Related Manuals for Kubota WG1605
Summary of Contents for Kubota WG1605
- Page 1 Kubota Engine Training: WG1605, spark ignited KUBOTA ENGINE AMERICA Service Training...
- Page 2 WG1605 Engine Training: System Overviews Mechanical Components Electronic Components and Sensors Operation Service Tool KUBOTA ENGINE AMERICA Service Training...
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Page 3: Fuel System Overview
Fuel System Overview: KUBOTA ENGINE AMERICA Service Training... - Page 4 Fuel System Overview: KUBOTA ENGINE AMERICA Service Training...
- Page 5 AIR FUEL MIXTURE ENGINE COOLANT EXHAUST GASES DUAL STAGE REGULATOR ECI ECM AIR FILTRATION MIXER SYSTEM TPS 1&2 TMAP BATTERY INTAKE MANIFOLD IGNITION COIL PACK ALTERNATOR STARTER EXHAUST MANIFOLD HEGO CATALYST HEGO ECI00001 REV A KUBOTA ENGINE AMERICA Service Training...
- Page 6 System Overview - Gasoline: KUBOTA ENGINE AMERICA Service Training...
- Page 7 ECI ECM FILTER AIR FILTRATION MIXER SYSTEM ELECTRIC FUEL PUMP TPS 1&2 RETURNLESS FUEL TMAP PRESSURE BATTERY REGULATOR INTAKE MANIFOLD IGNITION COIL PACK GASOLINE FUEL RAIL ALTERNATOR STARTER EXHAUST MANIFOLD HEGO CATALYST HEGO ECI00003 REV A KUBOTA ENGINE AMERICA Service Training...
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Page 8: Mechanical Components
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. KUBOTA ENGINE AMERICA Service Training... -
Page 9: Intake & Exhaust Manifolds
Intake & Exhaust Manifolds: Intake Exhaust manifolds are manifolds use shielded and engineered longer runners for higher temperatures KUBOTA ENGINE AMERICA Service Training... -
Page 10: Positive Crankcase Ventilation (Pcv) System
Positive Crankcase Ventilation (PCV) System: Valve Controls amount of blow-by gas and fresh air. KUBOTA ENGINE AMERICA Service Training... -
Page 11: Pistons And Rings
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 KUBOTA ENGINE AMERICA Service Training... -
Page 12: Cylinder Head And Valves
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. KUBOTA ENGINE AMERICA Service Training... - Page 13 Piston Recession Example: KUBOTA ENGINE AMERICA Service Training...
- Page 14 Cross-Flow Cylinder Head: Low heat conduction between intake and exhaust ports. KUBOTA ENGINE AMERICA Service Training...
- Page 15 Camshaft: The camshaft’s timing pin (5), is attached to the gear (4). KUBOTA ENGINE AMERICA Service Training...
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Page 16: Gear Shaft
Gear shaft: The gear shaft deletes the fuel cam from the 05-E3B engine. KUBOTA ENGINE AMERICA Service Training... - Page 17 Flywheel: The WG1605 flywheel is designed to work alongside the crankshaft sensor. KUBOTA ENGINE AMERICA Service Training...
- Page 18 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#) KUBOTA ENGINE AMERICA Service Training...
- Page 19 Fuel Delivery Pipe and Injectors: KUBOTA ENGINE AMERICA Service Training...
- Page 20 Fuel Delivery Pipe and Injectors: 12-Volt operation 2-wire injector Pulse-width modulation ECU Controlled ground driver. KUBOTA ENGINE AMERICA Service Training...
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Page 21: Three Way Catalyst
Three Way Catalyst: A 3-way catalyst oxidizes: (1)HC CO2 and H20 (2) CO CO2 (3) NOx N2 KUBOTA ENGINE AMERICA Service Training... -
Page 22: Electronic Control Unit (Ecu)
Electronic Control Unit, ECU: Utilizes inputs from the engine sensors to precisely meter fuel, control speed and remain emission compliant. KUBOTA ENGINE AMERICA Service Training... - Page 23 Electronic Control Unit, ECU: KUBOTA ENGINE AMERICA Service Training...
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Page 24: Ecu Wiring Diagram
ECU Wiring Diagram: KUBOTA ENGINE AMERICA Service Training... - Page 25 ECU Inputs and Outputs: KUBOTA ENGINE AMERICA Service Training...
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Page 26: Ignition Coil
Ignition Coil: ECU controlled inductive coils. As primary windings dwell then collapse, the secondary windings yield a high voltage output via the spark plug. KUBOTA ENGINE AMERICA Service Training... - Page 27 Ignition Coil: KUBOTA ENGINE AMERICA Service Training...
- Page 28 Gasoline System: Fuel lines are bold black color. Electrical circuits are think black. KUBOTA ENGINE AMERICA Service Training...
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Page 29: Electric Fuel Pump
Electric Fuel Pump: Variable controlled by ECU. KUBOTA ENGINE AMERICA Service Training... - Page 30 Electric Fuel Pump: KUBOTA ENGINE AMERICA Service Training...
- Page 31 Electric Fuel Pump: Power to pump supplied by ECU controlled relay. Fuel pump is Pulse Width Modulated (PWM) through ECU. KUBOTA ENGINE AMERICA Service Training...
- Page 32 Fuel Pressure Manifold, FPM: Outlet Press/Temp Sensor Return Manifold Inlet KUBOTA ENGINE AMERICA Service Training...
- Page 33 Fuel Pressure Manifold, FPM: KUBOTA ENGINE AMERICA Service Training...
- Page 34 LPG Fuel Content: Propane / Butane ratio chart. Depending on energy content, spark timing is adjusted. Note: pressure at low temperatures. KUBOTA ENGINE AMERICA Service Training...
- Page 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 KUBOTA ENGINE AMERICA Service Training...
- Page 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 KUBOTA ENGINE AMERICA Service Training...
- Page 37 Lock Off Valve: No electrical fault codes for valve. KUBOTA ENGINE AMERICA Service Training...
- Page 38 Dual Stage Regulator, DSR: Regulator performs 2 functions: Fuel Inlet Vaporizes liquid fuel Regulates fuel pressure Only maintenance is periodic draining See maintenance schedule Primary Coolant Test Port Secondary Fuel Outlet KUBOTA ENGINE AMERICA Service Training...
- Page 39 DSR – Exploded View: KUBOTA ENGINE AMERICA Service Training...
- Page 40 KUBOTA ENGINE AMERICA Service Training...
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Page 41: Pressure Regulator
DEPR (Direct Electronic Pressure Regulator): Stand alone module Controlled via CAN from ECU Contains: Control Module Pressure/Temp. sensor Fast acting solenoid valve KUBOTA ENGINE AMERICA Service Training... - Page 42 Harness pin out shown below (terminal view of engine harness) No user serviceable parts inside Cavity Color Function CAN Termination DB/PK CAN H PK/DG Power Relay Output Ground DB/WT CAN L RD/TN B+ from Fuse 2 KUBOTA ENGINE AMERICA Service Training...
- Page 43 KUBOTA ENGINE AMERICA Service Training...
- Page 44 Mixer: All mechanical unit No electrical/elec tronic controls KUBOTA ENGINE AMERICA Service Training...
- Page 45 KUBOTA ENGINE AMERICA Service Training...
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Page 46: Engine Coolant Temperature
Engine Coolant Temperature: KUBOTA ENGINE AMERICA Service Training... - Page 47 Engine Coolant Temperature: Temperature Sensor Senses engine temperature for running and shut- down KUBOTA ENGINE AMERICA Service Training...
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Page 48: Oil Pressure Switch
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. KUBOTA ENGINE AMERICA Service Training... - Page 49 Oil Pressure Switch: Standard Kubota Oil Pressure Switch: Closed: 0-7 psi Open > 7psi KUBOTA ENGINE AMERICA Service Training...
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Page 50: Electronic Throttle Body, Etb
Electronic Throttle Body, ETB controlled, electronic motor driven mechanical throttle body connected to the intake. KUBOTA ENGINE AMERICA Service Training... - Page 51 Electronic Throttle Body, ETB Electric motor connected to throttle. ECU controlled based on foot pedal input. KUBOTA ENGINE AMERICA Service Training...
- Page 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 FPP2 2.5-0v. KUBOTA ENGINE AMERICA Service Training...
- Page 53 Electronic Throttle Body, ETB KUBOTA ENGINE AMERICA Service Training...
- Page 54 Oxygen (O ) Sensor: Pre and Post catalyst feedback control for precise air-fuel ratio management. 4 wire sensor including heater. KUBOTA ENGINE AMERICA Service Training...
- Page 55 Oxygen (O ) Sensor: Pre- and Post-Catalyst Oxygen sensors KUBOTA ENGINE AMERICA Service Training...
- Page 56 Oxygen (O ) 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. KUBOTA ENGINE AMERICA Service Training...
- Page 57 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.
- Page 58 Pre-Cat O 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 KUBOTA ENGINE AMERICA Service Training...
- Page 59 Pre-Cat O Sensor electrical: KUBOTA ENGINE AMERICA Service Training...
- Page 60 Post-Cat O Sensor: Bosch LSF4 sensor Post-cat used mainly for catalyst efficiency checking Post cat O failure should not cause an engine running problem Only 1 DTC: EGO 2 Open/Lazy KUBOTA ENGINE AMERICA Service Training...
- Page 61 Post-Cat O Sensor electrical: KUBOTA ENGINE AMERICA Service Training...
- Page 62 Normal O Switching: KUBOTA ENGINE AMERICA Service Training...
- Page 63 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 KUBOTA ENGINE AMERICA Service Training...
- Page 64 Temperature and Manifold Absolute Pressure Sensor: TMAP. Mounted in the intake manifold and provides ECU data to calculate air flow pressure and density. KUBOTA ENGINE AMERICA Service Training...
- Page 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 KUBOTA ENGINE AMERICA Service Training...
- Page 66 Temperature and Manifold Absolute Pressure Sensor: KUBOTA ENGINE AMERICA Service Training...
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Page 67: Crankshaft Position Sensor
Crankshaft Position Sensor: Provides engine RPM information to the ECU. KUBOTA ENGINE AMERICA Service Training... - Page 68 Crankshaft Position Sensor: KUBOTA ENGINE AMERICA Service Training...
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Page 69: Camshaft Position Sensor
Camshaft Position Sensor: Identifies which cylinders are in compression to begin spark timing. KUBOTA ENGINE AMERICA Service Training... - Page 70 Camshaft Position Sensor: KUBOTA ENGINE AMERICA Service Training...
- Page 71 Cam and Crank Sensors: ATDC #1 Compression Crank KUBOTA ENGINE AMERICA Service Training...
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Page 72: Knock Sensor
Knock Sensor: Early detonation detection via mechanical vibration at the cylinder head/block deck level. KUBOTA ENGINE AMERICA Service Training... - Page 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 35 – 50 degrees from vertical. KUBOTA ENGINE AMERICA Service Training...
- Page 74 Service Manuals Workshop & Diagnosis Manuals KUBOTA ENGINE AMERICA Service Training...
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Page 75: Service Tool
Service Tool E-Com Interface Device Connects between USB port and connection on engine Can be connected any time, engine running or not KUBOTA ENGINE AMERICA Service Training... - Page 76 Service Tool Interface Connector KUBOTA ENGINE AMERICA Service Training...
- Page 77 Service Tool Software Interface available through KEA’s Parts Department. Software is Free, and available for download through K-ISS. KUBOTA ENGINE AMERICA Service Training...
- Page 78 Service Tool KUBOTA ENGINE AMERICA Service Training...
- Page 79 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 real- time ECU data. KUBOTA ENGINE AMERICA Service Training...
- Page 80 Service Tool Snap Shot Data Right click the icons you want to see and push “P” on keyboard KUBOTA ENGINE AMERICA Service Training...
- Page 81 Service Tool Diagnostic Trouble Codes (DTC’s) DTC’s will only display with key on KUBOTA ENGINE AMERICA Service Training...
- Page 82 Service Tool Diagnostic Trouble Codes – Active DTC KUBOTA ENGINE AMERICA Service Training...
- Page 83 Service Tool DTC Fault Information Double click on box next to DTC to display Historic Fault Information KUBOTA ENGINE AMERICA Service Training...
- Page 84 Service Tool DTC Fault Information – Snap Shot KUBOTA ENGINE AMERICA Service Training...
- Page 85 Service Tool DTC Fault Information – Flight Data Recorder 8 Seconds before fault, 2 Seconds after fault KUBOTA ENGINE AMERICA Service Training...
- Page 86 Service Tool Erasing Historic DTC’s Click on “Clear All Faults” KUBOTA ENGINE AMERICA Service Training...
- Page 87 Service Tool Test Screen KUBOTA ENGINE AMERICA Service Training...
- Page 88 Service Tool Spark Kill Test KUBOTA ENGINE AMERICA Service Training...
- Page 89 Service Tool Injector Kill Test KUBOTA ENGINE AMERICA Service Training...
- Page 90 Service Tool Drive By Wire (DBW) Test KUBOTA ENGINE AMERICA Service Training...
- Page 91 Service Tool Closed Loop Test KUBOTA ENGINE AMERICA Service Training...
- Page 92 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) KUBOTA ENGINE AMERICA Service Training...
- Page 93 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 KUBOTA ENGINE AMERICA Service Training...
- Page 94 GCP Display – Gauge Page KUBOTA ENGINE AMERICA Service Training...
- Page 95 GCP – Raw Volts Page KUBOTA ENGINE AMERICA Service Training...
- Page 96 GCP Display – Service 1 Page KUBOTA ENGINE AMERICA Service Training...
- Page 97 GCP Display – Service 2 Page KUBOTA ENGINE AMERICA Service Training...
- Page 98 GCP Display – Tests Page KUBOTA ENGINE AMERICA Service Training...
- Page 99 GCP Display – Test Page KUBOTA ENGINE AMERICA Service Training...
- Page 100 GCP Display – Faults Page KUBOTA ENGINE AMERICA Service Training...