Doosan Ingersoll Rand XP185WIR Series Electronic Service Manual
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Doosan Ingersoll Rand XP185WIR Series Electronic Service Manual

Doosan Ingersoll Rand XP185WIR Series Electronic Service Manual

7/51, 7/71
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ELECTRONIC SERVICE MANUAL
This manual contains important safety information.
Do not destroy this manual.
This manual must be available to the personnel who operate and maintain this machine.
Doosan Infracore Portable Power
P.O. Box 868 - 501 Sanford Ave
Mocksville, N.C. 27028
www.doosanportablepower.com
Book: 23307366 (6/08)
Revised (10-12)
XP185WIR
P260WIR
7/51
7/71
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.

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  • Page 1 Mocksville, N.C. 27028 to Ingersoll-Rand Company in this manual is historical or nominative www.doosanportablepower.com in nature, and is not meant to suggest a current affiliation between Ingersoll-Rand Company and Doosan Company or the products of either. Book: 23307366 (6/08) Revised (10-12)
  • 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: Manual Description

    SECTION 1 MANUAL DESCRIPTION This manual contains all of the information concerning the electrical and electronic systems for the XP185, P260WIR compressor family. It provides all information necessary to service, trou- bleshoot and order parts for this machine. It is organized into 12 sections. Sections 2 thru 4 cover systems operation and troubleshooting procedures.

  • Page 4: General Information

    SECTION 2 GENERAL INFORMATION OPERATIONAL THEORY Book No. 23307366 (06/08)
  • Page 5 GENERAL INFORMATION AND OPERATIONAL THEORY The first function of the controller is to scan all analog General and digital inputs at a fixed interval. These inputs are This family of machines has an electronic monitor and scanned every 10 milliseconds. The values are then control system to provide discharge air pressure compared against minimum and maximum values and control and engine and package monitor functions.
  • Page 6 Book No. 23307366 (06/08)
  • Page 7 Book No. 23307366 (06/08)
  • Page 8 Book No. 23307366 (06/08)
  • Page 9 The controller measures the pneumatic system regu- Figure 2--2 shows the signals between the engine lation pressure and computes an engine throttle set- controller and the SECU controller. ting. This throttle setting is sent to the engine via the J1939 throttle. Sensors and Transducers The electronics system contains sensors and trans- J1939 Data Link...
  • Page 10 KEY ELECTRICAL COMPONENTS FUNCTION PS- -1: PS--1 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. It also has a switch for low fuel level and low fuel shutdown. K1 is SPST, 12VDC relay used to activate the engine starter.

  • Page 11: Operational Information

    OPERATIONAL INFORMATION XP185/P260 Family Power “ON” at Control Panel: 1. Key switch signal (12VDC) supplied relay to engine ECU. Engine Start- -up: When the key is switched to the engine crank position: 1. K1 auxiliary start relay is engaged. When the engine speed reaches 600 RPM (engine start declared): Loading: When the “Service Air”...
  • Page 12 SECTION 3 SERVICE TOOLS Book No. 23307366 (06/08)
  • Page 13 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 14 22255947 Packard Electric Crimp Tool (12039500) Crimps 150 series pull to seat pins 22216709 Fluke Test Lead Set (TL20) Contains needle probes, alligator clips, test leads heat shrink tubing that are used on harnesses 22216725 Fluke Insulation Piercing Probe (AC--89) Used to connect to a wire for measurements 22216733 Fluke Meter Case (C25)
  • Page 15 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. 23307366 (06/08)
  • Page 16 54729710 Electrical Contact Cleaner 54729728 PDA Service Tool VIRTUAL TECHNICIAN 54699616 Deutsch Terminal Removal Tool 54749635 Connector Repair kit 54699657 Deutsch Terminal Removal Tool 54749643 Packard Metri- -Pack Removal Tool 22168868 Pressure Transducer Simulator Book No. 23307366 (06/08)
  • Page 17 22147540 Test Adapter Kit 22146393 Removal Tool Kit 22216675 Deutsch Crimp Tool 22216683 Packard Electric Crimp Tool Book No. 23307366 (06/08)
  • Page 18 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. 23307366 (06/08)
  • Page 19 22282172 1/4’’ Flex Shaft Nutdriver 22253009 CAN Communications Adapter 22253017 Adhesive Heat Shrink Assortment 22255947 Packard Electric Crimp Tool 22254734 Packard Electric Crimp Tool Book No. 23307366 (06/08)
  • Page 20 SECTION 4 ELECTRONIC SYSTEMS TROUBLESHOOTING PROCEDURES AND TECHNIQUES Book No. 23307366 (06/08)
  • Page 21 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 22 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 23 TROUBLE SHOOTING FLOW CHART Check F1 fuse Control panel key is turned to “ON” position, Check operation of switch S1 SECU controller display does not come on. Check wiring from S1 to SECU controller Check battery voltage, ensure battery dis- connect switch is turned ON J1939 CAN communications not working –...
  • Page 24 COMPRESSOR FAULT CODES DESCRIPTION AND 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 25 COMPRESSOR CODE 1 S3, Discharge Temperature Switch Explanation: The SECU has detected an open S3, compressor air discharge temperature Switch. Machine could be overheated or a faulty switch or wiring. Effect: Code 1 will cause a machine shutdown S3 Temperature Switch Circuit: W006 Pink/Black SECU Controller...
  • Page 26 TROUBLESHOOTING STEPS Code 1 Action Result Step 1: Continuous connection Check continuity of wire W006 form S3 ,pin 2 to SECU controller pin 10 Step 2: Continuous connection Check continuity of wire W088 from S3pin 1 to splice E16 Step3 : Machine functions correctly Replace S3 switch Book 23307366 (6-08) Rev.
  • Page 27 COMPRESSOR CODE 2 S2, Separator Tank Temperature Switch Explanation: The SECU has detected an open S2, compressor separator tank temperature Switch. Machine could be overheated or have a faulty switch or wiring. Effect: Code 2 will cause a machine shutdown S2 Temperature Switch Circuit: W005 Pink/Blue SECU...
  • Page 28 TROUBLESHOOTING STEPS Code 2 Action Result Step 1: Continuous connection Check continuity of wire W005 from S2, pin 2 to SECU controller pin 21 Step 2: Continuous connection Check continuity of wire W087 from S2 to splice E16 Step 3: Replace S2 switch Book 23307366 (6-08) Rev.
  • Page 29 COMPRESSOR CODE 3 Low Alternator/Battery Voltage Explanation: The SECU has detected a low alternator/battery voltage. It is below 11.6V. The alternator may not be charging the battery. Effect: Code 3 is an alert condition and will not shutdown the machine Alternator Circuit: W078 Red Battery...
  • Page 30 TROUBLESHOOTING STEPS Code 3 Action Result Step 1: Should be greater then 13.0 volts. If not, check Measure the voltage across the battery alternator belt then goto Step 2. terminals with the engine running. Step 2: If wiring faulty, replace, if not replace alternator Check continuity of wire W078 to batteries and wire W095 to SECU Book 23307366 (6-08) Rev.
  • Page 31 COMPRESSOR CODE 5 S5, Engine Oil Pressure Switch Explanation: The SECU has detected an open S5, engine oil pressure switch. Machine could have a loss of oil pressure. Effect: Code 5 will cause a machine shutdown S3 Temperature Switch Circuit: W008 Pink/Green SECU Controller...
  • Page 32 TROUBLESHOOTING STEPS Code 5 Action Result Step 1: Continuous connection Check continuity of wire W008 form S5 pin 2 to SECU controller pin 26 Step 2: Continuous connection Check continuity of wire W089 from S3 pin 1o splice E16 Step3 : Machine functions correctly Replace S3 switch Book 23307366 (6-08) Rev.
  • Page 33 COMPRESSOR CODE 6 PS1, Regulation Pressure Transducer Explanation: The SECU has detected an out of limits reading from the regulation transducer for 3 seconds while the machine is running. Effect: Code 6 will cause a machine shutdown PS1 Transducer Circuit: W003 Brown W002 Purple SECU...
  • Page 34 TROUBLESHOOTING STEPS Code 6 Action Result Step 1: 5 VDC is correct power supply voltage Check for +5 VDC at pin 2 on PS1 Continuous connection Step 2: Check continuity of wire W001 to pin 6 on the SECU controller Step3 : Machine functions correctly Replace PS1 transducer...
  • Page 35 COMPRESSOR CODE 8 Low Fuel Shutdown Explanation: The SECU has detected an open switch at U1 low fuel switch. This condition Will prevent engine cranking. Effect: Code 8 will cause a machine shutdown U1 Transducer Circuit: W013 Pink/Red W090 Red/Orange SECU Controller Splice E16...
  • Page 36 TROUBLESHOOTING STEPS Code 8 Action Result Step 1: Shutdown switch in U1 is working correctly Disconnect U1 harness plug and remove U1 from fuel tank. Connect ohmmeter across pins A and B, Tilt U1 and ohmmeter should go from close to infinite ohms to near zero ohms. Book 23307366 (6-08) Rev.
  • Page 37 COMPRESSOR CODE 9 Air Filter Restriction Switch Explanation: The SECU has detected a closed switch at the air filter restriction indicator. Effect: Code 9 is an alert condition and will not shutdown the machine. Air Filter Restriction Circuit: W009 Dark Blue Switch W091 Red/Orange SECU...
  • Page 38 TROUBLESHOOTING STEPS Code 9 Action Result Step 1: Alert goes away Replace air filter No voltage at SECU controller Step2: Check wire W009 continuity from filter restriction switch back to SECU controller. Replace if broken or shorted to + 12 VDC.. Book 23307366 (6-08) Rev.

  • Page 39: System Schematic Diagrams

    SECTION 5 SYSTEM SCHEMATIC DIAGRAMS Book No. 23307366 (06/08)
  • Page 40 DIAGRAMS ?? Book No. 23307366 (06/08)
  • Page 41 SECTION 6 ELECTRONIC COMPONENT LOCATIONS Book No. 23307366 (06/08)
  • Page 42 HARNESS CONNECTOR LOCATIONS Located on SECU controller 48 pin connector located on engine electronic control unit (ECU) 3 pin connector for termination resistor on CAN backbone near engine electronic control unit (ECU) J57: 9 pin connector for engine datalink service, located near engine control unit (ECU) 3 pin connector for termination resistor on CAN backbone near SECU controller J14: 9 pin connector for SECU RS232 communications, located at SECU controller...
  • Page 43 SECTION 7 INDIVIDUAL CIRCUIT DIAGRAMS Book No. 23307366 (06/08)

  • Page 44: Engine Start Circuit

    ENGINE START CIRCUIT YANMAR CHART A1 ENGINE CONTROLLER P2- -K3 WO48 WHITE 12VDC W081 RED START STARTER RELAY - - - - - - - - - - - - - - - - W103 RED- -OR W076 Red- -Yel SPLICE E18 Book No.

  • Page 45: Circuit Description

    CIRCUIT DESCRIPTION The Yanmar Engine Controller drives the engine starter through the auxiliary start relay, K1. K1 has a single set of contacts that connect to the starter solenoid. The control signal leaving the Yanmar Engine Controller on J2- -K3 connects to K1 coil.
  • Page 46 FUEL SENDER CIRCUIT CHART B1 Fuel Level Sender W090 RED - - OR W013 PINK - - RED P1- -18 J1- -18 SECU SPICE E16 to control panel fuel level gauge → to ground → CIRCUIT DESCRIPTION The fuel sender is a resistive device that sends a 10--180 ohm signal to the fuel gauge indicating fuel level.
  • Page 47 S2 SEPARATOR TANK TEMPERATURE SWITCH SECU CONTROLLER P1- -21 PINK- -BLU W005 SEPARATOR TANK TEMP SWITCH RED - - OR W087 12VDC SWITCHED SPLICED E16 CIRCUIT DESCRIPTION Separator tank temperature is read by S2 temperature switch. It is mounted in the side of the separator tank.
  • Page 48 S3 AIREND DISCHARGE TEMPERATURE SWITCH CIRCUIT SECU CONTROLLER P1- -10 PINK - - BLK W006 AIREND DISCHARGE TEMP SENSOR RED - - OR W088 12VDC SWITCHED SPLICE E16 CIRCUIT DESCRIPTION Airend discharge temperature is read by S2 Temperature Switch. It is mounted in the airend discharge piping.
  • Page 49 PS1 REGULATION SYSTEM PRESSURE CIRCUIT HARNESS SECU CONTROLLER P1- -31 BRN J1- -31 W003 REGULATION SYSTEM PRESSURE TRANSDUCER P1- -6 ORN J1- -6 SIG (+) W001 P1- -35 VIO J1- -35 5VDC+ W002 CIRCUIT DESCRIPTION The SECU reads regulation system pressure from PS1. It is a gauge pressure trans- ducer mounted near the inlet unloader.
  • Page 50 S6, S7 AIR FILTER SWITCHES OPTION W068 SECU P1- -25 J1- -25 W009 P11- -1 P11- -2 W091 RED - - OR SPLICE E16 SWITCHED POWER CIRCUIT DESCRIPTION The SECU reads the air filter switches, S6 and S7. S6 is connected to the compres- sor air filter and S7 is connected to the engine air filter.
  • Page 51 SECTION 8 ELECTRICAL CONNECTOR INFORMATION Book No. 23307366 (06/08)
  • Page 52 CONNECTOR PARTS INFORMATION The following is a list of the connector parts used with the harnesses and devices on various machine models. 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 53 Part Manufacturer Part Number Yanmar Engine Controller: (P2) Connector Housing Molex 98993--3319 Cover Molex 98993--1301 Terminal Molex 98913--1029 Engine Controller Communications: (P10) Connector Housing Deutsch DTM06--6S--E005 Wedgelock Deutsch WM--6S Socket Pin Deutsch 1062--20--0144 Book No. 23307366 (06/08)
  • Page 54 Deutsch DT Series Connector (Note the orange SECUlock) Packard Metri Pack Series Connector (Note the green wire seals and blue Terminal Position Assurance Connection) Deutsch HD Series Connector Removal Tools This picture shows the various removal tools for the Deutsch connectors.The following two pages will show how the Deutsch crimp tools are to be used.
  • Page 55 Book No. 23307366 (06/08)
  • Page 56 Book No. 23307366 (06/08)
  • Page 57 The 9--pin circular connectors are used for SECU Controller communications. Circular connectors J14 and J8 pinout. J5 is located near the SECU Controller and J8 is located near the engine controller. The pinout of these connectors is the same, however, they are keyed differently. (View from front side, non--wire side) Book No.

  • Page 58: Electrical Parts List

    SECTION 9 ELECTRICAL PARTS LIST Book No. 23307366 (06/08)
  • Page 59 ELECTRICAL PARTS LIST Ref Designator Description Part Number Wiring Harness 23215551 Compressor Controller 23217185 Keyswitch 22127385 15A Fuse 22071575 10A Fuse 22071591 Fuel Lift Pump 22226385 Pressure Transducer 36920825 Hourmeter 22054175 Diagnostic Lamp 36883825 K1, K2 12V Relay SPDT 36878361 K3, K4 12V Relay SPDT 23286610...
  • Page 60 SECTION 10 ALERTS AND SHUTDOWNS LIST Book No. 23307366 (06/08)
  • Page 61 YANMAR ENGINE FAULT CODES The engine controller may blink several codes one after another. A blink code is two digits and is counted after a pause. The first digit is blinked then the second. A digit may be ?? Bunk Code Description Analog Throttle (A) Input Engine Oil Pressure...

  • Page 62: Recommended Spare Parts

    SECTION 11 RECOMMENDED SPARE PARTS Quantity Description Part Number SECU Controller 22173579 0--100 psig Pres Transducer 36920825 Book No. 23307366 (06/08)

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