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Book:  23227143 (8-24-2010) Rev C

 

Page 81 

 

Содержание 10/105CWJD

Страница 1: ...ble Power 1293 Glenway Drive Statesville N C 28625 DoosanPortablePower com Book 23227143 12 2012 Rev D P425WJD 7 120 XP375WJD 9 110 HP350WJD 10 105 HP350WJD 14 85 P600WJD 7 170 HP450WJD 10 125 VHP400W...

Страница 2: ...2...

Страница 3: ...9 Reading and Setting Display Units 20 Wedge Service Diagnostic Display 21 Entering Machine ID for WEDGE Control Systems 21 Machine Models List 23 SECTION 3 Diagnostic Code Descriptions 25 Compressor...

Страница 4: ...hooting 67 Electrical Circuits 68 Engine Start Circuit 69 Air Filter Restriction Switch Circuit 70 SECTION 6 System Schematics WJDing Diagrams 73 John Deere Engine Models 4045HF285 and 6068HF285 Engin...

Страница 5: ...s 109 Deutsch HD30 and HDP20 Series Connector Service Procedures 110 AMP Crimp Tool 58440 1 Instructions 111 AMP Ampseal Series Connector Service Procedures 115 Molex Crimp Tool 0638118900 Instruction...

Страница 6: ...Book 23227143 8 24 2010 Rev C Page 4...

Страница 7: ...Book 23227143 8 24 2010 Rev C Page 5 SECTION 1 General Information...

Страница 8: ...all analog and digital inputs at a fixed interval These inputs are scanned every 50 milliseconds The analog values are then compared against minimum and maximum values and an ALERT or SHUTDOWN is issu...

Страница 9: ...l Inputs and Outputs The WEDGE controller scans digital inputs such as switch contacts These are either 24 VDC or 0 VDC These digital inputs are connected to switches within the package The WEDGE cont...

Страница 10: ...service tools to the CAN network This connector also provides 24 VDC to power these service tools Electrical System The electrical system consists of the WJDing harnesses and associated electrical de...

Страница 11: ...1 WEDGE CONTROLLER P1 SOLENOID VALVES PRESSURE SWITCHES FUEL LEVEL SWITCH PRESSURE SENSORS TEMPERATURE SENSORS BATTERY STARTING AND CHARGING SYSTEM ENGINE ECM CONTROL PANEL SWITCHES HOURMETER GAUGES J...

Страница 12: ...J1939 CAN LOW J1939 CAN HIGH J1939 CAN SHIELD KEY SWITCH SIGNAL ANALOG THROTTLE RANGE 2 5VDC 1500RPM to 3 9 VDC 2200RPM J02 B1 J02 A1 J02 K2 ENGINE ECM J02 B2 J02 A4 P1 34 P1 35 P1 1 WEDGE CONTROLLER...

Страница 13: ...143 8 24 2010 Rev C Page 11 ENGINE ECM WEDGE CONTROLLER J1939 CAN BUSS COMMUNICATIONS SCHEMATIC TERMINATOR CAN NODE with POWER P3 TR2 TR1 P2 TERMINATOR J10 P10 FIGURE 2 3 ENGINE ECM COMMUNICATIONS INT...

Страница 14: ...sensor that measures separator tank temperature RT2 RT2 is a 10K ohm Thermistor type temperature sensor that measures airend discharge temperature K1 K1 is a SPST 24 VDC relay used to engage the engin...

Страница 15: ...Compressor Diagnostic Code see WEDGE on inside of machine 2 Engine Malfunction Diagnostic Light Indicates ALERT or SHUTDOWN displayed number is an Engine Diagnostic Code see WEDGE on inside of machine...

Страница 16: ...ge Assembly if equipped 10 Compressor Oil Temperature Gauge 11 Engine Oil Pressure Gauge 12 Engine Coolant Temperature Gauge 13 Battery Voltage Gauge WEDGE Lights located inside machine on bracket 14...

Страница 17: ...T indication engine compressor air inlet filters need service if equipped 21 Restricted IQ Air Filters Diagnostic Light Indicates SHUTDOWN due to dirty IQ air filters if equipped 22 Compressor Malfunc...

Страница 18: ...gized Engine speed is set to 1600 RPM When the engine speed reaches 1450 RPM Start Run solenoid valve L1 is closed de energized Unloader solenoid valve L2 is opened energized When the separator tank r...

Страница 19: ...d Engine starter is de energized Engine speed is set to 1600 RPM When the engine speed reaches 1450 RPM Start Run solenoid valve L1 is closed de energized When the separator tank reaches 50 psi Start...

Страница 20: ...Book 23227143 8 24 2010 Rev C Page 18...

Страница 21: ...Book 23227143 8 24 2010 Rev C Page 19 SECTION 2 Settings...

Страница 22: ...osition The current units will be displayed for 2 seconds The units will be displayed as F PSI will be displayed as PSI C Bars will be displayed as bAr C kPa will be displayed as HPA C Kg cm2 will be...

Страница 23: ...ggle only works in the ascending order direction but it will wrap around and start over Display Parameter Remarks 2 Not Available 3 Engine RPM Filtered Value From WEDGE 4 Regulation System Pressure Fr...

Страница 24: ...er 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 switch and the number 20 will appear Continue to hold the...

Страница 25: ...ine Models Machine ID North America Models P425CWJD 11 HP375CWJD 11 XP375CWJD 11 EMEA Models 7 120CWJD 11 9 110CWJD 11 10 105CWJD 11 14 85CWJD 11 North America Models P600BWJD 12 HP450BWJD 12 VHP400BW...

Страница 26: ...Book 23227143 8 24 2010 Rev C Page 24...

Страница 27: ...Book 23227143 8 24 2010 Rev C Page 25 SECTION 3 Diagnostic Code Descriptions...

Страница 28: ...de is displayed the Compressor Malfunction diagnostic light will be illuminated When an Engine diagnostic code is displayed the Engine Malfunction diagnostic light will be illuminated Refer to the Ope...

Страница 29: ...t RT2 32 Compressor Malfunction 10 sec Separator Tank Pressure Sensor Fault PT1 33 Compressor Malfunction Separator Tank Pressure 20 psi at Crank engine will not start 34 Compressor Malfunction 0 sec...

Страница 30: ...Delay Compressor Malfunction Engine Malfunction Low Fuel Level 3 sec Restricted Air Filters Low Battery Voltage Low Engine Oil Pressure 18 psi ALERT SHUTDOWN by Engine ECM 4 sec High Engine Coolant T...

Страница 31: ...ressure Problem 105 Manifold Air Temperature Problem 110 Engine Coolant Temperature Problem 157 Fuel Rail Pressure Problem 158 ECU Power Down Error 174 Fuel Temperature Problem 189 Engine Speed Derate...

Страница 32: ...jector 3 Problem 654 Injector 4 Problem 655 Injector 5 Problem 656 Injector 6 Problem 1136 Engine ECU Temperature High 1347 Fuel Pump Pressurizing Problem 1569 Engine Protection De rate 3509 Sensor Su...

Страница 33: ...m High Engine Coolant Temperature 4045HF285 Warning 232o F 111o C Peak Power Level Above 118hp 88kw 237o F 114o C Peak Power Level Under 118hp 88kw Shutdown 235o F 113o C Peak Power Level Above 118hp...

Страница 34: ...Book 23227143 8 24 2010 Rev C Page 32...

Страница 35: ...Book 23227143 8 24 2010 Rev C Page 33 SECTION 4 Troubleshooting...

Страница 36: ...formed 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 will lead to solution...

Страница 37: ...ORTANT INFORMATION DO NOT USE MACHINE FRAME SHEET METAL PIPING OR OTHER METAL COMPONENTS AS COMMON OR GROUND WHEN MAKING VOLTAGE OR FREQUENCY MEASUREMENTS Measuring Resistance Extra care must be taken...

Страница 38: ...tic lamp is a COMPRESSOR malfunction or ENGINE malfunction Follow appropriate troubleshooting instructions Ignition switch S1 is turned to the START position and the engine does not crank Check WJDing...

Страница 39: ...uel hoses Air in fuel system Step 3 Retrieve active and inactive engine ECM fault codes via engine manufacturer s service tool Step 4 Check engine ECM setup via engine manufacturer s service tool Expl...

Страница 40: ...d inactive engine ECM fault codes via engine manufacturer s service tool Step 3 Check engine ECM setup via engine manufacturer s service tool Explanation The WEDGE has received an engine speed value g...

Страница 41: ...2 Check engine fuel system for restrictions Dirty fuel filters Clogged fuel hoses Air in fuel system Step 3 Verify machine cold weather kit is working properly if equipped Explanation The user has at...

Страница 42: ...el is low The dark blue WJDe is the sense line to the WEDGE The brown WJDe is the switch common to ground Component Location U1 fuel level sensor is located in top of the fuel tank Explanation The WED...

Страница 43: ...or Remove fuel level sensor from tank Using a multimeter measure resistance between U1 A and U1 B on fuel level sensor with it upside down Resistance value measured should be shorted with tank full of...

Страница 44: ...WEDGE diagnostic display 16 Crank machine Verify Throttle Position listed below Throttle Position 57 if engine coolant 100o F 50 if engine coolant 100o F Step 4 Check engine fuel system for restricti...

Страница 45: ...fuel system Step 3 Check the condition of the machine batteries and verify battery charger is working properly Step 4 Verify machine cold weather kit is working properly if equipped Explanation The WE...

Страница 46: ...battery and connections to the engine ECM Repair harness as needed Step 4 Verify KEYSWITCH signal 24 VDC connection from WEDGE to engine ECM Step 5 Retrieve active and inactive engine ECM fault codes...

Страница 47: ...ay 6 to verify temperature value is between 3o F and 13o F If temperature value on display 6 is not between 3o F and 13o F check for WJDing problems If temperature value on display 6 is between 3o F a...

Страница 48: ...0K ohm Thermistor type temperature sensor The yellow WJDe is the sense line to the WEDGE The brown WJDe is the sensor ground Component Location RT2 temperature sensor is located in the discharge port...

Страница 49: ...ct RT2 from harness and plug thermistor simulator Part No 22073878 into the harness connector Check WEDGE diagnostic display 6 to verify temperature value is between 3o F and 13o F If temperature valu...

Страница 50: ...e orange WJDe is the signal output to the WEDGE with a range of 0 5 to 4 5 VDC The brown WJDe is the sensor ground The pressure range of PT1 is 0 psig 0 5 VDC to 500 psig 4 5 VDC Component Location PT...

Страница 51: ...rom harness and plug pressure transducer simulator Part No 22168868 into the harness connector Check WEDGE diagnostic display 5 to verify pressure value is between 186 psi and 196 psi If pressure valu...

Страница 52: ...ducer simulator Part No 22168868 into the harness connector Check WEDGE diagnostic display 5 to verify pressure value is between 186 psi and 196 psi If pressure value on display 5 is not between 186 p...

Страница 53: ...nector Check WEDGE diagnostic display 7 to verify temperature value is between 3o F and 13o F If temperature value on display 7 is not between 3o F and 13o F check for WJDing problems If temperature v...

Страница 54: ...ol Systems in this manual Explanation The WEDGE does not have a machine ID loaded Code 51 will occur only when a new WEDGE is installed and the machine ID has never been loaded The machine ID defines...

Страница 55: ...De is the sense line to the WEDGE The brown WJDe is the switch common to ground Component Location S18 IQ air filter differential pressure switch is located on a bracket inside the machine beside the...

Страница 56: ...tions between WEDGE and S18 differential pressure switch Repair harness as needed Step 3 Disconnect S18 from harness Using a multimeter measure resistance between across switch terminals 1 and 2 on di...

Страница 57: ...mistor type temperature sensor The yellow WJDe is the sense line to the WEDGE The brown WJDe is the sensor ground Component Location RT1 temperature sensor is located on the side of the separator tank...

Страница 58: ...ct RT1 from harness and plug thermistor simulator Part No 22073878 into the harness connector Check WEDGE diagnostic display 7 to verify temperature value is between 3o F and 13o F If temperature valu...

Страница 59: ...WJDe is the signal output to the WEDGE with a range of 0 5 to 4 5 VDC The brown WJDe is the sensor ground The pressure range of PT2 is 0 psig 0 5 VDC to 100 psig 4 5 VDC Component Location PT2 pressur...

Страница 60: ...2 from harness and plug pressure transducer simulator Part No 22168868 into the harness connector Check WEDGE diagnostic display 4 to verify pressure value is between 33 psi and 43 psi If pressure val...

Страница 61: ...rt No 22168868 into the harness connector Check WEDGE diagnostic display 5 to verify pressure value is between 186 psi and 196 psi If pressure value on display 5 is not between 186 psi and 196 psi che...

Страница 62: ...GE The light blue WJDe is the TXD transmit signal from the WEDGE The brown WJDe is the serial link ground Component Location J5 connector is located inside the machine near the WEDGE controller Explan...

Страница 63: ...on Result Step 1 Check all harness connections between WEDGE and J5 connector Repair harness as needed Step 2 Substitute the current device laptop or test tool being used to communicate with the WEDGE...

Страница 64: ...The yellow WJDe is referred to as J1939 CAN High The green WJDe is referred to as J1939 CAN Low The gray WJDe is referred to as J1939 CAN Shield This cable is the communications link between the WEDG...

Страница 65: ...ce fuses as needed Step 2 Verify battery and connections to the engine ECM Repair harness as needed Step 3 Turn ignition switch to the ON position Using a multimeter measure the keyswitch signal volta...

Страница 66: ...ed between P1 35 and J02 A1 Continuity should be shorted between P1 34 and J0 B1 Continuity should be open between P1 34 and P1 35 If not check for defective splice and or shorted pins in connectors S...

Страница 67: ...link between the WEDGE and all devices connected to it The P10 J10 connector is the connection point where the Auto Start Stop harness connects to the chassis harness Component Location P1 connector i...

Страница 68: ...the WEDGE J02 connector from the engine ECM P100 from the Auto Start Stop controller and any other device connected to the J1939 CAN BUSS network Using a multimeter measure the resistance between P100...

Страница 69: ...Book 23227143 8 24 2010 Rev C Page 67 SECTION 5 Troubleshooting...

Страница 70: ...Book 23227143 8 24 2010 Rev C Page 68 Electrical Circuits Engine Start Circuit...

Страница 71: ...oubleshooting Steps If Starter Does Not Engage During Crank Action Result Step 1 Check display for fault codes Clear fault codes by following instructions in this manual Step 2 Check F1 fuse Replace f...

Страница 72: ...Book 23227143 8 24 2010 Rev C Page 70 Air Filter Restriction Switch Circuit...

Страница 73: ...se Action Result Step 1 Check all harness connections throughout air filter restriction switch circuit Repair harness as needed Step 2 Disconnect the harness from S16 and S17 air filter restriction sw...

Страница 74: ...Book 23227143 8 24 2010 Rev C Page 72...

Страница 75: ...Book 23227143 8 24 2010 Rev C Page 73 SECTION 6 System Schematics WJDing Diagrams...

Страница 76: ...Book 23227143 8 24 2010 Rev C Page 74...

Страница 77: ...Book 23227143 8 24 2010 Rev C Page 75...

Страница 78: ...Book 23227143 8 24 2010 Rev C Page 76...

Страница 79: ...Book 23227143 8 24 2010 Rev C Page 77...

Страница 80: ...Book 23227143 8 24 2010 Rev C Page 78...

Страница 81: ...Book 23227143 8 24 2010 Rev C Page 79...

Страница 82: ...Book 23227143 8 24 2010 Rev C Page 80...

Страница 83: ...Book 23227143 8 24 2010 Rev C Page 81...

Страница 84: ...Book 23227143 8 24 2010 Rev C Page 82...

Страница 85: ...Book 23227143 8 24 2010 Rev C Page 83...

Страница 86: ...Book 23227143 8 24 2010 Rev C Page 84...

Страница 87: ...Book 23227143 8 24 2010 Rev C Page 85 John Deere Engine Models 4045HF285 and 6068HF285 Engine Harness Schematic...

Страница 88: ...Book 23227143 8 24 2010 Rev C Page 86 SECTION 7 Electrical Component Locations...

Страница 89: ...Book 23227143 8 24 2010 Rev C Page 87 S1 S2 M1 M2 M3 M4 DS1 DS2 DS3 S16 S17 G1 U1 HR1 S15 WEDGE F1 F2 F3 B1...

Страница 90: ...Book 23227143 8 24 2010 Rev C Page 88 ELECTRICAL COMPONENT LOCATION L2 RT1 RT2 K1 K2 ENGINE ECM PT1 PT2 L1 S18...

Страница 91: ...istor on J1939 CAN BUSS near engine ECM C11 9 pin connector for engine ECM service tool located near engine ECM C07 3 pin connector for auxiliary power that connects to C02 on engine harness located o...

Страница 92: ...Book 23227143 8 24 2010 Rev C Page 90 SECTION 8 Electrical Parts List...

Страница 93: ...450 10 125 VHP400WJD 14 115 35376169 M1 Hourmeter 24VDC 22054175 M2 Fuel Level Gauge 22692602 M3 4 in 1 Gauge Assembly optional 22255046 M4 Tachometer 24 VDC optional 22055883 M4 Replacement Resistor...

Страница 94: ...85473999 G1 Alternator 24 VDC Model P600WJD 7 170 HP450 10 125 VHP400WJD 14 115 23229511 G1 Alternator 24 VDC Model P425WJD 7 120 XP375WJD 9 110 HP350WJD 10 105 14 85 22206221 B1 Starter 24 VDC 22206...

Страница 95: ...Book 23227143 8 24 2010 Rev C Page 93...

Страница 96: ...Book 23227143 8 24 2010 Rev C Page 94 SECTION 9 Harness Connector Information...

Страница 97: ...1 1631 22252993 46490983 Sealing plug size 16 12 Deutsch 114017 22252993 46490983 Rubber Boot Deutsch DRC40 BT P4 Control Panel Connector Plug 12 way Deutsch DT06 12SA EP08 Rubber Boot Deutsch DT12S B...

Страница 98: ...Receptacle 3 way terminator Deutsch DT04 3P EP10 46490983 C11 Engine Service Connector Receptacle 9 way Deutsch HD10 9 1939PE Connector Cap Deutsch HDC9 JDL082397 46490983 Pin size 16 Gold Deutsch 04...

Страница 99: ...Molex 98575 1010 46491411 D1 D2 Diode Terminals Plug Bullet AMP 60660 1 22252969 Receptacle Bullet AMP 60798 1 22252969 Quick Disconnects Ring Terminals and Butt Splices Most Common used Quick Discon...

Страница 100: ...cifications Description Connector Manufacturer Manufacturer Part Number Torque WEDGE Controller Deutsch DRC16 40S 25 in lbs Caterpillar C9 C15 C18 Tier 3 Engine ECM Amp 776241 1 53 in lbs Cummins QSL9...

Страница 101: ...Book 23227143 8 24 2010 Rev C Page 99...

Страница 102: ...Book 23227143 8 24 2010 Rev C Page 100 SECTION 10 Tools and Repair Kits...

Страница 103: ...ohn Deere ECM connector 54740675 RS232 Heavy Duty Serial Cable Used for communication connection to Doosan controllers 54699640 Deutsch Terminal Removal Tool Size 20 Used to remove Deutsch size 20 ter...

Страница 104: ...D type temperature sensor problems 54749551 Thermistor Simulator Used to troubleshoot Thermistor type temperature sensor problems 22073878 Thermistor Simulator Used to troubleshoot Thermistor type tem...

Страница 105: ...pair WEDGE connector and terminals 46491296 Kit Packard Connector Repair Assortment of Packard connectors and terminals 46491304 Kit Caterpillar C9 C15 and C18 Engine ECM Connector Repair Used to repa...

Страница 106: ...00 2221667 Socket size 14 Gold Deutsch 0462 209 1631 HDT 48 00 2221667 Pin size 14 Tin Deutsch 0460 215 16141 HDT 48 00 2221667 Pin size 14 Gold Deutsch 0460 215 1631 HDT 48 00 2221667 Socket size 12...

Страница 107: ...Book 23227143 8 24 2010 Rev C Page 105 Deutsch Crimp Tool HDT 48 00 Instructions...

Страница 108: ...tact straight into connector grommet until a positive stop is felt A slight tug will confirm that it is properly locked in place Contact Removal 1 With rear insert toward you snap appropriate size ext...

Страница 109: ...place insert orange wedge will arrow pointing toward exterior locking mechanism The orange wedge will snap into place Rectangular wedges are not oriented They may go in either way NOTE The receptacle...

Страница 110: ...l contacts are in place insert orange wedge receptacles with half holes aligning with contacts Plugs with contacts aligning behind full holes The orange wedge will snap into place NOTE The receptacle...

Страница 111: ...ommet until a positive stop is felt The retaining fingers in the connector will snap behind the shoulder of the contact and lock it in place A slight tug will confirm that it is properly sealed Contac...

Страница 112: ...ommet until a positive stop is felt A slight tug will confirm that it is properly locked in place NOTE For unused WJDe cavities insert sealing plugs for full environmental sealing Contact Removal 1 Wi...

Страница 113: ...Book 23227143 8 24 2010 Rev C Page 111 AMP Crimp Tool 58440 1 Instructions...

Страница 114: ...Book 23227143 8 24 2010 Rev C Page 112 AMP Crimp Tool 58440 1 Instructions...

Страница 115: ...Book 23227143 8 24 2010 Rev C Page 113 AMP Crimp Tool 58440 1 Instructions...

Страница 116: ...Book 23227143 8 24 2010 Rev C Page 114 AMP Crimp Tool 58440 1 Instructions...

Страница 117: ...Book 23227143 8 24 2010 Rev C Page 115 AMP Ampseal Series Connector Service Procedures...

Страница 118: ...Book 23227143 8 24 2010 Rev C Page 116 AMP Ampseal Series Connector Service Procedures...

Страница 119: ...Book 23227143 8 24 2010 Rev C Page 117 AMP Ampseal Series Connector Service Procedures...

Страница 120: ...Book 23227143 8 24 2010 Rev C Page 118 Molex Crimp Tool 0638118900 Instructions...

Страница 121: ...Book 23227143 8 24 2010 Rev C Page 119 Molex Crimp Tool 0638118900 Instructions...

Страница 122: ...Book 23227143 8 24 2010 Rev C Page 120 Molex Crimp Tool 0638118900 Instructions...

Страница 123: ...Book 23227143 8 24 2010 Rev C Page 121 Molex Crimp Tool 0638118900 Instructions...

Страница 124: ...Book 23227143 8 24 2010 Rev C Page 122 Molex Crimp Tool 0638118900 Instructions...

Страница 125: ...Book 23227143 8 24 2010 Rev C Page 123 Molex Crimp Tool 0638119200 Instructions...

Страница 126: ...Book 23227143 8 24 2010 Rev C Page 124 Molex Crimp Tool 0638119200 Instructions...

Страница 127: ...Book 23227143 8 24 2010 Rev C Page 125 Molex Crimp Tool 0638119200 Instructions...

Страница 128: ...Book 23227143 8 24 2010 Rev C Page 126 Molex Crimp Tool 0638119200 Instructions...

Страница 129: ...Book 23227143 8 24 2010 Rev C Page 127 Molex Crimp Tool 0638119200 Instructions...

Страница 130: ...Book 23227143 8 24 2010 Rev C Page 128 Molex Removal Tool 0638132400 Instructions...

Страница 131: ...Book 23227143 8 24 2010 Rev C Page 129 Molex Removal Tool 0638132400 Instructions...

Страница 132: ...Book 23227143 8 24 2010 Rev C Page 130 Molex Removal Tool 0638132300 Instruction...

Страница 133: ...Book 23227143 8 24 2010 Rev C Page 131 Molex Removal Tool 0638132300 Instruction...

Страница 134: ...Book 23227143 8 24 2010 Rev C Page 132 SECTION 11 Recommended Spare Parts...

Страница 135: ...ommended Spare Parts Quantity Description Part Number 1 WEDGE Controller 22173579 2 Thermistor Temperature Sensor 23294820 2 0 100 psig Pressure Transducer 36920825 2 0 500 psig Pressure Transducer 54...

Страница 136: ...Book 23227143 8 24 2010 Rev C Page 134 SECTION 12 Software Information...

Страница 137: ...5 Software Updates Software updates are available on a website for downloading The website will always contain the latest software revisions for all applications of Doosan Portable Power products The...

Страница 138: ...Revision History Rev EC Number Comments A Original release B Edits C SVC31262 Changed Model to WJD D CN026881 Doosan reference updates...

Страница 139: ...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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