Doosan Ingersoll Rand XP185WIR User manual
ELECTRONIC SERVICE MANUAL
Doosan Infracore Portable Power
1293 Glenway Drive
Statesville, N.C. 28625
www.doosanportablepower.com
Book: 23307366 (1-09) Rev B
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.
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.
Revised (10-12)
ManualNo.23307366(1‐09)Rev.B Page1
TableofContents
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
SECTION 3..................................................................................................................................17
TROUBLESHOOTING COMPRESSOR DIAGNOSTIC CODES........................................17
MEASURING VOLTAGE, RESISTANCE, FREQUENCY AND DUTY CYCLE................19
General Measuring Guidelines.............................................................................................19
Measuring Voltage..................................................................................................................19
Measuring Resistance...........................................................................................................19
Measuring Frequency:...........................................................................................................19
Measuring Duty Cycle:...........................................................................................................19
Troubleshooting Flow Chart......................................................................................................20
COMPRESSOR CODE -...........................................................................................................21
Center Bar on Display Blinking.............................................................................................21
COMPRESSOR CODE A..........................................................................................................22
Engine Model Not Recognized.............................................................................................22
COMPRESSOR CODE C..........................................................................................................23
Engine ECM Communication Failure..................................................................................23
COMPRESSOR CODE E..........................................................................................................26
ManualNo.23307366(1‐09)Rev.B Page2
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
Low Engine Oil Pressure.......................................................................................................38
COMPRESSOR CODE 6..........................................................................................................40
PS1,RegulationPressureSensorFault......................................................................................40
PS1PressureSensorCircuit:......................................................................................................40
COMPRESSOR CODE 7..........................................................................................................42
LowEngineSpeed......................................................................................................................42
COMPRESSOR CODE 8..........................................................................................................43
LowFuelLevel(optional)...........................................................................................................43
COMPRESSOR CODE 9..........................................................................................................45
HighAirFilterPressure(optional).............................................................................................45
SECUtoS6andS7PressureSwitchcircuit:...............................................................................45
SECTION 4..................................................................................................................................47
TROUBLESHOOTING ELECTRICAL CIRCUITS.................................................................47
Troubleshooting Procedures and Techniques.......................................................................48
EngineStartCircuit....................................................................................................................49
TroubleshootingStepsIfStarterDoesNotEngageDuringCrank.............................................50
EngineECMPowerRelayCircuit...................................................................................................52
TroubleshootingSteps...........................................................................................................52
EngineInletHeaterCircuit............................................................................................................54
ManualNo.23307366(1‐09)Rev.B Page3
TroubleshootingSteps...........................................................................................................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
HarnessConnectorInformation....................................................................................................69
P1SECUConnector................................................................................................................69
J14SECUControllerCommunicationConnector...................................................................69
S1IgnitionSwitchConnector................................................................................................69
PS1PressureSensorConnector............................................................................................69
P13AccessoryConnector(FullOptionHarnessOnly)...........................................................69
J13‐CapAccessoryConnector(FullOptionHarnessOnly)....................................................69
J10‐CapEngineCommunicationInterfaceConnector...........................................................70
P8,P9J1939CANTerminatorConnector..............................................................................70
TR1,TR2J1939CANTerminators
..........................................................................................70
J12-Cap Generator Enable Connector............................................................................70
B2 Fuel Lift Pump Connector............................................................................................70
U1 Low Fuel Shutdown/Gauge Sender Connector.......................................................70
U1-Jumper Low Fuel Shutdown/Gauge Sender Jumper Connector (Standard
Harness Only).....................................................................................................................70
K1 Engine Starter Relay....................................................................................................70
K2 Inlet Heater Relay.........................................................................................................71
K3 Engine ECM Power Relay Connector.......................................................................71
K4 Rack Actuator Relay Connector.................................................................................71
F1 Main Fuse Connector...................................................................................................71
F2 Engine ECM Fuse Connector.....................................................................................71
G1-IG Alternator Connector..............................................................................................71
ManualNo.23307366(1‐09)Rev.B Page4
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
Harness Connector Information................................................................................................73
SECTION 9..................................................................................................................................74
SERVICE TOOLS and REPAIR KITS.....................................................................................74
ServiceTools..................................................................................................................................75
ConnectorRepairKits....................................................................................................................77
TerminalCrimpToolUsage...........................................................................................................78
DeutschCrimpToolHDT‐48‐00Instructions.................................................................................80
DeutschDRCSeriesConnectorServiceProcedures......................................................................81
DeutschDTSeriesConnectorServiceProcedures........................................................................82
DeutschDTMSeriesConnectorServiceProcedures.....................................................................83
DeutschHD10SeriesConnectorServiceProcedures....................................................................84
DeutschHD30andHDP20SeriesConnectorServiceProcedures.................................................85
AMPCrimpTool58440‐1Instructions..........................................................................................86
AMPAmpsealSeriesConnectorServiceProcedures....................................................................90
Molex Crimp Tool 0638118900 Instructions...........................................................................93
Molex Crimp Tool 0638119200 Instructions...........................................................................98
Molex Removal Tool 0638132400 Instructions....................................................................103
Molex Removal Tool 0638132300 Instruction......................................................................105
SECTION 11..............................................................................................................................107
RECOMMENDED SPARES....................................................................................................107
SECTION 12..............................................................................................................................109
SOFTWARE INFORMATION.................................................................................................109
SoftwareUpdates........................................................................................................................110
ManualNo.23307366(1‐09)Rev.B Page5
SECTION 1
GENERAL INFORMATION
ManualNo.23307366(1‐09)Rev.B Page6
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.
SECU Controller
The 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 controller has a LED display for diagnostics. A number, 1-9, is shown to indicate a system
problem.
The first function of the controller is to scan all analog and digital inputs at a fixed interval. These
inputs are scanned every 10 milliseconds. The values are then compared against minimum and
maximum values and an ALERT or SHUTDOWN is issued, if a value is out of range. The
controller will indicate ALERTS and SHUTDOWNS for compressor system. These are indicated
through fault codes that are displayed on the SECU LED display.
The second function of the controller is to communicate with the diesel engine controller via the
J1939 CAN network. The CAN communication controls engine speed, start-up functions, and
start-up parameters as follows.
Engine Speed Control
The controller 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 regulator on
the separator tank.
Start Control
•Starter Protection
•Fuel Pump
•Start instructions to engine controller
•Inlet heater (glow plug) control
•Store diagnostic information
•Sets correct operating speeds based on compressor model
•Generator speed control
Start –Up
During SECU/power-up, the 8 digit lights to check the display. Next, the display will step through
the 3 digit software revision.
Figure 2-2 shows the connections between the engine controller and the SECU controller.
ManualNo.23307366(1‐09)Rev.B Page7
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.
The electronics system uses a pressure switch to monitor engine oil pressure. The pressure
switch opens when the oil pressure is below its threshold. The open switch disconnects battery
voltage input to the SECU controller indicating a problem.
The electronics system also uses a pressure transducer to measure compressor pressure
changes. This device has an output signal of 0.5 VDC to 4.5 VDC, corresponding to 0 psi and the
maximum measured psi for that particular device. The transducer is a gauge pressure device.
The transducer is powered with a 5 VDC excitation. The transducer is a three wire device:
excitation, signal, and ground.
Digital Inputs and Outputs
The controller scans digital inputs such as switch contacts. These are either “ON” (12V DC) or
“OFF” (0V DC). These digital inputs are connected to switches within the package such as
temperature switches, pressure switches, and ignition switch.
The controller provides 12V DC digital outputs to control relays, fuel pump, and hourmeter. These
are 12V DC “ON” and 0V DC “OFF”. They are current limited and short circuit protected.
Engine speed control is performed by a command over the J1939 CAN Network from the SECU
to the Engine ECM.
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 controller based on the position of the inlet valve. The controller measures the
pneumatic system regulation pressure and computes an engine throttle setting. This throttle
setting is sent to the engine via the J1939 throttle.
ManualNo.23307366(1‐09)Rev.B Page8
J1939 Data Link
The CAN network is twisted pair conductors located with 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 12V DC to
power these service tools.
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.
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.
ManualNo.23307366(1‐09)Rev.B Page9
HARNE
SS
S
Y
S
TEM
SC
HEMATI
C
Chassis Harness
FIGURE 2-1
SECU
Controller
SECU
Communication
Interface
Pressure Switches
Fuel Level Switch
Pressure Transducer
Temperature Switches
Starting and Charging
S
y
stem
Engine ECM
ManualNo.23307366(1‐09)Rev.B Page10
P2-J1
P2-K1
ENGINE
ECM
P2-H4
P2-E3
J1939 CAN LOW
(
-
)
SECU
CONTROLLER
J1939 CAN HIGH
(
+
)
ENGINE START
ENGINE STOP
SECU TO ENGINE INTERFACE
YANMAR TIER III ENGINE
FIGURE 2-2
P1-18
P1-17
P1-8
P1-2
ManualNo.23307366(1‐09)Rev.B Page11
P10
J14
TR1TR2 «»
ENGINE ECM
SECU
CONTROLLER
J1939 CAN COMMUNICATIONS SCHEMATIC
FIGURE 2-3
SECU
COMMUNICATION
INTERFACE
TERMINATOR TERMINATOR
ENGINE ECM
COMMUNICATION
INTERFACE
P9 P8
ManualNo.23307366(1‐09)Rev.B Page12
Key Electrical Component Functions
PS1: PS1 is a 0-100 psi gauge pressure transducer that measures
regulation system pressure.
S2: S2 is a 248oF/120oC NC temperature switch that monitors separator
tank temperature.
S3: S3 is a 248oF/120oC NC temperature switch that monitors airend
discharge temperature.
S4: S4 is a 230oF/110oC NC temperature switch that monitors engine
coolant temperature.
S5: S5 is a 12 psi NO pressure switch that monitors engine oil pressure.
K1: K1 is a SPDT, 12 VDC relay used to engage the starter solenoid.
K2: K2 is a SPDT, 12 VDC relay used to energize the inlet heater.
K3: K3 is a SPDT, 12 VDC relay used to energize the engine ECM.
K4: K4 is a SPDT, 12 VDC relay used to energize the fuel rack actuator.
ManualNo.23307366(1‐09)Rev.B Page13
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. The SECU controller energizes the engine inlet heater.
The engine inlet heater will be de-energized when operator releases switch or after 30 seconds
whichever occurs first.
Startup
When the Ignition switch is turned to the “START” position:
1. Engine Start signal (12 VDC) supplied to engine ECM from SECU.
2. Engine ECM energizes the engine starter.
When the engine speed reaches 600 RPM (engine start declared):
1. Engine Start signal (12 VDC) to engine ECM is turned off.
Load
When the Service Air button is pressed (if equipped):
1. SECU varies engine speed based on regulation pressure.
Shut Down
If a machine fault occurs:
1. The SECU controller turns the Engine Stop signal (12 VDC) “ON”.
2. Engine ECM de-energizes the Fuel Rack Actuator relay (K4).
3. The SECU displays SHUTDOWN code.
When the ignition switch is turned to the “OFF” position.
1. The switched battery power is turned off to the machine system.
ManualNo.23307366(1‐09)Rev.B Page14
SECTION 2
COMPRESSOR and ENGINE DIAGNOSTIC CODES
ManualNo.23307366(1‐09)Rev.B Page15
COMPRESSOR DIAGNOSTIC DISPLAY CODES
Small Electronic Control Unit (SECU)
- Center Bar Blinking Compressor is ready to start (no faults)
A Engine Model Not
Recognized Compressor will start and operate with a 1700-2300 rpm range.
C Engine ECM
Communication Failure SECU cannot communicate with engine ECM over J1939 CAN BUSS.
H Pre-Heat Signal or Start
Signal Detected Displayed while ignition switch is in the pre-heat or start position.
E Generator Switch “ON” Switch must be turned off to start the machine.
1 High A/E Temp SHUTDOWN condition due to high airend discharge temperature.
(248oF/120oC)
2 High Separator Temp SHUTDOWN condition due to high separator tank temperature.
(248oF/120oC)
3 Low Battery Voltage ALERT condition indicating battery or charging system needs service.
(<11.6 VDC)
4 High Eng Temp SHUTDOWN condition due to high engine coolant temperature.
(230oF/110oC)
5 Low Eng Oil Press SHUTDOWN condition due to low engine oil pressure. (12 psi/0.83
bar)
6 Comp Sensor SHUTDOWN condition due to PS1 pressure sensor failure. Machine
will not start.
7 Low Eng Speed SHUTDOWN condition due to low engine speed. (Idle speed < 200
rpm)
8 Low Fuel SHUTDOWN condition due to low fuel level. (Optional)
9 High Air Filter Press ALERT condition indicating engine/compressor air inlet filters need
service (20 in. of H2O/508 mm of H2O). (Optional)
ManualNo.23307366(1‐09)Rev.B Page16
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.
•The Failure Lamp is luminated for 2 seconds
when the ECU is powered on.
•A lamp flash duration of 0.5 seconds is a
“Short” Flash.
•A failure flash sequence of “1 long and 3
Short" would be displayed by flashing the
lamp one time with a duration of 1.5
seconds and three times with a duration of
.5 seconds.
•When two or more failures have occurred
simultaneously, the failure lamp will pause
for 3 seconds between flash sequences.
•Failure flash sequences continuously repeat
with 3 second pauses between flash
sequences until the failure is corrected.
Failure Failure Flashes Remark
Coolant temperature sensor failure 4 Short
Speed sensor failure 6 Short
Rack position sensor failure 7 Short
Rack actuator failure 8 Short
EGR valve failure 1 Long and 3 Short
CSD solenoid valve failure 1 Long and 4 Short
Main relay failure 1 Long and 6 Short
Rack actuator relay failure 1 Long and 7 Short
ECU temperature alarm 2 Long and 5 Short ECU temp > 221°F/105°C
Coolant temperature alarm 3 Long and 6 Short Coolant temp > 230°F/110°C
ECU failure 4 Long and 1 Short
Engine Failure Lamp
ManualNo.23307366(1‐09)Rev.B Page17
SECTION 3
TROUBLESHOOTING COMPRESSOR DIAGNOSTIC CODES
ManualNo.23307366(1‐09)Rev.B Page18
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. It is not possible to include all the solutions to problems that
can occur or list all possible problems. The charts are designed to stimulate a thinking process that will lead to
solution of the problem.
Basic Troubleshooting Steps
•Collect all facts concerning the problem
•Analyze the problem thoroughly
•Relate the symptoms to the basic electrical / electronic systems and components
•Consider any recent repairs that could relate to the problem
•Double check before replacing components
•Review the controller fault log for clues as to the problem
•Determine the cause of the problem and make a thorough repair
ManualNo.23307366(1‐09)Rev.B Page19
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.
Measuring Voltage
A digital voltmeter is recommended to make measurements. Voltage measurements are made by connecting the
RED + lead to the desired signal and the BLACK lead to the common. The test lead connections must be secure
or incorrect readings will result. Use circuit common for the Black lead, not chassis ground or other metal
connection. Circuit common will be any of the BROWN wires or battery negative can be used.
IMPORTANT INFORMATION
DO NOT USE MACHINE FRAME, SHEET METAL, PIPING OR OTHER METAL COMPONENTS AS COMMON
OR GROUND WHEN MAKING VOLTAGE OR FREQUENCY MEASUREMENTS.
Measuring Resistance
Extra care must be taken when making resistance measurements. Test probe connections are crucial to correct
readings. Ensure the test probe makes a solid connection with the wire(s) or connector pin(s) under test. the test
probe kit may help with these types of measurements. Make sure system power is turned OFF while making
resistance measurements.
Measuring Frequency:
Frequency is measured in the same manner as voltage, but the meter is set for "HZ" or frequency. Good
connections are important or false readings will occur.
Measuring Duty Cycle:
To measure duty cycle, setup the meter as if measuring frequency or voltage. Select the "%" or duty cycle
function and take the measurements. As of the date of this writing, Fluke is the only known digital voltmeter that
has the duty cycle feature. The Fluke Model 87 Digital Meter has the duty cycle function.
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