Yanmar YSAD Diagnostic Engine Service

Part Number 2041969 - Tool Kit, YSAD Expert

Refer to the Yanmar TNV Series Engine Troubleshooting Manual (TK 55740) and the Yanmar TNV Series Engine Service Manual (TK 55584) for engine service information not included in this manual.

Connect a PC with the Yanmar Smart Assist Direct (YSAD) diagnostic tool to the ECU to view the Yanmar engine Diagnostic Trouble Codes (DTC) and troubleshoot engine problems.

Engine Control Unit (ECU) software updates are flash loaded and Engine Control Module (ECM) software revisions are checked using the Yanmar Smart Assist Direct Tool.

Yanmar Diagnostic Trouble Codes (DTC)

Alarm Codes are triggered by Yanmar Common Rail Engine ECU Diagnostic Trouble Codes.

If the Yanmar Engine Control Unit (ECU) determines a problem exists, one or more DTCs will be set. Engine DTCs are viewed by means of the Yanmar Engine Diagnostic Tool

Use the Yanmar SmartAssist Direct (YSAD) Diagnostic Tool to determine what DTC Codes are set. For corrective actions, refer to the Yanmar Troubleshooting Guide.

Yanmar Diagnostic Trouble Codes (DTC) and Associated Thermo King Alarm Codes

When a Yanmar DTC Code is set, a corresponding 600 Series Thermo King Alarm Code is also set. The 600 Series Alarm Code is a general indication of what issues may exist. Always connect the Yanmar Service Tool and read all existing DTC codes. Use this information to diagnose the problem using the Yanmar Service documentation.

Clearing Yanmar DTC Codes and Associated Thermo King Alarm Codes

Yanmar DTC Codes are cleared using the Yanmar Service tool. When the Yanmar Fault Codes are cleared, the associated Thermo King Alarm Code is also cleared. The codes are still available by downloading the ServiceWatch Data Logger using the WinTrac Service Tool.

Connecting and Using the Yanmar Engine Diagnostic Tool

The Connect Engine Service Tool feature allows the unit to be powered down but maintains power to the Engine Control Unit (ECU) for diagnostic purposes. This allows the Yanmar Smart Assist Direct (YSAD) Diagnostic Tool to be connected to the Yanmar Engine Control Unit without having the rest of the unit powered up.

Purpose:

To connect and use the Yanmar Diagnostic Tool.

Materials Required:

  • Yanmar Diagnostic Tool

  • Yanmar SmartAssist Direct Diagnostic Software installed on a PC

Operation:

The Yanmar Diagnostic Tool is used to connect the Computer USB Port to the Yanmar Engine Control Unit data connector located in the Unit Control Box. Yanmar SmartAssist Direct (YSAD) Software installed on the Computer is used to communicate with the Yanmar Engine Control Unit (ECU). This allows ECU information to be retrieved, Yanmar Fault Codes to be read, operational data to be examined and updated and other diagnostic functions to be performed.

Connection:

There are three connections from the Thermo King Base Controller to the Yanmar Engine Control Unit (ECU):

  • Keyswitch Signal – This signal sends power to the ECU.

  • Run Signal – This signal is high when the Base Controller is requesting the engine to run.

  • CAN Bus – All other communications between the Base Controller and the ECU are via the CAN Bus.

Diagnostic Process:

Procedure

Step Action Result Comments
1 The unit battery must be connected and the Microprocessor Power Switch must be turned on.    
2 Turn the unit on and enter the Maintenance Menu.    
3 In the Maintenance Menu, scroll to and select Connect Engine Service Tool.   Connect Engine Service Tool is the last item in the Maintenance Menu.
4 Open the Control Box and locate the Yanmar Diagnostic Connector near the fuse panel.
Note Some early build SGUM units (before November 2020) have the YSAD connector located under the alternator near the power receptacle - NOT in the control box.

SGCO

SGUM

SGUM 5000 (early units, see note)

5 Connect the Yanmar Diagnostic Tool to the Yanmar Diagnostic Connector in the unit Control Box using the supplied cable.
6 Connect the Yanmar Diagnostic Tool to the PC using the supplied cable.   This cable is a standard USB cable. Excessive cable length of the USB cable may affect operation.
7 Start the Yanmar SA-Direct (YSAD) software. To maintain current status, the Yanmar SmartAssist Direct (YSAD) software must be started every 90 days while the PC is connected to the internet. This verifies the YSAD software and extends the license for another 90 days.
8 Complete the login information as shown.
9 Select ECU Access, then select Diagnostics (Execution).
10 Click OK.
11 Click Start.
12 Select ECU Information - Summary Information.   This displays engine information, such as the engine serial number, run hours, and start cycles.
   
13 Select Diagnostic Codes – Active DTC.
14 Select Diagnostic Codes – Logged DTC.   Any logged fault codes will be added to the list.
   
15 To clear all fault codes, click the All Clear button. Enter your password in the popup window when prompted. All fault codes in the ECU will be cleared. Operation must be performed in Connect Engine Service Tool mode. YSAD will not allow codes to be cleared while engine is operating.
   

For additional information, refer to the Yanmar Diagnostic Documentation.

Software Download for Flash to Replacement ECU

Purpose:

Preparing ECU for Replacement.

Materials Required:

  • Yanmar Diagnostic Tool

  • Computer with current Yanmar SmartAssist Direct Diagnostic Software

Operation:

The Yanmar Diagnostic Tool is used to connect the computer USB Port to the Yanmar Engine Control Unit data connector located in the Unit Control Box. Yanmar SmartAssist Direct (YSAD) Software installed on the computer is used to communicate with the Yanmar Engine Control Unit (ECU). This allows ECU information to be retrieved, Yanmar Fault Codes to be read, operational data to be examined and updated, and other diagnostic functions to be performed.

Procedure

Step Action Result Comments
1 With an internet connection, open YSAD, select Data Management tab, and click on ECU Soft Download.
2 Select ECU Exchange (Onboard Reprogramming)   Onboard programming is currently not supported.
   
3 Choose the reason for reprogramming the ECU and click Next.   This information is only used for data collection purposes, and does not affect the version of software downloaded.
   
4 Locate engine model number, serial number, and enter the values into data fields. Click Send when finished.
Note Use upper case letters when entering values.
  This information is used to compare ECU and engine serial number data against Yanmar’s database.
   
5 Click the ECU Serial No field.
Note Use scroll bar located at bottom of screen if required.
6 Enter the serial number of the new ECU and click Set.
7 Click the DL check box.
8 Verify Serial Number entered is correct and click Send. Download will start. ECU software has been downloaded to PC. If the following error is shown, the ECU serial number is already programmed to a different engine serial number.
   
9 Proceed to step 9 of Service Procedure F06A to continue.    

Uploading Information to Yanmar

Purpose:

To send ECU software back to database after ECU flash or if flash was cancelled.

Materials Required:

  • Yanmar Diagnostic Tool

  • Computer with current Yanmar SmartAssist Direct Diagnostic Software

Operation:

The Yanmar Diagnostic Tool is used to connect the Computer USB Port to the Yanmar Engine Control Unit data connector located in the Unit Control Box. Yanmar SmartAssist Direct (YSAD) Software installed on the computer is used to communicate with the Yanmar Engine Control Unit (ECU). This allows ECU information to be retrieved, Yanmar Fault Codes to be read, operational data to be examined and updated, and other diagnostic functions to be performed.

Procedure

Step Action Result Comments
1 Select Data Management, click on Exchange Information, then choose either Exchange Complete or Exchange Cancel.   Choose Exchange Complete after ECU flash or use Exchange Cancel if ECU flash was not performed.
   
2 Click check box to select software and click Send.
3 ECU software is being sent back to the Yanmar core.
4 Upload complete.

Updating ECU Software From Yanmar Core Database

Purpose:

To reprogram ECU / Required Data Exchange.

Materials Required:

  • Yanmar Diagnostic Tool

  • Computer with current Yanmar SmartAssist Direct Diagnostic Software

Operation:

The Yanmar Diagnostic Tool is used to connect the Computer USB Port to the Yanmar Engine Control Unit data connector located in the Unit Control Box. Yanmar SmartAssist Direct (YSAD) Software installed on the computer is used to communicate with the Yanmar Engine Control Unit (ECU). This allows ECU information to be retrieved, Yanmar Fault Codes to be read, operational data to be examined and updated, and other diagnostic functions to be performed.

Procedure

Step Action Result Comments
1 With an internet connection, open YSAD, select Data Management, and click on ECU Soft Download.
2 Choose Software Update (Onboard Reprogramming) and click Select.
3 Choose reason for ECU Reprogramming (Quality Improvement) and click Next.
4 Enter Engine Model Number and Serial Number into data boxes and click Send.
Note Use upper case letters when entering values.
5 Click on the Details button underneath the Notes heading.
Note Use scroll bar located at bottom of screen if required.
6 Compare MapSoftPno Pre Code and New Code. New code should be a different number if there is a software update available. Click OK.
7 Click the DL check box and click Send.
8 Software update has been downloaded. Click OK.   Begin to write software to ECU using YSAD.
   
9 Connect YSAD to unit.
Important Unit must be in Connect Engine Service Tool mode.
  Use Service Procedure A60A steps 1 to 8.
10 From the YSAD Main Menu, click the ECU Access tab and click ECU Programming.
11 If ECU replacement, select First Time ECU Programming. If software update only, select Update.
12 Click on correct engine serial number and click Next.
13 Click OK.
14 Click OK.
15 Progress bar is shown as ECU is being flashed. This may take over 10 minutes.   Programming will not initiate if YSAD is not properly connected.
   
16 Processing completed. Turn the unit off for a minimum of two minutes. Click OK.
17 Click Yes.
18 Exchange information is being transmitted to the YSAD core. Uploaded screen is displayed.
19 Click No.

ECU Recovery/Failures During Flash Load Procedures

Purpose:

In case of power failure or accidental disconnect etc. while performing F01A, F05A, or F06A.

Materials Required:

  • Yanmar Diagnostic Tool

  • Computer with current Yanmar SmartAssist Direct Diagnostic Software

Operation:

The Yanmar Diagnostic Tool is used to connect the computer USB Port to the Yanmar Engine Control Unit data connector located in the Unit Control Box. Yanmar SmartAssist Direct (YSAD) Software installed on the computer is used to communicate with the Yanmar Engine Control Unit (ECU). This allows ECU information to be retrieved, Yanmar Fault Codes to be read, operational data to be examined and updated, and other diagnostic functions to be performed.

Important Notes:

  • The procedures below include four types of ECU programming failure.

ECU Programming or ECU Updating of Software Failure During Flash

Procedure

Step Action Result Comments
1 Download of object failed during ECU update/flash. Click OK.
2 Click Cancel.
3 From ECU Access, select ECU Reprogramming (Flash).
4 Select Re-write (When error occurs while writing it).
5 Select engine model to begin re-write and click Next.
6 Verify engine model and serial number and click OK.
7 Verify and click OK.
8 ECU activation flashing process is resumed.

Communication Interruption During Flashing Process

Procedure

Step Action Result Comments
1 Communication with ECU failed message is displayed. Click OK.
2 Select the engine model to begin reprogramming and click Next. Reprogramming will be restarted.  
   

Abnormality Occurrence During Flashing Process

Procedure

Step Action Result Comments
1 Abnormality message is displayed. Click Yes and flash process should continue.

Accessing and Downloading YSAD Troubleshooting Manual

Downloading this manual will allow the technician to access much more information while diagnosing engine trouble codes.

  1. Open YSAD and log in using your ID and Password.

  2. Click the “Database Access” tab on the left side of the screen, then click “Troubleshooting Manual Download” tab.

  3. Check the box for “TNV Troubleshooting Manual (TK)”, then click download.

    Note If the manual was previously downloaded the manual will not show up here, skip to step 6 for manual viewing instructions.

  4. A pop-up will appear and show status of the download.

  5. When Download is complete, click “OK”, then click “Cancel”.

  6. Open the manual by clicking the “Data Management” tab and choose “Manual Search”.

  7. Click the “TK488CR (English)” Manual, then click “OK”.

  8. The manual will open within the web browser.

    Note Add the webpage to your Favorites for quick access.
    Note Next time you need to access a manual you will not need to go through the download process. Simply open your web browser (Ex - Internet Explorer) and open the Favorite link you created for the manual .
    Note You do not need internet access to open the manual within your web browser once it has been downloaded to your computer .