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

Doosan Ingersoll Rand XP185WIR Electronic Service Manual

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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
1293 Glenway Drive
Statesville, N.C. 28625
www.doosanportablepower.com
Book: 23307366 (1-09) Rev B
Revised (10-12)
XP185WIR
P260WIR
7/51
7/71
12/56
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 Ingersoll-Rand Company in this manual is historical or nominative in nature, and is not meant to suggest a current affiliation between www.doosanportablepower.com Ingersoll-Rand Company and Doosan Company or the products of either. Book: 23307366 (1-09) Rev B Revised (10-12)

  • Page 2: Table Of Contents

       Table of Contents  SECTION 1  ............................ 5  GENERAL INFORMATION  ...................... 5  Operational Theory  ........................ 6  Key Electrical Component Functions  ................... 12  OPERATIONAL INFORMATION  .................... 13  Power On ............................. 13  Pre-Heat ............................ 13  Startup ............................ 13  Load .............................. 13  Shut Down ........................... 13  SECTION 2  .......................... 14  COMPRESSOR and ENGINE DIAGNOSTIC CODES  ............ 14  Engine Diagnostic Codes ...................... 16 ...
  • Page 3    Generator Switch “ON” (Optional)  .................. 26  COMPRESSOR CODE H...................... 28  Pre-Heat Signal or Start Signal Detected ................ 28  COMPRESSOR CODE 1 ...................... 30  High Airend Discharge Temperature ................... 30  COMPRESSOR CODE 2 ...................... 32  High Separator Temperature .................... 32  COMPRESSOR CODE 3 ...................... 34  Low Battery Voltage ....................... 34  COMPRESSOR CODE 4 ...................... 36  High Engine Coolant Temperature .................. 36  COMPRESSOR CODE 5 ...................... 38 ...
  • Page 4    Troubleshooting Steps  ...................... 54  SECTION 5  .......................... 55  SYSTEM SCHEMATICS & WIRING DIAGRAMS .............. 55  SECTION 6  .......................... 62  ELECTRICAL COMPONENT LOCATIONS ................ 62  Harness Connector Locations .................... 65  SECTION 7  .......................... 66  ELECTRICAL PARTS LIST ...................... 66  SECTION 8  .......................... 68  HARNESS CONNECTOR & CONNECTOR PARTS INFORMATION  ....... 68  Harness Connector Information ...
  • Page 5    G1-P Alternator Tachometer Output Terminal (Full Option Harness Only)  .... 71  P2 Yanmar Engine ECM Connector ................ 71  P4 Rack Actuator Connector .................... 72  P6 Engine Coolant Temperature Sensor Connector............. 72  P7 Cold Start Device Solenoid Connector  .............. 72  P15 4-In-1 Gauge Connector (Full Option Harness Only) ........... 72  S4 Engine Coolant Temperature Switch Terminals ............ 72 ...

  • Page 6: Section 1

       SECTION 1 GENERAL INFORMATION Manual No.  23307366 (1‐09) Rev. B     Page 5 ...

  • Page 7: Operational Theory

       Operational Theory The P185/P260WIR machine has an electronic monitor and control system that is used to provide discharge air pressure control and manage monitor functions. The system uses the SECU controller to perform these functions. The electrical system connects all the necessary switches, sensors and transducers to the controller in order for it to perform the monitor and control functions.
  • Page 8    Sensors and Transducers The electronics system contains a transducer and switches that are used to monitor the compressor. Various machine temperatures are monitored using temperature switches that open when the switch exceeds its threshold. The open switch disconnects battery voltage input to the SECU controller indicating a problem.
  • Page 9 The SECU diagnostics connector is located near the SECU controller and is used to connect Doosan/IR diagnostic and reprogramming tools. Electrical System The schematic diagrams show the wiring harness connections. Figure 2-1 is a system schematic showing harness connection with devices and controllers.
  • Page 10    Manual No.  23307366 (1‐09) Rev. B     Page 9 ...
  • Page 11    Manual No.  23307366 (1‐09) Rev. B     Page 10 ...
  • Page 12    Manual No.  23307366 (1‐09) Rev. B     Page 11 ...

  • Page 13: Key Electrical Component Functions

       Key Electrical Component Functions PS1 is a 0-100 psi gauge pressure transducer that measures PS1: regulation system pressure. S2 is a 248 F/120 C NC temperature switch that monitors separator tank temperature. S3 is a 248 F/120 C NC temperature switch that monitors airend discharge temperature.

  • Page 14: Operational Information

       OPERATIONAL INFORMATION Power On When the Ignition switch is turned to the “ON” position: 1. Engine ECM energizes the Engine ECM power relay (K3). 2. Engine ECM energizes the Fuel Rack Actuator relay (K4). Pre-Heat When the Ignition switch is turned to the “PRE-HEAT” position: 1.

  • Page 15: Compressor And Engine Diagnostic Codes

       SECTION 2 COMPRESSOR and ENGINE DIAGNOSTIC CODES Manual No.  23307366 (1‐09) Rev. B     Page 14 ...
  • Page 16    COMPRESSOR DIAGNOSTIC DISPLAY CODES Small Electronic Control Unit (SECU)             Center Bar Blinking Compressor is ready to start (no faults) Engine Model Not Compressor will start and operate with a 1700-2300 rpm range. Recognized Engine ECM SECU cannot communicate with engine ECM over J1939 CAN BUSS.

  • Page 17: Engine Diagnostic Codes

       Engine Diagnostic Codes • Failure flashes can be read on the Engine Failure Lamp when the on/off ignition switch is “ON" or when the unit is running. • The Engine Failure Lamp is located behind the front end panel. •...

  • Page 18: Section 3

       SECTION 3 TROUBLESHOOTING COMPRESSOR DIAGNOSTIC CODES Manual No.  23307366 (1‐09) Rev. B     Page 17 ...
  • Page 19    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 20: Measuring Voltage, Resistance, Frequency And Duty Cycle

       MEASURING VOLTAGE, RESISTANCE, FREQUENCY AND DUTY CYCLE 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 21: Troubleshooting Flow Chart

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

  • Page 22: Compressor Code

       COMPRESSOR CODE - Center Bar on Display Blinking Explanation: The SECU has not received any active fault codes and is ready to start. Effect: Code - is an INDICATION condition that the machine is ready to start. Manual No.  23307366 (1‐09) Rev. B     Page 21 ...

  • Page 23: Compressor Code A

       COMPRESSOR CODE A Engine Model Not Recognized Explanation: The SECU has not received the engine model number from the engine ECM. Effect: Code A is an ALERT condition and will not stop the machine, however the machine will start and operate at a default rpm range of 1700-2300. This rpm may not be correct for certain machine models.

  • Page 24: Compressor Code C

       COMPRESSOR CODE C Engine ECM Communication Failure Explanation: The SECU cannot communicate with the engine ECM via J1939 CAN BUS network. Effect: Code C is a SHUTDOWN condition and will stop the machine. SECU to Engine ECM J1939 CAN BUS circuit: Manual No.  23307366 (1‐09) Rev. B    ...
  • Page 25    Circuit Description: The J1939 CAN BUS twisted pair conductor connects the SECU controller and the engine ECM together as shown in the circuit above. The yellow wire is referred to as J1939 CAN High (+). The green wire is referred to as J1939 CAN Low (-). The twisted pair conductors are the communications link between the SECU and all devices connected to it.
  • Page 26    Troubleshooting Steps Action Result Step 1: Check fuse F2. Replace fuse as needed Step 2: Verify battery + and – connections to the engine ECM. Repair harness as needed Step 3: Turn ignition switch S1 to the “ON” position. Using a Voltage measure should be 12 VDC multimeter, measure the ignition switch signal voltage at P2- at P2-G4.

  • Page 27: Compressor Code E

       COMPRESSOR CODE E Generator Switch “ON” (Optional) Explanation: The SECU has received an input indicating the Generator Enable Switch is turned “ON” at startup. Effect: Code E is a SHUTDOWN condition and will prevent cranking. SECU to S25 Generator Enable Switch circuit: Manual No.  23307366 (1‐09) Rev. B    ...
  • Page 28    Circuit Description: The generator enable switch connects to the SECU controller as shown in the circuit above. S25 is a single pole single throw latching switch. When the switch is closed it connects the SECU input to battery-. Component Location: S25 toggle switch is located on the control panel.

  • Page 29: Compressor Code H

       COMPRESSOR CODE H Pre-Heat Signal or Start Signal Detected Explanation: The SECU has received an input indicating the S1 ignition switch has been switched to the Pre-Heat position or Start position. Effect: Code H is an INDICATION condition that the machine is in Pre-Heat mode or Start mode.
  • Page 30    COMPRESSOR CODE H Troubleshooting Steps Action Result Step 1: No voltage should be measured. Disconnect S1 ignition switch from the harness. Using a multimeter, measure the voltage at: If voltage is measured, check 1. SECU connector (P1-14). harness for shorts to battery+ 2.

  • Page 31: High Airend Discharge Temperature

       COMPRESSOR CODE 1   High Airend Discharge Temperature Explanation: The SECU has detected an open switch contact from S3 temperature switch. Effect: Code 1 is a SHUTDOWN condition and will stop the machine.   SECU to S3 Temperature Switch circuit: Manual No.  23307366 (1‐09) Rev. B    ...
  • Page 32       Circuit Description: The temperature switch connects to the SECU controller as shown in the circuit above. S3 is a normally closed temperature switch that opens when the temperature rises above F/120 C. When the switch opens, the input to the SECU is disconnected from switched battery+.

  • Page 33: High Separator Temperature

       COMPRESSOR CODE 2 High Separator Temperature Explanation: The SECU has detected an open switch contact from S2 temperature switch. Effect: Code 2 is a SHUTDOWN condition and will stop the machine.   SECU to S2 Temperature Switch circuit: Manual No.  23307366 (1‐09) Rev. B     Page 32 ...
  • Page 34    Circuit Description: The temperature switch connects to the SECU controller as shown in the circuit above. S2 is a normally closed temperature switch that opens when the temperature rises above F/120 C. When the switch opens, the input to the SECU is disconnected from switched battery+.

  • Page 35: Low Battery Voltage

       COMPRESSOR CODE 3 Low Battery Voltage Explanation: The SECU has detected a battery voltage that is below 11.6 VDC. Effect: Code 3 is an ALERT condition and will not stop the machine. Alternator Circuit: Manual No.  23307366 (1‐09) Rev. B     Page 34 ...
  • Page 36    Circuit Description: The Alternator charging system connects to the SECU controller as shown in the circuit above. The IG terminal on the alternator is the ignition circuit, driven by the SECU, to start the alternator charging. The switched battery voltage to the SECU from the ignition is used by the SECU to measure system battery voltage.

  • Page 37: High Engine Coolant Temperature

       COMPRESSOR CODE 4   High Engine Coolant Temperature Explanation: The SECU has detected an open switch contact from S4 temperature switch. Effect: Code 4 is a SHUTDOWN condition and will stop the machine.   SECU to S4 Temperature Switch circuit: Manual No.  23307366 (1‐09) Rev. B    ...
  • Page 38       Circuit Description: The temperature switch connects to the SECU controller as shown in the circuit above. S4 is a normally closed temperature switch that opens when the temperature rises above F/110 C. When the switch opens the input to the SECU is disconnected from switched battery+.

  • Page 39: Low Engine Oil Pressure

       COMPRESSOR CODE 5   Low Engine Oil Pressure Explanation: The SECU has detected an open switch contact from S5 pressure switch. Effect: Code 5 is a SHUTDOWN condition and will stop the machine.   SECU to S5 Pressure Switch circuit: Manual No.  23307366 (1‐09) Rev. B    ...
  • Page 40    Circuit Description: The pressure switch connects to the SECU controller as shown in the circuit above. S5 is a normally open pressure switch that closes when the pressure rises above 12 psi/0.83 bar. When the switch opens the input to the SECU is disconnected from switched battery+. Component Location: S5 pressure switch is located on the engine in the oil galley.

  • Page 41: Ps1, Regulation Pressure Sensor Fault

       COMPRESSOR CODE 6 PS1, Regulation Pressure Sensor Fault  Explanation: The SECU has detected an out of range reading from the PS1 pressure sensor for 3 seconds while the machine is running. Effect: Code 6 is a SHUTDOWN condition and will stop the machine. PS1 Pressure Sensor Circuit: ...
  • Page 42    Troubleshooting Steps  Action Result Step 1: Check all harness connections between SECU and PS1 Repair harness as needed pressure sensor. Step 2: Turn the S1 ignition switch to the “ON” position. Using a Voltage measured should be 5 VDC multimeter,measure the voltage at PS1-2. If not, check harness connections Continuity should be shorted Using a multimeter, measure continuity from PS1-1 to battery-.

  • Page 43: Low Engine Speed

       COMPRESSOR CODE 7 Low Engine Speed  Explanation: The SECU has received an engine speed value less than 1500 RPM for 10 seconds from the engine ECM. Effect: Code 7 is a SHUTDOWN condition and will stop the machine. Troubleshooting Steps Action Result Step 1: Dirty fuel filters...

  • Page 44: Low Fuel Level (Optional)

       COMPRESSOR CODE 8  Low Fuel Level (optional)  Explanation: The SECU has detected an open switch contact from U1 fuel level shutdown/gauge sender. Effect: Code 8 is a SHUTDOWN condition and will stop the machine.   SECU to U1 Fuel Level Shutdown/Gauge Sender: Manual No.  23307366 (1‐09) Rev. B    ...
  • Page 45    Circuit Description: The low fuel level shutdown/gauge sender connects to the SECU controller as shown in the circuit above. U1 shutdown switch contacts are normally closed and when the fuel level falls below the lower limit the contacts open. When the switch opens the input to the SECU is disconnected from switched battery+.

  • Page 46: High Air Filter Pressure (Optional)

       COMPRESSOR CODE 9  High Air Filter Pressure (optional)  Explanation: The SECU has detected a closed switch contact from S6 and or S7 pressure switch. Effect: Code 9 is an ALERT condition and will not stop the machine. SECU to S6 and S7 Pressure Switch circuit:  Manual No.  23307366 (1‐09) Rev. B     Page 45 ...
  • Page 47       Circuit Description: The SECU receives a battery+ input from the air filter restriction switch (S6 and or S7) 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. Component Location: S7 air filter restriction switch is located behind the engine air filter housing.

  • Page 48: Section 4

       SECTION 4 TROUBLESHOOTING ELECTRICAL CIRCUITS Manual No.  23307366 (1‐09) Rev. B     Page 47 ...

  • Page 49: Troubleshooting Procedures And Techniques

       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 50: Engine Start Circuit

       Engine Start Circuit  Circuit Description: The SECU controls engine starter engagement using a 12 VDC input from the ignition switch (S1) and a 12 VDC output to the engine ECM. The engine ECM provides ground to the K1 relay coil, causing the relay to activate and energizing the starter solenoid. The SECU provides starter protection by turning off the output to the engine ECM when engine speed reaches 200 RPM even if the operator is still holding the ignition switch in the start position.

  • Page 51: Troubleshooting Steps If Starter Does Not Engage During Crank

       Troubleshooting Steps If Starter Does Not Engage During Crank  Action Result Step 1: Check display for fault codes. Clear fault codes by following instructions in this manual Step 2: Check F1 fuse. Replace fuse if needed Step 3: Check all harness connections throughout engine start Repair harness as needed circuit.

  • Page 52: Engine Ecm Power Relay Circuit

       Engine ECM Power Relay Circuit Circuit Description: When the ignition switch S1 is turned to the “ON” position, the engine ECM provides ground to the K3 relay coil causing the relay to energize. K3 relay provides the battery+ power to the engine ECM.

  • Page 53: Troubleshooting Steps

       Engine ECM Power Relay Circuit  Troubleshooting Steps   Action Result Step 1: Replace fuse if needed  Check F2 fuse. Step 2: Repair harness as needed  Check all harness connections throughout engine ECM power relay circuit. Step 3: Voltage measured should be 12  Using a multimeter, measure the voltage at: VDC  1. K3 relay connector (K3-2). 2.

  • Page 54: Engine Inlet Heater Circuit

       Engine Inlet Heater Circuit Manual No.  23307366 (1‐09) Rev. B     Page 53 ...

  • Page 55: Troubleshooting Steps

       Engine Inlet Heater Circuit  Circuit Description: The SECU controls the engine inlet heater using a 12 VDC output to energize heater relay coil (K2). When the ignition switch is turned to the “Pre-Heat” position, the SECU energizes the inlet heater relay, which turns on the inlet heaters. The inlet heater is disabled after 30 seconds even if the operator is still holding the ignition switch in the “Pre-Heat’...

  • Page 56: Section 5

       SECTION 5 SYSTEM SCHEMATICS & WIRING DIAGRAMS   Manual No.  23307366 (1‐09) Rev. B     Page 55 ...
  • Page 57    Manual No.  23307366 (1‐09) Rev. B     Page 61 ...
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  • Page 63: Section 6

       SECTION 6 ELECTRICAL COMPONENT LOCATIONS Manual No.  23307366 (1‐09) Rev. B     Page 62 ...
  • Page 64    ELECTRICAL COMPONENT LOCATION Manual No.  23307366 (1‐09) Rev. B     Page 63 ...
  • Page 65    ELECTRICAL COMPONENT LOCATION SECU ENGINE Manual No.  23307366 (1‐09) Rev. B     Page 64 ...

  • Page 66: Harness Connector Locations

       Harness Connector Locations P1: 35 pin connector located on SECU controller P2: 48 pin connector located on engine ECM P3: 6 pin connector located on EGR motor P4: 6 pin connector located on Fuel Rack Actuator P5: 2 pin connector located on Speed Sensor P6: 2 pin connector located on Engine Coolant Temperature Sensor P7: 1 pin connector located on Cold Start Device Solenoid P8: 2 pin connector for termination resistor on J1939 CAN BUSS near SECU controller...

  • Page 67: Electrical Parts List

       SECTION 7 ELECTRICAL PARTS LIST Manual No.  23307366 (1‐09) Rev. B     Page 66 ...
  • Page 68    Reference Description Part Number Designator 0-100 psig Pressure Transducer 36920825 Ignition Switch 22127385 Replacement Knob Assembly 22134118 Temperature Switch 248 F/120 22823181 Temperature Switch 248 F/120 22823199 Temperature Switch 230 F/110 15898059 Pressure Switch NO 12 psi 54757935 Fuel Lift Pump 22226385 TR1, TR2 J1939 CAN Terminating Resistor...

  • Page 69: Harness Connector & Connector Parts Information

       SECTION 8 HARNESS CONNECTOR & CONNECTOR PARTS INFORMATION Manual No.  23307366 (1‐09) Rev. B     Page 68 ...

  • Page 70: Harness Connector Information

    Engine ECM connector. Check the Electrical Parts List section for individual replacement harness parts for certain items. If the connectors and connector parts are not in the kits above, the manufacturer part numbers and contact information will be provided. Manufacturer’s Part Included in Doosan Connector and Parts Manufacturer Service Kit Part No.

  • Page 71: J10-Cap Engine Communication Interface Connector

       Manufacturer’s Part Included in Doosan Connector and Parts Manufacturer Service Kit Part No. P10 Engine Communication Interface Connector  Plug, 6 way Deutsch DTM06-6S-E005 Wedgelock Deutsch WM-6S Socket size 20 Gold Deutsch 0462-201-2031 46490983 Sealing plug size 20 Deutsch 0413-204-2005 46490983 J10­Cap Engine Communication Interface Connector  Receptacle, 6 way...

  • Page 72: K2 Inlet Heater Relay

       Manufacturer’s Part Included in Doosan Connector and Parts Manufacturer Service Kit Part No. K2 Inlet Heater Relay Plug, 4 way Relay Packard 12065686 46491296 Terminal, 20-18 Awg Packard 12020156 46491296 Terminal, 12-10 Awg Packard 12033997 46491296 K3 Engine ECM Power Relay Connector...

  • Page 73: P4 Rack Actuator Connector

    S4 Engine Coolant Temperature Switch Terminals Terminal, Bullet .156” Dia 42142-1 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. Manual No.  23307366 (1‐09) Rev. B     Page 72 ...

  • Page 74: Harness Connector Information

       Harness Connector Information Contact For Packard and Molex Connector and Connector Parts: Power and Signal Group 6675 Parkland Blvd. Solon, OH 44139 1-800-722-5273 Contact For Deutsch Connector and Connector Parts: Ladd Industries. Inc. 4849 Hempstead Station Dr. Kettering, OH 45429 1-800-223-1236 Contact For AMP Connector and Connector Parts: AMP Incorporated...

  • Page 75: Service Tools And Repair Kits

       SECTION 9 SERVICE TOOLS and REPAIR KITS Manual No.  23307366 (1‐09) Rev. B     Page 74 ...

  • Page 76: Service Tools

    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 77    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 Packard Metri-Pack Terminal Crimp Tool 46490967 Used to crimp Packard 150-GT series connector terminals Packard Metri-Pack Terminal Crimp Tool 46490975 Used to crimp Packard 630 series connector terminals...

  • Page 78: 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 79: 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 80    Contact for Packard & Molex Tools: Power and Signal Group 6675 Parkland Blvd. Solon, OH 44139 1-800-722-5273 Contact For AMP Tools: AMP Incorporated Harrisburg, PA 17105 1-800-522-6752 Contact for Deutsch Tools: Ladd Industries. Inc. 4849 Hempstead Station Dr. Kettering, OH 45429 1-800-223-1236 Manual No.  23307366 (1‐09) Rev. B    ...

  • Page 81: Deutsch Crimp Tool Hdt-48-00 Instructions

       Deutsch Crimp Tool HDT­48­00 Instructions  Manual No.  23307366 (1‐09) Rev. B     Page 80 ...

  • Page 82: 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 83: 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 84: 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 85: 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. Push the contact straight into the connector grommet until a positive stop is felt.

  • Page 86: 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 87: Amp Crimp Tool 58440-1 Instructions

       AMP Crimp Tool 58440­1 Instructions  Manual No.  23307366 (1‐09) Rev. B     Page 86 ...
  • Page 88      AMP Crimp Tool 58440-1 Instructions Manual No.  23307366 (1‐09) Rev. B     Page 87 ...
  • Page 89    AMP Crimp Tool 58440-1 Instructions Manual No.  23307366 (1‐09) Rev. B     Page 88 ...
  • Page 90    AMP Crimp Tool 58440-1 Instructions Manual No.  23307366 (1‐09) Rev. B     Page 89 ...

  • Page 91: Amp Ampseal Series Connector Service Procedures

       AMP Ampseal Series Connector Service Procedures  Manual No.  23307366 (1‐09) Rev. B     Page 90 ...
  • Page 92    AMP Ampseal Series Connector Service Procedures Manual No.  23307366 (1‐09) Rev. B     Page 91 ...
  • Page 93    AMP Ampseal Series Connector Service Procedures Manual No.  23307366 (1‐09) Rev. B     Page 92 ...

  • Page 94: Molex Crimp Tool 0638118900 Instructions

       Molex Crimp Tool 0638118900 Instructions Manual No.  23307366 (1‐09) Rev. B     Page 93 ...
  • Page 95    Molex Crimp Tool 0638118900 Instructions Manual No.  23307366 (1‐09) Rev. B     Page 94 ...
  • Page 96    Molex Crimp Tool 0638118900 Instructions Manual No.  23307366 (1‐09) Rev. B     Page 95 ...
  • Page 97    Molex Crimp Tool 0638118900 Instructions Manual No.  23307366 (1‐09) Rev. B     Page 96 ...
  • Page 98    Molex Crimp Tool 0638118900 Instructions Manual No.  23307366 (1‐09) Rev. B     Page 97 ...

  • Page 99: Molex Crimp Tool 0638119200 Instructions

       Molex Crimp Tool 0638119200 Instructions Manual No.  23307366 (1‐09) Rev. B     Page 98 ...
  • Page 100    Molex Crimp Tool 0638119200 Instructions Manual No.  23307366 (1‐09) Rev. B     Page 99 ...
  • Page 101    Molex Crimp Tool 0638119200 Instructions Manual No.  23307366 (1‐09) Rev. B     Page 100 ...
  • Page 102    Molex Crimp Tool 0638119200 Instructions Manual No.  23307366 (1‐09) Rev. B     Page 101 ...
  • Page 103    Molex Crimp Tool 0638119200 Instructions Manual No.  23307366 (1‐09) Rev. B     Page 102 ...

  • Page 104: Molex Removal Tool 0638132400 Instructions

       Molex Removal Tool 0638132400 Instructions Manual No.  23307366 (1‐09) Rev. B     Page 103 ...
  • Page 105    Molex Removal Tool 0638132400 Instructions Manual No.  23307366 (1‐09) Rev. B     Page 104 ...

  • Page 106: Molex Removal Tool 0638132300 Instruction

       Molex Removal Tool 0638132300 Instruction Manual No.  23307366 (1‐09) Rev. B     Page 105 ...
  • Page 107    Molex Removal Tool 0638132300 Instruction Manual No.  23307366 (1‐09) Rev. B     Page 106 ...

  • Page 108: Section 11

       SECTION 11 RECOMMENDED SPARES Manual No.  23307366 (1‐09) Rev. B     Page 107 ...
  • Page 109    Recommended Spare Parts Quantity Description Part Number SECU Controller 23217185 0-100 psig Pressure Transducer 36920825 Temperature Switch 248°F/120°C 22823181 Temperature Switch 248°F/120°C 22823199 Temperature Switch 230°F/110°C 15898059 Pressure Switch NO 12 psi 54757935 Relay 12V DC SPDT 36878361 Relay 12V DC SPDT 23286610 Manual No.  23307366 (1‐09) Rev. B    ...

  • Page 110: Section 12

       SECTION 12 SOFTWARE INFORMATION Manual No.  23307366 (1‐09) Rev. B     Page 109 ...

  • Page 111: 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 Manual No.  23307366 (1‐09) Rev. B     Page 110 ...
  • Page 112 Doosan Infracore Portable Power 1293 Glenway Drive Statesville, North Carolina 28625 www.doosanportablepower.com ©2008 Doosan Infracore International, Printed in the USA...

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