Kubota Engine Training: WG1605, spark ignited WG1605 Gas Engine...KUBOTA ENGINE AMERICA Service...
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Transcript of Kubota Engine Training: WG1605, spark ignited WG1605 Gas Engine...KUBOTA ENGINE AMERICA Service...
KUBOTA ENGINE AMERICAService Training
Kubota Engine Training: WG1605, spark ignited
KUBOTA ENGINE AMERICAService Training
WG1605 Engine Training: System OverviewsMechanical Components Electronic Components and SensorsOperationService Tool
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Fuel System Overview:
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Fuel System Overview:
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System Overview - Gaseous:
ECI ECM
LPG TANK FUELFILTER
ELECTRICLOCK OFF
MANUALVALVE
DUAL STAGEREGULATOR
EPR
MIXERAIR FILTRATIONSYSTEM
ETB
INTAKE MANIFOLD
EXHAUST MANIFOLD
CATALYST
ECTOIL
TMAP
IGNITIONCOIL PACK
CCKCPK
HEGO
HEGO
- +BATTERY
STARTER
ALTERNATOR
INSTURMENTPANEL
TPS 1&2
KNK
CAN
FRESH AIR
LIQUID FUEL HIGH PRESSURE
LOW PRESSURE FUEL
AIR FUEL MIXTURE
ENGINE COOLANT
EXHAUST GASES
ECI00001 REV A
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System Overview - Gasoline:
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System Overview - Dual Fuel:
ECI ECM
LPG TANKFUELFILTER
ELECTRICLOCK OFF
MANUALVALVE
DUAL STAGEREGULATOR
EPR
MIXERAIR FILTRATIONSYSTEM
ETB
INTAKE MANIFOLD
EXHAUST MANIFOLD
CATALYST
ECTOIL
TMAP
IGNITIONCOIL PACK
CCKCPK
HEGO
HEGO
- +BATTERY
STARTER
ALTERNATOR
INSTRUMENTPANEL
TPS 1&2
KNK
CAN
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
FPP
GASOLINE SUCTION
GASOLINE PRESSUREGASOLINE REGULATED
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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.
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Intake & Exhaust Manifolds: Exhaust manifolds are shielded and engineered for higher temperatures
Intake manifolds use longer runners
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Positive Crankcase Ventilation (PCV) System:
PCV Valve
Controls amount of blow-by gas and fresh air.
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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
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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.
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Piston Recession Example:
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Cross-Flow Cylinder Head: Low heat conduction between intake and exhaust ports.
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Camshaft: The camshaft’s timing pin (5), is attached to the gear (4).
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Gear shaft: The gear shaft deletes the fuel cam from the 05-E3B engine.
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Flywheel: The WG1605 flywheel is designed to work alongside the crankshaft sensor.
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Fuel Delivery Pipe and Injectors: ECU controlled fuel delivery (pulse width modulated).
Port Fuel InjectionFuel Pressure 40 – 45 PSI**(can fluctuate between 35-75#)
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Fuel Delivery Pipe and Injectors:
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12-Volt operation 2-wire injector Pulse-width
modulation ECU Controlled
ground driver.
Fuel Delivery Pipe and Injectors:
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Three Way Catalyst: A 3-way catalyst oxidizes:
(1)HC CO2 and H20
(2) CO CO2
(3) NOx N2
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Electronic Control Unit, ECU: Utilizes inputs from the engine sensors to precisely meter fuel, control speed and remain emission compliant.
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Electronic Control Unit, ECU:
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ECU Wiring Diagram:
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ECU Inputs and Outputs:
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Ignition Coil: ECU controlled inductive coils.
As primary windings dwell then collapse, the secondary windings yield a high voltage output via the spark plug.
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Ignition Coil:
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Fuel lines are bold black color. Electrical circuits are think black.
Gasoline System:
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Variable controlled by ECU.
Electric Fuel Pump:
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Electric Fuel Pump:
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Power to pump supplied by ECU controlled relay.
Fuel pump is Pulse Width Modulated (PWM) through ECU.
Electric Fuel Pump:
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Press/Temp Sensor
Manifold
Return
Inlet
Outlet
Fuel Pressure Manifold, FPM:
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Fuel Pressure Manifold, FPM:
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Propane / Butane ratio chart.
Depending on energy content, spark timing is adjusted.
LPG Fuel Content:
Note: pressure at low temperatures.
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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:
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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:
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No electrical fault codes for valve.Lock Off Valve:
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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
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DSR – Exploded View:
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Stand alone module Controlled via CAN from ECU Contains:
Control Module Pressure/Temp. sensor Fast acting solenoid valve
DEPR (Direct Electronic Pressure Regulator):
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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:
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All mechanical unit No
electrical/electronic controls
Mixer:
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Engine Coolant Temperature:
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Temperature SensorSenses engine
temperature for running and shut-down
Engine Coolant Temperature:
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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.
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Oil Pressure Switch: Standard Kubota Oil Pressure Switch:
Closed: 0-7 psiOpen > 7psi
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Electronic Throttle Body, ETBECU controlled, electronic motor driven mechanical throttle body connected to the intake.
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Electric motor connected to throttle.
ECU controlled based on foot pedal input.
Electronic Throttle Body, ETB
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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.
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Electronic Throttle Body, ETB
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Oxygen (O2) Sensor: Pre and Post catalyst feedback control for precise air-fuel ratio management.
4 wire sensor including heater.
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Pre- and Post-Catalyst Oxygen sensors
Oxygen (O2) Sensor:
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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:
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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:
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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:
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Pre-Cat O2 Sensor electrical:
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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:
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Post-Cat O2 Sensor electrical:
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Normal O2 Switching:
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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:
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Temperature and Manifold Absolute Pressure Sensor: TMAP.
Mounted in the intake manifold and provides ECU data to calculate air flow pressure and density.
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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:
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Temperature and Manifold Absolute Pressure Sensor:
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Crankshaft Position Sensor: Provides engine RPM information to the ECU.
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Crankshaft Position Sensor:
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Camshaft Position Sensor: Identifies which cylinders are in compression to begin spark timing.
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Camshaft Position Sensor:
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TDC TDC
Cam
Crank
18o ATDC #1 Compression
Cam and Crank Sensors:
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Knock Sensor: Early detonation detection via mechanical vibration at the cylinder head/block deck level.
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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:
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Service ManualsWorkshop & Diagnosis Manuals
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Service ToolE-Com Interface Device
Connects between USB port and connection on engine
Can be connected any time, engine running or not
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Service ToolInterface Connector
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Service ToolSoftware
Interface available through KEA’s Parts Department. Software is Free, and available for
download through K-ISS.
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Service Tool
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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.
A
B
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Service ToolSnap Shot Data
Right click the icons you want to see and push “P” on keyboard
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Service ToolDiagnostic Trouble Codes (DTC’s)
DTC’s will only display with key on
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Service ToolDiagnostic Trouble Codes – Active DTC
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Service ToolDTC Fault Information
Double click on box next to DTC to display Historic Fault Information
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Service ToolDTC Fault Information – Snap Shot
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Service ToolDTC Fault Information – Flight Data Recorder
8 Seconds before fault, 2 Seconds after fault
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Service ToolErasing Historic DTC’s
Click on “Clear All Faults”
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Service ToolTest Screen
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Service ToolSpark Kill Test
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Service ToolInjector Kill Test
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Service ToolDrive By Wire (DBW) Test
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Service ToolClosed Loop Test
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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)
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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
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GCP Display – Gauge Page
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GCP – Raw Volts Page
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GCP Display – Service 1 Page
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GCP Display – Service 2 Page
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GCP Display – Tests Page
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GCP Display – Test Page
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GCP Display – Faults Page