• Sensor connector is not attached correctly
• Sensor failure
• Engine ECU failure
Corresponding flow chart
Yes
No
_____________________________ ~: _(~h_e_c!<~n.9_~i!h_ ~~::.~ ________________________ ,
No
Yes
Yes
No
Check re-occurrence
-==>,-Ye::::;s,,--_~ Check re-occurrence
No
Yes
3. Is sensor broken? Replace sensor
No
Yes
::::::>-.::.:...--~ Replace the harness
Make sure the failure does not re-occur, and finish.
0697S9-00ENOO
Corresponding procedures
o Checking the monitor panel

Check the detail of the failure indicated in the monitor panel. (Refer to P173 [4.1 Confirmation Way of DTC CodeD
D Checking with SA-O

1. Connect the SA-D. (Refer to P175 [4.2 Measurement Using SA-D (DTC Code, Sensor Output Voltage)])
2. Check DTC code.
3.lfthere is no DTC appearing, check the history of the DTC code.
4. Make sure that the sensor detection temperature is within the specific range. (Refer to P175 [4.2.3 Check the
sensor output physical value/voltage valueD
5. Make sure that the sensor voltage is within the specified range. (Refer to P175 [4.2.3 Check the sensor output
physical value/voltage valueD
B Checking the sensor

1. Turn off the power switch and the main switch.
2. Take off the coupler of the sensor.
3. Measure the resistance between the terminals of the sensor.
4.lf the resistance value is not within 70 Q to 45 kQ, replace the sensor.
D Checking the engine harness

2. Check the appearance of the engine harness, and replace if there is anything wrong with it.
3. Check the open circuit of the engine harness.
1- Remove the sensor and the engine ECU from the engine harness.
2- Measure the resistance of the engine hamess (Sensor terminal- Engine ECU terminal). (Refer to charts and drawings)
3-lfthe resistance value exceeds the specified range (O.L.), the hamess is open circuit. Replace the engine harness.
Measuring points Sensor side connector
DTC SPN FMI Terminal

ECU side connector 2
E239 - E239
====~~i_2 E_2_39~
P0118 110 3
E242 - E242
____
Note: The connector positions on the engine ECU side are
explained in P176 [4.3 ECU Connector Pin Arrangement]. ~~~-----iO
Measure resistance
4. Check the short circuit of the engine harness.
2- Measure the resistance of the engine harness (Between engine ECU terminals). (Refer to charts and drawings)
3-lf the resistance value is positive, the harness is short circuit. Replace the engine harness.
Measuring points
DTC SPN FMI Terminal ECU side connector 2
C=====~~39 E2~
E239 - E207 E239 - E231 E239 - E233
E239 - E209 E239 - E211 E239 - E249
P0118 110 3
E239 - E250
E239 - E227
E239 - E251
E239 - E226
E239 - E225
E239 - E258
Lo=J
Measure resistance
E239 - E242 E239 - E265 E239 - E278 0697S6-00ENOO
E239 - E206 E239 - E290 E239 - E219

P0117 110 4 E239 - E260 E239 - E273 E239 - E274
E239 - E275 E239 - E201 E239 - E203
E239 - E202 E239 - E283
Note: The connector positions on the engine ECU side are explained in P176 [4.3 ECU Con-
nector Pin Arrangement].
1:1 Replacing the engine ECU

3.2.2 FUEL TEMP SENSOR

P0183 174 3 FUEL TEMP SENSOR H RANGE
P0182 174 4 FUEL TEMP SENSOR L RANGE
[0]100000 I~:IT]:1;1:IrDITlIITIEFllITrDl Fuel press/

temp sensor ECU
10000111N.~'~1111t41111llllfttEl
E231
S5V S5V
E235
SigP SigP
.,... Sig_T
E213
Sig_T
1000. . . . . . . Com
E206
Com
VB GND
100lt!ijil1lli!llillllll""""'11t'!!n Sensor side connector harness T-=-

-40 -30 -20 -10 010 20 30 40 50 60 70 80 90 100110120130
10~~~~~~~~~~~~~~~U
[OC]
069760-00JAOO
~~~Q
\....~~V~.~~)
Com
~-I Sig_T
I
S5V
~Sig_P
069761-00ENOO

1. Not cranking
P0183 174 3
3.0.5 seconds
1. Not cranking
P0182 174 4
3.0.5 seconds
Behavior at failure
• Fuel temperature indication: -
Fail mode
• Inside the engine ECU while operating: Substitution value 40°C
Fail release Automatically resumes 2 seconds after sensor voltage detects 0.2 to 4.8 V
Remarks N/A
Detail of trouble
• P0183: Open circuit of engine harness (Sig_T, Com)
Short circuit of engine harness (Sig_T - SSV, Sig_T - VB)
• P0182: Short circuit of engine harness (Sig_T - Com, Sig_T - GND)
• Sensor failure
Yes
No
2. Checking with SA-O

r--------------------- ---------------------------------------------------------------------,
No
Yes
Yes
No
Check re-occurrence
::::::",Y<.:.:e,,",s,,--_~ Check re-occurrence
No
Yes
No
Yes
-=::::-----?>I Replace the harness
070472-00ENOO


2. Check DTC code.

4.lf the resistance value is not within 89 Q to 45 kQ, replace the sensor.

2- Measure the resistance of the engine harness (Sensor terminal- Engine ECU terminal). (Refer to charts and
drawings)
3-lf the resistance value exceeds the specified range (O.L.), the harness is open circuit. Replace the engine
harness.
====~rlE213
E213-E213
P0183 174 3
E206 - E206

explained in P176 [4.3 ECU Connector Pin Arrangement].
~------~()~--~--~j--------~
Measure resistance 06976:< OOENOO

2- Measure the resistance of the engine harness (Between engine ECU terminals). (Refer to charts and draw-
ings)
Measuring points
c:===~~~J
E213 - E231, E207, E233, E209, E211
P0183 174 3
E213 - E249, E250, E251 , E225, E226, E227, E258
E213 - E265, E278, E242, E206, E290, E219, E290
P0182 174 4
E213 - E201, E202, E203, E273, E274, E275, E283
Measure resistance
Note: The connector positions on the engine ECU side are explained in P176 [4.3 ECU Con- 069764-00ENOO
B Replacing the engine ECU

3.2.3 FUEL PRESS SENSOR

P018D 94 3 FUEL PRESS SENSOR H RANGE
P018C 94 4 FUEL PRESS SENSOR L RANGE
[Vj6 r----..,.------,-----, Fuel press!

temp sensor ECU
E231
S5V S5V
E235
SigP SigP
E213
Si9_T Si9_T
E206
Com Com
VB GND
T--1-
400 800 1200
[kPaj
069765 -OOJAOO
~~~Q
\...~ ~.V ~B)~)
Com
~-I Si9_T
~ ~
S5V Sig_P

1. Not cranking
2. Sensor output voltage: 4.8 or higher
P018D 94 3
3.0.5 seconds
1. Not cranking
2. Sensor output voltage: 0.2 V or lower
P018C 94 4
3.0.5 seconds
Behavior at failure
• Fuel temperature indication: -
Fail mode
• Engine ECU internal value: Switch to 7400 hPa
Fail release Automatically resumes 0.5 seconds after sensor voltage detects 0.2 to 4.8 V
Remarks N/A
Detail of trouble
• P018D: Open circuit of engine harness (Sig_P, Com)
Short circuit of engine harness (Sig_P - SSV, Sig_P - VB, SSV - VB)
• P018C: Open circuit of engine harness (SSV)
Short circuit of engine harness (Sig_P - Com, Sig_P - GND, SSV - Com, SSV - GND)
• Sensor failure
Yes
No
_____________________________ ~: _~h_e_c!<~n.9_~i!h_ ~~::.~ ________________________ ,
No
Yes
Yes
"-:::;::>'f<;..:e",s_ _.:;;.t Check re-occurrence
No
Yes
Replace sensor
No
Yes
Replace the harness
069767-00ENOO


2. Check DTC code.
4. Make sure that the sensor detection pressure is within the specific range. (Refer to P175 [4.2.3 Check the sen-
sor output physical value/voltage valueD
B Replacing the sensor

2. Replace the sensor.
3. Test operate to see if the failure is still regenerated. If the failure does not regenerate, the sensor is normal.

drawings)
harness.
harness face
P018D 94 3 E235 - E235 I E206 - E206
P018C 94 4 E231 - E231 I ======11E235
Note: The connector positions on the engine ECU side are explained in
P176 [4.3 ECU Connector Pin Arrangement]. '----{Of-------'
LI------"
Measure resistance 069768-00ENOO

ings)
Measuring points
C=:::j~31 E23~
E231 - E235, E249, E250, E251, E225, E227, E226, E258
P018D 94 3 E235 - E249, E250, E251, E225, E227, E226, E258
E235 - E207, E192, E233, E208, E167, E166, E209, E211
E235 - E265, E278, E242, E206, E290, E219, E260
E235 - E273, E274, E275, E201, E203, E202, E283
Lo=J
Measure resistance
P018C 94 4 06C;769-00ENOO
E231 - E265, E278, E242, E206, E290, E219, E260
E231 - E273, E274, E275, E201, E203, E202, E283
Note: The connector positions on the engine ECU side are explained in P176 [4.3 ECU Connec-
tor Pin Arrangement].

3.2.4 CHARGE AIR TEMP SENSOR

P1015 105 3 CHARGE AIR TEMP SENSOR H RANGE
P1016 105 4 CHARGE AIR TEMP SENSOR L RANGE
[0]100000 Charge air press!

temp sensor ECU
E207
10000 S5V S5V
E286
Sig_P Sig_P
1000
.,... Si9_T
E237
Si9_T
E290
Com Com
VB GND
...,.. ,.... ,....
100
T-:-
10 i ! i ! i i ! i ! i ! i i i i
·40 -30 ·20 ·10 10 20 30 40 50 60 70 80 90 100110120130
rOC]
Q~~~
"BV ~V \!j ~)
~~I
Com Si9_T
~ ~
S5V Si9_P
069771- OOENOO

1. Not cranking
P1015 105 3
3.0.5 seconds
1. Not cranking
P1016 105 4
3.0.5 seconds
Behavior at failure
• Displayed charge air temperature: -
Fail mode • Inside the engine ECU: Switch to 40°C while operating
Switch to -15°C while stopping
Fail release Automatically resumes 0.5 seconds after sensor voltage detects 0.2 to 4.9 V
Remarks N/A
Detail of trouble
• P1015: Open circuit of engine harness (Sig_T, Com)
Short circuit of engine harness (Sig_T - S5V, Sig_T - VB)
• P1016: Short circuit of engine harness (Sig_T - Com, Sig_T - GND)
• Sensor failure
Yes
No
_____________________________ ~: _~h_e_c!<~n.9_~i!h_ ~~::.~ ________________________ ,
No
Yes
Yes
No
Yes
No Check re-occurrence
Yes
Replace sensor
No
Yes
=:;::-----1 Replace the harness
069772-00ENOO


2. Check DTC code.

3. Measure the resistance between the 237 - 290 Pin terminals of the sensor.
4.lf the resistance value is not within 80 Q to 50 kQ, the sensor is broken. Replace the sensor.

drawings)
harness.
--[i2r_
E237 - E237
P1015 105 3 7
E290 - E290 _ _------'
Note: The connector positions on the engine ECU side are '------{Ol-------'
Measure resistance

ings)
Measuring points
C=====~~37 E20~
E237 - E207, E231, E233, E209, E211
P1015 105 3
E237 - E249, E250, E251, E225, E226, E227, E258
P1016 105 4
E237 - E265, E278, E242, E206, E290, E219, E290
E213 - E201, E202, E203, E273, E274, E275, E283
Lo=J
Measure resistance

3.2.5 BOOST PRESS SENSOR

P0238 102 3 BOOST PRESS SENSOR H RANGE
P0237 102 4 BOOST PRESS SENSOR L RANGE
[Vj6 Charge air press/

temp sensor ECU
E207
S5V S5V
./ E286
3 ./
V Sig_P
Si9_T
E237
Sig_P
Si9_T
/" Com
E290
Com
VB GND
V
o
o
r 1000 2000 3000 4000 5000
T-=-
[hPaj
069775-00Jp.OO
Q,~~~
\..~V ~V '\.!j ~)
Yi-I
Com SigT
~ ~
S5V SigP

1. Not cranking
P0238 102 3
3.0.5 seconds
1. Not cranking
P0237 102 4
3.0.5 seconds
Behavior at failure
• Displayed charge air pressure: -
Fail mode
• Inside the engine ECU: Switch to 2800 hPa while operating
Remarks N/A
Detail of trouble
• P0238: Open circuit of engine harness (Sig_P, Com)
Short circuit of engine harness (Sig_P - SSV, Sig_P - VB)
• P0237: Short circuit of engine harness (Sig_P - Com, Sig_P - GND)
• Sensor failure
Yes
No
, ___________________-_---.--_-_-__________________________ ~: _(~h_e_c!<~n.9_~i!h_ ~~::.~ ________________________ ,
No
Yes
Yes
No
Yes
No Check re-occurrence
Yes
Sensor failure
No
Yes
::::::-----l Replace the harness
069777-00ENOO


2. Check DTC code.


drawings)
harness.
harness face
E286 - E286
P0238 102 3
E290 - E290 =====:::jn ~86
explained in P176 [4.3 ECU Connector Pin Arrangement]. ~====~~O~-~~j----~

ings)
Measuring points
P0238 102 3
E286 - E207, E231, E233, E209, E211
.-----~~86 E20~
E286 - E249, E250, E251, E225, E226, E227, E258
E286 - E265, E278, E242, E206, E290, E219, E290
E286 - E201, E202, E203, E273, E274, E275, E283
Lo=J
Measure resistance
P0237 102 4 069779-00ENOO
E207 - E265, E278, E242, E206, E290, E219, E290

E207-E201, E202, E203, E273, E274, E275, E283
Note: The connector positions on the engine ECU side are explained in P176 [4.3 ECU Connector Pin Arrangement].
D Replacing the engine ECU

3.2.6 LUBE OIL PRESS SENSOR

P0523 100 3 LUBE OIL PRESS SENSOR H RANGE
P0522 523552 4 LUBE OIL PRESS SENSOR L RANGE
[kPaj 1000 Fuel press!

temp sensor ECU
800 E233
/
V S5V
E216
S5V
600 Sig Sig
400 ./ Com
E219
Com V}! G;:!p
/'
V T-:-
200
0.0
/' 2.0 4.0 6.0
[Vj
069780-00JAOO
Sig Com S5V

1. Not cranking
P0523 100 3
3.3 seconds
1. Not cranking
P0522 523552 4
3.3 seconds
Behavior at failure
• Lube oil pressure display: -
Fail mode
• Inside the engine ECU: 4700 hPa
Remarks N/A
Detail of trouble
• POS23: Open circuit of engine harness (Sig, Com)
Short circuit of engine harness (Sig - SSV, Sig - VB, SSV - VB)
• POS22: Open circuit of engine harness (SSV)
Short circuit of engine harness (Sig - Com, Sig - GND, SSV - Com, SSV - GND)
• Sensor failure
Yes
No
~- .. --
• _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ____________________________ ~: _~h_e_c!<~nit~i!h_ ~;:.:.~ ________________________ ,
No
Yes
Yes
No
Check re-occurrence
-=::",Y<.:..:e:::.:s,--_~ Check re-occurrence
No
Yes
Sensor failure
No
Yes
~>-----l>I Replace the harness



2. Check DTC code.


drawings)
harness.
P0523 100 3
E216-E216 D ECU side connector 2
E219-E219
P0522 522352 4 E233 - E233

ings)
Measuring points
C=====~~16 E20~
E216 - E207, E231, E233, E209, E211
P0523 100 3
E216 - E249E250, E251, E225, E226, E227, E258
P0522 100 4
E216 - E265, E278, E242, E206, E290, E219, E260
E216 - E201, E202, E203, E273, E274, E275, E283
Lo=J
Measure resistance
E233 - E265, E278, E242, E206, E290, E219, E260 069784-00ENOO
E233 - E201, E202, E203, E273, E274, E275, E283


3.2.7 RAIL PRESS SENSOR

P0193 157 3 RAIL PRESS SENSOR H RANGE
P0192 157 4 RAIL PRESS SENSOR L RANGE
[MPa] 250 Rail press sensor ECU

E211
200
S5V S5V
/' Sig
E236
Sig
150 V E260
I'
100 Y Com Com
VB GND
T~
50
%
Y "" Sensor side connector harness
~©~~
o
o
y=c, r
[V]
OO~TAOO
e~
Com Sig S5V

1. Not cranking
P0193 157 3
3.0.2 seconds
4. Displays "CHECK ENGINE" "DERATE MODE"
1. Not cranking
P0192 157 4
3.0.2 seconds
Behavior at failure
Fail mode N/A
Limited operation Engine speed: 1100 min- 1 or lower. Limited injection amount.
Fail release Does not resume automatically (Wait 10 seconds after switching off the power)
Remarks N/A
Rail press sensor failure PLV (Rail pressure limiting valve) open
Fully pump fuel from PLV

Normal operation
the high pressure pump Open operation mode
Nole: P1666 (Number of opening limes of PLV > 50 limes) }

or Replace PLV
P1667 (PLV open> 5 hours)
0697S7-00ENOO
Detail of trouble
• P0193: Open circuit of engine harness (SSV, Sig, Com)
Short circuit of engine harness (SSV - Sig, SSV - Com, SSV - VB, SSV - GND)
• P0192: Short circuit of engine harness (Sig - Com, Sig - GND)
• Sensor failure
Yes
No
• _________________________-_-_- __________________________ ~. _~h_e_c~Ln.9-"'~i~h_ ~~:.Q. ________________________ ,
No
Yes
Yes
Yes
Check for re-occurrence
No
Yes
Sensor failure
No
Yes
Replace the harness
Make sure the failure does not re-occur when running the engine, and finish.
069788-00ENOO


2. Check DTC code.


drawings)
harness.
harness face
P0193 157 3
E211 - E211 I E236 - E236
E260 - E260?
P176 [4.3 ECU Connector Pin Arrangement]. 069789 -OOENOO

ings)
3-lf there is no resistance value, the harness is short circuit. Replace the engine harness.
Measuring points
.-----~~07 E23~
E236 - E207, E231, E233, E209, E211
P0193 157 3
E236 - E225, E226, E227, E249, E250, E251, E258
P0192 157 4
E236 - E260, E265, E278, E242, E206, E290, E219
E236 - E201, E202, E203, E273, E274, E275, E283
Lo=J
Measure resistance

3.2.8 MAIN THROTTLE SENSOR (ANALOG)

P0123 91 3 MAIN THROTTLE SENSOR1 H RANGE
P0122 91 4 MAIN THROTTLE SENSOR1 L RANGE
Wiring diagram
-----------------------------~
Accelerator VCi0 harness : Engine harness ECU

I
8 E166
S5V o-----u S5V S5V S5V S5V
Sig 9 Sig Sig Ei79 Sig
Sig 0 - - - - 0
Com 0 - - - - 0 Com Com Com Ei80 Com

VB GND
VCi0 system
Engine harness_ECU side connector

Engine harness_VCi0 side connector 06C;791-00ENOO

1. N/A
P0123 91 3
3.0.5 seconds
4. Displays "MAIN THROTTLE"
1. N/A
P0122 91 4
3.0.5 seconds
4. Displays "MAIN THROTTLE"
Behavior at failure
Depends on the condition of the throttle.
1. Main throttle is valid (Sub throttle invalid)
Fail mode Engine speed gradually changes to low IDLE
2. Main throttle is invalid (Sub throttle valid)
Does not perform the failure
Limited operation Engine speed: 450 min- 1 or lower.
1. When main throttle is valid
• 0.2 V < Sensor voltage < 4.8 V
Fail release • Operation is valid when target speed: low IDLE
2. When main throttle is invalid
0.2 V < Sensor voltage < 4.8 V
Remarks N/A
Detail of trouble
• P0123: Open circuit of engine harness (Com)
Short circuit of engine harness (SSV - Sig, Sig - VB, SSV - VB)
• P0122: Open circuit of engine harness (SSV, Sig)
• Throttle sensor (VC1 0 system) error
Yes
No
• ____________________-_-_-_____________________________ ~: _~h_e_c!<~n.9_~i!h_ ~~::.~ ________________________ ,
No
Yes
Yes
Yes
No
Yes
Replace the harness
No
Yes Replace the failed

part of VC1 0 system
069792-00ENOO


2. Check DTC code.
4. Make sure that the sensor voltage is within the specified range (0.2 to 4.8 V).

1- Remove the VC1 0 harness and the engine ECU from the engine harness.
2- Measure the resistance of the engine harness (VC1 0 terminal- Engine ECU terminal). (Refer to charts and
drawings)
harness.
Measuring points VC10 harness side connector
Terminal ECU side connector 1

DTC SPN FMI
Engine ECU side VC10 side
P0123 91 3 E180 10
E179 9
P0122 91 4
E166 8
06979J-OOENOO
P176 [4.3 ECU Connector Pin Arrangement].

ings)
Measuring points
C=====~~92 E17~
E179-E166,E192
P0123 91 3 E166 - E101, E125, E126, E149, E173, E127
E179 - E101, E125, E126, E149, E173, E127
E166-E180,E157
Lad
Measure resistance
E179-E180,E157
P0122 91 4
E166 - E103, E105, E128, E152, E175
E180 - E103, E105, E128, E152, E175
D Checking the throttle

Make sure there is nothing wrong with the throttle (VC1 0 system).

3.2.9 SUB THROTTLE SENSOR/BACKUP PANEL (ANALOG)

P0228 29 3 SUB THROTTLE SENSOR H RANGE
P0227 29 4 SUB THROTTLE SENSOR L RANGE
Wiring diagram
Sub throttle VC10 harness Engine harness ECU

11 E192
S5V S5V S5V S5V S5V
12 E178
Sig Sig Sig Sig Sig
Com Com Com Com E157 Com
VB GND
Backup panel
Engine harness_ECU side connector

Engine harness_VClO side connector

1. N/A
P0228 29 3
3.0.5 seconds
4. Displays "SUB THROTTLE"
1. N/A
P0227 29 4
3.0.5 seconds
4. Displays "SUB THROTTLE"
Behavior at failure
1. During operation by backup panel/sub throttle
• Engine speed decelerates to 1000 min- 1 , and stays at 1000 min- 1
Fail mode
2. During normal operation by main throttle without using backup panel/sub throttle
• Operates displays "SUB THROTTLE" normally without failing
1. During operation by backup panel/sub throttle
• Fix engine speed to 1000 min- 1
Limited operation
2. During normal operation by main throttle without using backup panel/sub throttle
• Does not perform the failure. Normal operation (No limited operation)
After fixing the failure and the sub throttle is back to normal, turn OFF the power switch once, and
Fail release
then turn it back ON after about 10 seconds
1. Failure during operation by backup panel/sub throttle
• Sub throttle operating knob is invalid, and engine speed is fixed to 1000 min- 1
• Unless clutch is operated, engine speed is fixed to 1000 min- 1
• When engaging the clutch:
Remarks
Engine speed switches to low idle in neutral gear, and the clutch is engaged
Then, the engine speed is fixed to 1000 min- 1
2. When an alarm is indicated during normal operation by main throttle, immediately reset failure
at returned port
Detail of trouble
• Sub throttle (backup panel) is abnormal
• P0228: Open circuit of engine harness (Com)
Short circuit of engine harness (Sig - SSV, Sig - VB, SSV - VB)
• P0227: Open circuit of engine harness (SSV, Sig)
Yes
No
Yes
Yes
-=:::::>Y<:..::ec::s_ _~ Check re-occurrence
No
Yes
-=::::>---~ Replace backup panel
No
Yes
::::;::,.:.='----3>1 Replace the harness
069796 -OlENOO


2. Check DTC code.
DChecking the sub throttle (Backup panel)

2. Check the resistance of the sub throttle of the backup panel.
1- Remove the VC1 0 harness and the backup panel.
2- Turn the sub throttle knob a little to measure the resistance between the terminals of the backup panel.
(Refer to charts and drawings)
3-lf the resistance value exceeds the specified range (OL), the harness is open circuit, and if it is 0 Q, the har-
ness is short circuit. Replace the backup panel.
Measuring points
DTC SPN FMI Terminal 65432 1
Short circuit 1 - 8, 1 - 9, 8 - 9 000000
P0228 29 3
Open circuit 9 -10 000000
Short circuit 8 - 10,9 - 10
P0227 29 4 7 8 9 10 11 12
Open circuit 10-11
3. Test operate to see if the failure is still regenerated. If the failure does not regenerate, the backup panel is nor-
mal.
4. Check the appearance of the VC1 0 harness, and replace if there is anything wrong with it.
5. Check the open circuit of the VC1 0 harness.
1- Remove the VC1 0 harness from the engine harness.
2- Turn the sub throttle knob a little to measure the resistance of the VC1 0 harness (between the terminals on
the VC1 0 side). (Refer to charts and drawings)
3-lf the resistance value exceeds the specified range (O.L.), the harness is open circuit. The harness is short
circuit if it is 0 Q.
Replace the VC1 0 harness.
Measuring points
Terminal
11 -12
12 -13
13-11
Measure resistance
OIENOO

2- Measure the resistance of the engine harness (VC1 0 terminal- Engine ECU terminal). (Refer to charts and
drawings)
harness.
Measuring points VCi0 harness side connector
DTC SPN FMI
Engine ECU side VC10 harness side
P0228 29 3 E157 11
E178 12
P0227 29 4
E192 13
Note: The connector positions on the engine ECU side are explained in 069797-00ENOO

ings)
Measuring points
'------I~LoJ~
E178-E192,E166
P0228 29 3 E178 - E101, E125, E126, E149, E173, E127
E192 - E101, E125, E126, E149, E173, E127
E192 - E157
Measure resistance
E178 - E157 069794 - OOENOO
P0227 29 4
E192 - E103, E105, E128, E152, E175, E180
E178 - E103, E105, E128, E152, E175, E180
[:JReplacing the engine ECU

3.2.10 CAN THROTTLE SENSOR

U1305 459726 19 CAN THROTTLE SIGNAL ERROR Y-PM1
U1307 523633 19 SUB CAN THROTTLE SIGNAL Y-PM1
U0593 522596 19 CAN THROTTLE SIGNAL ERROR TSC1
U059C 523632 19 SUB CAN THROTTLE SIGNAL TSC1
U1304 459726 9 CAN COMMUNICATION ERROR Y-PM1
U1306 523633 9 SUB CAN THROTTLE COMMUNICATION Y-PM1
U0292 522596 9 CAN COMMUNICATION ERROR TSC1
U029B 523632 9 SUB CAN THROTTLE COMMUNICATION TSC1
Wiring diagram
AGG fus.,,-e-EO~A3-_-[~~~J
1
VG10 system r Battery+
Accelerator VG10 harness Engine harness EGU

GAN_P 0 - - - · 0 GAN_P
GANO Hi ( ) - - - - { GANO Hi u--.=.c....",----u GANO Hi
GANO Lo 0 - - - - 0 GANO Lo u--.=.c....,;,--u GANO Lo
Engine harness_EGU side connector

Engine harness_VG10 side connector 069793- OOENOO

U1305 459726 19 1. Power switch ON
U1307 523633 19 2. Engine ECU receives throttle error message
U0593 522596 19 3.0 seconds
4. For U1305 and U0593, it displays "MAIN THROTTLE"
U059C 523632 19
U1304 459726 9 1. Power switch ON
U1306 523633 9 2. Detect CAN reception timeout for a certain amount of time
U0292 522596 9 3.0.2 seconds
4. Engine data indication disappears ("-" is indicated for speed, temperature, etc.)
U029B 523632 9
Behavior at failure
• Gradually changes its target speed to low idle
Fail mode
• Forcibly shifts to neutral
• Backup panel is valid: Operation by backup panel/sub throttle
Limited operation
• Backup panel is invalid: Speed is lower than low idle
• U1305, U1307, U0593, U059C: Throttle value is within 0 - 102.2 % and throttle is abnormal
Fail release Resumes after 0 seconds from receiving a message saying "bit = 0 (Inactive)"
• U1304, U1306, U0292, U029B: Resumes after 0.2 seconds from receiving "Y_PM1 message"
Remarks N/A
CANO failure occur Sub throttle valid
Rotational speed ~ Low idle

Normal operation Engine operation available
Shiflto Neutral
069799--00ENOO
Detail of trouble
• U130S and U1307: Throttle (VC10 system) error
Noise interruption on CAN communication line
Connecting harmful external equipment to CAN communication line
• P1304 and U1306: Open circuit of engine harness (CAN Hi, CAN Lo)
Short circuit of engine harness (CAN Hi - CAN Lo)
Short circuit of VC1 0 harness
No
No
Yes
Yes
U1305, U1307
U1304, U0593,0292 A
U1306, U029B, U059C
Yes
Change the setting of throttle type
Yes
Replace the engine harness
Yes
Replace the VC1 0 harness
Yes
Replace or inspect VC1 0 system
Make sure the failure does not re-occur after investigation, and finish.
075194-00ENOO
Yes
Fix noise
No
Yes
How to connect external equipment
Yes
Replace the VC1 0 system
No
Make sure the failure does not re-occur after investigation, and finish.
075195-00ENOO


2. Check DTC code.
D Checking the setting of throttle type

1. Connect SA-D, and check the throttle type.
2. Make sure it is the adequate type (Throttle type: 2, VC1 0).

2- Measure the resistance between terminals (VC10 side terminal - Engine ECU side terminal)
(VC10 side terminal - Accessory relay side terminal) (Refer to charts and drawings)
harness.
Measuring points
Terminal Terminal
Engine ECU side VC10 side Relay side I VC10 side
E146 6 B021 I 31
E147 7
VC10 harness side connector VC10 harness side connector Accessory relay
l====~nEt46 E147
~~~()r--~--~j--------~
069802 -OOENOO
OOENOO

ings)
Measuring points
Harness Terminal
Engine
VC10
E146-E147
(6) - (7)
.------~46 E14]

1=0=1
Measure resistance
069804-00ENOO
B Checking the VC10 harness

Make sure there is nothing wrong with VC1 0 harness connecting to the throttle.
11) Checking the VC10 system

Make sure there is nothing wrong with the throttle sensor (VC1 0 system).
o Replacing the engine ECU

Replace the engine ECU.
D Checking the wiring (Noise interruption on can communication line)

Make sure that the VC1 0 harness is attached with the designated method.
(Make sure other system harness, generator, or power line is nearby.)
D Checking for harmful external connection equipment using the CAN communication
1. Remove the equipment that uses CAN communication but that is not set as YANMAR default.
2.Again turn ON the main switch and the power switch.
If no error is detected, then the abnormal signal is generated by the removed equipment.
mAbnormal signal from CAN transmitter

Make sure there is nothing wrong with the throttle sensor (VC1 0 system).
3.3 Crank/Cam Sensor
3.3.1 CAM SENSOR

P1341 522401 7 CAM SENSOR SIGNAL ANGLE OFFSET
P0341 522401 2 CAM SENSOR IRREGULAR SIGNAL
P0342 522401 5 CAM SENSOR NO SIGNAL
Wiring diagram
Cam sensor ECU Sensor side connector

harness
E209
S5V S5V
E280
Sig r' ) Sig
Com y E278
? Com VB GND
I~ Com Sig S5V

069806-00ENOO
069805--00ENOO

1. Crank sensor is normal
2. Phase difference with the crank is larger than 30°
P1341 522401 7 Otherwise a value smaller than _20° is detected for certain times (2 times)
3.0 seconds
2. While the crank turns for a certain time (4 times), the sensor detects the number
P0341 522401 2 of cam pulse or the incorrect position
3. Crank 2 turns
2. No cam pulse input while the crankshaft rotates for a certain time (2.2 turns)
P0342 522401 5
3. Crank 2.2 turns
Behavior at failure
P0341: Invalidate cam signal during operating state
Fail mode P0342: Backup cam control by calculating during start
P1341: N/A
Fail release Resumes when normal signal is detected
Remarks N/A
Detail of trouble
• Open circuit of engine harness (Sig, Com, SSV)
• Short circuit of engine harness (SSV - Sig, SSV - Com, SSV - VB, SSV - GND, Sig - Com, Sig - VB, Sig - GND)
• Attaching failure of cam sensor connector
• Sensor failure
• Metal powder is attached
Yes
No
- _____________________________ ~: _~h_e_c~~nil_":'i~h_ ~~:.t:?

• ____________________-_-__ ________________________ ,
No
Yes
Yes
No
Yes
~---~ Replace the harness
Test and make sure the failure does not re-occur, and finish.
069807-00ENOO

Check the detail of the failure indicated in the monitor panels while idle operation. (Refer to P173 [4.1 Confirmation
Way of DTC CodeD
f) Checking with SA-O

2. Check DTC code.
D Replacing the sensor

2. Remove the sensor and check for metal powders on the sensor part. Clean them if there is any.
3.lf not, replace the sensor.


E209 - E209
I E209 - E280
E278 - E278 I
Measure resistance
Measuring points
Terminal
E209 - E280, E278, E1 01, E125, E126, E149
E209- E173, E103, E105, E128, E152, E175
(Example 1) ECU side connector 1 (Example 2) ECU side connector 2
~ =-h, .-----~9 E28~
:::::====~~
Em
E209
Me"",,
=t1 rn,;,ta"~ 1=o=l
ECU side connector 2 0753S8-00ENOO

3.3.2 CRANK SENSOR

P0336 522400 2 CRANK SENSOR IRREGULAR SIGNAL
P0337 522400 5 CRANK SENSOR NO SIGNAL
Wiring diagram
Crank sensor ECU Sensor side connector

harness
Sig o----.::E;;:.26:..;6,--O
E265
Corno----O
069810-00ENOO
069811- OOENOO

1. Cam sensor is normal
2. Detects a certain amount of abnormal pulse (25 times)
P0336 522400 2
3.0 seconds
4. Displays "CHECK ENGINE", "DERATE MODE"
1. Cam sensor is normal
2. No crank pulse input while the cam rotates for a certain time (2 turns)
P0337 522400 5
3. Cam 2 turns
Behavior at failure
Fail mode Continues operation by cam sensor
Limited operation Engine speed: 1500 min- 1 or lower, limited injection amount
Fail release N/A (After resuming from rail release, wait 10 seconds after switching off the power)
Remarks N/A
Detail of trouble
• Open circuit of engine harness (Sig, Com)
• Short circuit of the engine harness (Sig - Com, Sig - VB, Sig - GND, Com - VB, Com - GND)
• Attachment failure of crank sensor connector
• Foreign matter is adhered to the sensor detecting part
• Sensor failure
No
No
Yes Yes
No
Yes
Contamination
Yes
Sensor failure
Yes
Replace the harness
0752B4-00ENOO

Way of DTC CodeD

2. Check DTC code.
D Checking the flywheel process hole

1. Check the pulse process hole in the flywheel.
2. Remove sludges.
D Replacing the sensor

2. Remove the sensor and check for metal powders on the sensor part. Clean them if there is any.
3. If not, attach the sensor.
B Checking the engine harness


E265 - E265 E266 - E266


n
Measuring points (Example 1) ECU side connector 1
Terminal
U
=ti
E265 - E266 E265 - E101 E265 - E125 E173 Measure
:::::====:::j~
E265 - E126 E265 - E149 E265 - E173
E265 - E103 E265 - E105 E265 - E128 E265 ,,,;,1.0"
E265 - E152 E265 - E175
(Example 2) ECU side connector 2
o Replacing the engine ECU ~--~~5 E2~

Lad
Measure resistance 069814 -OOENOO
3.4 Relay (Contact Output)
3.4.1 ACCESSORY RELAY

P1004 523016 5 ACCESSORY RELAY OPEN CIRCUIT
Wiring diagram
Battery
Fuse
10A
B020
E150 Accessory relay

+
ECU
Main switch Fuse
30A E193 Power switch

1. N/A
2. Detects when power is turned from OFF to ON after open circuit of accessory
P1004 523016 5 relay
3.1 second
Behavior at failure
Fail mode N/A
Fail release After 1 second detected resume from accessory relay open circuit
Remarks N/A
Detail of trouble
• Accessory relay error
• Open circuit of engine harness
Yes
No
• ___________________-_-___-_-_- __________________________ ~: _~h_e_c~~nfl_~i!h_ ~~:.~ ________________________ ,
No
Yes
Yes
No
Check re-occurrence
Yes
Relay failure
No
Yes
-=:::"";"':-'--~ Replace the harness
069816-00ENOO

Way of DTC CodeD

2. Check DTC code.
D Replacing the relay

2. Replace the relay.
3. Turn ON the power switch and see if the failure is still regenerated. If the failure is regenerated, the failure is
occurring in a different place.
Accessory relay wiring
8020 ---+-{ }--!--- E021

Accessory relay r---+--- E193
124617-91860 -~T-l:~~~
"L--+_ _ E150
8020 E193
069817-00ENOO
D ~
~~ 8021 E150
069S18-00XOO

3. Remove the engine ECU from the engine harness. (Relay is attached)
4. Measure the resistance of the engine harness (Between engine ECU terminal side E150 - E193). (Refer to
charts and drawings)
Relay side connector
1-----~~50 E19~
Lo=J
Measure resistance
069819-00ENOO
5. If the resistance value exceeds the specified range (O.L.), the harness is open circuit.
Replace the engine harness.

3.4.2 START INTERLOCK RELAY

P0817 677 5 START INTERLOCK RELAY OPEN CIRCUIT
Wiring diagram
Start signal ....--::

- - - u 0------1 Starter relay
Hi o-E~1~1~9__________- .
ECU
La? E188
069S20-00ENOO
'--------------'

1. Power switch ON
2. After power is switched ON, start interlock relay is open circuit
P0817 677 5
3.1 second
Behavior at failure
Fail mode N/A
Fail release Resumes 1 second after the open circuit is fixed
Remarks N/A
Detail of trouble
• Failure of start interlock relay
Yes
No
• ___________________-_-___-_-_- __________________________ ~. _~h_e_c~~n.\l_~i~h_ ~~:~ ________________________ ,
No
Yes
Yes
Yes
Relay failure
No
Yes
-=::::>-=-=---~ Replace the harness
069821-00ENOO

Way of DTC CodeD

2. Check DTC code.
D Replacing the start interlock relay

1. Replace the start interlock relay.
2. Turn ON the power switch. If the failure is regenerated, the failure is occurring in a place other than the relay.
;;'
T~~ijj~ -,
8020 ---+-< }--!--- E163
Start interlock relay r - - - t - - - E188
124617-91860
Wr:IT""~-
I / -~-----ftl:J:\.-. j
i
'---+-- E119
8020 E188
\~
~wl
bzl
1"1
H .~!~I .~I~:
D ~~
E163 E119
072881-00ENOO
069822-00XOO

3. Remove the engine ECU from the engine harness. (Relay is attached)
4. Measure the resistance of the engine harness (Between engine ECU terminal side 119 - E188). (Refer to charts
and drawings)
Relay side connector
1------~~19 E18~
Lo=J
Measure resistance
5. If the resistance value exceeds the specified range (O.L.), the harness is open circuit.

3.4.3 MAIN RELAY

P068A 1485 2 MAIN RELAY EARLY OPEN
P068B 1485 7 MAIN RELAY STUCK
Wiring diagram
Fuse
Battery 150A
ECU
Power switch
+ T15 GND
Main switch E101, 125, 126,149,173
VB -----<:Ji0----
I
GND
Fuse
30A VB --lSI- GND
069824-(lOENOO

1. Power switch OFF (DTC code appears by turning ON the power switch after the
error)
2. Cut engine ECU power without after-run (EEPROM writing failure)
P068A 1485 2
x 2 times
3.0 seconds
1. Start engine --> Power switch OFF --> After-run
2. Main relay does not open 150 ms after engine ECU shut-off (After-run)
P068B 1485 7
3.0 seconds
Behavior at failure
Fail mode N/A
P068A: After run complete (EEPROM writing succeeded)
Fail release
P068B: Detects the opening of the main relay
Remarks N/A
Detail of trouble
• P068A: After turning OFF the power switch, the main switch turns OFF within approx. 10 seconds
• P068A: Engine ECU forced shutdown by 30 A fuse blown
• P068A, P068B: Engine ECU failure
Yes • The main switch is off right

after the power switch is OFF.
• Battery terminal is loose.
No

~------------------------ ---------------------------------------------------- ---------~
Yes Main relay is sticking

-> 4. Replace ECU
No
I I
~------------------------ ------------------------------------------------------ -------~
Yes Charge battery, and

tighten connection.
No
06982S-00ENOO
o Checking the DTC code at operation check

1. Turn OFF the power switch and wait for 10 seconds or more.
2. Turn OFF the main switch.
3. Turn ON the main switch and the power switch.
4. If the DTC code is off, after turning OFF the power switch, the main switch may have been cut off.
o Checking with SA-D

1. Turn only the main switch ON, and then connect the SA-D in the power OFF state.
(See P175 [4.2 Measurement Using SA-D (DTC Code, Sensor Output Voltage)] for the connecting layout.)
2.lf the connection and login is successful, the main relay in the engine ECU is fail (sticking).
(If the power switch is OFF but the power turns on, the ECU main relay is sticking.)
D Checking the battery state and connection

1. Check the battery charge. If 18 V or below, charge up to 24 V.
2. Make sure there are no loose parts or damage on the connecting terminal from the battery to the engine ECU.

3.5 Switch (Contact input)
3.5.1 START SWITCH STUCK

P2530 522308 7 START SWITCH STUCK
Wiring diagram
r----------------,
I Start switch I
I I
I I
I
I
I
I
I
I I
~----------------~
E163
VC10 system

1. Power switch ON
2. After starting the engine ECU, the start switch is kept ON from the start of moni-
P2530 522308 7 toring the starter signal
3.1 second
Behavior at failure
Fail mode The starter may move at the moment when the power switch is ON
Fail release After stopping the starting signal (power stop to E163), resumes immediately
Remarks N/A
Detail of trouble
• Sticking of start switch
• Short circuit of VC1 0 harness
• Short circuit of engine harness
Yes
Yes
Yes Replace the

switch or system
No
Yes
Replace the harness
No
Yes
Replace the harness
Yes
Check the system
069827-00ENOO

Way of DTC CodeD

1. Connect the SA-D. (Refer to P17S [4.2 Measurement Using SA-D (DTC Code, Sensor Output Voltage)])
2. Check DTC code.
D Checking the start switch

2. When the start switch is OFF, measure the resistance between terminals of the switch.
3. The switch is sticking if there is resistance.
If measuring is not possible, go on to D.
DChecking the VC10 harness

3. Remove the VC1 0 harness from the engine harness.
4. When the start switch is OFF, measure the resistance of the 21 Pin - 30 Pin of the VC1 0 harness connector.
5. The VC1 0 harness is short circuit if there is resistance. Replace the harness.
(Overview: If the check of D is not possible, the switch may be sticking so replace the switch itself as well.)
VC10 system Connector
Start switch
Stop switch
Power switch
etc.
06C;828-00ENOO
o Checking the engine harness

3. Remove the VC1 0 harness and measure the resistance between engine ECU connectors. (Refer to illustration
and chart)
4. It is short circuit if there is resistance. Replace the harness.
Measuring points
Terminal
E163-E101, E125, E126, E149, E173, E166, E192, E179, E178, E169, E162, E150
E163-E207, E231, E233, E209, E211, E225, E226, E227, E249, E250, E251, E258
C==[:63 E1:J
c:====G63
1=0=1 ~-~-~f-s~-~-~~-e----l
Measure resistance
.-----~~
E2_0_7________~
__
OChecking the VC10 system

Make sure there is nothing wrong with the VC1 0 system.

3.5.2 STOP SWITCH STUCK

P1005 522778 7 STOP SWITCH STUCK
Wiring diagram
lJ=~~_ _ _ _ :~\--s~-;:-:r~~::-t::W:-::-!'-Ch---E-18-2-9~~S~to_p-_~sw~~--II
: Stop switch :~ Battery
+ - -TJr-'
1-1
VC10 system (Engine) ECU 069830--00ENOO

1. N/A
2. After starting the engine ECU, the stop switch is kept ON from the start of moni-
P1005 522778 7 taring the stop signal
3.1 second
Behavior at failure
Fail mode Cannot start engine ("STARTER INTERLOCK" is displayed)
Fail release Immediately resume after the engine ECU detects that the engine stop switch is OFF
Remarks N/A
Detail of trouble
• Sticking of stop switch
• Short circuit of engine harness
• Short circuit of VC1 0 harness
• Failure of VC1 0 system
Yes
Yes
Yes
Replace the switch
Yes
=>----1 Replace the harness
Yes
=>----1 Replace the harness
Yes
Check the system


Turn ON the main switch and the power switch, and then check the detail of the failure indicated in the monitor
panel. (Refer to P173 [4.1 Confirmation Way of DTC CodeD

2. Check DTC code.
DChecking the stop switch

2. When the stop switch is OFF, measure the resistance between terminals of the switch.
3. The switch is sticking if there is resistance.
If measuring is not possible, go on to D.
DChecking the engine harness

3. Remove the VC1 0 harness and measure the resistance of the engine ECU connectors.
4. It is short circuit if there is resistance. Replace the harness.
Measuring points
Terminal
E182-E101, E125, E126, E149, E173, E166, E192, E179, E178, E169, E162, E150
E182-E207, E231, E233, E209, E211, E225, E226, E227, E249, E250, E251, E258
C==~82 E1:J
,-----G82
~ ~-~-e:-~-~~-~e-ce---'
Measure resistance
,-----~~_E_2_0_7 ______ ~
069S?2-00ENOO
o Checking the VC10 harness

4. When the start switch is OFF, measure the resistance of the 22 Pin - 30 Pin of the VC1 0 harness connector.
5. The VC1 0 harness is short circuit if there is resistance. Replace the harness.
D
(Overview: If the check of is not possible, the switch may be sticking.)
VC10 system Connector
Start switch
Stop switch
Power switch
etc.
069833-00ENOO
[lJChecking the VC10 system

Make sure there is nothing wrong with the VC1 0 system.

3.5.3 CHARGING SYSTEM ERROR

P1568 167 1 CHARGING SYSTEM ERROR
Wiring diagram
Battery
Starter Fuse Alternator ECU

150A
? ?
¢B B¢
Si
E138
+
EJ l Sig
069834- OOENOO

1. Engine speed: 425 min- 1 or higher
2. Charging signal from alternator to engine ECU stops
P1568 167 1
3. 10 seconds
4. Displays "CHARGING SYSTEM"
Behavior at failure
Fail mode N/A
Fail release Resumes after 10 seconds from charging signal restart
Remarks N/A
Detail of trouble
• Wiring failure
• Alternator - Fuse (150 A) fusing
• Alternator malfunction
Yes
Yes
Yes
Replace the fuse
Yes
Repair the wiring
Yes
::::;:::,-----l Replace the harness
Yes
Alternator rnalfunction


Way of DTC CodeD

2. Check DTC code.
DChecking the fuse

1. Make sure that the relay box fuse 150 A is not fusing. (Refer to figure)
2. Make sure the wiring to the B terminal of the alternator is not open circuit or short circuit.
Relay box Fuse 150 A
(0 1111111 0) 069836-00XOO
DChecking the wiring

1. Make sure the Battery - Battery cable are properly wired.
2. Make sure the Starter B terminal - Alternator B terminal are properly wired.
3. Make sure the engine harness and the alternator connector part are properly wired.
1:1 Checking the engine harness

3. Remove the connector of the alternator and the engine ECU from the engine harness.
4. Measure the resistance between the engine harnesses (Alternator side connector terminal - Engine ECU side
connector terminal). (Refer to illustration and chart)
5.lf the resistance exceeds the specified range, the harness is open circuit. Replace the engine harness.
Measuring points Alternator side connector
rr:r___
Terminal
E138- E138 E169 - E169 E 169
Note: The connector positions on the engine ECU side are _ _ ---,
<-------lQl----'-
III Replacing the alternator Measure resistance 069838-00ENOO

2. Replace the alternator.
3.Again turn ON the main switch and the power switch.
4. Make sure that the DTC code appears. If it does not appear, the alternator may be broken.

3.5.4 COOLANT LEVEL LOW

P2560 111 1 COOLANT LEVEL LOW
Wiring diagram
Water level switch ECU
0-- P SW P SW
~CWlV-SW )-=-':"':"::'-0 CWlv SW
VB S5V GND
069839-00ENOO

1. Power switch ON
2. Water level switch ON
P2560 111 1
3. 15 seconds
4. Displays "LOW COOLANT LEVEL"
Behavior at failure
Fail mode N/A
Fail release Turn OFF water level switch, and resume after 15 seconds
Remarks N/A
Detail of trouble
• Dropping level of cooling water
• Cooling water is leaking
• Water level switch is broken
• Damage or short circuit of engine harness (CWLv_SW - VB, CWLv_SW - SSV)
Yes
Yes
Yes
Add cooling water
Yes
Seal the said part
No
Yes
Replace the switch
Yes
:::::>----1 Replace the harness
Make sure the failure does not re-occur while operating, and finish.

Way of DTC CodeD

2. Check DTC code.
DChecking the cooling water amount

1. Check the cooling water tank when the engine is cool.
2. Check the amount in the cooling water tank and the sub tank, and then add cooling water.
DChecking the leakage of the cooling water

Check for water leaks via the cooling water passage, and then repair if there is any leakage.
o Checking the water level switch

1. Replace the water level switch. (Replace the cooling water tank when the engine is cool.)
2. Check the DTC code when operating the engine. If it does not appear, the switch may be broken.
[lJChecking the engine harness

3. Remove the VC1 0 harness and measure the resistance between engine ECU connectors. (Refer to illustration
and chart)
4. It is short circuit if there is resistance. Replace the engine harness.
Measuring points
C:===~~59
E159- E101 E159 - E125 E159 - E126
E159- E149 E159 - E173 E159 - E166 E10J
E159- E192
E159- E169
E159 - E179
E159 - E162
E159 - E178
E159 - E150
L=o=J
Measure resistance
Note: The connector positions on the engine ECU side are 069841-00ENOO

3.5.5 LUBE OIL FILTER CLOGGING

P1008 3359 0 LUBE OIL FILTER CLOGGING
Wiring diagram
ECU
0-- P_SW P SW
~Oil Filter SW )-=-':"':"::'-0 Oil Filter SW
VB S5V GND
069842 - OOENOO

1. N/A
2. Lube oil filter switch is ON (Filter pressure: 290 kPa or over)
P1008 3359 0
3. 10 seconds
Behavior at failure
Fail mode N/A
Fail release Immediately resume when lube oil filter switch is OFF
Remarks N/A
lube oil filter pressure> 290 [kPa] lube oil filter pressure> 590 [kPa]
Normal operation Normal operation

Normal operation
(Alarm indication) (Forcibly discharge lube oil)
069843-00ENOO
Detail of trouble
• Lube oil filter is clogged
• Failure of pressure regulating valve
• Degradation of lube oil
• Short circuit of engine harness (Oil_Filter_SW - VB, Oil_Filter_SW - SSV)
• Sensor failure
Yes
Yes
Yes
Replace cartridge
Yes
Replace lube oil
No
Yes
Replace the switch
No
Yes
Replace the harness
No
Yes Replace the pressure

regulating valve


Way of DTC CodeD

2. Check DTC code.
DChecking the lube oil filter

1. Check the lube oil filter, and replace if it is clogged.
2. Filter replacing time: Replace after 500 hours.
!9Replacing the lube oil

1. Check the operating time from the last replacement time of lube oil.
2. For standard oil pans, oil change is required with diesel operation: every 500 hours
with A heavy oil operation: every 250 hours
For wavy oil pans, oil change is required with diesel operation: every 300 hours
OChecking the lube oil filter switch

2. Measure the resistance of the lube oil filter switch.
The switch is sticking if there is resistance. Measure
resistance
3. Replace the lube oil filter switch.
OChecking the engine harness 07S190-00ENOO

3. Remove the switch and the engine ECU from the engine harness.
4. Measure the resistance between engine ECU connectors. (Refer to illustration and chart)
5. It is short circuit if there is resistance. Replace the engine harness.
Measuring points
Terminal
Ei37-Ei0i, Ei25, Ei26, Ei49, Ei73, Ei66, Ei92, Ei79, Ei78, Ei69, Ei62, Ei50
Ei37-E207, E23i, E233, E209, E2ii, E225, E226, E227, E249, E250, E25i, E258
.-----~37 E1~ c====G37
1=0=1 ~-~-e~-~-~~-~e-ce-----'
Measure resistance
C====~~_E_20_7 ______ ~
069846- OOENOO
o Inspection and checking the pressure regulating valve

III Replacing the engine ECU
3.5.6 LUBE OIL TEMP HIGH

P1019 175 0 LUBE OIL TEMP HIGH
Wiring diagram
lube oil temperature ECU

switch
069847 - OOENOO

1. N/A
2. Lube oil temperature switch is ON (Lube oil temperature: Exceed 100 ± 3°C)
P1019 175 0
3.1 second
Behavior at failure
Fail mode N/A
Resumes immediately after lube oil temperature switch is OFF
Fail release
(Lube oil temperature: Within 90 ± 3°C)
Remarks N/A
Detail of trouble
• Cooling water system is broken
• Lube oil cooler is broken
• Damage or short circuit of engine harness (Oil_T_SW - VB, Oil_T_SW - SSV)
• Sensor failure
2. Checking wilh SA-O
Yes
Yes
Yes Troubleshoollhe
cooling water system
No
Yes
Replace the switch
No
Yes
Replace the harness
No
Yes Check the lube

oil cooler


Way of DTC CodeD

2. Check DTC code.
D Checking the cooling water system

1. Make sure the following failures are not occurring at the same time.
2. If so, solve them first.
Rising of cooling water
P0217 110 0
temperature
P2560 111 1 Cooling water level is low
DChecking the switch

2. Measure the resistance of the lube oil temperature
switch. The switch is sticking if there is resistance. Measure
resistance
3. Replace the lube oil temperature switch.
o Checking the engine harness

3. Remove the switch and the engine ECU from the engine harness.
4. Measure the resistance between engine ECU connectors. (Refer to illustration and chart)
Measuring points
'----1~LoJJ
E158- E101 E158 - E125 E158 - E126
E158- E149 E158 - E173 E158 - E166
E158- E192 E158 - E179 E158 - E178
E158- E169 E158 - E162 E158 - E150
Measure resistance
Note: The connector positions on the engine ECU side are 069849 -OOENOO
OChecking the lube oil cooler

1. Inspect and check the lube oil cooler.
2.Clean or replace parts if there is clogging.

3.6 Common Rail System
3.6.1 PLV (RAIL PRESSURE LIMITING VALVE) OPEN

POOOF 157 16 PLV OPEN
Rail press sensor

072770-00ENOO

1. N/A
2. PLV is open
POOOF 157 16
3.0 seconds
Behavior at failure
Fail mode N/A
Fail release Engine speed: Resumes immediately when 400 min- 1 or lower
Remarks N/A
PLY: Open Actual rail pressure?: 175 MPa
PLY
Normal operation Engine stop
Open operation mode
Note: P1666 (Number of opening times of PLY > 50 times) }

or Replace the PLY
070409-00ENOO
Detail of trouble
• Rail press sensor system error • Fuel filter is clogged
• Fuel high pressure pump physical error • Abnormality of injector system
• Fuel leak • Engine ECU failure
• Fuel high pressure pump circuit error
Yes
No
• _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ____________________________ ~. _~h_e_c~~nfl_,,!:i!h_ ~~:.C? ________________________ ,

~-~
No
Yes
Yes
Yes
Check with other OTC codes
No
Yes
Check piping
No
Yes
Replace fuel filler
No
Yes
PLVfailure
No
Yes
::::::>------~ Fuel high pressure pump failure 1------1
070410-00ENOO

Way of DTC CodeD
f) Checking with SA-D

2. Check DTC code.
D Checking the other DTC codes

1. Make sure that other DTC code appears.
2.lf so, there may be a chance that the main DTC code (POOOF) appears as well.
Deal with the other appearing DTC code first, and then operate the engine.
D Checking the fuel leak

1. Check the pipings to make sure there is no fuel leakage.
2. Repair if there is ant leakage.
o Fuel filter is clogged

1 . Replace the fuel filter.
2. Operate the engine. If no DTC code appears, the fuel filter may have been clogged.
(1) Replacing the PLV

1. Replace the PLV.
2. Operate the engine. If no DTC code appears, the PLV may have been clogged.
DSeeing if replacing the fuel high pressure pump helps.

1. Replace the fuel high pressure pump.
2. Operate the engine. If no DTC code appears, the fuel high pressure pump may have been broken.

3.6.2 PLV (RAIL PRESSURE LIMITING VALVE) OPEN EXCEED SPECIFIED TIMESI
OPEN EXCEED SPECIFIED HOURS
P1666 523469 0 PLV OPEN EXCEED SPECIFIED TIMES
P1667 523470 0 PLV OPEN EXCEED SPECIFIED HOURS

1. N/A
2. Number of opening times of PLV is 50 or more
P1666 523469 0
3.0 seconds
1. N/A
2. Opening time of the PLV is 5 hours or more (total)
P1667 523470 0
3.0 seconds
Behavior at failure
Fail mode N/A
Fail release N/A (After resuming from the failure history reset by SA-D)
Remarks N/A
PLY: Open Actual rail pressure?: 175 MPa
PLY
Open operation mode
Nole: P1666 (Number of opening limes of PLY > 50 times) }

or Replace the PLY
070409-00ENOO
Detail of trouble
• Fuel high pressure pump circuit error • PLV error
Yes
No
• _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ____________________________ ~: _~h_e_c~~nil_,,:,i~h_ ~~:.t:? ________________________ ,
~---
No
Yes
Yes
Yes
Check with other OTC codes
No
Yes
Check piping
No
Yes
Replace fuel filler
No
Yes
PLVfailure
Yes
::::::>-'-'-----~ Fuel high pressure pump failure [ - - - - 1
9. Reset the failure history, make sure PLV does not open, and finish.

Way of DTC CodeD

2. Check DTC code.

2.lf so, there may be a chance that the main DTC code appears as well.


(1) Replacing the PLV

1. Replace the PLV.
2. Operate the engine. If no DTC code appears, the PLV may have been broken.
DSeeing if replacing the fuel high pressure pump helps.


D Reseting the failure history, and making sure PLV opens again
1. Use SA-D to delete the failure history.
2. Operate the engine, and check the DTC code.
3.6.3 RAIL PRESS TOO HIGH

P0088 157 0 RAIL PRESS TOO HIGH
P1668 523489 0 PLV ERROR
Rail press sensor

072770-00ENOO

1. Rail press sensor is normal
2. Rail pressure: 175 MPa or lower
P0088 157 0
3.1 second
2. Rail pressure while PVL is open: 160 MPa or lower
P1668 523489 0
3. 10 seconds
Behavior at failure
Fail mode Open PLV
P0088: Engine speed is 1100 min- 1 or lower, limited injection amount
Limited operation
P1668: Engine stop
Fail release N/A (Engine ECU reset)
Remarks N/A
PLY: Open Actual rail pressure?: 165 MPa (P1668)
PLY
Open operation mode
070412-00ENOO
Detail of trouble
• Fuel high pressure pump circuit error
Yes
No
• _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ____________________________ ~: _C::h_e_c~~n~_~i~h_ ~~:.E? ________________________ ,

-~---
No
Yes
Yes
Yes
Check piping
No
Yes
Add fuel
Yes
Rail press sensor failure
Yes
Replace filler
No
Yes
:::::::-------')1 Fuel high pressure pump failure 1-----1

070413 - OOENOO

Way of DTC CodeD

2. Check DTC code.

2.lf so, there may be a chance that the main DTC code appears as well.


OSeeing if replacing the rail press sensor helps.

o Seeing if replacing the fuel high pressure pump helps.

DReplacing the engine ECU

3.6.4 RAIL PRESS DEVIATION ERROR

P0094 157 18 RAIL PRESS DEVIATION ERROR L
P0093 157 15 RAIL PRESS DEVIATION ERROR H
. I
Fuel high pressure pump Rail press sensor
072770-00ENOI

2. Actual rail pressure keeps the target rail pressure +20 MPa or higher for a cer-
P0094 157 18 tain period of time (10 seconds)
3. 10 seconds
2. Actual rail pressure keeps the target rail pressure -20 MPa or higher for a certain
P0093 157 15 period of time (30 seconds)
3. 30 seconds
Behavior at failure
Fail mode N/A
Limited injection amount (75 % of the original limited amount).
Limited operation
Engine speed may drop while operating.
Fail release N/A (Engine ECU reset)
Remarks N/A
Detail of trouble
• Fuel high pressure pump physical error • Lack of fuel
• Fuel leak • Abnormality of injector system
• Fuel high pressure pump circuit error • Engine ECU failure
Yes
No
• _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ____________________________ ~: _~h_e_c!<~n11_~i~h_ ~~::.~ ________________________ ,
~----
No
Yes
Yes
Yes
3. Is fuel leaking? Check piping
Yes
Add fuel
No
Yes
Rail pressure sensor failure
No
Yes
Replace filter
No
Yes
Fuel high pressure pump failure
070414 - OOENOO

Way of DTC CodeD

2. Check DTC code.

D Checking the fuel in the fuel tank

Check the remaining amount of fuel.
o Replacing the rail press sensor

I.l.J Clogging of the fuel filter

o Replacing the fuel high pressure pump

I]Replacing the engine ECU

3.6.5 FUEL HIGH PRESSURE PUMP

P0627 633 5 FUEL PUMP OPEN CIRCUIT
P1645 522572 11 FUEL PUMP OVER LOAD
P0629 633 3 FUEL PUMP SHORT CIRCUIT VB-H
P1642 633 6 FUEL PUMP SHORT CIRCUIT GND-H
P1641 522571 3 FUEL PUMP SHORT CIRCUIT VB-L
P1643 522571 6 FUEL PUMP SHORT CIRCUIT GND-L
Fuel high pressure pump Electric wiring
Metering unit ECU
MET_P r' E258 MET_P
C MET_G
r' E283 MET_G
VB GND
r~
072820-00ENOO

1. N/A
2. Detects open circuit of the metering unit drive circuit
P0627 633 5
3.0.01 seconds
1. N/A
2. Detects abnormal heat from open circuit of the metering unit drive circuit
P1645 522572 11
3.0.3 seconds
1. N/A
2. Metering unit drive circuit (MET_P) and VB short circuit are detected after turn-
P0629 633 3 ing OFF the power switch
3.0.3 seconds
4.N/A
1. N/A
2. Metering unit drive circuit Hi side (MET_P) and GND short circuit are detected
P1642 633 6
3.0.1 seconds
1. N/A
2. Metering unit drive circuit Lo side (MET_G) and VB short circuit are detected
P1641 522571 3
3.0.01 seconds
1. N/A
2. Metering unit drive circuit Lo side (MET_G) and GND short circuit are detected
P1643 522571 6
3.0.01 seconds
Behavior at failure
P0629: N/A
Fail mode
P0627, P1645, P1642, P1641, P1643: Follow below chart
P0629: N/A
Limited operation P0627, P1645, P1642, P1641, P1643:
Engine speed/11 00 min- 1 or lower. Limited injection amount.
P0629: Power switch ON
Fail release P0627, P1645, P1642, P1641, P1643:
After resuming from the failure, wait 10 seconds after switching off the power.
Remarks N/A
PLY: Open Actual rail pressure ~ 175 MPa
PLY
Open operation mode
Nole: P1666 (Number of opening limes of PLY > 50 limes) }

or Replace the PLY
070409-00ENOO
Detail of trouble
• P0627: Open circuit of engine harness (MET_P, MET_G)
• P1645: MPROP circuit failure
• P0629: Short circuit of engine harness (MET_P - VB)
• P1642: Short circuit of engine harness (MET_P - GND)
• P1641: Short circuit of engine harness (MET_G - VB)
• P1643: Short circuit of engine harness (MET_G - GND)
• Attachment failure of metering unit (actuator) connector
• Failure of metering unit (actuator)
Yes
No
_____________________________ ~: _~h_e_c~~n.\l_~i~h_ ~~::.~ ________________________ ,
No
Yes
Yes
Yes
Replace the harness
No
Yes
Replacing the metering unit
No
Yes
=::::>-=-=---?>I Fuel high pressure pump failure
No
070416-00ENOO

Way of DTC CodeD

2. Check DTC code.
DChecking the open circuit/short circuit of engine harness

2. Check the appearance of the engine harness, and replace if there is anything wrong with it. Replace the engine harness.

E258 - E258
P0627 633 5
E283 - E283 E258
Measure resistance
1- Remove the metering unit and the engine ECU from the engine harness.
(Example 1) ECU side connector 1 (Example 2)
~--I----. ..........------' Measure

c===~~58 E2~
~
-.-r------'..J--I---, resistance
Measure resistance
070418 -OOENOO
Measuring points
E258 - E101, E125, E126, E149, E173
P0629 633 3
E258 - E249, E250, E251, E225, E227, E226, E258
E258 - E103, E105, E128, E152, E175
P1642 633 6
E258-E265, E278, E242, E206, E290, E219, E260, E273, E274, E275, E201, E203, E202, E283
E283 - E101, E125, E126, E149, E173
P1641 522571 3
E283 - E249, E250, E251, E225, E227, E226, E258
E283 - E103, E105, E128, E152, E175
P1643 522571 6
E283-E265, E278, E242, E206, E290, E219, E260, E273, E274, E275, E201, E203, E202, E283
D Replacing the metering unit

2. Replace the metering unit.
3. Turn ON the main switch and the power switch.
1.:1 Replacing the fuel high pressure pump

Replace the fuel high pressure pump, and turn ON the power switch.
OReplacing the engine ECU

3.6.6 INJECTOR
Injector Connector Harness Hi side: - - -

connector Lo side: - - - - - -
~~===o~E~2~49~~=;~==~VB
Injector 1 E273 -c::J- - Corn
E250
Lo Hi
side side Injector 2
E274 - - - -c::J- - Com
E251
Injector 3
E275 - - - - -c::J- - Com
ECU
~~===o~E~2~25~~-'~--~VB
Injector 4
E201 -c::J- - Com
Connector 2
E227
~~?O\EI
Injector 5
E203 - - - -c::J- - Com
' - -_ _J
E226
Injector 6 E202
- - - - -c::J- - Com
Injector1/No. 1 Cyl: FW side 070419-00ENOO


P0201 651 5
P0202 652 5 1. Detects pulse signal of cam and crank sensors
P0203 653 5 2. Detects open circuit at each injector circuit
P0204 654 5 3.0 seconds
P0205 655 5 4. Displays "CHECK ENGINE"
P0206 656 5
P1262 651 3
P1265 652 3
P1268 653 3
P1271 654 3
P1274 655 3
P1277 656 3 1. Detects pulse signal of cam and crank sensors
P0262 651 6 2. Detects short circuit each injector circuit
P0265 652 6 3.0 seconds
P0268 653 6 4. Displays "CHECK ENGINE"
P0271 654 6
P0274 655 6
P0277 656 6
P1146 2797 6
P1149 2798 6
Behavior at failure
Fail mode Injection of failure cylinder stops
P0201, P0202, P0203, P0204, P0205, P0206: Resumes after recovering from open circuit
Fail release
Others: N/A (After resuming from the failure, wait 10 seconds after switching off the power)
Remarks Output drops due to the failed cylinder's injection stop
Detail of trouble
• Injector of engine harness - Connector attachment failure
• Injector failure
• Open circuit fail: Open circuit of engine harness (Hi side and Lo side)
• Short circuit fail: Short circuit of engine harness
(Hi side - Lo side, Hi side - Com, Hi side - GND, Lo side - GND, Lo side - VB)
Yes
No
________________________ ,
r-------------------~-~-_______________________________
~
~. _~h_e_c~~nfl_,,!:i!h_ ~~:.I:?
No
Yes
Yes
Yes
-=::::==-'-'---1 Replace the harness
No
Yes
Injector failure
070420-00ENOO

Way of DTC CodeD

2. Check DTC code.

2. Check the appearance of the engine harness, and replace if there is anything wrong with it. Replace the engine
harness.
1- Remove the injector and the engine ECU from the engine harness.
2- Measure the resistance of the engine harness (Injector connector terminal - Engine ECU terminal). (Refer to
charts and drawings)
harness.
Measuring points
DTC SPN FMI Terminal In jector side can nectar
P0201 651 5 E249 - E249 E273 - E273
P0202 652 5 E250 - E250 E274 - E274
P0203 653 5 E251 - E251 E275 - E275
P0204 654 5 E225 - E225 E201 - E201
P0205 655 5 E227 - E227 E203 - E203
070421-00ENOO
P0206 656 5 E226 - E226 E202 - E202

1- Remove the injector and the engine ECU from the engine harness.
ings)

Injector====1~ ~
Measure
ECU side connector 2 resistance
==:=:::j~ I
072772-00ENOO
Measuring points
P1262 651 3 E249 - E103 E249 - E128 E249 - E175 E249 - E105
P0262 651 6 E249 - E152 E273 - E101 E273 - E125 E273 - E126
P1146 2797 6 E273 - E149 E273 - E173 E273 - E249
P1265 652 3 E250 - E1 03 E250 - E128 E250 - E175 E250 - E105
P0265 652 6 E250 - E152 E274- E101 E274 - E125 E274 - E126
P1146 2797 6 E274 - E149 E274 - E173 E250 - E274
P1268 653 3 E251 - E1 03 E251 - E128 E251-E175 E251 - E105
P0268 653 6 E251 - E152 E275 - E101 E275 - E125 E275 - E126
P1146 2797 6 E275 - E149 E275 - E173 E251 - E275
P1271 654 3 E225 - E1 03 E225 - E128 E225 - E175 E225 - E105
P0271 654 6 E225 - E152 E201 - E1 01 E201 - E125 E201 - E126
P1149 2798 6 E201 - E149 E201 - E173 E225 - E201
P1274 655 3 E227 - E1 03 E227 - E128 E227 - E175 E227 - E105
P0274 655 6 E227 - E152 E203 - E101 E203 - E125 E203 - E126
P1149 2798 6 E203 - E149 E203 - E173 E227 - E203
P1277 656 3 E226 - E1 03 E226 - E128 E226 - E175 E226 - E105
P0277 656 6 E226 - E152 E202 - E101 E202 - E125 E202 - E126
P1149 2798 6 E202 - E149 E202 - E173 E226 - E202
DReplacing the injector

2. Replace the injector.
3. Start the engine. If the failure code does not appear, the injector is not broken.
(;) Replacing the engine ECU

3.7 Engine Error
3.7.1 OVER HEATING

P0217 110 0 COOLANT TEMP TOO HIGH

1. During engine operation
2. Coolant temperature: 95°C or higher
P0217 110 0
3.1 second
4. Displays "HOT ENGINE", "DERATE MODE"
Behavior at failure
Fail mode N/A
Fail release Coolant temperature: 90°C or lower and resumes after 10 seconds
Remarks N/A
Detail of trouble
• Level of coolant is low (Lacking)
• Lack of cooling seawater
• Seawater pump impeller is damaged
• Thermostat is sticking
• Fresh water cooler/heat exchanger is clogged
• Water pump (coolant) is degraded
• Coolant temp sensor failure
__________________ -=-.;-...- -....

-..;c- - - - - - - - - - - - - - - - - - - - - - - - - - - X _~h_e_c!<~n~t~i~h_ §~:~ ________________________ _
No
Yes
Yes
No
Yes
Add coolant
Yes Secure sea water

for cooling water
No
Yes
Sensor failure
No
Yes
No
Yes
Clean or replace
No
Yes


Way of DTC CodeD

2. Check DTC code.
DChecking the coolant amount

1. Make sure there is no coolant leaking. If so, repair them.
2. When the engine is cool, check the coolant amount in the sub tank and the coolant tank.
3. Add coolant.
DChecking the cooling seawater

1. Check the discharge amount of cooling seawater.
2. Check the opening of Kingston valve.
3. Check the seawater filter clog.
4. Check the seawater intake port clog.
5. Check the damage of seawater pump impeller.
o Replacing the coolant temp sensor

1. Turn OFF the power switch.
2. Replace the coolant temp sensor attached to the exhaust manifold outlet.
3. Turn ON the power switch.
mInspecting the thermostat

1. Drain the coolant, and remove the thermostat.
2. Make sure that the thermostat is operating normally. If not, replace to new.
61 Inspecting the fresh water cooler/heat exchanger

Inspect and check the fresh water cooler.
Il)lnspecting the water pump (coolant)

Inspect the water pump (coolant).
Ii] Replacing the engine ECU

3.7.2 BOOST PRESS TOO HIGH

P0234 102 0 BOOST PRESS TOO HIGH
[V] Charge air press!

temp sensor ECU
E207
S5V S5V
E286
Sig_P Sig_P
E237
SigT SigT
E290
Com Com
VB GND
'"' '"'
50 400
T-=-
[kPa]
~~~~
\"~r;J \.:~ ~.) ~~)
~ I ~ ~
070424 - OOENOO

1. Not during cranking, engine speed: 425 min- 1 or higher
2. Boost pressure: 4000 hPa (absolute pressure) or higher
P0234 102 0
3. 30 seconds
4. Displays "TURBO BOOST', "DERATE MODE"
Behavior at failure
Fail mode N/A
Fail release Boost pressure: 3000 hPa (absolute pressure) or lower and resumes after 3 seconds
Remarks N/A
Detail of trouble
• Boost press sensor failure
• Turbocharger failure
Yes
Yes Mist piping or

lubricating oil suction
Yes
Sensor failure
07568S-00ENOO

Way of DTC CodeD

2. Check DTC code.
DChecking the suction of fuel or lube oil or mist

1. Make sure that no fuel, lube oil, or mist is leaking.
2. Repair if it is leaking.
3. Make sure that no fuel, lube oil, or mist is leaking in the charge air line of the engine.
DReplacing the boost press sensor

2. Replace the boost press/temp sensor attached to the charge air manifold.
3. Turn ON the power switch. If no failure indication appears, there is no failure.

3.7.3 CHARGE AIR TEMP ERROR

P1017 105 0 CHARGE AIR TEMP TOO HIGH
P1018 105 1 CHARGE AIR TEMP TOO LOW
[0]100000 I~:IT]: 1;1:IrDITlIITIEFllITrDl Charge air press!

temp sensor ECU
IIiN.~'~1111t41111llllfttEl
E207
S5V S5V
E286
10000 Sig_P Sig_P
.,... Si9_T
E237
Si9_T
E290
1000 . . . . . . . Com Com
VB GND
,.... ,....
100 !~iIMiM!imlMiMftlll""""'tlI t'

T-:-
10~~~~~~~~~~~~~~~U
-40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100110 120 130
[0C]
069760-00ENOO
Q~~~
"BV ~V \!j ~)
~~I
Com Si9_T
~ ~
S5V Si9_P
069771- OOENOO

1. Charge air temperature is normal, not cranking
2. Charge air temperature: 80°C or higher
P1017 105 0
3. 30 seconds
1. Charge air temperature is normal, not cranking
2. Charge air temperature: -15°C or lower
P1018 105 1
3. 30 seconds
Behavior at failure
Fail mode N/A
P1017: Immediately resume at charge air temperature 70°C or lower
Fail release
P1018: Immediately resume at charge air temperature -10°C or higher
Remarks N/A
Detail of trouble
• Boost press sensor failure
• Using under extreme cold (P1018)
• Lack of cooling seawater (P1 017)
• Clogging of heat exchanger (air cooler core) (P1017)
Yes
Yes
No
Yes
Sensor failure
Yes Check the usage

environment
No
Yes Secure sea water for

cooling water
No
Yes
Clean or replace

070426-00ENOO


2. Check DTC code.
DSeeing if replacing the charge air temp sensor helps.

2. Replace the boost press/temp sensor attached to the charge air manifold.
Charge air temp/press sensor
(148661_9~~FR~;=F
~r=~
072884--00ENOO
D Checking the using environment

This engine is made to work in an environment with the temperature -15°C or higher.
The engine may not start below that temperature.
r:J Lack of cooling seawater

1. Check the discharge amount of cooling seawater.
2. Check the opening of Kingston valve.
3. Check the seawater filter clog.
4. Check the seawater intake port clog.
5. Check the damage of seawater pump impeller.
o Checking the air cooler

3.7.4 LUBE OIL PRESS TOO HIGH

P1014 100 0 LUBE OIL PRESS TOO HIGH
[V] 6 Lube oil press!

temp sensor ECU
E233
,/ S5V S5V
E216
/( Sig
E219
Sig
V Com Com VB GND
/ T -L
--
V Sensor side connector hamess
-100 0 100 200 300 400 500 600 700 800 900
[kPa]
070427-00ENOO
Sig Com S5V

069844--00ENOO

1. Lube oil press sensor is normal, not cranking
2. Lube oil pressure: 780 kPa or higher
P1014 100 0
3. 30 seconds
Behavior at failure
Fail mode N/A
Fail release Resumes when lube oil pressure is 680 kPa or lower
Remarks N/A
Detail of trouble
• Lube oil press sensor failure
• Failure of pressure regulating valve
• Degradation of lube oil
Yes
Yes
Is lube oil degrading? Replace lube oil
Yes
Sensor failure
Yes Adjust or replace the

pressure regulating valve
07042S-00ENOO


2. Check DTC code.
DChecking the usage time of the lube oil

Check the operating time from the last oil change.
Timing for oil change: Diesel oil: 500 hours, A heavy oil: 250 hours
DReplacing the lube oil sensor

2. Replace the lube oil press sensor shown below.
Lube oil press sensor
D Checking the pressure regulating valve

Check the pressure regulating valve. Adjust or repair the valve if you find any error.

3.7.5 LUBE OIL PRESS TOO LOW

[V] 6 Lube oil press!

temp sensor ECU
E233
./ S5V S5V
E216
A Sig
E219
Sig
LA'" Com Com V)ll G~p
A 1-:-
(' Sensor side connector harness
·100 0 100 200 300 400 500 600 700 800 900
[kPa]
070427-00ENOO
Sig Com S5V

1. Lube oil press sensor is normal. After 8 seconds from actual speed is 450 min- 1
or higher.
P1022 100 18 2. Lube oil pressure: 150 kPa or lower
3.1 second
4. Indicates "CHECK ENGINE"
1. Lube oil press sensor is normal. After 8 seconds from actual speed is 450 min- 1
or higher.
P0524 523553 1 2. Lube oil pressure: 100 kPa or lower
3.1 second
Behavior at failure
Fail mode N/A
P1022: N/A
Limited operation P0524: Engine speed is 1100 min- 1 or lower. Limited injection amount (50 % of the limited injection
amount).
P1022: Resumes when lube oil pressure is 200 kPa or higher
Fail release
P0524: Resumes when lube oil pressure is 150 kPa or higher
Remarks N/A
Detail of trouble
• Lube oil press sensor failure • Failure of pressure regulating valve
• Low lube oil amount • Failure of lube oil pump
• Rising of lube oil temperature • Relief valve failure
• Lube oil filter is clogged
Yes
No
Yes Seek for low cause

Add lube oil
Yes
Replace filler
Yes
Sensor failure
No
Yes Adjusl or replace lhe

pressure regulating valve
No
Yes
Replace the pump
No
Yes
Replace relief valve



2. Check DTC code.
DChecking the lube oil amount

1. Check the amount of lube oil. Add if the amount is low.
2. Make sure there is no oil leakage.
3. Make sure the amount of blowby gas is much.
DChecking the lube oil filter

Check the replacing timing for the lube oil filter.
For diesel operation: 500 hours, A heavy oil operation: 250 hours
iii Seeing if replacing the lube oil sensor helps

2. Replace the lube oil press sensor shown below.
Lube oil press sensor 072885
III Checking the pressure regulating valve

Check the pressure regulating valve. Adjust or repair the valve if you find any error.
o Checking the lube oil pump

Check the lube oil pump in case it is damaged.
OChecking the relief valve failure

Check the relief valve.
li,]Replacing the engine ECU

3.7.6 FUEL PRESS TOO HIGH

P1012 94 0 FUEL PRESS TOO HIGH
Sensor characteristics
Fuel press sensor ~]6 ,-------,-------,------,
\ i
400 800 1200

Fuel filter Fuel high Feed pump
pressure pump [kPa]
072770-00EN06
OOENOO

1. Fuel press sensor is normal. Not cranking.
2. Fuel pressure: 800 kPa or higher
P1012 94 0
3. 30 seconds
Behavior at failure
Fail mode N/A
Fail release Resumes when fuel pressure is 700 kPa or lower
Remarks N/A
Detail of trouble
• Fuel press sensor failure
• Fuel high pressure pump return fuel is clogged
• Fuel filter is clogged
• Fuel feed pump is damaged
Yes
--------------------- ------------------------------------------------ --------------------
Yes Clean or replace

the clogged pari
Yes
Sensor failure
Yes Replace the

fuel high pressure pump
070431-00ENOO


2. Check DTC code.
DChecking the clog

Check the clogged parts shown below.
Clean or replace the clogged part.
D Replacing the fuel press sensor

2. Replace the fuel press/temp sensor attached at the upper part of the fuel filter.
D Replacing the fuel high pressure pump

mReplacing the engine ECU

3.7.7 FUEL PRESS TOO LOW

Sensor characteristics
~]6 r-------~------~------~
400 800 1200

Fuel filter Fuel high Feed pump
pressure pump [kPa]
072770-00EN06
070432-00ENOO

1. Engine speed: 425 min- 1 or higher, fuel press sensor is normal, not cranking
2. Fuel pressure: 400 kPa or lower
P1021 94 18
3. 30 seconds
1. Engine speed: 425 min- 1 or higher, fuel press sensor is normal, not cranking
2. Fuel pressure: 250 kPa or lower
P1013 94 1
3. 10 seconds
Behavior at failure
Fail mode N/A
P1 021: N/A
Limited operation
P1 013: Limited injection amount (75 % of the original limited amount)
P1 021: Resumes when fuel pressure is 450 kPa or higher
Fail release
P1 013: Resumes when fuel pressure is 300 kPa or higher
Remarks N/A
P1021: Low fuel pressure (Caution) P1 013: Low fuel pressure (Warning)
Fuel limit
Normal operation
Normal operation Possibility of engine
(Alarm indication only)
speed dropping
0704??
Detail of trouble
• Fuel press sensor failure
• Fuel filter is clogged
• Lack of fuel
• Fuel leak
• Fuel high pressure pump failure (Feed pump failure)
_______________________ ~._~~~c!<~n~_~i!t: ~C':l"2 ______________________________ _
Yes
Yes
Yes
Check piping
Yes
No
Yes
Replace filler
No
Yes
Sensor failure
No
Yes Fuel high pressure

pump failure
Make sure lhe failure does not re-occur, and finish.
070434-00ENOO


2. Check DTC code.

Check the pipings to make sure there is no fuel leakage.
DChecking the remaining amount of fuel

Check the level of fuel in the tank. Add more if the level is low.
r:J Checking the fuel filter

1. Check the fuel filter, and replace if it is clogged.
2. Check the fuel filter replacing time.
3. The fuel filter replacing time is
with diesel operation: every 1000 hours
I.l.J Replacing the fuel press sensor

3. Turn ON the power switch. If the failure code does not appear, the sensor is not broken.

3. Turn ON the power switch. If the failure code does not appear, the sensor is not broken.
DReplacing the engine ECU

3.7.8 FUEL TEMP TOO HIGH

P0168 174 0 FUEL TEMP TOO HIGH

1. The fuel temp sensor is normal and the cranking is not occurring
2. Fuel temperature (Filter outlet): 70°C or higher
P0168 174 0
3.60 seconds
Behavior at failure
Fail mode N/A
Fail release Fuel temperature (Filter outlet): Resumes after 60 seconds at 60°C or lower
Remarks N/A
Detail of trouble
• Out of fuel/low fuel
• Fuel pipe is damaged
• Fuel temp sensor failure
Yes
Yes
Yes
Yes
Sensor failure
070435- OOENOO

fJ Checking with SA-O

2. Check DTC code.
DChecking the remaining amount of fuel

Check the level of fuel in the tank. Add more if the level is low.
!9Replacing the fuel temp sensor


3.7.9 BATTERY VOLTAGE ERROR

P160C 158 0 BATTERY VOLTAGE TOO HIGH
Electric wiring
CE-tc-h-lEJ-F-us-e-t--IBk~>---+~-u-s-et---ID'
30A 150A
070436-00ENOO

1. Battery voltage sensor is normal
2. Battery voltage: 32 V or higher
P160C 158 0
3.1 second
4. Displays "BATTERY VOLTAGE"
1. Battery voltage sensor is normal
2. Sensor output voltage: 18 V or lower
P0560 158 1
3.1 second
4. Displays "BATTERY VOLTAGE"
Behavior at failure
Fail mode N/A
P160C: Resumes after 3 seconds when battery voltage is 32 V or lower
Fail release
P0560: Resumes after 3 seconds when battery voltage is 18 V or higher
Remarks N/A
Detail of trouble
• Battery is overcharged
• Battery is not fully charged
• Main switch is turned OFF
• Short circuit of battery cable
• Engine harness is damaged
• Alternator malfunction
• ECU failure
Yes
Yes
No
Yes
Main switch ON
Yes Always check the

energized part
Charge battery
::::>y<_e_s~ Charge or replace battery

Replacing the alternator
Yes
Replace battery cable
Repair wiring
Yes
Replace the fuse
Yes
Replace the harness
Yes
Replacing the alternator

07528S-00ENOO


2. Check DTC code.
DChecking the main switch

1. Check if the main switch is tilting OFF.
2. If it is OFF, turn it ON.
DChecking the dark current

1. Turn OFF the main switch.
2. Measure the current from the battery's plus terminal.
3. If the current is flowing, the current is still flowing despite the main switch is off.
4. Cut the current and charge the battery.
o Checking the battery voltage

1. Check the voltage between the battery terminals connecting the engine harness.
2. The battery is not normal if the voltage is between 18 V to 32 V.
1- Battery voltage: If 18 V or lower
Charge or replace the battery.
2- Battery voltage: If 32 V or higher
The alternator may be broken (overvoltage), or the battery cable and engine harness may be short circuit to
other electric wiring.
Replace the alternator, check the engine harness, and check the wiring (Go to 0, D, and 0).
o Checking the battery cable

1. Make sure there is no damage or short circuit in the battery cable.
2. If there is oxidized film (discoloration) to the Battery - Starter connection terminal, replace the terminal.
o Checking the fusing

1. Turn off the power switch and the battery switch.
2. Make sure that the fuse 150 A is not fusing. If the fuse is blown, the power generation from the alternator cannot
be acquired. Replace the fuse and check the alternator.
DChecking the engine harness

Check damages, short circuit, and wirings of the engine harness.
o Replacing the alternator

1. Measure the current flowing in the alternator B terminal and the battery power (+) while operating.
2.lf the current is not flowing, the alternator may be broken. Replace the alternator.
[[!JReplacing the ECU

3.7.10 ENGINE OVER SPEED

P0219 190 0 ENGINE OVER SPEED

1. N/A
2. Engine speed is higher than the threshold value (shown below)
P0219 190 0
3.1 second
4. Displays "OVER REV"
6AYEM-ET 6AYEM-ST
Model 6AYEM-GT 6AYEM-ET
(for EPA) (for EPA)
Rating S L M Continuous H (Continuous)
Speed (min-1) 2320 2320 2280 2200 2280 2280
Behavior at failure
Fail mode Injection stops to threshold value speed or below
Fail release N/A
Remarks N/A
Detail of trouble
• Fuel is leaking from injector and fuel high pressure pump
• Crank sensor error
• Cam sensor error
• ECU failure
Yes
Yes Check the fuel leaking

in the block
Yes
Failure of sensor
Yes
Failure of sensor
Yes
Injector failure
Yes Fuel high pressure

pump failure
07?926-00ENOO


2. Check DTC code.
D Checking the fuel return path

1. If there is fuel tank return valve, make sure it is "OPEN".
2. If the valve is closed, fuel may be dropping in the block.
3. Check the fuel leaking in the block.
4.lf it is leaking, wash the oiled part, and replace the lube oil.
DReplacing the crank sensor

2. Replace the crank sensor.
B Replacing the cam sensor

ll.J Replacing the injector

2. Replace the injector.
3. Start the engine. If the failure code does not appear, the injector is not broken.

Il)Replacing the ECU

3.8 ECU
3.8.1 EEPROM ERROR MEMORY WRITE

P160F 522578 12 EEPROM ERROR MEMORY WRITE

1. When accessing to write
2. EEPROM writing failure (This error occurs when writing fails three times per sin-
P160F 522578 12 gle data)
3.0 seconds
Behavior at failure
Fail mode N/A
Fail release N/A
Remarks N/A
Detail of trouble
• ECU failure
See P178 [4.4 ECU Failure Flow Chart].
3.8.2 EEPROM ERROR MEMORY DELETION

P0601 630 12 EEPROM ERROR MEMORY DELETION

1. When switching pages (sector)
2. There are 2 pages in EEPROM and data is stored alternately to each page.
When the first page is fully occupied with data, the data on the second page is
deleted to write in. Alternatively, when the second page is fully occupied with
P0601 630 12
data, then the data on the first page is deleted to secure space to write in.
This error occurs when this deleting failed at switching pages.
3.0 seconds
Behavior at failure
Fail mode N/A
Fail release N/A
Remarks N/A
Detail of trouble
• ECU failure
3.8.3 EEPROM error memory read

P160E 522576 12 EEPROM ERROR MEMORY READ

1. When accessing to read
2 .• EEPROM reading error
• Determine error by Check SUM
P160E 522576 12
• Apply to all EEPROM
3.0 seconds
Behavior at failure
Fail mode N/A
Fail release N/A
Remarks N/A
Detail of trouble
• ECU failure
3.8.4 ECU ERROR AD CONVERTER


1. N/A
2. Pulse error is detected with the AD converter diagnosis
P1469 523473 12
3.0 seconds
1. N/A
2. Voltage error is detected with the AD converter diagnosis
P1470 523474 12
3.0 seconds
Behavior at failure
Fail mode N/A
Limited operation Engine stop
Fail release N/A
Remarks N/A
Detail of trouble
• ECU failure
3.8.5 ECU ERROR CY146 SPI COMMUNICATION

P1613 522585 12 ECU ERROR CY146 SPI COMMUNICATION

1. N/A
2. Serial communication of CPU and H bridge control IC is abnormal
P1613 522585 12
3.0.05 seconds
Behavior at failure
• Gradually changes its target speed to low idle
Fail mode
• Forcibly shifts to neutral
Fail release N/A
Remarks N/A
Detail of trouble
• ECU failure
3.8.6 ECU ERROR ROM

P1473 523477 12 ECU ERROR ROM

1. N/A
2. Check SUM of ROM all-area is abnormal
P1473 523477 12
3.0 seconds
Behavior at failure
Fail mode N/A
Fail release N/A
Remarks N/A
Detail of trouble
• ECU failure
3.8.7 INJECTOR DRIVER IC ERROR


1. N/A
2. ECU detects the drive IC failure
P0611 523492 12
3.0 seconds
1. N/A
2. ECU detects the drive IC failure
P1023 523493 12
3.0 seconds
Behavior at failure
Fail mode N/A
Fail release N/A
Remarks N/A
Detail of trouble
• ECU failure
3.8.8 ECU ERROR EXT MONITOR IC & CPU


1. N/A
2. Error is detected from alternative diagnosis between external monitoring IC and
P1471 523475 12 CPU
3.0 seconds
1. N/A
2. Error is detected between external monitoring IC and CPU
P1472 523476 12
3.0 seconds
Behavior at failure
Fail mode N/A
Fail release N/A
Remarks N/A
Detail of trouble
• ECU failure
3.8.9 ECU ERROR SHUTOFF PATH


1. When diagnosing the energy shut-off function of the injector which is done after
turning on the ECU power
2. External monitoring IC detects the response error to the external monitoring IC
P1474 523478 12
from the CPU
3.0 seconds
2. External monitoring IC detects the run-error from the energy shut-off function
P1475 523479 12
diagnosis of the injector
3.0 seconds
2. External monitoring IC detects the reaction time error from the energy shut-off
P1476 523480 12
function diagnosis of the injector
3.0 seconds
2. External monitoring IC detects the communication error from the energy shut-off
P1477 523481 12
3.0 seconds
2. External monitoring IC detects the low voltage error from the energy shut-off
P1478 523482 12
3.0 seconds

2. External monitoring IC detects the external monitoring IC error from the energy
P1479 523483 12
shut-off function diagnosis of the injector
3.0 seconds
2. External monitoring IC detects the OS call time error from the energy shut-off
P1480 523484 12
3.0 seconds
2. External monitoring IC detects the positive test error from the energy shut-off
P1481 523485 12
3.0 seconds
2. External monitoring IC detects the run time error from the energy shut-off func-
P1482 523486 12
tion diagnosis of the injector
3.0 seconds
2. External monitoring IC detects the overvoltage error from the energy shut-off
P1483 523487 12
3.0 seconds
Behavior at failure
Fail mode N/A
P1475: Engine speed: 1500 min- 1 or lower, limited injection amount
Limited operation
Other than P1475: Engine stop
Fail release N/A
Remarks N/A
Detail of trouble
• ECU failure
3.8.10 ACTUATOR DRIVE SHORT CIRCUIT


1. N/A
2. ECU internal IC detects the overcurrent of the UB2 terminal
P1626 522744 4
3.0 seconds
1. N/A
P1633 522994 4
3.0 seconds
1. N/A
P1467 523471 6
3.0 seconds
Behavior at failure
Fail mode N/A
Fail release N/A
Remarks N/A
Detail of trouble
• ECU failure
Yes
Yes
Yes
No
P1633
P1467 Replace
the harness
P1626

075191-00ENOO


2. Check DTC code.
DChecking the short circuit of engine harness

2. Check the appearance of the engine harness, and replace if there is anything wrong with it. Replace the engine harness.
3. Remove the sensor and the ECU from the engine harness.
4. Measure the resistance of the engine harness (Between ECU terminals). (Refer to charts and drawings)
5. If the resistance value is positive, the harness is short circuit. Replace the engine harness.
Measuring points
C=====~~27 E1~
P1626 522744 4 E150 - E103, E105, E128, E152, E175
P1467 523471 6 E127 - E103, E105, E128, E152, E175
Lad
Measure resistance
075686-00ENOO
DReplacing the ECU

3.8.11 SUPPLY 1 VOLTAGE ERROR

P1608 522588 12 SUPPLY VOLTAGE H RANGE
P1617 522589 12 SUPPLY VOLTAGE L RANGE

1. N/A
2.5 V supply to actuator drive IC is overvoltage
P1608 522588 12
3.50 ms
1. N/A
2.5 V supply to actuator drive IC is low voltage
P1617 522589 12
3.50 ms
Behavior at failure
Fail mode N/A
Fail release N/A
Remarks N/A
Detail of trouble
• ECU failure
3.8.12 SENSOR SUPPLY VOLTAGE ERROR

Sensor 5 V power wiring
I E166
I Analog main throttle
I U VDD4
E233 E207
I Lube oil pres sensor
IU VDD5 U VDD1 I Boost press sensor
I
-
E192 I
I Cam sensor
I E209
I U VDD6
U VDD2 I
Analog sub throttle
I
E231 I
I E211 U VDD3 I
Fuel temp/press sensor
I
I Rail press sensor
I U VDD7
I U G1
1I
VB GND

1. Not cranking
2. UG1/UVDD1 to 3> 1.02, UG1/UVDD1 to 3 < 0.94
P1609 522590 12
3.0.05 seconds
1. Not cranking
2. UG2/UVDD4 to 6> 1.02, UG2/UVDD4 to 6 < 0.94
P1618 522591 12
3.0.05 seconds
1. Not cranking
2. UGyUVDD7 > 1.02, UG3/UVDD7 < 0.94
P1619 522592 12
3.0.05 seconds
Behavior at failure
Fail mode N/A
P1609: When sub throttle is valid 1000 min- 1
Limited operation P1618: N/A
P1619: N/A
0.94 < UG1/UVDD1 to 3 < 1.02
Fail release 0.94 < UG2/UVDD4 to 6 < 1.02
0.94 < UG3/UVDD7 < 1.02
Remarks During the failure, the cooling water temperature is indicated "-"
Detail of trouble
• P1609: Short circuit of the engine harness (S5V - BV, S5V - GND)
• ECU failure
No
No
Yes
Yes
Yes . - - - - - - - - - - - ,
~---~ Replace the harness

0752B6-00ENOO
Dis error detail indicated in the monitor panel?


2. Check DTC code.

1- Remove the sensor and the ECU from the engine harness.
2- Measure the resistance of the engine harness (Between ECU terminals). (Refer to charts and drawings)
Measuring points
E207, E192, E231 - E126
E207, E192, E231 - E125
E207, E192, E231 - E103
E207, E192, E231 - E105 c==~~ E207
P1609 522590 12 E207, E192, E231 - E101

E207, E192, E231 - E149
E207, E192, E231 - E173
E207, E192, E231 - E128
E207, E192, E231 - E152
E207, E192, E231 - E175
~:~:~;~, ~----'
E166, E233, E209 - E126
E166, E233, E209 - E125
E166, E233, E209-E103
E166, E233, E209-E105
.-------1~ E 126
P1618 522591 12 E166, E233, E209-E101 E166, E233, E209-E128

E166, E233, E209 - E149 E166, E233, E209-E152
E166, E233, E209 - E173 E166, E233, E209-E175
E211 - E126 E211 - E103
E211 - E125 E211 - E105
P1619 522592 12 E211 - E101 E211 - E128
E211 - E149 E211 - E152
E211 - E173 E211 - E175
!9Replacing the engine ECU

3.8.13 ECU ERROR ENGINE SPEED RECOGNITION

P1484 523488 0 ECU ERROR ENGINE SPEED RECOGNITION

1. N/A
2. Appears commonly with the detection of the engine overspeed error
P1484 523488 0
3.0 seconds
4. Displays "OVER REV"
Behavior at failure
Fail mode Injection stops to threshold value speed or below
Fail release N/A
Remarks N/A
6AYEM-ET 6AYEM-ST
Model 6AYEM-GT 6AYEM-ET
(for EPA) (for EPA)
Rating S L M Continuous H (Continuous)
Speed (min-1) 2320 2320 2280 2200 2280 2280
Detail of trouble
• ECU failure
3.9 No DTC Code Indication: Case 1

Problems
-
::: 1. Is battery ~
Yes
Charge battery
0
..c
tJ)
voltage low? Check the VC10
(5 harness and systern
c
2. 3.
--
tJ) Is fuse (15A) Is engine harness
Ql No
0
""0 t--------- No
blown? open circuit?
Qi No
c
<1l
0.. Replace the harness
Yes
.8
·c
0
::2:
4. Display does not
J END
Yes No
show after replacing
the fuse
Yes
5. Is the wiring
wrong?
~ Repair the wiring
6. Engine harness Replace the harness

Yes
L-Jo short circuit?
----,II
Check the VC10
No
No harness and systern
070442-00ENOO
-
Wiring diagram
Fuse ECU
(SYS15A)
+
Main switch
Power switch
VC10 systern
Detail of trouble
• Power supply to the monitor panel (VC10 system) is cut
• Failure of monitor panel and VC1 0 system
OChecking the battery voltage

1. Measure the battery voltage, and make sure it is 18 V or higher.
2. Make sure that the color of the battery terminal is not changed
DChecking the fuse

Check the fuse (15 A).
~~~~
Q I ~~~ II ~gt I
I JB~ II ~g~ I
C><I C><J i-------+~
1><11><1
1><11><1
075687-00ENOO
DChecking the open circuit of engine harness

1. Check the wiring of the battery cable and the engine harness.
2. Check the open circuit of the wiring (battery cable and engine harness) as shown below.
Fuse
+
Main switch (SYS15A)
EJ
EFV Ui69
t 0 J~t
Measure resistance
0
Measure resistance
r
07044S-00ENOO
DChecking the wiring

Check the wiring.
D Checking the short circuit of engine harness

Remove the ECU and the VC10 harness from the engine harness. Check the short circuit of the wiring.
It is short circuit if there is resistance.
Measuring terminal
30 - E103, E105, E128, E152, E175
Measure resistance

Problems
-
m
Ql
1. Is fuse 1-1. Engine state ~
No
END
(i0A_ACC) does not
--
CL
-
CL Replace the
<1l
blown? appear
0c 2. Engine harness
again after Yes
-
UJ
Ql Yes harness
0 Failure ofVC10
""0
~ replacing short 3. Failure of
.ill
.ill
UJ
Ql
.s:
Ol
c
w
the fuse f-:-:---
Yes
circuit?
--No
VCi0 harness
and system?
No i
Yes
N;7
system
Replacing the
ECU
--
5.
-
1-3. Engine
N: 1-2. (30A_ECU)
Is fuse
state does
Replace the
engine harness. Harness short
f-:-:---
Yes Yes circuit
blown? not appear Does it recover? Yes
again after
replacing
~
the fuse
END
~
4. Open
circuit of
engine
--Yes
Replace the
harness
-
harness
~ To 3. 070447-00ENOO
Wiring diagram
ECU
Ei46
""'-_-_-_-_-_--:_E:;-j~4..~7_-_-_-0 g~~~ ~
1-_ _-:E:;-i'-':7-=i_---<O CAN 1 H
+ _____Ej!l5___ CANi L
1
1
1
1
1
r--- 0-----,
1 I....J I....J 1
I 0... olol~I~1 I
1
: zzzzz :
IL (3(3(3(3(3
________________ I
~
VCi0 system
OChecking the fuse

1. Check the fuse (10 A).
2. Check the fuse (30 A).
~~~~
1 J~~ 1
1 ~B~ ::=::;;;::::
1 1
1><11><1i---~G
1><11><1 ~~
1><11><1
DChecking the short circuit of engine harness

1. Check the wiring of the battery cable and the engine harness.
3. Make sure the wiring of the engine harness is not open circuit or short circuit.
If there is no resistance between the below terminals of the tester, it is short circuit.
Measuring terminal
E171 - E195, E146, E147
E195- E146, E147
E146-E147
DChecking the VC10 harness and system

Measure resistance
Check the VC1 0 system.
DReplacing the engine harness

D Checking the open circuit of engine harness

2.lf there is no resistance between the below terminals of the tester, it is open circuit.
Measuring terminal
ECU side VC10 side
E171 4 VC10 side connector ECU side connector 1
E195 5 Main switch Q n:
'-----------{~ \j_~'-----------(\r---Oi----------'~y_1-
E146 6 +
E147 7
Main switch - VC1 0 side 31 Pin
Measure resistance Measure resistance

Problems
-
c 1 . Does starter 2. Is connection ~ Further tighten
2 of battery Yes the battery cable
pinion gear
"0
c
~
----Jo move ~ cable
(JJ
OJ
0 instanta-
Yes
incorrect?
3. Not enough
Yes
Charge battery I
u
No-1
-----lO battery voltage?
a; No
1:::
Cll
neously Replace the starter I
U5 when
start switch 4. Is abnormal
is ON?
~
Yes
load applied?
~
Yes
Release load
5. Does it show ~ Release the starter

Yes . . ..
the indication restricting condition
~ of start
interlock relay?
-----lO
No 6. Engine state ~
Yes
GotoCase2-B I
does not appear
(Speed,
No
temperature,
pressure, etc.)
7. Is the ~
Yes
Repair the wiring
wiring
wrong? Replace the
8. Is fuse
~
-Jo
-
-
No
(BOA_ST)
blown?
~
Yes
harness
8-1. After replacing ~END

No
the fuse, the
starter does ~ Replace the
not run again Yes harness
9. Is starter
relay
No-1 Replace the relay I
f----'I-
Yes working? ~
Yes
Replace the ECU I
Wiring diagram
+
Main switch
VC10 system
Fuse
(ECU_30A)
ECU
070453 -OOENOO
o Checking the operation when turning on the start switch

Press the start switch to make sure you hear a sound that the pinion gear moves instantaneously and hits the fly-
wheel.
f) Checking the battery cable

1. Make sure there is no damage or short circuit in the battery cable.
If there is oxidized film (discoloration) in the connection terminal, replace the terminal.
2. Make sure the connection of the battery cable is not loose.
DChecking the battery voltage

1. Make sure that the voltage between the battery terminals connecting the engine harness has 18 V to 32 V.
2. Charge or replace the battery.
DChecking the load

Make sure the flywheel moves with the turning bar.
D Checking the monitor panel

When turning ON the start switch, make sure the monitor panel indicates "STARTER INTERLOCK".
Condition for removing the interlock:
• Shift to Neutral
• Turn off emergency stop switch
(1) Checking the monitor panel

Turn ON the power switch and make sure the monitor panel indicates the engine speed, cooling water temperature.
o Checking the wiring

Check the wiring.
Make sure the starter relay and battery are wired correctly.
IlChecking the fuse

Make sure that the fuse (80 A) is not blown.
Relay box
I 5T C BDA fffiJ
@~~
'-
'Ft--
i :-t---
FUSE
I STC80A I
~,
~ \
' /,,~~
IAlTB150AI
) ' I
148661.Q7711 '~
D Checking the relay

Turn ON the start switch to make sure the starter relay makes a sound.

Problems
,--
t
21
-- 1. Is the ~ Release the emergency

(f)
"0c emergency Yes

(f)
stop switch
(j)
0
stop switch
""0
ON?
(j)
.~
2. Is the fuel ~ 3. Is fuel valve ~ Open the fuel valve
OJ
c ~ stopped? Yes
closed?
Yes
d
--
(j)
:; 4. Is fuel filter Replace filter
..Q Yes
(f)
No clogged?
c
2 Replace feed
Q;
t ~ pump
21
(j)
5.ls air ~ Bleed air

~ trapped?
Yes
Replace the fuel
6. Fuel high !---+ high pressure pump
~ pressure pump Yes
failure?
~ Check the cetane
-- 7. Is the
cranking
speed
slow?
--
Yes
8. Not enough
battery
voltage?
d Charge battery
9. Is abnormal ~
number
~
Release load
load applied?
10. Is the starter Yesd Tighten more
Check the fuel ~ terminal
~
~
injection device falling off? ~ Check the starter

No
11 . Are crankshaft!
~ camshaft
d Replace sensor
sensor both
broken?
--
No
Replacing the
Injector
OChecking the emergency stop switch is ON

Make sure the emergency stop switch is pressed from the monitor panel.
D Checking the fuel flow

Connect to SA-D, and check the fuel pressure and the rail pressure.
If... Fuel pressure;::: 400 kPa, Rail pressure;::: 60 MPa, the fuel is there.
DMaking sure the fuel valve is not open

Make sure the fuel valve is not open. Also check the remaining amount of fuel in the tank.
DChecking the fuel filter

Check the fuel filter, and replace if it is clogged.
D Checking for trapped air

If.... Fuel pressure::::; 400 kPa, and rail pressure::::; 60 MPa, air is trapped.
Loosen the bolt at the upper part of the filter, and bleed air.
o Checking the fuel high pressure pump

If the fuel pressure and the rail pressure are extremely low, replace the fuel high pressure pump.
o Checking the cranking speed

Check the cranking speed with SA-D, monitor panel, and pick up sensor.
::::; 70 min- 1 is low speed.
IlChecking the battery voltage

Make sure the battery voltage is > 18 V. Charge if low.
E! Checking the load

Make sure the loads on the clutch and generators are on.
mChecking the starter wiring

Check the starter wiring.
mChecking the failure of both crank/cam sensor

Replace both the crank sensor and the cam sensor.
If the engine starts after the replacement, it can be assumed that the crank/cam sensors were broken.

Problems
-
Cl..
.8
(J)
1. Power ~ Power switch and
c
Ql
f-----!o switch and Yes main switch
""0
""0
:::J main switch
~
(J)
Refer to OTC
~ 2. Battery
Ql
.f: are OFF
OJ
voltage Yes code P1568
c
w
< 18 V?
~ 3. Is fuse ~
Yes
GotoCase2-m I
(30A_ECU)
blown?
No
I
4.
-
Is the No
emergency
5.ls the ~ Turn the switch
d
stop Yes emergency Yes OFF
-lIo indicated in stop switch Replace the
6. Harness 7. Is the
-
the display? ON? ~ emergency stop Yes
switch
~
open circuit?
switch broken? Checking the
No
VC10 system
f----Jo Replace the
Yes
harness
f-----!o 8. Is fuel left? ~

No
Add fuel
9. d
-
Is fuel tank Open the valve
valve closed? Yes
Yes
~
10.ls air d
Yes
Bleedair
trapped in
-
fuel path?
~
No
Check for fuel leak
0704S5-00ENOl
OChecking the power switch

Make sure the power switch is ON (Display screen is lit).
DChecking the battery voltage

Make sure that the voltage between the battery terminals connecting the engine harness has 18 V.
DChecking the fuse

Make sure that the fuse (30 A) is not blown.
~~~~ .. ~
I ~~~ II ~g~ I¢
I ~5~ II 19~ I
1><11><1f----h"llP"
C><JC><I
1><11><1
DChecking the validity of the emergency stop switch

Check the display screen to make sure that the emergency stop switch is valid.
mChecking the emergency stop switch

Make sure the emergency stop switch is ON.
D Checking the open circuit of engine harness

1. Check the appearance of the engine harness.
2. Remove the ECU and the VC1 0 harness from the engine harness.
3.lf there is no resistance between the below terminals of the tester, it is open circuit.
• Main switch terminal- ECU side connector: E101, E12S, E126, E149, E173
• VC10 side connector 18 Pin - ECU side connector: E160
Fuse VC10 side connector

Main switch (ECU30A)
+
E101,E125 ..
~--~
Or---------+:
Measure resistance
L. _ _ _ _ _ .J
VC10 system
ECU side connector 1 (Emergency stop switch) 0704S8-00ENOO
61 Checking the emergency stop switch

VC10 system: Make sure that the resistance between the terminals when the emergency stop switch is OFF is zero.
The switch is broken when it is O.L.
[iJ mmChecking the fuel system

4. HELP OF TROUBLE SHOOTING - 173
4. HELP OF TROUBLE SHOOTING
4.1 Confirmation Way of DTC Code
4.1.1 Error details display

1. Press the button on the side of DETAIL showing the pop-up.
All of the warnings will be shown on the alarm list.
l~cQJ
~e+
®=======e~
b~~~~._. .~...~.~. ~.~
069070-00ENOO
No. Source Discripiion

~
~
Po"
( Scroll list: Up
ffi Port
Stb[j
P15es CHARGING SYSTEM
( Scroillisl: Down
m 4 Stbd
~
~
Return to
monitoring screen To error details)
069071-00ENOO
2. Press e error details to display the detailed contents of the warning selected with the scroll button (scroll list).
~ NAME (P1568) CHARGING SYSTEM ~

~ ~
SPN 167
FMI
ENGINE Po"
~ SourceA[idross
CALL SERVICE MECHANIC
155 ~
~ @'-----------' ~
Back to
warning screen
OOENOO
174 - 4. HELP OF TROUBLE SHOOTING
4.1.2 How to check the error detail when no warning pop-up is showing
(You accidentally closed the warning pop-up screen)
1. Press the menu button @.
©J
©J
©J
©J
+®=====e
I
"~-~~~;;;;;;;;;;;;;;;~~~;;;;.:;;.
~~~
2. Select "ALARM/DIAGs" from the button on the left
069069-00ENOO
3. Pick the error you wish to refer to using the cursor

on the left and presse OK button.
,, ~ Alarmlist (g)
II --.! ,~....----O=-.'"=p!'O.......
"'N'-'.-=-sO....... , ---,
!Ill;) I--",=-+-""p=ort+--=XXX=XXIY.=XXXX"""XXX=XXxx=xxxx,.........n ~
~ (l!1ib:±
:p+",'~~""'bd~~I
2
3 XXXXXXXA'XXXXXXA'XXXXXXX ~
~ ffi ~ ~
:f-----+-+-------ll
I Stbd xxxxxxxxxxxxxxxxxxxxxx
,~ ~
1111
~= :;t
4. Check the displayed contents.
Press @ button to return to the alert display page.
©J (P1::'68) CHARGING SYSTE:M
©J
©J 155
©J @ '---------'
+® ""====== e
L~~~~ ~_ ~
. ~~~~J
069151-00ENOO
4.2 Measurement Using SA-D

(DTC Code, Sensor Output Voltage)
4.2.1 Connecting position of SA-D

The connector for connecting the SA-D is located at the
lower part of the engine ECU.
Engine_~~
ECU
4.2.2 Checking the DTC code
Connect SA-D, turn on the power, and check the DTC code.
4.2.3 Check the sensor output physi- 072821-00ENOO
cal value/voltage value

Connect SA-D, turn on the power, and check the below indi-
cated normal voltage/temperature/pressure range .
• Engine
Temperature sensors
Sensor name Unit Normal value

V 0.2 -4.8
Cooling water temp sensor
°C -15 ~
V 0.2 -4.8
Fuel temp sensor
°C -40 -130
V 0.2 -4.9
Charge air temp sensor
°C -40 -130
Pressure sensors

V 0.05 - 4.5
kPa 0-784
V 0.5 -4.5
Rail press sensor
MPa 0-200
V 0.5 -4.5
Fuel press sensor
kPa 50 -1000
V 0.5 -4.5
Charge air press sensor
kPa 50 - 400
Analog throttle sensors

Sub throttle sensor V 0.2 - 4.8
• Marine gear
V 0.5 - 3.5
MPa 0-1
4.3 ECU Connector Pin Arrangement
4.3.1 Engine harness ECU side connector
Up ..
Connector 1 on ECU side of engine harness - ECU side
rI rI rI
B
-
~~-~~
E101 E103 E105 E111 E119
RB BR BR WL WR
~ ~ E126 E128 E136 E137 E138 E146 E147

RB RB R BR LW VB L YB GB
-
B
'--
~~~~B
E157 E158 E159 E160 E162 E163 E166 E169 E171
RB WG BR Gr VR OW V G YR RY WL Y
~
E173 E175 E178 E179 E180 E181 E182 E188 E192 E193 E195
RB BR Lg GY BY LG BrW BR P BL G
- '--
L-...I L-...I L-...I
Connector 2 on ECU side of engine harness - ECU side

rI rI rI
B
- ,-- ,--
~BB
E201 E202 E206 E207 E209 E211 E213 E216 E219
LB LB B R P RY LB G BL
r-- r--
E225 E226 E227 E231 E233 E235 E236 E237 E239 E242
LW LVII LW RB RG GB GY LR GL BL
'-- ' - - -
-
~~-BB
E249
LW
~~-
E273
LB
E250
LW
E27<1
LB
'-- ' - - -
E251
E275
L-...I
LW
LB
E278
Gr
E280
0
E258
LW
E283
LB
E260
BY
L-...I
E285
GR
E265
G
E266
L
E290
BR
L-...I
B
07046l-00ENOO
4.3.2 VC10 connector

4.4 ECU Failure Flow Chart
No
Checking with SA-D
No
Yes
Yes
No
No
Yes P1475
Yes
No
No
5. Replace ECU

070462-00ENOO
4.4.1 Ways of checking

D Checking with SA-D

Check the failure detail using SA-D. (Refer to P175 [4.2 Measurement Using SA-D (DTC Code, Sensor Output Volt-
age)])
DChecking the re-occurrence

1. Turn off the power switch and the main switch. 20 seconds later, turn them all back ON.
2. See if the same DTC with the failure appears.
DOverwriting the ECU software

Overwrite the ECU software again. (Refer to SMARTASSIST-Direct manual)
Note: Before over-writing, take out the engine setting value and the correction data, and then change the setting
after over-writing.
D Replacing the ECU

mChecking the DTC code at cranking

1. Do the cranking.
2. Make sure the DTC code (P1146 or P1149) appears.
o Failure diagnosis of injector bank short

If the above DTC code is showing, the injector bank is short.
Diagnose the DTC code: P1146 or P1149.
180 - 5. TROUBLESHOOTING OF VC1 0
5. TROUBLESHOOTING OF VC10
5.1 DTC Code List

P0840 127 3 GEAR OIL PRESS SENSOR HIGH RANGE
5.2.1
P0840 127 4 GEAR OIL PRESS SENSOR LOW RANGE
P0120 91 3 MAIN THROTTLE SENSOR H RANGE
5.2.2
P0120 91 4 MAIN THROTTLE SENSOR L RANGE
B1001 523543 4 NEUTRAL SW ACTIVATED 5.3.1
B1002 523542 4 SELECT SW ACTIVATED 5.3.2
B1003 523544 4 SYNCHRO SW ACTIVATED 5.3.3
B1005 523541 3 START/STOP SW ACTIVATED 5.3.4
P0560 158 1 BATTERY VOLTAGE TOO LOW 5.4.1
P0920 773 3 SHIFT FORWARD H RANGE
P0920 773 4 SHIFT FORWARD L RANGE
5.5.1
P0924 784 3 SHIFT REVERSE H RANGE
P0924 784 4 SHIFT REVERSE L RANGE
P1828 522045 1 GEAR OIL PRESS TOO LOW 5.5.2
B1020 91 13 THROTTLE CALIBRATION INCONSISTENCY 5.6.1
U103 525 10 CAN COM ERROR
U100 190 10 CAN COM ERROR ENGINE SPEED 5.7.1
U404 525 2 CAN COM ERROR SHIFT
U100 523760 9 CAN COM ERROR ENG-ECU TO HELM-ECU
U404 523761 9 CAN COM ERROR DRIVE-ECU TO HELM-ECU
5.7.2
U1201 523762 9 CAN COM ERROR HELM-ECU TO HELM-ECU
U1202 523763 9 CAN COM ERROR HELM-LOCAL
C1208 522041 9 CAN COM ERROR CAN-CONTROL HEAD 5.7.3
C1027 522042 11 THROTTLE/SHIFT SENSOR WARNING CAN-CONTROL 5.7.4
C1028 522043 11 THROTTLE/SHIFT SENSOR FAILURE CAN-CONTROL HEAD 5.7.5
P1628 630 12 DRIVE ECU EEPROM ERROR 5.8.1
P0605 628 12 ROM CRC ABNORMALITY 5.8.2
B1043 523768 12 HELM ECU EEPROM ERROR 5.8.3
C1010 521238 3 TANK1 LEVELSENSOR HIGH RANGE
C1010 521238 4 TANK1 LEVELSENSOR LOW RANGE
5.9.1
C1011 521239 3 TANK2 LEVELSENSOR HIGH RANGE
C1011 521239 4 TANK2 LEVELSENSOR LOW RANGE
C1051 521240 3 RUDDER ANGLE SENSOR HIGH RANGE
5.9.2
C1051 521240 4 RUDDER ANGLE SENSOR LOW RANGE
P1070 521243 3 SEAWATER TEMP SENSOR HIGH RANGE
5.9.3
P1070 521243 4 SEAWATER TEMP SENSOR LOW RANGE
U2003 521233 4 HOUSE BATTERY VOLTAGE LOW RANGE 5.9.4
C1012 521994 13 TANK1 LEVEL CALIBRATION ERROR
5.10.1
5. TROUBLESHOOTING OF VC1 0 - 181

C1052 521996 13 RUDDER ANGLE CALIBRATION ERROR 5.10.2
C1014 521997 13 SEAWATER TEMP CALIBRATION ERROR 5.10.3
5.2 Analog Input
5.2.1 GEAR OIL PRESS SENSOR

P0840 127 3 GEAR OIL PRESS SENSOR HIGH RANGE
P0840 127 4 GEAR OIL PRESS SENSOR LOW RANGE
[V] / "'\
3.5 A 820
Gear oil press 8 A24

sensor
2.5
C 89
1.5
'-
Drive ECU
0.5
Sensor connector harness face
200 400 600 800 1000 1200

[kPa]

1. Power ON
2. Input voltage: 4.8 V or higher
P0840 127 3
3.0.5 seconds
4. Displays "DRIVE ECU DETECT FAILURE"
1. Power ON
2. Input voltage: 0.2 V or lower
P0840 127 4
3.0.5 seconds
Behavior at failure
Fail mode Warning
P0840/3: Input voltage lasts for 0.5 seconds at 4.8 V or lower
Fail release
P0840/4: Input voltage lasts for 0.5 seconds at 0.2 V or higher
Note Failure is judged only when gear oil press sensor is used
Detail of trouble
• Open circuit or short circuit of wire-harness
• Connector is not connected or connected incorrectly
• Gear oil press sensor failure
• Drive ECU failure
Treatment
1. Initial diagnosis • Check the fault indication.
• Check the sensor value.
2. Connector/wiring • Always turn OFF the power switch when working.

check • Make sure that the connector of the gear oil press sensor is connected correctly.
• Make sure that the wirings of the gear oil press sensor is not disconnected, or the wiring coating
is not peeled.
3. Failure diagnosis • Check the input voltage (voltage value of sensor) of the gear oil press sensor.
• Make sure the harness is correctly conducted.
Yes
No
_____________________________ ~: _~h_e_c!<~n.9_~i!h_ ~~::.~ ________________________ ,
No
Yes
Yes
"-:::;::>'f<;...:e",s_ _.:;;.t Check re-occurrence
No
Yes
Replace sensor
No
Yes
Replace the harness
069767-00ENOO

(Refer to P173 [4.1 Confirmation Way of DTC CodeD

2. Check DTC code.

4. If the resistance value is below 10 kQ, the sensor is broken. Replace the sensor.
D Checking the harness

2. Check the appearance of the harness, and replace ifthere is anything wrong with it.
3. Check the open circuit of the harness.
1- Remove the sensor and the ECU from the harness.
2- Measure the resistance of the harness (Sensor terminal - ECU terminal). (Refer to charts and drawings)
Measuring points: The connector positions on the ECU side are explained in P176 [4.3 ECU Connector Pin
Arrangement].
3-lf the resistance value exceeds the specified range (O.L.), the harness is open circuit. Replace the harness.
4. Check the short circuit of the harness.
2- Measure the resistance of the harness (Between ECU terminals). (Refer to charts and drawings)
3- Replace the harness.
1.:1 Replacing the ECU

5.2.2 MAIN THROTTLE SENSOR (OPTIONAL START PANEL)

P0120 91 3 MAIN THROTTLE SENSOR H RANGE
P0120 91 4 MAIN THROTTLE SENSOR L RANGE
Wiring diagram
" < : - - - - - - 0 A28
\-----OA23
/-----OA34
Helm ECU

1. Power ON
P0120 91 3
3.1 second
4. Displays "HELM ECU DETECT FAILURE"
1. Power ON
P0120 91 4
3.1 second
Behavior at failure
• Warning
Fail mode
• Lower the engine speed to idle
Limited operation Cannot operate throttle dial
Fail release
• After resuming, this is not applied until the throttle dial input returns to the idle position
• If 2 or more engines are installed, the throttle of the engine that is not broken can be operated
Note after the speed is low
• When the throttle dial is broken, the throttle can still be operated using the sub throttle of the
backup panel
Detail of trouble
• Throttle dial sensor is broken
• Helm ECU failure
Treatment

check • Make sure that the connector of the throttle dial sensor is connected correctly.
• Make sure that the wirings of the throttle dial sensor is not disconnected, or the wiring coating is
not peeled.
3. Failure diagnosis • Check the input voltage (voltage value of sensor) of the throttle dial sensor.
5.3 Switch Input
5.3.1 NEUTRAL SW
81001 523543 4 NEUTRAL SW ACTIVATED
Wiring diagram
/' '\ f '\

2 A15
3 A16
4 B1
Control head Helm ECU

System ON

1. Power ON
2. ON input is kept for a certain time
81001 523543 4 3. (a) Continues for 1 second from power start
(b) In other cases, continues for 20 seconds
Behavior at failure
(a) Warnings and switches: Operates as OFF
Fail mode
(b) Warnings and switches: Operates as ON
Limited operation (a) Warm-up operation and engine speed limit mode are not available
Fail release Switches from OFF to ON once
Note N/A
Detail of trouble
• Stuck with the Neutral (NTRL) switch pressed
• Control head failure
Treatment
• Check the input state of the switch.

check • Make sure that the connector of the control head is connected correctly.
• Make sure that the wirings of the control head is not disconnected, or the wiring coating is not
peeled.
3. Failure diagnosis • Check the Neutral (NTRL) switch

• Check the control head.
• Replace the control head if anything is wrong with it.
5.3.2 SELECT SW
81002 523542 4 SELECT SW ACTIVATED
Wiring diagram
/" '\ '\

2 A15
3 A16
4 81

System ON 072478-00ENOO

1. Power ON
Behavior at failure
Fail mode
Limited operation (a) Cannot switch to concerned station
Note Can only be switched to stations working properly (If there is more than one station)
Detail of trouble
• Stuck with the station selection switch (SEL) pressed
Treatment

peeled.
3. Failure diagnosis • Check the station selection switch (SEL).

• Replace the control head if anything is wrong (Stuck, broken, ... ) with it.
5.3.3 SYNCHRO SW (2-ENGINES)

81003 523544 4 SYNCHRO SW ACTIVATED
Wiring diagram
/" '\ '\

2 A15
3 A16
4 81


1. Power ON
Behavior at failure
Fail mode
Limited operation (a) Cannot use engine SYNC mode from the concerned station
Note N/A
Detail of trouble
• Stuck with the engine synchronized (SYNC) switch pressed
Treatment

peeled.
3. Failure diagnosis • Check the engine synchronized (SYNC) switch.

• Replace the control head if anything is wrong with it.
5.3.4 START/STOP SW
81005 523541 3 START/STOP SWACTIVATED
Wiring diagram
Switch panel
Helm ECU
1 A1
SlarllSlop
2 r----l 4
Power L---...I
Fuse
15A DCfDC converter
072479-01ENOO

1. Power ON
Behavior at failure
Fail mode
Limited operation (a) Cannot start engine from the concerned station
Note N/A
Detail of trouble
• Switch panel failure
Treatment

check • Make sure that the connector of the switch panel is connected correctly.
• Make sure that the wirings of the switch panel are not disconnected, or the wiring coating is not
peeled.
3. Failure diagnosis • Check the conduction between the switch panel and the terminals of engine start/stop switch.
5.4 Battery
5.4.1 BATTERY
Wiring diagram
Switch panel Drive ECU

3 825
System ON
1 826
8 810
GND
2
I
r---1
6
4
Power L---..J
Fuse DCfDC converter
15A 043083-01ENOO

1. Power ON
2. Battery voltage: If 10 V or lower
P0560 158 1
3.5 seconds
Behavior at failure
Fail mode Warning
Fail release Resumes to 10 V or higher power voltage
Note This DTC does not apply when the starter is ON or within 2 seconds after the starter is turned OFF
Detail of trouble
• Power generation fail of alternator
• Fuse cut of alternator
• Connection failure between starter and alternator
• Low battery capacity
• Battery degradation
• Too much dark current
• DCfDC converter failure
• Switch panel failure
Treatment
• Check the power voltage.

check • Make sure that the switch panel and the drive ECU connectors are connected correctly.
• Make sure that the wirings of the switch panel and the drive ECU are not disconnected, or the
wiring coating is not peeled.
3. Failure diagnosis • Check the alternator and battery.

• Check the DC/DC converter.
• Check the power voltage of the drive ECU.
5.5 Marine Gear
5.5.1 SHIFT VALVE

P0920 773 3 SHIFT FORWARD H RANGE
P0920 773 4 SHIFT FORWARD L RANGE
P0924 784 3 SHIFT REVERSE H RANGE
P0924 784 4 SHIFT REVERSE L RANGE
Wiring diagram
,t
Shift valve (Forward) Drive ECU
C3 ~
,t
Shift valve (Reverse)
C4 )
B10~
I ~\ -- --, --, < I ~
Arrangement of shift valve terminals
GND Common
Solenoid B Solenoid A

1. Power is ON and shift (Forward) output is OFF
2. Shift valve (Forward) is short circuit
P0920 773 3
3.0.2 seconds
1. Power is ON and shift (Forward) output is ON
2. Shift valve (Forward) is open circuit
P0920 773 4
3.0.2 seconds
1. Power is ON and shift (Rear) output is OFF
2. Shift valve (Rear) is short circuit
P0924 784 3
3.0.2 seconds
1. Power is ON and shift (Rear) output is ON
2. Shift valve (Rear) is open circuit
P0924 784 4
3.0.2 seconds
Behavior at failure
Fail mode Warning
Limited operation Cannot switch shifts from drive ECU
Fail release Power switch turns from OFF to ON once
Note If there is nothing wrong with the shift valve and harness, the shifts can be operated from the backup panel
Detail of trouble
• Shift valve solenoid failure
Treatment

check • Make sure that the shift valve can be operated from backup panel.
• Make sure that the connector of the shift valve solenoid is connected correctly.
• Make sure that the wirings of the shift valve solenoid are not disconnected, or the wiring coating
is not peeled.
3. Failure diagnosis • Check both resistance values of the shift valve solenoid (Between A and common rail, and
between B and common rail).
No
No
Yes
Yes
No
No Attach correctly
to the terminal
Yes
No
No Repair or replace
the wiring
Yes
No
Replace the shift valve
070475-00ENOO


2. Check DTC code.
DChecking the wiring of the shift valve connection terminal

1. Check for loosened or detached connection terminal fixing bolts.
2. If loose, further tighten the terminal fixing bolt, and if it is completely off, attach the fixing bolt back on.
(Tightening torque of terminal fixing bolt: 0.6 ± 0.1 N· m)
D Checking the shift valve operation

1. Turn ON the power switch and the main switch.
2. Turn ON the backup panel.
3. Start the engine, and make sure that the shift valve can be operated from backup panel.
4. Check the wiring if shift valve is operable.
B Making sure there is no open circuit or damage to the wiring

2. Check the appearance of the harness, and replace if there is anything wrong with it. Replace the harness.
3. Remove the connector, and check the resistance of the wiring to make sure the conduction is correct.
4.lf the resistance value exceeds the specified range (O.L.), the harness is open circuit. Replace the harness.
5.lf there is nothing wrong with the wiring, check the shift valve solenoid.
mChecking the shift valve solenoid

2. Remove the wiring from the shift valve connection terminal.
3. Check the shift valve solenoid terminal to make sure that the resistance between A and common rail, and Band
common rail are 4 to 7 Q.
4.lf it is not between 4 and 7 Q, replace the shift valve.
o Replace the ECU

5.5.2 GEAR OIL PRESS TOO LOW

P1828 522045 1 GEAR OIL PRESS TOO LOW
[V] "\
3.5 A 820
Gear oil press 8 A24

sensor
2.5
C 89
1.5
'-
Dnve ECU
043060--00ENOO
0.5
Sensor connector harness face

200 400 600 800 1000 1200
[kPa]
070463-00ENOO

1. Power ON
2. Satisfies all the conditions below
(a) Engine speed is over a certain speed
P1828 522045 1 (b) After a certain time from shift engagement
(c) Gear oil pressure is below normal value
3.0.2 seconds
Behavior at failure
Fail mode Warning
Fail release Gear oil pressure is back to normal value
Note N/A
Detail of trouble
• Gear oil press sensor failure
Treatment

check • Make sure that the connector of the gear oil press sensor is connected correctly.
• Make sure that the wirings of the gear oil press sensor is not disconnected, or the wiring coating
is not peeled.
3. Failure diagnosis • Check the input voltage (voltage value of sensor) of the gear oil press sensor.
Yes
No
_____________________________ ~: _~h_e_c!<~n.9_~i!h_ ~~::.~ ________________________ ,
No
Yes
Yes
"-:::;::>'f<;...:e",s_ _.:;;.t Check re-occurrence
No
Yes
Replace sensor
No
Yes
Replace the harness
069767-00ENOO


2. Check DTC code.

4. If the resistance value is below 10 kQ, the sensor is broken. Replace the sensor.
D Checking the harness

2. Check the appearance of the harness, and replace ifthere is anything wrong with it.
3. Check the open circuit of the harness.
2- Measure the resistance of the harness (Sensor terminal - ECU terminal). (Refer to charts and drawings)
Measuring points: The connector positions on the ECU side are explained in P176 [4.3 ECU Connector Pin
Arrangement].
3-lf the resistance value exceeds the specified range (O.L.), the harness is open circuit. Replace the harness.
4. Check the short circuit of the harness.
2- Measure the resistance of the harness (Between ECU terminals). (Refer to charts and drawings)
3-lf the resistance value is positive, the harness is short circuit. Replace the harness.
1.:1 Replacing the ECU

5.6 Calibration
5.6.1 THROTTLE DIAL SENSOR

B1020 91 13 THROTTLE CALIBRATION INCONSISTENCY
Wiring diagram
.....-----OA28
\-----oA23
r-----OA34
Helm ECU
072477-00ENOO

1. Power ON
2. Setting value of throttle sensor is invalid
B1020 91 13
3. N/A
Behavior at failure
• Warning
Fail mode
• Send invalid value to display
Limited operation Cannot operate throttle
Fail release Restart in a state where matching value is set
Note When the throttle dial is broken, the throttle can still be operated from the backup panel
Detail of trouble
• Setting with incorrect procedure such as during calibration
• Throttle dial sensor is broken
Treatment
• Check the value of the throttle dial sensor.

check • Make sure that the connector of the throttle dial sensor is connected correctly.
• Make sure that the wirings of the throttle dial sensor is not disconnected, or the wiring coating is
not peeled.
3. Failure diagnosis • Calibrate again.

• Check the throttle dial sensor.
5.7 CAN Communication
5.7.1 CAN COM ERROR (DRIVE ECU)

U103 525 10 CAN COM ERROR
U100 190 10 CAN COM ERROR ENGINE SPEED
U404 525 2 CAN COM ERROR SHIFT
Wiring diagram
Helm ECU Drive ECU
Monitor panel
-,I
~j
Buzzer
0
j
Display
[(gJ Q
1-+--_~YJi_
rr i
,
Switch panel Helm ECU
YAilfMAR
-'" '" i • ....
-------1 ~
Engine
--~OINMEA I
Terminal 1 rnA Terminal2~

~
Q Remote control head
L----C::;~ IPressure sensor I

L[i ISift valve I
IllBackup panel
072481-01ENOO

1. Power ON
2. CAN communication error between drive ECU - helm ECU
U103 525 10
3.1 second
1. Power ON
2. CAN communication error between drive ECU - engine ECU
U100 190 10
3.0.15 seconds
1. Power ON
2. CAN communication error between drive ECU - helm ECU
U404 525 2
3. N/A
Behavior at failure
Fail mode Warning
U103/10: Change the shift command to Neutral
Limited operation U 100/10: Stop the gear noise control
U404/2: Change the shift command to Neutral
Fail release CAN communication is back to normal state
When the CAN communication is under error, the shift operation can be done from the backup
Note
panel
Detail of trouble
• Terminal adapter failure
• Voltage drop
Treatment

check • Make sure that the connector of the terminal adapter is connected correctly.
• Make sure that the connector of the drive ECU, helm ECU, and engine ECU are connected cor-
rectly.
• Make sure that the CAN communication and wirings of the drive ECU are not disconnected, or
the wiring coating is not peeled.
3. Failure diagnosis • Check the resistance value of the terminal adapter (end). (Proper value: About 120 0)
5.7.2 CAN COM ERROR (HELM ECU)

U100 523760 9 CAN COM ERROR ENG-ECU TO HELM-ECU
U404 523761 9 CAN COM ERROR DRIVE-ECU TO HELM-ECU
U1201 523762 9 CAN COM ERROR HELM-ECU TO HELM-ECU
U1202 523763 9 CAN COM ERROR HELM-LOCAL
Wiring diagram
Helm ECU Drive ECU
Monitor panel Display Switch panel Helm ECU
Engine
-~DINMEAI
:=pr
Terminal 2
Remote control head

L ____-[=:;~ IPressure sensor I
LO ISift valve I
IllSackup panel I
072481-01ENOO

1. Power ON
2. CAN communication error between helm ECU - engine ECU
U100 523760 9
3.3 times
1. Power ON
2. CAN communication error between helm ECU - drive ECU
U404 523761 9
3.3 times
1. Power ON
2. CAN communication error between helm ECUs with different stations
U1201 523762 9
3.3 times
1. Power ON
2. CAN communication error between helm ECUs in same stations
U1202 523763 9
3.3 times
Behavior at failure
Fail mode Warning
U100/9: Cannot use main throttle
U404/9: Cannot change shifts
U1201/9: Cannot acquire stations with applicable helm ECU
Limited operation
U1202/9: Cannot use engine sync. mode
Cannot use warm-up operation mode
Cannot use engine speed limit mode
When the CAN communication is under error, the throttle/shift operation can be done from the
Note
backup panel
Detail of trouble
• Terminal adapter (end) failure
• Voltage drop
Treatment

check • Make sure that the connector of the terminal adapter (end) is connected correctly.
• Make sure that the connector of the drive ECU, helm ECU, and engine ECU are connected cor-
rectly.
• Make sure that the CAN communication and the wirings are not detached from the helm ECU,
and that the wiring coating of the power cable or the GND wire is not peeled.
5.7.3 CAN COM ERROR CAN-CONTROL HEAD

C1208 522041 9 CAN COM ERROR CAN-CONTROL HEAD
Wiring diagram
/" '\ '\

2 A15
3 A16
4 81


1. Power ON
2. (a) Throttle/shift information not received
(b) CAN communication error (open circuit)
C1208 522041 9
3. (a) 1 second
(b) 0.3 seconds
Behavior at failure
• Warning
Fail mode
• Change the shift command to Neutral
• Lower the engine speed to idle
Limited operation
• Turn OFF all switch input of CAN control head
• Determine failure only when using CAN control head
• When the CAN communication is under error, the throttle/shift operation can be done from the
Note backup panel
• After resuming from failure, the release determination is not applied until the throttle lever once
returns to the idle position
Detail of trouble
• Voltage drop
• CAN control head failure
Treatment

• Make sure that the connectors of the CAN control head and helm ECU are connected correctly.
• Make sure that the CAN communication and the wirings are not detached from the CAN control
head, and that the wiring coating of the power cable or the GND wire is not peeled.
5.7.4 THROTTLE/SHIFT SENSOR WARNING CAN-CONTROL HEAD

C1027 522042 11 THROTTLE/SHIFT SENSOR WARNING CAN-CONTROL HEAD
Wiring diagram
/" '\ '\

2 A15
3 A16
4 81


1. Power ON
2. Receives error from sensor
C1027 522042 11
3. N/A
Behavior at failure
Fail mode Warning
Note Determine failure only when using CAN control head
Detail of trouble
• Voltage drop
Treatment

5.7.5 THROTTLE/SHIFT SENSOR FAILURE CAN-CONTROL HEAD

C1028 522043 11 THROTTLE/SHIFT SENSOR FAILURE CAN-CONTROL HEAD
Wiring diagram
/" '\ '\

2 A15
3 A16
4 81


1. Power ON
2. Receives error from sensor
C1028 522043 11
3. N/A
Behavior at failure
• Warning
Fail mode
• Change the shift command to Neutral
Limited operation Lower the engine speed to idle
• Determine failure only when using CAN control head
• When the control head is under error, the throttle/shift operation can be done from the backup
Note panel
• After resuming from failure, the release determination is not applied until the throttle lever once
returns to the idle position
Detail of trouble
• Voltage drop
Treatment

5.8 ECU
5.8.1 DRIVE ECU EEPROM ERROR

P1628 630 12 DRIVE ECU EEPROM ERROR

1. Power ON
2. Cannot read/write setting of drive ECU
P1628 630 12
3. N/A
Behavior at failure
Fail mode Warning
Limited operation Operates with initial setting value
Fail release Turn the power switch once from OFF to ON
Note N/A
Detail of trouble
Treatment
2. Connector/wiring
check
3. Failure diagnosis • Replace the drive ECU.

5.8.2 ROM CRC ABNORMALITY (DRIVE ECU)

P0605 628 12 ROM CRC ABNORMALITY

1. Power ON
2. ROM checksum does not match
P0605 628 12
3. N/A
Behavior at failure
Fail mode Warning
Limited operation Control function stops
Note N/A
Detail of trouble
Treatment
2. Connector/wiring
check
3. Failure diagnosis • Replace the drive ECU.

5.8.3 HELM ECU EEPROM ERROR

81043 523768 12 HELM ECU EEPROM ERROR

1. Power ON
2. Cannot read/write setting of helm ECU
81043 523768 12
3. N/A
Behavior at failure
Fail mode Warning
Limited operation Operates with initial setting value
Note N/A
Detail of trouble
Treatment
2. Connector/wiring
check
3. Failure diagnosis • Replace the helm ECU.

5.9 Options
5.9.1 TANK LEVEL SENSOR

C1010 521238 3 TANK1 LEVEL SENSOR HIGH RANGE
C1010 521238 4 TANK1 LEVEL SENSOR LOW RANGE
C1011 521239 3 TANK2 LEVEL SENSOR HIGH RANGE
C1011 521239 4 TANK2 LEVEL SENSOR LOW RANGE
Wiring diagram
,..-----c)-----Q A34
Tank1 level sensor
,..-----c)---j---Q A33
Tank21evelsensor
815
Drive ECU
0430SS-00ENOO

1. Power ON
C1010 521238 3
3.5 seconds
1. Power ON
C1010 521238 4
3.5 seconds
1. Power ON
C1011 521239 3
3.5 seconds
1. Power ON
C1011 521239 4
3.5 seconds
Behavior at failure
Fail mode Warning
Limited operation NIA
C1 01 0/3, C1011/3: Input voltage lasts for 5 seconds at 4.8 V or lower
Fail release
C1010/4, C1011/4: Input voltage lasts for 5 seconds at 0.2 V or higher
Note Failure is judged only when tank level sensor is used
Detail of trouble
• Tank level sensor failure
Treatment

check • Make sure that the connector of the tank level sensor is connected correctly.
• Make sure that the wirings of the tank level sensor are not disconnected, or the wiring coating is
not peeled.
3. Failure diagnosis • Check the input voltage (voltage value of sensor) of the tank level sensor.
5.9.2 RUDDER ANGLE SENSOR

C1051 521240 3 RUDDER ANGLE SENSOR HIGH RANGE
C1051 521240 4 RUDDER ANGLE SENSOR LOW RANGE
Wiring diagram
/'
88
A17
Rudder angle
sensor
822
" Drive ECU

0430S6-00ENOO

1. Power ON
C1051 521240 3
3.0.5 seconds
1. Power ON
C1051 521240 4
3.0.5 seconds
Behavior at failure
Fail mode Warning
C1051/3: Input voltage lasts for 0.5 seconds at 4.8 V or lower
Fail release
C1051/4: Input voltage lasts for 0.5 seconds at 0.2 V or higher
Note Failure is judged only when ladder angle sensor is used
Detail of trouble
• Ladder angle sensor failure
Treatment

check • Make sure that the connector of the ladder angle sensor is connected correctly.
• Make sure that the wirings of the ladder angle sensor is not disconnected, or the wiring coating is
not peeled.
3. Failure diagnosis • Check the input voltage (voltage value of sensor) of the ladder angle sensor.
5.9.3 SEAWATER TEMP SENSOR

P1070 521243 3 SEAWATER TEMP SENSOR HIGH RANGE
P1070 521243 4 SEAWATER TEMP SENSOR LOW RANGE
Wiring diagram
. - - - - - C f - - - - O A8
Seawater
temp sensor
815
Drive ECU
0430S8-00ENOO

1. Power ON
P1070 521243 3
3.0.5 seconds
1. Power ON
P1070 521243 4
3.0.5 seconds
Behavior at failure
Fail mode Warning
Fail release
Note Failure is judged only when outside seawater temp sensor is used
Detail of trouble
• Outside seawater temp sensor failure
Treatment

check • Make sure that the connector of the outside seawater temp sensor is connected correctly.
• Make sure that the wiring of the outside seawater temp sensor is not disconnected, or the wiring
coating is not peeled.
3. Failure diagnosis • Check the input voltage (voltage value of sensor) of the outside seawater temp sensor.
5.9.4 HOUSE BATTERY

U2003 521233 4 HOUSE BATTERY VOLTAGE LOW RANGE
Wiring diagram
A6
House battery
821
Dnve ECU

1. Power ON
U2003 521233 4
3.0.5 seconds
Behavior at failure
Fail mode Warning
Fail release Input voltage lasts for 0.5 seconds at 0.2 V or higher
Note Failure is judged only when house battery voltage sensor is used
Detail of trouble
• House battery failure
Treatment
• Check the house battery voltage.

check • Make sure that the connector of the house battery is connected correctly.
• Make sure that the wiring of the house battery is not disconnected, or the wiring coating is not
peeled.
3. Failure diagnosis • Check the house battery input voltage (sensor voltage value).
5.10 Optional Calibration
5.10.1 TANK LEVEL CALIBRATION

Wiring diagram
.--_ _ _O _ _ _ _OA34
Tank1 level sensor
,--_ _-o-_+--oA33
Tank21evelsensor
815
Drive ECU
043055-00ENOO

1. Power ON
2. Tank 1 level sensor is invalid setting value
C1012 521994 13
3. N/A
1. Power ON
2. Tank 2 level sensor is invalid setting value
C1013 521995 13
3. N/A
Behavior at failure
• Warning
Fail mode
Note Failure is judged only when tank level sensor is used
Detail of trouble
• Tank level sensor failure
Treatment

check • Make sure that the connector of the tank level sensor is connected correctly.
• Make sure that the wirings of the tank level sensor are not disconnected, or the wiring coating is
not peeled.

• Check the tank level sensor
5.10.2 LADDER ANGLE SENSOR

C1052 521996 13 RUDDER ANGLE CALIBRATION ERROR
Wiring diagram
88
A17
Rudder angle
sensor
822
" Dnve ECU

043056 - OOENOO

1. Power ON
2. Ladder angle sensor is invalid setting value
C1052 521996 13
3. N/A
Behavior at failure
• Warning
Fail mode
Note Failure is judged only when ladder angle sensor is used
Detail of trouble
• Ladder angle sensor failure
Treatment

check • Make sure that the connector of the ladder angle sensor is connected correctly.
• Make sure that the wirings of the ladder angle sensor is not disconnected, or the wiring coating is
not peeled.

• Check the ladder angle sensor.
5.10.3 SEAWATER TEMP SENSOR

C1014 521997 13 SEAWATER TEMP CALIBRATION ERROR
Wiring diagram
, - - - - - C l - - - - O A8
Seawater
temp sensor
815
Drive ECU
OOENOO

1. Power ON
2. Setting value of outside seawater temp sensor is invalid
C1014 521997 13
3. N/A
Behavior at failure
• Warning
Fail mode
Note Failure is judged only when outside seawater temp sensor is used
Detail of trouble
• Outside seawater temp sensor failure
Treatment

check • Make sure that the connector of the outside seawater temp sensor is connected correctly.
• Make sure that the wiring of the outside seawater temp sensor is not disconnected, or the wiring
coating is not peeled.

• Check the outside seawater temp sensor.
5.11 Pin Arrangement
5.11.1 Helm ECU

A connector terminal B connector terminal
Terminal Function Terminal Function
A1 Engine start/stop switch B1 GND
A8 Station select switch B2 GND
A14 CAN2 terminal adaptor resistance (Local) B3 Troubling lamp
A15 CAN2-H (Local) B9 Power 12 V
A16 CAN2-L (Local) B10 Power12V
A21 Back-up signal B11 Starter ON output
A22 Power survellance input B12 Station active lamp
A23 Throttle lever input
A28 Sensor 5 V
A32 CAN1-H
A33 CAN1-L
A34 Sensor GND
88 81 A17 A1
!l;{L ---- J) I { rl =:....

....
ur-----l-~'~···············iJ
J
816 89 A34 A18

04 JOSS-OOXCO
5.11.2 Drive ECU

A2 - B1 Accessory sensor
A6 House battery input B2 -
A7 - B5 DC/DC convertor 12 V
A8 Seawater temp sensor input B6 NMEAGND
A17 Rudder angle sensor input B7 NMEA 12 V power
A20 Emergency stop switch input B9 Engine/gear common sensor GND
A21 Back-up mode switch input B10 Battery power (-)
A24 Gear oil press sensor B12 NMEA CAN-H
A33 Tank level sensor input 2 B13 NMEA CAN-L
A34 Tank level sensor input 1 B15 Accessory GND
B18 J1939 CAN-H
C connector terminal B19 J1939 CAN-L
Terminal Function B20 Engine/gear common sensor 5 V
C1 - B21 House battery input GND
C2 - B23 DC/D Cconvertor 24 V
C3 Shift (F) output B25 Battery power (+)
C4 Shift (R) output B26 Battery power (+)
C6 -
C24 Common GND
A10 A1 81 C8 C1
"t-::~-~d
A18 A26 820 C14 C20
04?08C;-OOXOO
5.11.3 Display
A connector terminal
823 816 A23 A16
Terminal Function
A5 CAN L
A6 CAN H
A7 Battery
A8 GND
A15 Ignition-in
B connector terminal
Terminal Function
B4 RS-485 High
B5 RS-485 Low
5.11.4 Remote control head

Terminal Function
1 Power
2 CAN H
3 CAN L
4 PowerGND
5 -
6 -
5.11.5 Switch panel

Terminal Function
1 Start/stop 4 3 2
2 Battery
3 System ON
000 0
4 Emergency stop out
5 Emergency stop in 000 0
6 Check engine
5 6 7 8
7 -
8 GND
5.11.6 Back-up panel

Terminal Function
1 Power supply 65432
2 Start
3 Stop
000000
4 System ON switch 000000
5 Throttle lamp
7 8 9 10 11 12
6 Power supply GND ooxoo
7 -
8 Accelerate sensor power
9 Accelerate signal supply
10 Accelerate sensor GND
11 Shift switch (F)
12 Shift switch (R)
5.11.7 DC/DC convertor

Terminal Function
1 24 V power input
2 Ignition
6
3 GND
4 12 V UnSwitched 5
5 -
6 GND 4
5.11.8 Engine room start panel

A1 Power B1 Power
A2 Emergency stop B2 Emergency stop
A3 BUP active B3 BUP active
A4 System ON B4 System ON
A5 System ON B5 System ON
A6 CAN GND B6 CAN GND
A7 Start B7 Start
A8 GND B8 GND
A9 CAN power B9 CAN power
A10 CAN H B10 CAN H
A11 CAN L B11 CAN L
A12 Shield B12 Shield
C connector terminal
Terminal Function
C1 CAN power
C2
C3
System ON
Battery [§HEJJl ~.~.~.:.@ . . . . . ..
C4
C5
GND
Select LED
~lSJ
C6 Select switch
C7 Select LED
C8 Select switch
I
C9 CAN H /
I
' - -_ _ _ _ _. J ...............
......
C10 CAN L I
.............
C11 -
Ai2 Ai Ci2 Ci
C12 Shield
~flBi2~Bi~~
o 0 0 0 0 0
o 0 0 0 0 0
o 0 0 0 0 0
o 0 0 0 0 0
• .., I~,i) C'~) B7~B6 __ l~') ~~J ,..".
~~~ S2.J~~
072487 - ooxao
5.11.9 ECU box

A1 Power B1 Power
A2 Emergency stop B2 Start
A3 BUP active B3 Stop
A4 System ON B4 System ON switch
A5 System ON B5 Sub-throttle lamp
A6 CAN GNO B6 -
A7 Start B7 -
A8 GNO B8 Sub-throttle sensor power

A9 CAN power B9 Sub-throttle sensor signal
A10 CAN H B10 Sub-throttle sensor GNO
A11 CAN L B11 Shift switch (F)
A12 Shield B12 Shift switch (R)
C connector terminal D connector terminal

C1 Shift (F) 01 -
C2 Shift (R) 02 -
C3 Shift GNO 03 -
C4 Oil pressure power 04 -

C5 Oil pressure signal 05 -
C6 Oil pressure GNO 06 -

07 PWM+
08 PWM-
E connector terminal
E1 - E17 -
E2 Main GNO E18 Emergency stop
E3 Shield E19 -
E4 - E20 Terminal 15
E5 - E21 Start signal
E6 CAN H E22 BUP stop
E7 CAN L E23 -
E8 - E24 BUP active

E9 - E25 Sub-throttle lamp
E10 - E26 -
E11 Sub-throttle sensor power E27 System ON
E12 Sub-throttle sensor signal E28 -
E13 Sub-throttle sensor GNO E29 BUP power
E14 - E30 Main power
E15 - E31 CAN power 24 V
E16 -
5. TROUBLESHOOTING OF VC10 - 241
YANMAR CO., LTD.
a Large Power Products Management Division
Quality Assurance Division
5-3-1, Tsukaguchi-honmachi, Amagasaki
Hyogo, 661-0001, Japan
Phone: +81-6-6428-3137 Fax: +81-6-6421-5549
Overseas Office
aVanmar Europe B.V. (VEU)

Brugplein 11, 1332 BS Almere-de Vaart, Netherlands
Phone: +31-36-5493200 Fax: +31-36-5493209
aVanmar Asia (Singapore) Corporation Pte. Ltd. (VASC)

4 Tuas Lane, Singapore 638613
Phone: +65-6861-3855 Fax: +65-6862-5189
aVanmar America Corporation (VA)

101 International Parkway,
Adairsville, GA 30103, U.S.A.
Phone: +1-770-877-9894 Fax: +1-770-877-9009
aVanmar Engine (Shanghai) Co., Ltd.

10F, E-Block Poly Plaza, No.18 Dongfang Road,
Pudong Shanghai, China P.R.C. 200120
Phone: +86-21-6880-5090 Fax: +86-21-6880-8090
aVanmar South America Industria De Maquinas Ltda (VSA)

AV. Presidente Vargas, 1400 Indaiatuba/SP
Sao Paulo, Zip Code 13338-901, BRAZIL
Phone: +55-19-3801-9224 Fax: +55-19-3875-3899, 2241
As of April 1st, 2016
6AYEM-GT, 6AYEM-ET, 6AYEM-ST
1st edition: February 2017

1st edition 1st rev.: September 2017
Issued by: YANMAR CO., LTD. Large Power Products Operations Business
Edited by:YANMAR TECHNICAL SERVICE CO., LTD.
VANMAR
ODAYE-EN0010
PRINTED IN JAPAN
VANMAR CD., LTD.

6AYE Trouble Shooting Manual - Unlocked (OCR)

Uploaded by

Copyright:

Available Formats

6AYE Trouble Shooting Manual - Unlocked (OCR)

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

6AYE Trouble Shooting Manual - Unlocked (OCR)

Uploaded by

Copyright:

Available Formats

YANMAA

This manual is a troubleshooting manual for 6AYEM-common rail engines.

TROUBLESHOOTING MODEL 6A YEM-GT, 6A YEM-ET, 6AYEM-ST

All r~ights r~eserved, Copyright YANMAII CO., LTD.

2. PREPARING FOR FAILURE DIAGNOSIS .............................. 25

4. HELP OF TROUBLE SHOOTING ....................................... 173

5. TROUBLESHOOTING OF VC1 0 ....................................... 180

1.1 Engine Control SystemNC10

Display Helm ECU Drive ECU

1.2 Position of Engine's Sensor and Switch

Fuel pressure/temperature sensor Metering unit Rail pressure sensor

Lubricating oil pressure sensor

1.3 Wiring Diagram

1.3.1 Engine wiring diagram

~ACCrelay li'r-----·"" ------.. I Joint connector

~ INJECTOR 5 H E227/LW(1.25) 1227

_ FUEL T/P(FILTER OUT)SENSOR P E231!RB(0.85) 1

,sensor! LUBE OIL PRESS SENSOR G E219IBL(O.85) 219 i

1.3.2 Wiring diagram

\r~.·l. ·. ~~~~RlpOWE~ii~L~~.·l. ~[J~f~if(it. ~L===================.'j':~~. .~. .~;----I

164000-42300 mmmmmm\s:! g~~ powE9t~~~ !w:M~02!8i:[JTIBljiW'["

E-STOP ~8--M~O~3~'L~Yi2=;::============+=+t=+===~i~8'3 BUPACTIVE

~ BUP:~l~~ ~ _ ~~_ ~i_ ~~~--(~il ~~~~g~

~~;i;;r2 ~gig;ii:r I I I ['[urn

'10l!..::..!Wl rv l..... IIE)

Type2 (3/4) --!.

AB~~~g;r,~~ ~~~~g~~~r~~~~J~003~2~~~~2 ~r2-~Y~0~2~Y~R~~~~~~~~~~~~~~~~~~~~~~~~~~~I l

Y10 0 12 BUPSHIFTR LBUP8HI

164000-22950 Power "" ~

@DIODE 2, En'; (VII

1 HARNESS, WIRE DRIVE F

ii\J~ -~- SA I SHIELD USB ! I M12G ISH

M12D is iSG Y06(P Y06(W Y06(W

i;~l:~~~~: i ;~J :~~!~:~~

:Lj Oil Temp t

@TROLLING (j)ECU BOX 2 I Oil Temp-

:g22: ~~-In D.iI Pres~ +

Type 3 (1/3) Type 3 (2/3) Type 3 (3/3)

Portable Controller Option i 119578-66722

~ lim 21 0 :3 §§~~ ti~~ii

Type3 (3/3) 164000-30011

iBUP S'~p '~F£~ BUP

@RELAYSYSon(12V) !i ! ! ! ~~bAct"' BUPActive

I"h~A (\~N @CLUTCH

!164000-253xO HARNESS,EXT CL!

E638 (G ~Jj I : ~-1.-~ ~ @SHIFTb

1;~~~: ®ACC HARNESS, FNR SHIFT

- --- :- =- --- --- -::: --- ---

nENGINE ®NEXTSTATION (1)ENGINE i@PORTNEXTST nENGINE ®NEXTSTATION (1)ENGINE ®NEXTSTATION

IGN-ON 11.5J1,M"~'1,4,1",,A\,',(R".......... ,................... , M04D ~ SYS-ON tD---" I

IA[)AF'T~R,T~Rrv1INALj 164000-21710 1("AOOO-22930 10M

S.!S~~~ SYS-o~fT i4' . ~. ;.•.~. C.W.\_,.~.L

!CA-1A (1 E691 0-82500) I

11321331341 !41 5 16 1819110[' 1[12[13[14[15[161

--- -- --- -- ---

Type4 (3/4) 164000-22950

PANEL ASSY.BUP NO CL 1&1000-22980 20M I

®B/U P A N E L L - - - - - - - - - - - - ' ( D - ENGINE i (§)BUP

~-----+'--_H4 '"~T'''C' Y04 L 4 BUPACTIVE BUPACTIVE 4I_Y-"0,E4UhLY'----------~

164000-42300 mmmmmm\s:! g powE9t~ !w:M~02!8i:[JTIBljiW'["

AB~g;r, ~~g~r~~~~J~003~2~~~~2 ~r2-~Y~0~2~Y~R~~~~~~~~~~~~~~~~~~~~~~~~~~~I l

~ lim 21 0 :3 §§ tiii