kubota engine training: wg1605, spark ignited wg1605 gas engine...kubota engine america service...

KUBOTA ENGINE AMERICAService Training

Kubota Engine Training: WG1605, spark ignited

WG1605 Engine Training: System OverviewsMechanical Components Electronic Components and SensorsOperationService Tool

Fuel System Overview:

System Overview - Gaseous:

ECI ECM

LPG TANK FUELFILTER

ELECTRICLOCK OFF

MANUALVALVE

DUAL STAGEREGULATOR

MIXERAIR FILTRATIONSYSTEM

INTAKE MANIFOLD

EXHAUST MANIFOLD

CATALYST

ECTOIL

IGNITIONCOIL PACK

CCKCPK

- +BATTERY

STARTER

ALTERNATOR

INSTURMENTPANEL

TPS 1&2

FRESH AIR

LIQUID FUEL HIGH PRESSURE

LOW PRESSURE FUEL

AIR FUEL MIXTURE

ENGINE COOLANT

EXHAUST GASES

ECI00001 REV A

System Overview - Gasoline:

System Overview - Dual Fuel:

ECI ECM

LPG TANKFUELFILTER

ELECTRICLOCK OFF

MANUALVALVE

DUAL STAGEREGULATOR

MIXERAIR FILTRATIONSYSTEM

INTAKE MANIFOLD

EXHAUST MANIFOLD

CATALYST

ECTOIL

IGNITIONCOIL PACK

CCKCPK

- +BATTERY

STARTER

ALTERNATOR

INSTRUMENTPANEL

TPS 1&2

FRESH AIR

LIQUID LPG FUEL HIGH PRESSURE

LPG LOW PRESSURE FUEL

LPG AIR FUEL MIXTURE

ENGINE COOLANT

EXHAUST GASES

ECI00003 REV A

GASOLINE FUEL RAIL

GASOLINETANK

FUELFILTER

ELECTRICFUELPUMP

RETURNLESSFUEL

PRESSUREREGULATOR

SELECTSWITCH

GASOLINE SUCTION

GASOLINE PRESSUREGASOLINE REGULATED

Mechanical Components: WG1605 engines are similar to V1505. Some differences include: Intake and exhaust manifolds. Positive Crankcase Ventilation system. Pistons. Cylinder heads and valves. Crankcase, Camshaft.

Intake & Exhaust Manifolds: Exhaust manifolds are shielded and engineered for higher temperatures

Intake manifolds use longer runners

Positive Crankcase Ventilation (PCV) System:

PCV Valve

Controls amount of blow-by gas and fresh air.

Pistons and Rings: “Dished” pistons are the main combustion chamber. (Gaseous compression ratios are nearly a third of a comparable diesel.)

Top Ring: Barrel ShapeSecond Ring: Tapered

Oil Control Ring

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.

Piston Recession Example:

Cross-Flow Cylinder Head: Low heat conduction between intake and exhaust ports.

Camshaft: The camshaft’s timing pin (5), is attached to the gear (4).

Gear shaft: The gear shaft deletes the fuel cam from the 05-E3B engine.

Flywheel: The WG1605 flywheel is designed to work alongside the crankshaft sensor.

Fuel Delivery Pipe and Injectors: ECU controlled fuel delivery (pulse width modulated).

Port Fuel InjectionFuel Pressure 40 – 45 PSI**(can fluctuate between 35-75#)

Fuel Delivery Pipe and Injectors:

12-Volt operation 2-wire injector Pulse-width

modulation ECU Controlled

ground driver.

Fuel Delivery Pipe and Injectors:

Three Way Catalyst: A 3-way catalyst oxidizes:

(1)HC CO2 and H20

(2) CO CO2

(3) NOx N2

Electronic Control Unit, ECU: Utilizes inputs from the engine sensors to precisely meter fuel, control speed and remain emission compliant.

Electronic Control Unit, ECU:

ECU Wiring Diagram:

ECU Inputs and Outputs:

Ignition Coil: ECU controlled inductive coils.

As primary windings dwell then collapse, the secondary windings yield a high voltage output via the spark plug.

Ignition Coil:

Fuel lines are bold black color. Electrical circuits are think black.

Gasoline System:

Variable controlled by ECU.

Electric Fuel Pump:

Power to pump supplied by ECU controlled relay.

Fuel pump is Pulse Width Modulated (PWM) through ECU.

Electric Fuel Pump:

Press/Temp Sensor

Manifold

Return

Outlet

Fuel Pressure Manifold, FPM:

Propane / Butane ratio chart.

Depending on energy content, spark timing is adjusted.

LPG Fuel Content:

Note: pressure at low temperatures.

1. Liquid Output2. Quick Fill Valve3. Safety Valve4. 80% Fill Valve5. Gauge6. Vapor Pickup Tube7. 80% Fill Valve Tube8. Gauge Float9. Liquid Pickup Tube

LPG Tank and Filter:

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:

No electrical fault codes for valve.Lock Off Valve:

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

Dual Stage Regulator, DSR:

Test Port

DSR – Exploded View:

Stand alone module Controlled via CAN from ECU Contains:

Control Module Pressure/Temp. sensor Fast acting solenoid valve

DEPR (Direct Electronic Pressure Regulator):

Cavity Color Function

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

engine harness) No user serviceable parts inside

DEPR – Electrical:

All mechanical unit No

electrical/electronic controls

Mixer:

Engine Coolant Temperature:

Temperature SensorSenses engine

temperature for running and shut-down

Engine Coolant Temperature:

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 illumination, especially with LEDs.

Oil Pressure Switch: Standard Kubota Oil Pressure Switch:

Closed: 0-7 psiOpen > 7psi

Electronic Throttle Body, ETBECU controlled, electronic motor driven mechanical throttle body connected to the intake.

Electric motor connected to throttle.

ECU controlled based on foot pedal input.

Electronic Throttle Body, ETB

Electronic Throttle Body, ETBDual throttle position

sensors, FPP1 and FPP2.

Depending on the specification, TPS faults force engine idle or shutdown.

KEA standard: FPP1 0-5v and FPP2 2.5-0v.

Electronic Throttle Body, ETB

Oxygen (O2) Sensor: Pre and Post catalyst feedback control for precise air-fuel ratio management.

4 wire sensor including heater.

Pre- and Post-Catalyst Oxygen sensors

Oxygen (O2) Sensor:

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:

Feedback Control (Closed Loop)Orange line is air fuel ratio as controlled by the ECU based 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 is controlled by closed-loop mode for all operating parameters.

Theoretical air/fuel ratio

Lean Zone

Rich Zone

Oxygen (O2) Sensor:

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:

Pre-Cat O2 Sensor electrical:

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 O2 Sensor:

Post-Cat O2 Sensor electrical:

Normal O2 Switching:

Test located at bottom 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 appropriate DTC sets

Test Status Indicator

O2 Sensor Testing:

Temperature and Manifold Absolute Pressure Sensor: TMAP.

Mounted in the intake manifold and provides ECU data to calculate air flow pressure and density.

Combines both intake air temperature and intake manifold pressure

Will compensate for intake temperature, altitude, and air cleaner restriction

Temperature and Manifold Absolute Pressure Sensor:

Crankshaft Position Sensor: Provides engine RPM information to the ECU.

Crankshaft Position Sensor:

Camshaft Position Sensor: Identifies which cylinders are in compression to begin spark timing.

Camshaft Position Sensor:

TDC TDC

18o ATDC #1 Compression

Cam and Crank Sensors:

Knock Sensor: Early detonation detection via mechanical vibration at the cylinder head/block deck level.

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.

Knock Sensor:

Service ManualsWorkshop & Diagnosis Manuals

Service ToolE-Com Interface Device

Connects between USB port and connection on engine

Can be connected any time, engine running or not

Service ToolInterface Connector

Service ToolSoftware

Interface available through KEA’s Parts Department. Software is Free, and available for

download through K-ISS.

Service Tool

Service ToolData 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: Shows real-time ECU data.

Service ToolSnap Shot Data

Right click the icons you want to see and push “P” on keyboard

Service ToolDiagnostic Trouble Codes (DTC’s)

DTC’s will only display with key on

Service ToolDiagnostic Trouble Codes – Active DTC

Service ToolDTC Fault Information

Double click on box next to DTC to display Historic Fault Information

Service ToolDTC Fault Information – Snap Shot

Service ToolDTC Fault Information – Flight Data Recorder

8 Seconds before fault, 2 Seconds after fault

Service ToolErasing Historic DTC’s

Click on “Clear All Faults”

Service ToolTest Screen

Service ToolSpark Kill Test

Service ToolInjector Kill Test

Service ToolDrive By Wire (DBW) Test

Service ToolClosed Loop Test

Engine Mechanical DamageIf the engine is mechanically damaged it

will not 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 operation)

Fuel pressure problems can cause the system to go rich or lean also VERIFY CORRECT FUEL PRESSURE (ALSO

VOLUME)

Engine Mechanical DamageBad 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 ALWAYS VALIDATE THAT THE SENSOR

INPUTS ARE ACCURATE

GCP Display – Gauge Page

GCP – Raw Volts Page

GCP Display – Service 1 Page

GCP Display – Service 2 Page

GCP Display – Tests Page

GCP Display – Test Page

GCP Display – Faults Page

kubota engine training: wg1605, spark ignited wg1605 gas engine...kubota engine america service...

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