Download - Ddec master 2000 current4 6
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Detroit DieselElectronic Controls
DDECDDECDDEC
DDECDDEC IVIII
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25ST0072-2 Rev. 04/4/00 3
DDEC AGENDA
• Pre-Test• Objectives• Review Manuals• Features & Components• System Hardware• Repair Tools• Basic Electricity• Trouble Shooting• DDEC Reprogramming• Post-Test, Evaluations
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25ST0072-2 Rev. 04/4/00 4
DDEC History
• DDEC I Introduced in 1985 on 92 Series• Series 60 Introduced in 1987 As the First Engine
Ever Designed Exclusively for Electronic Controls• DDEC II Introduced in 1987• DDEC III Introduced April, 1993• DDEC III Full Production January, 1994• DDEC IV Initial Release, August, 1997• DDEC IV Full Production, January, 1998
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25ST0072-2 Rev. 04/4/00 5
What is DDEC?
An advanced electronic fuel injection control system that can be integrated into many applications
DDEC Consists of:• Sensors and switches• Conductors and connections• ECM (computer)
– Hardware– Software
• Injectors
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25ST0072-2 Rev. 04/4/00 7
Electronic Engine Advantages
• Engine Protection• Engine Diagnostics• Reduced Maintenance• Improved Engine Governing• Fuel Economy Optimization• Enhanced Cold Starting• Smoke Control• Reduced Emission Levels
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25ST0072-2 Rev. 04/4/00 9
DDEC IV Features• Four New ECM’s
ECM DescriptionStandard Truck 6 Cylinder 12 VoltUniversal 8 Cylinder 12/24 VoltS4000 8 Cylinder 12/24 VoltNatural Gas 8 Cylinder 12/24 Volt
• Increased Memory - 57% Over DDEC III• Faster Processing Time - 50% Over DDEC III• J1939 Communication Link - Standard• Battery Backed Real Time Clock & Calendar• DDEC Data (Enhanced ECM Data Pages) -
Standard
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25ST0072-2 Rev. 04/4/00 10
DDEC Necessities
Ignition
ElectronicControlModule(ECM)
EEPROM
+-Battery
Timing Reference
Synch Reference
EUI
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25ST0072-2 Rev. 04/4/00 11
Schematic Diagram DDEC III/ IV
ElectronicControlModule(ECM)
EEPROM
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25ST0072-2 Rev. 04/4/00 12
Electronic Control Module
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25ST0072-2 Rev. 04/4/00 13
Electronic Control Module
DDC responsibility
Engine sensors, harness, & connectors
Injector harness & connectorsInjectors
OEM responsibility
Mandatory circuits Power and Ground
J1922,J1939, Ignition
Throttle position sensorOptional circuits Manual fan on switch, Jake Brake, 439 Ignition wire
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25ST0072-2 Rev. 04/4/00 14
Schematic Diagram DDEC III / IV
ElectronicControlModule(ECM)
EEPROM
+-Battery
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25ST0072-2 Rev. 04/4/00 15
Power Supply
• DDEC II - 12 Volt• DDEC III - 12/24 Volt• DDEC IV- 12 or 24 Volt• Source must be Isolated from any other Vehicle Accessory• The ECM Power Source must be Fused with the Proper Amp• The ECM Must Be Incorporated with a 5 Amp Fuse on the
440 wire going into the 439 wire.• The ECM Case Must be Electrically Isolated from any
Chassis Ground
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25ST0072-2 Rev. 04/4/00 16
Power Supply DDEC III/ IV
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25ST0072-2 Rev. 04/4/00 17
Power Supply DDEC III / IV
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25ST0072-2 Rev. 04/4/00 18
Schematic Diagram DDEC III / IV
ElectronicControlModule(ECM)
EEPROM
+-Battery
EUI
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25ST0072-2 Rev. 04/4/00 19
Electronic Unit Injectors
Series 71/92 EUI Series 149 EUI Series 50/60 EUI
Series 4000 Spray Nozzle Series 2000 EUP
Series 53 EUI
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Series 50/60 Injector
Animation
Fuel out
Fuel in
Voltage in
Solenoid
Plunger
Poppet Valve
Needle Valve
Rocker Arm
Cam
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Series 4000 Nozzle
AnimationCAM
Rocker ArmSolenoid
filter
Fuel Return
High Pressure
Fuel
Needle Valve
Nozzle
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Series 2000 EUP
AnimationCAM
Rocker ArmSolenoid
EUP
Cam
Spay Nozzle
Fuel In
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25ST0072-2 Rev. 04/4/00 23
Electronic Unit Pump
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25ST0072-2 Rev. 04/4/00 24
Top Of Stroke
InjectorTip
FuelIn
FuelOut
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25ST0072-2 Rev. 04/4/00 25
Start Of Injection
InjectorTip
FuelIn
FuelOut
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25ST0072-2 Rev. 04/4/00 26
End Of Injection
InjectorTip
FuelIn
FuelOut
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25ST0072-2 Rev. 04/4/00 27
Injection Sequence
InjectorTip
FuelInFuelOut
InjectorTip
FuelIn
FuelOut
InjectorTip
FuelIn
FuelOut
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25ST0072-2 Rev. 04/4/00 28
Injector Calibration Codes
• DDEC II No Calibration Codes• DDEC III/ IV Calibration Codes From 00-99
Calibration Code
Part Number
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25ST0072-2 Rev. 04/4/00 29
Injector Cycle Terminology
IRT Injector Response Time - Length of Time (ms) required to close the Control Valve
PW Pulse Width - Degrees of Crankshaft Rotation when Fuel is Injected
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25ST0072-2 Rev. 04/4/00 30
Injector Response Times
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25ST0072-2 Rev. 04/4/00 31
Cylinder Cut-Out
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25ST0072-2 Rev. 04/4/00 32
Injection Cycle
BOE BOI EOE EOIIRT
Time
PW
(Inflection Point)
BAT
Voltage0V
V_REG, 5V
Current0A
ClosedOpenControl Valve Lift
Injection Rate
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25ST0072-2 Rev. 04/4/00 34
Sensor Operations
Operates on 5 Volts for All D.C. Sensors
.25 4.75
NormalOperating
Range
Low Voltage
0 5
High Voltage
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25ST0072-2 Rev. 04/4/00 35
Sensor Wiring
• Common Return Circuit. #452• Thermistor
• Piezoresistive Pressure sensor
• Voltage is Proportional to Pressure
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25ST0072-2 Rev. 04/4/00 36
2-wire Sensors
5V Supply
Signal
Return
ECM SensorOpen = HI VOLTAGEShort = LO VOLTAGE
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25ST0072-2 Rev. 04/4/00 37
3-wire Sensors
ECM Sensor5V Supply
Signal
Return
Open Supply = LO VOLTAGEOpen Signal = LO VOLTAGE Open Return = HI VOLTAGE
HI VOLTAGESupply short to Signal =Supply short to Return = LO VOLTAGESignal short to Return = LO VOLTAGE
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25ST0072-2 Rev. 04/4/00 38
SRS/TRS Sensors
• SRS/TRS: Magnetic pickup sensors generate alternating current (A.C.). The frequency will change dependent on the speed of the pulse wheel (RPM of engine).
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25ST0072-2 Rev. 04/4/00 39
ElectronicControlModule(ECM)
EEPROM
+-Battery
Timing Reference
Synch Reference
Schematic Diagram DDEC III / IV
EUI
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25ST0072-2 Rev. 04/4/00 41
Series 50/60SRS/TRS Sensors
SRS/TRS
Timing WheelDDEC III/ IVBull Gear
DDEC III/ IV
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Series 60 Sensor
Locations
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25ST0072-2 Rev. 04/4/00 43
Series 2000SRS/TRS Sensors
SRS/TRS
Cam Gear/SRS
TIMING WHEEL
TIMING WHEEL
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Series 2000 Sensor
Locations
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25ST0072-2 Rev. 04/4/00 45
Series 4000SRS/TRS Sensors
SRS/TRS
Cam Gear/SRS
Timing Wheels
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Series 4000 Sensor
Locations
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25ST0072-2 Rev. 04/4/00 47
Two Cycle SRS/TRS with Timing Wheel
SRS/TRSSensor
Series 71 Series 92 / 6V, 8V, 12V-71
SRS/TRSSensor
Timing Wheel& Cam Pulley
Timing Wheel& Cam Pulley
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25ST0072-2 Rev. 04/4/00 48
Two Cycle SRS/TRS with Timing Wheel
SRS/TRSSensors
TimingWheels
TimingWheels
Series 92, 12V, 16V
SRS/TRSSensors
Series 149
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25ST0072-2 Rev. 04/4/00 49
Series 53 SRS/TRS with Timing Wheel
SRS/TRSSensors
TimingWheel
SRS PIN
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25ST0072-2 Rev. 04/4/00 50
Schematic Diagram DDEC IV
ElectronicControlModule(ECM)
EEPROM
Timing Reference
Synch Reference
Electronic FootPedal Assembly
EUI
+-Battery
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25ST0072-2 Rev. 04/4/00 51
Throttle Position SensorElectronic Foot Pedal Assembly
• 5 volt, three wire circuit
• Electronic Foot Pedal Assembly signals throttle position for the Limiting Speed Governor.
• Optional idle validation switch insures that the engine will remain at idle in the event of a TPS circuit failure
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25ST0072-2 Rev. 04/4/00 53
Schematic Diagram DDEC IV
ElectronicControlModule(ECM)
EEPROM
Turbo Boost Pressure
Timing Reference
Synch Reference
Electronic FootPedal Assembly
EUI
+-Battery
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25ST0072-2 Rev. 04/4/00 54
Turbo Boost Sensor
DDEC III Series 50/60/2-Cycle
Series 2000 / 4000 Series 50/60 DDEC IV
Series 53
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25ST0072-2 Rev. 04/4/00 55
Schematic Diagram DDEC III / IV
ElectronicControlModule(ECM)
EEPROM
+-Battery
Fuel / Oil / Coolant/ AirTemperature
Turbo Boost Pressure
Timing Reference
Synch Reference
Electronic FootPedal Assembly
EUI
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25ST0072-2 Rev. 04/4/00 56
Temperature Sensors
Coolant Temperature SensorSeries 50/60
Air Temperature SensorSeries 50/60
Fuel/Oil/Coolant Temperature SensorSeries 50/60/2-Cycle - Air Temp 53
Fuel/Oil/Coolant Temperature SensorSeries 2000/4000
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25ST0072-2 Rev. 04/4/00 58
Schematic Diagram DDEC III / IV
ElectronicControlModule(ECM)
EEPROM
+-Battery
Fuel / Oil / CoolantTemperature
Turbo Boost Pressure
Timing Reference
Synch Reference
Electronic FootPedal Assembly
Oil / Fuel Pressure
EUI
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25ST0072-2 Rev. 04/4/00 59
Pressure Sensors
Series 50/60/2-Cycle
Series 2000/4000
Series 2000/4000Different Harness Connectors
CoolantPressure Oil / Fuel
Pressure
Series 4000 High Pressure Fuel
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25ST0072-2 Rev. 04/4/00 60
Schematic Diagram DDEC III / IV
ElectronicControlModule(ECM)
EEPROM
+-Battery
Oil / Fuel Pressure
Fuel / Oil / CoolantTemperature
Turbo Boost Pressure
Timing Reference
Synch Reference
Electronic FootPedal Assembly
Oil level/Fuel Restriction
EUI
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25ST0072-2 Rev. 04/4/00 61
On Engine Components
• Oil Level Sensor– Mounts in Front Sump Non-
metal Oil Pan– Utilizes Optical Technology to
"See" Oil Level– Engine Must Be Off (Zero
RPM ) for "X" Minutes (Based on Oil Temp.) to Drain Oil Back to the Pan
– Switches at Four Quart Low Level
– OEM Impact» Order Maintenance Alert
System on the Engine
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25ST0072-2 Rev. 04/4/00 62
On Engine Components
• Fuel Restriction Sensor– Measures Fuel System
Restriction at Fuel Pump Inlet– Sensor Measures Actual Inlet
Restriction – OEM Impact
» Order Maintenance Alert System on the Engine
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25ST0072-2 Rev. 04/4/00 63
Schematic Diagram DDEC III / IV
ElectronicControlModule(ECM)
EEPROM
+-Battery
Oil / Fuel Pressure
Fuel / Oil / CoolantTemperature
Turbo Boost Pressure
Coolant Level
Timing Reference
Synch Reference
Electronic FootPedal Assembly
Oil level/Fuel Restriction
EUI
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25ST0072-2 Rev. 04/4/00 64
Coolant Level Sensor
DDEC III or IVCoolant Level Sensor
DDEC II/ III Coolant Level Sensor
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25ST0072-2 Rev. 04/4/00 65
Schematic Diagram DDEC III / IV
ElectronicControlModule(ECM)
EEPROM
+-Battery
Oil / Fuel Pressure
Fuel / Oil / CoolantTemperature
Turbo Boost Pressure
Coolant Level
Timing Reference
Synch Reference
VSG Control
Electronic FootPedal Assembly
Oil level/Fuel Restriction
EUI
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25ST0072-2 Rev. 04/4/00 66
VSG Control
• Variable Speed Governor– Throttle Position Controls RPM
• Droop– Difference in RPM Between Full Load
(Rated Speed) and Maximum Engine RPM (No Load)
– Allows the engine to overrun the rated or governed engine speed.
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25ST0072-2 Rev. 04/4/00 67
Schematic Diagram DDEC III / IV
ElectronicControlModule(ECM)
EEPROM
+-Battery
Oil / Fuel Pressure
Fuel / Oil / CoolantTemperature
Turbo Boost Pressure
Coolant Level
Timing Reference
Synch Reference
VSG Control
Electronic FootPedal Assembly
Progressive Shift
Oil level/Fuel Restriction
EUI
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25ST0072-2 Rev. 04/4/00 68
Progressive Shift
• Use Spec Manager to determine values to program for Progressive Shift
• Example
Low Gear #1 off 12 Max MPH LimitLow Gear #1 limit 1400Low Gear #1 max 1800Low Gear #2 off 27 Max MPH LimitLow Gear #2 limit 1600Low Gear #2 max 1800High Gear on 50 Max MPH LimitHigh Gear max 1700
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25ST0072-2 Rev. 04/4/00 69
Progressive Shift
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25ST0072-2 Rev. 04/4/00 70
Schematic Diagram DDEC III / IV
ElectronicControlModule(ECM)
EEPROM
+-Battery
Oil / Fuel Pressure
Fuel / Oil / CoolantTemperature
Turbo Boost Pressure
Coolant Level
Timing Reference
Synch Reference
VSG Control
Electronic FootPedal Assembly
Progressive ShiftPressure Governor
Oil level/Fuel Restriction
EUI
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25ST0072-2 Rev. 04/4/00 71
Pressure Governor
Mastermind
Fire Commander
High PressureSensor
•Fire Commander and Mastermind use the same digital inputs and outputs as cruise control
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25ST0072-2 Rev. 04/4/00 74
Electronic Fire Commander
Engine Data
System Status
Message Window
Control Buttons
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25ST0072-2 Rev. 04/4/00 75
Schematic Diagram DDEC III / IV
ElectronicControlModule(ECM)
EEPROM
+-Battery
Oil / Fuel Pressure
Fuel / Oil / CoolantTemperature
Turbo Boost Pressure
Coolant Level
Timing Reference
Synch Reference
VSG Control
Electronic FootPedal Assembly
Progressive ShiftPressure Governor
DiagnosticRequest
Stop EngineOverride
Oil level/Fuel Restriction
EUI
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25ST0072-2 Rev. 04/4/00 76
Diagnostic Requestor Stop Engine Override
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25ST0072-2 Rev. 04/4/00 78
Engine Protection
• Warning- Illumination of CEL,SEL only
• Rampdown- Immediate reduction to 70% power, ramping down to 40% over 30 seconds and maintains 40% power.
• Shutdown- Same as rampdown except engine is shutdown at the end of 30 seconds.
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25ST0072-2 Rev. 04/4/00 79
Schematic Diagram DDEC III / IV
ElectronicControlModule(ECM)
EEPROM
+-Battery
Oil / Fuel Pressure
Fuel / Oil / CoolantTemperature
Turbo Boost Pressure
Pressure Governor
Coolant Level
Timing Reference
Synch Reference
VSG Control
Electronic FootPedal Assembly
Progressive Shift
DiagnosticRequest
Stop EngineOverride
Engine Rating / Cruise Power / Switch Power
Oil level/Fuel Restriction
EUI
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25ST0072-2 Rev. 04/4/00 80
Multiple Horsepower Ratings
• Three Independent Ratings• One Dependent Cruise Power Rating
• Switch Power Options (C&I)– Max. Power for Fully Loaded Engine– Min. Power for a Lightly Loaded Engine
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25ST0072-2 Rev. 04/4/00 81
Schematic Diagram DDEC III / IV
ElectronicControlModule(ECM)
EEPROM
+-Battery
Cruise Control Vehicle Speed LimitingVehicle Speed Sensor
Oil / Fuel Pressure
Fuel / Oil / CoolantTemperature
Turbo Boost Pressure
Pressure Governor
Coolant Level
Timing Reference
Synch Reference
VSG Control
Electronic FootPedal Assembly
Progressive Shift
DiagnosticRequest
Stop EngineOverride
Engine Rating / Cruise Power / Switch Power
Oil level/Fuel Restriction
EUI
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25ST0072-2 Rev. 04/4/00 82
Cruise Control
• Determined by vehicle speed (VSS) or engine speed (RPM) DDEC IV changed
• Must be above 20 MPH or 1100 RPM to set• Cruise Power can provide higher HP while in cruise
control by using the C. P. rating.• Uses up to 5 digital inputs and one digital output • VSG can be controlled by the cruise switch• Use cruise switches to set PTO high idle and lower
high idle. You use a step up or step down & step up by pressing or toggling the resume switch.
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25ST0072-2 Rev. 04/4/00 83
Vehicle Speed Sensor• Revs per Mile
High Gear RatioRear End RatioSensor Type (Magnetic)# of teeth on Pulse Wheel
• Vehicle Speed Limit• Vehicle Overspeed with Fuel (typically set 3-4 mph above
road speed limit)• Vehicle Overspeed without Fuel (typically set 5-6 mph above
road speed limit)• VSS Antitamper
– Will not go above Idle– Code will be logged
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25ST0072-2 Rev. 04/4/00 84
Cruise Control
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25ST0072-2 Rev. 04/4/00 85
Schematic Diagram DDEC III / IV
ElectronicControlModule(ECM)
EEPROM
+-Battery
Cruise Control Vehicle Speed LimitingVehicle Speed Sensor
Oil / Fuel Pressure
Fuel / Oil / CoolantTemperature
Turbo Boost Pressure
Pressure Governor
Coolant Level
Timing Reference
Synch Reference
VSG Control
Electronic FootPedal Assembly
Progressive Shift
DiagnosticRequest
Stop EngineOverride
Engine Rating / Cruise Power / Switch Power
Oil level/Fuel Restriction
EUI
Crankcase Pressure
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25ST0072-2 Rev. 04/4/00 86
Crankcase Pressure
Series 149 CCM Series 4000 CCPS Series 60 CCM
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25ST0072-2 Rev. 04/4/00 87
Schematic Diagram DDEC III / IV
ElectronicControlModule(ECM)
EEPROM
+-Battery
Cruise Control Vehicle Speed LimitingVehicle Speed Sensor
Oil / Fuel Pressure
Fuel / Oil / CoolantTemperature
Turbo Boost Pressure
Pressure Governor
Coolant Level
Timing Reference
Synch Reference
VSG Control
Electronic FootPedal Assembly
Progressive Shift
DiagnosticRequest
Stop EngineOverride
Engine Rating / Cruise Power / Switch Power
Oil level/Fuel RestrictionCrankcase Pressure
EUI
CheckEngine
StopEngine
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25ST0072-2 Rev. 04/4/00 88
Stop Engine / Check Engine Lights
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25ST0072-2 Rev. 04/4/00 89
Schematic Diagram DDEC III / IV
ElectronicControlModule(ECM)
EEPROM
+-Battery
StopEngine
CheckEngine
Cruise Control Vehicle Speed LimitingVehicle Speed Sensor
Oil / Fuel Pressure
Fuel / Oil / CoolantTemperature
Turbo Boost Pressure
Pressure Governor
Coolant Level
Timing Reference
Synch Reference
VSG Control
Electronic FootPedal Assembly
Progressive Shift
DiagnosticRequest
Stop EngineOverride
Engine Rating / Cruise Power / Switch Power
Oil level/Fuel RestrictionCrankcase Pressure
EUI
PWM Ports
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25ST0072-2 Rev. 04/4/00 90
Pulse Width Modulated Outputs
• 50 Hz duty cycle modulated• Four ports available-- circuits 908, 909, 910, 911• Factory programmed only
1 Hz
50%20%
1 Hz
80%
1 HzSignal LowSignal High
• Signals sent by the ECM to other microprocessor controlled systems
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25ST0072-2 Rev. 04/4/00 91
PWM
Circuit Wire No. Color• PWM #1 Output - VIH (Transmission) 908 White• PWM #2 Output - ESH (Throttle/GAS) 909 Lt. Green• PWM #3 Output - ESH (Gas Valve/GAS) 910 Orange• PWM #4 Output - ESH (Fan Control) 911 Pink
• ESH = Engine Sensor Harness• VIH = Vehicle Sensor Harness
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25ST0072-2 Rev. 04/4/00 92
Schematic Diagram DDEC III / IV
ElectronicControlModule(ECM)
EEPROM
+-Battery
StopEngine
CheckEngine
Cruise Control Vehicle Speed LimitingVehicle Speed Sensor
Oil / Fuel Pressure
Fuel / Oil / CoolantTemperature
Turbo Boost Pressure
Pressure Governor
Coolant Level
Timing Reference
Synch Reference
VSG Control
PWM Ports
Electronic FootPedal Assembly
Progressive Shift
DiagnosticRequest
Stop EngineOverride
Engine Rating / Cruise Power / Switch Power
Oil level/Fuel RestrictionCrankcase Pressure
EUI
DDR Interface/ DDDL/ Reprogramming
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25ST0072-2 Rev. 04/4/00 93
DDR Interface with MPSI Printer
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SAE Standards
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25ST0072-2 Rev. 04/4/00 95
SAE Standards
•MIDs
•PIDs
•FMIs
•SIDs
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25ST0072-2 Rev. 04/4/00 96
SAE Code Format
• PID - Parameter Identifier (can be measured)• SID - System Identifier (cannot be measured)• FMI - Failure Mode Identifier
Example
PID 100 FMI 0 - Parameter High 1 - Parameter Low3 - Circuit High (HI VOLT)4 - Circuit Low (LO VOLT)Oil Pressure
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25ST0072-2 Rev. 04/4/00 97
Detroit Diesel Diagnostic Link
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25ST0072-2 Rev. 04/4/00 98
DDDL Information
• New PC based DDEC service tool– Release 1.X
» Windows 3.1» PC-486, 33 MHz, 8MB RAM» Support Features up to DDEC III, R5.0
– Release 2.X» Windows 95 (98 2.11)» PC-486, 66MHz, 16MB RAM» Supports all DDEC Systems» Support Data Extractions & Trip Reporting Features
– Release 3.X» Windows 95/98» VGA color monitor» PC-486, 66MHz, 16MB RAM» Supports all DDEC Systems» Support Data Extractions & Trip Reporting Features
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25ST0072-2 Rev. 04/4/00 99
Detroit Diesel Diagnostic Link
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25ST0072-2 Rev. 04/4/00 100
Detroit Diesel Diagnostic Link
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25ST0072-2 Rev. 04/4/00 101
Detroit Diesel Diagnostic Link
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25ST0072-2 Rev. 04/4/00 102
DDR Communication- On Highway
DDEC III/ IV6-Pin
DDEC II or III12-Pin
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25ST0072-2 Rev. 04/4/00 103
DDR Communication- On Highway
DDEC IV
9 Pin
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DDEC II / III / IV Reprogramming
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25ST0072-2 Rev. 04/4/00 105
Reprogramming Station
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25ST0072-2 Rev. 04/4/00 106
Software
• Software is programmable• Numbered like computer software
– Major version changes number before dot ( X.00 )– Minor version changes number after dot ( 9.XX )
• DDEC III software will be 19.XX or lower– Current DDEC III software is 9.00
• DDEC IV software will be 20.00 or higher– Current DDEC IV software is 28.00
• Software level can ONLY go UP, it can NEVER go back down
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25ST0072-2 Rev. 04/4/00 107
Reprogramming StationWindows Based for Download
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25ST0072-2 Rev. 04/4/00 108
Reprogramming StationWindows Based for Download
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25ST0072-2 Rev. 04/4/00 109
Reprogramming StationWindows Based for Download
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25ST0072-2 Rev. 04/4/00 112
Schematic Diagram DDEC III / IV
ElectronicControlModule(ECM)
EEPROM
+-Battery
StopEngineCheck
Engine
Cruise Control Vehicle Speed LimitingVehicle Speed Sensor
Oil / Fuel Pressure
Fuel / Oil / CoolantTemperature
Turbo Boost Pressure
Pressure Governor
Coolant Level
Timing Reference
Synch Reference
VSG Control
PWM Ports
Electronic FootPedal Assembly
Progressive Shift
DiagnosticRequest
Stop EngineOverride
Engine Rating / Cruise Power / Switch Power
Oil level/Fuel RestrictionCrankcase Pressure
EUI
DDR Interface/ DDDL/ ReprogrammingCommunication
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25ST0072-2 Rev. 04/4/00 113
Communication
• J1587– 9600 Baud Rate, used to transmit sensor and engine data
(electronic dash display, vehicle management systems and electronic transmissions). MPSI readers, DDDL
• J1922– 9600 Baud Rate, controls Transmissions, braking
systems and retarders • J1939
– 250k Baud Rate, controls Transmissions, braking systems and retarders also used as the property data link in multi ECM engines
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25ST0072-2 Rev. 04/4/00 114
Schematic Diagram DDEC III / IV
ElectronicControlModule(ECM)
EEPROM
+-Battery
StopEngineCheck
Engine
Cruise Control Vehicle Speed LimitingVehicle Speed Sensor
Oil / Fuel Pressure
Fuel / Oil / CoolantTemperature
Turbo Boost Pressure
Pressure Governor
Coolant Level
Timing Reference
Synch Reference
VSG Control
PWM Ports
Electronic FootPedal Assembly
Progressive Shift
DiagnosticRequest
Stop EngineOverride
Engine Rating / Cruise Power / Switch Power
Idle Shut Down/Vehicle Power Down
Oil level/Fuel RestrictionCrankcase Pressure
EUI
DDR Interface/ DDDL/ ReprogrammingCommunication
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25ST0072-2 Rev. 04/4/00 115
Idle Shut Down (ISD)/ Vehicle Power Shutdown
• Idle Shut Down (ISD): Turns engine off after programmed idle time has elapsed (optional “override” disables idle timer if the engine speed is increased by 100 during last 90 seconds of ISD sequence. The check engine light (CEL) will flash during this 90 seconds.
• Vehicle Power Shutdown relay (optional/OEM) turns off electrical power to the vehicle as well as stopping the engine
2 - 100 Minutes
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25ST0072-2 Rev. 04/4/00 116
Vehicle Power Shutdown
To Vehicle
Ignition OnIdle ShutdownIgnition switch
ECM
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25ST0072-2 Rev. 04/4/00 117
Schematic Diagram DDEC III / IV
ElectronicControlModule(ECM)
EEPROM
+-Battery
StopEngineCheck
Engine
Cruise Control Vehicle Speed LimitingVehicle Speed Sensor
Oil / Fuel Pressure
Fuel / Oil / CoolantTemperature
Turbo Boost Pressure
Pressure Governor
Coolant Level
Timing Reference
Synch Reference
VSG Control
PWM Ports
Electronic FootPedal Assembly
Progressive Shift
DiagnosticRequest
Stop EngineOverride
Engine Rating / Cruise Power / Switch Power
Idle Shut Down/Vehicle Power Down
Oil level/Fuel RestrictionCrankcase Pressure
EUI
DDR Interface/ DDDL/ ReprogrammingCommunication
Engine Brake
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25ST0072-2 Rev. 04/4/00 118
DDEC III/IVEngine Brakes
• DDEC III/IV controls engine brake operation• If configured for “cruise control engine brake”
the ECM will automatically turn on the brake if the set speed is exceeded.
• Two digital inputs and two ‘positive’ outputs are used to control the brake.
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25ST0072-2 Rev. 04/4/00 120
Engine Brakes• Must be at least 150 rpm above idle speed
Clutch Released input must be ON/GNDECM must see 0% throttle
Range Example• Cruise Engine Brake Yes/No Yes
Engine Brake MPH 1-10 3 Engine Brake Increment 0-4 2
• Engine Brake/Service Brake Yes/No Yes• Engine Brake Min MPH 0-VSL 35
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DDEC Engine Brakes
ECM
S3
T3
#953 (Battery Negative)
Brake Off LO On
Low
Med.
Low
Med.
MEDHIGH
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25ST0072-2 Rev. 04/4/00 122
Schematic Diagram DDEC III / IV
ElectronicControlModule(ECM)
EEPROM
+-Battery
StopEngineCheck
Engine
Cruise Control Vehicle Speed LimitingVehicle Speed Sensor
Oil / Fuel Pressure
Fuel / Oil / CoolantTemperature
Turbo Boost Pressure
Pressure Governor
Coolant Level
Timing Reference
Synch Reference
VSG Control
PWM Ports
Electronic FootPedal Assembly
Progressive Shift
DiagnosticRequest
Stop EngineOverride
Engine Rating / Cruise Power / Switch Power
Idle Shut Down/Vehicle Power Down
Oil level/Fuel RestrictionCrankcase Pressure
EUI
DDR Interface/ DDDL/ ReprogrammingCommunication
Engine BrakeFan Controls
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25ST0072-2 Rev. 04/4/00 123
Fan Control
• Four fan configurations can be used– Single fan– Dual fans– Two speed fan– Variable speed fan (PWM) # 4 Hydraulically
Operated (Bus)• Fan controlled by digital output(s)• “Fan override” & “air conditioning active” digital
inputs can force the fan on • Series 4000 uses (PWM) #2 To Operate a Rockford Fan
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25ST0072-2 Rev. 04/4/00 124
Fan Control
• Conditions which activate the fan;– High Oil, Coolant, or Air Temp– Circuit fault codes (HI VOLT, LO VOLT) on any of
these three sensors– AC input– Fan Override input– Dynamic Braking (Fan is Activated During Engine
Overspeed to Help Slow The Vehicle)
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DDEC Fan Controls
ECM
Temp sensorInputs
Air Supply
Ign. +
Output“off”
Fan “on”
Optional Fan # 2
#953 (-)
Fan Override (Input Off)
Aux. Fan Control (Input On) Air Conditioning - off
Temp sensorInputs
High Temperatures Turn Fan OnNormal Temperatures Allow Fan Off
Output“on”
Fan “off”
Aux. Fan Control (Input Off)Air Conditioning - On(Fan on for at least 3 minutes)
Output“off”
“on”
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25ST0072-2 Rev. 04/4/00 129
Schematic Diagram DDEC III / IV
ElectronicControlModule(ECM)
EEPROM
+-Battery
StopEngine
CheckEngine
Cruise Control Vehicle Speed LimitingVehicle Speed Sensor
Oil / Fuel Pressure
Fuel / Oil / CoolantTemperature
Turbo Boost Pressure
Pressure Governor
Coolant Level
Timing Reference
Synch Reference
VSG Control
PWM Ports
Electronic FootPedal Assembly
Progressive Shift
DiagnosticRequest
Stop EngineOverride
Engine Rating / Cruise Power / Switch Power
Oil level/Fuel RestrictionCrankcase Pressure
EUI
DDR Interface/ DDDL/ ReprogrammingCommunication
ISD / VehiclePower Down
Engine Brake
Fan ControlsOptimized Idle
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25ST0072-2 Rev. 04/4/00 130
Optimized Idle
• Automatic Starting and Stopping of the Engine• Maintains Engine Temperature and / or Battery
Voltage• Optional Sleeper Thermostat• Truck Skin Temperature Sensor is used for
continuous run• Saves Fuel by Running the Engine Only When
Needed• Warm Engines Start Much Easier With Less Exhaust
Emissions
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25ST0072-2 Rev. 04/4/00 131
Requirements for Optimized Idle Cruise Enable Switch Idle Shutdown Enabled Vehicle Power Down
Relay Op Idle light on dash Park Brake Switch Transmission Neutral
Switch (Some transmissions require high range in Neutral)
Hood SwitchUnder-hood AlarmStart RelayOverlay RelayVSS EnabledOptional Sleeper Thermostat
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25ST0072-2 Rev. 04/4/00 132
Optimized Idle Shutdown Sequence Park Brake set with hood closed and transmission in Neutral
supplies ground to the Park Brake input and the Overlay Relay. Idle Timer starts and the Overlay Relay closes supplying power to the Start Relay.
Optimized Idle is activated by turning on the Cruise Enable Switch which supplies ground on the Cruise Enable input.
Optimized Idle Light flashes until the engine shuts down then remains on.
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25ST0072-2 Rev. 04/4/00 133
Optimized Idle Shutdown Sequence With Battery Voltage above 12.2V, Oil Temp between
15ºC/60ºF and 40ºC/104F, and Sleeper Temp within limits, the Idle Timer shuts the engine down.
Vehicle Power Down Relay opens powering down the vehicle Ignition Circuit.
With Ignition key on, the ECM is still awake and it continuously monitors Battery Voltage, Oil Temperature and Sleeper Temperature.
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25ST0072-2 Rev. 04/4/00 134
Optimized Idle Start Sequence • With the hood closed, Transmission in Neutral, Park Brake set, and the Optimized Idle dash light ON,the ECM supplies ground on PWM #2, wire 909 which activates the under-hood alarm. • ECM then supplies ground on PWM #3, wire 910
which closes the Start Relay. • After the engine starts, the ECM supplies ground to the Vehicle Power Down relay which closes to
supply Ignition power to the vehicle
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25ST0072-2 Rev. 04/4/00 137
Schematic Diagram DDEC III / IV
ElectronicControlModule(ECM)
EEPROM
+-Battery
Engine Brake
StopEngineCheck
Engine
Cruise ControlVehicle Speed LimitingVehicle Speed Sensor
Oil / Fuel Pressure
Fuel / Oil / CoolantTemperature
Turbo Boost Pressure
Pressure Governor
Coolant Level
Timing Reference
Synch Reference
Fan Controls
VSG Control
PWM Ports
Electronic FootPedal Assembly
Progressive Shift
DiagnosticRequest
Stop EngineOverride
ISD / VehiclePower Down
Engine Rating / Cruise Power / Switch Power
CommunicationDDR Interface/ DDDL/ Reprogramming
Optimized IdleEUI
Oil level/Fuel RestrictionCrankcase Pressure
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Digital Inputs
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25ST0072-2 Rev. 04/4/00 140
Digital Input Functions
• External switch requests function from the ECM• 31 options to choose from• 12 pins available on the 30 pin vehicle harness
connector for input functions • Functions are assignable to any of these pins
through the use of a “Reprogramming Station”
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25ST0072-2 Rev. 04/4/00 141
DIGITAL INPUTS
Battery
_+
#953
Cruise EnableFan Override
#150
No FunctionNo FunctionNo Function
ECM
EEPROM
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25ST0072-2 Rev. 04/4/00 142
Digital Inputs
• Air Compressor Controls– Air Compressor Load Switch
• Cruise Control (Uses Up to Five Inputs)– Cruise Enable– Clutch Released– Service Brake Released– Set/Coast On (Decrease)– Resume/Acceleration On
(Increase)• Engine Brake
– Engine Brake Disable– Engine Brake Low– Engine Brake Medium
• Engine Protection– Auxiliary Input Protection #1– Auxiliary Input Protection #2– Diagnostic Request Switch– SEO/Diagnostic Request Switch
• Engine Ratings– Limiting Torque Curve– Rating Switch #1– Rating Switch #2
• Fan Control– Transmission Retarder Status
(Release 2.00 or Later only)– Air Conditioner Status– Fan Control Override
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25ST0072-2 Rev. 04/4/00 143
Digital Inputs (Cont’d)
• Throttle Control– Alternate Minimum VSG/Fast
Idle (Release 2.00 or Later Only)
– Dual Throttle (LSG)– Idle Validation Switch– Throttle Inhibit– VSG Station Change– VSG Station Complement
• Pressure Governor System (PGS) (Uses Five Inputs)– Pressure Governor System
Enable– Pressure/RPM Mode Switch– Set/Coast On (Decrease)– Resume/Acceleration On
(Increase)
• Additional Functions– Auxiliary Coolant Level
Sensor– Parking Brake Interlock
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Digital Outputs
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25ST0072-2 Rev. 04/4/00 145
Digital Output Functions
• ECM commands (internal switches/grounds) action of some external device- fan control
• 22 output options• 6 pins available, 3 on the 30 pin vehicle connector, 3
on the 30 pin engine harness connector (auxiliary outputs)
• Configurable with the distributor or dealer reprogramming station
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25ST0072-2 Rev. 04/4/00 146
OUTPUTS
ECM
SEL
To Jake brake
Ignition#439
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25ST0072-2 Rev. 04/4/00 147
Digital Outputs
• Coolant Level Low Light• Cruise Control Active Light (PGS
Active Light)• Deceleration Light• Engine Brake Active• Fan Control #1• Fan Control #2• Low DDEC Voltage• Pressure Governor System
Pressure Mode Light• Starter Lockout• Transmission Retarder• Vehicle Power Shutdown
• VSG Active Indication• (Release 2.00 or Later only)
– Low Oil Pressure Light– High Oil Temperature Light– High Coolant Temp. Light
• (Release 3.00 or Later Only)– Ether Injection– Low Coolant Pressure Light– High Crankcase Pressure Light
• (Release 4.00 or Later Only)– Optimized Idle Active light
• Gas Solenoid Shutdown• Air Compressor Load Switch
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25ST0072-2 Rev. 04/4/00 148
• Encourages better driving habits by rewarding good fuel economy with extra road speed
• If driver exceeds the target fuel economy extra road speed will automatically be added to his maximum vehicle speed
Fuel Economy Incentive
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25ST0072-2 Rev. 04/4/00 149
Fuel Economy Incentive
Parameter Range ExampleMin MPG 5-10 mpg 7.0Max MPH 0-10 mph 4Scaler MPH/MPG 0.1-20 mph/mpg 10.0Calc Type Filtered/Trip Trip
If Scaler is set at:20.0 = 1 extra mph for every .05 mpg above target mpg 10.0 = 1 extra mph for every .1 mpg above target mpg 5.0 = 1 extra mph for every .2 mpg above target mpg 2.0 = 1 extra mph for every .5 mpg above target mpg 1.0 = 1 extra mph for every 1.0 mpg above target mpg
If Calc Type is set at:Filtered - Calculates using Total Engine DataTrip - Calculates using Trip Data
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25ST0072-2 Rev. 04/4/00 150
PasSmart• Electronically Controlled Increased Passing Speed
– PasSmart is an electronic feature that enables a fleet manager to enable a second Vehicle Speed Limit (VSL) to assist drivers during passing.
– This second Vehicle Speed Limit (VSL) is programmed for a limited duration during a given period This feature is available with DDEC IV Software version R28.00.
– As and example: If the fleet policy is 65 Miles Per Hour (MPH) the fleet manager can increase the Vehicle Speed Limit (VSL) an additional 5-20 MPH for 1- 255 minutes per day.
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Maintenance Alert System
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25ST0072-2 Rev. 04/4/00 152
Maintenance Alert Sensors System
• Designed to Provide Preventative Maintenance Information to Mechanics and Operators
• Reduces Unexpected Downtime
• Optimizes Normal Routine Service
• Used on Highway Trucks only at this time
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25ST0072-2 Rev. 04/4/00 153
Maintenance Alert System
• Overview– Based on Inputs from Customers, the Maintenance Alert
System Provides Preventative Maintenance Information to Mechanics and Drivers to Reduce Unexpected Downtime and to Assist Normal Routine Service Scheduling
• Features– Uses DDEC IV ECM– New DDEC Software Processes Information– Incorporates Four New Sensors (Both On and Off Engine)– Optional Remote Mounted Monitor Display Unit Available
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25ST0072-2 Rev. 04/4/00 154
Maintenance Alert System
Oil Level Sensor Air Filter Restriction Sensor 2nd Coolant Level Sensor
Fuel Restriction Sensor Monitor Display Unit
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25ST0072-2 Rev. 04/4/00 155
DDC Installed Components
• Includes Two Maintenance Alert System Sensors– Oil Level Sensor (Requires Front Sump Non-metal Oil
Pan) Will not work on Rear Sump Applications
– Fuel Restriction Sensor
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25ST0072-2 Rev. 04/4/00 156
On Engine Components
• Oil Level Sensor– Mounts in Front Sump Non-
metal Oil Pan– Utilizes Optical Technology to
"See" Oil Level– Engine Must Be Off (Zero
RPM ) for "X" Minutes (Based on Oil Temp.) to Drain Oil Back to the Pan
– Switches at Four Quart Low Level
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25ST0072-2 Rev. 04/4/00 157
On Engine Components
• Fuel Restriction Sensor– Measures Fuel System
Restriction at Fuel Pump Inlet– Sensor Measures Actual Inlet
Restriction
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25ST0072-2 Rev. 04/4/00 158
Optional OEM Installed Components
• OEMs Install These Components if Ordered by Customer (Any Combination but Must Include On Engine Components)– 2nd Coolant Level Sensor – Air Filter Restriction Sensor – Monitor Display Unit
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25ST0072-2 Rev. 04/4/00 159
OEM Installed Components• 2nd Coolant Level Sensor (CLS)
– Separate Sensor from Current Primary CLS
– Mounted in Coolant Surge Tank Above Primary CLS
– Requires Interface Module– OEM Impact
» Order Engine Mounted Sensors» Purchase CLS Sensor and Module
from PDC» Mount Sensor in Surge Tank» Mount Interface Module» Provide Wiring Between the
Sensor/Module/Engine Harness» Use VEPS( Vehicle Engine Program
Station) to "Turn On” OEM Only
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25ST0072-2 Rev. 04/4/00 160
OEM Installed Components
• Air Filter Restriction Sensor– Electronic Version of the
Mechanical Filter Minder®– Switch Points at 15 and 20
Inches of Water– OEM Impact
» Order Engine Mounted Sensors» Purchase Sensor from
Engineered Products or PDC» Install into Turbo Inlet Tube» Provide Wiring from Sensor to
Engine Harness Pigtail» Use VEPS to "Turn On"
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25ST0072-2 Rev. 04/4/00 161
OEM Installed Components
• Monitor Display Unit– 2 Buttons and 8 LEDs (Green, Red, &
Yellow)– Mounted in Cab– Reads Engine J1587 Data Link for
Information– Can Access Maintenance Information
with Ignition On or Up to 2 Hours After Ignition Off
– Stores Status after 2 Hours for Later Display
– OEM Impact» Order Engine Mounted Sensors» Purchase Display from PDC» Design and Install Display Bracket» Provide Wiring to Display
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25ST0072-2 Rev. 04/4/00 162
Service Tools
• Diagnostic Data Reader-(DDR) (Version 24.0 and higher• Detroit Diesel Diagnostic Link (DDDL) - Version 3.0
and higher
– Sensor Alerts Due to Failed Sensors– Quick Access Screen to Show Maintenance Alert System
Alerts» Clear Maintenance Alert System (MAS) Filter Alerts
– Maintenance Alert System sensors added to Data List– Warning Light Option Programming
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25ST0072-2 Rev. 04/4/00 163
Summary
Engine
Vehicle
• Monitors and Displays Service Requirements– Oil Level– Fuel System Restriction – Air Filter Restriction– 2nd Coolant Level– Monitor Display Unit - in Cab– DDR and DDDL
• Engine Only or Engine and Any Vehicle Sensors• Oil Level Requires Front Sump Plastic Plan• Display is Optional
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Construction & Industrial
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25ST0072-2 Rev. 04/4/00 165
Construction & Industrial
• Electronic Display Module (EDM) • Auxiliary Interface Module (AIM)• Air Comp Controls• Fuel Pressure Sensor (Low HP)• Nylon Vs. Plastic Harness• Multiple ECM• Optimized Idle• Switch Power• J1939
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Wire Crimping Exercise
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25ST0072-2 Rev. 04/4/00 167
Wire Crimping Tools
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25ST0072-2 Rev. 04/4/00 168
Wire Crimping Tools
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25ST0072-2 Rev. 04/4/00 169
Wire Crimping Tools
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25ST0072-2 Rev. 04/4/00 170
Wire Crimping Tools
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25ST0072-2 Rev. 04/4/00 171
Wire Crimping
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Wire Splicing
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25ST0072-2 Rev. 04/4/00 173
Wire Splicing Tools
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Series 71 & 92 SRS / TRS Adjustment
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25ST0072-2 Rev. 04/4/00 175
Series 71/92 SRS/TRS Adjustment
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Basic Electricity -Wire Harness Exercise
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25ST0072-2 Rev. 04/4/00 200
Sensor Operations
Operates on 5 Volts for All D.C. Sensors
.25 4.75
NormalOperating
Range
Low Voltage
0 5
High Voltage
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25ST0072-2 Rev. 04/4/00 201
Sensor Wiring
• Common Return Circuit. #452
• Thermistor
• Piezoresistive Pressure sensor
• Voltage is Proportional to Pressure
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25ST0072-2 Rev. 04/4/00 202
2-wire Sensors
5V Supply
Signal
Return
ECM SensorOpen = HI VOLTAGEShort = LO VOLTAGE
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25ST0072-2 Rev. 04/4/00 203
3-wire Sensors
ECM Sensor5V Supply
Signal
Return
Open Supply = LOW VOLTAGEOpen Signal = LOW VOLTAGEOpen Return = HI VOLTAGESupply short to Signal = HI VOLTAGESupply short to Return = LOW VOLTAGESignal short to Return = LOW VOLTAGE
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25ST0072-2 Rev. 04/4/00 204
Electrical System
452
Definitions• Open Circuit
– An “open” describes a complete break in the path of current at some point in the circuit. The result of an “open” is that one or more loads in the circuit do not work.
OpenHigh voltage
code
120
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25ST0072-2 Rev. 04/4/00 205
Electrical System452432416
Cavity ACavity BCavity C
Definitions• Open Circuit
– An “open” describes a complete break in the path of current at some point in the circuit. The result of an “open” is that one or more loads in the circuit do not work.
OpenLow voltage code
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25ST0072-2 Rev. 04/4/00 206
Electrical System
432416
Cavity ACavity BCavity C
Definitions• Short Circuit
– A “short” occurs when a load in the circuit is accidentally bypassed. Electricity will always take the path of least resistance. The result of a “short” is that higher current flows, causing excessive heat or action from a device protecting the circuit (blown fuse or activated circuit breaker).
Short High Voltage Code
452
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25ST0072-2 Rev. 04/4/00 207
Electrical System452432416
Cavity ACavity BCavity C
Definitions• Grounded Circuit
– A “ground” is similar to a “short” because current accidentally bypasses a load in the circuit. The difference is that the bypass connects directly to the negative terminal of the power source by way of the chassis ground path.
Ground Low Voltage Code
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Troubleshooting Tools
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25ST0072-2 Rev. 04/4/00 209
Troubleshooting Tools
Volt-Ohm Meter
To properly probe terminals use Kentmoore jumper wire kit number J39197. Within this kit the proper leads are provided.
The use of the lead ends of the volt ohm meter to probe the terminal ends will damage the DDEC connectors and will cause intermittent codes.
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25ST0072-2 Rev. 04/4/00 210
Troubleshooting Tools
Sensor TesterJ37164-A
Breakout Box (30 Pin)J35634
DDEC III/IV InterfaceJ41005
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25ST0072-2 Rev. 04/4/00 211
Troubleshooting Tools
• NEW DDEC Engine Protection Test Kit Number 23526923
Purpose: To Reduce Diagnostic Troubleshooting time
KIT INCLUDES
1. Coolant Level Low Simulator P/N 23524785
2. High Oil/Coolant Temperature P/N 23524787
3. Low Oil Pressure Simulator P/N 23524786
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