Kubota Engine Training: WG1605, spark ignited

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Walter Charles
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1 Kubota Engine Training: WG1605, spark ignited

2 WG1605 Engine Training: System Overviews Mechanical Components Electronic Components and Sensors Operation Service Tool

3 Fuel System Overview:

4 Fuel System Overview:

5 System Overview - Gaseous: LPG TANK MANUAL VALVE FUEL FILTER INSTURMENT PANEL FRESH AIR LIQUID FUEL HIGH PRESSURE LOW PRESSURE FUEL AIR FUEL MIXTURE ELECTRIC LOCK OFF ENGINE COOLANT EXHAUST GASES DUAL STAGE REGULATOR EPR CAN ECI ECM AIR FILTRATION SYSTEM MIXER TPS 1&2 ETB TMAP INTAKE MANIFOLD - + BATTERY IGNITION COIL PACK ALTERNATOR ECT OIL CCK CPK KNK STARTER EXHAUST MANIFOLD HEGO CATALYST HEGO ECI00001 REV A

6 System Overview - Gasoline:

7 System Overview - Dual Fuel: FRESH AIR LIQUID LPG FUEL HIGH PRESSURE LPG LOW PRESSURE FUEL LPG AIR FUEL MIXTURE FUEL FILTER MANUAL VALVE LPG TANK INSTRUMENT PANEL ENGINE COOLANT EXHAUST GASES GASOLINE SUCTION GASOLINE PRESSURE ELECTRIC LOCK OFF SELECT SWITCH GASOLINE REGULATED GASOLINE TANK DUAL STAGE REGULATOR FPP FUEL FILTER EPR CAN ECI ECM AIR FILTRATION SYSTEM MIXER ELECTRIC FUEL PUMP RETURNLESS FUEL PRESSURE REGULATOR TPS 1&2 ETB TMAP INTAKE MANIFOLD - + BATTERY ALTERNATOR STARTER GASOLINE FUEL RAIL EXHAUST MANIFOLD HEGO IGNITION COIL PACK ECT OIL CCK CPK KNK CATALYST HEGO ECI00003 REV A

8 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.

9 Intake & Exhaust Manifolds: Intake manifolds use longer runners Exhaust manifolds are shielded and engineered for higher temperatures

10 Positive Crankcase Ventilation (PCV) System: PCV Valve Controls amount of blow-by gas and fresh air.

11 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 Oil Control Ring

12 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.

13 Piston Recession Example:

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

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

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

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

18 Fuel Delivery Pipe and Injectors: ECU controlled fuel delivery (pulse width modulated). Port Fuel Injection Fuel Pressure PSI* *(can fluctuate between 35-75#)

19 Fuel Delivery Pipe and Injectors:

20 Fuel Delivery Pipe and Injectors: 12-Volt operation 2-wire injector Pulse-width modulation ECU Controlled ground driver.

21 Three Way Catalyst: A 3-way catalyst oxidizes: (1)HC CO2 and H20 (2) CO CO2 (3) NOx N2

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

23 Electronic Control Unit, ECU:

24 ECU Wiring Diagram:

25 ECU Inputs and Outputs:

26 Ignition Coil: ECU controlled inductive coils. As primary windings dwell then collapse, the secondary windings yield a high voltage output via the spark plug.

27 Ignition Coil:

28 Gasoline System: Fuel lines are bold black color. Electrical circuits are think black.

29 Electric Fuel Pump: Variable controlled by ECU.

30 Electric Fuel Pump:

31 Electric Fuel Pump: Power to pump supplied by ECU controlled relay. Fuel pump is Pulse Width Modulated (PWM) through ECU.

32 Fuel Pressure Manifold, FPM: Press/Temp Sensor Outlet Return Inlet Manifold

33 Fuel Pressure Manifold, FPM:

34 LPG Fuel Content: Propane / Butane ratio chart. Depending on energy content, spark timing is adjusted. Note: pressure at low temperatures.

35 LPG Tank and Filter: 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

36 Lock Off Valve: Normally closed. Grounded provided by ECU. Pilot opens, allowing pressure to outlet side. Pressure begins to equalize and main valve opens fully. Pilot

37 Lock Off Valve: No electrical fault codes for valve.

Only maintenance is periodic draining See maintenance

38 Dual Stage Regulator, DSR: Regulator performs 2 functions: Vaporizes liquid fuel Regulates fuel pressure Only maintenance is periodic draining See maintenance schedule Coolant Fuel Inlet Primary Test Port Secondary Fuel Outlet

39 DSR Exploded View:

41 DEPR (Direct Electronic Pressure Regulator): Stand alone module Controlled via CAN from ECU Contains: Control Module Pressure/Temp. sensor Fast acting solenoid valve

42 DEPR Electrical: DTC s are communicated to ECU via CAN Harness pin out shown below (terminal view of engine harness) No user serviceable parts inside 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

44 Mixer: All mechanical unit No electrical/elec tronic controls

46 Engine Coolant Temperature:

47 Engine Coolant Temperature: Temperature Sensor Senses engine temperature for running and shutdown

48 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.

49 Oil Pressure Switch: Standard Kubota Oil Pressure Switch: Closed: 0-7 psi Open > 7psi

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

51 Electronic Throttle Body, ETB Electric motor connected to throttle. ECU controlled based on foot pedal input.

52 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 FPP v.

53 Electronic Throttle Body, ETB

54 Oxygen (O 2 ) Sensor: Pre and Post catalyst feedback control for precise air-fuel ratio management. 4 wire sensor including heater.

55 Oxygen (O 2 ) Sensor: Pre- and Post-Catalyst Oxygen sensors

56 Oxygen (O 2 ) 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.

57 Oxygen (O 2 ) Sensor: Lean Zone Theoretical air/fuel ratio Rich Zone Feedback Control (Closed Loop) Orange line is air fuel ratio as controlled by the ECU based on O 2 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 closedloop mode for all operating parameters.

58 Pre-Cat O 2 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

59 Pre-Cat O 2 Sensor electrical:

60 Post-Cat O 2 Sensor: Bosch LSF4 sensor Post-cat used mainly for catalyst efficiency checking Post cat O 2 failure should not cause an engine running problem Only 1 DTC: EGO 2 Open/Lazy

61 Post-Cat O 2 Sensor electrical:

62 Normal O 2 Switching:

63 O 2 Sensor Testing: 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

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

65 Temperature and Manifold Absolute Pressure Sensor: Combines both intake air temperature and intake manifold pressure Will compensate for intake temperature, altitude, and air cleaner restriction

66 Temperature and Manifold Absolute Pressure Sensor:

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

68 Crankshaft Position Sensor:

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

70 Camshaft Position Sensor:

71 Cam and Crank Sensors: Cam 18 o ATDC #1 Compression Crank TDC TDC

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

73 Knock Sensor: Reacts with a specific frequency from detonation. When knock is detected, voltage output is increased. ECU retards ignition timing. Installed sensor at degrees from vertical.

74 Service Manuals Workshop & Diagnosis Manuals

75 Service Tool E-Com Interface Device Connects between USB port and connection on engine Can be connected any time, engine running or not

76 Service Tool Interface Connector

77 Service Tool Software Interface available through KEA s Parts Department. Software is Free, and available for download through K-ISS.

78 Service Tool

79 Service Tool A B 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: Shows realtime ECU data.

80 Service Tool Snap Shot Data Right click the icons you want to see and push P on keyboard

81 Service Tool Diagnostic Trouble Codes (DTC s) DTC s will only display with key on

82 Service Tool Diagnostic Trouble Codes Active DTC

83 Service Tool DTC Fault Information Double click on box next to DTC to display Historic Fault Information

84 Service Tool DTC Fault Information Snap Shot

85 Service Tool DTC Fault Information Flight Data Recorder 8 Seconds before fault, 2 Seconds after fault

86 Service Tool Erasing Historic DTC s Click on Clear All Faults

87 Service Tool Test Screen

88 Service Tool Spark Kill Test

89 Service Tool Injector Kill Test

90 Service Tool Drive By Wire (DBW) Test

91 Service Tool Closed Loop Test

92 Engine Mechanical Damage If the engine is mechanically damaged it will not move O 2 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)

93 Engine Mechanical 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 ALWAYS VALIDATE THAT THE SENSOR INPUTS ARE ACCURATE

94 GCP Display Gauge Page

95 GCP Raw Volts Page

96 GCP Display Service 1 Page

97 GCP Display Service 2 Page

98 GCP Display Tests Page

99 GCP Display Test Page

100 GCP Display Faults Page

PSI ENGINE CODES CODE LIST

PSI ENGINE CODES CODE LIST 2007 2009 PSI ENGINE CODES BLINK CODE FUNCTION Although the DST is considered a required tool to access the DTC codes, codes may be retrieved without a laptop computer using the blink code function. To