Doosan - 02032015094056 - 722 - 46651193 - Electronic Service Manual PDF
Doosan - 02032015094056 - 722 - 46651193 - Electronic Service Manual PDF
COMPRESSOR MODELS
                                     P185WDZ-T4F
                                     C185WDZ-T4F
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
                                                                                                                            3
          TABLE OF CONTENTS
        Electronic Service Manual
TITLE                               PAGE
4
General Information
  46651193 Rev. A     5
Electronic Service Manual                                                 General Information
Operational Theory
The C185WDZ/P185WDZ Tier 4F compressor has an electronic system using the Titan
controller to provide discharge air pressure control and package monitoring functions. The
electrical system connects all the necessary switches, sensors, and transducers to the Titan
controller.
Titan Controller
The Titan controller is the heart of the compressor monitoring and control system and
provides data collection, package monitoring, and control functions for compressor
operations. The Titan controller is a microprocessor-based controller with analog and digital
inputs and outputs.
The first function of the Titan controller is to scan all inputs at a fixed interval. The analog
values are compared to preset minimum and maximum values and an ALERT or FAULT is
issued when a value is out of range. The various ALERTS and FAULTS are listed in the
Compressor Diagnostic Code Troubleshooting section.
The second function of the Titan controller is compressor discharge pressure control. The
Titan monitors the regulation system air pressure and varies the engine throttle to maintain
the setpoint discharge air pressure. The setpoint pressure is set by adjusting the pressure
regulator. For compressors equipped with dual pressure option, the setpoint pressure for
each mode is set by adjusting the high and low pressure regulators.
The third function of the Titan controller is to communicate diagnostic and control information
between the Titan, engine ECM, Air Pressure gauge with Mini-Port display, and other optional
controllers via the J1939 CAN network. The engine throttle setting is sent from the Titan to
the engine ECM.
The pressure sensors used to measure compressor pressures are transducer type devices.
These sensors have an output signal range of 0.5 VDC to 4.5 VDC, where 0.5 VDC
corresponds to 0 PSI and 4.5 VDC corresponds to the maximum PSI rating for a particular
transducer. Pressure sensors are provided with 5 VDC excitation voltage from the Titan
controller. Also, the sensor return or ground connects to the Titan controller. The output
voltage of the pressure sensor changes with a corresponding pressure change of the
parameter being monitored. The Titan controller receives the voltage of the sensor and
converts it to a pressure value. The Titan uses the pressure value to ensure the parameter
being monitored is within its operating limits and relays the value to the Mini-Port display for
operator viewing.
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General Information                                              Electronic Service Manual
The Titan controller scans digital inputs such as switch contacts. Inputs are 12 VDC or 0 VDC.
Digital inputs with 12 VDC represent a closed switch contact. Digital inputs with 0 VDC
represent an open switch contact.
The Titan controller provides 12 VDC digital outputs to control solenoids, relays, and other
devices. Outputs are 12 VDC ON and 0 VDC OFF and are current limited and short circuit
protected.
Controller Outputs
Pressure Control
The discharge pressure is controlled by manipulating engine speed and compressor inlet
valve position. The inlet valve position is controlled pneumatically and the engine speed is
controlled by the Titan controller. The Titan measures the pneumatic system regulation
pressure and computes the engine throttle setting. The throttle setting is sent to the engine
ECM via the J1939 CAN network. This throttle technique is referred to as J1939 throttle. The
engine ECM will control engine speed to the J1939 throttle setting.
Engine Electronic
The display located in the Air Pressure Gauge is referred to as the Mini-Port display. The
Mini-Port displays compressor and engine operational information to the operator. The Mini-
Port display can be navigated by using the UP, DOWN, and ENTER buttons on the Keypad.
The Air Pressure Gauge portion of the gauge is mechanically driven by air pressure at the
Separator Element. The Air Pressure Gauge is connected to the Separator Element via an
air line located inside the harness.
The Air Pressure Gauge with Mini-Port display is connected to the J1939 CAN network for
communication with other devices on the network.
The J1939 CAN network is a twisted pair of wires located in the compressor and engine
harnesses. These wires are the network link between all electronic control modules. The
wires are color coded yellow and dark green. The yellow wire is referred to as CAN High (+)
and the dark green wire is referred to as CAN Low (-).
Located on each end of the J1939 CAN network are termination resistors (terminator). The
terminators prevent reflections on the transmission line and must be in place for the network
to function properly.
                                    46651193 Rev. A                                            7
Electronic Service Manual                                              General Information
Electrical System
The electrical system consists of the wiring harnesses and associated electrical devices such
as relays, switches, sensors, and solenoids. There are three wiring harnesses on this
compressor:
The electrical circuits are protected by ATM mini style fuses. A fuse should only be replaced
with one of the same rating. Installing a larger rated fuse could lead to wiring harness
damage.
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Compressor Operation Sequence
        46651193 Rev. A         9
Electronic Service Manual                                 Compressor Operation Sequence
Power On
     1. Key ON/OFF signal (12 VDC) supplied to Titan controller while power switch is
        pressed.
4. Air Pressure Gauge with Mini-Port display and Keypad will initialize.
Start
When the engine speed reaches 400 RPM (engine start declared):
Loading
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Electronic Service Manual                                Compressor Operation Sequence
Shutdown
Close the service valves(s). Allow the compressor to run at idle speed for 3 to 5 minutes to
allow cool down. Do not use E-Stop (if equipped) to stop machine unless it is an emergency.
   4. The Mini-Port will remain on for viewing operating parameters and any active
      diagnostic codes.
   8. If active FAULTS are present, the Compressor Control System will remain ON
      until the Power Switch is pressed to turn it OFF.
When the Power Switch is pressed to turn the Compressor Control System OFF:
                                    46651193 Rev. A                                      11
Electronic Service Manual                     Compressor Operation Sequence
12                          46651193 Rev. A
Compressor Diagnostic Code
     Troubleshooting
      46651193 Rev. A        13
Electronic Service Manual
General
The charts 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 the solution
of a problem.
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Since the electrical system uses sealed connectors and splices, access of test
points can be difficult. It is recommended 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
IMPORTANT INFORMATION
Measuring Resistance
Extra care must be taken when making resistance measurements. Test probe
connections are crucial to correct readings. Ensure the test probe makes a solid
connection with the wire(s) or connector pin(s) under test. The test probe kit may
help with these types of measurements. Electrical system must be powered 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.
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                                                           Electronic Service Manual
                                                                                     Code
  LCD Display         Display Name                      Description
                                                                                     Type
 CPR CODE 1         Low Engine Speed        Engine speed less than 1300 RPM          FAULT
 LOW ENGINE                                          for 30 seconds.
   SPEED
 CPR CODE 2         High Engine Speed        Engine speed greater than 2720          FAULT
 HIGH ENGINE                                      RPM for 30 seconds.
    SPEED
 CPR CODE 3        Engine Crank Timeout      Engine crank attempt longer than        FAULT
 WAIT 30 SEC                                 15 seconds above 50°F or longer
 RETRY START                                   than 30 seconds below 32°F.
 CPR CODE 4             Out of Fuel         Fuel level in tank below usable limit.   FAULT
 OUT OF FUEL
 CPR CODE 10      Engine Speed Response      Engine target idle speed not met        ALERT
  ENG SPEED                                   within 10 seconds after loading
  RESPONSE                                              compressor.
 CPR CODE 12          Low Fuel Level           Fuel level in tank approaching        ALERT
 FUEL LEVEL                                                 empty.
    LOW
 *CPR CODE 33     Separator Tank Pressure    Separator Tank Pressure Sensor          FAULT
SEP TANK PRES             Sensor                  reading out of range.
   SENSOR
 *CPR CODE 34       High Separator Tank       Separator tank pressure greater        ALERT
 HIGH PRES AT        Pressure At Start         than 20 psi at crank attempt.
    START
 *CPR CODE 35       High Separator Tank      Air pressure in the separator tank      FAULT
   HIGH SEPT             Pressure                     exceeded limit.
  TANK PRES
*CPR CODE 36        Safety Valve Open       Safety relief valve on separator tank    FAULT
SAFETY VALVE                                               opened.
   OPEN
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Electronic Service Manual
                                                                                        Code
  LCD Display          Display Name                        Description
                                                                                        Type
 CPR CODE 38          Intake Air Filters         Intake filters restricting air flow.   ALERT
 AIR FILTERS             Restricted
 RESTRICTED
 CPR CODE 39       Low System Voltage/          Electrical system voltage below         ALERT
 LOW SYSTEM       Alternator Not Charging                   13.5VDC.
   VOLTAGE
 CPR CODE 42         Fuel Level Sensor          Fuel Level Sensor reading out of        ALERT
  FUEL LEVEL                                                range.
   SENSOR
*CPR CODE 43        Low Separator Tank         Separator tank pressure below 40         FAULT
LOW SEP TANK            Pressure                psi after compressor is loaded.
    PRES
 *CPR CODE 44     High IQ Filter Restriction       IQ filters restricting air flow.     ALERT
HIGH IQ FILTERS
    RESTR
 CPR CODE 50        High Separator Tank        Separator tank temperature greater       FAULT
HIGH SEP TANK          Temperature                  than or equal to 251°F.
    TEMP
CPR CODE 51        Compressor ID Invalid        The Titan controller and Engine         FAULT
COMPRESSOR                                     Tachometer with Mini-Port display
 ID INVALID                                    do not have a valid compressor ID.
 *CPR CODE 55         Emergency Stop           Emergency Stop Button has been           FAULT
    E-E-STOP            Activated                        activated.
   ACTIVATED
 *CPR CODE 61     IQ Filter Pressure Error       IQ filter outlet pressure reading      ALERT
IQ FILTER PRES                                     higher than inlet pressure.
    ERROR
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                                                                                 Code
 LCD Display         Display Name                     Description
                                                                                 Type
                               46651193 Rev. A                                      19
Electronic Service Manual
COMPRESSOR CODE 1
Explanation:
The Titan controller has received an engine speed value less than 1300 RPM for
30 seconds from the engine ECM.
Effect:
Code 1 is a FAULT condition and will shut down the compressor. CPR CODE 1
LOW ENGINE SPEED will be shown on the Mini-Port display.
Troubleshooting Steps
Action Result
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COMPRESSOR CODE 2
Explanation:
The Titan controller has received an engine speed value greater than 2720 RPM
for 30 seconds from the engine ECM.
Effect:
Code 2 is a FAULT condition and will shut down the compressor. CPR CODE 2
HIGH ENGINE SPEED will be shown on the Mini-Port display.
Troubleshooting Steps
Action Result
                               46651193 Rev. A                                    21
Electronic Service Manual
COMPRESSOR CODE 3
Explanation:
The electronic system has attempted to start the compressor longer than 15
seconds above 50°F ambient or longer than 30 seconds below 32°F ambient.
Effect:
Code 3 is a FAULT condition and will prevent further cranking. CPR CODE 3 WAIT
30 SEC RETRY START will be shown on the Mini-Port display. Operator must wait
30 seconds before electronic system will allow another start attempt.
Troubleshooting Steps
Action Result
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COMPRESSOR CODE 4
Out Of Fuel
Explanation:
The Titan controller has detected a condition from U1 Fuel Level Sensor indicating
the fuel level in the tank is below a usable limit.
Effect:
Code 4 is a FAULT condition and will shut down the compressor. CPR CODE 4
OUT OF FUEL will be displayed on the Mini-Port display.
Troubleshooting Steps
Action Result
                               46651193 Rev. A                                      23
Electronic Service Manual
COMPRESSOR CODE 10
Explanation:
The engine has failed to reach target idle speed within 10 seconds after loading
compressor.
Effect:
Code 10 is an ALERT condition and will not shut down the compressor, however
minimum start pressure will not be met and pressure control will not be engaged.
CPR CODE 10 ENGINE SPEED RESPONSE will be shown on the Mini-Port
display.
Troubleshooting Steps
Action Result
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COMPRESSOR CODE 12
Explanation:
The Titan controller has detected a condition from U1 Fuel Level Sensor indicating
the fuel level in the tank is approaching empty.
Effect:
Code 12 is an ALERT condition and will not shut down the compressor. CPR
CODE 12 FUEL LEVEL LOW will be shown on the Mini-Port display.
Troubleshooting Steps
Action Result
                               46651193 Rev. A                                      25
Electronic Service Manual
                            COMPRESSOR CODE 12
Action Result
Step 5:
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COMPRESSOR CODE 29
Explanation:
The engine has shut down and the Titan did not detect an Engine Diagnostic Code
from the engine ECM.
Effect:
Code 29 is a FAULT condition and will shut down the compressor. CPR CODE 29
ENGINE SHUTDOWN?? will be shown on the Mini-Port display.
Troubleshooting Steps
Action Result
                             46651193 Rev. A                                      27
Electronic Service Manual
                            COMPRESSOR CODE 12
Action Result
Step 5:
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COMPRESSOR CODE 30
Explanation:
The Titan controller has detected a temperature from RT2 Temperature Sensor
that is greater than or equal to 251°F.
Effect:
Code 30 is a FAULT condition and will shut down the compressor. CPR CODE 30
HIGH AIREND TEMP will be shown on the Mini-Port display.
Troubleshooting Steps
Action Result
                                  46651193 Rev. A                                   29
Electronic Service Manual
COMPRESSOR CODE 32
Explanation:
The Titan controller has detected an out of range reading from the RT2
Temperature Sensor.
Effect:
Code 32 is a FAULT condition and will shut down the compressor. CPR CODE 32
AIREND DISC TEMP SENSOR will be shown on the Mini-Port display.
                                                          RT2
                                                                  DISCHARGE
    TITAN        P1-27            YELLOW                   A          AIR
 CONTROLLER      P1-26          BROWN-WHITE                B     TEMPERATURE
                                                                    SENSOR
Circuit Description:
The RT2 Temperature Sensor connects to the Titan controller as illustrated in the
circuit diagram. RT2 is a 10K ohm thermistor type temperature sensor. The yellow
wire is the sense line to the Titan. The brown-white wire is the sensor ground.
Component Location:
30                            46651193 Rev. A
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Action Result
                            46651193 Rev. A                                  31
Electronic Service Manual
COMPRESSOR CODE 38
Explanation:
The Titan controller has detected a closed contact from S10 (Engine Air Filter) and/
or S11 (Airend Air Filter) pressure switch indicating the filter(s) is restricted.
Effect:
Code 38 is an ALERT condition and will not shut down the compressor. CPR
CODE 38 AIR FILTERS RESTRICTED will be shown on the Mini-Port display.
                                                              S10          ENGINE
                                                          1          2    AIR FILTER
    TITAN          P1-15         PURPLE-WHITE
 CONTROLLER                                                              RESTRICTION
                   P1-25            GRAY
                                                                           SWITCH
                                                              S11          AIREND
                                                                          AIR FILTER
                                                          1          2
                                                                         RESTRICTION
                                                                           SWITCH
Circuit Description:
The air filter restriction switches connect to the Titan controller as illustrated in the
circuit diagram. S10 and S11 are normally open pressure switches that close when
the air filter restriction reaches 20 inches of water. When S10 and/or S11 switch
contacts close, a 12 VDC input is sent to the Titan. The purple-white wire is the
switch common supply (12 VDC). The gray wire is the input to the Titan.
Component Location:
S10 Air Filter Restriction Switch is located behind the Engine Air Filter housing.
S11 Air Filter Restriction Switch is located behind the Airend Air Filter housing.
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Action Result
                                46651193 Rev. A                                       33
Electronic Service Manual
COMPRESSOR CODE 39
Explanation:
The Titan controller has detected the system voltage during compressor operation
has reached a level below 13.5 VDC.
Effect:
Code 39 is an ALERT condition and will not shut down the compressor; however,
if the system voltage reaches too low of a level the electronics will shut off and the
compressor will shut down. CPR CODE 39 LOW SYSTEM VOLTAGE will be
shown on the Mini-Port display.
Troubleshooting Steps
Action Result
34                              46651193 Rev. A
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                                  COMPRESSOR CODE 39
Action Result
                               46651193 Rev. A                                   35
Electronic Service Manual
COMPRESSOR CODE 42
Explanation:
The Titan controller has detected an out of range reading from the U1 Fuel Level
Sensor.
Effect:
Code 42 is an ALERT condition and will not shut down the compressor; however,
if the fuel level in the tank reaches a level below the pickup tube the compressor
will shut down with no indication of reason. CPR CODE 42 FUEL LEVEL SENSOR
will be shown on the Mini-Port display.
U1
Circuit Description:
The U1 Fuel Level Sensor connects to the Titan controller as illustrated in the
circuit diagram. The purple wire is the 5 VDC excitation supply from the Titan. The
orange wire is the signal output to the Titan.
Component Location:
36                             46651193 Rev. A
                                                      Electronic Service Manual
                               COMPRESSOR CODE 42
Troubleshooting Steps
Action Result
                              46651193 Rev. A                                      37
Electronic Service Manual
Action Result
Step 6:
38                          46651193 Rev. A
                                                    Electronic Service Manual
COMPRESSOR CODE 50
Explanation:
The Titan controller has detected a temperature from RT1 Temperature Sensor
that is greater than or equal to 251°F.
Effect:
Code 50 is a FAULT condition and will shut down the compressor. CPR CODE 50
HIGH SEP TANK TEMP will be shown on the Mini-Port display.
Troubleshooting Steps
Action Result
                             46651193 Rev. A                                   39
Electronic Service Manual
COMPRESSOR CODE 51
Compressor ID Invalid
Explanation:
The Titan controller and the Mini-Port display do not have a valid compressor ID.
Code 51 will occur only when a new Titan and a new Engine Tachometer with Mini-
Port display are installed at the same time. The compressor ID defines the proper
operational profile of the compressor. Absence of Code 51 does not ensure the
compressor ID is correct.
Effect:
Code 51 is a FAULT condition and will prevent any operation of the compressor.
CPR CODE 51 COMPRESSOR ID INVALID will be shown on the Mini-Port display.
Troubleshooting Steps
Action Result
40                             46651193 Rev. A
                                                     Electronic Service Manual
COMPRESSOR CODE 53
Explanation:
The Titan controller has detected an out of range reading from the RT1
Temperature Sensor.
Effect:
Code 53 is a FAULT condition and will shut down the compressor. CPR CODE 53
SEP TANK TEMP SENSOR will be shown on the Mini-Port display.
                                                         RT1
                                                                  SEPARATOR
    TITAN        P1-21            YELLOW                   A         TANK
 CONTROLLER      P1-26          BROWN-WHITE                B     TEMPERATURE
                                                                   SENSOR
Circuit Description:
The RT1 Temperature Sensor connects to the Titan controller as illustrated in the
circuit diagram. RT1 is a 10K ohm thermistor type temperature sensor. The yellow
wire is the sense line to the Titan. The brown-white wire is the sensor ground.
Component Location:
                              46651193 Rev. A                                  41
Electronic Service Manual
COMPRESSOR CODE 53
Troubleshooting Steps
Action Result
42                           46651193 Rev. A
                                                      Electronic Service Manual
COMPRESSOR CODE 54
Explanation:
The Titan controller has detected an out of range reading from the PT2 Pressure
Sensor.
Effect:
Code 54 is a FAULT condition and will shut down the compressor. CPR CODE 54
REG SYSTEM PRES SENSOR will be shown on the Mini-Port display.
PT2
                                                           2        REGULATION
    TITAN         P1-14            PURPLE                             SYSTEM
 CONTROLLER       P1-12            ORANGE                         3 PRESSURE
                  P1-26          BROWN-WHITE                          SENSOR
                                                           1
Circuit Description:
The PT2 Pressure Sensor connects to the Titan controller as illustrated in the
circuit diagram. The purple wire is the 5 VDC excitation supply from the Titan. The
orange wire is the signal output to the Titan with a range of 0.5 to 4.5 VDC. The
brown-white wire is the sensor ground. The pressure range of PT2 is 0 psig (0.5
VDC) to 100 psig (4.5 VDC).
Component Location:
PT2 Pressure Sensor is located on the side of the Separator Element Manifold.
                               46651193 Rev. A                                   43
Electronic Service Manual
                          COMPRESSOR CODE 54
Troubleshooting Steps
Action Result
44                            46651193 Rev. A
                                                      Electronic Service Manual
COMPRESSOR CODE 58
Explanation:
The Titan controller has detected an out of range reading from the RT3 Ambient
Temperature Sensor.
Effect:
Code 58 is an ALERT condition and will not stop the compressor. CPR CODE 58
AMBIENT TEMP SENSOR will be shown on the Mini-Port display.
                                                           RT3
                                                                     AMBIENT
    TITAN         P1-19           YELLOW                     A         AIR
 CONTROLLER       P1-26         BROWN-WHITE                  B     TEMPERATURE
                                                                     SENSOR
Circuit Description:
Component Location:
C185WDZ: RT3 Ambient Temperature Sensor is mounted on the Air Filter Bracket.
                               46651193 Rev. A                                   45
Electronic Service Manual
                            COMPRESSOR CODE 58
Troubleshooting Steps
Action Result
46                           46651193 Rev. A
                                                             Electronic Service Manual
COMPRESSOR CODE 71
Explanation:
The Titan controller cannot communicate with the engine ECM via J1939 CAN
BUS network.
Effect:
Code 71 is a FAULT condition and will shut down the compressor. CPR CODE 71
ENG ECM COMMS will be shown on the Mini-Port display.
                                   P2-6    P2-7
                                   J2-6    J2-7
                              YELLOW                     YELLOW
          120
                                                                                120
                 1    1                                              1      1
                 2    2      DARK GREEN              DARK GREEN      2      2
Circuit Description:
The twisted pair yellow and dark green wires are the communications link (J1939
CAN BUS) connecting the Titan controller and the engine ECM as illustrated in the
circuit diagram. The yellow wire is referred to as J1939 CAN High (+). The dark
green wire is referred to as J1939 CAN Low (-). The compressor harness and the
control panel are connected together at P2/J2 connection point.
The CAN network has two terminating resistors TR1 and TR2. The resistance
value of each terminator is 120 ohms. The terminators are connected together in
parallel across the High (+) and Low (-) wires. When connected the resistance
value between the High (+) and Low (-) wires is 60 ohms.
Component Location:
P1 connector is connected to the Titan controller and the D2.2 connector is
connected to the engine ECM. Terminating resistor TR1 is located on the control
panel harness inside the control panel. Terminating resistor TR2 is located near the
engine ECM.
                                       46651193 Rev. A                                    47
Electronic Service Manual
COMPRESSOR CODE 71
Troubleshooting Steps
Action Result
48                           46651193 Rev. A
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COMPRESSOR CODE 71
Troubleshooting Steps
Action Result
                            46651193 Rev. A                                   49
Electronic Service Manual
COMPRESSOR CODE 76
Explanation:
The Air Pressure Gauge with Mini-Port display cannot communicate with the Titan
controller via J1939 CAN BUS network.
Effect:
Code 76 is an ALERT condition and will not stop the compressor. CPR CODE 76
CPR CTRL COMMS will be shown on the Mini-Port display.
Air Pressure Gauge with Mini-Port display to Titan controller J1939 CAN
BUS circuit:
Circuit Description:
The twisted pair yellow and dark green wires are the communications link (J1939
CAN BUS) that connects the Air Pressure Gauge with Mini-Port display and the
Titan controller together as illustrated in the circuit diagram. The yellow wire is
referred to as J1939 CAN High (+). The dark green wire is referred to as J1939
CAN Low (-).The compressor harness and the control panel harness are
connected together at P2/J2 connection point.
Component Location:
50                                46651193 Rev. A
                                                   Electronic Service Manual
                         COMPRESSOR CODE 76
Troubleshooting Steps
Action Result
                            46651193 Rev. A                                     51
Electronic Service Manual
COMPRESSOR CODE 77
Explanation:
The Titan controller cannot communicate with the Keypad via J1939 CAN BUS
network.
Effect:
Code 77 is a FAULT condition and will shut down the compressor. CPR CODE 77
KEYPAD COMMS will be shown on the Mini-Port display.
Circuit Description:
The twisted pair yellow and dark green wires are the communications link (J1939
CAN BUS) that connects the Keypad and the Titan controller together as illustrated
in the circuit diagram. The yellow wire is referred to as J1939 CAN High (+). The
dark green wire is referred to as J1939 CAN Low (-).The compressor harness and
the control panel harness are connected together at P2/J2 connection point.
Component Location:
52                                46651193 Rev. A
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COMPRESSOR CODE 77
Troubleshooting Steps
Action Result
                            46651193 Rev. A                                     53
Electronic Service Manual
54                          46651193 Rev. A
Electrical Circuit Troubleshooting
         46651193 Rev. A             55
Electronic Service Manual                                Electrical Circuit Troubleshooting
Introduction
All electrical circuits throughout the compressor do not have a Compressor Diagnostic Code
for when a problem arises. This section includes troubleshooting steps to help resolve some
common electrical circuit problems. It is not possible to include all the solutions to problems
that can occur or list all possible problems. 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. Start with simple troubleshooting first and then work up to
the more complex troubleshooting methods.
56                                  46651193 Rev. A
Electrical Circuit Troubleshooting                                   Electronic Service Manual
Operation Description:
The Engine Starter Relay provides positive battery voltage to the engine starter for cranking
the engine. When the compressor electronic system is energized and the Start button on the
Keypad is pressed, a signal is sent to the Titan Controller over the J1939 CAN BUS to the
Engine ECM requesting the engine to start cranking. The Engine ECM provides 12VDC and
ground return to the Starter Relay. The Titan will provide the engine start signal to the Engine
ECM in an attempt to crank the compressor for 15 seconds above 55°F. ambient or 30
seconds below 32°F. The Titan controls starter protection by energizing and de-energizing
the engine start signal to the Engine ECM once the compressor is declared started.
                                                                           ENGINE ECM
                                                            YELLOW
                                                                           D2.2-35
                                                                                         S
                                                                                        POS
                                                                  ENGINE                      BAT +
                                                                 STARTER
                                                                            GND
                                                                                BROWN
                                     46651193 Rev. A                                                  57
Electronic Service Manual                                Electrical Circuit Troubleshooting
Circuit Description:
The Engine Start Relay connects to the Engine ECM as illustrated in the circuit diagram. The
Keypad connects to the Titan by J1939 CAN BUS. The yellow wire is the engine start signal
from the Titan to the Engine ECM.
Component Location:
K1 Relay is located on the starter. KP1 Keypad is located on the Control Panel.
Troubleshooting Steps
Action Result
58                                    46651193 Rev. A
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Operation Description:
The regulation heaters provide heat to orifices and regulators that may freeze during cold
weather. The Titan controls the regulation heaters by energizing and de-energizing the
Regulation Heaters Relay. When the Power Switch is pressed to energize the compressor
electronic system and the ambient temperature is below 45°F, the regulation heaters will be
energized. The heaters remain energized, even if the compressor is running, as long as the
ambient temperature is below 45°F. When the ambient temperature is above 45°F, the
heaters are de-energized.
                          TITAN
                       CONTROLLER
                            P1-5
                                BLACK
                                                               FB1-F6
                                                         AA6             A6
                                                  RED           10A             RED
                           D5                D6                                       BATTERY +
                           85                30                                         12VDC
                                                        REGULATION
                 FB1-K12                                 HEATERS
                                                          RELAY
                           86           87        87A
                           B6           B5   C5
                                BROWN
                                                                   REGULATION
                                                                     HEATER
                                                                     OPTION
                                             46651193 Rev. A                                            59
Electronic Service Manual                               Electrical Circuit Troubleshooting
Circuit Description:
The Regulation Heater connects to the Titan Controller as illustrated in the circuit diagram.
The black wire is the output control (12VDC) from the Tital to the FB1-K12 Relay Coil. The
dark blue wire is the output from the relay to the Regulation Heater. The Regulation Heater
and relay contacts are protected by the FB1-F6 (10 amp) Fuse.
Component Location:
Troubleshooting Steps
Action Result
60                                  46651193 Rev. A
Electrical Circuit Troubleshooting                             Electronic Service Manual
                     Action                                        Result
   Step 4:                                        1. Voltage measured should be 12VDC.
   Press the Power Switch to energize the         2. Voltage measured should be 12VDC. If
   compressor electronic system. Ensure the       not, check fuse and/or defective harness
   ambient temperature on the MiniPort            connections.
   display is 45°F or below with or without the
   use of Simulator Plug (Part No. 22073878).     3. Continuity should be shorted. If not,
   Using a Multimeter, complete the following     check for defective harness connections.
   measurements.
                                                  4. Voltage measured should be 12VDC. If
   1. Voltage between P1-5 and battery            not, check for defective harness
   Negative.                                      connections.
   2. Voltage between K12-D6 and battery          5. Voltage measured should be 12VDC. If
   Negative.                                      not, replace K12 relay.
   3. Resistance between K12-D6 and battery       6. Continuity should be shorted. If not,
   Negative.                                      check for defective harness connections.
   4. Voltage between K12-D5 and battery          7. Voltage measured should be 12VDC. If
   Negative.                                      not, check for defective harnesses. If
                                                  12VDC is measured at HR1, replace bad
   5. Voltage between K12-B5 and battery          heater.
   Negative.
                                   46651193 Rev. A                                       61
Electronic Service Manual                                                                Electrical Circuit Troubleshooting
Operation Description:
The Switched Power Relay provides Positive battery voltage to the Control Panel. When the
Power Switch is pressed, the Titan energizes the Switched Power Relay. The Switched
Power Relay will remain on until the Power Switch is pressed to turn the compressor
electronic system off. Also after 3 minutes (15 mins. < 45°F), without pressing the Start Button
the Titan will de-energize the Switched Power Relay and itself which will turn off the
compressor electronic system.
                                                                            PINK-GREEN
                           FB1-F2                    3            4
          BATTERY +
                                                     5            6
            12VDC
                                                         POWER
                                                         SWITCH
                                                                           P1-2
                                                                         TITAN
                                                                      CONTROLLER
                                                                          P1-10
                                                                            DARK BLUE
                                                                                                             RED
                                                                          D9                       D10              BATTERY +
                                                                          85                           30             12VDC
                                                               FB1-K13
                                                                                                                SWITCHED
                                                                                                                 POWER
                                                                          86 87                             87A  RELAY
                                                                         B10 B9                        C9
                                                                                          RED ORANGE
                                                                            BROWN
                                                                                                             FB1-F7
                                                                                                        A7            AA7   GAUGES/
                                                                                                              10A           KEYPAD
                                                                                                             FB1-F8
                                                                                                        A8            AA8 ENG. COMMS /
                                                                                                              10A         TITAN COMMS.
62                                                46651193 Rev. A
Electrical Circuit Troubleshooting                              Electronic Service Manual
Circuit Description:
The Switch Power Relay connects to the Titan as illustrated in the circuit diagram. The pink-
green wire is the power On signal (12VDC) from the Power Switch to the Titan. The dark blue
wire is the output from the Titan to energize the Switch Power Relay. The Power Switch is
protected by FB1-F2 (5 amp) fuse. The Switched Power Relay common contact terminal 30
is connected directly to battery+ (12VDC).
Component Location:
The S1 Power Switch is located on the Control Panel. K13 relay, F2 fuse, F7 fuse, and F8
fuse are located in the FB1 Fuse/Relay center.
Troubleshooting Steps
Action Result
                                   46651193 Rev. A                                        63
Electronic Service Manual                          Electrical Circuit Troubleshooting
Action Result
64                               46651193 Rev. A
C185WDZ-T4F System Schematics and
        Wiring Diagrams
              46651193 Rev. A       65
46652763 S1 of 2 REV. A
46652763 S2 of 2 REV. A
46652764 S1 of 3 REV. A
46652764 S2 of 3 REV. A
46652764 S3 of 3 REV. A
46652765 S1 of 1 REV. A
                                                   RIGHT                                LEFT                                           RIGHT                                                                                                                                                                        LEFT
                                                   FRONT                               FRONT                                            REAR                   RIGHT                                                       LICENSE                   LEFT                                                           REAR
                                                SIDE MARKER                         SIDE MARKER                                     SIDE MARKER            STOP/TURN/TAIL                                                   PLATE                STOP/TURN/TAIL                                                 SIDE MARKER
                                                    LAMP                                LAMP                                            LAMP                   LAMP                                                          LAMP                    LAMP                                                           LAMP
                                                             1                 2      1                                2              1              2        1 2 3                                                        1               2        1 2 3                                                          1                               2
                                                                                                                                                                                                                                                    W001 - WHITE - 16
                                                                                                                                                                                                                                                                                                                   W001 - WHITE - 16
                                                                                                                                       W004 - WHITE - 16
                                                                                                                                                                                                                             W002 - WHITE - 16
W003 - WHITE - 16
                                                                W006 - WHITE - 16
                                                                                       W005 - WHITE - 16
                                                                                                                                                                                                                                                                                            W019 - GREEN - 16
                                                               W008 - BROWN - 14
                                                                                                           W009 - BROWN - 16
                                                                                                                                                                                                                                                                        W013 - BROWN - 16
                                                                                                                                                                                  W011 - BROWN - 16
                                                                                                                                                                                                                            W012 - BROWN - 16
                                                                                                                                                                                                                                                                                                                                       W014 - BROWN - 16
                                                                                                                                      W010 - BROWN - 16
                                                                                                                                                                                                      W020 - YELLOW - 16
            TCI
            1     W018 - WHITE - 14
  TRAILER   2     W008 - BROWN - 14
CONNECTOR   3     W015 - YELLOW - 14
                                                                                     E2
            4     W016 - GREEN - 14
                                                                                                                               E1
                                                 W017 - WHITE - 16
                                        FRAME
                                       GROUND
                                                GND
                                                                                                                                                                                                                                                                                                                                                           46652766 S1 of 1 REV. A
Compressor and Engine                                                        Compressor and Engine
 Reference                                                                    Reference
                              Description                  Part Number                                      Description                Part Number
Designator                                                                   Designator
           Titan Controller                                 46651421             RT3    Ambient Air Temperature Sensor                   23294838
           Engine ECM                                       46638371             S10    Engine Air Filter Restriction Switch             36847838
           Compressor & Engine Harness                      46630242             S11    Airend Air Filter Restriction Switch             36847838
           Glow Plug Harness                                46633423             TR2    J1939 CAN BUS Terminating Resistor               23091804
           Battery Positive Cable                           46650391             TR3    J1939 CAN BUS Terminating Resistor               23091804
           Battery Negative Cable                           46650392             U1     Fuel Level Sensor (option)                       22540645
           Frame Ground Strap 350mm                         22451249              X1    Battery Positive Power Distribution Post         23322738
    B1     Engine Starter                                   46652658
    B2     Fuel Pump                                        46638370
    BT1    Battery, 12 VDC 700 CCA                          36844264
    BT1    Battery, 12 VDC 1000 CCA                         36844975         Control Panel
    D1     Diode                                            35376169          Reference
                                                                                                            Description                Part Number
    D2     Diode                                            35376169         Designator
    FB1    Fuse/Relay Center Replacement                    46556356                      Control Panel Harness                          46647719
    FB1    Fuse/Relay Center Replacement Cover              23366172             KP1      Keypad                                         46585699
    FB1    Fuse/Relay Center Decal Outside Cover            46574381             M1       Air Pressure Gauge with Mini-Port Display      46626121
    FB1    Fuse/Relay Center Decal Inside Cover             46650215              S1      Power Switch                                   46605159
  FB1-F1   Titan Controller Fuse 10 Amp                     23091812             M2       Hourmeter                                      46557109
  FB1-F2   Power Switch Fuse 5 Amp                          23326069             TR1      J1939 CAN BUS Terminating Resistor             23091804
  FB1-F3   Titan Communication 10 Amp                       23091812
  FB1-F4   Engine ECM Fuse 30 Amp                           23091853
  FB1-F5   Fuel Pump Fuse 20 Amp                            23091838
  FB1-F6   Regulation Heaters Fuse 10 Amp                   23091812         Trailer
  FB1-F7   Gauges / Keypad Fuse 10 Amp                      23091812          Reference
                                                                                                            Description                Part Number
  FB1-F8   Engine / Titan Communication Fuse 10 Amp         23091812         Designator
    F11    Engine Glow Plug Fuse 150 Amp                    46556477                      Trailer Harness                                23050180
    F11    Replacement Fuse Holder                          45671534             L1       Right Front Side Marker Lamp                   35367051
    F78    Water In Fuel Sensor (Built into Fuel Filter)    46651561             L2       Left Front Side Marker Lamp                    35367051
    G1     Engine Alternator                                46652659             L3       Right Rear Side Marker Lamp                    35367044
     J5    Replacement Cap with Lanyard                     23366768             L4       Right Stop/Turn/Tail Lamp                      36788081
    J5A    Replacement Cap with Lanyard                     23366768             L5       License Plate Lamp                             54726468
    K1     Engine Starter Relay                             46652660             L6       Left Stop/Turn/Tail Lamp                       36788081
    K2     Engine Intake Air Heater Relay                   36856250             L7       Left Rear Side Marker Lamp                     35367044
  FB1-K11  Fuel Pump Relay                                  46650951
  FB1-K12  Regulation Heater Relay                          46650951
  FB1-K13  Switched Power Relay                             46650951
     L1    Start/Run Solenoid Valve                         46626320
    PT2    Regulation System Pressure Sensor 0 – 100PSIG    36920825
    RT1    Separator Element Temperature Sensor             46626400
    RT2    Discharge Air Temperature Sensor                 46626400
              46651193 Rev. A       74
46652769 S1 of 2 REV. A
46652769 S2 of 2 REV. A
46652770 S1 of 3 REV. A
46652770 S2 of 3 REV. A
46652770 S3 of 3 REV. A
46652772 S1 of 1 REV. B
                                                   RIGHT                                LEFT                                           RIGHT                                                                                                                                                                        LEFT
                                                   FRONT                               FRONT                                            REAR                   RIGHT                                                       LICENSE                   LEFT                                                           REAR
                                                SIDE MARKER                         SIDE MARKER                                     SIDE MARKER            STOP/TURN/TAIL                                                   PLATE                STOP/TURN/TAIL                                                 SIDE MARKER
                                                    LAMP                                LAMP                                            LAMP                   LAMP                                                          LAMP                    LAMP                                                           LAMP
                                                             1                 2      1                                2              1              2        1 2 3                                                        1               2        1 2 3                                                          1                               2
                                                                                                                                                                                                                                                    W001 - WHITE - 16
                                                                                                                                                                                                                                                                                                                   W001 - WHITE - 16
                                                                                                                                       W004 - WHITE - 16
                                                                                                                                                                                                                             W002 - WHITE - 16
W003 - WHITE - 16
                                                                W006 - WHITE - 16
                                                                                       W005 - WHITE - 16
                                                                                                                                                                                                                                                                                            W019 - GREEN - 16
                                                               W008 - BROWN - 14
                                                                                                           W009 - BROWN - 16
                                                                                                                                                                                                                                                                        W013 - BROWN - 16
                                                                                                                                                                                  W011 - BROWN - 16
                                                                                                                                                                                                                            W012 - BROWN - 16
                                                                                                                                                                                                                                                                                                                                       W014 - BROWN - 16
                                                                                                                                      W010 - BROWN - 16
                                                                                                                                                                                                      W020 - YELLOW - 16
            TCI
            1     W018 - WHITE - 14
  TRAILER   2     W008 - BROWN - 14
CONNECTOR   3     W015 - YELLOW - 14
                                                                                     E2
            4     W016 - GREEN - 14
                                                                                                                               E1
                                                 W017 - WHITE - 16
                                        FRAME
                                       GROUND
                                                GND
                                                                                                                                                                                                                                                                                                                                                           46652766 S1 of 1 REV. A
Compressor and Engine                                                        Compressor and Engine
 Reference                                                                    Reference
                              Description                  Part Number                                      Description                Part Number
Designator                                                                   Designator
           Titan Controller                                 46651421             RT3    Ambient Air Temperature Sensor                   23294838
           Engine ECM                                       46638371             S10    Engine Air Filter Restriction Switch             36847838
           Compressor & Engine Harness                      46635543             S11    Airend Air Filter Restriction Switch             36847838
           Glow Plug Harness                                46635544             TR2    J1939 CAN BUS Terminating Resistor               23091804
           Battery Positive Cable                           46650389             TR3    J1939 CAN BUS Terminating Resistor               23091804
           Battery Negative Cable                           46650390             U1     Fuel Level Sensor (option)                       22058531
           Frame Ground Strap 350mm                         36783488              X1    Battery Positive Power Distribution Post         23322738
    B1     Engine Starter                                   46652658
    B2     Fuel Pump                                        46638370
    BT1    Battery, 12 VDC 700 CCA                          36844264
    BT1    Battery, 12 VDC 1000 CCA                         36844975         Control Panel
    D1     Diode                                            35376169          Reference
    D2     Diode                                            35376169                                        Description                Part Number
                                                                             Designator
    FB1    Fuse/Relay Center Replacement                    46556356                      Control Panel Harness                          46646825
    FB1    Fuse/Relay Center Replacement Cover              23366172             KP1      Keypad                                         46585699
    FB1    Fuse/Relay Center Decal Outside Cover            46574381             M1       Air Pressure Gauge with Mini-Port Display      46626121
    FB1    Fuse/Relay Center Decal Inside Cover             46650215              S1      Power Switch                                   46605159
  FB1-F1   Titan Controller Fuse 10 Amp                     23091812             M2       Hourmeter                                      46557109
  FB1-F2   Power Switch Fuse 5 Amp                          23326069             TR1      J1939 CAN BUS Terminating Resistor             23091804
  FB1-F3   Titan Communication 10 Amp                       23091812
  FB1-F4   Engine ECM Fuse 30 Amp                           23091853
  FB1-F5   Fuel Pump Fuse 20 Amp                            23091838
  FB1-F6   Regulation Heaters Fuse 10 Amp                   23091812         Trailer
  FB1-F7   Gauges / Keypad Fuse 10 Amp                      23091812         Reference
                                                                                                            Description                Part Number
  FB1-F8   Engine / Titan Communication Fuse 10 Amp         23091812         Designator
    F11    Engine Glow Plug Fuse 150 Amp                    46556477                      Trailer Harness                                23050180
    F11    Replacement Fuse Holder                          45671534             L1       Right Front Side Marker Lamp                   35367051
    F78    Water In Fuel Sensor (Built into Fuel Filter)    46651561             L2       Left Front Side Marker Lamp                    35367051
    G1     Engine Alternator                                46652659             L3       Right Rear Side Marker Lamp                    35367044
     J5    Replacement Cap with Lanyard                     23366768             L4       Right Stop/Turn/Tail Lamp                      36788081
    J5A    Replacement Cap with Lanyard                     23366768             L5       License Plate Lamp                             54726468
    K1     Engine Starter Relay                             46652660             L6       Left Stop/Turn/Tail Lamp                       36788081
    K2     Engine Intake Air Heater Relay                   36856250             L7       Left Rear Side Marker Lamp                     35367044
  FB1-K11  Fuel Pump Relay                                  46650951
  FB1-K12  Regulation Heater Relay                          46650951
  FB1-K13  Switched Power Relay                             46650951
     L1    Start/Run Solenoid Valve                         46626320
    PT2    Regulation System Pressure Sensor 0 – 100PSIG    36920825
    RT1    Separator Element Temperature Sensor             46626400
    RT2    Discharge Air Temperature Sensor                 46626400
 72                         46651193 Rev. A
Electrical Component Locations
        46651193 Rev. A          84
Electronic Service Manual                          Electrical Component Locations
                                                    FB1
                                                    K2
                                                    RT3
                                                    F11
                                           TITAN
                          B1               CONTROLLER
              S10                          P1
              S11
B2
                                                   M1
                                                   KP1
                                                   S1
                                                   M2
F78
           RT2
                                      U1
                    PT2
                    RT1
                     L1
85                             46651193 Rev. A
Electrical Component Locations                            Electronic Service Manual
                                       S10                   B1
                                       S11
                           M1
                          KP1
                           S1                                                 F78
                           M2
                  TITAN                                                   B2
             CONTROLLER
                     P1
U1
                                                    BT1      RT2
                                  L1    RT3   RT1
                                 PT2
                                                                   K2
                                                                   F11
FB1
                           G1                             ENGINE ECM
                                                          D2.1 & D2.2
                                 46651193 Rev. A                                    86
Electronic Service Manual                                   Electrical Component Locations
     P2 / J2: 8-pin connector system located behind Control Panel. Connector system
     connects the Control Panel harness to the compressor harness.
     P12 / J12-CAP: 2-pin connector system located near the Pressure Regulator. Connector
     system connects the Regulation Heater option harness to the compressor harness.
     P15: 2-pin connector located behind Control Panel for Termination Resistor TR1 on J1939
     CAN BUS.
     P16: 2-pin connector located near engine ECM for Termination Resistor TR2 on J1939
     CAN BUS.
P40: 2-pin connector located on the engine for connection of glow plugs.
     X17.1: 62-pin connector located on the engine for connection of engine harness to Engine
     ECM.
87                                    46651193 Rev. A
                        Revision History