This document is an Electronic Service Manual for Doosan Infracore Portable Power compressor models, specifically covering the P425WJD (7/120), XP375WJD (9/110), HP350WJD (10/105), HP350WJD (14/85), P600WJD (7/170), HP450WJD (10/125), and VHP400WJD (14/115) series. The manual provides detailed information on the operational theory, controls, diagnostic codes, troubleshooting, system schematics, electrical component locations, parts lists, and repair kits.
The core of these machines is an electronic monitor and control system that utilizes a WEDGE controller. This microcontroller-based unit manages discharge air pressure control and various monitoring functions. It features analog and digital inputs and outputs, scanning all inputs every 50 milliseconds. The WEDGE controller compares analog values against predefined minimum and maximum thresholds, issuing an ALERT or SHUTDOWN if values fall outside these ranges.
Operational Theory and Control System:
The WEDGE controller is responsible for machine discharge pressure control. It monitors the regulation system air pressure and adjusts the engine throttle to maintain the setpoint discharge air pressure. Setpoint pressure is configured using high and low-pressure regulators. Communication with the diesel engine's Electronic Control Module (ECM) occurs via the J1939 CAN network, allowing the WEDGE to retrieve diagnostic and runtime data. The engine throttle signal ranges from 2.5 VDC (1500 rpm) to 3.9 VDC (2200 rpm).
Sensors and Transducers:
The system employs various sensors and transducers to collect data:
- Temperature Sensors: Thermistor and RTD types measure temperature (e.g., separator tank and airend discharge). Changes in resistance are interpreted as temperature variations.
- Pressure Transducers: These devices measure compressor pressure changes, providing an output signal from 0.5 VDC (0 psi) to 4.5 VDC (maximum measured psi). They are gauge pressure devices, powered by a 5 VDC excitation.
- PT1: 0-500 psi gauge pressure transducer for discharge air pressure.
- PT2: 0-100 psi gauge pressure transducer for regulation system pressure.
- RT1: 10K ohm Thermistor for separator tank temperature.
- RT2: 10K ohm Thermistor for airend discharge temperature.
The WEDGE controller scans digital inputs (switch contacts) at either 24 VDC or 0 VDC. It also provides 24 VDC digital outputs to control solenoids, relays, and other devices, with these outputs being current-limited and short-circuit protected. Controller outputs include frequency, pulse width modulated (PWM), and 24 VDC digital (ON/OFF) signals.
Electrical System:
The electrical system comprises WJDing harnesses and associated devices like relays, switches, lights, and solenoids. Two main chassis harnesses are identified:
- 22984009: For P600WJD (7/170), HP450WJD (10/125), & VHP400WJD (14/115) models.
- 22969554: For P425WJD (7/120), XP375WJD (9/110), HP350WJD (10/105), & (14/85) models.
- 22835680: Control Panel WJDing Harness (All Models).
Electrical circuits are protected by ATC style fuses, which must be replaced with the same rating to prevent harness damage.
Operating Controls and Instruments:
The control panel features:
- Compressor Malfunction Diagnostic Light: Indicates ALERT or SHUTDOWN for compressor diagnostic codes.
- Engine Malfunction Diagnostic Light: Indicates ALERT or SHUTDOWN for engine diagnostic codes.
- Hourmeter: Displays machine operating hours.
- Discharge Air Pressure Gauge: Shows receiver tank pressure (0 psi(kPa) to rated pressure).
- Fuel Level Gauge: Indicates fuel tank level.
- Main Ignition Switch: ON/OFF Start Switch.
- Service Air Switch: Momentary ON/OFF switch to load the compressor after engine warm-up.
- Wait To Start Lamp: Indicates engine inlet heater operation.
- Engine Tachometer (if equipped): Displays engine speed in RPM.
- Compressor Oil Temperature Gauge (if equipped).
- Engine Oil Pressure Gauge (if equipped).
- Engine Coolant Temperature Gauge (if equipped).
- Battery Voltage Gauge (if equipped).
WEDGE Lights (located inside machine on bracket):
- High Compressor Temperature Diagnostic Light: SHUTDOWN due to high compressor temperature.
- Low Engine Oil Pressure Diagnostic Light: ALERT or SHUTDOWN due to low engine oil pressure.
- High Engine Coolant Temperature Diagnostic Light: ALERT or SHUTDOWN due to high engine coolant temperature.
- Low Fuel Level Diagnostic Light: ALERT or SHUTDOWN due to low fuel level.
- Low Battery Voltage Diagnostic Light: ALERT for battery or charging system service.
- Numeric Display: Shows diagnostic codes and operational parameters.
- Restricted Air Filter Diagnostic Light (if equipped): ALERT for engine/compressor air inlet filter service.
- Restricted IQ Air Filters Diagnostic Light (if equipped): SHUTDOWN due to dirty IQ air filters.
- Compressor Malfunction Diagnostic Light: Indicates Compressor Diagnostic Code.
- Engine Malfunction Diagnostic Light: Indicates Engine Diagnostic Code.
- Data Input Switch: Momentary ON/OFF switch for toggling through diagnostic display, setting units, and machine ID.
- Power On: Ignition switch to "ON" supplies 24 VDC keyswitch signal to engine ECM from WEDGE.
- Startup: Ignition switch to "START" energizes engine starter, opens Start/Run solenoid (L1).
- At 600 RPM: Starter de-energized, engine speed set to 1600 RPM.
- At 1450 RPM: Start/Run solenoid (L1) closes, Unloader solenoid (L2) opens.
- At 50 psi in separator tank: Start/Run solenoid (L1) opens.
- After 5 seconds: Engine idles (1600 RPM until coolant reaches 100°F, then 1500 RPM).
- Load: Service Air switch pressed sets engine speed to 2200 RPM.
- At 2000 RPM: Start/Run solenoid (L1) closes.
- After 2 seconds, if regulation system pressure is 4 psi or greater: Engine speed control engages.
Settings and Diagnostics:
The WEDGE display units can be set to °F, PSI; °C, Bars; °C, kPa; or °C, Kg/cm2. The WEDGE service diagnostic display allows viewing of various machine parameters (e.g., Engine RPM, pressures, temperatures, engine fault codes, engine hours). Machine ID must be correctly entered for proper operation, defining the machine's operational profile.
Troubleshooting:
The manual provides detailed troubleshooting steps for various compressor and engine diagnostic codes. These codes indicate specific issues, categorized as ALERT (blinking light) or SHUTDOWN (solid light). Examples include:
- Compressor Code 1 (Low Engine Speed): SHUTDOWN if engine speed < 1100 RPM for 30 seconds.
- Compressor Code 2 (High Engine Speed): SHUTDOWN if engine speed > 2300 RPM for 30 seconds.
- Compressor Code 3 (Engine Crank Time Exceeded): SHUTDOWN if cranking exceeds 30 seconds.
- Compressor Code 4 (Low Fuel Level): SHUTDOWN if U1 fuel level sensor detects open switch.
- Compressor Code 10 (Engine Not Responding To Throttle Command): ALERT if target RPM not reached within 10 seconds of starting.
- Compressor Code 11 (Too Many Start Attempts During Auto Start): SHUTDOWN after three failed auto-start attempts.
- Compressor Code 29 (Engine SHUTDOWN: Reason Unknown): SHUTDOWN if engine stops without a detected ECM fault code.
- Compressor Code 30 (High Airend Discharge Temperature): SHUTDOWN if RT2 temperature ≥ 248°F.
- Compressor Code 32 (RT2, Airend Discharge Temperature Sensor Fault): SHUTDOWN if RT2 sensor reading is out of range.
- Compressor Code 33 (PT1, Separator Tank Pressure Sensor Fault): ALERT if PT1 sensor reading is out of range.
- Compressor Code 34 (Separator Tank Pressure Greater Than 20 psi at Crank): SHUTDOWN if PT1 pressure > 20 psi at crank.
- Compressor Code 50 (High Separator Tank Temperature): SHUTDOWN if RT1 temperature ≥ 248°F.
- Compressor Code 51 (Machine ID Not Installed): SHUTDOWN if no machine ID is loaded.
- Compressor Code 52 (IQ Filter Restriction): SHUTDOWN if S18 IQ air filter differential pressure switch detects restriction.
- Compressor Code 53 (RT1, Separator Tank Temperature Sensor Fault): SHUTDOWN if RT1 sensor reading is out of range.
- Compressor Code 54 (PT2, Regulation System Pressure Sensor Fault): ALERT if PT2 sensor reading is out of range.
- Compressor Code 56 (Minimum Start Pressure Not Met): ALERT if 50 psi not met within 20 seconds of start.
- Compressor Code 70 (Serial Communications Failure): ALERT if RS232 serial link problem detected.
- Compressor Code 71 (Engine ECM Communication Failure): SHUTDOWN if WEDGE cannot communicate with engine ECM via J1939 CAN BUS.
- Compressor Code 73 (Auto Start/Stop Controller Communication Failure): ALERT if WEDGE cannot communicate with Auto Start/Stop Controller via J1939 CAN BUS.
John Deere Engine Diagnostic Codes (4045HF285 and 6068HF285):
The manual lists specific engine fault codes (e.g., Throttle Signal Out of Range, Fuel Pressure Problem, Engine Oil Pressure Problem, Engine Coolant Temperature Problem, Injector Problems, Sensor Supply Voltage Problems) and their corresponding ALERT/SHUTDOWN parameters (e.g., Low Engine Oil Pressure, High Engine Coolant Temperature, High Engine Manifold Air Temperature, High Fuel Temperature) with specific trip points.
Maintenance and Repair:
The manual includes information on:
- Electrical Component Locations: Diagrams and descriptions for components like the WEDGE controller, sensors, relays, and switches.
- Harness Connector Information: A comprehensive list of connectors and their parts, including manufacturer details and Doosan Service Kit part numbers.
- Electrical Torque Specifications: Recommended torque values for electronic controller connector screws.
- Tools and Repair Kits: A list of specialized service tools (e.g., multimeters, test lead sets, crimp tools, terminal removal tools, simulators) and connector repair kits (e.g., Deutsch, Packard, Molex, AMP) available from Doosan Portable Power.
- Crimp Tool Usage and Connector Service Procedures: Detailed instructions for using various crimp tools and servicing Deutsch DRC, DT, DTM, HD10, HD30, HDP20, AMP Ampseal, and Molex connectors, including contact insertion and removal procedures.
- Recommended Spare Parts: A list of essential spare parts for the WEDGE controller, temperature sensors, pressure transducers, and solenoid valves.
- Software Information: Notes on software updates available from WWW.irembedded.com.
This manual serves as a critical resource for diagnosing, troubleshooting, and repairing the electronic control systems of Doosan Infracore Portable Power compressors, ensuring efficient and safe operation.
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