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:
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Yanmar Diagnostic Tool
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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):
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Keyswitch Signal – This signal sends power to the ECU.
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Run Signal – This signal is high when the Base Controller is requesting the engine to run.
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CAN Bus – All other communications between the Base Controller and the ECU are via the CAN Bus.
Procedure
Software Download for Flash to Replacement ECU
Purpose:
Preparing ECU for Replacement.
Materials Required:
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Yanmar Diagnostic Tool
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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
Uploading Information to Yanmar
Purpose:
To send ECU software back to database after ECU flash or if flash was cancelled.
Materials Required:
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Yanmar Diagnostic Tool
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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
Updating ECU Software From Yanmar Core Database
Purpose:
To reprogram ECU / Required Data Exchange.
Materials Required:
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Yanmar Diagnostic Tool
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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
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:
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Yanmar Diagnostic Tool
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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:
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The procedures below include four types of ECU programming failure.
ECU Programming or ECU Updating of Software Failure During Flash
Procedure
Communication Interruption During Flashing Process
Abnormality Occurrence During Flashing Process
Accessing and Downloading YSAD Troubleshooting Manual
Downloading this manual will allow the technician to access much more information while diagnosing engine trouble codes.
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Open YSAD and log in using your ID and Password.
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Click the “Database Access” tab on the left side of the screen, then click “Troubleshooting Manual Download” tab.
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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. -
A pop-up will appear and show status of the download.
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Open the manual by clicking the “Data Management” tab and choose “Manual Search”.
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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 .