Doosan HP1600WCU Electronic Service Manual
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Doosan HP1600WCU Electronic Service Manual

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ELECTRONIC SERVICE
T
D
T
Doosan Infracore Portable Power
1293 Glenway Drive
Statesville, N.C. 28625
DoosanPortablePower.com
Book: 22772784 (12-2012) Rev B
MANUAL
HP1300WCU (25/300) B84
HP1600WCU (25/330) B83
COMPRESSOR MODELS

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Summary of Contents for Doosan HP1600WCU

  • Page 1 ELECTRONIC SERVICE MANUAL HP1300WCU (25/300) B84 HP1600WCU (25/330) B83 COMPRESSOR MODELS Doosan Infracore Portable Power 1293 Glenway Drive Statesville, N.C. 28625 DoosanPortablePower.com Book: 22772784 (12-2012) Rev B...
  • Page 3 TABLE OF CONTENTS SECTION 1 ..Manual Description SECTION 2 ..General Information And Operational Theory SECTION 3 ..Service Tools SECTION 4 ..Electronic Systems Troubleshooting Procedures And Techniques SECTION 5 .
  • Page 4 SECTION 1 MANUAL DESCRIPTION This manual contains all of the information concerning the electrical and electronic systems for the HP1600/1300 compressor. It provides all information necessary to service, troubleshoot and order parts for this machine. It is organized into 12 sections. Sections 2 -- 4 cover systems operation and troubleshooting procedures.

  • Page 5: General Information

    SECTION 2 GENERAL INFORMATION OPERATIONAL THEORY Book No. 22772784 (9--8--06) HP1300/1600WCU Electrical Manual...
  • Page 6 The WEDGE is attached to the control panel with four GENERAL INFORMATION AND OPERATIONAL #10 size nuts. THEORY The first function of the WEDGE controller is to scan all General analog and digital inputs at a fixed interval. These The HP1600/1300 machine has an electronic monitor inputs are scanned every 50 milliseconds.
  • Page 7 Book No. 22772784 (9--8--06) HP1300/1600WCU Electrical Manual...
  • Page 8 Book No. 22772784 (9--8--06) HP1300/1600WCU Electrical Manual...
  • Page 9 Book No. 22772784 (9--8--06) HP1300/1600WCU Electrical Manual...
  • Page 10 Controller Outputs Software versions under 2.0 use the frequency throttle The WEDGE controller has three types of outputs: to communicate with the engine. A square wave frequency, pulse width modulated (PWM) and 24 VDC frequency signal from 150 Hz to 375 Hz is sent from digital (ON /OFF).
  • Page 11 The electrical circuits are protected using ATC style J1939 Data Link fuses. A fuse should only be replaced with one of the The CAN network is a single pair shielded cable same rating. Replacing a fuse with one of a large located with the W1 main harness.
  • Page 12 KEY ELECTRICAL COMPONENTS FUNCTION PT1: PT1 is a 0--225 psi gauge pressure transducer that measures discharge air pressure. PT2: PT2 is a 0--100 psi gauge pressure transducer that measures regulation system pressure. U1 is resistive level detector that measures the fuel level in the fuel tank. It provides a continuous reading of fuel level.

  • Page 13: Operational Information

    OPERATIONAL INFORMATION Power “ON” at Control Panel: 1. Key switch signal (24VDC) supplied to engine controller by WEDGE controller 2. Frequency throttle signal OFF Unloader solenoid valve (L2) is closed (de--energized) 4. Start--up compressor is turned on for 10 seconds Engine Start- -up: When the key is switched to the engine crank position: 1.
  • Page 14 Restricted IQ Air Filters: Fault indicator lamp. Indicates shutdown due to dirty IQ air filters (if equipped). E STOP Low Fuel Level: Fault indicator lamp. Indicates shutdown due to low fuel level. Lamp blinks at low fuel warning. Compressor Malfunction: Fault indicator lamp.
  • Page 15 READING AND SETTING THE DISPLAY UNITS The WEDGE has four choices for display units: _F, PSI _C, Bars _C, kPa _C, Kg/cm2 To determine which units the WEDGE has been configured for: 1. With the machine power off (Key turned OFF) 2.
  • Page 16 WEDGE SERVICE DIAGNOSTICS The WEDGE controller provides a diagnostic capability that allows various internal parameters to be viewed on the 4--digit LED display. These can be accessed with the machine stopped or while it is operating. If the machine is stopped, the “Service Air” switch on the control panel is used to toggle through the list of parameters. If the ma- chine is operating, the “Start”...
  • Page 17 ENTERING MACHINE ID FOR WEDGE CONTROL SYSTEMS with V1.60 or Greater Software For machines with the WEDGE controller mounted inside the control panel/instrument panel box, the “Service Air” switch is used to enter the machine ID. Disconnect the fuel level gauge (located in the fuel tank) before starting the process and reconnect once the process is completed.
  • Page 18 ESA Models/Wedge Machine ID Models Machine ID 7/120,9/110. 10/105, 14/85 7/170. 10/125.14/115 9/230,9/270,9/300. 12/235 17/235,21/215 MSA Models/Wedge Machine ID Models Machine ID P425AWJD, XP375AWJD, HP375WJD VHP300AWJD P600WJD, HP450WJD, VHP400WJD XP1060WCU, HP935WCU, MHP825WCU VHP750WCU XHP750WCU MHP825WCAT, VHP750WCAT XP1060HACAT,XP950HACAT SHP825WCAT, XHP750WCAT. XHP650WCAT HP1300CWCU,HP1600CWCU XHP1170WCU 1 XHP1070AWCAT, XHP1170WCAT.
  • Page 19 SECTION 3 SERVICE TOOLS Book No. 22772784 (9--8--06) HP1300/1600WCU Electrical Manual...

  • Page 20: Service Tools

    SERVICE TOOLS Service Tools The following special tools are recommended to perform service procedures in this manual. The tools can be purchased from Portable Power or other sources as listed. Tool Tool Description 22216691 Digital Multimeter (Fluke 87) Used to measure electrical circuits; Volts, amps, ohms 54729660 Packard Weather--Pack Terminal Removal Tool Used to repair Packard Electric Weather--Pack Connectors...
  • Page 21 22168868 Pressure Transducer Simulator Used to test pressure transducer circuits 22147540 Test Adapter Kit Test adapters for various connectors to be Used when making electrical measurements 22146393 Removal Tool Kit Assortment of most used Deutsch removal tools 22216675 Deutsch Crimp Tool (DTT --20--00) Used to crimp Deutsch connector terminals 22216683 Packard Electric Crimp Tool (12155975)
  • Page 22 22221303 Service Tool Kit Kit consists of the following 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, 7--1/2, 10, 15,20,25, and 30 Amp fuses 22254734 Packard Crimp Tool (12014254) Crimps Sealed Weather Pack Connector pins...
  • Page 23 Tool No. 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) 54699624 Deutsch Terminal Removal Tool (Yellow) 22216667 Deutsch Crimp Tool Book No. 22772784 (9--8--06) HP1300/1600WCU Electrical Manual...
  • Page 24 54729710 Electrical Contact Cleaner 54729728 Virtual Technician Service Tool Kit 54699616 Deutsch Terminal Removal Tool 54749544 RTD Simulator Plug 22073878 Thermistor Plug 54749635 Connector Repair kit 54699657 Deutsch Terminal Removal Tool Book No. 22772784 (9--8--06) HP1300/1600WCU Electrical Manual...
  • Page 25 54749643 Packard Metri- -Pack Removal Tool 22168868 Pressure Transducer Simulator 22147540 Test Adapter Kit 22146393 Removal Tool Kit 22216675 Deutsch Crimp Tool 22216683 Packard Electric Crimp Tool Book No. 22772784 (9--8--06) HP1300/1600WCU Electrical Manual...
  • Page 26 22216709 Fluke Test Lead Set 22216725 Fluke Insulation Piercing Probe (single probe) 22216733 Fluke Meter Case 54740675 RS232 Serial Cable 22253969 Wire Terminal Kit Book No. 22772784 (9--8--06) HP1300/1600WCU Electrical Manual...
  • Page 27 22281588 Connector Wrenches 22282107 22282172 1/4’’ Flex Shaft Nutdriver 22252993 WEDGE Connector Kit 22253009 CAN Communications Adapter 22253017 Adhesive Heat Shrink Assortment Book No. 22772784 (9--8--06) HP1300/1600WCU Electrical Manual...
  • Page 28 22255947 Packard Electric Crimp Tool 22254734 Packard Electric Crimp Tool Book No. 22772784 (9--8--06) HP1300/1600WCU Electrical Manual...
  • Page 29 SECTION 4 ELECTRONIC SYSTEMS TROUBLESHOOTING PROCEDURES AND TECHNIQUES General A thorough analysis of the problem is the key to successful troubleshooting. The more information known about a problem, the faster and easier the problem can be solved. Troubleshooting charts are included to act as a guide to the troubleshooting process. They are organized so the easiest and most logical things are performed first.
  • Page 30 MEASURING VOLTAGE, RESISTANCE, FREQUENCY AND DUTY CYCLE General Measuring Guidlines: Since the electrical system uses sealed connectors and splices, access of test points can be difficult. It is rec- ommended that a test probe kit be used to access the signals to prevent damage to wires and connectors. Back probing connectors and insulation piercing test probes can cause damage that can cause future failures.
  • Page 31 COMPRESSOR FAULT CODES DESCRIPTION & TROUBLESHOOTING Following are the descriptions of the COMPRESSOR fault codes. These are indicated when the “COMPRESSOR MALFUNCTION” lamp is 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 MALFUNCTION”...

  • Page 32: Troubleshooting Flowchart

    TROUBLE SHOOTING FLOW CHART Check F1 fuse Control panel key is turned to “ON” position, Check operation of switch S1 WEDGE controller annunciator lamps and 4 Check wiring from S1 to WEDGE controller digit LED display do not come on Check battery voltage, ensure battery dis- connect switch is turned ON J1939 CAN communications not working –...
  • Page 33 COMPRESSOR CODE 1 Engine Speed Less Than 800 RPM Explanation: 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 fault codes for an engine...
  • Page 34 COMPRESSOR CODE 2 Engine Speed Greater 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 Action Result Check engine fault codes for an engine...
  • Page 35 COMPRESSOR CODE 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 Crank engine for less than 15 seconds. Book 22772784 (9/08/06)
  • Page 36 COMPRESSOR CODE 5 Engine Oil Temperature Explanation: 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 Step1: Refer to the engine manufacturer’s service manual for instructions.
  • Page 37 COMPRESSOR CODE 6 Engine Intake Manifold Temperature Explanation: 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 Result Step1: Refer to the engine manufacturer’s service manual for...
  • Page 38 COMPRESSOR CODE 8 Water in Fuel Explanation: The WEDGE has received 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 engine fuel filters. Step 2: Refer to the engine manufacturer’s service manual for instructions.
  • Page 39 COMPRESSOR CODE 10 Engine Not Responding To Throttle Command Explanation: The engine has not responded to a request from the WEDGE for 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.
  • Page 40 TROUBLESHOOTING STEPS Code 10 Action Result Step1: Measure the throttle signal at the engine connector. If signal not present, check wiring and verify throttle output at WEDGE. Replace fuel filter (s) Step 2: Engine may not be able to fuel properly due to restricted fuel filters Step 3: Verify correct machine ID is installed.
  • Page 41 COMPRESSOR CODE 11 Too Many Start Attempts During Auto Start Explanation: The WEDGE has made three attempts to start the machine as commanded by the Auto Start Stop controller. The machine failed to start. Effect: Code 11 is a SHUTDOWN condition and will shutdown the machine. TROUBLESHOOTING STEPS Code 11 Action...
  • Page 42 COMPRESSOR CODE 29 Engine shut itself down: reason unknown Explanation: The engine has shut down. The WEDGE did not shut down the engine. Effect: Code 29 is a SHUTDOWN condition and will shutdown the machine. TROUBLESHOOTING STEPS Code 29 Action Result Step1: Check the machine fuel system and engine fuel filters.
  • Page 43 COMPRESSOR CODE 31 Low Air End Oil Pressure Explanation: The WEDGE received a closed contact from pressure switch S9, located in the air end. This indicates a low oil pressure in the air end. Effect: Code 31 is a shutdown condition and will shutdown the machine. The cause of the low air end oil pressure must be repaired to continue machine operation.
  • Page 44 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. Book 22772784 (9/08/06)
  • Page 45 COMPRESSOR CODE 32 RT2, Discharge Temperature Sensor Fault Explanation: The WEDGE has received an out of limits reading from the RT2 temperature sensor. This reading could be on the high or low end of the range. It is out of the normal range for temperature measurement. Effect: Code 32 is a shutdown condition and will shutdown the machine.
  • Page 46 TROUBLESHOOTING STEPS Code 32 Action Result Step1: Substitute the thermistor simulator (I-R # 22073878) for RT2 Should read approx. 32 Deg F Use the WEDGE service diagnostics to read the value for RT2 It should be approximately 32 degrees F. If not, there is a harness or WEDGE problem.
  • Page 47 COMPRESSOR CODE 33 PT1 Pressure Transducer Sensor Fault Explanation: The WEDGE has received an out of limits reading from the PT1 pressure transducer. This reading could be on the high or low end of the range. It is out of the normal range for pressure. Effect: Code 33 is an ALERT condition and will not shutdown the machine.
  • Page 48 TROUBLESHOOTING STEPS Code 33 Action Result Step1: Substitute the pressure transducer simulator (I-R # 22168868) Should read 30 – 50 psi. for PT1. Use the WEDGE service diagnostics to read the value for PT1. It should be approximately 30 – 50 psi. If not, there is a harness or WEDGE problem.
  • Page 49 COMPRESSOR CODE 34 Separator Tank Pressure Greater Than 20 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 crank. Once The separator tank bleeds down below 20 psi, engine crank will be allowed.
  • Page 50 COMPRESSOR CODE 35 Machine Over Pressure Condition Explanation: The WEDGE has received a pressure from PT1 that is greater than 175 psi. Effect: Code 35 is a shutdown condition and will shutdown the machine. The separator tank high pressure has been exceeded. TROUBLESHOOTING STEPS Code 35 Action...
  • Page 51 COMPRESSOR CODE 36 Safety Valve Open Explanation: The WEDGE has received a switch closure from S14. This indicates the separator tank safety valve has opened. Effect: Code 36 is a shutdown condition and will shutdown the machine. S14 Pressure Switch Circuit: W220 W219 J1-11...
  • Page 52 TROUBLESHOOTING STEPS Code 36 Action Result Verify PT1 pressure transducer is reading correctly. Book 22772784 (9/08/06)
  • Page 53 COMPRESSOR CODE 50 Separator Tank Temperature Explanation: The WEDGE 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 Result Step1:...
  • Page 54 COMPRESSOR CODE 53 RT1, Discharge Temperature Sensor Fault Explanation: The WEDGE has received an out of limits reading from the RT1 temperature sensor. This reading could be on the high or low end of the range. It is out of the normal range for temperature measurement. Effect: Code 53 is a shutdown condition and will shutdown the machine.
  • Page 55 TROUBLESHOOTING STEPS Code 53 Action Result Step1: Substitute the thermistor simulator (I-R # 22073878) for RT1 Should read approx. 32 Deg F Use the WEDGE service diagnostics to read the value for RT1 It should be approximately 32 degrees F. If not, there is a harness or WEDGE problem.
  • Page 56 COMPRESSOR CODE 54 PT2 Regulation System Sensor Fault Explanation: The WEDGE has received an out of limits reading from the PT2 pressure transducer. This reading could be on the high or low end of the range. It is out of the normal range for pressure. Effect: Code 54 is an ALERT condition and will not shutdown the machine.
  • Page 57 TROUBLESHOOTING STEPS Code 54 Action Result Step1: Substitute the pressure transducer simulator (I-R # 22168868) Should read 30 – 50 psi. for PT2. Use the WEDGE service diagnostics to read the value for PT2. It should be approximately 30 – 50 psi. If not, there is a harness or WEDGE problem.
  • Page 58 COMPRESSOR CODE 55 Estop Button Explanation: The WEDGE has received an indication that the emergency stop button has 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 key switch signal turn off.
  • Page 59 Circuit Description: The estop button is in series with the engine key switch signal and the auxiliary start relay, K1. Pressing the button opens both of these circuits simultaneously. The WEDGE reads a sense input that is connected to the estop button to determine if the estop button is pressed.
  • Page 60 COMPRESSOR CODE 56 Minimum Pressure Not Met Explanation: The separator tank has not 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:...
  • Page 61 COMPRESSOR CODE 70 Serial Communications Explanation: The WEDGE controller cannot communicate with an external computer over the RS232 serial link. Effect: This code can only occur when a laptop computer or PDA Service Tool is Connected to the WEDGE. The WEDGE may otherwise be functional and This event may not be mission disabling.
  • Page 62 TROUBLESHOOTING STEPS Code 70 Action Result Step1: If the current RS232 device (laptop computer, etc.) will not If second device will not communicate with the WEDGE, substitute another RS232 communicate with WEDGE, device. Note: The second device must have proper software replace the WEDGE loaded to communicate with the WEDGE.
  • Page 63 COMPRESSOR CODE 71 CAN Communications Explanation: The WEDGE controller cannot communicate with the engine controller. The J1939 CAN (Controller Area Network) broadcast of engine parameters cannot be received. Effect: The WEDGE will not be able to display engine parameters using the diagnostic Display function.
  • Page 64 Circuit Description: The CANH, CANL and SHLD wires are a cable that is located in the main harness. CANH refers to CAN HI and CANL refers to CAN LO and SHLD is the shield of the CAN cable. This is the cable that carries the communications between the engine and WEDGE controller and any other devices that are connected to the CAN cable.
  • Page 65 TROUBLESHOOTING STEPS Code 71 Action Result Step 1: Verify P1 harness connector pins 34, 35, and 1 are firmly seated into The connector at the WEDGE controller. Step 2: Verify P2 harness connector pins 37, 46, and 36 for Cummins engine are firmly seated into the connector at the engine electronic controller.
  • Page 66 Disconnect the test lead from P1-34 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 controller is OK, harness should be checked as outlined in Step 4.
  • Page 67 COMPRESSOR CODE 73 Auto Start Stop Controller Communications Failure Explanation: The WEDGE has not been able to communicate with the Auto Start Stop controller for 17 seconds. A communications failure is determined. Effect: Code 73 is an ALERT condition and will not stop the machine. The Auto Start system may not function properly due to communications failure.

  • Page 68: System Schematic Diagrams

    SECTION 5 SYSTEM SCHEMATIC DIAGRAMS HP1300/1600WCU Electrical Manual Book No. 22772784 (9--8--06)
  • Page 70 Control System Wiring Diagram 22742951_071_06/04_A 22742951...
  • Page 72 Control System Wiring Diagram 22742951_072_06/04_A 22742951...
  • Page 74 Control System Wiring Diagram 22742951_073_06/04_A 22742951...
  • Page 76 Control System Wiring Diagram 22742951_074_06/04_A 22742951...
  • Page 78 IQ Wiring Diagram 22742951_074_06/04_A 22742951...
  • Page 80 SECTION 6 ELECTRONIC COMPONENT LOCATION DRAWINGS HP1300/1600WCU Electrical Manual Book No. 22772784 (9--8--06)
  • Page 81 ELECTRICAL COMPONENTS LOCATION WEDGE S12 , S13 K1 , K2 F1--F4 S10 , S11 ENGINE CONTROLLER HP1300/1600WCU Electrical Manual Book No. 22772784 (9--8--06)
  • Page 82 SECTION 7 INDIVIDUAL CIRCUIT DIAGRAMS HP1300/1600WCU Electrical Manual Book No. 22772784 (9--8--06)

  • Page 83: Engine Start Circuit

    ENGINE START CIRCUIT CHART A1 WEDGE J1- -28 P1- -28 W213 P9- -3 J9- -3 24VDC W217 J9- -4 P9- -4 W135 RED W129 W178 YEL START STARTER RELAY - - - - - - - - - - - - - - - - W005 W179 W132 Red- -Yel...

  • Page 84: Circuit Description

    CIRCUIT DESCRIPTION The WEDGE drives the engine starter through the auxiliary start relay, K1. K1 is mounted on the lifting rail near the engine. K1 has a single set of contacts that connect to the starter solenoid. Diode D4 is for field suppression across K1’s coil. The control signal leaving the WEDGE on J1- -28 passes through the W1 harness and through a jumper plug.
  • Page 85 FUEL SENDER CIRCUIT CHART B1 P1- -17 WEDGE J1- -17 W113 W106 ALERT Fuel Level Sender W102 SHUTDOWN W011 P1- -18 J1- -18 WEDGE to control panel fuel level → to ground → CIRCUIT DESCRIPTION The fuel sender is a resistive device that provides a 10--180 ohm resistance to the fuel gauge indicating fuel level.
  • Page 86 RT1 SEPARATOR TANK TEMPERATURE CIRCUIT CHART C1 WEDGE CONTROLLER J1- -4 W1 P1- -4 Resistance Temp_F Temp_C (Ohms) --20 25,490 W1 W095 --10 18,088 12,221 9,369 7,240 4,427 SEPARATOR TANK 2,786 TEMP SENSOR 1460 668.7 467.2 241.0 177.5 W1 W097 153.1 132.8 W1 P1- -6...
  • Page 87 RT2 AIREND DISCHARGE TEMP CHART D1 WEDGE CONTROLLER J1- -5 Resistance W1 P1- -5 Temp_F (Ohms) Temp_C --20 25,490 --10 18,088 W1 W096 12,221 9,369 7,240 4,427 AIREND DISCHARGE 2,786 1460 TEMP SENSOR 668.7 467.2 241.0 177.5 W1 W097 153.1 132.8 W1 P1- -6 J1- -6...
  • Page 88 PT1 SEPARATOR TANK PRESSURE CIRCUIT CHART E1 HARNESS WEDGE CONTROLLER P1- -8 BRN J1- -8 W099 SEPARATOR TANK PRESSURE TRANSDUCER P1- -7 ORN J1- -7 SIG (+) W098 P1- -10 VIO J1- -10 5VDC+ W101 CIRCUIT DESCRIPTION The WEDGE reads separator tank pressure from PT1. It is a gauge pressure transducer mounted on the separator tank.
  • Page 89 PT2 REGULATION SYSTEM PRESSURE CIRCUIT CHART F1 HARNESS WEDGE CONTROLLER P1- -8 BRN J1- -8 W121 REGULATION SYSTEM PRESSURE TRANSDUCER P1- -9 ORN J1- -9 SIG (+) W100 P1- -10 VIO J1- -10 5VDC+ W122 CIRCUIT DESCRIPTION The WEDGE reads regulation system pressure from PT2. It is a gauge pressure transducer mounted near the inlet unloader.
  • Page 90 DC HEATER CIRCUIT CHART G1 +24V “Heaters” switch on control panel W117 W183 R1 = Regulation Heater R3 = Orifice Heater R1- -1 R3- -1 R3- -2 R1- -2 W182 W181 CIRCUIT DESCRIPTION A DC heater system is provided to prevent the orifices from freezing in cold tem- peratures.
  • Page 91 B2 STARTUP AIR COMPRESSOR CHART H1 K2 Relay 30 85 87A 87 86 W007 BRN W091 B2- -1 B2- -2 W014 BRN W090 B2 START- -UP COMPRESSOR W009 F4 20A W078 B1_Pos 24V BATT P1- -29 J1- -29 WEDGE CIRCUIT DESCRIPTION The WEDGE connects to the startup compressor through relay K2.
  • Page 92 S10, S11 AIR FILTER SWITCHES CHART I1 W094 WEDGE P1- -2 J1- -2 W162 S10- -1 S11- -1 W163 W010 CIRCUIT DESCRIPTION The WEDGE reads the air filter switches, S10 and S11. S10 is connected to the compressor air filter and S11 is connected to the engine air filter. These are normally open switches and close when the air filter restriction reaches 20 inches of water.
  • Page 93 U2 ENGINE COOLANT LEVEL SENSOR CHART K1 Coolant Sensor W1 Harness CIRCUIT DESCRIPTION The engine coolant level sensor is a capacitive probe mounted in the radiator top tank. The probe connects to the engine controller. The probe has two complementary outputs (when one is on, the other is off).
  • Page 94 SECTION 8 ELECTRICAL CONNECTOR INFORMATION Book No. 22772784 (9--8--06) HP1300/1600WCU Electrical Manual...
  • Page 95 CONNECTOR PARTS INFORMATION The following is a list of the connector parts used with the harnesses and devices on the HP1600/1300 machine. Most connectors consist of 1 to 4 items per side (harness or device). The devices can be located on the schematics and then referenced to this list.
  • Page 96 PART Manufacturer Part No. P2, Cummins ECM Plug, 50 Way Deutsch 22869580 Seal, Cavity, Size 20 Deutsch 22870018 Socket, Size 20 Deutsch 54699608 Back Shell, 50 Way Deutsch 22870018 P3, ECM Plug, 31 Way Deutsch 22871867 Back Shell Deutsch 22870034 Socket, 16 AWG, Tin Stamp Deutsch 22869044...
  • Page 97 Receptacle, 4 Way Deutsch 22869036 Wedge Lock, 4 Way, Pin Deutsch 22880876 Pin, Size 16, Gold Stamp Deutsch 22869093 F1, F4; Fuse Connectors Connector, 2 Way; Fuse Packard 22871677 Cover, Fuse Packard 22861735 Terminal, Female; 12--10 AWG Packard 22869432 F2, F3; Fuse Connectors Connector, 2 Way;...
  • Page 98 Removal Tool Usage TERMINAL P/N Manufacturer Removal Tool P/N 54699525 Deutsch 54699624 22869044 Deutsch 54699632 22869069 Deutsch 54699632 22868947 Deutsch 54699624 22869093 Deutsch 54699632 22880405 Deutsch 54699632 22880413 Deutsch 54699624 54699608 Deutsch 54699640 22880710 Deutsch 54699624 22869531 Packard 54749643 22869507 Packard 54749643 54750526...
  • Page 99 Deutsch DT Series Connector (Note the orange wedgelock) Packard Metri Pack Series Connector (Note the green wire seals and blue Terminal Position Assurance Connection) Deutsch HD Series Connector Deutsch DRC Series Connector It is very important that connectors be properly assembled.
  • Page 100 Use of Harness Tools These pictures describe the proper methods of use of harness tools. Proper removal tool usage is shown in the above picture. The removal tools are color coded as to wire size. The Table below lists the colors and wire sizes.
  • Page 101 HP1300/1600WCU Electrical Manual Book No. 22772784 (9--8--06)
  • Page 102 HP1300/1600WCU Electrical Manual Book No. 22772784 (9--8--06)
  • Page 103 Engine electronic controller connnector (J2) location: HP1300/1600WCU Electrical Manual Book No. 22772784 (9--8--06)
  • Page 104 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 FROM WIRE ENTRY SIDE HP1300/1600WCU Electrical Manual Book No. 22772784 (9--8--06)
  • 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 differently. View from front side -- non wire side HP1300/1600WCU Electrical Manual Book No.

  • Page 106: Electrical Parts List

    SECTION 9 ELECTRICAL PARTS LIST HP1300/1600WCU Electrical Manual Book No. 22772784 (9--8--06)
  • Page 107 ELECTRICAL PARTS LIST Ref Designator Description Part Number IQ Wiring Harness 54757224 Coolant Level Switch 54474572 Battery Disconnect Switch 36896975 0--225 psi pressure transducer 54496973 0--100 psi Pressure Transducer 36920825 Relay, 24VDC SPDT 36892362 Mag Speed Sensor 36785319 RT1,RT2 Thermistor Temperature Sensor 36898922 Start / Run Solenoid Valve 36842300...
  • Page 108 SECTION 10 ALERTS AND SHUTDOWNS LIST HP1300/1600WCU Electrical Manual Book No. 22772784 (9--8--06)
  • Page 109 ALERT/SHUTDOWN CONDITIONS Version 2.07 ALERT SHUTDOWN LIGHT Machine LIGHT DELAY Machine CODE CODE (sec) (BLINKS) (STEADY) Engine Speed < Min. RPM CPRSR Malf All# Engine Speed > Max. RPM CPRSR Malf All$ Engine Crank Time Exceeded CPRSR Malf All! Engine Oil Temperature > 252 deg. F CPRSR Malf.
  • Page 110 Notes: 1) Max. crank time 0- -6 = 15 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...
  • Page 111 FAULT CODES FOR QSX15 CUMMINS ENGINE Fault Code Description Engine Control Module -- Critical Internal Failure Engine Speed/Position Sensor Circuit -- Lost both signals from Magnetic Pickup Sensor Engine Speed/Position Sensor Circuit -- Lost One of Two Signals From the Magnetic Pickup Sensor Intake Manifold Pressure Sensor #1 Circuit -- Shorted High Intake Manifold Pressure Sensor #1 Circuit -- Shorted Low Engine Oil Pressure Sensor Circuit -- Shorted High...
  • Page 112 Engine Speed High -- Critical Engine Coolant Level Low -- Critical Vehicle Speed Sensor Circuit -- Data Incorrect Fan Clutch Circuit -- Shorted Low Fuel Shutoff Valve Circuit -- Shorted Low Fuel Shutoff Valve Circuit -- Shorted High Fuel Shutoff Valve -- Stuck Open Engine Speed/Position Sensor #1 (Crankshaft) Supply Voltage Circuit -- Shorted Low SAE J1939 Multiplexing PGN Timeout Error SAE J1939 Multiplexing Configuration Error...
  • Page 113 Timing Actuator #1 Circuit -- Grounded Circuit Fueling Actuator #2 Circuit -- Open Circuit Fueling Actuator #2 Circuit -- Grounded Circuit Timing Actuator #2 Circuit -- Open Circuit Timing Actuator #2 Circuit -- Grounded Circuit Engine Oil Pressure Low -- Critical Water In Fuel Indicator High -- Maintenance Engine Coolant Level Sensor Circuit -- Data Incorrect SAE J1939 Datalink -- Cannot Transmit...
  • Page 114 Fuel Delivery Pressure Sensor Circuit -- Shorted Low Injector Metering Rail #1 Pressure High -- Warning Fuel Supply Pump Inlet Pressure Sensor Circuit -- Shorted High Fuel Supply Pump Inlet Pressure Sensor Circuit -- Shorted Low Fuel Supply Pump Inlet Pressure Low -- Warning Level Turbocharger #1 Speed High -- Warning Level Electrical Charging System Voltage High -- Warning Level Electrical Charging System Voltage Low -- Warning Level...

  • Page 115: Recommended Spare Parts

    SECTION 11 RECOMMENDED SPARE PARTS Quantity Description Part Number WEDGE Controller 22173579 Thermistor Temperature Sensor 36898922 0--100 psig Pres Transducer 36920825 0--225 psig Pres Transducer 54496773 HP1300/1600WCU Electrical Manual Book No. 22772784 (9--8--06)
  • Page 116 SECTION 12 Software Information HP1300/1600WCU Electrical Manual Book No. 22772784 (9--8--06)
  • Page 117 Software Updates Software updates are available on a website for downloading. The website will always contain the latest software revisions for all applications of Utility Equipment products. Software files will be available for the Virtual Technician I (PDA based service tool), and Virtual Technician II PC based service tool.
  • Page 118 Revision History   Rev. EC Number Comments Original release SVC31234 CN026881 Doosan reference updates...
  • Page 119 Doosan Infracore Portable Power 1293 Glenway Drive Statesville, N.C. 28625 www.doosanportablepower.com ©2012 Doosan Infracore Portable Power Printed in the U.S.A.

This manual is also suitable for:

Hp1300wcu25/33025/300

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