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Summary of Contents for 25/300

Page 1: ...U 25 300 B84 COMPRESSOR MODELS Doosan Infracore Portable Power 1293 Glenway Drive Statesville N C 28625 DoosanPortablePower com Book 22772784 12 2012 Rev B T D T ELECTRONIC SERVICE HP1600WCU 25 330 B8...

Page 2: ...2...

Page 3: ...ools SECTION 4 Electronic Systems Troubleshooting Procedures And Techniques SECTION 5 System Schematic Diagrams SECTION 6 Electronic Component Location Drawings SECTION 7 Individual Circuit Diagrams S...

Page 4: ...s organized into 12 sections Sections 2 4 cover systems operation and troubleshooting procedures Sections 5 7 have location diagrams drawings of specific circuits and systems schematics Section 8 has...

Page 5: ...3 Book No 22772784 9 8 06 HP1300 1600WCU Electrical Manual SECTION 2 GENERAL INFORMATION and OPERATIONAL THEORY...

Page 6: ...can be seen through the laminate on the front of the control panel The WEDGE is attached to the control panel with four 10 size nuts The first function of the WEDGE controller is to scan all analog an...

Page 7: ...EM SCHEMATIC WEDGE Controller CONTROL PANEL SWITCHES GAUGES 24VDC HEATERS ENGINE ECM DIAGNOSTIC INTERFACE ESTOP SWITCHES SOLENOID VALVES SPEED SENSOR FUEL LEVEL SWITCH PRESSURE TRANSDUCERS TEMPERATURE...

Page 8: ...2 2 WEDGE CONTROLLER WEDGE TO ENGINE INTERFACE CUMMINS QSX15 ENGINE J1 34 J1 35 J1 1 J1 37 J1 24 ENGINE CONTROLLER J2 46 J2 37 J2 36 J2 38 J3 22 J3 16 CAN HI CAN LO CANSHLD J1 38 J1 31 FREQ THT RANGE...

Page 9: ...00 1600WCU Electrical Manual HP XHP VIKING J1939 CAN COMMUNICATIONS SCHEMATIC ENGINE CONTROLLER WEDGE CONTROLLER P15 TERMINATOR TERMINATOR ENGINE DIAGNOSTICS JACK J8 R5 R4 P7 AUTO START OPTION CAN NOD...

Page 10: ...C OFF They are current limited and short circuit protected Controller Outputs The WEDGE controller has three types of outputs frequency pulse width modulated PWM and 24 VDC digital ON OFF The frequenc...

Page 11: ...o the CAN network This connector also provides 24 VDC to power these service tools Electrical System The electrical system consists of the wiring harnesses and associated electrical devices such as re...

Page 12: ...ovides a continuous reading of fuel level It also has a switch for low fuel level and low fuel shutdown These switches connect to WEDGE RT1 RT1 is a 10K ohm Thermistor temperature sensor that measures...

Page 13: ...conds after the key is released if the engine does not start When the engine speed reaches 600 RPM engine start declared 1 Engine speed is set to 1500 RPM When the engine speed reaches 1450 RPM 1 Unlo...

Page 14: ...r Malfunction Fault indicator lamp Indicates shutdown due to compressor system fault Refer to Fault Code List 10 Low Battery Voltage Alarm indicator lamp Indicates battery or charging system requires...

Page 15: ...ase Service Air switch release key switch to ON Units will be displayed for 2 seconds after which the current selection will be displayed as _F PSI will be displayed as PSI _C Bars will be displayed a...

Page 16: ...ED display After 3 seconds it will extinguish and the parameter will be displayed The toggle only works in the ascending order direction but it will wrap around and start over Display Parameter Remark...

Page 17: ...ead the machine ID on the display if it matches the proper machine ID in Step 1 stop If not proceed to step 4 4 Continue to toggle the switch until number 19 is reached Push and hold the data input sw...

Page 18: ...XP375AWJD HP375WJD 7 VHP300AWJD P600WJD HP450WJD VHP400WJD 8 XP1060WCU HP935WCU MHP825WCU 5 VHP750WCU XHP750WCU 6 MHP825WCAT VHP750WCAT 2 XP1060HACAT XP950HACAT SHP825WCAT XHP750WCAT XHP650WCAT 3 HP1...

Page 19: ...17 Book No 22772784 9 8 06 HP1300 1600WCU Electrical Manual SECTION 3 SERVICE TOOLS...

Page 20: ...o repair Deutsch connectors 22216667 Deutsch Terminal Crimp Tool HDT 48 00 Used to crimp Deutsch connector terminals 54729710 Electrical Contact Cleaner Used to clean electrical contacts and connector...

Page 21: ...nesses 22216725 Fluke Insulation Piercing Probe AC 89 Used to connect to a wire for measurements 22216733 Fluke Meter Case C25 Case for Fluke 87 meter including storage for test leads and probes 54740...

Page 22: ...g P N s 22216691 22216667 22216675 22216683 54729660 54749643 54699657 22146393 22147540 22073878 54749635 22168868 22216709 22216725 22216733 54740675 22254775 ATC Fuse Assorlment Kit Kit contains 5...

Page 23: ...Tool Description Tool Illustration 22216691 Digital Multimeter 54729660 Weather Pack Terminal Removal Tool 54699632 Deutsch Terminal Removal Tool Blue 54699640 Deutsch Terminal Removal Tool Red 546996...

Page 24: ...l Manual 54729710 Electrical Contact Cleaner 54729728 Virtual Technician Service Tool Kit 54699616 Deutsch Terminal Removal Tool 54749544 RTD Simulator Plug 22073878 Thermistor Plug 54749635 Connector...

Page 25: ...P1300 1600WCU Electrical Manual 54749643 Packard Metri Pack Removal Tool 22168868 Pressure Transducer Simulator 22147540 Test Adapter Kit 22146393 Removal Tool Kit 22216675 Deutsch Crimp Tool 22216683...

Page 26: ...2772784 9 8 06 HP1300 1600WCU Electrical Manual 22216709 Fluke Test Lead Set 22216725 Fluke Insulation Piercing Probe single probe 22216733 Fluke Meter Case 54740675 RS232 Serial Cable 22253969 Wire T...

Page 27: ...4 9 8 06 HP1300 1600WCU Electrical Manual 22281588 22282107 Connector Wrenches 22282172 1 4 Flex Shaft Nutdriver 22252993 WEDGE Connector Kit 22253009 CAN Communications Adapter 22253017 Adhesive Heat...

Page 28: ...26 Book No 22772784 9 8 06 HP1300 1600WCU Electrical Manual 22255947 Packard Electric Crimp Tool 22254734 Packard Electric Crimp Tool...

Page 29: ...ical things are performed first It is not possible to include all the solutions to problems that can occur or list all possible problems The charts are designed to stimulate a thinking process that wi...

Page 30: ...or battery negative can be used IMPORTANT INFORMATION DO NOT USE MACHINE FRAME SHEET METAL PIPING OR OTHER METAL COM PONENTS AS COMMON OR GROUND WHEN MAKING VOLTAGE OR FREQUENCY MEASUREMENTS Measurin...

Page 31: ...illuminated The compressor malfunction lamp is shown on the control panel picture in Section 2 of this manual It is indicated by Item number 9 The engine fault codes are indicated by the ENGINE MALFUN...

Page 32: ...ommunications not working Check for 24VDC key switch at engine CAN network wiring problem Ensure 24VDC power to engine ECM Check connector pins Engine cranks but will not start Ensure key switch 24VDC...

Page 33: ...ion The WEDGE has received an engine speed less than 800 RPM for 30 seconds Effect Code 1 is a shutdown condition and will shutdown the machine TROUBLESHOOTING STEPS Code 1 Action Result Check engine...

Page 34: ...r Than 1900 RPM Explanation The WEDGE has received an engine speed greater than 1900 RPM for 30 seconds Effect Code 2 is a shutdown condition and will shutdown the machine TROUBLESHOOTING STEPS Code 2...

Page 35: ...DE 3 Engine Crank Time Exceeded Explanation The engine crank time has exceeded 15 seconds Effect Code 3 is a shutdown condition and will shutdown the machine TROUBLESHOOTING STEPS Code 3 Action Result...

Page 36: ...lanation The WEDGE has received an engine oil temperature greater than 252 Deg F Effect Code 5 is an ALERT condition and will not halt machine operation TROUBLESHOOTING STEPS Code 5 Action Result Step...

Page 37: ...lanation The WEDGE has received an engine intake manifold temperature greater than 180 deg F Effect Code 6 is an ALERT condition and will not halt machine operation TROUBLESHOOTING STEPS Code 6 Action...

Page 38: ...a water in fuel indication from the engine Effect Code 8 is an ALERT condition and will not halt machine operation TROUBLESHOOTING STEPS Code 8 Action Result Step1 Check the machine fuel system and en...

Page 39: ...r engine speed change during engine start This ALERT will only occur during the idle speed time right after engine start Effect Code 10 is an ALERT condition and will not shutdown the machine The mach...

Page 40: ...nector If signal not present check wiring and verify throttle output at WEDGE Step 2 Engine may not be able to fuel properly due to restricted fuel filters Replace fuel filter s Step 3 Verify correct...

Page 41: ...o start Effect Code 11 is a SHUTDOWN condition and will shutdown the machine TROUBLESHOOTING STEPS Code 11 Action Result Step1 Check the machine fuel system and engine fuel filters Step 2 Check the co...

Page 42: ...gs in the fuel piping that could allow air to be drawn into the fuel system Step 2 Verify the throttle signal from the WEDGE is continuously supplied to the engine A quick drop in the throttle signal...

Page 43: ...wn condition and will shutdown the machine The cause of the low air end oil pressure must be repaired to continue machine operation S9 Pressure Switch Circuit WEDGE CONTROLLER J1 21 S9 Blu Circuit Des...

Page 44: ...Book 22772784 9 08 06 42 TROUBLESHOOTING STEPS Code 31 Action Result Step1 Check the air end oil pressure with a mechanical gauge If 12 psi replace S9 If not there is a harness or WEDGE problem...

Page 45: ...erature measurement Effect Code 32 is a shutdown condition and will shutdown the machine RT2 Temperature Sensor Circuit Circuit Description The thermistor temperature sensor connects to the WEDGE cont...

Page 46: ...32 Action Result Step1 Substitute the thermistor simulator I R 22073878 for RT2 Use the WEDGE service diagnostics to read the value for RT2 It should be approximately 32 degrees F Should read approx...

Page 47: ...PT1Pressure Transducer Circuit Circuit Description The pressure transducer is a 3 wire device that connects to the WEDGE controller as shown in the schematic above The violet wire W120 is the 5 VDC e...

Page 48: ...33 Action Result Step1 Substitute the pressure transducer simulator I R 22168868 for PT1 Use the WEDGE service diagnostics to read the value for PT1 It should be approximately 30 50 psi Should read 3...

Page 49: ...0 psi at Crank Explanation The WEDGE has received a pressure from PT1 that is greater than 20 psi at The time of engine crank Effect Code 34 is a shutdown condition and will not allow the engine to cr...

Page 50: ...down condition and will shutdown the machine The separator tank high pressure has been exceeded TROUBLESHOOTING STEPS Code 35 Action Result Verify PT1 pressure transducer is reading correctly The pres...

Page 51: ...down condition and will shutdown the machine S14 Pressure Switch Circuit Circuit Description S14 is a normally open 12 psi pressure switch When the safety valve opens S14 s pressure is raised above 12...

Page 52: ...Book 22772784 9 08 06 50 TROUBLESHOOTING STEPS Code 36 Action Result Verify PT1 pressure transducer is reading correctly...

Page 53: ...GE has received a separator tank temperature from RT1 that is greater than 247 degrees F Effect Code 50 is a shutdown condition and will shutdown the machine TROUBLESHOOTING STEPS Code 50 Action Resul...

Page 54: ...ture measurement Effect Code 53 is a shutdown condition and will shutdown the machine RT1 Temperature Sensor Circuit Circuit Description The thermistor temperature sensor connects to the WEDGE control...

Page 55: ...53 Action Result Step1 Substitute the thermistor simulator I R 22073878 for RT1 Use the WEDGE service diagnostics to read the value for RT1 It should be approximately 32 degrees F Should read approx...

Page 56: ...ressure transducer is a 3 wire device that connects to the WEDGE controller as shown in the schematic above The violet wire W122 is the 5 VDC excitation supply This is spliced in the harness near the...

Page 57: ...54 Action Result Step1 Substitute the pressure transducer simulator I R 22168868 for PT2 Use the WEDGE service diagnostics to read the value for PT2 It should be approximately 30 50 psi Should read 3...

Page 58: ...been pressed Effect Code 55 is a shutdown condition and will shutdown the machine If the machine Is in the cranking mode when estop is pressed the starter will be disengaged simultaneously with engine...

Page 59: ...he estop button is located above the machine control panel on the front of the machine TROUBLESHOOTING STEPS Code 55 Action Result Step1 If the estop button is installed determine if it is pressed Rel...

Page 60: ...reached 50 psi within 20 seconds from time engine starts Effect Code 56 is an ALERT condition and will not halt machine operation TROUBLESHOOTING STEPS Code 56 Action Result Step1 Check air piping sys...

Page 61: ...ng RS232 Communications Circuit J5 RS232 Connector WEDGE CONTROLLER J5 B J5 A J1 33 J1 32 TXD RXD Circuit Description The RS232 serial communications link is used for re programming the WEDGE controll...

Page 62: ...p1 If the current RS232 device laptop computer etc will not communicate with the WEDGE substitute another RS232 device Note The second device must have proper software loaded to communicate with the W...

Page 63: ...rk broadcast of engine parameters cannot be received Effect The WEDGE will not be able to display engine parameters using the diagnostic Display function The compressor will continue to operate since...

Page 64: ...ear the WEDGE controller The value of each of these resistors is 120 ohms They are connected in parallel as shown below across the network The resistors are mounted in a special Deutsch connector One...

Page 65: ...d approximately 60 ohms If so go to Step 5 If not go to Step 4 Step 4 If you did not get the results of Step 3 there is a problem with the wiring harness This problem could be a defective splice broke...

Page 66: ...4 wire and connect to P1 35 wire Multimeter should read approximately 2 5 volts DC Multimeter should read approximately 2 5 volts DC If 2 5 volts cannot be read replace WEDGE controller If WEDGE contr...

Page 67: ...3 is an ALERT condition and will not stop the machine The Auto Start system may not function properly due to communications failure TROUBLESHOOTING STEPS Code 73 Action Result Step1 If CAN communicati...

Page 68: ...66 Book No 22772784 9 8 06 HP1300 1600WCU Electrical Manual SECTION 5 SYSTEM SCHEMATIC DIAGRAMS...

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Page 70: ...22742951 Control System Wiring Diagram 22742951_071_06 04_A...

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Page 72: ...22742951 Control System Wiring Diagram 22742951_072_06 04_A...

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Page 74: ...22742951 Control System Wiring Diagram 22742951_073_06 04_A...

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Page 76: ...22742951 Control System Wiring Diagram 22742951_074_06 04_A...

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Page 78: ...22742951 IQ Wiring Diagram 22742951_074_06 04_A...

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Page 80: ...72 Book No 22772784 9 8 06 HP1300 1600WCU Electrical Manual SECTION 6 ELECTRONIC COMPONENT LOCATION DRAWINGS...

Page 81: ...73 Book No 22772784 9 8 06 HP1300 1600WCU Electrical Manual ELECTRICAL COMPONENTS LOCATION S9 U1 K1 K2 F1 F4 S10 S11 ENGINE CONTROLLER U2 B2 G2 L2 RT5 PT2 RT2 WEDGE S12 S13 R2 TCU K3 PT1 RT1 L1...

Page 82: ...74 Book No 22772784 9 8 06 HP1300 1600WCU Electrical Manual SECTION 7 INDIVIDUAL CIRCUIT DIAGRAMS...

Page 83: ...P1300 1600WCU Electrical Manual J1 28 YEL YEL START RELAY K1 D4 K1 STARTER B1 24VDC M S B BRN YEL CHART A1 ENGINE START CIRCUIT P1 28 WEDGE P9 3 W132 Red Yel P9 4 W213 J9 3 W217 J9 4 W129 W178 YEL W17...

Page 84: ...on J1 28 passes through the W1 harness and through a jumper plug The jumper plug is replaced with an ESTOP switch for ESA versions If the starter will not engage during a crank cycle check the voltage...

Page 85: ...check the fuel level in the tanks to see if it corresponds with the gauge If not remove the fuel sender and disconnect the harness plug Connect an ohmeter across terminals A and B on the Packard Weath...

Page 86: ...istor Simulator Plug PN 22073878 into the harness connector Read the channel again and it should read 32 degrees F 5 degrees 0C 3C If the reading is correct replace the thermistor If not disconnect th...

Page 87: ...Simulator Plug PN 22073878 into the harness connector Read the channel again and it should read 32 degrees F 5 degrees 0C 3C If the reading is correct replace the thermistor If not disconnect the WEDG...

Page 88: ...separator tank The WEDGE provides 5 VDC excitation voltage to pin B 5 and pin A GND The pressure signal on pin C connects to the WEDGE input The signal range is 45 to 4 5 volts The transducer range i...

Page 89: ...let unloader The WEDGE controller provides 5 VDC excitation voltage to pin B 5 and pin A GND The pressure signal on pin C connects to the WEDGE input The signal range is 45 to 4 5 volts The transducer...

Page 90: ...provided to prevent the orifices from freezing in cold tem peratures It is turned on by control panel switch S5 Fuse F1 a 20 amp fuse supplies power to the heaters 24V Heaters switch on control panel...

Page 91: ...the high side driver outputs on the WEDGE controller through P1 29 K2 Relay W090 RED F4 20A W078 RED B1_Pos 24V BATT W009 BLU W091 BLU B2 1 B2 2 W014 BRN P1 29 J1 29 1 2 3 4 5 30 85 87A 87 86 WEDGE M...

Page 92: ...nd connection to an opto coupler input on the WEDGE controller WEDGE CIRCUIT TROUBLESHOOTING To verify the circuit operation another type of switch can be substituted for the filter switch or a wire j...

Page 93: ...or is powered by a 5VDC supply from the engine controller The sensor connects to the engine controller at the J3 connector near the engine controller CIRCUIT TROUBLESHOOTING If the probe fails shorted...

Page 94: ...86 Book No 22772784 9 8 06 HP1300 1600WCU Electrical Manual SECTION 8 ELECTRICAL CONNECTOR INFORMATION...

Page 95: ...rd 22869531 PT1 PT2 Plug 3 Way Packard 22869499 TPA 3 Way Packard 22869754 Seal Cable Packard 22869762 Contact Female 18AWG Packard 22869507 U1 Fuel Level Plug 6 Way Packard 22869416 Seal Cable Packar...

Page 96: ...83 Seal Cavity Packard 22869465 Contact Packard 54750674 P7 Auto Start Option P15 Can Drop W PWR Plug 6 Way Deutsch 22868988 Wedge Lock 6 Way Deutsch 22868996 Socket Size 14 Tin Stamp Deutsch 22868947...

Page 97: ...AMP 22869606 Shur Plug 180 dia AMP 22869598 M2 M3 M4 M7 M8 Control Panel Housing Connector 3 Way Siemens VDO 22972089 Pin Connector 14 18 AWG AMP 22872097 S1 Key Switch Plug 4 Way Packard 22871966 TP...

Page 98: ...Deutsch 54699632 22868947 Deutsch 54699624 22869093 Deutsch 54699632 22880405 Deutsch 54699632 22880413 Deutsch 54699624 54699608 Deutsch 54699640 22880710 Deutsch 54699624 22869531 Packard 54749643...

Page 99: ...commended for harness troubleshooting Some examples of these are shown in Section 2 concerning multimeters Use of these adapters will prevent harness dam age during testing The first item to perform d...

Page 100: ...llow 12 15 54699624 Green 8 10 54699616 The wire is placed into the slot on the removal tool and the tool is slid along the wire inserted into the back of the connector Gently pull on the wire as the...

Page 101: ...93 Book No 22772784 9 8 06 HP1300 1600WCU Electrical Manual...

Page 102: ...94 Book No 22772784 9 8 06 HP1300 1600WCU Electrical Manual...

Page 103: ...95 Book No 22772784 9 8 06 HP1300 1600WCU Electrical Manual Engine electronic controller connnector J2 location J2...

Page 104: ...9 8 06 HP1300 1600WCU Electrical Manual Circular Connector P3 located under the engine controller ECM VIEW FROM WIRE ENTRY SIDE Circular Connector P4 located in the back of the control panel box VIEW...

Page 105: ...Circular connectors J5 and J8 pinout J5 is located on the back of the control panel and J8 is located near the engine controller The pinout on these connectors is the same however they are keyed diffe...

Page 106: ...98 Book No 22772784 9 8 06 HP1300 1600WCU Electrical Manual SECTION 9 ELECTRICAL PARTS LIST...

Page 107: ...36841138 S9 Airend Oil Press Switch 36757581 S14 Safety Valve Press Switch 36757581 B2 Startup Compressor 36850691 K1 Auxiliary Start Relay 35577873 R3 Control Orifice Heater 36841526 R1 Regulator He...

Page 108: ...100 Book No 22772784 9 8 06 HP1300 1600WCU Electrical Manual SECTION 10 ALERTS AND SHUTDOWNS LIST...

Page 109: ...crank 34 CPRSR Malf 0 0 10 Machine Over Pressure 35 CPRSR Malf 1 0 6 Safety Valve Open 36 CPRSR Malf 2 0 6 Sep Tank Temp 247 degrees F 50 CPRSR Malf 3 All Machine ID Not Valid 51 CPRSR Malf 0 All Sep...

Page 110: ...sec 7 8 30 sec 2 IQ equipped machines 3 ID 0 6 800 RPM 7 8 900 4 ID 0 6 1900 RPM 7 8 2500 5 Via fault code 235 6 ID 7 8 Option Machine ID 0 Viking HP CU 1 Viking XHP CU 2 EMU LP CAT 3 EMU HP CAT 4 Vi...

Page 111: ...e Low Warning 144 Engine Coolant Temperature Sensor Circuit Shorted High 145 Engine Coolant Temperature Sensor Circuit Shorted Low 147 Frequency throttle signal low see note 1 151 Engine Coolant Tempe...

Page 112: ...cuit Data Incorrect 299 Engine Shutdown Commanded By J1939 311 Injector Solenoid Valve Cylinder 1 Circuit Grounded Circuit 312 Injector Solenoid Valve Cylinder 5 Circuit Grounded Circuit 313 Injector...

Page 113: ...Sensor Circuit Data Incorrect 434 Power Lost Without Ignition Off 435 Engine Oil Pressure Sensor Circuit Data Incorrect 441 Battery 1 Voltage Low Warning 442 Battery 1 Voltage High Warning 449 Fuel Pr...

Page 114: ...Speed High Warning Level 596 Electrical Charging System Voltage High Warning Level 597 Electrical Charging System Voltage Low Warning Level 598 Electrical Charging System Voltage Low Critical Level 6...

Page 115: ...00WCU Electrical Manual SECTION 11 RECOMMENDED SPARE PARTS Quantity Description Part Number 1 WEDGE Controller 22173579 2 Thermistor Temperature Sensor 36898922 3 0 100 psig Pres Transducer 36920825 3...

Page 116: ...108 Book No 22772784 9 8 06 HP1300 1600WCU Electrical Manual SECTION 12 Software Information...

Page 117: ...for the Virtual Technician I PDA based service tool and Virtual Technician II PC based service tool The website address is WWW irembedded com Service Manuals The website has Electrical Electronics se...

Page 118: ...Revision History Rev EC Number Comments A SVC31234 Original release B CN026881 Doosan reference updates...

Page 119: ...2012 Doosan Infracore Portable Power Printed in the U S A Doosan Infracore Portable Power 1293 Glenway Drive Statesville N C 28625 www doosanportablepower com...

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