Ingersoll-Rand P425AWIR, XP375AWIR, HP375AWIR, VHP300AWIR, P600WIR Electrical/electronic Service Manual

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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)

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TABLE OF CONTENTS

SECTION1.......ManualDescription

SECTION2.......GeneralInformationAndOperationalTheory

SECTION3.......ServiceTools

SECTION4.......ElectronicSystemsTroubleshooting

Procedures And Techniques

SECTION5.......SystemSchematicDiagrams

SECTION6.......ElectronicComponent Location Drawings

SECTION7.......IndividualCircuitDiagrams

SECTION8.......ElectricalConnector Information

SECTION9.......ElectricalPartsList

SECTION10......AlertsandShutdownsList

SECTION11......RecommendedSpareParts

SECTION 12 IR Engine....

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SECTION 1

MANUAL DESCRIPTION

Thismanualcontainsall of the information concerning the electrical and electronic systems for theP425 Familyof compressors. It providesall information necessary to service, troubleshoot and order parts for this machine.

It is organized into 12 sections. Sections 2 -- 4 cover systems operation and troubleshooting procedures. Sections 5 -- 7 have location diagrams, drawings of specific circuits and systems schematics. Section8 hasinformation concerningthe electricalconnectors used,including removaland re-

placement. 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.

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SECTION 2

GENERAL INFORMATION

and

OPERATIONAL THEORY

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GENERAL INFORMATION AND OPERATIONAL THEORY

General

The P425 Family of machines has an electronic monitor and control system to provide discharge air pressure control and engine and package 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.

The WEDGE is attached to the control panel with four #10 size nuts.

ThefirstfunctionoftheWEDGEcontrolleristoscanall analog and digital inputs at a fixed interval. These inputsarescannedevery50milliseconds. Theanalog values are then compared against minimum and maximum values and an ALERT or SHUTDOWN is issued,ifavalue is outofrange. The variousALERTS and SHUTDOWNS are listed in Section 10 of this manual.

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 the back of the control panel. The LED annunciators are part of the front panel of the WEDGE. They can be seen through the laminate on the front of the control panel.

The second function of the WEDGE controller is machine discharge pressure control. The WEDGE monitorstheregulationsystemairpressureandvaries the engine throttle to maintain the setpoint discharge air pressure. The setpoint pressure is set using the regulator on the separator tank.

The third function of the WEDGE controller is to communicate with the diesel engine via the J1939 CAN network. Itretrievesdiagnosticinformation over J1939.

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SOLENOID VALVES

SPEED SENSOR

FUEL LEVEL SWITCH

PRESSURE TRANSDUCERS

TEMPERATURESENSORS

BATTERY STARTINGAND

CHARGING SYSTEM

W1W1

P425/P600 HARNESS SYSTEM SCHEMATIC

24VDC HEATERS

CONTROL PANEL SWITCHES

INTERFACE

ENGINE ECM DIAGNOSTIC

HOURMETER

ESTOP SWITCHES

FIGURE 2--1

GAUGES

CONTROL PANEL HARNESS

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WEDGE

Controller

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J1--34

WEDGE

CONTROLLER

J1--35

J1--24

J1--38

J1--13

WEDGE TO ENGINE INTERFACE

IR ENGINE

CAN LO

J50--G1

CAN HI

CANSHLD

J50--J1

41RD5AE

KEY SWITCH

J50--A2

61IRF8TE

ENGINE

ANALOG THROTTLE

ANALOG THROTTLE RANGE = 1.10VDC (1400RPM) TO 3.7VDC (2400 RPM)

J50--F2

FIGURE 2--2

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CONTROLLER

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WEDGE

CONTROLLER

ENGINE DIAGNOSTICS JACK

J57

TERMINATOR

P425/P600 J1939 CAN COMMUNICATIONS SCHEMATIC

ENGINE ECM

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P1 1

P10

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FIGURE 2--3

P425AWIR Family Electrical Manual

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The wedge uses an analog signal to communicate withtheJohnDeere engine.Thissignalhasa range of

1.1V to 3.7V. This range corresponds to an engine speed range of 1400 to 2400 RPM.

Figure 2--2 shows the signals between the engine controller and the WEDGE controller.

Sensors and Transducers

The electronics system contains sensors and transducersthatareusedtocollectdata from the compressor. The temperature is measured by a thermistor. Thisdeviceexhibitsa changeinresistanceasthetemperature 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 transducerstomeasurecompressorpressurechanges. These devices have an output signal of .45 VDC to 4.5 VDC, corresponding to 0 psi and the maximum measured psi for a particular device. The maximum pressure transducer ranges are 100 or 225 psi. The 100 and 225 psi 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 “ON” (24VDC) or “OFF” (0 VDC). These digital inputs are connected to switches within the package such as the key start switch, air filter switches and IQ filter switches.

The WEDGE controller provides 24 VDC digital outputsto control solenoids,start compressor andDC heaters. These are 24 VDC “ON” and 0 VDC “OFF”. They are current limited and short circuit protected.

TheWEDGEvariestheanalogsignalfrom1.25to4.25 volts,correspondingto1400 to2100RPM. Thissignal is used with the John Deere engine. The frequency throttle signal is used with the Cummins engine and thepulsewidth modulated signal is used with the CAT engine.

Pressure Control

The discharge pressure is controlled by manipulating theengine speed andcompressor inlet valveposition. Theinletvalvepositioniscontrolledpneumaticallyand the engine speed is determined by the WEDGE controller.The WEDGE measures the pneumatic system regulation pressure and computes an engine throttle setting.Thisthrottle settingissent totheengineviathe frequencythrottle, Analog,PWM or J1939throttle, depending on which technique is used. The engine controller will control engine speed to this throttle setting.

Electronic Engine -- P425 Family of Machines

The P425 Family of machines contains an emissions certifieddiesel engine. Inordertomeet the emissions requirements, the engine has an electronic control system.

The control system handles all monitor, alarm and controlfunctions for the engine. The WEDGEcontroller communicates with the engine controller over the J1939 CAN network.

The WEDGE controller sends throttle settings to the engineandreceivesdiagnosticandruntimedatafrom the engine over the J1939 CAN network. An analog throttle interface is currently used with the engine. Figure 2--2 shows the connections between the WEDGE controller and the engine controller.

Controller Outputs

The WEDGE controller has four types of outputs: frequency, pulse width modulated, analog and 24VDC digital (ON/OFF). The analog output is used as the throttle signal to the engine.

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J1939 Data Link

The CAN network is a single pair shielded cable located with the W1 main harness. Figure 2--3 shows a layout of the CAN harness or “backbone” as it is referredto. The termination resistors(Terminator)are important to prevent reflections on the transmission line and must be in place for the network to function properly.

Theenginediagnostics connectorislocatedonthe left side of the engine. This is used to connect the engine manufacturer’sservicetoolstotheCANnetwork. This connector also provides 24 VDC to power these service tools.

Electrical System

Theelectrical systemconsists of thewiring harnesses and associated electrical devices such as relays, switches, lights, solenoids and alarm horn. There is one wiring harnesses in the P425 machine.

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 andthecircuitdoes nothavetheappropriatesizefuse, wires could be burned in the harness and damage other circuits.

Machine ID

Software versions 1.60 and greater use software to setthe machine ID. Versionsless than 1.60usean ID resistor plug, R2. The ID plug is located behind the control panel box on the W1 harness trunk. The resistor plugs are molded in colors for easy identification. Refer to Section 7, Individual Circuit Diagrams and the page entitled R @ MACHINE ID PLUG for details.

It is recommended that all machines be upgraded to Version1.60orgreater.Thesoftware setmachineIDis much more reliable than the resistor plug.

P/N 22199061 W1 Chassis Main Harness

Theschematicdiagramsshow theconnectionsfor this harness. Figure 2--1 is a system schematic showing harnessconnectionwithdevicesandcontrollers. Section 8 includes information on connectors used in the harness.

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PT1:

PT2:

U1:

RT1:

RT2:

K1:

KEY ELECTRICAL COMPONENTS FUNCTION

PT1 is a 0--225 psi gauge pressure transducer that measures discharge air pressure.

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

U1 is resistive level detector that measures the fuel level in the fuel tank. Itprovidesa continuous reading of fuel level. Italso has a switch for low fuellevel andlow fuelshutdown. These switches connect to WEDGE.

RT1 is a 10K ohm Thermistor temperature sensor that measures separator tank temperature. Its range is --30 to 255_ F.

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:

K2 is a SPST, 24VDC relay used to activate the engine inlet heater.

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CONTROL PANEL

DIAGNOSTIC SHUTDOWN (Standard)

1. Compressor Fault: Indicates shutdown due

to compressor system fault. Refer to fault code list in Section 10.

2. Engine Fault: Indicates shutdown due to

engine fault. Refer to fault code list in Section

10.

3. Hourmeter: Indicates machine operating

hours.

4. Discharge Air Pressure Gage: Indicates

pressure in receiver tank, psi (kPa).

5. Fuel Level Gage: Indicate fuel level in tank.

CONTROLS

6. PowerSwitch: Flip“ON” to activate systems

7. Service Air Switch: After warm--up, PUSH.

Book No. 22235428 (11/03)

(Standard)

prior to starting. Flip ’off” to stop engine.

Providesfull air pressure atthe service outlet.

OPTIONAL CONTROLS

8. Engine Speed Gauge: Indicates engine speed.

9. DischargeAirTemp.Gauge: Indicatesin_F and _C. Normal operating range: 185_F/85_C to 248_F/120_C.

10. Engine Oil Pressure Gauge: Indicates engine oil pressure psi (kPa).

11. Engine Water Temp Gauge: Indicates coolant temperature with normal operating range from 180_F/82_C to 210_F/99_C.

12. Voltmeter: Indicates battery condition.

13. Spare

14. Wait to Start Lamp

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OPERATIONAL INFORMATION

Power “ON” at Control Panel:

1. Key switch signal (24VDC) supplied to engine controller by WEDGE controller

Engine Start--up:

When the key is switched to the engine crank position:

1. K1 auxiliary start relay is energized.

2. Run/Start solenoid valve (L1) is opened (energized). Note: Run/start solenoid stays open for 10 seconds after the key is released if the engine does not start.

When the engine speed reaches 600 RPM (engine start declared):

1. Engine speed is set to 1600 RPM.

When the engine speed reaches 1450 RPM:

1. Unloader solenoid valve is opened (energized), L2.

2. Run/Start solenoid valve is closed (de--energized, L1).

When the separator tank pressure reaches 50 psi:

1. Run/Start solenoid valve is opened (energized), L1.

After 5 seconds:

1. Engine speed is set to idle (1400 RPM if air end discharge temperature is approximately 150 degrees F or (if J1939 CAN is functioning) the engine coolant is 100 degrees F. Otherwise, the engine idle stays at 1500 RPM.

Loading:

When the “Service Air” s witch is pushed:

1. Engine speed is set to 2400 RPM

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.

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READING AND SETTING THE 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 machine power off (Key turned OFF)

2. Press and hold the “Service Air” Switch

3. Turn the key switch directly to the crank position.

4. Hold these switch positions until the 4 digit LED display on the WEDGE goes blank.

5. Release “Service Air” switch, release key switch to “ON”.

Units will be displayed for 2 s econds after which the current selection 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 theWEDGE showingthe currentsetting, pressandrelease the“Service Air”switch untilthedesired setting appears on the display.

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.

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WEDGE SERVICE DIAGNOSTICS

The WEDGE controller provides a diagnostic capability that allows various internal parameters to be viewed on the 4--digit LED display.These can be accessed with the machine stopped or while it is operating. 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 key switch is used. Toview the parameters, toggle the switch or key and a number (2--20) will appear on the LED display. After 3 seconds, it will extinguish and the parameter will be displayed. The toggle only works in the ascending order direction, but it will wrap around and start over.

Display Parameter Remarks

2 RPM From Engine Flywheel Sensor 3 Engine RPM Filtered RPM Value 4 Reg. Sys. Pressure PSI 5 Sep. Tank Pressure PSI 6 Discharge Temperature Deg F 7 Sep. Tank Temperature Deg F 8 Engine Target RPM Wedge Signal to Engine 9 Machine Type * 10 Engine Coolant Temp. From CAN, Deg F 11 Engine Oil Temp. From CAN, Deg F 12 Engine Oil Pressure From CAN, PSI 13 Intake Manifold Temp. From CAN, Deg F 14 RPM From CAN 15 Fault Code List Cummins/CAT codes 16 Throttle Position 17 Boost Pressure 18 Engine Hours 19 Load At Speed Percent 20 Set Machine ID

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ENTERING MACHINE ID FOR WEDGE CONTROL SYSTEMS with V1.60 or Greater Software

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 gauge (located in the fuel tank) before starting the process and reconnect once the process is completed.

For machines with the WEDGE controller mounted in the engine compartment, the rocker switch beside the WEDGE is used to enter the machine ID.

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 and the machine models list on page 2 of this document, locate the proper machine ID.

2. Turn power 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 LED 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” willappear.Continue toholdthe switch.After 1second,the currentmachine IDwillappear in the display. Continue to hold for 9 more seconds and a blinking “--” will appear. Release the switch.

5. Togglethedatainputswitch, thedisplaywillshow“0”.Togglethedata inputswitchuntiltheproper machine ID appears on the display, then stop the toggle sequence.

6. Waituntil the controller performs a reset function (or power up) (approximately 10 seconds). At reset, the controllerdisplayfirstgoesblank,thenal110annunciato rLED’slight,the4--digitLEDdisplayshowsall8’s, thedisplay then shows the installed software version and finally the display goes blank and the engine oil pressureand alternatorLED begin flashing.At thispoint thecontrollerhas storedthemachine IDselected 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.

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ESA Models/Wedge Machine

Models

7/120,9/110. 10/105, 14/85 7 7/170. 10/125.14/115 8 9/230,9/270,9/300. 12/235 5 17/235,21/215 6

MSA Models/Wedge Machine

Models

P425AWIR, XP375AWIR, HP375WIR 7 VHP300AWIR P600WIR, HP450WIR, VHP400WIR 8 XP1060WCU, HP935WCU, MHP825WCU 5 VHP750WCU XHP750WCU 6 MHP825WCAT, VHP750WCAT 2 XP1060HACAT,XP950HACAT

SHP825WCAT, XHP750WCAT. XHP650WCAT 3 HP1300CWCU,HP1600CWCU 0 XHP1170WCU 1 XHP1070AWCAT, XHP1170WCAT. XHP1170SCAT 4 HP1600WCAT 9

Machine ID

SIRC Models/Wedge Machine

Models

P1060WCAT, XP950WCAT, HP935WCAT 2 MHP825WCAT .VHP750WCAT XHP750WCAT 3

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Machine ID

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SECTION 3

SERVICE TOOLS

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SERVICE TOOLS

Service Tools

The following special tools are recommended to perform service procedures in this manual. The tools can be purchased from Ingersoll Rand or other sources as listed.

Tool Tool Description

22216691 Digital Multimeter (Fluke 87)

Used to measure electrical circuits; Volts, amps, ohms

54729660 Packard Weather--Pack Terminal Removal Tool

Used to repair Packard Electric Weather--Pack Connectors

54699632 Deutsch Terminal Removal Tool (Blue)

Used to repair Deutsch connectors

54699640 Deutsch Terminal Removal Tool (Red)

Used to repair Deutsch connectors

54699624 Deutsch Terminal Removal Tool (Yellow)\

Used to repair Deutsch connectors

22216667 Deutsch Terminal Crimp Tool (HDT--48--00)

Used to crimp Deutsch connector terminals

54729710 Electrical Contact Cleaner

Used to clean electrical contacts and connectors

54729728 PDA Service Tool

Used to load software & extract service and fault logs

54699616 Deutsch Terminal Removal Tool

Used to repair Deutsch connectors

54749544 RTD Simulator Plug

Used to test RTD circuits

54749551 Thermistor Simulator Plug

Used to test thermistor circuits for INTELLISYS controller systems

22073878 Thermistor Simulator Plug

Used to test thermistor circuits for WEDGE controller systems

54749635 Connector Repair Kit

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

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22168868 Pressure Transducer Simulator

Used to test pressure transducer circuits

22147540 Test Adapter Kit Test adapters for various connectors to be

Used when making electrical measurements 22146393 Removal Tool Kit Assortment of most used Deutsch removal tools 22216675 Deutsch Crimp Tool (DTT --20--00)

Used to crimp Deutsch connector terminals 22216683 Packard Electric Crimp Tool (12155975)

Crimps 150 and 280 series pins 22255947 Packard Electric Crimp Tool (12039500)

Crimps 150 series pull to seat pins 22216709 Fluke Test Lead Set (TL20)

Contains needle probes, alligator clips, test leads

heat shrink tubing that are used on harnesses 22216725 Fluke Insulation Piercing Probe (AC--89)

Used to connect to a wire for measurements 22216733 Fluke Meter Case (C25)

Case for Fluke 87 meter including storage for test leads and probes 54740675 RS232 Heavy Duty Serial Cable

Connects lap top computer or PDA Service Tool

to WEDGE or Intellisys controller 22252969 Wire Terminal Kit

Contains a selection of terminals with

corresponding heat shrink tubing that are used on harnesses 22281588 Connector Wrench

22282107 5/32 “T” hex screwdriver wrench 22282172 1/4” Flex Shaft Nutdriver

Used to remove ECM connector on J ohn Deere engines 22252993 WEDGE Connector Kit

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

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22221303 Service Tool Kit

Kit consists of the following P/N’s: 22216691 22216667

22216675 22216683 54729660 54749643 54699657

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

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Tool No. Tool Description Tool Illustration

22216691

54729660 Weather--Pack Terminal Removal Tool

54699632 Deutsch Terminal Removal Tool (Blue)

54699640 Deutsch Terminal Removal Tool (Red)

Digital Multimeter

54699624 Deutsch Terminal Removal Tool (Yellow)

22216667 Deutsch Crimp Tool

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54729710

54729728 PDA Service Tool

54699616 Deutsch Terminal Removal Tool

54749544 RTD Simulator Plug

Electrical Contact Cleaner

22073878 Thermistor Plug

54749635 Connector Repair kit

54699657 Deutsch Terminal Removal Tool

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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

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22216709

Fluke Test Lead Set

22216725 Fluke Insulation Piercing Probe

(single probe)

22216733 Fluke Meter Case

54740675 RS232 Serial Cable

22253969 Wire Terminal Kit

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Connector Wrenches

22281588

22282172

22282172 1/4’’ Flex Shaft Nutdriver

22252993 WEDGE Connector Kit

22253009 CAN Communications Adapter

22253017 Adhesive Heat Shrink Assortment

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22255947

22254734 Packard Electric Crimp Tool

Packard Electric Crimp Tool

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SECTION 4

ELECTRONIC SYSTEMS TROUBLESHOOTING

PROCEDURES AND TECHNIQUES

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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

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MEASURING VOLTAGE, RESISTANCE,

FREQUENCY AND DUTY CYCLE

General Measuring Guidlines:

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. Testprobe connections are crucial to correct readings. Ensure the test probe makes a solid connection with the wire(s) or connector pin(s) under test. the test probe kit may help with these types of measurements. Make sure system power is turned OFF while making resistance measurements.

Measuring Frequency:

Frequency is measured in the same manner as voltage, but the meter is set for “HZ” or frequency. Good connections are important or false readings will occur.

Measuring Duty Cycle:

To measure duty cycle, setup the meter as if measuring frequency or voltage. Select the “%” or duty cycle function and take the measurements. As of the date of this writing, Fluke is the only known digital voltmeter that has the duty cycle feature. The Fluke Model 87 Digital Meter has the duty cycle function.

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TROUBLE SHOOTING FLOW CHART

Control panel key is turned to “ON” position, WEDGE controller annunciator lamps and 4 digit LED display do not come on

WEDGE controller annunciator lamps & 4 digit LED display initialize OK but alternator lamp and engine oil pressure lamps do not blink.

Engine cranks but will not start

Check F1 fuse Check operation of switch S1 Check wiring from S1 to WEDGE controller Check battery voltage, ensure battery disconnect switch is turned ON

J1939 CAN communications not working – Check for 24VDC key switch at engine, CAN network wiring problem Ensure 24VDC power to engine ECM Check connector pins

Ensure key switch (24VDC) at engine Frozen fuel cooler or associated piping Estop button pressed (ESA units) or

Estop jumpers not making connection Clear active engine fault code

Engine does not crank when key turned to crank position

Compressor fails to load when “Service Air” switch pressed

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Check switch S1 Check relay K1 Check starter solenoid Check starter motor Check WEDGE output to K1 relay Check battery voltage

Check Run/Start valve operation Verify frequency throttle signal at engine Check “Service Air” switch operation

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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” lamp that is located under the “COMPRESSOR MALFUNCTION” lamp. The engine fault codes are listed in Section 10 of this manual.

Be sure to determine which malfunction lamp is illuminated before beginning the troubleshooting process.

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 shutdown. Check for engine fuel system restriction (filter).

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 shutdown.

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 Step1:

Refer to the engine manufacturer’s service manual for instructions.

Result

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 Step1:

Refer to the engine manufacturer’s service manual for instructions.

Result

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 Step1:

Check the machine fuel system and engine fuel filters.

Step 2:

Refer to the engine manufacturer’s service manual for instructions.

Result

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. The machine will not perform properly due to the low speed condition.

Throttle Circuits:

J3-22 J1-38

W131

Freq Throttle

Blu

WEDGE

CONTROLLER

J2-10 J1-38

W131

PWM

Throttle

Blu

WEDGE

CONTROLLER

J50-F2 J1-13

W054

Analog Throttle

Blu

WEDGE

CONTROLLER

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 Step1:

Measure the throttle signal at the engine connector.

Result

If signal not present, check wiring and verify throttle output at WEDGE.

Step 2:

Engine may not be able to fuel properly due to restricted fuel filters

Step 3:

Verify correct machine ID plug is installed. If so, verify resistance value of ID plug and its connection to WEDGE controller.

Step 4:

Check connector pins at WEDGE controller and connector at engine controller for corrosion.

Replace fuel filter (s)

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 Step1:

Check the machine fuel system and engine fuel filters.

Step 2:

Check the condition of the machine batteries.

Step 3:

Cycle machine power, activate the Auto Start input so the machine will make another start attempt. Machine will go through 3 crank cycles to attempt start before a Code 11 is issued.

Result

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 Step1:

Check the machine fuel system and engine fuel filters. Check for loose fittings in the fuel piping that could allow air to be drawn into the fuel system.

Step 2:

Verify the throttle signal from the WEDGE is continuously supplied to the engine.

Step 3: Verify battery + and – connections to the engine controller,

inspect harness connections and measure voltage drop at engine ECM.

Step 4:

In the case of the I-R (John Deere) engine, check the connections for the crank sensor which is mounted at the front of the engine. Loose pin connections in the connector will cause code 29.

Result

A quick drop in the throttle signal could cause the engine to stop

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. The cause of the low air end oil pressure must be repaired to continue machine operation.

S9 Pressure Switch Circuit:

Blu

J1-21

WEDGE

CONTROLLER

Circuit Description:

Switch S9 is a 12 psi, normally open pressure switch. If the pressure falls below 12 psi, the switch will close, indicating to the WEDGE controller a low air end oil pressure.

Component Location:

S9 is located in the back of the air end.

Page 44

TROUBLESHOOTING STEPS

Code 31

Action Step1:

Check the air end oil pressure with a mechanical gauge.

Result

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.

RT2 Temperature Sensor Circuit:

W066

Yel

J1-5

W025

Brn

J1-6

WEDGE

CONTROLLER

Circuit Description:

The thermistor temperature sensor connects to the WEDGE controller as shown in the schematic above. The temperature range of RT2 is –30 to 255 degrees F. The thermistor is a 10K ohm device.

Component Location:

RT2 thermistor is located in the airend discharge pipe.

Page 46

TROUBLESHOOTING STEPS

Code 32

Action Step1:

Substitute the thermistor simulator (I-R # 22073878) for RT2 Use the WEDGE service diagnostics to read the value for RT2 It should be approximately 32 degrees F.

Result

Should read approx. 32 Deg 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. If the Transducer is defective, the machine could shutdown due to an out of range pressure

PT1Pressure Transducer Circuit:

W099

Gnd

Brn

J1-8

W098

W101

Sig

+5 VDC

Orn

Vio

J1-7

J1-10

WEDGE

CONTROLLER

Circuit Description:

The pressure transducer is a 3-wire device that connects to the WEDGE controller as shown in the schematic above. The violet wire (W101) is the 5 VDC excitation supply. This is spliced in the harness near the breakout for the harness branch that goes to the separator tank. The “sig” wire is the output signal that has a range o .45 to 4.5 volts DC. The pressure range of this transducer is 0 – 100 psig.

Component Location:

PT1 pressure transducer is located in the top of the separator tank.

Page 48

TROUBLESHOOTING STEPS

Code 33

Action Step1:

Substitute the pressure transducer simulator (I-R # 22168868) for PT1. Use the WEDGE service diagnostics to read the value for PT1. It should be approximately 30 – 50 psi.

Result

Should read 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 Result

Verify PT1 pressure transducer is reading correctly. The pressure simulator (IR#22168868) can be substituted for PT1. This will verify operation of harness and WEDGE controller. Using the simulator, PT1 on the WEDGE Diagnostics should read 30-50 psi.

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:

S14

WEDGE

W239

W237

Blu

J1-11

CONTROLLER

Circuit Description:

S14 is a normally open, 12 psi pressure switch. When the safety valve opens, S14’s pressure is raised above 12 psi and the switch closes. This grounds the WEDGE input, indicating the safety valve has opened.

Component Location:

S14 is screwed into the outlet of the safety valve.

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 Step1:

Check for package air inlet restrictions.

Step 2:

Check for dirty or clogged coolers.

Result

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:

BLU

VIO

+ 5 VDC

J1-15

WEDGE

CONTROLLER

Circuit Description:

The machine ID plug is a resistor plug connected to one of the analog inputs to the WEDGE. % VDC is connected to the other pin of the resistor. The resistor values are different for each machine model.

Component Location:

The machine ID plug is located behind the control panel box, inside the machine.

Page 55

TROUBLESHOOTING STEPS

Code 51

Action Step1:

Make sure an ID plug is installed.

Step 2:

If an ID plug is installed, remove it and measure its resistance.

Step 3:

Check for corrosion at ID Plug Pins.

Result

The ID plug resistance values are listed in the “Individual Circuit 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.

RT1 Temperature Sensor Circuit:

W067

Yel

J1-4

W024

Brn

J1-6

WEDGE

CONTROLLER

Circuit Description:

The thermistor temperature sensor connects to the WEDGE controller as shown in the schematic above. The temperature range of RT1 is –30 to 255 degress F. The thermistor is a 10K ohm device.

Component Location:

RT1 thermistor is located in the side of the separator tank.

Page 57

TROUBLESHOOTING STEPS

Code 53

Action Step1:

Substitute the thermistor simulator (I-R # 22073878) for RT1 Use the WEDGE service diagnostics to read the value for RT1 It should be approximately 32 degrees F.

Result

Should read appx. 32 Deg 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.

PT2 Pressure Transducer Circuit:

W21

Gnd

Brn

J1-8

W100

W101

Sig

+5 VDC

Orn

Vio

J1-9

J1-10

WEDGE

CONTROLLER

Circuit Description:

Component Location:

PT2 pressure transducer is located in the pneumatic circuit near the compressor inlet valve.

Page 59

TROUBLESHOOTING STEPS

Code 54

Action Step1:

Substitute the pressure transducer simulator (I-R # 22168868) for PT2. Use the WEDGE service diagnostics to read the value for PT2. It should be approximately 30 – 50 psi.

Result

Should read 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.

Emergency Stop Button Circuit:

Yel

Vio

J2-38

Vio

CUMMINS

ENGINE

CONTROLLER

WEDGE

CONTROLLER

J1-28

J1-24

J1-22

Yel

J2-26

Vio

CAT

ENGINE

CONTROLLER

WEDGE

CONTROLLER

J1-28

J1-24

J1-22 Vio

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.

Component Location:

The estop button is located above the machine control panel on the front of the machine.

TROUBLESHOOTING STEPS

Code 55

Action Step1:

If the estop button is installed, determine if it is pressed.

Step 2: If the estop button is not installed, a jumper plug will be

installed in the harness at the connection point for the estop button, P9.

Result

Release the estop button to operate the machine.

Verify the jumper plug is functional

Step 3:

Perform a continuity check of the harness wires from the WEDGE through the jumper plug to the engine connector.

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 Step1:

Check air piping system for restriction.

Step 2:

Verify engine speed has increased to 1800 rpm when Service Air switch is pressed.

Result

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.

RS232 Communications Circuit:

J5-B

J5-A

TXD

RXD

J1-33

J1-32

WEDGE

CONTROLLER

Circuit Description:

The RS232 serial communications link is used for re-programming the WEDGE controller and is the communications port used with the PDA Service Tool. The J5 connector contains the RS232 port. It is normally located very close to the WEDGE. There are two signals associated with the RS232, TXD and RXD. TXD is the transmit signal and RXD is the received signal.

Component Location:

The J5 harness connector is located near the WEDGE controller.

Page 64

TROUBLESHOOTING STEPS

Code 70

Action Step1:

If the current RS232 device (laptop computer, etc.) will not communicate with the WEDGE, substitute another RS232 device. Note: The second device must have proper software loaded to communicate with the WEDGE.

Result

If second device will not communicate with WEDGE, replace 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. The compressor will continue to operate since Code 71 is an ALERT condition.

CAN Communications Circuit:

J2-46

W151

CANH

Yel

J1-35

J2-37

J2-36

W152

W199

CANL

SHLD

Grn

Gry

J1-34

J1-1

WEDGE

CONTROLLER

J2-17

J2-18

J2-16

W151

W152

W150

CANH

CANL

SHLD

Yel

Grn

Gry

J1-35

J1-34

J1-1

WEDGE

CONTROLLER

Page 66

J50-G1

J50-F1

CANH

CANL

SHLD

Yel

Grn

Gry

J1-35

J1-34

J1-1

WEDGE

CONTROLLER

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. This cable is also referred to as the CAN Network since it may have multiple devices connected to it.

The CAN network has two terminating resistors, one located near the engine controller and one near the WEDGE controller. The value of each of these resistors is 120 ohms. They are connected in parallel, as shown below, across the network. The resistors are mounted in a special Deutsch connector. One connector is tagged R4 and the other is tagged R5.

CANH

CUMMINS

ENGINE

CONTROLLER

CANL

WEDGE

CONTROLLER

Component Location:

The Cummins engine controller is located on the left side of the engine. Connector J2 is located on the left side of the controller and is the OEM connector. The machine harness (P2) plugs into the J2 connector. The CAT controller is located on the left side of the engine. The harness P2 connector plugs into the CAT J61 customer connector located near the controller.

The WEDGE controller is mounted to the machine control panel on the back side. Resistor R5 is stubbed out of the harness near the engine controller and resistor R4 is stubbed out of the harness near the WEDGE controller.

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.

Step 3:

Setup the digital multimeter to read ohms. (Refer to the section in this manual on how to use the multimeter). Disconnect P1 harness connector from the WEDGE controller. If the engine is a Cummins, disconnect the P2 harness connector from the engine controller. If the engine is a CAT engine, leave P2 connected to the engine Controller.

Connect one of the multimeter test leads to P1-34 and the other test Lead to P1-35.

Step 4:

If you did not get the results of Step 3, there is a problem with the wiring harness. This problem could be a defective splice, broken wire or defective wire connection at a pin. The CANH and CANL wires should be tested for continuity from P1 to P2. The resistor stub outs should be tested for continuity.

Step 5:

Setup the multimeter to read DC volts. (Refer to the section in this manual on how to use the multimeter). The harness should be connected to the engine controller and the WEDGE controller. Turn the machine power to the “ON” position, but do not start the engine. Using insulation piercing probes (I-R P/N 22216725), connect the red multimeter lead to P1-34 wire and connect the black multimeter lead to the battery negative post or one of the brown wires on the back of the control panel.

Meter should read approximately 60 ohms. If so, go to Step 5. If not, go to Step

Make harness repairs as necessary.

Page 68

Disconnect the test lead from P1-34 wire and connect to P1-35 wire.

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.

TROUBLESHOOTING STEPS

Code 73

Action Step1:

If CAN communications is OK with the engine, check the CANpower stub connection for the Auto Start module. If CAN with the engine is not working, check CAN wiring in harness.

Step 2:

Verify the Auto Start controller has power and ground.

Step 3: Replace the Auto Start module.

Result

Page 70

Page 71

SECTION 5

SYSTEM SCHEMATIC DIAGRAMS

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SECTION 6

ELECTRONIC COMPONENT

LOCATION DRAWINGS (not available)

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HARNESS CONNECTOR LOCATIONS

J1: Located on back of WEDGE controller J50: 30 pin connector located on engine electronic controller P4: 12 pin connector located on back of control panel box P6: 3 pin connector for termination resistor on CAN backbone near Engine electronic controller J57: 9 pin connector for engine datalink service, located near engine controller P11: 3 pin connector for termination resistor on CAN backbone near batteries

J5: 9 pin connector for RS232 communications, located behind control panel

P7: 2 pin connector for option harness located behind control panel

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SECTION 7

INDIVIDUAL CIRCUIT DIAGRAMS

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ENGINE START CIRCUIT

WEDGE

J1--28

P1--28

YEL

WO13

CHART A1

START RELAY

-- -- -- -- -- -- -- --

W005

BRN

W042 RED

W045 Red--Yel

24VDC

B+

STARTER

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CIRCUIT DESCRIPTION

The WEDGE drives the engine starter through the auxiliary start relay, K1.

K1 is mounted on the lifting rail near the engine. K1 has a single set of contacts that connect to the starter solenoid. The control signal leaving the WEDGE on J1--28 passes through the

W1 harness and through a jumper plug. The jumper plug is replaced with an ESTOP switch for ESA versions.

CIRCUIT TROUBLESHOOTING

If the starter will not engage during a crank cycle, check the voltage at the coil of K1 during the crank cycle. It should be 14--22VDC. If voltage is not at K1, check for voltage back through the ESTOP jumper and to the WEDGE.

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.

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FUEL SENDER CIRCUIT

CHART B1

W057

BLU

P1--18

J1--18

WEDGE

B A

→

to control panel fuel level

→

to ground

U1 Fuel Level Sender

W052

BRN

CIRCUIT DESCRIPTION

The fuel sender is a resistive device that sends a 10--180 ohm signal to the fuel gauge indicating fuel level. It also contains two switches, one for low fuel level and another that will shutdown the machine when the fuel reaches this level. These two switch inputs connect to the WEDGE controller.

CIRCUIT TROUBLESHOOTING

If the fuel reading appears incorrect, check the fuel level in the tanks to see if it corresponds with the gauge. If not, remove the fuel sender and disconnect the harness plug. Connect an ohmeter across terminals A and B on the Packard Weather--Pack connector. Tilting the sender tube should produce resistance reading between 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.

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RT1 SEPARATOR TANK TEMPERATURE CIRCUIT

CHART C1

Temp_C

Temp_F

--20 --4 25,490

--10 14 18,088

--5 23 12,221 0 32 9,369 5 41 7,240 15 59 4,427 25 77 2,786 40 104 1460 60 140 668.7 70 158 467.2 90 194 241.0 100 212 177.5 105 221 153.1 110 230 132.8

Resistance

(Ohms)

WEDGE CONTROLLER

J1--4 W1 P1--4

YEL

W1 W067

RT1 SEPARATOR TANK TEMP SENSOR

BRN W1 W024

W1 P1--6 J1--6

WEDGE CONTROLLER

CIRCUIT DESCRIPTION

Separator tank temperature is read by RT1 thermistor. It is mounted in the side of the separator tank and connects to the W1 harness. The temperature range is --30 to 255_F.

CIRCUIT TROUBLESHOOTING

If the WEDGE Controller has an incorrect reading for the RT1 channel, disconnect the thermistor and install the Thermistor Simulator Plug (IR# 22073878) into the harness connector. Read the channel again and it should read 32 degrees F ± 5 degrees (0C ± 3C). If the reading is correct, replace the thermistor. If not, disconnect the WEDGE Controller P1 connector. Connect an ohmmeter between pins P1--4 and 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.

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RT2 AIREND DISCHARGE TEMP

CHART D1

WEDGE CONTROLLER

Temp_C

Temp_F

--20 --4 25,490

--10 14 18,088

--5 23 12,221 0 32 9,369 5 41 7,240 15 59 4,427 25 77 2,786 40 104 1460 60 140 668.7 70 158 467.2 90 194 241.0 100 212 177.5 105 221 153.1 110 230 132.8

Resistance

(Ohms)

J1--5 W1 P1--5

YEL

W1 W066

RT2 AIREND DISCHARGE TEMP SENSOR

BRN W1 W025

W1 P1--6 J1--6

WEDGE CONTROLLER

CIRCUIT DESCRIPTION

Airend discharge temperature is read by RT2 thermistor. It is mounted in the airend discharge piping and connects to the W1 harness. The temperature range is --30 to 255_F.

CIRCUIT TROUBLESHOOTING

If the WEDGE Controller has an incorrect reading for the RT2 channel, disconnect the thermistor and install the Thermistor Simulator Plug (IR# 22073878) into the harness connector. Read the channel again and it should read 32 degrees F ± 5 degrees (0C ± 3C). If the reading is correct, replace the thermistor. If not, disconnect the WEDGE Controller P1 connector. Connect an ohmmeter between pins P1--5 and 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.

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PT1 SEPARATOR TANK PRESSURE CIRCUIT

CHART E1

HARNESS

WEDGE CONTROLLER

GND

SIG (+)

J1--8

J1--7

P1--8 BRN

W022

P1--7 ORN

W064

PT1

SEPARAT OR TANK PRESSURE TRANSDUCER

5VDC+

J1--10

P1--10 VIO

W023

CIRCUIT DESCRIPTION

The WEDGE reads separator tank pressure from PT1. It is a gauge pressure transducer mounted on the separator tank. The WEDGE provides 5 VDC excitation voltage to pin B (+5) and pin A (GND). The pressure signal on pin C connects to the WEDGE input. The signal range is .45 to 4.5 volts. The transducer range is 0 to 225 psig.

CIRCUIT TROUBLESHOOTING

To verify the operation of PT1, connect a gauge in parallel with it. The test gauge should be at least 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.

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PT2 REGULATION SYSTEM PRESSURE CIRCUIT

CHART F1

WEDGE CONTROLLER

HARNESS

GND

SIG (+)

PT2

REGULATION SYSTEM PRESSURE TRANSDUCER

J1--8

J1--9

P1--8 BRN

W027

P1--9 ORN

W061

J1--10

P1--10 VIO

5VDC+

W026

CIRCUIT DESCRIPTION

The WEDGE reads regulation system pressure from PT2. It is a gauge pressure transducer mounted near the inlet unloader. The WEDGE controller provides 5 VDC excitation voltage to pin B (+5) and pin A (GND). The pressure signal on pin C connects to the WEDGE input. The signal range is .45 to 4.5 volts. The transducer range is 0 to 100 psig.

CIRCUIT TROUBLESHOOTING

To check the operation of PT2, connect a gauge in parallel with it. The test gauge should be at least 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.

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S10, S11 AIR FILTER SWITCHES

CHART I1

S10--1

S10

W068 BLU

P1--2 J1--2

W162

BLU

S11--1

S11

W163

BRN

W010

BRN

WEDGE

CIRCUIT DESCRIPTION

The WEDGE reads the air filter switches, S10 and S11. S10 is connected to the compressor air filter and S11 is connected to the engine air filter. These are normally open switches and close when the air filter restriction reaches 20 inches of water. The switches provide a ground connection to an opto coupler input on the WEDGE controller.

CIRCUIT TROUBLESHOOTING

To verify the circuit operation, another type of switch can be substituted for the filter switch, or a wire jumper can be used to activate the circuit. Disconnect S10 and S11 and install the test switch or jumper. 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.

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R2 MACHINE ID PLUG

CHART J1

WEDGE

J1--15

P1--15

W059

BLU

R2--1

R2 Resistor Machine ID Plug

R2--2

W012

VIO

+5 V

CIRCUIT DESCRIPTION

The machine ID plug is used to indicate to the WEDGE controller which type of machine is connected. The plug consists of a resistor and is connected to one of the WEDGE analog inputs. The resistor plugs are color coded for easy identification. Refer to table below for color codes. The WEDGE reads the ID plug at power up. If it cannot read the plug or reads an invalid voltage, a shutdown will be issued with fault code 51.

The ID plug can be removed and checked with an ohmeter. The table below lists the resistance values associated with various machines.

ID Plug Color

Grey

Resistance Ω

45300

Machine Model

P425

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SECTION 8

ELECTRICAL CONNECTOR INFORMATION

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CONNECTOR PARTS INFORMATION

The following is a list of the connector parts used with the harnesses and devices on the HP1600/1300 machine. Mostconnectorsconsist of1 to4itemsperside (harnessordevice).Thedevices canbelocatedonthe schematics and then referenced to this list. A connector repair kit, I--R P/N 54749635, containing terminals and housings, is available for repairs.

Part Manufacturer Part Number Thermistor Connector:

(RT1, RT2)

Harness Socket Terminal Packard Harness Housing Packard

Pressure Transducers:

(PT1 -- PT2)

Harness Female Terminal Packard Metri--Pack 54750500 Harness Housing Packard Metri--Pack 54750518

Fuel Level Sender:

(U1)

Harness Female Terminal Packard Weather Pack 54750526 Harness Housing Packard Weather Pack Sensor male Terminal Packard Weather Pack 54750542 Sensor Housing Packard Weather Pack Cable Seal Packard Weather Pack 54750567

WEDGE Serial Port / Engine Diagnostic Port: J8

Harness Pins Packard

Engine OEM 30 Pin Conn:

Harness Pin Packard Harness Housing

J1939 CAN Cable:

Harness Socket Deutsch 54699566 Harness Housing Deutsch 54750633

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REMOVAL TOOL USAGE

Terminal Part Number Manufacturer Removal Tool No. Manufacturer

Crimp Tool No.

54699541 Deutsch 54699632 22216667 54699558 54699632 22216667 54699582 54699640 22216675 54699590 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

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Deutsch DT Series Connector

(Note the orange wedgelock)

Packard Metri Pack Series Connector

(Note the green wire seals and blue Terminal Position Assurance Connection)

Deutsch HD Series Connector

Deutsch DRC Series Connector

It is very important that connectors be properly assembled. Use of the correct pin crimp tool is required to ensure high quality terminations. The manufacturer’s instructions must be followed as to selection and use o f crimp tools. Improper crimps not only provide unreliable connections but can damage the connector housing.

Troubleshooting Harnesses -- For extensive harness troubleshooting, a detailed schematic will be required. Splice location details can be very useful since problems do occur at splices.

The proper test adapters are recommended for harness troubleshooting. Some examples of these are shown in Section 2 concerning multimeters. Use of these adapters will prevent harness damage during testing.

The first item to perform during harness troubleshooting is a physical inspection of the harness for damage. Look for cut or frayed conductors, melted insulation and conductors pulled from connectors.

The next item to check is connector pin seating. Ensure the connector pins in the circuit under test are properly seated in the connector housing. A tug on the wire should confirm this.

If the harness is not physically damaged and all connector pins are seated, perform a continuity check of the circuit conductors. The ohmeter function of the multimeter can be used for this test.

Check to ensure there are not any ground faults or conductor shorts to ground.

Finally, measure the signals on the circuit under test. Start at the point of origin of the signal and verify at as many points along the harness as possible, ending at the termination point.

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Use of Harness Tools

These pictures describe the proper methods of use of harness tools.

Proper removal tool usage is shown in the above picture. The removal tools are color coded as to wire size. The Table below lists the colors and wire sizes.

Removal Tool Color Wire Size IR

P/N

Red 20--24 54699640 Blue 16--18 54699632 Yellow 12--15 54699624 Green 8--10 54699616

The wire is placed into the slot on the removal tool and the tool is slid along the wire inserted into the back of the connector. Gently pull on the wire as the tool is pushed into the connector. The pin should release from the connector. To insert a pin, push it into the connector until it locks.

Removal Tools

This picture shows the various removal tools for the 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.

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Circular connectors J5 and J8 pinout. J5 is located near the Wedge Controller 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)

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SECTION 9

ELECTRICAL PARTS LIST

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ELECTRICAL PARTS LIST

Ref Designator Description Part Number

PT1 Sep. Tank Pressure Xducer 54496773 PT2 Reg. Pressure Xducer 36920825

RT1, RT2 Temperature Sensor 36898922 L1 Start/Run Solenoid 36840841 K1, K2 SPST Relay 36853521

Engine Ground Strap 35578194

U1 Fuel Level Sender 54731427

WEDGE Controller 22173579 W1 Chassis Harness 22199061 F1 ATC 20 AMP Fuse 36792083 F2 ATC 10 AMP Fuse 22071591 S15 Diagnostic Switch 54475777 D1 Diode 35376169 R2 Machine ID Plug 22201354

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SECTION 10

ALERTS AND SHUTDOWNS LIST

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ALERT/SHUTDOWN CONDITIONS Software V1.60

ALERT SHUTDOWN

CODE

Engine Speed < Min. RPM 1 CPRSR Malf 30 Engine Speed > Max. RPM 2 CPRSR Malf 30 Engine Crank Time Exceeded 3 CPRSR Malf 0 Engine Oil Temperature> 252 deg. F 5 CPRSR Malf. 0--6 Intake Manifold Temperature> 180 deg. F 6 CPRSR Malf. 0--7 Water In Fuel 8 CPRSR Malf. 5,6 Engine Not Responding to Throttle Cmd. 10 CPRSR Malf. All Too Many Start Attempts during Autostart 11 CPRSR Malf 0 All Engine Shuts Itself Down: reason unknown 29 CPRSR Malf 0 All Low AE Oil Pressure 31 CPRSR Malf 20 0,2,5 Disch. Temp (RT2) Sensor Fault 32 CPRSR Malf 10 All Separator Tank (PT1) Sensor Fault 33 CPRSR Malf. All Separator Tank Pressure >20 PSI during start

attempt (Engine will not crank) Machine Over Pressure 35 CPRSR Malf 1 0--6 Safety Valve Open 36 CPRSR Malf 2 0--6 Sep. Tank Temp > 247 degrees F 50 CPRSR Malf 3 All Machine ID Not Valid 51 CPRSR Malf 0 All Sep. Tank Temp. (Rt1) Sensor Fault 53 CPRSR Malf 10 All Reg. System Pressure (PT2) Sensor Fault 54 CPRSR Malf. All Estop Button Pushed 55 CPRSR Malf. 0--6 55 CPRSR Malf 3 0--6 Minimum Pressure Not Met 56 CPRSR Malf. All Serial Comm. Problem 70 CPRSR Malf. All CAN Bus Problem 71 CPRSR Malf. All Auto Start/Stop Module Failure -- No Comm

for 17 seconds

Dedicated Lights:

Low Fuel Level Fuel Level 0--6 Fuel Level 3 All Air Filter Restriction Soiled Filter Low Battery Voltage Battery Charging

Engine Oil Pressure < 18 PSI Low Engine Oil

Low Coolant Level Engine Coolant

Engine Coolant Temp > = 215 deg F. High Engine

Engine Coolant Temp> = 220 deg F. High Engine

IQ Filter Restriction IQ Filter Re-

High Discharge Temp.(RT2 > 247 deg. F) High Comp.

73 CPRSRMalf. All

LIGHT

(BLINKS)

Condition

Pressure

Level

Temp

Machine ID

All^ All

All

0,1,5, 6%

All

CODE

34 CPRSR Malf 0 0--6

LIGHT

(STEADY)

Temp

striction

Temp.

DELAY

(sec)

10 All

3 All

Machine ID

All# All$ All!

0--6@

CAN Derived Data =

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