Ingersoll-Rand NHP1500WCU Service Manual
  1. Manuals
  2. Brands
  3. Ingersoll-Rand Manuals
  4. Test Equipment
  5. NHP1500WCU
  6. Service manual
Ingersoll-Rand NHP1500WCU Service Manual

Ingersoll-Rand NHP1500WCU Service Manual

Hide thumbs Also See for NHP1500WCU:
Table of Contents

Advertisement

Quick Links

Download this manual
Utility Equipment
P.O. Box 868 - - 501 Sanford Ave
Mocksville, N.C. 27028
www.portablepower.irco.com
ELECTRICAL/ELECTRONIC
SERVICE MANUAL FOR
NHP1500WCU (10/425)
Doosan purchased Bobcat Company from Ingersoll-Rand Company in
2007. Any reference to Ingersoll-Rand Company or use of trademarks,
service marks, logos, or other proprietary identifying marks belonging
to Ingersoll-Rand Company in this manual is historical or nominative
in nature, and is not meant to suggest a current affiliation between
Ingersoll-Rand Company and Doosan Company or the products of
either.
Book No. 22103592 (7/05)
Revised (10-12)

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the NHP1500WCU and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Ingersoll-Rand NHP1500WCU

Summary of Contents for Ingersoll-Rand NHP1500WCU

  • Page 1 SERVICE MANUAL FOR NHP1500WCU (10/425) Doosan purchased Bobcat Company from Ingersoll-Rand Company in 2007. Any reference to Ingersoll-Rand Company or use of trademarks, service marks, logos, or other proprietary identifying marks belonging to Ingersoll-Rand Company in this manual is historical or nominative...
  • Page 2 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 3 SECTION 1 MANUAL DESCRIPTION This manual contains all of the information concerning the electrical and electronic systems for the NHP1500 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 4: General Information

    SECTION 2 GENERAL INFORMATION OPERATIONAL THEORY Book No. 22103592 (7/05) NHP1500 Electrical Manual...
  • Page 5 GENERAL INFORMATION AND OPERATIONAL The signal is a linear signal from 150 Hz at engine idle THEORY (1200 RPM) to 375 Hz at maximum run speed (1800 RPM). General Figure 2--1 on page 5 shows the signal connections The NHP1500 machine has and electronic monitor from the INTELLISYS controller and the engine and control system to provide discharge air pressure controller.
  • Page 6 Book No. 22103592 (7/05) NHP1500 Electrical Manual...
  • Page 7 Book No. 22103592 (7/05) NHP1500 Electrical Manual...
  • Page 8 Book No. 22103592 (7/05) NHP1500 Electrical Manual...
  • Page 9 Controller Outputs The INTELLISYS controller receives diagnostic and run time data from the engine over the J1939 CAN The INTELLISYS controller has three types of outputs: network. A frequency throttle interface with the engine frequency, pulse width modulated (PWM) and 24 VDC is used.
  • Page 10 The electrical circuits are protected using ATC style fuses. A fuse should only be replaced with one of the same rating. Replacing a fuse with one of a large rating could lead to harness damage. If a fault occurs and the circuit does not have the appropriate size fuse, wires could be burned in the harness and damage other circuits.
  • Page 11 KEY ELECTRICAL COMPONENTS FUNCTION PT1: PT1 is a 0--30 psi vacuum pressure transducer that measures airend inlet vacuum. PT2: PT2 is a 0--100 psi gauge pressure transducer that measures airend Interstage pressure. PT3: PT3 is a 0--225 psi gauge pressure transducer that measures airend stage 2 discharge pressure.
  • Page 12 RT4: RT4 is a 100 ohm RTD temperature sensor that measures package discharge air temperature. Its range is --12 to 580_F. RT5: RT5 is a 10K ohm thermistor temperature sensor that measures compressor oil supply temperature. Its range is --30 to 255_F. RT6: RT6 is a 10K ohm thermistor temperature sensor that measures stage 1 inlet temperature.

  • Page 13: Operational Information

    OPERATIONAL INFORMATION Power “ON” (S1) at Control Panel: Key switch signal (24VDC) supplied to engine controller by Intellisys controller Frequency throttle signal OFF Fuel Pump OFF DC Heaters “ON” if RT6 Temp < 45 degrees F. “START” button on Intellisys Controller pressed: Key switch signal at 24VDC Fuel Pump ON Frequency throttle signal ON...
  • Page 14 TYPICAL OPERATING PARAMETER VALUES *** Values taken at : ambient temp = 77_F Parameter Loaded Unloaded Units Hydraulic Press 2250 1150 -- 1250 Hydraulic Temp Amb+30 Amb+15 RT4, Package Discharge Temp Amb+25 PT4, Package Discharge Press 0 -- 2 RT6, Stage 1 Inlet Temp Amb+10 Amb+10 RT1, Stage 1 Discharge Temp...
  • Page 15 SECTION 3 SERVICE TOOLS Book No. 22103592 (7/05) NHP1500 Electrical Manual...

  • Page 16: 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 Ingersoll Rand 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 17 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 18 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 19 Tool No. Tool Description Tool Illustration Digital Multimeter 22216691 Weather- -Pack Terminal Removal Tool 54729660 Deutsch Terminal Removal Tool (Blue) 54699632 Deutsch Terminal Removal Tool (Red) 54699640 Deutsch Terminal Removal Tool (Yellow) 54699624 Deutsch Crimp Tool 22216667 Book No. 22103592 (7/05) NHP1500 Electrical Manual...
  • Page 20 Electrical Contact Cleaner 54729710 Virtual Technician Service Tool Kit 54729728 Deutsch Terminal Removal Tool 54699616 RTD Simulator Plug 54749544 Thermistor Plug 22073878 Connector Repair kit 54749635 Deutsch Terminal Removal Tool 54699657 Book No. 22103592 (7/05) NHP1500 Electrical Manual...
  • Page 21 Packard Metri- -Pack Removal Tool 54749643 Pressure Transducer Simulator 22168868 Test Adapter Kit 22147540 Removal Tool Kit 22146393 Deutsch Crimp Tool 22216675 Packard Electric Crimp Tool 22216683 Book No. 22103592 (7/05) NHP1500 Electrical Manual...
  • Page 22 Fluke Test Lead Set 22216709 Fluke Insulation Piercing Probe 22216725 (single probe) Fluke Meter Case 22216733 RS232 Serial Cable 54740675 Wire Terminal Kit 22253969 Book No. 22103592 (7/05) NHP1500 Electrical Manual...
  • Page 23 Connector Wrenches 22281588 22282107 1/4’’ Flex Shaft Nutdriver 22282172 WEDGE Connector Kit 22252993 CAN Communications Adapter 22253009 Adhesive Heat Shrink Assortment 22253017 Book No. 22103592 (7/05) NHP1500 Electrical Manual...
  • Page 24 Packard Electric Crimp Tool 22255947 Packard Electric Crimp Tool 22254734 Engine Communication Kit 22253009 Book No. 22103592 (7/05) NHP1500 Electrical Manual...
  • Page 25 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 26 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 27: 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 28: Troubleshooting

    ELECTRONIC CONTROL SYSTEMS TROUBLESHOOTING CORRECTION PROBLEM Make Sure Battery Disconnect Switch is ON Check Fuse F4 Control Panel Power Switch On, Check Seating of P3 Connector at Intellisys Controller Battery Voltage Too Low Intellisys Controller Does Not Come On Check Control Panel ON / OFF Switch Check Wiring From BAT to Intellisys Controller Defective Membrane Panel Switch Defective K1 relay...
  • Page 29 PROBLEM CORRECTION Defective Switch on Membrane Panel Engine Speed Will Not Increase When Intellisys Controller J1939 Throttle Command To Engine Not Working or Intellisys Controller Frequency Load Button is Pressed Throttle Signal Not Working Intellisys Controller Frequency Throttle Engine Idle Speed Is Less Than 1200 RPM Intellisys Controller J1939 Throttle Command Engine Fueling Ensure the Engine Keyswitch Signal is 24 VDC...

  • Page 30: System Schematic Diagrams

    SECTION 5 SYSTEM SCHEMATIC DIAGRAMS Book No. 22103592 (7/05) NHP1500 Electrical Manual...
  • Page 31 Exhaust Out Top IC, AC HC, FC Book No. 22103592 (7/05) NHP1500 Electrical Manual...
  • Page 32 Legend: Mechanical Components Legend: Electrical Components -- Stg 1 Inlet Vacuum -- Inlet Valve -- 2nd Stg Inlet Pressure -- Blowdown Valve -- 2nd Stg Discharge Pressure -- Blowdown Muffler -- Package Discharge Pressure -- 1st Stage Venturi -- Oil Filter In Pressure 1st MS -- 1st Stage Moisture Separator -- Oil Filter Out Pressure -- 2nd Stage Venturi...
  • Page 43 SECTION 6 ELECTRONIC COMPONENT LOCATION DRAWINGS Book No. 22103592 (7/05) NHP1500 Electrical Manual...
  • Page 44 ELECTRICAL COMPONENTS LOCATION Intellisys Controller S1 , M1 , S11 , S4 & DS8 DS1 , DS2 , DS3, S1A & S15 PT1 -- PT7 RT3 & RT5 K1 -- K5 F1 -- F7 R5 & R6 MANUAL NO. DRAWING NO. DATE / REV: 54665302 04/01 A...
  • Page 45 ELECTRICAL COMPONENTS LOCATION -- CONTROL PANEL Intellisys Controller ITEM DESCRIPTION ITEM DESCRIPTION Intellisys 54441753 CONTROLLER MANUAL NO. DRAWING NO. DATE / REV: 54665302 04/01 A Book No. 22103592 (7/05) NHP1500 Electrical Manual...
  • Page 46 ELECTRICAL COMPONENTS LOCATION -- FUEL TANK ITEM DESCRIPTION ITEM DESCRIPTION 36876845 SENDER , FUEL MANUAL NO. DRAWING NO. DATE / REV: 54665302 04/01 A Book No. 22103592 (7/05) NHP1500 Electrical Manual...
  • Page 47 ELECTRICAL COMPONENTS LOCATION -- CONTROL PANEL ITEM DESCRIPTION ITEM DESCRIPTION 54615067 LIGHT , RED INDICATOR 54615083 LIGHT , AMBER INDICATOR 54615075 LIGHT , BLUE INDICATOR 36841252 LIGHT , CONTROL PANEL PART OF HARNESS CONNECTOR 36841245 HOURMETER 54475686 SWITCH , ROCKER 54475686 SWITCH , ROCKER 54475777...
  • Page 48 ELECTRICAL COMPONENTS LOCATION -- HYDRAULIC TANK PT1 -- PT7 ITEM DESCRIPTION ITEM DESCRIPTION 54757232 TRANSDUCER , 0--30 VACUUM 36920825 TRANSDUCER , O--100 PSIG 54496773 TRANSDUCER , 0--225 PSIG 54496773 TRANSDUCER , 0--225 PSIG 36920825 TRANSDUCER , 0--100 PSIG 36920825 TRANSDUCER , 0--100 PSIG 54496773 TRANSDUCER , 0--225 PSIG 54581327...
  • Page 49 ELECTRICAL COMPONENTS LOCATION -- OIL MANIFOLD ASSEMBLY ITEM DESCRIPTION ITEM DESCRIPTION 54512611 VALVE , SOLENOID 54557087 SENSOR MANUAL NO. DRAWING NO. DATE / REV: 54665302 04/01 A Book No. 22103592 (7/05) NHP1500 Electrical Manual...
  • Page 50 ELECTRICAL COMPONENTS LOCATION -- AFTERCOOLER ITEM DESCRIPTION ITEM DESCRIPTION 54557087 SENSOR MANUAL NO. DRAWING NO. DATE / REV: 54665302 04/01 A Book No. 22103592 (7/05) NHP1500 Electrical Manual...
  • Page 51 ELECTRICAL COMPONENTS LOCATION -- AIREND AIR INTAKE ITEM DESCRIPTION ITEM DESCRIPTION 35388982 NUT , WING 36864361 ELEMENT , PRIMARY 36867778 VALVE , EVACUATOR 54631338 PLATE , MOUNTING 36864379 ELEMENT , SAFETY 54656509 INTAKE HOUSING , CURB SIDE 35120211 ELBOW , RUBBER 35129071 CLAMP 54638143...
  • Page 52 ELECTRICAL COMPONENTS LOCATION -- ENCLOSURE ITEM DESCRIPTION ITEM DESCRIPTION 54485404 LATCH , TEE 54690755 PANEL , SERVICE ACCESS 54373113 HINGE , DOOR 36793602 LATCH , SLAM 36924033 PANEL , STREET SIDE REAR 54477286 LIGHT , AMBER WARNING 54430855 STRAP , REAR SUPPORT 36924058 PANEL , REAR MIDDLE TOP 54483722...
  • Page 53 HARNESS CONNECTOR LOCATIONS P1, P2, P3: Located at back of Intellisys controller 50 pin connector located on engine electronic controller 31 Pin connector located near P4 at engine electronic controller 3 pin connector for termination resistor on CAN backbone near Engine electronic controller 4 pin connector for engine coolant level sensor, located at sensor in radiator 9 pin connector for Cummins datalink service, located inside control panel 3 pin connector for the stub for the CAN termination resistor...
  • Page 54 P30: 2 pin connector for battery charger option P31: 5 pin connector for auto start option P24: 3 pin CAN backbone connector at Cummins datalink stub P25: 3 pin CAN backbone connector at Intellisys controller stub P26: 3 pin CAN backbone connector at Intellisys controller stub P27: 3 pin CAN backbone connector at engine controller stub P28:...
  • Page 55 SECTION 7 INDIVIDUAL CIRCUIT DIAGRAMS Book No. 22103592 (7/05) NHP1500 Electrical Manual...

  • Page 56: Engine Start Circuit

    ENGINE START CIRCUIT CHART A1 INTELLISYS CONTROLLER J3- -9 P3- -9 W1 W63 P14- -6 J14- -6 W4 W306 E- -STOP W4 W313 E- -STOP W4 W307 J14- -7 P14- -7 24VDC W1 W111 P17- -4 J17- -4 W278 AUXILIARY START STARTER RELAY...

  • Page 57: Circuit Description

    CIRCUIT DESCRIPTION The Intellisys Controller drives the engine starter through the auxil- iary start relay, K1. K1 is mounted in the relay box near the engine starter. K1 has a single set of contacts that connect to the starter solenoid. Diode D1 is for field suppression across K1’s coil.
  • Page 58 FUEL SENDER CIRCUIT CHART E1 INTELLISYS CONTROLLER J1- -25 W1 P1- -25 W1 W53 Fuel Level Sender W1 W257 J1- -37 W1 P1- -37 INTELLISYS CONTROLLER CIRCUIT DESCRIPTION The fuel sender is a resistive device that provides a 10--180 ohm signal to the Intelli- sys Controller, indicating fuel level.
  • Page 59 STAGE 1 DISCHARGE TEMP CIRCUIT CHART F1 INTELLISYS CONTROLLER J1- -1 W1 P1- -1 W1 W1 STAGE 1 DISCHARGE TEMP SENSOR W1 W2 W1 P1- -2 J1- -2 INTELLISYS CONTROLLER CIRCUIT DESCRIPTION Stage 1 discharge temperature is read by RT1 RTD. It is mounted in the Stage 1 discharge piping and connects to the W1 harness.
  • Page 60 STAGE 2 INLET TEMP CIRCUIT CHART G1 INTELLISYS CONTROLLER J1- -3 W1 P1- -3 W1 W3 STAGE 2 INLET TEMP SENSOR W1 W4 W1 P1- -4 J1- -4 INTELLISYS CONTROLLER CIRCUIT DESCRIPTION Stage 2 inlet temperature is read by RT2 RTD. It is mounted in the Stage 2 inlet piping and connects to the W1 harness.
  • Page 61 STAGE 2 OUTLET TEMP CIRCUIT CHART H1 INTELLISYS CONTROLLER J1- -5 W1 P1- -5 W1 W5 STAGE 2 OUTLET TEMP SENSOR W1 W6 W1 P1- -6 J1- -6 INTELLISYS CONTROLLER CIRCUIT DESCRIPTION Stage 2 outlet temperature is read by RT3 RTD. It is mounted in the Stage 2 outlet piping and connects to the W1 harness.
  • Page 62 DISCHARGE AIR TEMP CIRCUIT CHART INTELLISYS CONTROLLER J1- -7 W1 P1- -7 W1 W7 DISCHARGE AIR TEMP SENSOR W1 W8 W1 P1- -8 J1- -8 INTELLISYS CONTROLLER CIRCUIT DESCRIPTION Discharge air temperature is read by RT4 RTD. It is mounted in the service air piping and connects to the W1 harness.
  • Page 63 COMPRESSOR OIL SUPPLY TEMP CIRCUIT CHART INTELLISYS CONTROLLER J1- -9 W1 P1- -9 W1 W9 COMPRESSOR OIL SUPPLY TEMP SENSOR W1 W11 W1 P1- -10 J1- -10 INTELLISYS CONTROLLER CIRCUIT DESCRIPTION Compressor oil supply temperature is read by RT5 thermistor. It is mounted in the oil supply piping and connects to the W1 harness.
  • Page 64 STAGE 1 INLET TEMP CIRCUIT CHART INTELLISYS CONTROLLER J1- -11 W1 P1- -11 W1 W12 STAGE 1 INLET TEMP SENSOR W1 W13 W1 P1- -12 J1- -12 INTELLISYS CONTROLLER CIRCUIT DESCRIPTION Stage 1 inlet temperature is read by RT6 thermistor. It is mounted in the Stage 1 inlet piping and connects to the W1 harness.
  • Page 65 ENGINE COOLANT TEMP CIRCUIT CHART INTELLISYS CONTROLLER J1- -13 W1 P1- -13 W1 W14 ENGINE COOLANT TEMP SENSOR W1 W15 W1 P1- -14 J1- -14 INTELLISYS CONTROLLER CIRCUIT DESCRIPTION Engine coolant temperature is read by RT7 RTD. It is mounted in the Engine Block and connects to the W1 harness.
  • Page 66 INTERCOOLER TEMP CIRCUIT CHART INTELLISYS CONTROLLER J1- -15 W1 P1- -15 W1 W16 INTERCOOLER TEMP SENSOR W1 W17 W1 P1- -16 J1- -16 INTELLISYS CONTROLLER CIRCUIT DESCRIPTION Intercooler temperature is read by RT8 RTD. It is mounted in the intercooler piping and connects to the W1 harness.
  • Page 67 PT1 STAGE 1 INLET VACUUM PRESSURE CIRCUIT CHART N1 INTELLISYS CONTROLLER P2- -2 BRN J2- -2 STAGE 1 INLET VACUUM PRESSURE TRANSDUCER P2- -1 ORN J2- -1 SIG (+) P2- -18 VIO J2- -3 5VDC+ CIRCUIT DESCRIPTION The Intellisys Controller reads the stage 1 inlet pressure from PT1. It is a vaccum pressure transducer mounted on the pressure transducer rail on the hydraulic fluid tank.
  • Page 68 PT2 INTERSTAGE PRESSURE CIRCUIT CHART O1 INTELLISYS CONTROLLER P2- -4 BRN J2- -4 INTERSTAGE PRESSURE TRANSDUCER P2- -3 ORN J2- -5 SIG (+) P2- -18 VIO J2- -18 5VDC+ CIRCUIT DESCRIPTION The Intellisys Controller reads the interstage pressure from PT2. It is a gauge pressure transducer mounted on the pressure transducer rail on the hydraulic fluid tank.
  • Page 69 PT3 STAGE 2 DISCHARGE PRESSURE CIRCUIT CHART P1 INTELLISYS CONTROLLER P2- -6 BRN J2- -6 STAGE 2 DISCHARGE PRESSURE TRANSDUCER P2- -5 ORN J2- -7 SIG (+) P2- -18 VIO J2- -18 5VDC+ CIRCUIT DESCRIPTION The Intellisys Controller reads the stage 2 discharge pressure from PT3. It is a gauge pressure transducer mounted on the pressure transducer rail on the hydraulic fluid tank.
  • Page 70 PT4 PACKAGE DISCHARGE PRESSURE CIRCUIT CHART Q1 INTELLISYS CONTROLLER P2- -8 BRN J2- -8 PACKAGE DISCHARGE PRESSURE TRANSDUCER P2- -7 ORN J2- -7 SIG (+) P2- -18 VIO J2- -18 5VDC+ CIRCUIT DESCRIPTION The Intellisys Controller reads the package discharge pressure from PT4. It is a gauge pressure transducer mounted on the pressure transducer rail on the hydraulic fluid tank.
  • Page 71 PT5 AIREND OIL FILTER INLET PRESSURE CIRCUIT CHART R1 INTELLISYS CONTROLLER P2- -10 BRN J2- -10 AIREND OIL FILTER INLET PRESSURE TRANSDUCER P2- -9 ORN J2- -9 SIG (+) P2- -18 VIO J2- -18 5VDC+ CIRCUIT DESCRIPTION The Intellisys Controller reads the airend oil filter inlet pressure from PT5. It is a gauge pressure transducer mounted on the pressure transducer rail on the hydraulic fluid tank.
  • Page 72 PT6 AIREND OIL FILTER OUTLET PRESSURE CIRCUIT CHART S1 INTELLISYS CONTROLLER P2- -12 BRN J2- -12 AIREND OIL FILTER OUTLET PRESSURE TRANSDUCER P2- -11 ORN J2- -11 SIG (+) P2- -18 VIO J2- -18 5VDC+ CIRCUIT DESCRIPTION The Intellisys Controller reads the airend oil filter outlet pressure from PT6. It is a gauge pressure transducer mounted on the pressure transducer rail on the hydraulic fluid tank.
  • Page 73 PT7 REMOTE PRESSURE CIRCUIT CHART T1 INTELLISYS CONTROLLER P2- -14 BRN J2- -14 REMOTE PRESSURE TRANSDUCER P2- -13 ORN J2- -13 SIG (+) P2- -18 VIO J2- -18 5VDC+ CIRCUIT DESCRIPTION The Intellisys Controller reads the remote pressure from PT7. It is a gauge pressure transducer mounted on the pressure transducer rail on the hydraulic fluid tank.
  • Page 74 U2 HYDRAULIC FLUID LEVEL SWITCH CHART U1 INTELLISYS CONTROLLER P2- -16 VIO J2- -16 5VDC+ HYDRAULIC FLUID LEVEL SWITCH P2- -15 BLU J2- -15 SIG (+) P2- -18 BRN J2- -18 CIRCUIT DESCRIPTION The Intellisys Controller reads the hydraulic fluid level from U2. It is a capacitive level transducer mounted on the side of the hydraulic fluid tank.
  • Page 75 DC HEATER CIRCUIT INTELLISYS CONTROLLER J3- -5 K3 HEATER RELAY K3 and F5 are located in Fuse Box F5 15A J17- -10 P17- -10 W197 W198 BRN SPL5 CIRCUIT DESCRIPTION A DC heater system is provided to prevent the orifices from freezing in cold temperatures. It is automatically turned on by the Intellisys Controller when the ambient temperature reaches 45_F (7C).
  • Page 76 SECTION 8 ELECTRICAL CONNECTOR INFORMATION Book No. 22103592 (7/05) NHP1500 Electrical Manual...
  • Page 77 CONNECTOR PARTS INFORMATION The following is a list of the connector parts used with the harnesses and devices on the NHP1500 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 78 Engine OEM 31 Pin Conn: (P5 ) Harness Socket #16 Wire Deutsch 54699541 Fuel Filter Heaters: Harness Socket Deutsch 54699525 Harness Housing Deutsch 54750575 Heater Conn Pin Deutsch 54699533 Heater Conn Housing Deutsch 54750583 Harness Housing Wedgelock Deutsch 54750591 Heater Conn Wedgelock Deutsch 54750609 Engine OEM 50 Pin Conn:...
  • Page 79 REMOVAL TOOL USAGE Terminal Part Number Manufacturer Removal Tool No. Manufacturer Crimp Tool No. 54699541 Deutsch 54699632 22216667 54699558 54699632 22216667 54699582 54699640 22216675 54699590 54699640 22216675 54750500 Packard Metri--Pack 54749643 12155975 54750674 54749643 12155975 54750526 Packard Weather Pack 54729660 12155975 54750542 54729660...
  • Page 80 Book No. 22103592 (7/05) NHP1500 Electrical Manual...

  • Page 81: Electrical Parts List

    SECTION 9 ELECTRICAL PARTS LIST Book No. 22103592 (7/05) NHP1500 Electrical Manual...
  • Page 82 Ref Designator Description Part Number S1, S4 Rocker switch, lighted 54475686 Rocker switch, momentary 54475777 Hourmeter 36841245 Intellisys Controller 54441753 Light, panel 36841252 Panel light bulb 35290089 Wiring harness, control panel 54597497 Toggle switch SPST 54615091 Toggle switch SPDT momentary 54615109 Red indicator lamp 54615067...
  • Page 83 Ref Designator Description Part Number Battery Disconnect Switch 36896975 Battery Jumper Cable 35128982 Positive Battery Cable 35128982 Pos Battery Jumper Cable 54511282 Negative Battery Cable 54658323 Frame Ground Strap 54511241 Fuel Level Sender 36842011 D1 -- D6 Diode 35376169 Chassis Harness 54631791 Alarm Harness 54631809...
  • Page 84 SECTION 10 ALERTS AND SHUTDOWNS LIST Book No. 22103592 (7/05) NHP1500 Electrical Manual...
  • Page 85 INTELLISYS CONTROLLER Software V1.7 ALERT SHUTDOWN AIREND Parameters Units Value Type Value Type High Inlet Restriction psiv >3.05 >13.5 Hi Stg 2 Inlet Press >43 & >5 psi & psig RT1>430F PT1>5 Hi Stg 2 Disch Press psig >200 >100 @ Hi Pkg Disch Press psig >Pset+10...
  • Page 86 FAULT CODES FOR QSX15 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...
  • Page 87 Ambient Air Pressure Sensor Circuit -- Shorted High Ambient Air Pressure Sensor Circuit -- Shorted Low Engine Oil Burn Valve Solenoid Circuit -- Shorted Low Sensor Supply Voltage #2 Circuit -- Shorted High 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...
  • Page 88 Real Time Clock -- Power Interrupt Engine Control Module -- Data Lost Engine Control Module -- Warning Internal Hardware Failure Engine Control Module -- Warning Software Error Sensor Supply Voltage #1 Circuit -- Shorted Low Fueling Actuator #1 Circuit -- Open Circuit Fueling Actuator #1 Circuit -- Grounded Circuit Sensor Supply Voltage #1 Circuit -- Shorted High Timing Actuator #1 Circuit -- Open Circuit...
  • Page 89 Engine Oil Pressure Sensor Circuit -- Data Incorrect Battery #1 Voltage Low -- Warning Battery #1 Voltage High -- Warning Fuel Pressure High -- Warning Injector Metering Rail #1 Pressure Sensor Circuit -- Shorted High Injector Metering rail#1 Pressure Sensor Circuit -- Shorted low Turbocharger #1 Wastegate Control Circuit -- Data Incorrect Fuel Pressure Low -- Warning Injector Metering Rail #2 Pressure Sensor Circuit -- Shorted High...
  • Page 90 Electrical Charging System Voltage Low -- Critical Level Engine Hot Shutdown Engine Speed/Position #2 Cam Sync Error Injector Metering Rail #1 Pressure Malfunction Injector Metering Rail #2 Pressure Malfunction Cylinder Power Imbalance Between Cylinders Notes: Code 147 will be logged each time the compressor controller stops the engine. This is an operational fault and does not indicate any engine fault.

  • Page 91: Recommended Spare Parts

    SECTION 11 RECOMMENDED SPARE PARTS Quantity Description Part Number INTELLISYS Controller 54441753 RTD Temperature Probe 54557087 Thermistor Temperature Probe 54557095 Hydraulic Level Switch 54581327 0--100 psig Pres Transducer 36920825 0--30 In Hg Vacuum Transducer 54496757 0--225 psig Pres Transducer 54496773 Book No.

  • Page 92: Engine Information

    SECTION 12 ENGINE INFORMATION Book No. 22103592 (7/05) NHP1500 Electrical Manual...

Table of Contents