Doosan Ingersoll Rand P425CWIR User manual

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

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Book: 23227143 (6-09) Rev BPage1
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
Reading and Setting Display Units......................................................................................20
Wedge Service Diagnostic Display......................................................................................21
Entering Machine ID for WEDGE Control Systems...........................................................21
Machine Models List...............................................................................................................23
SECTION 3 - Diagnostic Code Descriptions..........................................................................25
Compressor Diagnostic Display Codes...............................................................................27
CompressorDiagnosticLights...................................................................................................28
Delay......................................................................................................................................28
JohnDeereEngineModels4045HF285and6068HF285DiagnosticDisplayCodes.................29
SECTION 4 - Troubleshooting..................................................................................................33
Compressor Diagnostic Codes.............................................................................................34
Procedures and Techniques.................................................................................................34
Troubleshooting Flow Chart..................................................................................................36
COMPRESSOR CODE 1..........................................................................................................37
COMPRESSOR CODE 2..........................................................................................................38
COMPRESSOR CODE 3..........................................................................................................39
COMPRESSOR CODE 4..........................................................................................................40
COMPRESSOR CODE 10........................................................................................................42

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Book: 23227143 (6-09) Rev BPage2
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
COMPRESSOR CODE 73........................................................................................................65
SECTION 5 - Troubleshooting..................................................................................................67
Electrical Circuits....................................................................................................................68
Engine Start Circuit.................................................................................................................69
Air Filter Restriction Switch Circuit.......................................................................................70
SECTION 6 - System Schematics & Wiring Diagrams.........................................................73
John Deere Engine Models 4045HF285 and 6068HF285 Engine Harness Schematic
...................................................................................................................................................85
SECTION 7- Electrical Component Locations.......................................................................86
Harness Connector Locations..................................................................................................89
SECTION 8 - Electrical Parts List............................................................................................90
SECTION 9 - Harness Connector Information.......................................................................94
Electrical Torque Specifications...........................................................................................98
SECTION 10 - Tools and Repair Kits....................................................................................100
Service Tools and Repair Kits............................................................................................101
Connector Repair Kits..........................................................................................................103
Terminal Crimp Tool Usage................................................................................................104
Deutsch Crimp Tool HDT-48-00 Instructions.......................................................................105

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Book: 23227143 (6-09) Rev BPage3
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........................................................115
Molex Crimp Tool 0638118900 Instructions.........................................................................118
Molex Crimp Tool 0638119200 Instructions.........................................................................123
Molex Removal Tool 0638132400 Instructions....................................................................128
Molex Removal Tool 0638132300 Instruction......................................................................130
SECTION 11 - Recommended Spare Parts.........................................................................132
SECTION 12 - Software Information.....................................................................................134
SoftwareUpdates....................................................................................................................135

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Book: 23227143 (6-09) Rev BPage4

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

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Book: 23227143 (6-09) Rev BPage6
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.
WEDGE Controller
The WEDGE controller is the heart of the machine monitor and control system.
It provides data collection, alarming and control functions for compressor
operations. It is a microcontroller based unit with analog and digital inputs and
outputs.
The WEDGE controller is attached to a bracket mounted to the lifting bail inside
the machine over the fuel tank. A laminate is attached to the bracket to identify
the diagnostic lamps and the display.
The first function of the WEDGE controller is to scan all analog and digital inputs
at a fixed interval. These inputs are scanned every 50 milliseconds. The analog
values are then compared against minimum and maximum values and an ALERT
or SHUTDOWN is issued, if a value is out of range. The various ALERTS and
SHUTDOWNS are listed in this manual.
The second function of the WEDGE controller is machine discharge pressure
control. The WEDGE monitors the regulation system air pressure and varies the
engine throttle to maintain the setpoint discharge air pressure. The setpoint
pressure is set using the high pressure regulator and low pressure regulator.
The third function of the WEDGE controller is to communicate with the diesel
engine via the J1939 CAN network. The WEDGE controller retrieves diagnostic
information via the J1939 CAN Network.
The Engine Throttle Setting is sent from the WEDGE Analog Throttle Output to
the engine ECM. The throttle signal range is from 2.5 VDC (1500 rpm) to 3.9
VDC (2200 rpm).The WEDGE controller receives diagnostic and run time data
from the engine ECM over the J1939 CAN network. Figure 2-2 shows the
connections between the WEDGE controller and the engine ECM.

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Book: 23227143 (6-09) Rev BPage7
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. The resistance causes an input voltage change to the
WEDGE controller input and is interpreted as a temperature change.
The electronics system also uses pressure transducers to measure compressor
pressure changes. These devices have an output signal of 0.5 VDC to 4.5 VDC,
corresponding to 0 psi and the maximum measured psi for a particular device.
The devices are gauge pressure devices. These transducers are provided with 5
VDC excitation to power the device. These are three wire devices: excitation,
signal and ground.
Digital Inputs and Outputs
The WEDGE controller scans digital inputs such as switch contacts. These are
either 24 VDC or (0 VDC). These digital inputs are connected to switches within
the package.
The WEDGE controller provides 24 VDC digital outputs to control solenoids,
relays, and other devices. These are 24 VDC "ON" and 0 VDC "OFF". They are
current limited and short circuit protected.
Controller Outputs
The WEDGE controller has three types of outputs: frequency, pulse width
modulated (PWM) and 24 VDC digital (ON /OFF).
Pressure Control
The discharge pressure is controlled by manipulating the engine speed and
compressor inlet valve position. The inlet valve position is controlled
pneumatically and the engine speed is determined by the WEDGE controller.
The WEDGE measures the pneumatic system regulation pressure and computes
an engine throttle setting. This throttle setting is sent to the engine via the
frequency, PWM, Analog, or J1939 throttle, depending on which technique is
used. The engine controller will control engine speed to this throttle setting.

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Book: 23227143 (6-09) Rev BPage8
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.
J1939 Data Link
The CAN network is a single pair shielded cable located in the main chassis
harness. Figure 2-3 shows a layout of the CAN harness or "backbone" as it is
referred to. The termination resistors (Terminator) are important to prevent
reflections on the transmission line and must be in place for the network to
function properly.
The engine diagnostics connector is located near the engine ECM. This is used
to connect the engine manufacturer's service tools to the CAN network. This
connector also provides 24 VDC to power these service tools.
Electrical System
The electrical system consists of the wiring harnesses and associated electrical
devices such as relays, switches, lights and solenoids. There are two wiring
harnesses in the machines. They are as follows:
22984009 Main Chassis Harness (Models: P600WIR (7/170), HP450WIR
(10/125, VHP400WIR (14/115)
22969554 Main Chassis Harness (Models: P425WIR (7/120), XP375WIR
(9/110),HP350WIR (10/105) & (14/85).
22835680 Control Panel Wiring Harness (All Models)
The schematic diagrams show the connections for these harnesses. Figure 2-1
is a system schematic showing harness connection with devices and controllers.
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.

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Book: 23227143 (6-09) Rev BPage9
CHASSIS HARNESS Figure 2-1
WEDGE
CONTROLLER
P1
SOLENOID VALVES
PRESSURE SWITCHES
FUEL LEVEL SWITCH
PRESSURE SENSORS
TEMPERATURE SENSORS
BATTERY STARTING AND
CHARGING SYSTEM
ENGINE ECM
CONTROL PANEL
SWITCHES
HOURMETER
GAUGES
«
J4 P4
P425/P600 HARNESS SYSTEM SCHEMATIC
CONTROL PANEL HARNESS

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Book: 23227143 (6-09) Rev BPage10
WEDGE
CONTROLLER
WEDGE
CONTROLLER
J1939 CAN LOW (
-
)
J1939 CAN HIGH (
+
)
J1939
CAN SHIELD
KEY SWITCH SIGNAL
ANALOG THROTTLE RANGE = 2.5VDC (1500RPM) to 3.9 VDC (2200RPM)
J02-B1 J02-A1 J02-K2 ENGINE ECM J02-B2 J02-A4
P1-34
P1-35
P1-1
WEDGE
CONTROLLER
P1-24 P1-13
ANALOG THROTTLE
FIGURE 2-2
WEDGE TO ENGINE INTERFACE
IR ENGINE

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Book: 23227143 (6-09) Rev BPage11
ENGINE ECM WEDGE
CONTROLLER
J1939 CAN BUSS
COMMUNICATIONS SCHEMATIC
>> TERMINATOR
>>
CAN NODE with POWER
>>
P3 TR2 TR1 P2
TERMINATOR
J10 P10
FIGURE 2-3
ENGINE ECM COMMUNICATIONS
INTERFACE
C11

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Book: 23227143 (6-09) Rev BPage12
Key Electrical Component Functions
PT1: PT1 is a 0-500 psi gauge pressure transducer that measures
discharge air pressure.
PT2: PT2 is a 0-100 psi gauge pressure transducer that measures
regulation system pressure.
RT1: RT1 is a 10K ohm Thermistor type temperature sensor that
measures separator tank temperature.
RT2: RT2 is a 10K ohm Thermistor type temperature sensor that
measures airend discharge temperature.
K1: K1 is a SPST, 24 VDC relay used to engage the engine starter
solenoid.
K2: K2 is a SPST, 24 VDC relay used to energize the engine inlet
heater.
U1:
U1 is a resistive level detector and low level switch sensor used to
monitor fuel level. The resistive function drives the fuel gauge and
the switch function opens to shut the machine down on low fuel
level.

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Book: 23227143 (6-09) Rev BPage13
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. Engine Malfunction Diagnostic Light: Indicates ALERT or SHUTDOWN
displayed number is an Engine Diagnostic Code. (see WEDGE on inside
of machine)
3. Hourmeter: Indicates machine operating hours.
4. Discharge Air Pressure Gage: Indicates pressure in receiver tank,
normally from 0 psi(kPa) to the rated pressure of the machine.
5. Fuel Level Gauge: Indicates level of fuel in fuel tank.
6. Main Ignition Switch: ON/OFF Start Switch
9
4
12
35
6 7 8
10 11
13
12

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Book: 23227143 (6-09) Rev BPage14
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. (If equipped)
4 –IN-1 Gauge Assembly (if equipped)
10. Compressor Oil Temperature Gauge
11. Engine Oil Pressure Gauge
12. Engine Coolant Temperature Gauge
13. Battery Voltage Gauge
WEDGE Lights (located inside machine on bracket)
14. High Compressor Temperature Diagnostic Light: Indicates
SHUTDOWN due to high compressor temperature.
15. Low Engine Oil Pressure Diagnostic Light: Indicates ALERT or
SHUTDOWN due to low engine oil pressure.
16. High Engine Coolant Temperature Diagnostic Light: Indicates ALERT
or SHUTDOWN due to high engine coolant temperature.
19
14
15
16
17
18
20
21
22
23
24

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Book: 23227143 (6-09) Rev BPage15
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.
20. Restricted Air Filter Diagnostic Light: ALERT indication
engine/compressor air inlet filters need service. (if equipped)
21. Restricted IQ Air Filters Diagnostic Light: Indicates SHUTDOWN due
to dirty IQ air filters (if equipped).
22. Compressor Malfunction Diagnostic Light: Indicates ALERT or
SHUTDOWN displayed number is a Compressor Diagnostic Code.
23. Engine Malfunction Diagnostic Light: Indicates ALERT or
SHUTDOWN displayed number is an Engine Diagnostic Code.
24. Data Input Switch: Momentary ON/OFF switch. Allows user to toggle
through WEDGE service diagnostic display, set display units, and set
machine ID.

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Book: 23227143 (6-09) Rev BPage16
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:
•Engine starter is energized.
•Start/Run solenoid valve (L1) is opened (energized).
When the engine speed reaches 600 RPM (engine start declared):
•Engine starter is de-energized.
•Engine speed is set to 1600 RPM.
When the engine speed reaches 1450 RPM:
•Start/Run solenoid valve (L1) is closed (de-energized).
•Unloader solenoid valve (L2) is opened (energized).
When the separator tank reaches 50 psi:
•Start/Run solenoid valve (L1) is opened (energized).
After 5 seconds:
•Engine speed is set to idle. (1600 RPM until engine coolant temperature reaches
100oF, then idle is set to 1500 RPM).
Load
When the Service Air switch is pressed:
•Engine speed is set to 2200 RPM.
When the engine speed reaches 2000 RPM:
•Start/Run solenoid valve (L1) is closed (de-energized).
After 2 seconds, if the regulation system pressure is 4 psi or greater:
•Engine speed control is engaged.

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Book: 23227143 (6-09) Rev BPage17
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:
•Engine starter is energized.
•Start/Run solenoid valve (L1) is opened (energized).
When the engine speed reaches 600 RPM (engine start declared):
•Engine starter is de-energized.
•Engine speed is set to 1600 RPM.
When the engine speed reaches 1450 RPM:
•Start/Run solenoid valve (L1) is closed (de-energized).
When the separator tank reaches 50 psi:
•Start/Run solenoid valve (L1) is opened (energized).
After 5 seconds:
•Engine speed is set to idle. (1600 RPM until engine coolant temperature reaches
100oF, then idle is set to 1500 RPM).
Load
When the Service Air switch is pressed:
•Engine speed is set to 2200 RPM.
When the engine speed reaches 2000 RPM:
•Start/Run solenoid valve (L1) is closed (de-energized).
After 2 seconds, if the regulation system pressure is 4 psi or greater:
•Engine speed control is engaged.

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Book: 23227143 (6-09) Rev BPage18

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