Page 1 DIAGNOSIS MANUAL ECM SYSTEM WG1605-E3 KiSC issued 12, 2016 A...
Page 2 Record of Revisions For pdf, use search function {Search word} to find all the revised locations. Last digit Issue Reference of the Main Revised Point and Corrective Measures {Search word} month Page Code No. 2014.05 Added the models – (WG1605-N-E3, WG1605-LN-E3, WG1605-GLN-E3) 2016.05 Updated the DTC(s) –...
Page 3 INFORMATION KiSC issued 12, 2016 A...
Page 4 INFORMATION CONTENTS 1. SAFETY FIRST ..........................I-1 KiSC issued 12, 2016 A...
Page 5 INFORMATION WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM 1. SAFETY FIRST SAFETY FIRST • This symbol, the industry's "Safety Alert Symbol", is used throughout this manual and on labels on the machine itself to warn of the possibility of personal injury. Read these instructions carefully. •...
Page 6 INFORMATION WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM SAFETY WORKING • Do not work on the machine while under the influence of alcohol, medication, or other substances or while fatigued. • Wear close fitting clothing and safety equipment appropriate to the job. • Use tools appropriate to the work. Makeshift tools, parts, and procedures are not recommended.
Page 7 INFORMATION WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM VENTILATE WORK AREA • If the engine must be running to do some work, make sure the area is well ventilated. Never run the engine in a closed area. The exhaust gas contains poisonous carbon monoxide. PREVENT ACID BURNS •...
Page 8 ECM SYSTEM KiSC issued 12, 2016 A...
Page 9: Table Of Contents
SERVICING CONTENTS 1. OUTLINE ............................1-1 [1] OVERALL DIAGONOSTIC PROCEDURE ................1-1 [2] QUESTIONING ........................1-2 [3] ABBREVIATIONS........................1-5 2. SYMPTOM CHARTS BY COMPONENTS ..................1-9 [1] GASOLINE SYMPTOM CHARTS ................... 1-9 [2] LPG / NATURAL GAS SYMPTOM CHARTS ................ 1-18 3.
Page 10 (23)Spark Coil Primary (DTC 2300, 2301, 2303, 2304, 2306, 2307, 2309, 2310)....1-228 KiSC issued 12, 2016 A...
Page 11: Outline
ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM 1. OUTLINE [1] OVERALL DIAGONOSTIC PROCEDURE KiSC issued 12, 2016 A...
Page 12: Questioning
ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM [2] QUESTIONING • Use the trouble check sheet to ensure that the customer's explanation is fully understood. • Accurately judge information concerning the malfunction. Grasp the situation firmly, using five 5W1H (Who, What, When, Where, Why, How) as a basis. Ex: Low ambient temperature, starting, normal conditions, proximity to engine, metallic noise, etc.
Page 13 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM Trouble Check Sheet for WG Engines Machine details Customer name Customer address Machine serial Machine model number Engine serial Purchase date number Hourmeter Repair date hours indicator Warranty Warranty Judgment Injector Ignition Coil Defective parts Fuel Filter Others ( Replace parts details Quantity...
Page 14 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM Condition when problem occurs (Duplicated answers can be possible) a. Fine b. Cloudy c. Rainy d. Snow 1. Weather e. Flood f. Others ( 2. Outdoor temperature Approx. °C ( °F) 3. Altitude Approx. a. Cold Write the position of the indicator on coolant temperature gauge.
Page 15: Abbreviations
ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM [3] ABBREVIATIONS ACRONYM DEFINITION Alternating Current Air Fuel Ratio Adaptive Learn After Top Center ATDC After Top Dead Center Air Valve Vacuum BARO Barometric Pressure Battery Brake Horse Power Block Learn Barometric Pressure British Thermal Unit °C Celsius Cubic Centimeter...
Page 16 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM ACRONYM DEFINITION Electromagnetic Interference EMWT Exhaust Manifold Water Temperature EOBD Euro Onboard Diagnostic Electronic Pressure Regulator ERWT Exhaust Manifold Riser Temperature Electronic Throttle Body Electronic Throttle Control EVAP Evaporative Emissions °F Fahrenheit Fan Control Flight Data Recorder Flex Fuel Failure Mode Indicator Firing Order...
Page 17 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM ACRONYM DEFINITION Kilopascals Kilometers Per Hour KOEC Key On Engine Cranking KOEO Key On Engine Off KOER Key On Engine Running Knock Sensor Kilovolt Liter lb.ft. Pound Feet LDGCP Light-Duty Global Control Platform (Industrial, Smart/Logic Coil) Light Emitting Diode Liquefied Propane Gas LTFT...
Page 18 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM ACRONYM DEFINITION Radio Frequency Interference Revolutions Per Minute Receive Source Address Sequential Fuel Injection SOHC Single Overhead Cam SPFI Sequential Port Fuel Injection Suspect Parameter Number Service Reminder Indicator System Readiness Test Tach Tachometer Throttle Body Injection Top Dead Center Throttle Inlet Pressure TPS1...
Page 19: Symptom Charts By Components
ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM 2. SYMPTOM CHARTS BY COMPONENTS [1] GASOLINE SYMPTOM CHARTS Important Preliminary Checks Checks Action Before using this section you should have performed On Board Diagnostic Checks and determined that: • The Control Module and MIL (Malfunction Indicator Lamp) are operating correctly. •...
Page 20 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM Intermittent Checks Action DEFINITION: The problem may or may not turn ON the Malfunction Indicator Lamp (MIL), or store a Diagnostic Trouble Code (DTC). • Refer to Important Preliminary Checks. Preliminary Checks • Do not use the DTC tables. If a fault is an intermittent, the use of the DTC tables may result in the replacement of good parts.
Page 21 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM No Start Checks Action DEFINITION: The engine cranks OK but does not start. Preliminary Checks • Refer to Important Preliminary Checks. • Check the battery cranking voltage, voltage should not be less then 9.0 VDC. • Check the inline fuse in the ECM battery power circuit. Refer to Engine Controls Schematics. Control Module Checks •...
Page 22 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM Hard Start Checks Action DEFINITION: The engine cranks OK, but does not start for a long time. The engine does eventually run, or may start but immediately dies. • Refer to Important Preliminary Checks. Preliminary Checks •...
Page 23 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM Cuts Out, Misses Checks Action DEFINITION: A surging or jerking that follows engine speed, usually more pronounced as the engine load increases, which is not normally felt above 1500 RPM. The exhaust has a steady spitting sound at idle, low speed, or hard acceleration for the fuel starvation that can cause the engine to cut-out.
Page 24 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM Backfire Checks Action DEFINITION: The fuel ignites in the intake manifold, or in the exhaust system, making a loud popping noise. A backfire which is heard in the intake manifold and air stream indicates that the fuel is being ignited in the intake manifold and is a result of a spark igniting the fuel air mixture. A backfire heard in the exhaust system indicates that there is an over fueling condition or a late spark event which ignites unburned fuel in the exhaust.
Page 25 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM Poor Fuel Economy Checks Action DEFINITION: Fuel economy, as measured by refueling records is noticeably lower than expected. Also, the economy is noticeably lower, than it was on this vehicle at one time as previously shown by refueling records. •...
Page 26 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM Rough, Unstable or Incorrect Idle or Stalling Checks Action DEFINITION: The engine runs unevenly at idle. If severe enough, the engine or vehicle may shake. The engine idle speed may vary in RPMs. Either condition may be severe enough to stall the engine. Preliminary Check •...
Page 27 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM Surges/Chuggles Checks Action DEFINITION: The engine has a power variation under a steady throttle or cruise. The vehicle feels as if it speeds up and slows down with no change in the accelerator pedal. • Refer to Important Preliminary Checks. Preliminary Checks •...
Page 28: Lpg / Natural Gas Symptom Charts
ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM [2] LPG / NATURAL GAS SYMPTOM CHARTS Important Preliminary Checks Checks Action Before using this section, you should have performed On Board Diagnostic Check and determined that: • The Control Module and MIL (Malfunction Indicator Lamp) are operating correctly. •...
Page 29 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM Intermittent Checks Action DEFINITION: The problem may or may not turn ON the Malfunction Indicator Lamp (MIL), or store a Diagnostic Trouble Code (DTC). • Refer to Important Preliminary Checks. Preliminary Checks • Do not use the DTC tables, if a fault is an intermittent, the use of the DTC tables may result in the replacement of good parts.
Page 30 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM No Start Checks Action DEFINITION: The engine cranks OK, but does not start. Preliminary Checks • Refer to Important Preliminary Checks. • Check the battery charge condition. • Check the battery cranking voltage, voltage less the 9.00 V are outside the parameters of Battery and Voltage Check operation.
Page 31 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM Hard Start Checks Action DEFINITION: The engine cranks OK, but does not start for a long time. The engine does eventually run, or may start, but immediately dies. • Refer to Important Preliminary Checks. • Make sure the vehicle’s operator is using the correct starting procedure. Preliminary Checks •...
Page 32 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM Cuts Out, Misses Checks Action DEFINITION: A surging or jerking, that follows engine speed, usually more pronounced as the engine load increases, which is not normally felt, above 1500 RPM. The exhaust has a steady spitting sound at idle, low speed, or hard acceleration, for the fuel starvation, that can cause the engine to cut-out.
Page 33 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM Hesitation, Sag, Stumble Checks Action DEFINITION: The vehicle has a momentary lack of response when depressing the accelerator. The condition can occur at any vehicle speed. The condition may cause the engine to stall if it’s severe enough. •...
Page 34 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM Lack of Power, Sluggishness, or Sponginess Checks Action DEFINITION: The engine delivers less than expected power. There is little or no increase in speed, when partially applying the accelerator pedal. • Refer to Important Preliminary Checks. •...
Page 35 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM Poor Fuel Economy Checks Action DEFINITION: Fuel economy, as measured by refueling records, is noticeably lower than expected. Also, the economy is noticeably lower, than it was on this vehicle at one time, as previously shown by refueling records. •...
Page 36 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM Rough, Unstable, or Incorrect Idle, Stalling Checks Action DEFINITION: The engine runs unevenly at idle. If severe enough, the engine or vehicle may shake. The engine idle speed may vary, in RPM. Either condition may be severe enough, to stall the engine. Preliminary Check •...
Page 37 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM Surges/Chuggles Checks Action DEFINITION: The engine has a power variation, under a steady throttle or cruise. The vehicle feels as if it speeds up and slows down, with no change in the accelerator pedal. • Refer to Important Preliminary Checks. Preliminary Checks •...
Page 38: Set Up And Procedure Diagnostic Tool
ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM 3. SET UP AND PROCEDURE DIAGNOSTIC TOOL [1] DIAGNOSTIC CONNECTOR POSITION The connector for connecting the diagnostic tool is in the position shown in the figure. (A) Diagnostic Tool Connector 1-28 KiSC issued 12, 2016 A...
Page 39: Diagnostic Tool Connection Procedure
ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM [2] DIAGNOSTIC TOOL CONNECTION PROCEDURE IMPORTANT • At first time usage, it is necessary to install the software with administrator user account. • Prepare a PC on which the diagnostic software has been installed. • When connecting the diagnosis cable, don’t have to switch off the key of the vehicle. 1.
Page 40: Set Up And Procedure
(1) Overview This manual is intended to be used as an aid for KUBOTA LSI engine customers. Certain portions of this manual are only intended for use by the KUBOTA LSI engine customers to understand the fault detection system. This section of the manual defines the diagnostics and recommended troubleshooting procedures associated with an EControls Global Control Platform (GCP) engine control module (ECM) for use on industrial and heavy-duty gas engines.
Page 41 Each fault within the GCP is capable of being corrective actions available for configuration of each uniquely configured in the engine’s diagnostic calibration fault. The desired action is set by KUBOTA. to cause one or more corrective actions while a given fault is active.
Page 42 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM Fault/Diagnostic Trouble Code Interaction Figure 1 shows an example of the fault page when All fault and diagnostic information is managed an active fault has been generated. Notice that the fault through the Faults page. Interaction includes viewing is present in both the active and historic lists and the fault messages, downloading fault data (fault snapshot malfunction indicator lamp (MIL) has been illuminated.
Page 43 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM Figure 2: Faults Page with Historic Fault Message 1-33 KiSC issued 12, 2016 A...
Page 44 Base variables for FSS and FDR are includes eight-seconds prior and two-seconds after generally defined by the Kubota to include variables triggering the fault. An FDR is saved for each of the first most often referenced during fault diagnosis. The base two (2) faults for the first time the fault becomes active.
Page 45 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM Accessing fault information is accomplished through Table 3 outlines the options displayed in the Historic a double left-click of the fault LED in the historic fault list. Fault Information screen. Historic faults are not This produces the Historic Fault Information interface overwritten if the same fault becomes active, storing shown in Figure 4.
Page 46 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM Figure 5 is an example of a fault snapshot after View Once retrieved, the FSS data may be saved to the PC in Fault Snapshot is selected. Data is presented in two text format with an .fss extension. A FSS saved to a PC columns, base and custom variables.
Page 47 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM Fault information may be manually erased using the "Clear" button functions. Once a "Clear" function has been selected, the dialog prompt shown in Figure 7 will be displayed. Choosing YES deletes all fault information from the ECM. Figure 7: Clear Faults Prompt 1-37...
Page 48: Diagnostic Tests
ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM [4] DIAGNOSTIC TESTS The GCP engine control module for spark-ignited Injector Kill Test engine applications incorporates a set of four (4) "Inj X" disables individual cylinders at any operating diagnostic tests that perform specific functions used as condition for the duration defined in calibration or until an aid for verifying proper engine control.
Page 49 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM Closed-Loop Test heaters are operating at the final impedance target. Tests the closed-loop fueling feedback system to c. CL pre-cat test status will indicate “Test Running” verify that exhaust gas oxygen sensors are properly through steps 2-3. functioning and are providing reliable information.
Page 50 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM (Continued) 3. Pre-Catalyst EGO Sensor Check (CL Test State= the final target plus the impedance error Pre-cat voltage test & Pre-cat BM test) tolerance the heater power is deemed low, the • The purpose of this portion of the test is: CL post-cat test status "Post-cat EGO Power 1.
Page 51 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM (Continued) States (CL Test State) 1) Inactive 2) Pre-cat init test 3) Pre-cat heater test 4) Pre-cat power test 5) Pre-cat voltage test 6) Pre-cat BM test 7) Post-cat heater test 8) Post-cat power test 9) Post-cat rich test 10) Post-cat lean test 11) Finished 12) Invalid...
Page 52: Basic System Information
Kubota LSI engines use EControls fuel system. In Kubota fuel system will utilize an EControls Engine this section of the manual, Kubota fuel system will be Control Module (ECM), to control fueling and control explained further to provide the technician the ability to emissions output, in the exhaust.
Page 53 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM Figure 8: Gasoline Schematic (1) FRESH AIR (6) EXHAUST GASES (11) AIR FILTRATION SYSTEM (16) EXHAUST MANIFOLD (2) LIQUID FUEL HIGH (7) GASOLINE TANK (12) INTAKE MANIFOLD (17) MUFFLER PRESSURE (8) FUEL FILTER (13) GASOLINE FUEL RAIL (18) IGNITION COIL PACK (3) REGULATED PRESSURE (9) ELECTRIC FUEL PUMP...
Page 54 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM Figure 9: LPG / Natural Gas Schematic (1) FRESH AIR (7) LPG / NATURAL GAS TANK (12) AIR FILTRATION SYSTEM (17) EXHAUST MANIFOLD (2) LIQUID FUEL HIGH (8) MANUAL VALVE (13) MIXER (18) MUFFLER PRESSURE (9) FUEL FILTER (14) INTAKE MANIFOLD (19) IGNITION COIL PACK (3) LOW PRESSURE FUEL...
Page 55 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM Figure 10: Bi-fuel Schematic (1) FRESH AIR (8) GASOLINE PRESSURE (16) LPG / NATURAL GAS TANK (24) STARTER (2) LPG / NATURAL GAS FUEL (9) GASOLINE REGULATED (17) ELECTRIC LOCK OFF (25) EXHAUST MANIFOLD HIGH PRESSURE (10) GASOLINE TANK (18) DUAL STAGE REGULATOR (26) CATALYST...
Page 56 ELECTRIC GASOLINE FUEL PUMP (G, GL, GLN) GASOLINE FUEL PRESSURE MANIFOLD (G, GL, GLN) To supply gasoline to the fuel system, the Kubota bi-fuel system will utilize an external electric gasoline fuel The Kubota gasoline fuel system, utilizes a Fuel pump.
Page 57 Fuel Pressure Manifold, to control fuel delivery to the rail, off device. Kubota fuel system does not use a separate return line, LPG / NATURAL GAS FUEL LOCK OFF (L, N, GL, LN, from the fuel rail assembly. Gasoline injectors are an...
Page 58 The packaging of the regulator, into the engine and chassis, must be approved by Kubota, to insure continued long term operation, of the fuel delivery and emission control system. You should never relocate the regulator, or any of the fuel system components, as...
Page 59 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DIRECT ELECTRONIC PRESSURE REGULATOR (DEPR) (L, N, LN, GL, GLN) The Direct Electronic Pressure Regulator (DEPR) is the primary fuel control device, used to maintain both performance and emissions control. The DEPR contains an internal computer, which communicates to the EControls Engine Control Module (ECM), via a Communications Area Network (CAN), high speed connection.
Page 60 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM MIXER ASSEMBLY (L, N, LN, GL, GLN) The air valve mixer is an air-fuel metering device, and is completely self-contained. The mixer is an air valve design, utilizing a relatively constant pressure drop, to draw fuel into the mixer from cranking, to full load.
Page 61 WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM ELECTRONIC THROTTLE BODY (ETB) (ALL) THREE WAY CATALYST (ALL) The Kubota fuel systems utilize Drive By Wire The emission certified engine has been designed (DBW), to control engine speed, in this type of and calibrated, to meet the emission standards in effect application.
Page 62 The Heated Exhaust Gas Oxygen Sensor is an emissions control component. If the HEGO fails to operate, replace only with Kubota to 0.100 to 0.300 V. When the air/fuel mixture is perfectly replacement part.
Page 63 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM ENGINE CONTROL MODULE (ECM) Figure 19: Gasoline ECM Input and Outputs (1) BATTERY PLUS (9) THROTTLE POSITION 1 (16) SPARK CONTROL TO (21) GAGE OUTPUT (2) BATTERY MINUS (10) THROTTLE POSITION 2 IGNITION COILS (22) INSTURMENT PANEL (3) ENGINE RPM (11) FOOT PEDAL POSITION (17) THROTTLE SPEED...
Page 64 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM ENGINE CONTROL MODULE (ECM) Figure 20: LPG / Natural Gas ECM Input and Outputs (1) BATTERY PLUS (9) THROTTLE POSITION 1 (16) FUEL CONTROL LOCATION (21) DIAGNOSTIC TOOL (2) BATTERY MINUS (10) THROTTLE POSITION 2 (17) SPARK CONTROL TO (22) MIL LIGHT (3) ENGINE RPM (11) FOOT PEDAL POSITION...
Page 65 (31) HIGH SPEED CAN LINK receives input data from sensors, fitted to the engine and In Kubota fuel systems, the Engine Control Module fuel system, and then outputs various signals, to control (ECM) provides total control, of the engine, fuel control, engine operation.
Page 66 In Kubota fuel system designs, the EOP is mounted The TMAP sensor is a combination sensor, and in the cylinder block, and is supplied by Kubota. The provides the ECM with the Intake Air Temperature (IAT), EOP is a 5.00 V reference signal sensor, which operates and the Manifold Absolute Pressure (MAP).
Page 67 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM FOOT PEDAL POSITION SENSORS (FPP) Kubota fuel systems, utilize a "drive by wire" technique, to allow the operator to accelerate the engine. This type of technique does not use a physical connection, between the operator foot pedal and the throttle body.
Page 68 Kubota gasoline fuel system, utilizes a Knock Sensor, which is installed to the engine block, and attached by Kubota. The Knock Sensor is a 5 volt reference signal sensor, which operates by the resistance change in the sensor, to output a reference voltage for the ECM to use.
Page 69: Electrical System
Some pins may STRIPPING TOOLS, ELECTRICAL not be used in certain Kubota fuel system and are DIAGNOSTIC TOOLS blanked in the connector. • BEFORE ADDING ANY OPTIONAL ELECTRICAL EQUIPMENT TO THE VEHICLE FITTED WITH AN...
Page 70: System Wiring Diagram
ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM (1) System Wiring Diagram [A] VEHICLE SIDE OF SYSTEM WIREING DIAGRAM (WG1605-G) 1-60 KiSC issued 12, 2016 A...
Page 71 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM JOINT POINTS (A, B, C, D) • A: The points below are jointed. IGNITION_FUSE (15A) ALTERNATOR_PIN_2 VIC2_PIN_S COIL_CYL_#1,2,3,4_PIN_1 INJ_CYL_#1,2,3,4_PIN_2 _SENSOR_PRE_CATALYST_PIN_C _SENSOR_POST_CATALYST_PIN_C • B: The points below are jointed. BATTERY + KEY_SWITCH_PIN_OFF ALTERNATOR_CHARGE_INDICATION_LAMP FUEL_SEL_PIN_NG MIL_LAMP • C: The points below are jointed. ECM_PIN_19 (5 V_EXT1) THROTTLE_ACTUATOR_PIN_3 TMAP (BOOST) PIN_B...
Page 72 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM [B] ENGINE SIDE OF SYSTEM WIREING DIAGRAM (WG1605-G) 1-62 KiSC issued 12, 2016 A...
Page 73 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM JOINT POINTS (A, B, C, D) • A: The points below are jointed. IGNITION_FUSE (15A) ALTERNATOR_PIN_2 VIC2_PIN_S COIL_CYL_#1,2,3,4_PIN_1 INJ_CYL_#1,2,3,4_PIN_2 _SENSOR_PRE_CATALYST_PIN_C _SENSOR_POST_CATALYST_PIN_C • B: The points below are jointed. BATTERY + KEY_SWITCH_PIN_OFF ALTERNATOR_CHARGE_INDICATION_LAMP FUEL_SEL_PIN_NG MIL_LAMP • C: The points below are jointed. ECM_PIN_19 (5 V_EXT1) THROTTLE_ACTUATOR_PIN_3 TMAP (BOOST) PIN_B...
Page 74 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM [C] VEHICLE SIDE OF SYSTEM WIREING DIAGRAM (WG1605-L, WG1605-N, WG1605-LN) 1-64 KiSC issued 12, 2016 A...
Page 75 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM JOINT POINTS (A, B, C, D) • A: The points below are jointed. IGNITION_FUSE (15A) ALTERNATOR_PIN_2 VIC2_PIN_S COIL_CYL_#1,2,3,4_PIN_1 INJ_CYL_#1,2,3,4_PIN_2 _SENSOR_PRE_CATALYST_PIN_C _SENSOR_POST_CATALYST_PIN_C • B: The points below are jointed. BATTERY + KEY_SWITCH_PIN_OFF ALTERNATOR_CHARGE_INDICATION_LAMP FUEL_SEL_PIN_NG MIL_LAMP • C: The points below are jointed. ECM_PIN_19 (5 V_EXT1) THROTTLE_ACTUATOR_PIN_3 TMAP (BOOST) PIN_B...
Page 76 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM [D] ENGINE SIDE OF SYSTEM WIREING DIAGRAM (WG1605-L, WG1605-N, WG1605-LN) 1-66 KiSC issued 12, 2016 A...
Page 77 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM JOINT POINTS (A, B, C, D) • A: The points below are jointed. IGNITION_FUSE (15A) ALTERNATOR_PIN_2 VIC2_PIN_S COIL_CYL_#1,2,3,4_PIN_1 INJ_CYL_#1,2,3,4_PIN_2 _SENSOR_PRE_CATALYST_PIN_C _SENSOR_POST_CATALYST_PIN_C • B: The points below are jointed. BATTERY + KEY_SWITCH_PIN_OFF ALTERNATOR_CHARGE_INDICATION_LAMP FUEL_SEL_PIN_NG MIL_LAMP • C: The points below are jointed. ECM_PIN_19 (5 V_EXT1) THROTTLE_ACTUATOR_PIN_3 TMAP (BOOST) PIN_B...
Page 78 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM [E] VEHICLE SIDE OF SYSTEM WIREING DIAGRAM (WG1605-GL, WG1605-GLN) 1-68 KiSC issued 12, 2016 A...
Page 79 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM JOINT POINTS (A, B, C, D) • A: The points below are jointed. IGNITION_FUSE (15A) ALTERNATOR_PIN_2 VIC2_PIN_S COIL_CYL_#1,2,3,4_PIN_1 INJ_CYL_#1,2,3,4_PIN_2 _SENSOR_PRE_CATALYST_PIN_C _SENSOR_POST_CATALYST_PIN_C • B: The points below are jointed. BATTERY + KEY_SWITCH_PIN_OFF ALTERNATOR_CHARGE_INDICATION_LAMP FUEL_SEL_PIN_NG MIL_LAMP • C: The points below are jointed. ECM_PIN_19 (5 V_EXT1) THROTTLE_ACTUATOR_PIN_3 TMAP (BOOST) PIN_B...
Page 80 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM [F] ENGINE SIDE OF SYSTEM WIREING DIAGRAM (WG1605-GL, WG1605-GLN) 1-70 KiSC issued 12, 2016 A...
Page 81 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM JOINT POINTS (A, B, C, D) • A: The points below are jointed. IGNITION_FUSE (15A) ALTERNATOR_PIN_2 VIC2_PIN_S COIL_CYL_#1,2,3,4_PIN_1 INJ_CYL_#1,2,3,4_PIN_2 _SENSOR_PRE_CATALYST_PIN_C _SENSOR_POST_CATALYST_PIN_C • B: The points below are jointed. BATTERY + KEY_SWITCH_PIN_OFF ALTERNATOR_CHARGE_INDICATION_LAMP FUEL_SEL_PIN_NG MIL_LAMP • C: The points below are jointed. ECM_PIN_19 (5 V_EXT1) THROTTLE_ACTUATOR_PIN_3 TMAP (BOOST) PIN_B...
Page 82: Ecu Terminal Layout
ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM (2) ECU Terminal Layout Connector Number: C001 Name: ECM CONNECTOR ECM PIN LOCATIONS DISCRIPTION DISCRIPTION DISCRIPTION LT_GREEN/ BLACK/ SPK_COIL1A YELLOW 18 5 V EXT 2 EGOH 2 PURPLE 18 YELLOW 18 YELLOW/ LT_GREEN/ BLACK/ SPK_COIL1B 5 V RTN 2 EGOH 1 BLACK 18 BLACK 18...
Page 83 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM ECM PIN LOCATIONS DISCRIPTION DISCRIPTION DISCRIPTION DK_BLUE/ WHITE/ LT_GREEN 18 FPP1 AUX PWM5 REC ORANGE 18 BROWN 16 (FPP2) PURPLE/ BROWN/ AUX ANA PUD3 BLANK AUX PWM5 FPP2 IVS YELLOW 18 WHITE 16 PURPLE/ CRANK + PC TX BLANK AUX PWM1...
Page 84: Connector Views
ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM (3) Connector Views Connector Number: C002* Name: Starter Solenoid Pin Number Description Wire Color Starter Solenoid WHITE Connector Number: C003* Name: Crankshaft Sensor Pin Number Description Wire Color CRANK + PURPLE/WHITE CRANK  WHITE/PURPLE Connector Number: C004* Name: Oil Pressure Switch Pin Number Description...
Page 85 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM Connector Number: C005* Name: Heated O Sensor (Pre-Cat) Pin Number Description Wire Color 5 V_RTN 1 BLACK/LT_GREEN EGO 1 DK_GREEN/ORANGE 12 V_RELAYED_POWER PINK/DK_GREEN EGOH 1 BLACK/WHITE Connector Number: C006* Name: Heated O Sensor (Post-Cat) Pin Number Description Wire Color 5 V_RTN 1...
Page 86 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM Connector Number: C007* Name: TMAP Pin Number Description Wire Color LT_GREEN 5 V_RTN 1 BLACK/LT_GREEN 5 V_EXT 1 LT_GREEN/RED YELLOW/GRAY Connector Number: C008* Name: Engine Coolant Temperature Pin Number Description Wire Color 5 V_RTN 1 BLACK/LT_GREEN TAN/WHITE NOTE •...
Page 87 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM Connector Number: C009* Name: Vehicle Interface Connector1 Pin Number Description Wire Color PINK 18 CHARGE_INDICATION PURPLE 18 FUEL_PUMP  BLACK/RED 16 FUEL_PUMP + PINK/YELLOW 16 AUX_PWM2 DK_BLUE 18 START_COMMAND LT_BLUE/PINK 18 GREEN/YELLOW 18 AUX_DIG1 (FUEL_SELECT) DK_GREEN/PURPLE 18 (FPP 2) FPP 2_IVS PURPLE/YELLOW 18 FPP1...
Page 88 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM Connector Number: C010* Name: Vehicle Interface Connector2 Pin Number Description Wire Color NOT_USE AUX_PWM5_RECIRC WHITE/BROWN 16 AUX_PWM5 BROWN/WHITE 16 TACH GRAY 18 GROUND BLACK 16 AUX_PWM1 TAN 16 AUX_ANA_PU3 YELLOW/DK_BLUE 18 AUX_ANA_PU1 DK_BLUE/YELLOW 18 GOV_SELECT2 GRAY/RED 18 GOV_SELECT1 GRAY/DK_BLUE 18 AUX_DIG2...
Page 89 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM Connector Number: C012 Name: 12 Volt Battery + Connection Pin Number Description Wire Color Battery 12 V + Connector Number: C013 Name: Alternator Battery + Pin Number Description Wire Color Battery 12 V + 1-79 KiSC issued 12, 2016 A...
Page 90 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM Connector Number: C014* Name: Diagnostic Tool Connector Pin Number Description Wire Color ANA_RTN 5 V_REF PC TX PC RX VBAT CAN 1 + BLUE/PINK CAN 1  BLUE/WHITE Connector Number: C015* Name: Alternator Connector Pin Number Description Wire Color Not Used...
Page 91 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM Connector Number: C016* Name: DEPR Connector Pin Number Description Wire Color CAN Termination WHITE CAN 1 + DK_BLUE/PINK VRELAY PINK/DK_GREEN Ground BLACK CAN  DK_BLUE/WHITE (12 V) RED/TAN Connector Number: C017* Name: Bosch Throttle Connector Pin Number Description Wire Color DBW ...
Page 92 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM Connector Number: C018* Name: LPG / Natural Gas Fuel Lock Off Connector Pin Number Description Wire Color Lock Off WHITE/BLACK 12 V PINK/TAN Connector Number: C019* Name: Knock Sensor Connector Pin Number Description Wire Color Knock + BLACK/YELLOW Knock ...
Page 93 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM Connector Number C021* Name: Ignition Coil Connector Cylinder Number Pin Number Description Wire Color 1 to 4 (All) 12 V_RELAYED_POWER PINK/DK_GREEN SPK_COIL1A YELLLOW SPK_COIL2B YELLLOW/WHITE SPK_COIL2A YELLLOW/RED SPK_COIL1B YELLLOW/BLACK Connector Number C022* Name: Injector Connector Cylinder Number Pin Number Description Wire Color...
Page 94 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM Connector Number C023 Name: FUSE BOX 1-84 KiSC issued 12, 2016 A...
Page 95 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM Connector Number C024 Name: FUSE BOX (LAYOUT) • WG1605-G (1) Fuel Pump Relay (4) 15 A FUSE (6) 15 A FUSE (8) 10 A FUSE (2) Power Relay (5) 15 A FUSE (7) BLANK (9) 5 A FUSE (3) Starter Relay •...
Page 96: Repair Of Wiring Harness
ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM (4) Repair of Wiring Harness INTRODUCTION CONNECTORS AND TERMINALS EControls both certified As stated earlier always use care when probing a non-certified fuel system relies on precise voltage input connector or replacing terminals in a connector housing. and outputs to maintain precise fuel control during Improper repair of a connector can resulting in shorts at normal operation.
Page 97 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM REPAIR OF WIRING HARANESS CONNECTOR END REPAIR OR REPLACEMENT TWISTED LEADS Before making a connector repair, be certain of the type of connector for example Weather-Pack connectors and Compact Three connectors look very similar but are service differently.
Page 98 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM WEATHER PACK CONNECTOR A Weather-Pack connector can be identified by a rubber seal installed to the wire at the rear of the connector. This type of connector is use in the engine compartment to protect against moisture intrusion into the connector.
Page 99: Diagnosis
Kubota, and requires regularly scheduled maintenance. For maintenance of IMPORTANT the base engine and or chassis, refer to the Kubota • When refueling the cylinder, clean both the fill manual which covers the maintenance of the equipment.
Page 100 EControls designed fuel system; the filter have been Kubota. These lines are made of special rubber or metal attached with additional filtration, (Refer to Kubota Base material, which meet the design working pressures, engine section).
Page 101 NOTE • Check to make sure the rail bracket is securely • Certain Kubota LPG / Natural Gas systems may attached to the engine. be fitted with a Direct Electronic Pressure • Check to make sure the rail brackets have no Regulator (DEPR) which is downstream of the cracking or breaking.
Page 102 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM BATTERY MISCELLANEOUS ELECTRICAL • Check and clean the battery terminal connections • Check the instrument panel to insure all warning and insure the connections are tight. lights are functioning, MIL, oil pressure and • Check the battery for any cracks or damage to the temperature gauges are registering case.
Page 103: Fuel System Diagnosis
ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM [2] FUEL SYSTEM DIAGNOSIS Gasoline Fuel System Diagnosis A fuel temperature and pressure sensor mounted in Fuel System Description the manifold measures the gasoline temperature and pressure for feedback to the ECM. By controlling the fuel Engines which use the EControls gasoline fuel pump outlet pressure, excess fuel is not being sent to the injection system will utilize a gasoline fuel tank which is...
Page 104 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM Diagnostic Aids This procedure is intended to diagnose a vehicle operating on Gasoline. If the vehicle will not continue to run on Gasoline, refer to Hard Start for preliminary checks. Before proceeding with this procedure, verify that the vehicle has a sufficient quantity of fuel.
Page 105 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM Gasoline Fuel System Diagnosis Step Action Value(s) Were you referred to this procedure by a DTC Go to Go to – diagnostic chart? Step G3 Step G2 Connect the EControls GCP Display SW tool Perform the On Board Diagnostic (OBD) System Check. Key On Engine Off.
Page 106 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM Step Action Value(s) Check the fuel pump signal circuit at the ECM. Using DVOM place the Positive probe at the relay and ground. Go to Go to – Key On Engine Off. Step G14 Step G15 Was the voltage present? Replace fuel pump relay.
Page 107 The low pressure hose should only be replaced with recommended Kubota hose replacement. DUAL STAGE REGULATOR (DSR) The packaging of the regulator, into the engine and This section of the manual has been prepared to...
Page 108 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM (Continued) Tools Required: • 7/16 Open end wrench (for test port plugs) • Straight Blade screw driver • DVOM Diagnostic Scan Tool • GCP Display Software (laptop) Pressure Gauges • 0 to 69 kPa (0 to 0.70 kgf/cm , 0 to 10 psi) Gauge Test Description The numbers below refer to step numbers, on the...
Page 109 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM LPG / Natural Gas Fuel System Diagnosis Step Action Value(s) Were you referred to this procedure by a DTC Go to Go to – diagnostic chart? Step L3 Step L2 Connect the EControls GCP display SW (EDIS). Go to the Key On Engine Off System Mode Stopped Go to...
Page 110 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM Step Action Value(s) With the fuel line loose at the fuel filter inlet (in-line filter) or at the LPL inlet. Slowly open and close the manual valve. Go to Go to – Step L14 Step L10 Did fuel begin to flow when the manual valve was opened? Check the fuel supply system, the hoses are plugged...
Page 111: Restricted Exhaust System Diagnosis
ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM (1) Restricted Exhaust System Diagnosis Exhaust System Description Check at Heated Exhaust Gas Oxygen Sensor The emission certified engine has been designed (HEGO) and calibrated to meet the emission standards in effect 1. Carefully remove the HEGO. for 2010.
Page 112: Dtc List
ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC LIST Name Cam/Crank Sensors Crank and/or Cam Could Not DTC Name Fuel pressure low Fuel pressure high Synchronize During Start J1939 • Mechanical misalignment between • Fuel presure abnomality (High side) Detected Item • Fuel presure abnomality (Low side) cam and crank DTC Set •...
Page 113 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM Name DTC Name MAP high pressure IAT Higher Than Expected Stage 1 IAT Low Voltage J1939 • Sensor/wiring harness short to • Intake air temperature abnormality • Sensor/wiring harness short to Detected Item power (High side stage 1) ground •...
Page 114 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM Name ECT/CHT DTC Name ECT/CHT High Voltage TPS1 % Lower Than TPS2 % TPS1 Signal Voltage Low J1939 • Sensor/wiring harness open/short • TPS malfunction • TPS circuit in the harness short to Detected Item to power ground •...
Page 115 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM Name EGO Sensors EGO Sensors Adaptive Learn DTC Name EGO1 Open/Lazy (HO2S1) EGO2 Open/Lazy (HO2S2) Adaptive Learn Bank 1 High (Gasoline) 3217 3227 4237 J1939 • Open feed circuit to O heater • Open feed circuit to O heater •...
Page 116 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM Name Adaptive Learn DTC Name Adaptive Learn Bank1 Low (Gasoline) FT gasoline low FT gasoline high 4237 J1939 • an inoperative O sensor • Operating in a frigid atmosphere • Operating in a hot environment • high fuel supply pressure or •...
Page 117 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM Name ECT/CHT Engine Speed RPM Higher Than Max Allowed DTC Name FT Gaseous Fuel Extremery Low ECT Higher Than Expected 2 Governed Speed 3468 J1939 • Not vaporized completely • Engine coolant temperature • Engine over speed condition, stuck Detected Item abnormality (High side stage 2) throttle, large vacuum leak into...
Page 118 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM Name Injectors Injectors Injectors Injector Driver #1 Injector Driver #2 DTC Name Injector Driver #1 Short-To-Power Open/Short-To-Ground Open/Short-To-Ground J1939 • Loss of 12.0 V feed to injector • Injector coil shorted internally • Loss of 12.0 V feed to injector •...
Page 119 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM Name Injectors Injectors Knock Injector Driver #4 DTC Name Injector Driver #4 Short-To-Power Knock 1 Excessive or Erratic Signal Open/Short-To-Ground J1939 • Loss of 12.0 V feed to injector • Injector coil shorted internally • Knock signal abnormality •...
Page 120 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM Name Cam/Crank Sensors Cam/Crank Sensors Lockoff/Fuel Diagnostics DTC Name Camshaft Input Signal Noise Loss of Camshaft Input Signal Fuel run-out longer than expected J1939 • Cam+ or Cam circuits in wrong • Loss of feed voltage to Cam sensor Detected Item connector terminal slot •...
Page 121 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM Name Battery Voltage Internal Processor Diagnostics Internal Processor Diagnostics DTC Name Battery Voltage (VBAT) High Microprocessor Failure-FLASH Microprocessor Failure-RAM J1939 • System voltage abnormality • Faulty ECU • Faulty ECU Detected Item (High side) DTC Set •...
Page 122 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM Fuel Pump Relay Fuel Pump Motor Name 5 V External 5 V External Control/Coil Feedback DTC Name Fuel Pump Relay Coil Short-To-Power Sensor Supply Voltage 1 Low (5Vext1) Sensor Supply Voltage 1 High (5Vext1) 1348 1347 1079 1079 J1939...
Page 123 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM 1111 1112 Name Power Relay Control/Coil Engine Speed Engine Speed DTC Name Power Relay Coil Short-To-Power RPM Above Fuel Rev Limit Level RPM Above Spark Rev Limit Level 1485 J1939 • Shorted relay pull in coil •...
Page 124 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM 1153 1154 1155 Name Closed Loop Closed Loop Closed Loop DTC Name Closed Loop High (NG) Closed Loop Low (NG) Closed Loop Bank 1 High (Gasoline) 4236 4236 4236 J1939 • exhaust leaks upstream or near the •...
Page 125 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM 1156 1161 1162 Name Closed Loop Adaptive Learn Adaptive Learn DTC Name Closed Loop Bank 1 Low (Gasoline) Adaptive Learn High (LPG) Adaptive Learn Low (LPG) 4236 4237 4237 J1939 • high fuel supply pressure to the fuel •...
Page 126 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM 1163 1164 1165 Name Adaptive Learn Adaptive Learn Catalyst DTC Name Adaptive Learn High (NG) Adaptive Learn Low (NG) Catalyst inactive on LPG 4237 4237 3050 J1939 • exhaust leaks upstream or near the • high fuel supply pressure to the HEGO sensor gaseous fuel control or faulty •...
Page 127 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM 1166 1171 1172 Name Catalyst EPR Diagnostics EPR Diagnostics EPR/CFV Regulation Pressure Higher EPR/CFV Regulation Pressure Lower DTC Name Catalyst inactive on NG than Expected than Expected 3050 520260 520260 J1939 • Inlet pressure to DEPR is too high. •...
Page 128 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM 1173 1174 1175 Name EPR Diagnostics EPR Diagnostics EPR Diagnostics DTC Name EPR/CFV comm lost EPR/CFV Voltage Supply High EPR/CFV Voltage Supply Low 520620 520260 520260 J1939 • Faulty CAN cinnection • Supply voltage to the EPR/CFV is •...
Page 129 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM 1612 1613 1614 Name Internal Processor Diagnostics Internal Processor Diagnostics Internal Processor Diagnostics DTC Name Microprocessor Failure-RTI 1 Microprocessor Failure-RTI 2 Microprocessor Failure-RTI 3 J1939 Detected Item • Faulty ECU • Faulty ECU • Faulty ECU DTC Set •...
Page 130 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM 2111 2112 2121 Name DTC Name Unable to Reach Lower TPS Unable to Reach Higher TPS FPP1 Lower Than FPP2 J1939 • TPS malfunction • TPS malfunction • Wiring harness open/short/damage Detected Item • FPP malfunction DTC Set •...
Page 131 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM 2127 2128 2135 Name TPS1/2 Simultaneous Voltages out of DTC Name FPP2 voltage low FPP2 voltage high range J1939 ON 2Hz ON 2Hz • Wiring harness open/short/damage • Wiring harness open/short/damage • TPS malfunction Detected Item •...
Page 132 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM 2304 2306 2307 Name Spark Coil Primary Spark Coil Primary Spark Coil Primary Spark Coil #3 Primary DTC Name Spark Coil #2Primary Short-to-Power Spark Coil #3 Primary Short-to-Power Open/Short-to-Ground 1269 1270 1270 J1939 • a short to power in the harness •...
Page 133: Diagnosis Procedure By Dtc
ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM Diagnosis Procedure by DTC (1) Crank/Cam Sensors (DTC 16, 336, 337, 341, 342) DTC 16-Crank and/or Cam Could Not Synchronize During Start • Hardware: Crankshaft Position Sensor/Camshaft Position Sensor Input Circuits • Enabling Conditions: Engine Cranking or Running •...
Page 134 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 336-Crank Input Signal Noise • Hardware: Crankshaft Position sensor • Enabling Conditions: Key On, Engine On • Set Conditions: Electrical noise or irregular crank pattern detected causing more than 1 crank re-synchronization events in less than 800 ms •...
Page 135 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 336-Crank Input Signal Noise Diagnostic Aids Chart 1-125 KiSC issued 12, 2016 A...
Page 136 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 337-Loss of Crankshaft Input Signal Diagnostic Aids Chart 1-126 KiSC issued 12, 2016 A...
Page 137 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 341-Camshaft Input Signal Noise • Hardware: Camshaft Position sensor • Enabling Conditions: Key On, Engine Running • Set Conditions: Electrical noise or irregular cam pattern detected causing more than 1 cam re-synchronization events in less than 700 ms. •...
Page 138 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 341-Camshaft Input Signal Noise Diagnostic Aids Chart 1-128 KiSC issued 12, 2016 A...
Page 139 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 342-Loss of Camshaft Input Signal Diagnostic Aids Chart 1-129 KiSC issued 12, 2016 A...
Page 140: Fp (Fuel Pressure Sensor) (Dtc 87, 88, 91, 92)
ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM (2) FP (Fuel Pressure Sensor) (DTC 87, 88, 91, 92) DTC 87-Fuel Pressure Low • Hardware: Liquid Fuel Pressure and Temperature Sensor • Enabling Conditions: Engine Running • Set Conditions: FP fault mode Gasoline only, run time wait for fuel pressure low faults 5.0 sec, FP pressure <...
Page 141 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 91-FP (Fuel Pressure Sensor) Low Voltage • Hardware: Liquid Fuel Pressure and Temperature Sensor • Enabling Conditions: Key ON • Set Conditions: Fuel pressure feedback voltage lower than 0.100 V for longer than 5 seconds •...
Page 142 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 87-Fuel Pressure Low Diagnostic Aids Chart 1-132 KiSC issued 12, 2016 A...
Page 143 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 88-Fuel Pressure High Diagnostic Aids Chart 1-133 KiSC issued 12, 2016 A...
Page 144 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 91-FP (Fuel Pressure) Low Voltage Diagnostic Aids Chart 1-134 KiSC issued 12, 2016 A...
Page 145 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 92-FP (Fuel Pressure Sensor) High Voltage Diagnostic Aids Chart 1-135 KiSC issued 12, 2016 A...
Page 146: Map (Manifold Absolute Pressure Sensor) (Dtc 107, 108)
ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM (3) MAP (Manifold Absolute Pressure Sensor) (DTC 107, 108) DTC 107-MAP Low Voltage • Hardware: Manifold Absolute Pressure Sensor • Enabling Conditions: Engine Cranking or Running • Set Conditions: MAP sensor voltage feedback less than 0.050 V when throttle position is greater than 5 % and engine speed is less than 4000 min (rpm).
Page 147 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 107-MAP Low Voltage Diagnostic Aids Chart 1-137 KiSC issued 12, 2016 A...
Page 148 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 108-MAP High Pressure Diagnostic Aids Chart 1-138 KiSC issued 12, 2016 A...
Page 149: Iat (Intake Air Temperature Sensor) (Dtc 111, 112, 113, 127, 129)
ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM (4) IAT (Intake Air Temperature Sensor) (DTC 111, 112, 113, 127, 129) DTC 111-IAT Higher Than Expected Stage 1 • Hardware: Intake Air Temperature Sensor • Enabling Conditions: Engine Running higher than 1000 min (rpm) • Set Conditions: Intake Air Temperature greater than stage 1 limit (71 °C (160 °F)) for longer than 60 seconds when rpm is above 1000 min (rpm).
Page 150 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM The Intake Air Temperature sensor is a thermistor (temperature sensitive resistor) located in the intake manifold of the engine. It is used to monitor incoming air and the output, in conjunction with other sensors, is used to determine the airflow to the engine.
Page 151 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 112-IAT Low Voltage Diagnostic Aids Chart 1-141 KiSC issued 12, 2016 A...
Page 152 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 113-IAT High Voltage Diagnostic Aids Chart DTC 127-IAT Higher Than Expected Stage 2 Diagnostic Aids • This fault will set when inlet air is hotter than normal. The most common cause of high inlet air temperature is a result of a problem with routing of the inlet air.
Page 153 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 129-BP Low Pressure Daiganostic Aids Chart 1-143 KiSC issued 12, 2016 A...
Page 154: Ect (Engine Coolant Temperature) (Dtc 116, 117, 118, 217)
ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM (5) ECT (Engine Coolant Temperature) (DTC 116, 117, 118, 217) DTC 116-ECT Higher Than Expected Stage 1 • Hardware: Engine Coolant Temperature Sensor • Enabling Conditions: Engine Running above 500 min (rpm) • Set Conditions: Engine Coolant Temperature reading or estimate greater than the stage 1 limit (110 °C (230 °F)) for longer than 30 seconds •...
Page 155 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM The Engine Coolant Temperature sensor is a thermistor (temperature sensitive resistor) located in the engine coolant. The ECT is used for engine fuel calculation (cold engine), ignition timing control, to enable certain features, and for engine protection (overheats). The ECM provides a voltage divider circuit so when the sensor reading is cool the sensor reads higher voltage, and lower when warm.
Page 156 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 117-ECT Low Voltage Diagnostic Aids Chart 1-146 KiSC issued 12, 2016 A...
Page 157 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 118-ECT High Voltage Diagnostic Aids Chart 1-147 KiSC issued 12, 2016 A...
Page 158 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 217-ECT Higher Than Expected Stage 2 Diagnostic Aids • If the "ECT High Voltage" fault is also present, follow the troubleshooting procedures for that fault as it may have caused "ECT Higher Than Expected 2". •...
Page 159: Tps (Throttle Position Sensor) (Dtc 121 To 123, 221 To 223, 2111, 2112, 2135)
ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM (6) TPS (Throttle Position Sensor) (DTC 121 to 123, 221 to 223, 2111, 2112, 2135) DTC 121-TPS1 % Lower Than TPS2 % • Hardware: Throttle Body-Throttle Position Sensors 1 & 2 relationship • Enabling Conditions: Key-On, Engine Cranking, or Running •...
Page 160 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 123-TPS1 Signal Voltage High • Hardware: Throttle Body-Throttle Position Sensor 1 • Enabling Conditions: Engine running • Set Conditions: TPS1 sensor voltage higher than 4.80 V for longer than 0.5 seconds • Corrective Action(s): Illuminate MIL, shutdown engine •...
Page 161 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 2112: Unable to Reach Higher TPS • Hardware: Throttle Position Sensor • Enabling Conditions: Cranking or Running • Set Conditions: Throttle command is 20 % more than actual throttle position • Corrective Action(s): MIL-On during active fault, Adaptive-Enabled, Closed Loop-Enabled, Engine Shut Down •...
Page 162 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 121-TPS1 % Lower Than TPS2 % Diagnostic Aids Chart 1-152 KiSC issued 12, 2016 A...
Page 163 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 122-TPS1 Signal Voltage Low Diagnostic Aids Chart 1-153 KiSC issued 12, 2016 A...
Page 164 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 123-TPS1 Signal Voltage High Diagnostic Aids Chart 1-154 KiSC issued 12, 2016 A...
Page 165 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 221-TPS1 % Higher Than TPS2 % Diagnostic Aids Chart 1-155 KiSC issued 12, 2016 A...
Page 166 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 222-TPS2 Signal Voltage Low Diagnostic Aids Chart 1-156 KiSC issued 12, 2016 A...
Page 167 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 223-TPS2 Signal Voltage High Diagnostic Aids Chart 1-157 KiSC issued 12, 2016 A...
Page 168 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 2111: Unable to Reach Lower TPS Diagnostic Aids Chart 1-158 KiSC issued 12, 2016 A...
Page 169 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 2112: Unable to Reach Higher TPS Diagnostic Aids Chart DTC 2135-TPS1/2 Simultaneous Voltages Out-of-Range Diagnostic Aids Troubleshoot according to TPS1 voltage out-of-range following DTC 122 and 123 procedures. Troubleshoot according to TPS2 voltage out-of-range following DTC 222 and 223 procedures. 1-159 KiSC issued 12, 2016 A...
Page 170: Ego Sensors ((Exhaust Gas Oxygen) Sensors) (Dtc 134, 154)
ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM (7) EGO Sensors ((Exhaust Gas Oxygen) Sensors) (DTC 134, 154) DTC 134-EGO1 Open/Lazy (HO • Hardware: Heated Exhaust Gas Oxygen Sensor (Pre-Catalyst) • Enabling Conditions: Engine Running • Set Conditions: HEGO/HO S cold or non-responsive for longer than 120 seconds •...
Page 171 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 154-EGO2 Open/Lazy (HO • Hardware: Heated Exhaust Gas Oxygen Sensor (Post-Catalyst) • Enabling Conditions: Engine Running • Set Conditions: HEGO/HO S cold or non-responsive longer than 120 seconds • Corrective Action(s): Illuminate MIL. • Emissions related fault •...
Page 172 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 134-EGO1 Open/Lazy (HO Diagnostic Aids Chart 1-162 KiSC issued 12, 2016 A...
Page 173 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 154-EGO2 Open/Lazy (HO Diagnostic Aids Chart 1-163 KiSC issued 12, 2016 A...
Page 174: Adaptive Learn (Dtc 171, 172, 1161 To 1164)
ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM (8) Adaptive Learn (DTC 171, 172, 1161 to 1164) DTC 171-Adaptive Learn Bank 1 High (Gasoline) • Hardware: HEGO Sensor (Pre-Catalyst) rich-lean switch rate • Enabling Conditions: Engine Running in closed loop active mode updating adaptive learn multiplier (CL+Adap mode) •...
Page 175 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM The purpose of the Adaptive Learn Multiplier is to adjust fuel flow due to variations in fuel composition, engine wear, engine-to-engine build variances, and component degradation. The Adaptive Learn multiplier values are held in a table and are remembered between key cycles. Adaptive memory tables are erased at battery disconnects and with the DST.
Page 176 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 172-Adaptive Learn Bank1 Low (Gasoline) Diagnostic Aids NOTE • If any other DTCs are present, diagnose those first. • Oxygen Sensor Wire - Sensor may be mispositioned contacting the exhaust. Check for short to ground between harness and sensor and on sensor harness •...
Page 177 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 1161-Adaptive Learn High (LPG) DTC 1163-Adaptive Learn High (NG) • Hardware: Heated or Universal Exhaust Gas Oxygen Sensor (Bank 1-Sensor 1/Bank 1-Before Catalyst) • Enabling Conditions: Engine Running in closed loop and with fuel adaptive learn active •...
Page 178 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM The HEGO/HO S sensor is a switching-type sensor around stoichiometry that measures the oxygen content present in the exhaust to determine if the fuel flow to the engine is correct. A UEGO sensor measures the exhaust content across a wide-range of air-fuel ratios with a linear output proportional to lambda/equivalence ratio/air-fuel ratio.
Page 179: Fuel Temp (Fuel Temperature Sensor) (Dtc 182, 183, 187)
ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM (9) Fuel Temp (Fuel Temperature Sensor) (DTC 182, 183, 187) DTC 182-Fuel Temp (Gasoline) Low Voltage/Low Temp • Hardware: Liquid Fuel Temperature Sensor • Enabling Conditions: Engine Running • Set Conditions: FT sensor voltage less than 0.050 V OR indicated temperature below 37 °C (35 °F) for longer than 1 second •...
Page 180 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 183-Fuel Temp (Gasoline) High Voltage/High Temp • Hardware: Liquid Fuel Temperature Sensor • Enabling Conditions: Engine Running • Set Conditions: FT sensor voltage higher than 4.90 V OR indicated temperature above 59 °C (138 °F) for longer than 2 minutes •...
Page 181 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 182-Fuel Temp (Gasoline) Low Voltage/Low Temp Diagnostic Aids Chart (Low Voltage/Low Temp) 1-171 KiSC issued 12, 2016 A...
Page 182 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM Diagnostic Aids Chart (Low Voltage/Low Temp) 1-172 KiSC issued 12, 2016 A...
Page 183 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 183-Fuel Temp (Gasoline) High Voltage/High Temp Diagnostic Aids Chart 1-173 KiSC issued 12, 2016 A...
Page 184: Engine Speed (Dtc 219, 1111, 1112)
ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM (10) Engine Speed (DTC 219, 1111, 1112) DTC 219-RPM Higher Than Max Allowed Governed Speed • Hardware: Max Govern Speed Override- Crankshaft Position Sensor • Enabling Conditions: Engine Running • Fault Condition-Engine speed greater 3900 min (rpm) for longer than 1 second •...
Page 185 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 1112-RPM Above Spark Rev Limit Level • Hardware: Spark Rev Limit- Crankshaft Position Sensor • Enabling Conditions: Engine Running • Set Conditions: Engine speed greater than the Spark Rev Limit speed (4200 min (rpm)) for longer than 0.5 seconds •...
Page 186: Injectors (Dtc 261, 262, 264, 265, 267, 268, 270, 271)
ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM (11) Injectors (DTC 261, 262, 264, 265, 267, 268, 270, 271) DTC 261-Injector Driver #1 Open/Short-To-Ground DTC 264-Injector Driver #2 Open/Short-To-Ground DTC 267-Injector Driver #3 Open/Short-To-Ground DTC 270-Injector Driver #4 Open/Short-To-Ground • Hardware: Each Injector Driver (each cylinder in the block order) •...
Page 187 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 261-Injector Driver #1 Open/Short-To-Ground DTC 264-Injector Driver #2 Open/Short-To-Ground DTC 267-Injector Driver #3 Open/Short-To-Ground DTC 270-Injector Driver #4 Open/Short-To-Ground Diagnostic Aids Chart 1-177 KiSC issued 12, 2016 A...
Page 188 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 262-Injector Driver #1 Short-To-Power DTC 265-Injector Driver #2 Short-To-Power DTC 268-Injector Driver #3 Short-To-Power DTC 271-Injector Driver #4 Short-To-Power Diagnostic Aids Chart 1-178 KiSC issued 12, 2016 A...
Page 189: Knock Sensor (Dtc 326, 327)
ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM (12) Knock Sensor (DTC 326, 327) DTC 326-Knock 1 Excessive or Erratic Signal • Hardware: Knock sensor #1 • Enabling Conditions: Key On, Engine On • Set Conditions: Knock sensor 1 voltage above 2.00 V with MAP less than 62 kPa [abs] (0.63 kgf/cm , 9 psia) and knock retard is a maximum retard value for longer than 3 seconds.
Page 190 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 326-Knock 1 Excessive or Erratic Signal Diagnostic Aids Chart 1-180 KiSC issued 12, 2016 A...
Page 191 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 327-Knock 1 Sensor Open or Not Present Diagnostic Aids Chart 1-181 KiSC issued 12, 2016 A...
Page 192: Catalyst Monitor (Dtc 420, 1165, 1166)
ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM (13) Catalyst Monitor (DTC 420, 1165, 1166) DTC 420-Catalyst Inactive on Gasoline (Bank1) • Hardware: Bank 1 Pre-Catalyst Exhaust Gas Oxygen Sensor and Bank 1 Post-Catalyst Exhaust Gas Oxygen Sensor • Enabling Conditions: Engine Running • Set Conditions: Bank 1 catalyst inactive on gasoline or LPG / natural gas engine •...
Page 193: Oil Pressure Sensor (Dtc 524)
ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM (14) Oil Pressure Sensor (DTC 524) DTC 524-Oil Pressure Low • Hardware: Engine Oil Pressure Sensor or Switch • Enabling Conditions: Key on, Engine Running longer than 15 seconds and running higher than 1300 min (rpm) •...
Page 194 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 524-Oil Pressure Low Diagnostic Aids Chart 1-184 KiSC issued 12, 2016 A...
Page 195: Battery Voltage (Dtc 562, 563)
ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM (15) Battery Voltage (DTC 562, 563) DTC 562-Battery Voltage (VBat) Low • Hardware: System voltage to ECM • Enabling Conditions: Key on, Engine running above 1000 min (rpm) • Set Conditions: Battery voltage to ECM less than 9.00 V for longer than 5 seconds •...
Page 196 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 562-Battery Voltage (VBat) Low Diagnostic Aids Chart 1-186 KiSC issued 12, 2016 A...
Page 197 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 563-Battery Voltage (VBat) High Diagnostic Aids Chart 1-187 KiSC issued 12, 2016 A...
Page 198: Internal Processor Diagnostics (Dtc 601, 604, 606, 1612 To 1616, 1673)
ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM (16) Internal Processor Diagnostics (DTC 601, 604, 606, 1612 to 1616, 1673) DTC 601-Microprocessor Failure-FLASH • Hardware: Engine Control Module-Flash Memory • Enabling Conditions: Key on • Set Conditions: Internal microprocessor error • Corrective Action(s): Illuminate MIL, disable fuel adaptive learn for remainder of key cycle, activate power derate 2 and never forget code (code must be manually erased by technician with DST) •...
Page 199 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM The ECM has checks that must be satisfied each time an instruction is executed. Several different things can happen within the microprocessor that will cause this fault. If this fault sets, the ECM will reset itself and log the code. DTC 1612-Microprocessor Failure-RTI 1 •...
Page 200 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 1615-Microprocessor Failure-A/D • Hardware: Engine Control Module • Enabling Conditions: Key on • Set Conditions: Internal microprocessor error • Corrective Action(s): MIL- On, fuel adaptive learn disabled and power derate 2 while code is active fault remembered until fault is cleared manually with a scan tool •...
Page 201 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 601-Microprocessor Failure-FLASH Diagnostic Aids Chart 1-191 KiSC issued 12, 2016 A...
Page 202 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 604-Microprocessor Failure-RAM Diagnostic Aids Chart 1-192 KiSC issued 12, 2016 A...
Page 203 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 606-Microprocessor Failure-COP Diagnostic Aids Chart 1-193 KiSC issued 12, 2016 A...
Page 204 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 1612-Microprocessor Failure-RTI 1 Diagnostic Aids Chart 1-194 KiSC issued 12, 2016 A...
Page 205 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 1613-Microprocessor Failure-RTI 2 Diagnostic Aids Chart 1-195 KiSC issued 12, 2016 A...
Page 206 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 1614-Microprocessor Failure-RTI 3 Diagnostic Aids Chart 1-196 KiSC issued 12, 2016 A...
Page 207 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 1615-Microprocessor Failure-A/D Diagnostic Aids Chart 1-197 KiSC issued 12, 2016 A...
Page 208 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 1616-Microprocessor Failure-nterrupt Diagnostic Aids Chart 1-198 KiSC issued 12, 2016 A...
Page 209: Fuel Pump Relay Control/Coil (Dtc 627 To 629)
ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM (17) Fuel Pump Relay Control/Coil (DTC 627 to 629) DTC 627-Fuel Pump Relay Coil Open • Hardware: Fuel Pump Relay Pull in Coil • Enabling Conditions: Key On • Set Conditions: Fuel Pump relay coil output open circuit for more than 10 samples of the circuit •...
Page 210 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 629-Fuel Pump Relay Coil Short-To-Power • J1939 SPN: 1348 FMI: 3 • Hardware: Fuel Pump Relay Pull in Coil • Enabling Conditions: Key On, Engine Off • Set Conditions: Fuel Pump relay coil output short to power/voltage •...
Page 211 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 627-Fuel Pump Relay Coil Open Diagnostic Aids Chart 1-201 KiSC issued 12, 2016 A...
Page 212 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 628-Fuel Pump Relay Ground Short Diagnostic Aids Chart 1-202 KiSC issued 12, 2016 A...
Page 213 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 629-Fuel Pump Relay Coil Short-To-Power Diagnostic Aids Chart 1-203 KiSC issued 12, 2016 A...
Page 214: V External (Dtc 642, 643, 652, 653, 1611)
ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM (18) 5 V External (DTC 642, 643, 652, 653, 1611) DTC 642-Sensor Supply Voltage 1 Low (5 Vext1) • Hardware: External Sensor Supply Voltage Regulator 1 • Enabling Conditions: Key On, Engine Off or Running • Fault Condition- Voltage feedback on sensor supply circuit #1 below 4.60 V for longer than 1 second •...
Page 215 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 1611-Sensor Supply Voltage (5 Vext1/2) Simultaneous out-of-range • Hardware: External Sensor Supply Voltage Regulator 1/2 • Enabling Conditions: Engine On • Fault Condition: Voltage feedback on sensor supply circuit #1 above 5.40 V or below 4.60 V for longer than 1 second, and Voltage feedback on sensor supply circuit #2 above 5.40 V or below 4.60 V for longer than 1 second •...
Page 216 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 642-Sensor Supply Voltage 1 Low (5 Vext1) Diagnostic Aids Chart DTC 643-Sensor Supply Voltage 1 High (5 Vext1) Diagnostic Aids Chart 1-206 KiSC issued 12, 2016 A...
Page 217 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 652-Sensor Supply Voltage 2 Low (5 Vext2) Diagnostic Aids Chart DTC 653-Sensor Supply Voltage 2 High (5 Vext2) Diagnostic Aids Chart 1-207 KiSC issued 12, 2016 A...
Page 218 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 1611-Sensor Supply Voltage (5 Vext1/2) Simultaneous out-of-range Daiganostic Aids Chart 1-208 KiSC issued 12, 2016 A...
Page 219: Power Relay Control / Coil (Dtc 686, 687)
ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM (19) Power Relay Control / Coil (DTC 686, 687) DTC 686-Power Relay Ground Short • Hardware: Power Relay Pull in Coil • Enabling Conditions: Key On, Engine Off • Set Conditions: Power relay coil output shorted to ground for more than 10 samples of circuit •...
Page 220 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 686-Power Relay Ground Short Diagnostic Aids Chart 1-210 KiSC issued 12, 2016 A...
Page 221 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 687-Power Relay Coil Short-To-Power Diagnostic Aids Chart 1-211 KiSC issued 12, 2016 A...
Page 222: Closed Loop (Dtc 1151 To 1156)
ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM (20) Closed Loop (DTC 1151 to 1156) DTC 1151-Closed Loop High (LPG) DTC 1153-Closed Loop High (NG) DTC 1155-Closed Loop Bank 1 High (Gasoline) • Hardware: Heated or Universal Exhaust Gas Oxygen Sensor (Bank 1-Sensor 1/Bank 1-Before Catalyst) •...
Page 223 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM The HEGO/HO S sensor is a switching-type sensor around stoichiometry that measures the oxygen content present in the exhaust to determine if the fuel flow to the engine is correct. A UEGO sensor measures the exhaust content across a wide-range of air-fuel ratios with a linear output proportional to lambda/equivalence ratio/air-fuel ratio.
Page 224 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 1152-Closed Loop Low (LPG) DTC 1154-Closed Loop Low (NG) Diagnostic Aids NOTE • If any other DTCs are present, diagnose those first. • Oxygen Sensor Wire - Sensor may be mispositioned contacting the exhaust. Check for short to ground between harness and sensor and on sensor harness •...
Page 225: Epr (Hd Epr) Or Cfv (Dtc 1171 To 1177)
ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM (21) EPR (HD EPR) or CFV (DTC 1171 to 1177) DTC 1171-EPR/CFV Regulation Pressure Higher than Expected • Hardware: EPR (HD EPR) or CFV • Enabling Conditions: Engine Running • Set Conditions: EPR (actual-commanded) pressure is higher than 2.5 in H O for longer than 5 seconds •...
Page 226 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 1174-EPR/CFV Voltage Supply High • Hardware: EPR (HD EPR) or CFV • Enabling Conditions: Engine Running • Set Conditions: Voltage supply to EPR is higher than 33.0 VDC for longer than 5 seconds. • Corrective Action(s): Illuminate MIL, AL disable, AL disable in key-cycle, power derate 2, Low rev limit •...
Page 227 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 1171-EPR/CFV Regulation Pressure Higher than Expected Daiganostic Aids Chart 1-217 KiSC issued 12, 2016 A...
Page 228 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 1172-EPR/CFV Regulation Pressure Lower than Expected Daiganostic Aids Chart 1-218 KiSC issued 12, 2016 A...
Page 229 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 1173-EPR/CFV Comm Lost Daiganostic Aids Chart 1-219 KiSC issued 12, 2016 A...
Page 230: Fpp (Foot Pedal Position Switch) (Dtc 1121, 2121, 2126, 2122, 2123, 2127, 2128)
ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM (22) FPP (Foot Pedal Position Switch) (DTC 1121, 2121, 2126, 2122, 2123, 2127, 2128) DTC 1121-FPP1/2 Simultaneous Voltages Out-of-Range • Hardware: Foot Pedal Position/Throttle control sensor • Enabling Conditions: Key On, Engine Off • Set Conditions: FPP voltage is higher than 4.80 V or lower than 0.20 V, and FPP voltage is higher than 4.80 V or lower than 0.20 V for longer than 0.5 second •...
Page 231 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 2126-FPP1 Higher Than FPP2 • Hardware: Foot Pedal Position /Throttle control sensor • Enabling Conditions: Key On, Engine Off • Set Conditions: (FPP1 % - FPP2 %) is higher than 20 for longer than 1.5 seconds •...
Page 232 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 2121-FPP1 Lower Than FPP2 Daiganostic Aids Chart 1-222 KiSC issued 12, 2016 A...
Page 233 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 2126-FPP1 Higher Than FPP2 Daiganostic Aids Chart 1-223 KiSC issued 12, 2016 A...
Page 234 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 2122-FPP1 Voltage High Diagnostic Aids Chart 1-224 KiSC issued 12, 2016 A...
Page 235 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 2127-FPP1 Voltage High Diagnostic Aids Chart 1-225 KiSC issued 12, 2016 A...
Page 236 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 2123-FPP1 Voltage Low Diagnostic Aids Chart 1-226 KiSC issued 12, 2016 A...
Page 237 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 2128-FPP2 Voltage Low Diagnostic Aids Chart 1-227 KiSC issued 12, 2016 A...
Page 238 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM (23) Spark Coil Primary (DTC 2300, 2301, 2303, 2304, 2306, 2307, 2309, 2310) DTC 2300-Spark Coil #1 Primary Open/Short-to-Ground DTC 2303-Spark Coil #2 Primary Open/Short-to-Ground DTC 2306-Spark Coil #3 Primary Open/Short-to-Ground DTC 2309-Spark Coil #4 Primary Open/Short-to-Ground •...
Page 239 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 2300-Spark Coil #1 Primary Open/Short-to-Ground DTC 2303-Spark Coil #2 Primary Open/Short-to-Ground DTC 2306-Spark Coil #3 Primary Open/Short-to-Ground DTC 2309-Spark Coil #4 Primary Open/Short-to-Ground Diagnostic Aids Chart 1-229 KiSC issued 12, 2016 A...
Page 240 ECM SYSTEM WG1605-G-E3,WG1605-L-E3,WG1605-GL-E3, DM DTC 2301-Spark Coil #1 Primary Short-to-Power DTC 2304-Spark Coil #2 Primary Short-to-Power DTC 2307-Spark Coil #3 Primary Short-to-Power DTC 2310-Spark Coil #4 Primary Short-to-Power Diagnostic Aids Chart 1-230 KiSC issued 12, 2016 A...
Page 241 : Farm and Industrial Machinery International Service Department Address 64, Ishizu-Kitamachi, Sakai-Ku, Sakai-City, Osaka, 590-0823, Japan Phone +81- 72-241-1129 +81- 72-245-2484 E-mail : ks_g.ksos-pub@kubota.com Printed in Japan 2016. 11, S, EI, EI, engusa Code No.9Y110-01763 2011. 12, S, EI, EI, engusa KUBOTA Corporation...

Kubota WG1605-E3 Diagnostic Manual

1 Outline

2 Symptom Charts by Components

3 Set up and Procedure Diagnostic Tool

4 Basic System Information

5 Diagnosis

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