P425 XP375 HP350 P600 HP450 VHP400WIR 7-120 9-110 14-105 JUN09 CPN23227143 GB

ELECTRONIC SERVICE MANUAL
Codes:
P425WIR (7/120) C46 (C95)
XP375WIR (9/110) C48 (C94)
HP350WIR (10/105) C47 (C96)
HP350WIR (14/85) C47 (D17)
P600WIR (7/170) C54 (D18)

HP450WIR (10/125) C55 (D19)
VHP400WIR (14/115) C56 (D20)
COMPRESSOR MODELS
Doosan purchased Bobcat Company from Ingersoll-Rand Company in

2007. Any reference to Ingersoll-Rand Company or use of trademarks,
service marks, logos, or other proprietary identifying marks belonging
to Ingersoll-Rand Company in this manual is historical or nominative
in nature, and is not meant to suggest a current affiliation between
Ingersoll-Rand Company and Doosan Company or the products of
either.
Doosan Infracore Portable Power

1293 Glenway Drive
Statesville, N.C. 28625
www.doosanportablepower.com
Book: 23227143 (6-09) Rev B

Revised (10-12)
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
Book: 23227143 (6-09) Rev B Page 1

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
Book: 23227143 (6-09) Rev B Page 2

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
Book: 23227143 (6-09) Rev B Page 3

Book: 23227143 (6-09) Rev B Page 4
SECTION 1 – General Information
Book: 23227143 (6-09) Rev B Page 5

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.
Book: 23227143 (6-09) Rev B Page 6

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.
Book: 23227143 (6-09) Rev B Page 7

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.
Book: 23227143 (6-09) Rev B Page 8

P425/P600 HARNESS SYSTEM SCHEMATIC
CONTROL PANEL SOLENOID VALVES

SWITCHES
ENGINE ECM
PRESSURE SWITCHES
HOURMETER
Book: 23227143 (6-09) Rev B

WEDGE FUEL LEVEL SWITCH
CONTROLLER
GAUGES
PRESSURE SENSORS
CONTROL PANEL HARNESS

TEMPERATURE SENSORS
J4
«
P4 BATTERY STARTING AND
CHARGING SYSTEM
P1
CHASSIS HARNESS
Figure 2-1
Page 9
WEDGE TO ENGINE INTERFACE
IR ENGINE
P1-34 J1939 CAN LOW (-) J02-B1
P1-35 J1939 CAN HIGH (+) J02-A1
P1-1 J1939 CAN SHIELD J02-K2
Book: 23227143 (6-09) Rev B

WEDGE ENGINE ECM
CONTROLLER
WEDGE
WEDGE
CONTROLLER
CONTROLLER
KEY SWITCH SIGNAL

P1-24 J02-B2
ANALOG THROTTLE RANGE = 2.5VDC (1500RPM) to 3.9 VDC (2200RPM)

P1-13 J02-A4
ANALOG THROTTLE
Page 10
FIGURE 2-2
J1939 CAN BUSS
COMMUNICATIONS SCHEMATIC
ENGINE ECM WEDGE

CONTROLLER
Book: 23227143 (6-09) Rev B

TR2 TR1
P2
P3
>>
>> TERMINATOR TERMINATOR
J10 P10
>>
CAN NODE with POWER
C11
FIGURE 2-3
Page 11
ENGINE ECM COMMUNICATIONS
INTERFACE
Key Electrical Component Functions
PT1 is a 0-500 psi gauge pressure transducer that measures

PT1:
discharge air pressure.
PT2 is a 0-100 psi gauge pressure transducer that measures

PT2:
regulation system pressure.
RT1 is a 10K ohm Thermistor type temperature sensor that

RT1:
measures separator tank temperature.
RT2 is a 10K ohm Thermistor type temperature sensor that

RT2:
measures airend discharge temperature.
K1 is a SPST, 24 VDC relay used to engage the engine starter

K1:
solenoid.
K2 is a SPST, 24 VDC relay used to energize the engine inlet

K2:
heater.
U1 is a resistive level detector and low level switch sensor used to

monitor fuel level. The resistive function drives the fuel gauge and
U1:
the switch function opens to shut the machine down on low fuel
level.
Book: 23227143 (6-09) Rev B Page 12

OPERATING CONTROLS AND INSTRUMENTS
4 10
11
13
9 12
1 2
3 5
6 7 8
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
Book: 23227143 (6-09) Rev B Page 13

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
15 20
16 21
17 22
18 23
19 24
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.
Book: 23227143 (6-09) Rev B Page 14

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.
Book: 23227143 (6-09) Rev B Page 15

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:
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:
After 2 seconds, if the regulation system pressure is 4 psi or greater:
• Engine speed control is engaged.
Book: 23227143 (6-09) Rev B Page 16

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.

When the engine speed reaches 600 RPM (engine start declared):
• Engine starter is de-energized.

When the separator tank reaches 50 psi:
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:
After 2 seconds, if the regulation system pressure is 4 psi or greater:
• Engine speed control is engaged.
Book: 23227143 (6-09) Rev B Page 17

Book: 23227143 (6-09) Rev B Page 18
SECTION 2 - Settings
Book: 23227143 (6-09) Rev B Page 19

Reading and Setting Display Units
The WEDGE has four choices for display units:
°F, PSI
°C, Bars
°C, kPa
°C, Kg/cm2
To determine which units the WEDGE has been configured for:
1. With the ignition switch turned “OFF”
2. Press and hold the "Service Air" Switch
3. Turn the ignition switch directly to the crank position.
4. Hold these switch positions until the numeric display on the WEDGE
goes blank.
5. Release "Service Air" switch, release ignition switch to the "ON"

position.
The current units will be displayed for 2 seconds. The units will be displayed as:
°F, PSI will be displayed as "PSI"

°C, Bars will be displayed as "bAr"
°C, kPa will be displayed as "HPA"
°C, Kg/cm2 will be displayed as "H9C"
To change the units setting:
1. With the WEDGE showing the current units setting, press and release the
"Service Air" switch until the desired units appear on the display.
2. Once it appears, do not release the "Service Air" switch. Keep the switch
pressed until the WEDGE restarts. This will change the units to the desired
selection.
3. Release the "Service Air" switch.
4. Cycle the power using the ignition switch. The machine is now ready to start
and displaying the units selected.
Book: 23227143 (6-09) Rev B Page 20

Wedge Service Diagnostic Display
The WEDGE controller provides a diagnostic capability that allows various machine parameters
to be viewed on the numeric display. The diagnostic display can be accessed with the machine
stopped or while it is operating. The “Data Input” switch located beside the WEDGE controller
inside the unit is used to toggle through the list of parameters.
If the “Data Input” switch is broken then the following method can be used: If the
machine is stopped, the “Service Air” switch on the control panel is used to toggle through the list
of parameters. If the machine is operating, the “START” position of the ignition switch is used to
toggle through the list of parameters.
To view the parameters, use the “Data Input” switch to scroll to the desired display
number. After 1 second, the display number will disappear and the desired parameter will be
displayed. After 3 minutes, the display will return to normal mode. The toggle only works in the
ascending order direction, but it will wrap around and start over.
Display Parameter Remarks

2 Not Available
3 Engine RPM Filtered Value From WEDGE
4 Regulation System Pressure From PT2
5 Separator Tank Pressure From PT1
6 Airend Discharge Temperature From RT2
7 Separator Tank Temperature From RT1
8 Target Engine RPM Throttle Command to Engine
9 Machine ID Selected Machine Type
10 Engine Coolant Temperature From Engine ECM
11 Not Available
12 Engine Oil Pressure From Engine ECM
13 Engine Intake Manifold Temperature From Engine ECM
14 Engine RPM From Engine ECM
15 Engine Fault Codes From Engine ECM
16 Engine Throttle Position From Engine ECM (Percent %)
17 Not Available
18 Engine Hours From Engine ECM
19 Engine Load at Speed From Engine ECM (Percent %)
20 Set Machine ID To Set Selected Machine Type
Entering Machine ID for WEDGE Control Systems
For machines with the WEDGE controller mounted inside the control
panel/instrument panel box, the "Service Air" switch is used to enter the machine
ID. Disconnect the fuel level sensor (if equipped, will be located in the fuel tank),
before starting the process and reconnect once the process is completed.
Book: 23227143 (6-09) Rev B Page 21

For machines with the WEDGE controller mounted in the engine compartment,
the rocker switch beside the WEDGE is used to enter the machine ID. If a
machine ID other than 11 or 12 has been entered into the WEDGE, then the
“Service Air” switch on the front control panel will have to be used to enter the
correct machine ID. This may require the help of an additional person to see the
WEDGE display.
For the instructions below, the "Service Air" or rocker switch will be referred to as
the "data input switch".
1. Examine the machine data plate to confirm the machine model.

Using the machine model from the data plate, locate the proper machine ID
from the “Machine Models List” in this manual.
2. Turn ignition switch to the "ON" position. Machine must not be operating.
3. Toggle the data input switch twice and the number "2" will appear on the
WEDGE 4-digit numeric display. Continue to toggle the switch until the
number "9" is reached. Read the machine ID on the display. If it matches the
proper machine ID in Step 1, stop. If not, proceed to step 4.
4. Continue to toggle the switch until number "19" is reached. Push and hold
the data input switch and the number "20" will appear. Continue to hold the
switch. After 1 second, the current machine ID will appear in the display.
Continue to hold for 9 more seconds and a blinking "-" will appear. Release
the switch.
5. Toggle the data input switch, the display will show "0". Toggle the
data input switch until the proper machine ID appears on the display, then
stop the toggle sequence.
6. Wait until the controller performs a reset function (approximately 10 seconds).

At reset, the controller display first goes blank, then all 10 diagnostic lights
come on, the numeric display shows all 8's, the display then shows the
installed software version and finally the display goes blank and the engine oil
pressure and alternator diagnostic lights begin flashing. At this point the
controller has stored the machine ID selected in step 5.
7. Using the data input switch, toggle to service diagnostic number "9".
The number "9" will appear for 1 second and then the machine ID will appear.
The ID should be the same as the one entered in steps 4-6. If not go back to
step 4 and enter the ID again.
Book: 23227143 (6-09) Rev B Page 22

Machine Models List
Machine Models Machine ID

North America Models
P425CWIR 11
HP375CWIR 11
XP375CWIR 11
EMEA Models
7/120CWIR 11
9/110CWIR 11
10/105CWIR 11
14/85CWIR 11
North America Models

P600BWIR 12
HP450BWIR 12
VHP400BWIR 12
12
EMEA Models
7/170BWIR 12
10/125BWIR 12
14/115BWIR 12
Book: 23227143 (6-09) Rev B Page 23

Book: 23227143 (6-09) Rev B Page 24
SECTION 3 - Diagnostic Code Descriptions
Book: 23227143 (6-09) Rev B Page 25

Compressor and Engine Diagnostic Code Descriptions
The following are descriptions of Compressor and Engine diagnostic codes.

When a Compressor diagnostic code is displayed the “Compressor Malfunction”
diagnostic light will be illuminated. When an Engine diagnostic code is displayed
the “Engine Malfunction” diagnostic light will be illuminated. Refer to the
“Operating Controls and Instruments” page to determine the location of the
malfunction lights. Be sure to determine which malfunction light is illuminated
before beginning the troubleshooting process.
Book: 23227143 (6-09) Rev B Page 26

Compressor Diagnostic Display Codes
Wedge Software Version 2.20 or greater Compressor Malfunction Diagnostic Light
ALERT SHUTDOWN
Light Light
Condition Code Code Delay
(Blinks) (Steady)
Compressor 30
Low Engine Speed 1
Malfunction sec.
Compressor 30
High Engine Speed 2
Malfunction sec.
Compressor
Engine Crank time Exceeded 3 0 sec.
Malfunction
Compressor
Low Fuel Level 4 3 sec.
Malfunction
Engine Not Responding To Throttle Compressor
10
Command Malfunction
Too Many Start Attempts During Auto Start Compressor
11 0 sec.
Malfunction
Engine SHUTDOWN: Reason Unknown Compressor
29 0 sec.
Malfunction
High Airend Discharge Temperature (RT2) Compressor
(248oF) 30
Malfunction
3 sec.
Airend Discharge Temperature Sensor Compressor 10

32
Fault (RT2) Malfunction sec.
Separator Tank Pressure Sensor Fault Compressor
33
(PT1) Malfunction
Separator Tank Pressure > 20 psi at Crank Compressor
34 0 sec.
(engine will not start) Malfunction
High Separator Tank Temperature (RT1) Compressor
(248oF) 50
Malfunction
3 sec.
Compressor
Machine ID Not Installed 51 0 sec.
Malfunction
Compressor
IQ Filter Restriction 52 3 sec.
Malfunction
Separator Tank Temperature Sensor Fault Compressor 10
53
(RT1) Malfunction sec.
Regulation System Pressure Sensor Fault Compressor
54
(PT2) Malfunction
Minimum Start Pressure Not Met (50 psi) Compressor
56
Malfunction
Compressor
Serial Communications Failure 70
Malfunction
Engine ECM Communication Failure Compressor 13
71
Malfunction sec.
Auto/Stop Controller Communication Compressor
73
Failure Malfunction
Book: 23227143 (6-09) Rev B Page 27

Compressor Diagnostic Lights
Wedge Software Version 2.20 or greater
Compressor ALERT/SHUTDOWN Diagnostic Lights

ALERT SHUTDOWN
Diagnostic Light Light (Blinks) Light (Steady)
Delay
Compressor Malfunction • •
Engine Malfunction • •
Low Fuel Level • 3 sec.
Restricted Air Filters •

Low Battery Voltage •
Low Engine Oil Pressure
(18 psi ALERT) • • 4 sec.
(SHUTDOWN by Engine ECM)
High Engine Coolant Temperature
(220oF ALERT) • • 10 sec.
(SHUTDOWN by Engine ECM)
High Compressor Temperature (RT2)
• 3 sec.
o
(248 F)
Restricted IQ Air Filter
• 3 sec.
Book: 23227143 (6-09) Rev B Page 28

John Deere Engine Models 4045HF285 and 6068HF285 Diagnostic
Display Codes
Engine Malfunction Diagnostic Light
Code Definition
29 Throttle #2 Signal Out of Range
91 Throttle #1 Signal Out of Range
94 Fuel Pressure Problem
97 Water In Fuel
100 Engine Oil Pressure Problem
105 Manifold Air Temperature Problem
110 Engine Coolant Temperature Problem
157 Fuel Rail Pressure Problem
158 ECU Power Down Error
174 Fuel Temperature Problem
189 Engine Speed Derate Condition Exists
611 Injector Wiring Problem
627 All Injector Circuits Have High Resistance
629 ECU Failure
636 Engine Position Sensor Error
637 Engine Timing Sensor Error
651 Injector #1 Problem
Book: 23227143 (6-09) Rev B Page 29

Engine Malfunction Diagnostic Light
Code Definition
1136 Engine ECU Temperature High
1347 Fuel Pump Pressurizing Problem
1569 Engine Protection De-rate
3509 Sensor Supply Voltage #1 Problem
Book: 23227143 (6-09) Rev B Page 30

John Deere 4045HF285 Engine ECM ALERT/SHUTDOWN Parameters
Description Trip Point

Low Engine Oil Pressure
Less than .14psi (1kPa): 770 rpm
Less than 19psi (132kPa): 775 rpm
Warning Less than 31psi (212kPa): 1500 rpm
Less than .14psi (1kPa): 770 rpm
Shutdown
High Engine Coolant Temperature 4045HF285
232oF (111oC): Peak Power Level Above 118hp (88kw)
Warning
237oF (114oC): Peak Power Level Under 118hp (88kw)
Shutdown
High Engine Coolant Temperature 6068HF285
Warning
Shutdown
High Engine Manifold Air Temperature
Warning 193oF (89.5oC)
Shutdown 196oF (91.0oC)
High Fuel Temperature
Shutdown 212oF (100.0oC)
Book: 23227143 (6-09) Rev B Page 31

Book: 23227143 (6-09) Rev B Page 32
SECTION 4 - Troubleshooting
Book: 23227143 (6-09) Rev B Page 33

Compressor Diagnostic Codes
Procedures and Techniques
General
A thorough analysis of the problem is the key to successful troubleshooting. The

more information known about a problem, the faster and easier the problem can
be solved.
Troubleshooting charts are included to act as a guide to the troubleshooting

process. 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
Book: 23227143 (6-09) Rev B Page 34

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.
Book: 23227143 (6-09) Rev B Page 35

Troubleshooting Flow Chart
Ignition switch (S1) is turned to the Check F1 fuse

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

“START” position and the engine does WEDGE
not crank. Check relay K1 operation and
connections
Ignition switch (S1) is turned to the Check fuel system

“START” position and the engine Check battery voltage
cranks but will not start.
Service Air switch (S2) is pressed and Check wiring from S2 switch to
compressor fails to load. WEDGE
Check Start/Run solenoid (L1)
operation and connections
Check for fault codes
Verify Machine ID
Book: 23227143 (6-09) Rev B Page 36

COMPRESSOR CODE 1
Low Engine Speed
Explanation:
The WEDGE has received an engine speed value less than 1100 RPM for 30
seconds from the engine ECM.
Effect:
Code 1 is a SHUTDOWN condition and will stop the machine. The Compressor
Malfunction light will be on solid, and Code 1 will be displayed.
Troubleshooting Steps
Action Result
Step 1:
Check WEDGE diagnostic display 15 for engine fault
codes.
Step 2: Dirty fuel filters
Check engine fuel system for restrictions. Clogged fuel hoses
Air in fuel system
Step 3:
Retrieve active and inactive engine ECM fault codes
via engine manufacturer’s service tool.
Step 4:
Check engine ECM setup via engine manufacturer’s

service tool.
Book: 23227143 (6-09) Rev B Page 37

COMPRESSOR CODE 2
High Engine Speed
Explanation:
The WEDGE has received an engine speed value greater than 2300 RPM for 30
seconds from the engine ECM.
Effect:
Action Result
Step 1:
Check WEDGE diagnostic display 15 for engine fault
codes.
Step 2:
Step 3:
Check engine ECM setup via engine manufacturer’s
service tool.
Book: 23227143 (6-09) Rev B Page 38

COMPRESSOR CODE 3
Engine Crank Time Exceeded
Explanation:
The user has attempted to crank the engine longer than 30 seconds.
Effect:
Code 3 is a SHUTDOWN condition and will prevent further cranking. The
Compressor Malfunction light will be on solid, and Code 3 will be displayed.
Action Result
Step 1:
Cycle power and wait 1 minute before attempting to
crank machine again.
Step 2:
Check engine fuel system for restrictions. Dirty fuel filters
Clogged fuel hoses
Air in fuel system
Step 3:
Verify machine cold weather kit is working properly
(if equipped).
Book: 23227143 (6-09) Rev B Page 39

COMPRESSOR CODE 4
Low Fuel Level
Explanation:
The WEDGE has detected an open switch contact from the U1 fuel level sensor.
Effect:
Code 4 is a SHUTDOWN condition and will stop the machine. The Low Fuel
diagnostic lamp will be on solid, the Compressor Malfunction light will be on solid,
and Code 4 will be displayed.
U1 Fuel Level Sensor Circuit:
Circuit Description:
The fuel level sensor connects to the WEDGE controller as shown in the circuit
above. U1 has a switch contact that opens when the fuel level is low. The dark
blue wire is the sense line to the WEDGE. The brown wire is the switch common
to ground.
Component Location:
U1 fuel level sensor is located in top of the fuel tank
Book: 23227143 (6-09) Rev B Page 40

COMPRESSOR CODE 4
Action Result
Step 1:
Check fuel level in tank. Add fuel if needed.
Step 2:
Check all harness connections between WEDGE Repair harness as needed
and U1 fuel level sensor.
Step 3: Resistance value measured
Disconnect U1 from harness. Using a multimeter, should be shorted with tank
measure resistance between U1-A and U1-B on fuel full of fuel.
level sensor.
Remove fuel level sensor from tank. Using a Resistance value measured
multimeter, measure resistance between U1-A and should be shorted, if not
U1-B on fuel level sensor with it upside down. replace U1 fuel level sensor.
Step 4: The low fuel light, compressor
Turn ignition switch to the “ON” position. Jumper malfunction light, and Code 4
across U1-A and U1-B on the harness connector. should appear on the WEDGE
controller, if not check wiring
Step 5:
If Steps 1 through 4 checkout OK, replace WEDGE.
Book: 23227143 (6-09) Rev B Page 41

COMPRESSOR CODE 10
Engine Not Responding To Throttle Command
Explanation:
The engine has failed to reach target RPM within 10 seconds after starting.
Effect:
Code 10 is an ALERT condition and will not stop the machine, however minimum
pressure will not be met and pressure control will not be engaged. The Compressor
Malfunction light will be blinking, and Code 10 will be displayed.
Action Result
Step 1:
Check WEDGE diagnostic display 9 to verify correct Machine ID incorrect select
machine ID. correct ID and reload into
WEDGE
Step 2:
Scroll to WEDGE diagnostic display 8. Crank machine.
Verify Target RPM listed below.
Target RPM = 1600 if engine coolant < 100oF
1500 if engine coolant > 100oF
Step 3:
Scroll to WEDGE diagnostic display 16. Crank machine.
Verify Throttle Position listed below.
Throttle Position = 57 if engine coolant < 100oF

50 if engine coolant > 100oF
Step 4:
Check engine fuel system for restrictions. Dirty filters
Clogged Hoses
Air in fuel system
Step 5:
Refer to the engine manufacturer’s service manual for
instructions.
Book: 23227143 (6-09) Rev B Page 42

COMPRESSOR CODE 11
Too Many Start Attempts During Auto Start
Explanation:
The WEDGE has made three attempts to start the machine as commanded by the
Auto Start/Stop controller and the machine failed to start.
Effect:
Code 11 is a SHUTDOWN condition and will prevent further cranking. The
Compressor Malfunction light will be on solid, and Code 11 will be displayed.
Action Result
Step 1:
Crank machine manually to verify proper operation.
Step 2:
Clogged Hoses
Air in fuel system
Step 3:
Check the condition of the machine batteries and
verify battery charger is working properly.
Step 4:
Verify machine cold weather kit is working properly
(if equipped).
Book: 23227143 (6-09) Rev B Page 43

COMPRESSOR CODE 29
Engine SHUTDOWN: Reason Unknown
Explanation:
The engine has shut down and the WEDGE did not detect a fault code from the
engine ECM.
Effect:
Action Result
Step 1:
Check fuse F2. Replace fuses as needed
Step 2:
Clogged Hoses
Air in fuel system
Step 3:
Verify battery + and – connections to the engine Repair harness as needed
ECM.
Step 4:
Verify KEYSWITCH signal (24 VDC) connection
from WEDGE to engine ECM.
Step 5:
Book: 23227143 (6-09) Rev B Page 44

COMPRESSOR CODE 30
High Airend Discharge Temperature
Explanation:
The WEDGE has detected a temperature from RT2 temperature sensor that is
greater than or equal to 248oF.
Effect:
Code 30 is a SHUTDOWN condition and will stop the machine. The High Airend
Discharge Temperature diagnostic light will be on solid, the Compressor Malfunction
light will be on solid, and code 30 will be displayed.
Action Result
Step 1: Clogged coolers
Check coolers and clean if necessary.
Step 2: Repair harness as needed
Check all harness connections between Wedge and
RT2 temperature sensor.
Step 3: If temperature value on display
Disconnect RT2 from harness and plug thermistor 6 is not between -3oF and
simulator (Part No. 22073878) into the harness -13oF, check for wiring
connector. Check WEDGE diagnostic display 6 to problems
verify temperature value is between -3oF and -13oF.
If temperature value on display
6 is between -3oF and -13oF,
replace RT2 temperature
sensor
Step 4:
Book: 23227143 (6-09) Rev B Page 45

COMPRESSOR CODE 32
RT2, Airend Discharge Temperature Sensor Fault
Explanation:
The WEDGE has detected an out of range reading from the RT2 temperature
sensor.
Effect:
RT2 Temperature Sensor Circuit:
The temperature sensor connects to the WEDGE controller as shown in the
circuit above. RT2 is a 10K ohm Thermistor type temperature sensor. The yellow
wire is the sense line to the WEDGE. The brown wire is the sensor ground.
Component Location:
RT2 temperature sensor is located in the discharge port of the airend.
Book: 23227143 (6-09) Rev B Page 46

COMPRESSOR CODE 32
Action Result
Check all harness connections between WEDGE
and RT2 temperature sensor.
sensor
Step 3:
If Steps 1 and 2 checkout OK, replace WEDGE.
Book: 23227143 (6-09) Rev B Page 47

COMPRESSOR CODE 33
PT1, Separator Tank Pressure Sensor Fault
Explanation:
The WEDGE has detected an out of range reading from the PT1 pressure sensor.
Effect:
Code 33 is an ALERT condition and will not stop the machine. The Compressor
PT1 Pressure Sensor Circuit:
The pressure sensor connects to the WEDGE controller as shown in the circuit
above. The purple wire is the 5 VDC excitation supply from the WEDGE. The
orange wire is the signal output to the WEDGE with a range of 0.5 to 4.5 VDC.
The brown wire is the sensor ground. The pressure range of PT1 is 0 psig (0.5
VDC) to 500 psig (4.5 VDC).
Component Location:
PT1 pressure sensor is located on top of the separator tank.
Book: 23227143 (6-09) Rev B Page 48

COMPRESSOR CODE 33
Action Result
and PT1 pressure sensor.
Step 2: If pressure value on display 5
Disconnect PT1 from harness and plug pressure is not between 186 psi and
transducer simulator (Part No. 22168868) into the 196 psi, check for wiring
harness connector. Check WEDGE diagnostic problems
display 5 to verify pressure value is between 186 psi
and 196 psi. If pressure value on display 5
is between 186 psi and 196
psi, replace PT1 pressure
sensor
Step 3:
Book: 23227143 (6-09) Rev B Page 49

COMPRESSOR CODE 34
Separator Tank Pressure Greater Than 20 psi at Crank
Explanation:
The WEDGE has detected a pressure from PT1 pressure sensor that is greater than
20 psi at the time of engine crank.
Effect:
Code 34 is a SHUTDOWN condition and will prevent cranking until the separator
tank pressure is below 20 psi. The Compressor Malfunction light will be on solid, and
Code 34 will be displayed.
Action Result
Step 1:
Wait until separator tank pressure is below 20 psi
and try to crank the machine.
Step 2:
With air system completely blown down, check
WEDGE diagnostic display 5 to verify pressure value
is 0 psi.
sensor
Step 5:
Book: 23227143 (6-09) Rev B Page 50

COMPRESSOR CODE 50
High Separator Tank Temperature
Explanation:
The WEDGE has detected a temperature from RT1 temperature sensor that is
greater than or equal to 248oF.
Effect:
Action Result
Step 1: Clogged coolers
Check coolers and clean if necessary.
sensor
Step 4:
Book: 23227143 (6-09) Rev B Page 51

COMPRESSOR CODE 51
Machine ID Not Installed
Explanation:
The WEDGE does not have a machine ID loaded. Code 51 will occur only when a
new WEDGE is installed and the machine ID has never been loaded. The machine
ID defines the proper operational profile of a machine type. Absence of code 51 does
not ensure the machine ID is correct.
Effect:
Code 51 is a SHUTDOWN condition and will prevent any operation of the machine.
The Compressor Malfunction light will be on solid, and Code 51 will be displayed.
Action Result
Step 1:
Select correct machine ID from the “Machine Models
List” in this manual and load into the WEDGE. Refer
to the section “Entering Machine ID For Wedge
Control Systems” in this manual.
Book: 23227143 (6-09) Rev B Page 52

COMPRESSOR CODE 52
IQ Filter Restriction
Explanation:
The WEDGE has detected a closed switch contact from the IQ air filter S18
differential pressure switch.
Effect:
Code 52 is a SHUTDOWN condition and will stop the machine. The Restricted IQ Air
Filter diagnostic light will be on solid, the Compressor Malfunction light will be on
solid, and Code 52 will be displayed.
S18 Differential Switch Circuit:
The differential pressure switch connects to the WEDGE controller as shown in
the circuit above. S18 has a switch contact that closes when the pressure across
the IQ air filter is restricted. The dark blue wire is the sense line to the WEDGE.
The brown wire is the switch common to ground.
Component Location:
S18 IQ air filter differential pressure switch is located on a bracket inside the
machine beside the IQ air filter.
Book: 23227143 (6-09) Rev B Page 53

COMPRESSOR CODE 52
Action Result
Step 1: Clogged filter
Check IQ air filter.
and S18 differential pressure switch.
Disconnect S18 from harness. Using a multimeter, should be open, if not replace
measure resistance between across switch terminals S18 differential pressure
1 and 2 on differential pressure switch. switch
Step 4:
Book: 23227143 (6-09) Rev B Page 54

COMPRESSOR CODE 53
RT1, Separator Tank Temperature Sensor Fault
Explanation:
The WEDGE has detected an out of range reading from the RT1 temperature
sensor.
Effect:
RT1 Temperature Sensor Circuit:
The temperature sensor connects to the WEDGE controller as shown in the
circuit above. RT1 is a 10K ohm Thermistor type temperature sensor. The yellow
wire is the sense line to the WEDGE. The brown wire is the sensor ground.
Component Location:
RT1 temperature sensor is located on the side of the separator tank near the
safety valve.
Book: 23227143 (6-09) Rev B Page 55

COMPRESSOR CODE 53
Action Result
sensor
Step 3:
Book: 23227143 (6-09) Rev B Page 56

COMPRESSOR CODE 54
PT2, Regulation System Pressure Sensor Fault
Explanation:
The WEDGE has detected an out of range reading from the PT2 pressure sensor.
Effect:
PT2 Pressure Sensor Circuit:
The pressure sensor connects to the WEDGE controller as shown in the circuit
above. The purple wire is the 5 VDC excitation supply from the WEDGE. The
orange wire is the signal output to the WEDGE with a range of 0.5 to 4.5 VDC.
The brown wire is the sensor ground. The pressure range of PT2 is 0 psig (0.5
VDC) to 100 psig (4.5 VDC).
Component Location:
PT2 pressure sensor is located in regulation system on top of the separator tank.
Book: 23227143 (6-09) Rev B Page 57

COMPRESSOR CODE 54
Action Result
Disconnect PT2 from harness and plug pressure is not between 33 psi and 43
transducer simulator (Part No. 22168868) into the psi, check for wiring problems
harness connector. Check WEDGE diagnostic
display 4 to verify pressure value is between 33 psi If pressure value on display 4
and 43 psi. is between 33 psi and 43 psi,
replace PT2 pressure sensor
Step 3:
Book: 23227143 (6-09) Rev B Page 58

COMPRESSOR CODE 56
Minimum Start Pressure Not Met
Explanation:
The minimum start pressure (50 psi) has not been met within 20 seconds of machine
start.
Effect:
Code 56 is an ALERT condition and will not stop the machine, however the machine
will not load. The Compressor Malfunction light will be blinking, and Code 56 will be
displayed.
Action Result
Step 1: Loose fittings
Check air piping system for leaks and or restrictions. Clogged hoses or pipes
Step 2: Stuck unloader
Check unloader operation.
sensor
Step 5:
Book: 23227143 (6-09) Rev B Page 59

COMPRESSOR CODE 70
Serial Communications Failure
Explanation:
The WEDGE has detected an RS232 serial link problem. The serial link is used to
install software and to communicate with a test tool.
Effect:
Serial Communications Circuit:
The communication connector connects to the WEDGE controller as shown in
the circuit above. The dark blue wire is the RXD (received) signal at the WEDGE.
The light blue wire is the TXD (transmit) signal from the WEDGE. The brown wire
is the serial link ground.
Component Location:
J5 connector is located inside the machine near the WEDGE controller.
Book: 23227143 (6-09) Rev B Page 60

COMPRESSOR CODE 70
Action Result
and J5 connector.
Step 2:
Substitute the current device (laptop or test tool)
being used to communicate with the WEDGE with
another one.
Step 3:
If Steps 1 and 2 do not resolve the problem, replace
WEDGE.
Book: 23227143 (6-09) Rev B Page 61

COMPRESSOR CODE 71
Engine ECM Communication Failure
Explanation:
The WEDGE cannot communicate with the engine ECM via J1939 CAN BUS
network.
Effect:
WEDGE to Engine ECM J1939 CAN BUSS circuit:
The J1939 CAN BUSS cable connects the WEDGE 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
gray wire is referred to as J1939 CAN Shield. This cable is the communications
link between the WEDGE and all devices connected to it.
Book: 23227143 (6-09) Rev B Page 62

COMPRESSOR CODE 71
The CAN network has two terminating resistors TR1 and TR2. The resistance
value of each terminator is 120 ohms. The terminators are connected together in
parallel across the High (+) and Low (-) wires in the cable. When connected the
resistance value between the High (+) and Low (-) wires is 60 ohms.
Component Location:
P1 connector is connected to the WEDGE controller and the J02 connector is
connected to the engine ECM. Terminating resistor TR1 is located on the main
harness near the WEDGE controller. Terminating resistor TR2 is located on the
main harness near the engine ECM.
Action Result
Step 1: Replace fuses as needed
Check fuse F2.
Verify battery + and – connections to the engine
ECM.
Step 3: Voltage measure should be 24
Turn ignition switch to the “ON” position. Using a VDC at J02-B2.
multimeter, measure the keyswitch signal voltage at
J02-B2. If not, check all harness
connections in the keyswitch
signal circuit from WEDGE to
engine ECM.
Disconnect P1 connector from the WEDGE, J02 should be 60 ohms across P1-
connector from the engine ECM, and any other 34 and P1-35
devices connected to the J1939 CAN BUSS. Using a
multimeter, measure the resistance between P1-34 Resistance value measured
and P1-35. should be 60 ohms across
J02-A1 and J02-B1
Using a multimeter, measure the resistance between
J02-A1 and J02-B1. If not, measure resistance
value of each terminator (120
ohms) and or check for
defective splice, broken wire,
and loose connection at
Book: 23227143 (6-09) Rev B Page 63

connector pins
Step 5: Continuity should be shorted
Disconnect P1 connector from the WEDGE and J02 between P1-35 and J02-A1
connector from the engine ECM. Disconnect TR1
and TR2 from the harness. Using a multimeter,
measure continuity between P1-35 and J02-A1.
Using a multimeter, measure continuity between P1-

34 and J02-B1. Continuity should be shorted
between P1-34 and J0-B1
Using a multimeter, measure continuity between P1-
34 and P1-35. Continuity should be open
between P1-34 and P1-35. If
not, check for defective splice
and or shorted pins in
connectors.
Step 6: Voltage measured at P1-34
Disconnect any devices that are connected to the and P1-35 should be 2.5 VDC.
J1939 CAN BUSS except the WEDGE and engine
ECM. Turn ignition switch to the “ON” position. Using If not, replace engine ECM.
a multimeter, measure the voltage at P1-34 to
battery -.
Using a multimeter, measure the voltage at P1-35 to

battery -.
Step 7:
If steps 1 through 6 checkout OK, replace WEDGE.
Book: 23227143 (6-09) Rev B Page 64

COMPRESSOR CODE 73
Auto Start/Stop Controller Communication Failure
Explanation:
The WEDGE cannot communicate with the Auto Start/Stop Controller via J1939 CAN
BUSS network.
Effect:
WEDGE to Auto Start/Stop Controller J1939 CAN BUSS circuit:
The J1939 CAN BUSS cable connects the WEDGE controller and the Auto
Start/Stop Controller 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 (-). This cable is the communications link between the WEDGE and all
devices connected to it. The P10/J10 connector is the connection point where the
Auto Start/Stop harness connects to the chassis harness.
Component Location:
P1 connector is connected to the WEDGE controller and the P100 connector is
connected to the Auto Start/Stop Controller. P10/J10 connectors are located
close to the lift bail on the curb side of the machine.
Book: 23227143 (6-09) Rev B Page 65

COMPRESSOR CODE 73
Action Result
Step 1: Replace fuse if needed
Check fuse F9 to verify that it has not blown.
Check all harness connections at WEDGE and Auto
Start/Stop Controller.
Disconnect P1 connector from the WEDGE, J02 should be 60 ohms across
connector from the engine ECM, P100 from the Auto P100-20 and P100-23
Start/Stop controller, and any other device
connected to the J1939 CAN BUSS network. Using If not, measure resistance
a multimeter, measure the resistance between P100- value of each terminator (120
20 and P100-23 ohms) and or check for
defective splice, broken wire,
and loose connection at
connector pins
Step 4:
If steps 1 through 3 checkout OK, replace Auto
Start/Stop Controller.
Book: 23227143 (6-09) Rev B Page 66

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

Electrical Circuits
Engine Start Circuit
Book: 23227143 (6-09) Rev B Page 68

Engine Start Circuit
The WEDGE controls engine starter engagement using a 24 VDC input from the
ignition switch (S1) and a 24 VDC output to the starter relay coil (K1). The
WEDGE provides starter protection by turning off the output to K1 relay coil when
engine speed reaches 600 RPM even if the operator is still holding the ignition
switch in the start position. The WEDGE prevents cranking if a SHUTDOWN
code is active.
Component Location:
K1 relay is located on a bracket inside the lift bail. S1 ignition switch is located on
the control panel.
Troubleshooting Steps If Starter Does Not Engage During Crank
Action Result
Step 1: Clear fault codes by following
Check display for fault codes. instructions in this manual
Step 2: Replace fuse if needed
Check F1 fuse.
Check all harness connections throughout engine
start circuit.
Step 4: Replace batteries if needed
Check battery voltage.
Step 5: Voltage measured should be 24
Hold the ignition switch (S1) in the “Start” position. VDC
Using a multimeter, measure the voltage at:
1. Ignition switch (S1-C).

2. WEDGE controller connector (P1-23). If not, replace S1 ignition switch
3. WEDGE controller connector (P1-28). If not, replace WEDGE
4. Starter relay (K1-A).
5. Starter relay (K1-1). If not, replace K1 relay
6. Starter relay (K1-2). If 24 VDC is measured at B1-S,
7. Engine starter (B1-S). replace starter
Book: 23227143 (6-09) Rev B Page 69

Air Filter Restriction Switch Circuit
Book: 23227143 (6-09) Rev B Page 70

The WEDGE receives a battery ground input from the air filter restriction switch
(S16 and or S17) when the switch closes signaling that the filters are clogged.
The air filter restriction switch contacts are normally open. The contacts close
when the air filter restriction reaches 20 inches of water.
Component Location:
S16 and S17 air filter restriction switches are located behind the engine and
airend air filter housing.
Troubleshooting Steps If The Air Filter Switches Do Not Close
Action Result
Check all harness connections throughout air filter
restriction switch circuit.
Step 2: Continuity should be shorted
Disconnect the harness from S16 and S17 air filter between each brown wire and
restriction switches. Using a multimeter, measure the battery negative.
continuity from the brown wire on the harness at
each switch to battery negative. If not, repair harness
Step 3: Air filter restriction diagnostic
Turn the ignition switch to the “ON” position. light on panel should come on.
Disconnect the harness from S16 and S17 air filter
restriction switches. Place a jumper across the If not, replace WEDGE
harness terminals at S16. Remove jumper at S16
and place across harness terminals at S17.
Book: 23227143 (6-09) Rev B Page 71

Book: 23227143 (6-09) Rev B Page 72
SECTION 6 - System Schematics & Wiring
Diagrams
Book: 23227143 (6-09) Rev B Page 73

Book: 23227143 (6-09) Rev B Page 74
Book: 23227143 (6-09) Rev B Page 75
Book: 23227143 (6-09) Rev B Page 76
Book: 23227143 (6-09) Rev B Page 77
Book: 23227143 (6-09) Rev B Page 78
Book: 23227143 (6-09) Rev B Page 79
Book: 23227143 (6-09) Rev B Page 80
Book: 23227143 (6-09) Rev B Page 81
Book: 23227143 (6-09) Rev B Page 82
Book: 23227143 (6-09) Rev B Page 83
Book: 23227143 (6-09) Rev B Page 84
John Deere Engine Models 4045HF285 and 6068HF285 Engine Harness Schematic
Book: 23227143 (6-09) Rev B Page 85

SECTION 7- Electrical Component Locations
Book: 23227143 (6-09) Rev B Page 86

S15
S16
S17
G1
S1
S2 F1
M1 F2
M2 F3
M3
M4
DS1
DS2
DS3 U1
WEDGE
B1
HR1
Book: 23227143 (6-09) Rev B Page 87

ELECTRICAL COMPONENT LOCATION
L2 RT1
PT1
PT2
L1
RT2
S18
K1
K2
ENGINE
ECM
Book: 23227143 (6-09) Rev B Page 88

Harness Connector Locations
P1: 40 pin connector located on WEDGE controller
J02: 48 pin connector located on engine ECM
J5: 9 pin connector for WEDGE RS232 communication, located near WEDGE controller
P4/J4: 12 pin connector located at back of control panel
P2: 3 pin connector for termination resistor on J1939 CAN BUSS near WEDGE controller
P3: 3 pin connector for termination resistor on J1939 CAN BUSS near engine ECM
C11: 9 pin connector for engine ECM service tool, located near engine ECM
C07: 3 pin connector for auxiliary power that connects to C02 on engine harness, located on
engine
C18: 3 pin connector for intake heater control that connects to C03 on engine harness, located on
engine
P10/J10: 6 pin connector for various options, located near airend
P7/J7: 2 pin connector for Full Gauge option power, located behind control panel
P8/J8: 2 pin connector for Air Filter Restriction option, located near lift bail
P12/J12: 2 pin connector for IQ Filter Restriction option, located near lift bail
Book: 23227143 (6-09) Rev B Page 89

SECTION 8 - Electrical Parts List
Book: 23227143 (6-09) Rev B Page 90

Electrical Parts List
Reference
Description Part Number
Designator
RT1, RT2 Thermistor Temperature Sensor 23294820
PT1 0-500 psig Pressure Transducer 54765946
PT2 0-100 psig Pressure Transducer 36920825
S1 Ignition Switch 22127385
S1 Replacement Knob Assembly 22134118
S2 Service Air Switch 22054076
S15 Display Scroll Push Button 54475777
L1 Solenoid Valve 24VDC NC 36840841
Solenoid Valve 24VDC NC
L2 Model: P600WIR (7/170), HP450 (10/125), 36840841
VHP400WIR (14/115)
K1, K2 Relay 100 Amp 24VDC SPST 36853521
U1 Fuel Level Sender/Shutdown Sensor 54731427
TR1, TR2 J1939 CAN Terminating Resistor 23366784
F1, F2 Blade Fuse 20 Amp 36792083
F3 Blade Fuse 40 Amp 22986962
Diode
D1 D2 only on Model: P600WIR (7/170), HP450 (10/125), 35376169
VHP400WIR (14/115)
Diode
D2 Model: P600WIR (7/170), HP450 (10/125), 35376169
VHP400WIR (14/115)
M1 Hourmeter 24VDC 22054175
M2 Fuel Level Gauge 22692602
M3 4 in 1 Gauge Assembly (optional) 22255046
M4 Tachometer 24 VDC (optional) 22055883
M4 Replacement Resistor Board 24VDC 22271779
M5 Pressure Gauge 0-250 psi 36891216
M2, M3, M4, M5 Replacement Bulb 28VDC 22137426
DS1,DS2 Module 2 Light Warning 22172423
DS3 Wait To Start Light 22050553
RP1 Pressure Sender 0-150 psi (optional) 36870608
RT3 Temperature Sender 0-300oF (optional) 35367218
RT4 Temperature Sender 0-300oF (optional) 35372457
S16, S17 Air Filter Vacuum Switch NO (optional) 36847838
S18 Differential Pressure Indicator 25 psi (optional) 36899615
WEDGE Controller 22173579
Battery Positive Cable 35583582
Battery Negative Cable 35587088
Battery Terminal Jumper 35128982
Frame Ground Strap
Model: P425WIR (7/120), XP375WIR (9/110), 35578194
HP350WIR (10/105), & (14/85)
Frame Ground Strap
Model: P600WIR (7/170), HP450 (10/125), 36783488
VHP400WIR (14/115)
Chassis Harness
Model: P425WIR (7/120), XP375WIR (9/110), 22969554
HP350WIR (10/105), & (14/85)
Book: 23227143 (6-09) Rev B Page 91

Chassis Harness
Model: P600WIR (7/170), HP450 (10/125), 22984009
VHP400WIR (14/115)
Trailer Harness 54761101
Control Panel Harness 22835680
Full Gauge Panel Harness (optional) 22251896
Air Filter Restriction Switch Harness (optional) 22251904
IQ Filter Switch Harness (optional) 22293484
Gauge Illumination Harness (optional) 22681845
Tachometer Harness (optional) 22261465
BT1, BT2 Battery 12 VDC 1000 CCA 36844975
HR1 Air Inlet Heater 24 VDC 85473999
Alternator 24 VDC
G1 Model: P600WIR (7/170), HP450 (10/125), 23229511
VHP400WIR (14/115)
Alternator 24 VDC
G1 Model: P425WIR (7/120), XP375WIR (9/110), 22206221
HP350WIR (10/105), & (14/85)
B1 Starter 24 VDC 22206213
J5, C11 Replacement Cap with Lanyard 23366768
S20 Switch SPST (Autostart option) 54615091
DS10 Indicator Lamp (Autostart option) 22307698
DS10 Replacement Lamp (Autostart option) 35290089
LS1 Audible Horn (Autostart option) 36785145
TB1 2 x 8 Terminal Block (Autostart option) 22307706
Autostart Harness (Autostart option) 22864631
Autostart Controller (Autostart option) 22743322
Battery Charger (Autostart option) 54715941
Battery Charger Harness (Autostart option) 22327175
Book: 23227143 (6-09) Rev B Page 92

Book: 23227143 (6-09) Rev B Page 93
SECTION 9 - Harness Connector Information
Book: 23227143 (6-09) Rev B Page 94

Harness Connector Information
The following is a complete list of the connectors and connector parts that are used on the
machine harnesses. The most common replacement connectors and connector parts will be
found in the Deutsch terminal repair kit, Packard terminal repair kit, and Wire terminal repair kit. A
repair kit is available for the WEDGE connector and 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.
Included in
Manufacturer’s Part
Connector and Parts Manufacturer Doosan Service
No.
Kit Part No.
P1 WEDGE Connector
Plug, 40 way Deutsch DRC16-40S 22252993
Socket size 16 Tin Deutsch 0462-201-16141 22252993 /
46490983
Socket size 14 Tin Deutsch 0462-209-16141 22252993 /
46490983
Socket size 16 Gold Deutsch 0462-201-1631 22252993 /
46490983
Sealing plug size 16-12 Deutsch 114017 22252993 /
46490983
Rubber Boot Deutsch DRC40-BT
P4 Control Panel Connector
Plug, 12 way Deutsch DT06-12SA-EP08
Rubber Boot Deutsch DT12S-BT-BK
Socket size 16 Tin Deutsch 0462-201-16141 46490983
Sealing plug size 16-12 Deutsch 114017 46490983
J4 Control Panel Connector
Receptacle, 12 way Deutsch DT04-12PA-E005
Rubber Boot Deutsch DT12P-BT-BK
Pin size 16 Tin Deutsch 0460-202-16141 46490983
Pin size 14 Tin Deutsch 0460-215-16141 46490983
P10 Accessory Connector
Plug, 6 way Deutsch DT06-6S-EP06 46490983
Wedgelock Deutsch W6S-P012 46490983
Socket size 16 Gold Deutsch 0462-201-1631 46490983
J10-Cap Accessory Connector
Receptacle, 6 way Deutsch DT04-6P-E005 46490983
RT1, RT2 Temperature Sensor Connector
Plug, 2 way Packard 15300027 46491296
TPA Packard 15300014 46491296
Terminal, 18-16 Awg Packard 12077411 46491296
Cable Seal Packard 12089679 46491296
PT1, PT2 Pressure Sensor Connector
Plug, 3 way Packard 13532244 46491296
TPA Packard 15452678 46491296
Book: 23227143 (6-09) Rev B Page 95

Included in
No.
Kit Part No.
J5 WEDGE Controller Communication Connector
Receptacle, 9 way Deutsch HD10-9-96P 46490983
Connector Cap Deutsch HDC9-JDL082397 46490983
Pin size 16 Gold Deutsch 0460-202-1631 46490983
P7, P8, P12 Options Connectors

Wedgelock Deutsch W2S-P012 46490983
J7-Cap, J8-Cap, J12-Cap Options Connector
Receptacle, 2 way Deutsch DT04-2P-E005 46490983
P2, P3 J1939 CAN Terminator Connector
Wedgelock Deutsch W3S-1939-P012 46490983
Socket size 16 Gold Deutsch 0462-201-1631 46490983
TR1, TR2 J1939 CAN Terminators
Receptacle, 3 way
Deutsch DT04-3P-EP10 46490983
terminator
C11 Engine Service Connector
Receptacle, 9 way Deutsch HD10-9-1939PE
Connector Cap Deutsch HDC9-JDL082397 46490983
Pin size 16 Gold Deutsch 0460-202-1631 46490983
S1 Ignition Switch Connector
Plug, 4 way Packard 12052856 46491296
TPA Packard 15324456 46491296
Terminal 18-16 Awg Packard 12034046 46491296
U1 Low Fuel Shutdown/Gauge Sender Connector
Plug, 4 way Packard 12015797 46491296
F1, F2, F3 Fuse Connector
Plug, 2 way Fuse Packard 12085030 46491296
Fuse Connector Cap Packard 12033731 46491296
C07 Auxiliary Power Connector
Plug, 3 way Packard 12040977
TPA Packard 12034145
Terminal, 12-14 Awg Packard 12129493
Cable Seal 12 Awg Packard 12015193
Cable Seal 16 Awg Packard 12089679 46491296
C18 Connector To C03 on Engine
Plug, 3 way Packard 12110293
TPA Packard 12052845
Book: 23227143 (6-09) Rev B Page 96

Included in
No.
Kit Part No.
J02 Engine ECM Connector

Plug, 48 way Molex 98993-3319 46491411
Cover, 48 way Molex 98993-1301 46491411
Terminal, 1.5mm Molex 98915-1029 46491411
Terminal, 0.6mm Molex 98913-1029 46491411
Cavity Seal, 1.5mm Molex 98575-1023 46491411
Cavity Seal, 0.6mm Molex 98575-1010 46491411
D1, D2 Diode Terminals
Plug, Bullet AMP 60660-1 22252969
Receptacle, Bullet AMP 60798-1 22252969
Quick Disconnects, Ring Terminals, and Butt Splices
Most Common used Quick Disconnects, Ring Terminals, and Butt
22252969
Splices can be found in the Doosan Wire Terminal Service Kit.
Contact For Packard and Molex Connector and Connector Parts:

Power and Signal Group
6675 Parkland Blvd.
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
Harrisburg, PA 17105
1-800-522-6752
Book: 23227143 (6-09) Rev B Page 97

Electrical Torque Specifications
Electronic Controller Connector Screw Torque Specifications

Connector Manufacturer
Description Torque
Manufacturer Part Number
WEDGE Controller Deutsch DRC16-40S 25 in.lbs
Caterpillar C9,C15, &
C18 Tier 3 Engine Amp 776241-1 53 in.lbs
ECM
Cummins QSL9 &
QSC8.3 Tier 3 Deutsch DRC26-50S-04 25 in.lbs
Engine ECM
Cummins QSX15
Deutsch DRC26-50S-01 25 in.lbs
Tier 3 Engine ECM
Book: 23227143 (6-09) Rev B Page 98

Book: 23227143 (6-09) Rev B Page 99
SECTION 10 - Tools and Repair Kits
Book: 23227143 (6-09) Rev B Page 100

Service Tools and Repair Kits
The following list of special service tools are recommended to perform service
and troubleshooting procedures in this manual. These tools can be purchased
through
Doosan Infracore Portable Power.
Part Number Description

Digital Multimeter (Fluke 87)
22216691
Used to measure electrical circuits: Volts, Amps, Ohms
Fluke Meter Case
22216733
Storage Case for Fluke meter and test leads
Fluke Test Lead Set
22216709
Contains needle probes, alligator clips, and test leads
Fluke Wire Insulation Piercing Probe
22216725
Used to pierce wire insulation when making electrical measurements
Kit, Test Adapters
22147540 Used to interconnect between devices and harness for electrical
measurements
T-Handle Hex Wrench 5/32”
22281588 Used to remove WEDGE, Caterpillar ECM, and Cummins ECM
connectors
Screw Driver Hex 5/32”
22282107 Used to remove WEDGE, Caterpillar ECM, and Cummins ECM
connectors
Flex Driver ¼”
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
54699632
46490942
54699624
54699616
Deutsch Wedgelock and Terminal Removal Tool
54699657 Used to remove Deutsch DT style connector wedgelocks and
terminals
Kit, Deutsch Terminal Removal Tool Size 20 Through 8
22146393
Used to remove Deutsch size 20 through 8 terminals from connectors
Deutsch Terminal Crimp Tool
22216667
Used to crimp Deutsch connector terminals
Packard Weather-Pack Terminal Removal Tool
54729660
Used to remove Packard Weather-Pack connector terminals
Packard Metri-Pack Terminal Removal Tool
54749643
Used to remove Packard Metri-Pack connector terminals
Book: 23227143 (6-09) Rev B Page 101

Packard Metri-Pack Terminal Removal Tool
46490959
Used to remove Packard Metri-Pack connector terminals
Packard Weather-Pack Terminal Crimp Tool
22254734
Used to crimp Packard Weather-Pack connector terminals
Packard Metri-Pack Terminal Crimp Tool

22216683
Used to crimp Packard 150 and 280 series connector terminals
22255947
Used to crimp Packard 150 series pull-to-seat connector terminals
46490967
Used to crimp Packard 150-GT series connector terminals
46490975
Used to crimp Packard 630 series connector terminals
RTD Simulator
54749544
Used to troubleshoot RTD type temperature sensor problems
Thermistor Simulator
54749551
Used to troubleshoot Thermistor type temperature sensor problems
Thermistor Simulator
22073878
Used to troubleshoot Thermistor type temperature sensor problems
Pressure Transducer Simulator
22168868
Used to troubleshoot pressure sensor problems
Electrical Contact Cleaner
54729710
Used to clean electrical terminals and connectors
Electrical Grease
22409114
Used to prevent corrosion in connector terminals
Molex 1.5 Terminal Crimp Tool
46491338
Used to crimp Molex CMC 1.5 series connector terminals
Molex 0.6 Terminal Crimp Tool
46491346
Used to crimp Molex CMC 0.6 series connector terminals
Molex 1.5 Terminal Removal Tool
46491653
Used to remove Molex CMC connector terminals
Molex 0.6 Terminal Removal Tool
46491361
Used to remove Molex CMC connector terminals
AMP Ampseal Terminal Crimp Tool
46491320
Used to crimp Ampseal series connector terminals
Book: 23227143 (6-09) Rev B Page 102

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
Kit, Wire Terminal Repair
22252969
Assortment of ring and quick disconnect terminals
Kit, Fuses
22254775
Assortment of ATC and ATM style fuses
Kit, Adhesive Lined Heat Shrink
22253017
Assortment of adhesive lined heat shrink sizes
Kit, WEDGE Connector Repair
22252993
Used to repair WEDGE connector and terminals
Kit, Packard Connector Repair
46491296
Assortment of Packard connectors and terminals
Kit, Caterpillar C9, C15, and C18 Engine ECM Connector Repair
46491304
Used to repair engine ECM connector and terminals
Kit, OTC and AutoStart Controller Connector Repair
46491312
Used to repair 23 way controller connector and terminals
Kit, John Deere and Yanmar Tier 3 Engine ECM Connector Repair
46491411
Kit, Cummins QSX15 Engine ECM Connector Repair
46491429
Kit, SECU and Mote Controller Connector Repair
46491502
Used to repair 35 way controller connector and terminals
Kit, Cummins OSL9 and QSC 8.3 Engine ECM Connector Repair used
46491569
to repair engine ECM connector and terminals.
Book: 23227143 (6-09) Rev B Page 103

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.
Terminal Manufacturer’s Doosan

Terminal Manufacturer Manufacturer’s Crimp Tool Part Crimp Tool Part
Part No. No. No.
Socket size 20 Tin Deutsch 0462-201-20141 HDT-48-00 2221667
Socket size 20 Gold Deutsch 0462-201-2031 HDT-48-00 2221667
Pin size 20 Tin Deutsch 0460-202-20141 HDT-48-00 2221667
Pin size 20 Gold Deutsch 0460-202-2031 HDT-48-00 2221667
Terminal Packard 15326267 15359996 46490967
Terminal 16-18 Awg Packard 12110847 12155975 22216683
Pin Grip Terminal Packard 08911072 12155975 22216683
Terminal 20-16 Awg
AMP 770854-3 58440-1 46491320
Gold
Terminal 1.5mm Molex 98915-1029 0638118900 46491338
Terminal 0.6mm Molex 98913-1029 0638119200 46491346
Contact For Packard and 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
Book: 23227143 (6-09) Rev B Page 104

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

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.
Contact Removal
1. With rear insert toward you, snap

appropriate size extractor tool over the
wire of contact to be removed.
2. Slide tool along wire into the insert

cavity until it engages contact and
resistance is felt.
NOTE: Do not twist or insert tool at an
angle.
3. Pull contact-wire assembly out of

connector.
Book: 23227143 (6-09) Rev B Page 106

Deutsch DT Series Connector Service Procedures
Contact Insertion
1. Grasp crimped contact

approximately (25.2 mm) one inch
behind the contact barrel.

facing you.

grommet until a click is felt. A slight tug
will confirm that it is properly locked in
place.
Once all contacts are in place, insert

orange wedge will arrow pointing
toward exterior locking mechanism.
The orange wedge will snap into place.
Rectangular wedges are not oriented.
They may go in either way.
NOTE: The receptacle is shown - use
the same procedure for plug.
Contact Removal
1. Remove orange wedge using needle

nose pliers or a hook shaped wire to
pull wedge straight out.
2. To remove the contacts, gently pull

wire backwards, while at the same time
releasing the locking finger by moving
it away from the contact with a
screwdriver.
3. Hold the rear seal in place, as

removing the contact will displace the
seal.
Book: 23227143 (6-09) Rev B Page 107

Deutsch DTM Series Connector Service Procedures
Contact Insertion
1. Grasp crimped contact

approximately 1.0" (25.4 mm) behind
the contact barrel.

facing you.

grommet until a click is felt. A slight tug
will confirm that it is properly locked in
place.
Once all contacts are in place, insert

orange wedge: receptacles - with half
holes aligning with contacts. Plugs -
with contacts aligning behind full holes.
The orange wedge will snap into place.
NOTE: The receptacle is shown - use
the same procedure for plug.
Contact Removal
1. Remove orange wedge using needle

nose pliers to pull wedge straight out.
2. To remove the contacts, gently pull

wire backwards, while at the same time
releasing the locking finger by moving
it away from the contact with a
screwdriver.
3. Hold the rear seal in place, as

removing the contact will displace the
seal.
Book: 23227143 (6-09) Rev B Page 108

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. The retaining fingers in the
connector will snap behind the
shoulder of the contact and lock it in
place. A slight tug will confirm that it is
properly sealed.
Contact Removal
1. With rear insert toward you, snap the

appropriate size plastic tool over the
wire of the contact to be removed.
2. Slide the tool along the wire into the

insert cavity until it engages the contact
and resistance is felt. The contact
retaining clip will be in the unlocked
position.
3. Pull the contact-wire assembly out of
the connector.
Book: 23227143 (6-09) Rev B Page 109

Deutsch HD30 and HDP20 Series Connector Service Procedures
Contact Insertion
1. Grasp contact approximately (25.4

mm) one inch behind the contact crimp
barrel.

facing you.

grommet until a positive stop is felt. A
slight tug will confirm that it is properly
locked in place.
NOTE: For unused wire cavities, insert
sealing plugs for full environmental
sealing
Contact Removal
1. With rear insert toward you, snap

appropriate size extractor tool over the
wire of contact to be removed.
2. Slide tool along into the insert cavity

until it engages contact and resistance
is felt.
3. Pull contact-wire assembly out of

connector.
NOTE: Do not twist or insert tool at an
angle
Book: 23227143 (6-09) Rev B Page 110

AMP Crimp Tool 58440-1 Instructions
Book: 23227143 (6-09) Rev B Page 111

Book: 23227143 (6-09) Rev B Page 112

Book: 23227143 (6-09) Rev B Page 113

Book: 23227143 (6-09) Rev B Page 114

AMP Ampseal Series Connector Service Procedures
Book: 23227143 (6-09) Rev B Page 115

Book: 23227143 (6-09) Rev B Page 116

Book: 23227143 (6-09) Rev B Page 117

Molex Crimp Tool 0638118900 Instructions
Book: 23227143 (6-09) Rev B Page 118

Book: 23227143 (6-09) Rev B Page 119

Book: 23227143 (6-09) Rev B Page 120

Book: 23227143 (6-09) Rev B Page 121

Book: 23227143 (6-09) Rev B Page 122

Book: 23227143 (6-09) Rev B Page 123

Book: 23227143 (6-09) Rev B Page 124

Book: 23227143 (6-09) Rev B Page 125

Book: 23227143 (6-09) Rev B Page 126

Book: 23227143 (6-09) Rev B Page 127

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

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

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

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

SECTION 11 - Recommended Spare Parts
Book: 23227143 (6-09) Rev B Page 132

Recommended Spare Parts
Quantity Description Part Number
1 WEDGE Controller 22173579
2 Thermistor Temperature Sensor 23294820
2 0-100 psig Pressure Transducer 36920825
2 0-500 psig Pressure Transducer 54765946
2 Solenoid Valve 24VDC NC 36840841
Book: 23227143 (6-09) Rev B Page 133

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

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
Book: 23227143 (6-09) Rev B Page 135

Doosan Infracore Portable Power
1293 Glenway Drive
Statesville, N.C. 28625
www.doosanportablepower.com

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ELECTRONIC SERVICE MANUAL

P600WIR (7/170) C54 (D18)

Doosan purchased Bobcat Company from Ingersoll-Rand Company in

Doosan Infracore Portable Power

Book: 23227143 (6-09) Rev B

Book: 23227143 (6-09) Rev B Page 1

Book: 23227143 (6-09) Rev B Page 2

Book: 23227143 (6-09) Rev B Page 3

Book: 23227143 (6-09) Rev B Page 5

The second function of the WEDGE controller is machine discharge pressure

Book: 23227143 (6-09) Rev B Page 6

The electronics system also uses pressure transducers to measure compressor

Digital Inputs and Outputs

The WEDGE controller provides 24 VDC digital outputs to control solenoids,

The discharge pressure is controlled by manipulating the engine speed and

Book: 23227143 (6-09) Rev B Page 7

These machines contain an emissions certified diesel engine. In order to meet

J1939 Data Link

22984009 Main Chassis Harness (Models: P600WIR (7/170), HP450WIR

Book: 23227143 (6-09) Rev B Page 8

CONTROL PANEL SOLENOID VALVES

Book: 23227143 (6-09) Rev B

CONTROL PANEL HARNESS

P1-34 J1939 CAN LOW (-) J02-B1

P1-35 J1939 CAN HIGH (+) J02-A1

P1-1 J1939 CAN SHIELD J02-K2

Book: 23227143 (6-09) Rev B

KEY SWITCH SIGNAL

ANALOG THROTTLE RANGE = 2.5VDC (1500RPM) to 3.9 VDC (2200RPM)

ENGINE ECM WEDGE

Book: 23227143 (6-09) Rev B

PT1 is a 0-500 psi gauge pressure transducer that measures

PT2 is a 0-100 psi gauge pressure transducer that measures

RT1 is a 10K ohm Thermistor type temperature sensor that

RT2 is a 10K ohm Thermistor type temperature sensor that

K1 is a SPST, 24 VDC relay used to engage the engine starter

K2 is a SPST, 24 VDC relay used to energize the engine inlet

U1 is a resistive level detector and low level switch sensor used to

Book: 23227143 (6-09) Rev B Page 12

1. Compressor Malfunction Diagnostic Light: Indicates ALERT or

2. Engine Malfunction Diagnostic Light: Indicates ALERT or SHUTDOWN

3. Hourmeter: Indicates machine operating hours.

4. Discharge Air Pressure Gage: Indicates pressure in receiver tank,

5. Fuel Level Gauge: Indicates level of fuel in fuel tank.

6. Main Ignition Switch: ON/OFF Start Switch

Book: 23227143 (6-09) Rev B Page 13

9. Engine Tachometer: Indicates engine speed in RPM from 0 when

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

15. Low Engine Oil Pressure Diagnostic Light: Indicates ALERT or

16. High Engine Coolant Temperature Diagnostic Light: Indicates ALERT

Book: 23227143 (6-09) Rev B Page 14

18. Low Battery Voltage Diagnostic Light: ALERT indication battery or