Doosan P425WCU-EX-T2 Electronic Service Manual
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Doosan P425WCU-EX-T2 Electronic Service Manual

Doosan P425WCU-EX-T2 Electronic Service Manual

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ELECTRONIC SERVICE MANUAL
COMPRESSOR MODELS
P425WCU-EX-T2 (F66)
HP375WCU-EX-T2 (F67)
XP375WCU-EX-T2 (F65)
P425WCU-EX-T2 (G02)
HP375WCU-EX-T2 (G03)
XP375WCU-EX-T2 (G04)
Doosan Infracore Portable Power
1293 Glenway Drive
Statesville, N.C. 28625
DoosanPortablePower.com
Book: 46673131 (06-2015) Rev A

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  • Page 1 ELECTRONIC SERVICE MANUAL COMPRESSOR MODELS P425WCU-EX-T2 (F66) HP375WCU-EX-T2 (F67) XP375WCU-EX-T2 (F65) P425WCU-EX-T2 (G02) HP375WCU-EX-T2 (G03) XP375WCU-EX-T2 (G04) Doosan Infracore Portable Power 1293 Glenway Drive Statesville, N.C. 28625 DoosanPortablePower.com Book: 46673131 (06-2015) Rev A...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Electronic Service Manual TITLE PAGE GENERAL INFORMATION ..........5 COMPRESSOR OPERATION SEQUENCE.
  • Page 4 TABLE OF CONTENTS Electronic Service Manual TITLE PAGE...

  • Page 5: General Information

    General Information 46673131 Rev. A...
  • Page 6 Electronic Service Manual General Information Operational Theory The P425/XP375/HP375WCU-EX-T2 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.
  • Page 7 General Information Electronic Service Manual The Titan controller scans digital inputs such as switch contacts. Inputs are 24 VDC, 12 VDC, or 0 VDC. Digital inputs with 24 VDC or 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.
  • Page 8 Electronic Service Manual General Information Figure 1-2 : J1939 CAN BUS CONNECTION LAYOUT 46673131 Rev. A...
  • Page 9 General Information Electronic Service Manual Figure 1-3 : HARNESS SYSTEM CONNECTION LAYOUT 46673131 Rev. A...
  • Page 10 Electronic Service Manual General Information 46673131 Rev. A...

  • Page 11: Compressor Operation Sequence

    Compressor Operation Sequence 46673131 Rev. A...
  • Page 12 Electronic Service Manual Compressor Operation Sequence Power On When the Keyswitch is in the ON position: 1. Key ON/OFF signal (12 VDC) supplied to Titan controller. 2. Titan controller energizes Switched Power Relay (FB1-K3). 3. Micro-Port display and gauges will initialize. 4.
  • Page 13 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. When the Keyswitch is moved to the OFF position: 1.
  • Page 14 Electronic Service Manual Compressor Operation Sequence 46673131 Rev. A...

  • Page 15: Compressor Diagnostic Code Troubleshooting

    Compressor Diagnostic Code Troubleshooting 46673131 Rev. A...
  • Page 16 Electronic Service Manual Compressor Diagnostic Code Troubleshooting 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.
  • Page 17 Compressor Diagnostic Code Troubleshooting Electronic Service Manual General Measuring Guidelines 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.
  • Page 18 Electronic Service Manual Compressor Diagnostic Code Troubleshooting Troubleshooting Flow Chart 46673131 Rev. A...
  • Page 19 Compressor Diagnostic Code Troubleshooting Electronic Service Manual Compressor Diagnostic Codes Code LCD Display Display Name Description Type CPR CODE 1 Low Engine Speed Engine speed less than 1100 FAULT LOW ENGINE RPM for 30 seconds. SPEED CPR CODE 2 High Engine Speed Engine speed greater than 2350 FAULT HIGH ENGINE...
  • Page 20 Electronic Service Manual Compressor Diagnostic Code Troubleshooting Code LCD Display Display Name Description Type CPR CODE 36 Safety Valve Open Safety relief valve on separator FAULT SAFETY VALVE tank opened. OPEN CPR CODE 38 Intake Air Filters Intake filters restricting air flow. ALERT AIR FILTERS Restricted...
  • Page 21 Compressor Diagnostic Code Troubleshooting Electronic Service Manual COMPRESSOR CODE 1 Low Engine Speed Explanation The Titan controller has received an engine speed value less than 1100 RPM for 30 seconds from the engine. Effect Code 1 is a FAULT condition and will shut down the compressor. CPR CODE 1 LOW ENGINE SPEED will be shown on the Micro-Port display.
  • Page 22 Electronic Service Manual Compressor Diagnostic Code Troubleshooting Action Result Step 4: If Steps 1 thru 3 checkout OK, refer to the engine manufacturer service dealer. 46673131 Rev. A...
  • Page 23 Compressor Diagnostic Code Troubleshooting Electronic Service Manual COMPRESSOR CODE 2 High Engine Speed Explanation: The Titan controller has measured an engine speed value greater than 2350 RPM for 30 seconds. Effect: Code 2 is a FAULT condition and will shut down the compressor. CPR CODE 2 HIGH ENGINE SPEED will be shown on the Micro-Port display.
  • Page 24 Electronic Service Manual Compressor Diagnostic Code Troubleshooting COMPRESSOR CODE 3 Engine Crank Timeout 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 Micro-Port display.
  • Page 25 Compressor Diagnostic Code Troubleshooting Electronic Service Manual 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 Micro-Port display.
  • Page 26 Electronic Service Manual Compressor Diagnostic Code Troubleshooting Action Result Step 5: If Steps 1 thru 4 checkout OK, replace Titan controller. 46673131 Rev. A...
  • Page 27 Compressor Diagnostic Code Troubleshooting Electronic Service Manual COMPRESSOR CODE 12 Low Fuel Level 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 Micro-Port display.
  • Page 28 Electronic Service Manual Compressor Diagnostic Code Troubleshooting Action Result Step 5: If Steps 1 thru 4 checkout OK, replace Titan controller. 46673131 Rev. A...
  • Page 29 Compressor Diagnostic Code Troubleshooting Electronic Service Manual COMPRESSOR CODE 29 Engine Shutdown Unknown Explanation: The engine has shut down for any reason without user input and the Titan did not detect an Engine Diagnostic Code. Effect: Code 29 is a FAULT condition and will shut down the compressor. CPR CODE 29 ENGINE SHUTDOWN?? will be shown on the Micro-Port display.
  • Page 30 Electronic Service Manual Compressor Diagnostic Code Troubleshooting COMPRESSOR CODE 30 High Airend Discharge Temperature Explanation: The Titan controller has detected a temperature from RT2 Discharge Air Temperature Sensor that is greater than or equal to 251°F for 3 seconds or more. Effect: Code 30 is a FAULT condition and will shut down the compressor.
  • Page 31 Compressor Diagnostic Code Troubleshooting Electronic Service Manual COMPRESSOR CODE 32 Airend Discharge Temperature Sensor 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 Micro-Port display.
  • Page 32 Electronic Service Manual Compressor Diagnostic Code Troubleshooting COMPRESSOR CODE 32 Troubleshooting Steps Action Result Step 1: If harness connections are loose or damaged, repair harness as needed. Check all harness connections between Titan and RT2 temperature sensor. Step 2: If temperature value on Micro-Port display is not between -3°F and -13°F, Disconnect RT2 from harness and check for defective harness...
  • Page 33 Compressor Diagnostic Code Troubleshooting Electronic Service Manual COMPRESSOR CODE 33 Separator Tank Pressure Sensor Explanation: The Titan controller has detected an out of range reading from the PT1 Pressure Sensor. Effect: Code 33 is a FAULT condition and will shut down the compressor. CPR CODE 33 SEP TANK PRES SENSOR will be shown on the Micro-Port display.
  • Page 34 Electronic Service Manual Compressor Diagnostic Code Troubleshooting COMPRESSOR CODE 33 Troubleshooting Steps Action Result Step 1: If harness connections are loose or damaged, repair harness as needed. Check all harness connections between Titan and PT1 Pressure Sensor. Step 2: Voltage measured should be 5 VDC between PT1-1 and PT1-2.
  • Page 35 Compressor Diagnostic Code Troubleshooting Electronic Service Manual COMPRESSOR CODE 34 High Separator Tank Pressure At Start Explanation: The Titan controller has detected a pressure from PT1 Pressure Sensor that is greater than 20 psi at the time of engine start. Effect: Code 34 is a FAULT condition and will prevent starting until the Separator Tank pressure is below 20 psi.
  • Page 36 Electronic Service Manual Compressor Diagnostic Code Troubleshooting COMPRESSOR CODE 34 Troubleshooting Steps Action Result Step 1: If air pressure is not below 20 psi and the system continues to hold pressure, Wait until air pressure is below 20 psi proceed to Step 2. before trying to start the compressor.
  • Page 37 Compressor Diagnostic Code Troubleshooting Electronic Service Manual COMPRESSOR CODE 36 Safety Valve Open Explanation: The Titan controller has detected an open contact from S14 Pressure Switch indicating the Safety Valve has opened. Effect: Code 36 is a FAULT condition and will shut down the compressor. CPR CODE 36 SAFETY VALVE OPEN will be shown on the Micro-Port display.
  • Page 38 Electronic Service Manual Compressor Diagnostic Code Troubleshooting COMPRESSOR CODE 36 Troubleshooting Steps Action Result Step 1: If the Safety Valve is not operating properly, replace the Safety Valve. Verify that the Safety Valve is operating properly. Step 2: If harness connections are loose or damaged, repair harness as needed.
  • Page 39 Compressor Diagnostic Code Troubleshooting Electronic Service Manual COMPRESSOR CODE 38 Intake Air Filters Restricted 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.
  • Page 40 Electronic Service Manual Compressor Diagnostic Code Troubleshooting COMPRESSOR CODE 38 Troubleshooting Steps Action Result Step 1: If the filters are dirty or clogged, replace filters as needed. Check the engine and airend filters. Step 2: If harness connections are loose or damaged, repair harness as needed.
  • Page 41 Compressor Diagnostic Code Troubleshooting Electronic Service Manual COMPRESSOR CODE 39 Low System Voltage Explanation: The Titan controller has detected the system voltage during compressor operation has reached a level below 13.3 VDC for 30 seconds or more. While compressor is not in operation, the Titan controller has detected the system voltage has reached a level below 11.5 VDC for 30 seconds or more.
  • Page 42 Electronic Service Manual Compressor Diagnostic Code Troubleshooting COMPRESSOR CODE 39 Action Result Step 4: Voltage measured should be 13.3 VDC or above at all 3 measured Start and run compressor at idle. points. Using a multimeter, measure the voltage between the Titan P1-1 and If voltage measured is not 13.3 VDC battery Negative.
  • Page 43 Compressor Diagnostic Code Troubleshooting Electronic Service Manual COMPRESSOR CODE 42 Fuel Level Sensor 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.
  • Page 44 Electronic Service Manual Compressor Diagnostic Code Troubleshooting COMPRESSOR CODE 42 Troubleshooting Steps Action Result Step 1: If harness connections are loose or damaged, repair harness as needed. Check all harness connections between Titan and U1 Fuel Level Sensor. Step 2: Continuity should be shorted between U1-D and P1-14.
  • Page 45 Compressor Diagnostic Code Troubleshooting Electronic Service Manual COMPRESSOR CODE 43 Low Separator Tank Pressure Explanation: The Titan controller has detected a pressure from PT1 Pressure Sensor less than 40 psi after the compressor is loaded. Effect: Code 43 is a FAULT condition and will shut down the compressor. CPR CODE 43 LOW SEP TANK PRES will be shown on the Micro-Port display.
  • Page 46 Electronic Service Manual Compressor Diagnostic Code Troubleshooting COMPRESSOR CODE 50 High Separator Tank Temperature Explanation: The Titan controller has detected a temperature from RT1 Temperature Sensor that is greater than or equal to 251°F for 3 seconds or more. Effect: Code 50 is a FAULT condition and will shut down the compressor.
  • Page 47 Compressor Diagnostic Code Troubleshooting Electronic Service Manual COMPRESSOR CODE 51 Compressor ID Invalid Explanation: The Titan controller and the Micro-Port display do not have a valid compressor ID. Code 51 will occur only when a new Titan and a new Engine Tachometer with Micro-Port display are installed at the same time.
  • Page 48 Electronic Service Manual Compressor Diagnostic Code Troubleshooting COMPRESSOR CODE 52 IQ Filters Restricted Explanation: The Titan controller has detected a pressure from S7 IQ Filter System Differential Pressure Switch indicating the IQ Filters are restricting air flow past a usable level. Effect: Code 52 is a FAULT condition and will shut down the compressor.
  • Page 49 Compressor Diagnostic Code Troubleshooting Electronic Service Manual COMPRESSOR CODE 53 Separator Tank Temperature Sensor Explanation: The Titan controller has detected an out of range reading from the RT1 Separator Element 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 Micro-Port display.
  • Page 50 Electronic Service Manual Compressor Diagnostic Code Troubleshooting COMPRESSOR CODE 53 Troubleshooting Steps Action Result Step 1: If harness connections are loose or damaged, repair harness as needed. Check all harness connections between Titan and RT1 Separator Element Temperature Sensor. Step 2: If temperature value on Micro-Port display is not between -3°F and -13°F, Disconnect RT1 from harness and...
  • Page 51 Compressor Diagnostic Code Troubleshooting Electronic Service Manual COMPRESSOR CODE 58 Ambient Temperature Sensor Explanation: The Titan controller has detected an out of range reading from the RT3 Ambient Air 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 Micro-Port display.
  • Page 52 Electronic Service Manual Compressor Diagnostic Code Troubleshooting COMPRESSOR CODE 58 Troubleshooting Steps Action Result Step 1: If harness connections are loose or damaged, repair harness as needed. Check all harness connections between Titan and RT3 Temperature Sensor. Step 2: If temperature value on Micro-Port display is not between -3°F and -13°F, Disconnect RT3 from harness and check for defective harness...
  • Page 53 Compressor Diagnostic Code Troubleshooting Electronic Service Manual COMPRESSOR CODE 76 Titan Controller Communication Explanation: The Micro-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 Micro-Port display.
  • Page 54 Electronic Service Manual Compressor Diagnostic Code Troubleshooting COMPRESSOR CODE 76 Troubleshooting Steps Action Result Step 1: Resistance value measured should be 60 ohms across P1-32 and P1-34. Disconnect P1 connector from the Titan. M2 Connector from the Micro- If resistance value measure is not 60 Port display, and any other devices ohms, measure resistance value of connected to the J1939 CAN BUS.

  • Page 55: Electrical Circuit Troubleshooting

    Electrical Circuit Troubleshooting 46673131 Rev. A...
  • Page 56 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.
  • Page 57 Electronic Service Manual Engine Starter Relay Circuit 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 BUSS requesting the engine to start cranking.
  • Page 58 Electronic Service Manual Engine Starter Relay Circuit Circuit Description: The Engine Starter Relay connects to the Titan controller as illustrated in the circuit diagram. The Key Switch connects to the Titan by J1939 CAN BUS. The yellow wire is the output control (12 VDC) from the Titan to the K1 Relay Coil.
  • Page 59 Electronic Service Manual Engine Starter Relay Circuit Action Result Step 4: 1. Voltage measured should be 12VDC. If not, replace Titan controller and or Keypad. Turn the Keyswitch to the ON position to energize the compressor electronic system. 2. Voltage measured should be 12VDC. If Turn the Keyswitch to the START position.
  • Page 60 Electronic Service Manual Start Compressor Circuit Operation Description: The B4 Start Compressor provides air to close the Airend Unloader Valve for ease of engine starting. The Titan controls the start compressor by energizing and de-energizing the Start Compressor Relay. When the Keyswitch is moved to the ON position, the start compressor will be energized for 10 seconds.
  • Page 61 Electronic Service Manual Start Compressor Circuit Component Location: B2 Start Compressor is located on top of the Fuel Tank beside the Airend. FB1-K2 Relay and FB1-F3 fuse are located in the FB1 Fuse/Relay center mounted above the fuel tank. Troubleshooting Steps Action Result Step 1:...
  • Page 62 Electronic Service Manual Regulation Heater Circuit Operation Description: The regulation heater provides heat to orifices and regulators that may freeze during cold weather. The Titan controls the regulation heater directly. When the Keyswitch is turned to the ON position to energize the compressor electronic system and the ambient temperature is below 45°F, the regulation heaters will be energized.
  • Page 63 Electronic Service Manual Regulation Heater Circuit Circuit Description: The regulation heaters connect to the Titan controller as illustrated in the circuit diagram. The black wire is the output control (12VDC) from the Titan to the regulation heater. The ground to the regulation heaters. Component Location: HR100 is located on the pressure regulator mounted on top of the Separator Tank.
  • Page 64 Electronic Service Manual Switched Power Relay Circuit Operation Description: The Switched Power Relay provides Positive battery voltage to the Control Panel and Accessory option.When the Keyswitch is in the ON position, the Titan energizes the Switched Power Relay. The Switched Power Relay will remain on until the Keyswitch is turned to the OFF position turning the compressor electronic system off.
  • Page 65 Electronic Service Manual Switched Supply Relay Circuit Circuit Description: The Switch Supply Relay connects to the Titan as illustrated in the circuit diagram. The pink- green wire is the power On signal (12VDC) from the Keyswitch to the Titan. The dark blue wire is the output from the Titan to energize the Switch Supply Relay.
  • Page 66 Electronic Service Manual Action Result 7. Voltage between K3-D10 and battery 7. Voltage measured should be 12VDC. If Negative. not, check for defective harness connections. 8. Voltage between K3-B9 and battery 8. Voltage measured should be 12VDC. If Negative. not, replace K3 switched power relay. 46673131 Rev.

  • Page 67: Electrical Component Locations

    Electrical Component Locations 46673131 Rev. A...
  • Page 68 Electronic Service Manual Electrical Component Locations 46673131 Rev. A...
  • Page 69 Electrical Component Locations Electronic Service Manual Harness Connector Locations P1: 35-pin connector that connects to the Titan controller. P15: 2-pin connector located behind control panel for termination resistor TR1 on J1939 CAN BUS. P16: 2-pin connector located near Titan controller for termination resistor TR2 on J1939 CAN BUS.
  • Page 70 Electronic Service Manual Electrical Component Locations 46673131 Rev. A...

  • Page 71: Electrical Parts List

    Electrical Parts List 46673131 Rev. A...
  • Page 72 Electronic Service Manual 46673131 Rev. A...
  • Page 74 Electronic Service Manual 46673131 Rev. A...

  • Page 75: System Schematics And Wiring Diagrams

    System Schematics and Wiring Diagrams 46673131 Rev. A...
  • Page 76 Electronic Service Manual System Schematics and Wiring Diagrams 46673131 Rev. A...
  • Page 89 Revision History Rev. EC Number Comments Original release...
  • Page 90 Doosan Infracore Portable Power 1293 Glenway Drive Statesville, N.C. 28625 www.doosanportablepower.com © Doosan Infracore Portable Power Printed in the U.S.A.

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