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Ingersoll-Rand P425AWIR Electrical/Electronic Service Manual
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Ingersoll-Rand P425AWIR Electrical/Electronic Service Manual

Ingersoll-Rand P425AWIR Electrical/Electronic Service Manual

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Portable Power
P.O. Box 868 - - 501 Sanford Ave
Mocksville, N.C. 27028
www.portablepower.irco.com
ELECTRICAL/ELECTRONIC
SERVICE MANUAL FOR
P425AWIR (7/120)
XP375AWIR (9/110)
HP375AWIR (10/105)
VHP300AWIR (14/85)
P600WIR
HP450WIR
VHP400WIR
Book No. 22235428 (11/03)

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Summary of Contents for Ingersoll-Rand P425AWIR

  • Page 1 ELECTRICAL/ELECTRONIC SERVICE MANUAL FOR P425AWIR (7/120) XP375AWIR (9/110) HP375AWIR (10/105) VHP300AWIR (14/85) P600WIR HP450WIR VHP400WIR Portable Power P.O. Box 868 - - 501 Sanford Ave Mocksville, N.C. 27028 www.portablepower.irco.com Book No. 22235428 (11/03)
  • Page 2 SECTION 9 ..Electrical Parts List SECTION 10 ..Alerts and Shutdowns List SECTION 11 ..Recommended Spare Parts SECTION 12 ..IR Engine Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 3 Section 9 contains the parts list with ordering information. Section 10 contains the list of Alerts and Shutdowns. Section 11 contains a list of recommended spare parts for servicing. Section 12 contains engine information. Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 4 SECTION 2 GENERAL INFORMATION OPERATIONAL THEORY Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 5 J1939 front panel of the WEDGE. They can be seen through CAN network. It retrieves diagnostic information over the laminate on the front of the control panel. J1939. Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 6 Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 7 Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 8 Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 9 Controller Outputs The WEDGE controller has four types of outputs: fre- quency, pulse width modulated, analog and 24VDC digital (ON/OFF). The analog output is used as the throttle signal to the engine. Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 10 The schematic diagrams show the connections for this harness. Figure 2--1 is a system schematic showing harness connection with devices and controllers. Sec- tion 8 includes information on connectors used in the harness. Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 11 RT2 is a 10K ohm Thermistor temperature sensor that measures airend discharge temperature. Its range is --30 to 255_F. K1 is SPST, 24VDC relay used to activate the engine starter. K2 is a SPST, 24VDC relay used to activate the engine inlet heater. Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 12 Power Switch: Flip “ON” to activate systems prior to starting. Flip ’off” to stop engine. Wait to Start Lamp Service Air Switch: After warm--up, PUSH. Provides full air pressure at the service outlet. Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 13 When engine speed reaches 2200 RPM: 1. Run/Start solenoid valve is closed (de--energized). After 2 seconds and if the regulation system pressure is 4 psi or greater: 1. Compressor pressure control is engaged. Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 14 2. Once it appears, do not release the “Service Air” switch. Hold it in the ON position until the WEDGE restarts. This will select units selection that was displayed. 3. Release the “Service Air” switch. The compressor is ready to start. Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 15 Engine Oil Pressure From CAN, PSI Intake Manifold Temp. From CAN, Deg F From CAN Fault Code List Cummins/CAT codes Throttle Position Boost Pressure Engine Hours Load At Speed Percent Set Machine ID Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 16 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 No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 17 P600WIR, HP450WIR, VHP400WIR XP1060WCU, HP935WCU, MHP825WCU VHP750WCU XHP750WCU MHP825WCAT, VHP750WCAT XP1060HACAT,XP950HACAT SHP825WCAT, XHP750WCAT. XHP650WCAT HP1300CWCU,HP1600CWCU XHP1170WCU 1 XHP1070AWCAT, XHP1170WCAT. XHP1170SCAT HP1600WCAT SIRC Models/Wedge Machine ID Models Machine ID P1060WCAT, XP950WCAT, HP935WCAT MHP825WCAT .VHP750WCAT XHP750WCAT Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 18 SECTION 3 SERVICE TOOLS Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 19 Used to make connector repairs for Deutsch and Packard Electric Connectors 54699657 Deutsch Terminal removal Tool Used to repair Deutsch connectors 54749643 Packard Metri--Pack Terminal Removal Tool Used to repair Packard Electric connectors Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 20 Includes the 40--pin connector housing and pins for the harness connector 22253009 CAN Communications Adapter Converts RS232 to J1939 CAN, used with lap top computer or PDA Service T 001 22253017 Adhesive Heat Shrink Assortment Selection of most used heat shrink sizes Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 21 22146393 22147540 22073878 54749635 22168868 22216709 22216725 22216733 54740675 22254775 ATC Fuse Assorlment Kit Kit contains 5, 7--1/2, 10, 15,20,25, and 30 Amp fuses 22254734 Packard Crimp Tool (12014254) Crimps Sealed Weather Pack Connector pins Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 22 Tool Illustration 22216691 Digital Multimeter 54729660 Weather- -Pack Terminal Removal Tool 54699632 Deutsch Terminal Removal Tool (Blue) 54699640 Deutsch Terminal Removal Tool (Red) 54699624 Deutsch Terminal Removal Tool (Yellow) 22216667 Deutsch Crimp Tool Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 23 54729710 Electrical Contact Cleaner 54729728 PDA Service Tool 54699616 Deutsch Terminal Removal Tool 54749544 RTD Simulator Plug 22073878 Thermistor Plug 54749635 Connector Repair kit 54699657 Deutsch Terminal Removal Tool Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 24 54749643 Packard Metri- -Pack Removal Tool 22168868 Pressure Transducer Simulator 22147540 Test Adapter Kit 22146393 Removal Tool Kit 22216675 Deutsch Crimp Tool 22216683 Packard Electric Crimp Tool Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 25 22216709 Fluke Test Lead Set 22216725 Fluke Insulation Piercing Probe (single probe) 22216733 Fluke Meter Case 54740675 RS232 Serial Cable 22253969 Wire Terminal Kit Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 26 Connector Wrenches 22281588 22282172 22282172 1/4’’ Flex Shaft Nutdriver 22252993 WEDGE Connector Kit 22253009 CAN Communications Adapter 22253017 Adhesive Heat Shrink Assortment Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 27 22255947 Packard Electric Crimp Tool 22254734 Packard Electric Crimp Tool Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 28 SECTION 4 ELECTRONIC SYSTEMS TROUBLESHOOTING PROCEDURES AND TECHNIQUES Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 29 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 No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 30 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 No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 31 Check WEDGE output to K1 relay Check battery voltage Compressor fails to load Check Run/Start valve operation when “Service Air” switch pressed Verify frequency throttle signal at engine Check “Service Air” switch operation Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 32 COMPRESSOR FAULT CODES DESCRIPTION AND TROUBLESHOOTING Following, are the descriptions of the COMPRESSOR fault codes. These are indicated when the “COMPERSSOR MALFUNCTION” lamp is illuminated. The compressor malfunction lamp is shown on the control panel picture in Section 2 of this manual. It is indicated by Item number 9. The engine fault codes are indicated by the “ENGINE MALFUNCTION”...
  • Page 33 COMPRESSOR CODE 1 Engine Speed Less Than 800 RPM Explanation: The WEDGE has received an engine speed less than 800 RPM for 30 seconds. Effect: Code 1 is a shutdown condition and will shutdown the machine. TROUBLESHOOTING STEPS Code 1 Action Result Check engine fault codes for an engine...
  • Page 34 COMPRESSOR CODE 2 Engine Speed Greater Than 1900 RPM Explanation: The WEDGE has received an engine speed greater than 1900 RPM for 30 seconds. Effect: Code 2 is a shutdown condition and will shutdown the machine. TROUBLESHOOTING STEPS Code 2 Action Result Check engine fault codes for an engine...
  • Page 35 COMPRESSOR CODE 3 Engine Crank Time Exceeded Explanation: The engine crank time has exceeded 15 seconds. Effect: Code 3 is a shutdown condition and will shutdown the machine. TROUBLESHOOTING STEPS Code 3 Action Result Crank engine for less than 15 seconds.
  • Page 36 COMPRESSOR CODE 5 Engine Oil Temperature Explanation: The WEDGE has received an engine oil temperature greater than 252 Deg F Effect: Code 5 is an ALERT condition and will not halt machine operation. TROUBLESHOOTING STEPS Code 5 Action Result Step1: Refer to the engine manufacturer’s service manual for instructions.
  • Page 37 COMPRESSOR CODE 6 Engine Intake Manifold Temperature Explanation: The WEDGE has received an engine intake manifold temperature greater than 180 deg F. Effect: Code 6 is an ALERT condition and will not halt machine operation. TROUBLESHOOTING STEPS Code 6 Action Result Step1: Refer to the engine manufacturer’s service manual for...
  • Page 38 COMPRESSOR CODE 8 Water in Fuel Explanation: The WEDGE has received a water in fuel indication from the engine. Effect: Code 8 is an ALERT condition and will not halt machine operation. TROUBLESHOOTING STEPS Code 8 Action Result Step1: Check the machine fuel system and engine fuel filters. Step 2: Refer to the engine manufacturer’s service manual for instructions.
  • Page 39 COMPRESSOR CODE 10 Engine Not Responding To Throttle Command Explanation: The engine has not responded to a request from the WEDGE for engine speed change during engine start. This ALERT will only occur during the idle speed time, right after engine start. Effect: Code 10 is an ALERT condition and will not shutdown the machine.
  • Page 40 Circuit Description: As shown in the circuits above, the WEDGE provides three types of throttle outputs: frequency, PWM and analog. TROUBLESHOOTING STEPS Code 10 Action Result Step1: Measure the throttle signal at the engine connector. If signal not present, check wiring and verify throttle output at WEDGE.
  • Page 41 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. The machine failed to start. Effect: Code 11 is a SHUTDOWN condition and will shutdown the machine. TROUBLESHOOTING STEPS Code 11 Action...
  • Page 42 COMPRESSOR CODE 29 Engine shut itself down: reason unknown Explanation: The engine has shut down. The WEDGE did not shut down the engine. Effect: Code 29 is a SHUTDOWN condition and will shutdown the machine. TROUBLESHOOTING STEPS Code 29 Action Result Step1: Check the machine fuel system and engine fuel filters.
  • Page 43 COMPRESSOR CODE 31 Low Air End Oil Pressure (HP1600 Only) Explanation: The WEDGE received a closed contact from pressure switch S9, located in the air end on the HP1600 machine. This indicates a low oil pressure in the air end. Effect: Code 31 is a shutdown condition and will shutdown the machine.
  • Page 44 TROUBLESHOOTING STEPS Code 31 Action Result Step1: Check the air end oil pressure with a mechanical gauge. If > 12 psi, replace S9 If not, there is a harness or WEDGE problem.
  • Page 45 COMPRESSOR CODE 32 RT2, Discharge Temperature Sensor Fault Explanation: The WEDGE has received an out of limits reading from the RT2 temperature sensor. This reading could be on the high or low end of the range. It is out of the normal range for temperature measurement. Effect: Code 32 is a shutdown condition and will shutdown the machine.
  • Page 46 TROUBLESHOOTING STEPS Code 32 Action Result Step1: Substitute the thermistor simulator (I-R # 22073878) for RT2 Should read approx. 32 Deg F Use the WEDGE service diagnostics to read the value for RT2 It should be approximately 32 degrees F. If not, there is a harness or WEDGE problem.
  • Page 47 COMPRESSOR CODE 33 PT1 Pressure Transducer Sensor Fault Explanation: The WEDGE has received an out of limits reading from the PT1 pressure transducer. This reading could be on the high or low end of the range. It is out of the normal range for pressure. Effect: Code 33 is an ALERT condition and will not shutdown the machine.
  • Page 48 TROUBLESHOOTING STEPS Code 33 Action Result Step1: Substitute the pressure transducer simulator (I-R # 22168868) Should read 30 – 50 psi. for PT1. Use the WEDGE service diagnostics to read the value for PT1. It should be approximately 30 – 50 psi. If not, there is a harness or WEDGE problem.
  • Page 49 COMPRESSOR CODE 34 Separator Tank Pressure Greater Than 20 psi at Crank Explanation: The WEDGE has received a pressure from PT1 that is greater than 20 psi at The time of engine crank. Effect: Code 34 is a shutdown condition and will not allow the engine to crank. Once The separator tank bleeds down below 20 psi, engine crank will be allowed.
  • Page 50 COMPRESSOR CODE 35 Machine Over Pressure Condition Explanation: The WEDGE has received a pressure from PT1 that is greater than 175 psi. Effect: Code 35 is a shutdown condition and will shutdown the machine. The separator tank high pressure has been exceeded. TROUBLESHOOTING STEPS Code 35 Action...
  • Page 51 COMPRESSOR CODE 36 Safety Valve Open Explanation: The WEDGE has received a switch closure from S14. This indicates the separator tank safety valve has opened. Effect: Code 36 is a shutdown condition and will shutdown the machine. S14 Pressure Switch Circuit: WEDGE CONTROLLER W239...
  • Page 52 TROUBLESHOOTING STEPS Code 36 Action Result Verify PT1 pressure transducer is reading correctly.
  • Page 53 COMPRESSOR CODE 50 Separator Tank Temperature Explanation: The WEDGE has received a separator tank temperature from RT1 that is greater than 247 degrees F. Effect: Code 50 is a shutdown condition and will shutdown the machine. TROUBLESHOOTING STEPS Code 50 Action Result Step1:...
  • Page 54 COMPRESSOR CODE 51 Machine ID Not Valid Explanation: The WEDGE has not received a reading from the machine ID plug. Effect: Code 51 is a shutdown condition and since a valid machine ID has not been received the machine will shutdown. Machine ID Plug Circuit: J1-15 WEDGE...
  • Page 55 TROUBLESHOOTING STEPS Code 51 Action Result Step1: Make sure an ID plug is installed. Step 2: The ID plug resistance values are listed in the “Individual Circuit If an ID plug is installed, remove it and measure its resistance. Diagrams” section of this service manual.
  • Page 56 COMPRESSOR CODE 53 RT1, Discharge Temperature Sensor Fault Explanation: The WEDGE has received an out of limits reading from the RT1 temperature sensor. This reading could be on the high or low end of the range. It is out of the normal range for temperature measurement. Effect: Code 53 is a shutdown condition and will shutdown the machine.
  • Page 57 TROUBLESHOOTING STEPS Code 53 Action Result Step1: Substitute the thermistor simulator (I-R # 22073878) for RT1 Should read appx. 32 Deg F Use the WEDGE service diagnostics to read the value for RT1 It should be approximately 32 degrees F. If not, there is a harness or WEDGE problem.
  • Page 58 COMPRESSOR CODE 54 PT2 Regulation System Sensor Fault Explanation: The WEDGE has received an out of limits reading from the PT2 pressure transducer. This reading could be on the high or low end of the range. It is out of the normal range for pressure. Effect: Code 54 is an ALERT condition and will not shutdown the machine.
  • Page 59 TROUBLESHOOTING STEPS Code 54 Action Result Step1: Substitute the pressure transducer simulator (I-R # 22168868) Should read 30 – 50 psi. for PT2. Use the WEDGE service diagnostics to read the value for PT2. It should be approximately 30 – 50 psi. If not, there is a harness or WEDGE problem.
  • Page 60 COMPRESSOR CODE 55 Estop Button Explanation: The WEDGE has received an indication that the emergency stop button has been pressed. Effect: Code 55 is a shutdown condition and will shutdown the machine. If the machine Is in the cranking mode when estop is pressed, the starter will be disengaged simultaneously with engine key switch signal turn off.
  • Page 61 Circuit Description: The estop button is in series with the engine key switch signal and the auxiliary start relay, K1. Pressing the button opens both of these circuits simultaneously. The WEDGE reads a sense input that is connected to the estop button to determine if the estop button is pressed.
  • Page 62 COMPRESSOR CODE 56 Minimum Pressure Not Met Explanation: The separator tank has not reached 50 psi within 20 seconds from time engine starts. Effect: Code 56 is an ALERT condition and will not halt machine operation. TROUBLESHOOTING STEPS Code 56 Action Result Step1:...
  • Page 63 COMPRESSOR CODE 70 Serial Communications Explanation: The WEDGE controller cannot communicate with an external computer over the RS232 serial link. Effect: This code can only occur when a laptop computer or PDA Service Tool is Connected to the WEDGE. The WEDGE may otherwise be functional and This event may not be mission disabling.
  • Page 64 TROUBLESHOOTING STEPS Code 70 Action Result Step1: If the current RS232 device (laptop computer, etc.) will not If second device will not communicate with the WEDGE, substitute another RS232 communicate with WEDGE, device. Note: The second device must have proper software replace the WEDGE loaded to communicate with the WEDGE.
  • Page 65 COMPRESSOR CODE 71 CAN Communications Explanation: The WEDGE controller cannot communicate with the engine controller. The J1939 CAN (Controller Area Network) broadcast of engine parameters cannot be received. Effect: The WEDGE will not be able to display engine parameters using the diagnostic Display function.
  • Page 66 CANH J50-G1 J1-35 CANL WEDGE J50-F1 J1-34 CONTROLLER SHLD J1-1 Circuit Description: The CANH, CANL and SHLD wires are a cable that is located in the main harness. CANH refers to CAN HI and CANL refers to CAN LO and SHLD is the shield of the CAN cable. This is the cable that carries the communications between the engine and WEDGE controller and any other devices that are connected to the CAN cable.
  • Page 67 TROUBLESHOOTING STEPS Code 71 Action Result Step 1: Verify P1 harness connector pins 34, 35, and 1 are firmly seated into The connector at the WEDGE controller. Step 2: Verify P2 harness connector pins 37, 46, and 36 for Cummins engine or pins 17, 18, and 16 for CAT engine are firmly seated into the connector at the engine electronic controller.
  • Page 68 Multimeter should read Disconnect the test lead from P1-34 wire and connect to P1-35 wire. approximately 2.5 volts DC. Multimeter should read approximately 2.5 volts DC. If 2.5 volts cannot be read, replace WEDGE controller. If WEDGE controller is OK, harness should be checked as outlined in Step 4.
  • Page 69 COMPRESSOR CODE 73 Auto Start Stop Controller Communications Failure Explanation: The WEDGE has not been able to communicate with the Auto Start Stop controller for 17 seconds. A communications failure is determined. Effect: Code 73 is an ALERT condition and will not stop the machine. The Auto Start system may not function properly due to communications failure.
  • Page 71 SECTION 5 SYSTEM SCHEMATIC DIAGRAMS Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 77 SECTION 6 ELECTRONIC COMPONENT LOCATION DRAWINGS (not available) Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 78 P11: 3 pin connector for termination resistor on CAN backbone near batteries 9 pin connector for RS232 communications, located behind control panel 2 pin connector for option harness located behind control panel Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 79 SECTION 7 INDIVIDUAL CIRCUIT DIAGRAMS Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 80 J1- -28 P1- -28 WO13 24VDC W042 RED START STARTER RELAY - - - - - - - - - - - - - - - - W005 W045 Red- -Yel V1.5 Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 81 If voltage is at K1 coil, verify voltage is sent to the starter solenoid by K1 contact. Voltage available at the starter solenoid during a no- -crank condition indicates a starter problem. Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 82 10 and 180 ohms. If not, replace the sender. The two switches can be checked with the sender removed from the tank. Use an ohmeter to verify switch operation. Tilting the sender tube back and forth should activate the switches. Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 83 P1--6. The ohmmeter should read 33.2K ohms ±1%. If the reading is correct, replace the WEDGE Controller. If not, there is a problem with the W1 harness or the P1--4, P1--6 connector pins. Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 84 P1--6. The ohmmeter should read 33.2K ohms ±1%. If the reading is correct, replace the WEDGE Controller. If not, there is a problem with the W1 harness or the P1--5, P1--6 connector pins. Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 85 1% accuracy to match the accuracy of PT1. Use the WEDGE diagnostics to display the readings of PT1. If PT1 does not track the test gauge, replace it. Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 86 1% accuracy to match the accuracy of PT2. Use the WEDGE diagnostics to display the readings of PT2. If PT2 does not track the test gauge, replace it. Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 87 Closing the test switch or installing the jumper should activate the circuit, and the “Air Filter” alarm light on the control panel should light. Forcing the alarm lamp to turn on and off will verify proper circuit operation. Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 88 The ID plug can be removed and checked with an ohmeter. The table below lists the resistance values associated with various machines. Resistance Ω Machine Model ID Plug Color Grey P425 45300 Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 89 SECTION 8 ELECTRICAL CONNECTOR INFORMATION Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 90 54750567 WEDGE Serial Port / Engine Diagnostic Port: Harness Pins Packard Engine OEM 30 Pin Conn: Harness Pin Packard Harness Housing J1939 CAN Cable: Harness Socket Deutsch 54699566 Harness Housing Deutsch 54750633 Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 91 54699640 22216675 54750500 Packard Metri--Pack 54749643 12155975 54750674 54749643 12155975 54750526 Packard Weather Pack 54729660 12155975 54750542 54729660 12155975 54699525 Deutsch 54699624 22216667 54699509 54699616 22216667 54699533 54699624 22216667 54699566 54699632 22216667 Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 92 The ohmeter func- tion of the multimeter can be used for this test. Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 93 Deutsch connectors. The following two pages will show how the Deutsch crimp tools are to be used. One is used for machined contacts and the other for stamped and formed contacts. Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 94 Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 95 Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 96 Circular connectors J5 and J8 pinout. J5 is located near the Wedge Con- troller and J8 is located near the engine controller. The pinout of these connectors is the same, however, they are keyed differently. (View from front side, non--wire side) Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 97 SECTION 9 ELECTRICAL PARTS LIST Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 98 Engine Ground Strap 35578194 Fuel Level Sender 54731427 WEDGE Controller 22173579 Chassis Harness 22199061 ATC 20 AMP Fuse 36792083 ATC 10 AMP Fuse 22071591 Diagnostic Switch 54475777 Diode 35376169 Machine ID Plug 22201354 Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 99 SECTION 10 ALERTS AND SHUTDOWNS LIST Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 100 Engine Coolant Temp > = 220 deg F. High Engine Temp IQ Filter Restriction IQ Filter Re- 0--6@ striction High Discharge Temp. (RT2 > 247 deg. F) High Comp. Temp. CAN Derived Data = Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 101 2 = EMU LP CAT 3 = EMU HP CAT 4 = Viking XHP CAT 5 = EMU LP CU 6 = EMU HP CU 7 = Zenith P425 8 = WW600 Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 102 Crank Position Circuit CAN Error Auxiliary Engine Shutdown Switch Active External Engine Derate Switch Active 1076 Pump Circuit 1079 Sensor Supply Voltage 1110 Engine Protection Shutdown 1569 Fuel Derate 2000 Internal ECU Error Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 103 SECTION 11 RECOMMENDED SPARE PARTS Quantity Description Part Number WEDGE Controller 22173579 Thermistor Temperature Probe 36898922 0--100 psig Pres Transducer 36920825 0--225 psig Pres Transducer 54496773 Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...
  • Page 104 SECTION 12 INGERSOLL- -RAND ENGINE INFORMATION Book No. 22235428 (11/03) P425AWIR Family Electrical Manual...

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