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KUBOTA ENGINE AMERICA

Service Training

Service Tool

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Summary of Contents for WG1605

Page 1: ...KUBOTA ENGINE AMERICA Service Training Kubota Engine Training WG1605 spark ignited...

Page 2: ...KUBOTA ENGINE AMERICA Service Training WG1605 Engine Training System Overviews Mechanical Components Electronic Components and Sensors Operation Service Tool...

Page 3: ...KUBOTA ENGINE AMERICA Service Training Fuel System Overview...

Page 4: ...KUBOTA ENGINE AMERICA Service Training Fuel System Overview...

Page 5: ...DUAL STAGE REGULATOR EPR MIXER AIR FILTRATION SYSTEM ETB INTAKE MANIFOLD EXHAUST MANIFOLD CATALYST ECT OIL TMAP IGNITION COIL PACK CCK CPK HEGO HEGO BATTERY STARTER ALTERNATOR INSTURMENT PANEL TPS 1 2...

Page 6: ...KUBOTA ENGINE AMERICA Service Training System Overview Gasoline...

Page 7: ...ATALYST ECT OIL TMAP IGNITION COIL PACK CCK CPK HEGO HEGO BATTERY STARTER ALTERNATOR INSTRUMENT PANEL TPS 1 2 KNK CAN FRESH AIR LIQUID LPG FUEL HIGH PRESSURE LPG LOW PRESSURE FUEL LPG AIR FUEL MIXTURE...

Page 8: ...Service Training Mechanical Components WG1605 engines are similar to V1505 Some differences include Intake and exhaust manifolds Positive Crankcase Ventilation system Pistons Cylinder heads and valve...

Page 9: ...KUBOTA ENGINE AMERICA Service Training Intake Exhaust Manifolds Exhaust manifolds are shielded and engineered for higher temperatures Intake manifolds use longer runners...

Page 10: ...KUBOTA ENGINE AMERICA Service Training Positive Crankcase Ventilation PCV System PCV Valve Controls amount of blow by gas and fresh air...

Page 11: ...ERICA Service Training Pistons and Rings Dished pistons are the main combustion chamber Gaseous compression ratios are nearly a third of a comparable diesel Top Ring Barrel Shape Second Ring Tapered O...

Page 12: ...KUBOTA ENGINE AMERICA Service Training Cylinder Head and Valves Spark plugs are recessed in head and protrude into the main combustion chamber Valves are equipped with special heat resistant alloy...

Page 13: ...KUBOTA ENGINE AMERICA Service Training Piston Recession Example...

Page 14: ...KUBOTA ENGINE AMERICA Service Training Cross Flow Cylinder Head Low heat conduction between intake and exhaust ports...

Page 15: ...KUBOTA ENGINE AMERICA Service Training Camshaft The camshaft s timing pin 5 is attached to the gear 4...

Page 16: ...KUBOTA ENGINE AMERICA Service Training Gear shaft The gear shaft deletes the fuel cam from the 05 E3B engine...

Page 17: ...KUBOTA ENGINE AMERICA Service Training Flywheel The WG1605 flywheel is designed to work alongside the crankshaft sensor...

Page 18: ...KUBOTA ENGINE AMERICA Service Training Fuel Delivery Pipe and Injectors ECU controlled fuel delivery pulse width modulated Port Fuel Injection Fuel Pressure 40 45 PSI can fluctuate between 35 75...

Page 19: ...KUBOTA ENGINE AMERICA Service Training Fuel Delivery Pipe and Injectors...

Page 20: ...KUBOTA ENGINE AMERICA Service Training 12 Volt operation 2 wire injector Pulse width modulation ECU Controlled ground driver Fuel Delivery Pipe and Injectors...

Page 21: ...KUBOTA ENGINE AMERICA Service Training Three Way Catalyst A 3 way catalyst oxidizes 1 HC CO2 and H20 2 CO CO2 3 NOx N2...

Page 22: ...KUBOTA ENGINE AMERICA Service Training Electronic Control Unit ECU Utilizes inputs from the engine sensors to precisely meter fuel control speed and remain emission compliant...

Page 23: ...KUBOTA ENGINE AMERICA Service Training Electronic Control Unit ECU...

Page 24: ...KUBOTA ENGINE AMERICA Service Training ECU Wiring Diagram...

Page 25: ...KUBOTA ENGINE AMERICA Service Training ECU Inputs and Outputs...

Page 26: ...KUBOTA ENGINE AMERICA Service Training Ignition Coil ECU controlled inductive coils As primary windings dwell then collapse the secondary windings yield a high voltage output via the spark plug...

Page 27: ...KUBOTA ENGINE AMERICA Service Training Ignition Coil...

Page 28: ...KUBOTA ENGINE AMERICA Service Training Fuel lines are bold black color Electrical circuits are think black Gasoline System...

Page 29: ...KUBOTA ENGINE AMERICA Service Training Variable controlled by ECU Electric Fuel Pump...

Page 30: ...KUBOTA ENGINE AMERICA Service Training Electric Fuel Pump...

Page 31: ...KUBOTA ENGINE AMERICA Service Training Power to pump supplied by ECU controlled relay Fuel pump is Pulse Width Modulated PWM through ECU Electric Fuel Pump...

Page 32: ...KUBOTA ENGINE AMERICA Service Training Press Temp Sensor Manifold Return Inlet Outlet Fuel Pressure Manifold FPM...

Page 33: ...KUBOTA ENGINE AMERICA Service Training Fuel Pressure Manifold FPM...

Page 34: ...KUBOTA ENGINE AMERICA Service Training Propane Butane ratio chart Depending on energy content spark timing is adjusted LPG Fuel Content Note pressure at low temperatures...

Page 35: ...TA ENGINE AMERICA Service Training 1 Liquid Output 2 Quick Fill Valve 3 Safety Valve 4 80 Fill Valve 5 Gauge 6 Vapor Pickup Tube 7 80 Fill Valve Tube 8 Gauge Float 9 Liquid Pickup Tube LPG Tank and Fi...

Page 36: ...KUBOTA ENGINE AMERICA Service Training Pilot Normally closed Grounded provided by ECU Pilot opens allowing pressure to outlet side Pressure begins to equalize and main valve opens fully Lock Off Valve...

Page 37: ...KUBOTA ENGINE AMERICA Service Training No electrical fault codes for valve Lock Off Valve...

Page 38: ...raining Fuel Inlet Fuel Outlet Coolant Primary Secondary Regulator performs 2 functions Vaporizes liquid fuel Regulates fuel pressure Only maintenance is periodic draining See maintenance schedule Dua...

Page 39: ...KUBOTA ENGINE AMERICA Service Training DSR Exploded View...

Page 40: ...KUBOTA ENGINE AMERICA Service Training...

Page 41: ...KUBOTA ENGINE AMERICA Service Training Stand alone module Controlled via CAN from ECU Contains Control Module Pressure Temp sensor Fast acting solenoid valve DEPR Direct Electronic Pressure Regulator...

Page 42: ...n 1 WT CAN Termination 2 DB PK CAN H 3 PK DG Power Relay Output 4 BK Ground 5 DB WT CAN L 6 RD TN B from Fuse 2 DTC s are communicated to ECU via CAN Harness pin out shown below terminal view of engin...

Page 43: ...KUBOTA ENGINE AMERICA Service Training...

Page 44: ...KUBOTA ENGINE AMERICA Service Training All mechanical unit No electrical elec tronic controls Mixer...

Page 45: ...KUBOTA ENGINE AMERICA Service Training...

Page 46: ...KUBOTA ENGINE AMERICA Service Training Engine Coolant Temperature...

Page 47: ...KUBOTA ENGINE AMERICA Service Training Temperature Sensor Senses engine temperature for running and shut down Engine Coolant Temperature...

Page 48: ...ice Training Oil Pressure Switch If oil pressure falls below specification the warning lamp will illuminate ECU pin 35 Note water ingress may also cause the contacts to corrode and cause false illumin...

Page 49: ...KUBOTA ENGINE AMERICA Service Training Oil Pressure Switch Standard Kubota Oil Pressure Switch Closed 0 7 psi Open 7psi...

Page 50: ...KUBOTA ENGINE AMERICA Service Training Electronic Throttle Body ETB ECU controlled electronic motor driven mechanical throttle body connected to the intake...

Page 51: ...KUBOTA ENGINE AMERICA Service Training Electric motor connected to throttle ECU controlled based on foot pedal input Electronic Throttle Body ETB...

Page 52: ...E AMERICA Service Training Electronic Throttle Body ETB Dual throttle position sensors FPP1 and FPP2 Depending on the specification TPS faults force engine idle or shutdown KEA standard FPP1 0 5v and...

Page 53: ...KUBOTA ENGINE AMERICA Service Training Electronic Throttle Body ETB...

Page 54: ...KUBOTA ENGINE AMERICA Service Training Oxygen O2 Sensor Pre and Post catalyst feedback control for precise air fuel ratio management 4 wire sensor including heater...

Page 55: ...KUBOTA ENGINE AMERICA Service Training Pre and Post Catalyst Oxygen sensors Oxygen O2 Sensor...

Page 56: ...UBOTA ENGINE AMERICA Service Training Heated for more accuracy beyond exhaust temps HEGO1 pre cat senses rich lean to adjust fuel mixture HEGO2 post cat checks catalyst for efficiency Oxygen O2 Sensor...

Page 57: ...sed on O2 sensor feedback Oxygen sensor is sensing mixture and providing feedback WG1605 is in Open Loop for one minute after start up predetermined fuel mixture not controlled by oxygen sensor then i...

Page 58: ...KUBOTA ENGINE AMERICA Service Training Bosch LSF4 sensor Pre cat used for closed loop fuel control Used as a rich lean switch Only 1 DTC EGO 1 Open Lazy Pre Cat O2 Sensor...

Page 59: ...KUBOTA ENGINE AMERICA Service Training Pre Cat O2 Sensor electrical...

Page 60: ...INE AMERICA Service Training Bosch LSF4 sensor Post cat used mainly for catalyst efficiency checking Post cat O2 failure should not cause an engine running problem Only 1 DTC EGO 2 Open Lazy Post Cat...

Page 61: ...KUBOTA ENGINE AMERICA Service Training Post Cat O2 Sensor electrical...

Page 62: ...KUBOTA ENGINE AMERICA Service Training Normal O2 Switching...

Page 63: ...tom right of Tests page Automated tests Tests sensor integrity and response Tests pre then post sensor Pre must pass before post can be tested Test status provides notification of failure type and app...

Page 64: ...KUBOTA ENGINE AMERICA Service Training Temperature and Manifold Absolute Pressure Sensor TMAP Mounted in the intake manifold and provides ECU data to calculate air flow pressure and density...

Page 65: ...MERICA Service Training Combines both intake air temperature and intake manifold pressure Will compensate for intake temperature altitude and air cleaner restriction Temperature and Manifold Absolute...

Page 66: ...KUBOTA ENGINE AMERICA Service Training Temperature and Manifold Absolute Pressure Sensor...

Page 67: ...KUBOTA ENGINE AMERICA Service Training Crankshaft Position Sensor Provides engine RPM information to the ECU...

Page 68: ...KUBOTA ENGINE AMERICA Service Training Crankshaft Position Sensor...

Page 69: ...KUBOTA ENGINE AMERICA Service Training Camshaft Position Sensor Identifies which cylinders are in compression to begin spark timing...

Page 70: ...KUBOTA ENGINE AMERICA Service Training Camshaft Position Sensor...

Page 71: ...KUBOTA ENGINE AMERICA Service Training TDC TDC Cam Crank 18o ATDC 1 Compression Cam and Crank Sensors...

Page 72: ...KUBOTA ENGINE AMERICA Service Training Knock Sensor Early detonation detection via mechanical vibration at the cylinder head block deck level...

Page 73: ...AMERICA Service Training Reacts with a specific frequency from detonation When knock is detected voltage output is increased ECU retards ignition timing Installed sensor at 35 50 degrees from vertical...

Page 74: ...KUBOTA ENGINE AMERICA Service Training Service Manuals Workshop Diagnosis Manuals...

Page 75: ...KUBOTA ENGINE AMERICA Service Training Service Tool E Com Interface Device Connects between USB port and connection on engine Can be connected any time engine running or not...

Page 76: ...KUBOTA ENGINE AMERICA Service Training Service Tool Interface Connector...

Page 77: ...KUBOTA ENGINE AMERICA Service Training Service Tool Software Interface available through KEA s Parts Department Software is Free and available for download through K ISS...

Page 78: ...KUBOTA ENGINE AMERICA Service Training Service Tool...

Page 79: ...vice Training Service Tool Data Monitor page can be chosen using either Page on Menu Bar or arrows Historic Faults Shows historic data This can only be erased using the service tool Active Faults Show...

Page 80: ...KUBOTA ENGINE AMERICA Service Training Service Tool Snap Shot Data Right click the icons you want to see and push P on keyboard...

Page 81: ...KUBOTA ENGINE AMERICA Service Training Service Tool Diagnostic Trouble Codes DTC s DTC s will only display with key on...

Page 82: ...KUBOTA ENGINE AMERICA Service Training Service Tool Diagnostic Trouble Codes Active DTC...

Page 83: ...KUBOTA ENGINE AMERICA Service Training Service Tool DTC Fault Information Double click on box next to DTC to display Historic Fault Information...

Page 84: ...KUBOTA ENGINE AMERICA Service Training Service Tool DTC Fault Information Snap Shot...

Page 85: ...KUBOTA ENGINE AMERICA Service Training Service Tool DTC Fault Information Flight Data Recorder 8 Seconds before fault 2 Seconds after fault...

Page 86: ...KUBOTA ENGINE AMERICA Service Training Service Tool Erasing Historic DTC s Click on Clear All Faults...

Page 87: ...KUBOTA ENGINE AMERICA Service Training Service Tool Test Screen...

Page 88: ...KUBOTA ENGINE AMERICA Service Training Service Tool Spark Kill Test...

Page 89: ...KUBOTA ENGINE AMERICA Service Training Service Tool Injector Kill Test...

Page 90: ...KUBOTA ENGINE AMERICA Service Training Service Tool Drive By Wire DBW Test...

Page 91: ...KUBOTA ENGINE AMERICA Service Training Service Tool Closed Loop Test...

Page 92: ...move O2 properly i e piston or ring damage valve not sealing This will cause a low O2 condition in the exhaust and the ECU will react by SUBTRACTING fuel in the CL BM program if in closed loop operat...

Page 93: ...ical Damage Bad sensor inputs to the engine can cause the system to go rich or lean depending on the failure For example a bad MAP input can either starve or flood and engine depending on how it fails...

Page 94: ...KUBOTA ENGINE AMERICA Service Training GCP Display Gauge Page...

Page 95: ...KUBOTA ENGINE AMERICA Service Training GCP Raw Volts Page...

Page 96: ...KUBOTA ENGINE AMERICA Service Training GCP Display Service 1 Page...

Page 97: ...KUBOTA ENGINE AMERICA Service Training GCP Display Service 2 Page...

Page 98: ...KUBOTA ENGINE AMERICA Service Training GCP Display Tests Page...

Page 99: ...KUBOTA ENGINE AMERICA Service Training GCP Display Test Page...

Page 100: ...KUBOTA ENGINE AMERICA Service Training GCP Display Faults Page...

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