Doosan Ingersoll Rand P425CWIR Electronic Service Manual
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Doosan Ingersoll Rand P425CWIR Electronic Service Manual

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ELECTRONIC SERVICE MANUAL
P425WIR (7/120)
XP375WIR (9/110)
HP350WIR (10/105)
HP350WIR (14/85)
P600WIR (7/170)
HP450WIR (10/125)
VHP400WIR (14/115)
COMPRESSOR MODELS
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.
Doosan Infracore Portable Power
1293 Glenway Drive
Statesville, N.C. 28625
www.doosanportablepower.com
Book: 23227143 (6-09) Rev B
Revised (10-12)
Codes:
C46 (C95)
C48 (C94)
C47 (C96)
C47 (D17)
C54 (D18)
C55 (D19)
C56 (D20)

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Summary of Contents for Doosan Ingersoll Rand P425CWIR

  • Page 1 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. Doosan Infracore Portable Power 1293 Glenway Drive Statesville, N.C.

  • Page 2: Table Of Contents

       Table of Contents SECTION 1 – General Information .................... 5  Operational Theory  ........................ 6  WEDGE Controller ........................ 6  Key Electrical Component Functions  ................... 12  OPERATING CONTROLS AND INSTRUMENTS  .............. 13  Operational Information ...................... 16  Models ............................ 16  P600WIR (7/170), HP450WIR (10/125), & VHP400 (14/115) ......... 16  Models ............................ 17  P425WIR (7/120), XP375WIR (9/110), HP350WIR (10/105), & (14/85)  ...... 17  SECTION 2 - Settings ........................ 19 ...
  • Page 3    COMPRESSOR CODE 11 ...................... 43  COMPRESSOR CODE 29 ...................... 44  COMPRESSOR CODE 30 ...................... 45  COMPRESSOR CODE 32 ...................... 46  COMPRESSOR CODE 33 ...................... 48  COMPRESSOR CODE 34 ...................... 50  COMPRESSOR CODE 50 ...................... 51  COMPRESSOR CODE 51 ...................... 52  COMPRESSOR CODE 52 ...................... 53  COMPRESSOR CODE 53 ...................... 55  COMPRESSOR CODE 54 ...................... 57  COMPRESSOR CODE 56 ...................... 59  COMPRESSOR CODE 70 ...................... 60  COMPRESSOR CODE 71 ...................... 62 ...
  • Page 4    Deutsch DRC Series Connector Service Procedures  ............ 106  Deutsch DT Series Connector Service Procedures ............ 107  Deutsch DTM Series Connector Service Procedures  ............ 108  Deutsch HD10 Series Connector Service Procedures ............ 109  Deutsch HD30 and HDP20 Series Connector Service Procedures ......... 110  AMP Crimp Tool 58440-1 Instructions .................. 111  AMP Ampseal Series Connector Service Procedures ...
  • Page 5      Page 4  Book: 23227143 (6-09) Rev B...

  • Page 6: Section 1 - General Information

       SECTION 1 – General Information   Page 5  Book: 23227143 (6-09) Rev B...

  • Page 7: Operational Theory

       Operational Theory These machines have an electronic monitor and control system that is used to provide discharge air pressure control and monitor functions. The system uses the WEDGE controller to perform these functions. The electrical system connects all the necessary switches, sensors and transducers to the WEDGE controller in order for it to perform the monitor and control functions.
  • Page 8    Sensors and Transducers The electronics system contains sensors and transducers that are used to collect data from the compressor. The temperature is measured by thermistor and RTD type temperature sensors. These devices exhibit a change in resistance as the temperature changes.
  • Page 9    Electronic Engine These machines contain an emissions certified diesel engine. In order to meet the emissions requirements, the engine has an electronic control system. The control system handles all monitor, alarm and control functions for the engine. The WEDGE controller communicates with the engine controller over the J1939 CAN network.
  • Page 10    «   Page 9  Book: 23227143 (6-09) Rev B...
  • Page 11      Page 10  Book: 23227143 (6-09) Rev B...
  • Page 12      Page 11  Book: 23227143 (6-09) Rev B...

  • Page 13: Key Electrical Component Functions

       Key Electrical Component Functions PT1 is a 0-500 psi gauge pressure transducer that measures PT1: discharge air pressure. PT2 is a 0-100 psi gauge pressure transducer that measures PT2: regulation system pressure. RT1 is a 10K ohm Thermistor type temperature sensor that RT1: measures separator tank temperature.

  • Page 14: Operating Controls And Instruments

       OPERATING CONTROLS AND INSTRUMENTS The operating controls and instruments are arranged on the control panel as shown above. A description of each panel device is as follows: 1. Compressor Malfunction Diagnostic Light: Indicates ALERT or SHUTDOWN displayed number is a Compressor Diagnostic Code. (see WEDGE on inside of machine) 2.
  • Page 15    7. Service Air Switch: Momentary ON/OFF switch. Allows user to load compressor after engine warm-up. 8. Wait To Start Lamp: Indicates engine inlet heater is operating wait till lamp turns off before starting machine. 9. Engine Tachometer: Indicates engine speed in RPM from 0 when stopped to full speed.
  • Page 16    17. Low Fuel Level Diagnostic Light: Indicates ALERT or SHUTDOWN due to low fuel level. 18. Low Battery Voltage Diagnostic Light: ALERT indication battery or charging system requires service. 19. Numeric Display: Used to display diagnostic codes and machine operational parameters.

  • Page 17: Operational Information

       Operational Information Models P600WIR (7/170), HP450WIR (10/125), & VHP400 (14/115) Power On When the Ignition switch is turned to the “ON” position: • Keyswitch signal (24 VDC) supplied to engine ECM from WEDGE. Startup When the Ignition switch is turned to the “START” position: •...

  • Page 18: Models

       Operational Information Models P425WIR (7/120), XP375WIR (9/110), HP350WIR (10/105), & (14/85) Power On When the Ignition switch is turned to the “ON” position: • Keyswitch signal (24 VDC) supplied to engine ECM from WEDGE. Startup When the Ignition switch is turned to the “START” position: •...
  • Page 19      Page 18  Book: 23227143 (6-09) Rev B...

  • Page 20: Section 2 - Settings

       SECTION 2 - Settings   Page 19  Book: 23227143 (6-09) Rev B...

  • Page 21: Reading And Setting Display Units

       Reading and Setting 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 ignition switch turned “OFF” 2. Press and hold the "Service Air" Switch 3.

  • Page 22: Wedge Service Diagnostic Display

       Wedge Service Diagnostic Display The WEDGE controller provides a diagnostic capability that allows various machine parameters to be viewed on the numeric display. The diagnostic display can be accessed with the machine stopped or while it is operating. The “Data Input” switch located beside the WEDGE controller inside the unit is used to toggle through the list of parameters.
  • Page 23    For machines with the WEDGE controller mounted in the engine compartment, the rocker switch beside the WEDGE is used to enter the machine ID. If a machine ID other than 11 or 12 has been entered into the WEDGE, then the “Service Air”...

  • Page 24: Machine Models List

       Machine Models List Machine Models Machine ID North America Models P425CWIR HP375CWIR XP375CWIR EMEA Models 7/120CWIR 9/110CWIR 10/105CWIR 14/85CWIR North America Models P600BWIR HP450BWIR VHP400BWIR EMEA Models 7/170BWIR 10/125BWIR 14/115BWIR   Page 23  Book: 23227143 (6-09) Rev B...
  • Page 25      Page 24  Book: 23227143 (6-09) Rev B...

  • Page 26: Section 3 - Diagnostic Code Descriptions

       SECTION 3 - Diagnostic Code Descriptions   Page 25  Book: 23227143 (6-09) Rev B...
  • Page 27    Compressor and Engine Diagnostic Code Descriptions The following are descriptions of Compressor and Engine diagnostic codes. When a Compressor diagnostic code 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 “Operating Controls and Instruments”...

  • Page 28: Compressor Diagnostic Display Codes

       Compressor Diagnostic Display Codes Wedge Software Version 2.20 or greater Compressor Malfunction Diagnostic Light ALERT SHUTDOWN Light Light Condition Code Code Delay (Blinks) (Steady) Compressor Low Engine Speed Malfunction sec. Compressor High Engine Speed Malfunction sec. Compressor Engine Crank time Exceeded 0 sec.

  • Page 29: Compressor Diagnostic Lights

       Compressor Diagnostic Lights  Wedge Software Version 2.20 or greater Compressor ALERT/SHUTDOWN Diagnostic Lights ALERT SHUTDOWN Diagnostic Light Light (Blinks) Light (Steady) Delay  • • Compressor Malfunction • • Engine Malfunction • Low Fuel Level 3 sec. • Restricted Air Filters • Low Battery Voltage Low Engine Oil Pressure •...

  • Page 30: John Deere Engine Models 4045Hf285 And 6068Hf285 Diagnostic Display Codes

       John Deere Engine Models 4045HF285 and 6068HF285 Diagnostic  Display Codes  Engine Malfunction Diagnostic Light Code Definition Throttle #2 Signal Out of Range Throttle #1 Signal Out of Range Fuel Pressure Problem Water In Fuel Engine Oil Pressure Problem Manifold Air Temperature Problem Engine Coolant Temperature Problem Fuel Rail Pressure Problem ECU Power Down Error Fuel Temperature Problem Engine Speed Derate Condition Exists...
  • Page 31    Engine Malfunction Diagnostic Light Code Definition Injector #3 Problem Injector #4 Problem Injector #5 Problem Injector #6 Problem 1136 Engine ECU Temperature High 1347 Fuel Pump Pressurizing Problem 1569 Engine Protection De-rate 3509 Sensor Supply Voltage #1 Problem 3510 Sensor Supply Voltage #2 Problem 3511 Sensor Supply Voltage #3 Problem...
  • Page 32    John Deere 4045HF285 Engine ECM ALERT/SHUTDOWN Parameters Description Trip Point Low Engine Oil Pressure Less than .14psi (1kPa): 770 rpm Less than 19psi (132kPa): 775 rpm Warning Less than 31psi (212kPa): 1500 rpm Less than 37psi (256kPa): 2000 rpm Less than 42psi (291kPa): 2500 rpm Less than .14psi (1kPa): 770 rpm Less than 17psi (118kPa): 775 rpm...
  • Page 33      Page 32  Book: 23227143 (6-09) Rev B...

  • Page 34: Section 4 - Troubleshooting

       SECTION 4 - Troubleshooting   Page 33  Book: 23227143 (6-09) Rev B...

  • Page 35: Compressor Diagnostic Codes

       Compressor Diagnostic Codes 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.
  • Page 36    General Measuring Guidelines: Since the electrical system uses sealed connectors and splices, access of test points can be difficult. It is recommended 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 37: Troubleshooting Flow Chart

       Troubleshooting Flow Chart Ignition switch (S1) is turned to the Check F1 fuse “ON” position, WEDGE controller does Check wiring connections from S1 to not initialize. WEDGE controller Check battery voltage WEDGE controller initializes but there Verify fault code and or diagnostic is a fault code listed on the display and lamp is a COMPRESSOR malfunction or there is a diagnostic lamp on solid.

  • Page 38: Compressor Code 10

       COMPRESSOR CODE 1 Low Engine Speed Explanation: The WEDGE has received an engine speed value less than 1100 RPM for 30 seconds from the engine ECM. Effect: Code 1 is a SHUTDOWN condition and will stop the machine. The Compressor Malfunction light will be on solid, and Code 1 will be displayed.

  • Page 39: Compressor Code 11

       COMPRESSOR CODE 2 High Engine Speed Explanation: The WEDGE has received an engine speed value greater than 2300 RPM for 30 seconds from the engine ECM. Effect: Code 2 is a SHUTDOWN condition and will stop the machine. The Compressor Malfunction light will be on solid, and Code 2 will be displayed.

  • Page 40: Engine Crank Time Exceeded

       COMPRESSOR CODE 3 Engine Crank Time Exceeded Explanation: The user has attempted to crank the engine longer than 30 seconds. Effect: Code 3 is a SHUTDOWN condition and will prevent further cranking. The Compressor Malfunction light will be on solid, and Code 3 will be displayed. Troubleshooting Steps Action Result...

  • Page 41: Low Fuel Level

       COMPRESSOR CODE 4 Low Fuel Level Explanation: The WEDGE has detected an open switch contact from the U1 fuel level sensor. Effect: Code 4 is a SHUTDOWN condition and will stop the machine. The Low Fuel diagnostic lamp will be on solid, the Compressor Malfunction light will be on solid, and Code 4 will be displayed.
  • Page 42    COMPRESSOR CODE 4 Troubleshooting Steps Action Result Step 1: Add fuel if needed. Check fuel level in tank. Step 2: Repair harness as needed Check all harness connections between WEDGE and U1 fuel level sensor. Step 3: Resistance value measured Disconnect U1 from harness.

  • Page 43: Engine Not Responding To Throttle

       COMPRESSOR CODE 10 Engine Not Responding To Throttle Command Explanation: The engine has failed to reach target RPM within 10 seconds after starting. Effect: Code 10 is an ALERT condition and will not stop the machine, however minimum pressure will not be met and pressure control will not be engaged. The Compressor Malfunction light will be blinking, and Code 10 will be displayed.

  • Page 44: Too Many Start Attempts During Auto Start

       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 and the machine failed to start. Effect: Code 11 is a SHUTDOWN condition and will prevent further cranking. The Compressor Malfunction light will be on solid, and Code 11 will be displayed.

  • Page 45: Engine Shutdown: Reason Unknown

       COMPRESSOR CODE 29 Engine SHUTDOWN: Reason Unknown Explanation: The engine has shut down and the WEDGE did not detect a fault code from the engine ECM. Effect: Code 29 is a SHUTDOWN condition and will stop the machine. The Compressor Malfunction light will be on solid, and Code 29 will be displayed.

  • Page 46: Compressor Code 30

       COMPRESSOR CODE 30 High Airend Discharge Temperature Explanation: The WEDGE has detected a temperature from RT2 temperature sensor that is greater than or equal to 248 Effect: Code 30 is a SHUTDOWN condition and will stop the machine. The High Airend Discharge Temperature diagnostic light will be on solid, the Compressor Malfunction light will be on solid, and code 30 will be displayed.

  • Page 47: Fault (Rt2)

       COMPRESSOR CODE 32 RT2, Airend Discharge Temperature Sensor Fault Explanation: The WEDGE has detected an out of range reading from the RT2 temperature sensor. Effect: Code 32 is a SHUTDOWN condition and will stop the machine. The Compressor Malfunction light will be on solid, and Code 32 will be displayed. RT2 Temperature Sensor Circuit: Circuit Description: The temperature sensor connects to the WEDGE controller as shown in the...

  • Page 48: Compressor Code 32

       COMPRESSOR CODE 32 Troubleshooting Steps Action Result Step 1: Repair harness as needed Check all harness connections between WEDGE and RT2 temperature sensor. Step 2: If temperature value on display Disconnect RT2 from harness and plug thermistor 6 is not between -3 F and simulator (Part No.

  • Page 49: Compressor Code 33

       COMPRESSOR CODE 33 PT1, Separator Tank Pressure Sensor Fault Explanation: The WEDGE has detected an out of range reading from the PT1 pressure sensor. Effect: Code 33 is an ALERT condition and will not stop the machine. The Compressor Malfunction light will be blinking, and Code 33 will be displayed.

  • Page 50: Compressor Code 34

       COMPRESSOR CODE 33 Troubleshooting Steps Action Result Step 1: Repair harness as needed Check all harness connections between WEDGE and PT1 pressure sensor. Step 2: If pressure value on display 5 Disconnect PT1 from harness and plug pressure is not between 186 psi and transducer simulator (Part No.
  • Page 51    COMPRESSOR CODE 34 Separator Tank Pressure Greater Than 20 psi at Crank Explanation: The WEDGE has detected a pressure from PT1 pressure sensor that is greater than 20 psi at the time of engine crank. Effect: Code 34 is a SHUTDOWN condition and will prevent cranking until the separator tank pressure is below 20 psi.

  • Page 52: Compressor Code 50

       COMPRESSOR CODE 50 High Separator Tank Temperature Explanation: The WEDGE has detected a temperature from RT1 temperature sensor that is greater than or equal to 248 Effect: Code 50 is a SHUTDOWN condition and will stop the machine. The Compressor Malfunction light will be on solid, and Code 50 will be displayed.

  • Page 53: Compressor Code 51

       COMPRESSOR CODE 51 Machine ID Not Installed 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 the proper operational profile of a machine type. Absence of code 51 does not ensure the machine ID is correct.

  • Page 54: Compressor Code 52

       COMPRESSOR CODE 52 IQ Filter Restriction Explanation: The WEDGE has detected a closed switch contact from the IQ air filter S18 differential pressure switch. Effect: Code 52 is a SHUTDOWN condition and will stop the machine. The Restricted IQ Air Filter diagnostic light will be on solid, the Compressor Malfunction light will be on solid, and Code 52 will be displayed.
  • Page 55    COMPRESSOR CODE 52 Troubleshooting Steps Action Result Step 1: Clogged filter Check IQ air filter. Step 2: Repair harness as needed Check all harness connections between WEDGE and S18 differential pressure switch. Step 3: Resistance value measured Disconnect S18 from harness. Using a multimeter, should be open, if not replace measure resistance between across switch terminals S18 differential pressure...
  • Page 56    COMPRESSOR CODE 53 RT1, Separator Tank Temperature Sensor Fault Explanation: The WEDGE has detected an out of range reading from the RT1 temperature sensor. Effect: Code 53 is a SHUTDOWN condition and will stop the machine. The Compressor Malfunction light will be on solid, and Code 53 will be displayed. RT1 Temperature Sensor Circuit: Circuit Description: The temperature sensor connects to the WEDGE controller as shown in the...

  • Page 57: Compressor Code 53

       COMPRESSOR CODE 53 Troubleshooting Steps Action Result Step 1: Repair harness as needed Check all harness connections between WEDGE and RT2 temperature sensor. Step 2: If temperature value on display Disconnect RT1 from harness and plug thermistor 7 is not between -3 F and simulator (Part No.

  • Page 58: Compressor Code 54

       COMPRESSOR CODE 54 PT2, Regulation System Pressure Sensor Fault Explanation: The WEDGE has detected an out of range reading from the PT2 pressure sensor. Effect: Code 54 is an ALERT condition and will not stop the machine. The Compressor Malfunction light will be blinking, and Code 54 will be displayed.

  • Page 59: Compressor Code 56

       COMPRESSOR CODE 54 Troubleshooting Steps Action Result Step 1: Repair harness as needed Check all harness connections between WEDGE and PT2 pressure sensor. Step 2: If pressure value on display 4 Disconnect PT2 from harness and plug pressure is not between 33 psi and 43 transducer simulator (Part No.

  • Page 60: Compressor Code 70

       COMPRESSOR CODE 56 Minimum Start Pressure Not Met Explanation: The minimum start pressure (50 psi) has not been met within 20 seconds of machine start. Effect: Code 56 is an ALERT condition and will not stop the machine, however the machine will not load.

  • Page 61: Compressor Code 71

       COMPRESSOR CODE 70 Serial Communications Failure Explanation: The WEDGE has detected an RS232 serial link problem. The serial link is used to install software and to communicate with a test tool. Effect: Code 70 is an ALERT condition and will not stop the machine. The Compressor Malfunction light will be blinking, and Code 70 will be displayed.

  • Page 62: Compressor Code 73

       COMPRESSOR CODE 70 Troubleshooting Steps Action Result Step 1: Repair harness as needed Check all harness connections between WEDGE and J5 connector. Step 2: Substitute the current device (laptop or test tool) being used to communicate with the WEDGE with another one.

  • Page 63: Engine Ecm Communication Failure

       COMPRESSOR CODE 71 Engine ECM Communication Failure Explanation: The WEDGE cannot communicate with the engine ECM via J1939 CAN BUS network. Effect: Code 71 is a SHUTDOWN condition and will stop the machine. The Compressor Malfunction light will be on solid, and Code 71 will be displayed. WEDGE to Engine ECM J1939 CAN BUSS circuit: Circuit Description: The J1939 CAN BUSS cable connects the WEDGE controller and the engine...

  • Page 64: Compressor

       COMPRESSOR CODE 71 The CAN network has two terminating resistors TR1 and TR2. The resistance value of each terminator is 120 ohms. The terminators are connected together in parallel across the High (+) and Low (-) wires in the cable. When connected the resistance value between the High (+) and Low (-) wires is 60 ohms.
  • Page 65    connector pins Step 5: Continuity should be shorted Disconnect P1 connector from the WEDGE and J02 between P1-35 and J02-A1 connector from the engine ECM. Disconnect TR1 and TR2 from the harness. Using a multimeter, measure continuity between P1-35 and J02-A1. Using a multimeter, measure continuity between P1- 34 and J02-B1.

  • Page 66: Compressor

       COMPRESSOR CODE 73 Auto Start/Stop Controller Communication Failure Explanation: The WEDGE cannot communicate with the Auto Start/Stop Controller via J1939 CAN BUSS network. Effect: Code 73 is an ALERT condition and will not stop the machine. The Compressor Malfunction light will be blinking, and Code 73 will be displayed. WEDGE to Auto Start/Stop Controller J1939 CAN BUSS circuit: Circuit Description: The J1939 CAN BUSS cable connects the WEDGE controller and the Auto...

  • Page 67: Compressor

       COMPRESSOR CODE 73 Troubleshooting Steps Action Result Step 1: Replace fuse if needed Check fuse F9 to verify that it has not blown. Repair harness as needed Step 2: Check all harness connections at WEDGE and Auto Start/Stop Controller. Step 3: Resistance value measured Disconnect P1 connector from the WEDGE, J02...

  • Page 68: Section 5 - Troubleshooting

       SECTION 5 - Troubleshooting   Page 67  Book: 23227143 (6-09) Rev B...

  • Page 69: Electrical Circuits

       Electrical Circuits Engine Start Circuit   Page 68  Book: 23227143 (6-09) Rev B...
  • Page 70    Engine Start Circuit Circuit Description: The WEDGE controls engine starter engagement using a 24 VDC input from the ignition switch (S1) and a 24 VDC output to the starter relay coil (K1). The WEDGE provides starter protection by turning off the output to K1 relay coil when engine speed reaches 600 RPM even if the operator is still holding the ignition switch in the start position.

  • Page 71: Air Filter Restriction Switch Circuit

       Air Filter Restriction Switch Circuit   Page 70  Book: 23227143 (6-09) Rev B...
  • Page 72    Circuit Description: The WEDGE receives a battery ground input from the air filter restriction switch (S16 and or S17) when the switch closes signaling that the filters are clogged. The air filter restriction switch contacts are normally open. The contacts close when the air filter restriction reaches 20 inches of water.
  • Page 73      Page 72  Book: 23227143 (6-09) Rev B...

  • Page 74: Section 6 - System Schematics & Wiring Diagrams

       SECTION 6 - System Schematics & Wiring Diagrams   Page 73  Book: 23227143 (6-09) Rev B...
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  • Page 86: John Deere Engine Models 4045Hf285 And 6068Hf285 Engine Harness Schematic

       John Deere Engine Models 4045HF285 and 6068HF285 Engine Harness Schematic   Page 85  Book: 23227143 (6-09) Rev B...

  • Page 87: Section 7- Electrical Component Locations

       SECTION 7- Electrical Component Locations   Page 86  Book: 23227143 (6-09) Rev B...
  • Page 88    WEDGE   Page 87  Book: 23227143 (6-09) Rev B...
  • Page 89    ELECTRICAL COMPONENT LOCATION ENGINE   Page 88  Book: 23227143 (6-09) Rev B...

  • Page 90: Harness Connector Locations

       Harness Connector Locations P1: 40 pin connector located on WEDGE controller J02: 48 pin connector located on engine ECM J5: 9 pin connector for WEDGE RS232 communication, located near WEDGE controller P4/J4: 12 pin connector located at back of control panel P2: 3 pin connector for termination resistor on J1939 CAN BUSS near WEDGE controller P3: 3 pin connector for termination resistor on J1939 CAN BUSS near engine ECM C11: 9 pin connector for engine ECM service tool, located near engine ECM...

  • Page 91: Section 8 - Electrical Parts List

       SECTION 8 - Electrical Parts List   Page 90  Book: 23227143 (6-09) Rev B...
  • Page 92    Electrical Parts List Reference Description Part Number Designator RT1, RT2 Thermistor Temperature Sensor 23294820 0-500 psig Pressure Transducer 54765946 0-100 psig Pressure Transducer 36920825 Ignition Switch 22127385 Replacement Knob Assembly 22134118 Service Air Switch 22054076 Display Scroll Push Button 54475777 Solenoid Valve 24VDC NC 36840841...
  • Page 93    Chassis Harness Model: P600WIR (7/170), HP450 (10/125), 22984009 VHP400WIR (14/115) Trailer Harness 54761101 Control Panel Harness 22835680 Full Gauge Panel Harness (optional) 22251896 Air Filter Restriction Switch Harness (optional) 22251904 IQ Filter Switch Harness (optional) 22293484 Gauge Illumination Harness (optional) 22681845 Tachometer Harness (optional) 22261465...
  • Page 94      Page 93  Book: 23227143 (6-09) Rev B...

  • Page 95: Section 9 - Harness Connector Information

       SECTION 9 - Harness Connector Information   Page 94  Book: 23227143 (6-09) Rev B...
  • Page 96 Included in Manufacturer’s Part Connector and Parts Manufacturer Doosan Service Kit Part No. P1 WEDGE Connector Plug, 40 way Deutsch DRC16-40S 22252993...
  • Page 97    Included in Manufacturer’s Part Connector and Parts Manufacturer Doosan Service Kit Part No. Cable Seal Packard 15305351 46491296 J5 WEDGE Controller Communication Connector Receptacle, 9 way Deutsch HD10-9-96P 46490983 Connector Cap Deutsch HDC9-JDL082397 46490983 Pin size 16 Gold Deutsch...
  • Page 98 Quick Disconnects, Ring Terminals, and Butt Splices Most Common used Quick Disconnects, Ring Terminals, and Butt 22252969 Splices can be found in the Doosan Wire Terminal Service Kit. Contact For Packard and Molex Connector and Connector Parts: Power and Signal Group 6675 Parkland Blvd.

  • Page 99: Electrical Torque Specifications

       Electrical Torque Specifications Electronic Controller Connector Screw Torque Specifications Connector Manufacturer Description Torque Manufacturer Part Number WEDGE Controller Deutsch DRC16-40S 25 in.lbs Caterpillar C9,C15, & C18 Tier 3 Engine 776241-1 53 in.lbs Cummins QSL9 & QSC8.3 Tier 3 Deutsch DRC26-50S-04 25 in.lbs Engine ECM...
  • Page 100      Page 99  Book: 23227143 (6-09) Rev B...

  • Page 101: Section 10 - Tools And Repair Kits

       SECTION 10 - Tools and Repair Kits   Page 100  Book: 23227143 (6-09) Rev B...

  • Page 102: Service Tools And Repair Kits

    22282172 Used to remove John Deere ECM connector RS232 Heavy Duty Serial Cable 54740675 Used for communication connection to Doosan controllers Deutsch Terminal Removal Tool Size 20 54699640 Used to remove Deutsch size 20 terminals from connectors Deutsch Terminal Removal Tool Size 16...
  • Page 103    Packard Metri-Pack Terminal Removal Tool 46490959 Used to remove Packard Metri-Pack connector terminals Packard Weather-Pack Terminal Crimp Tool 22254734 Used to crimp Packard Weather-Pack connector terminals Packard Metri-Pack Terminal Crimp Tool 22216683 Used to crimp Packard 150 and 280 series connector terminals Packard Metri-Pack Terminal Crimp Tool 22255947 Used to crimp Packard 150 series pull-to-seat connector terminals...

  • Page 104: Connector Repair Kits

       Connector Repair Kits The following is a list of harness connector repair kits that can be purchased through Doosan Portable Power to service or repair the most common used connectors. Part Number Description Kit, Deutsch Connector Repair 46490983 Assortment of Deutsch connectors and terminals...

  • Page 105: Terminal Crimp Tool Usage

    The following chart shows which manufacturer’s crimp tool to use with each terminal when making repairs. Most of the common crimp tools are available through Doosan Portable Power. If the tools needed are not available through Doosan Portable Power, the manufacturer part numbers and contact information will be provided.

  • Page 106: Deutsch Crimp Tool Hdt-48-00 Instructions

       Deutsch Crimp Tool HDT-48-00 Instructions   Page 105  Book: 23227143 (6-09) Rev B...

  • Page 107: Deutsch Drc Series Connector Service Procedures

       Deutsch DRC Series Connector Service Procedures Contact Insertion 1. Grasp contact approximately 1.00" (25.4 mm) behind the contact crimp barrel. 2. Hold connector with rear grommet facing you. 3. Push contact straight into connector grommet until a positive stop is felt. A slight tug will confirm that it is properly locked in place.

  • Page 108: Deutsch Dt Series Connector Service Procedures

       Deutsch DT Series Connector Service Procedures Contact Insertion 1. Grasp crimped contact approximately (25.2 mm) one inch behind the contact barrel. 2. Hold connector with rear grommet facing you. 3. Push contact straight into connector grommet until a click is felt. A slight tug will confirm that it is properly locked in place.

  • Page 109: Deutsch Dtm Series Connector Service Procedures

       Deutsch DTM Series Connector Service Procedures Contact Insertion 1. Grasp crimped contact approximately 1.0" (25.4 mm) behind the contact barrel. 2. Hold connector with rear grommet facing you. 3. Push contact straight into connector grommet until a click is felt. A slight tug will confirm that it is properly locked in place.

  • Page 110: Deutsch Hd10 Series Connector Service Procedures

       Deutsch HD10 Series Connector Service Procedures Contact Insertion 1. Grasp the contact-wire assembly between the thumb and forefinger on the wire approximately one inch behind the contact crimp barrel. 2. Hold the connector with the rear grommet facing you. 3.

  • Page 111: Deutsch Hd30 And Hdp20 Series Connector Service Procedures

       Deutsch HD30 and HDP20 Series Connector Service Procedures Contact Insertion 1. Grasp contact approximately (25.4 mm) one inch behind the contact crimp barrel. 2. Hold connector with rear grommet facing you. 3. Push contact straight into connector grommet until a positive stop is felt. A slight tug will confirm that it is properly locked in place.

  • Page 112: Amp Crimp Tool 58440-1 Instructions

       AMP Crimp Tool 58440-1 Instructions   Page 111  Book: 23227143 (6-09) Rev B...
  • Page 113    AMP Crimp Tool 58440-1 Instructions   Page 112  Book: 23227143 (6-09) Rev B...
  • Page 114    AMP Crimp Tool 58440-1 Instructions   Page 113  Book: 23227143 (6-09) Rev B...
  • Page 115    AMP Crimp Tool 58440-1 Instructions   Page 114  Book: 23227143 (6-09) Rev B...

  • Page 116: Amp Ampseal Series Connector Service Procedures

       AMP Ampseal Series Connector Service Procedures   Page 115  Book: 23227143 (6-09) Rev B...
  • Page 117    AMP Ampseal Series Connector Service Procedures   Page 116  Book: 23227143 (6-09) Rev B...
  • Page 118    AMP Ampseal Series Connector Service Procedures   Page 117  Book: 23227143 (6-09) Rev B...

  • Page 119: Molex Crimp Tool 0638118900 Instructions

       Molex Crimp Tool 0638118900 Instructions   Page 118  Book: 23227143 (6-09) Rev B...
  • Page 120    Molex Crimp Tool 0638118900 Instructions   Page 119  Book: 23227143 (6-09) Rev B...
  • Page 121    Molex Crimp Tool 0638118900 Instructions   Page 120  Book: 23227143 (6-09) Rev B...
  • Page 122    Molex Crimp Tool 0638118900 Instructions   Page 121  Book: 23227143 (6-09) Rev B...
  • Page 123    Molex Crimp Tool 0638118900 Instructions   Page 122  Book: 23227143 (6-09) Rev B...

  • Page 124: Molex Crimp Tool 0638119200 Instructions

       Molex Crimp Tool 0638119200 Instructions   Page 123  Book: 23227143 (6-09) Rev B...
  • Page 125    Molex Crimp Tool 0638119200 Instructions   Page 124  Book: 23227143 (6-09) Rev B...
  • Page 126    Molex Crimp Tool 0638119200 Instructions   Page 125  Book: 23227143 (6-09) Rev B...
  • Page 127    Molex Crimp Tool 0638119200 Instructions   Page 126  Book: 23227143 (6-09) Rev B...
  • Page 128    Molex Crimp Tool 0638119200 Instructions   Page 127  Book: 23227143 (6-09) Rev B...

  • Page 129: Molex Removal Tool 0638132400 Instructions

       Molex Removal Tool 0638132400 Instructions   Page 128  Book: 23227143 (6-09) Rev B...
  • Page 130    Molex Removal Tool 0638132400 Instructions   Page 129  Book: 23227143 (6-09) Rev B...

  • Page 131: Molex Removal Tool 0638132300 Instruction

       Molex Removal Tool 0638132300 Instruction   Page 130  Book: 23227143 (6-09) Rev B...
  • Page 132    Molex Removal Tool 0638132300 Instruction   Page 131  Book: 23227143 (6-09) Rev B...

  • Page 133: Section 11 - Recommended Spare Parts

       SECTION 11 - Recommended Spare Parts   Page 132  Book: 23227143 (6-09) Rev B...
  • Page 134    Recommended Spare Parts Quantity Description Part Number WEDGE Controller 22173579 Thermistor Temperature Sensor 23294820 0-100 psig Pressure Transducer 36920825 0-500 psig Pressure Transducer 54765946 Solenoid Valve 24VDC NC 36840841   Page 133  Book: 23227143 (6-09) Rev B...

  • Page 135: Section 12 - Software Information

       SECTION 12 - Software Information   Page 134  Book: 23227143 (6-09) Rev B...

  • Page 136: Software Updates

       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 website address is: WWW.irembedded.com   Page 135  Book: 23227143 (6-09) Rev B...
  • Page 137         Doosan Infracore Portable Power 1293 Glenway Drive Statesville, N.C. 28625 www.doosanportablepower.com...

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