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DDEC

DDEC

DDEC

DDEC

III DDEC

IV

Detroit Diesel
Electronic Controls

DDEC AGENDA

25ST0072-2
Rev. 04/4/00

Pre-Test
Objectives
Review Manuals
Features & Components
System Hardware
Repair Tools
Basic Electricity
Trouble Shooting
DDEC Reprogramming
Post-Test, Evaluations
3

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

25ST0072-2
Rev. 04/4/00

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

25ST0072-2
Rev. 04/4/00

Electronic Engine Advantages


Engine Protection
Engine Diagnostics
Reduced Maintenance
Improved Engine Governing
Fuel Economy Optimization
Enhanced Cold Starting
Smoke Control
Reduced Emission Levels

25ST0072-2
Rev. 04/4/00

DDEC IV Features
Four New ECMs

25ST0072-2
Rev. 04/4/00

Standard Truck
Universal
S4000
Natural Gas

ECM Description
6 Cylinder
8 Cylinder
8 Cylinder
8 Cylinder

12
12/24
12/24
12/24

Volt
Volt
Volt
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
9

25ST0072-2
Rev. 04/4/00

DDEC Necessities
Ignition

EUI

Electronic
Control
Module
(ECM)

Synch Reference
Timing Reference

EEPROM

+
Battery

10

25ST0072-2
Rev. 04/4/00

Schematic Diagram DDEC III/ IV


Electronic
Control
Module
(ECM)

EEPROM

11

25ST0072-2
Rev. 04/4/00

Electronic Control Module

12

Electronic Control Module


OEM responsibility
Mandatory circuits Power
and Ground
J1922,J1939, Ignition
Throttle position sensor
Optional circuits Manual
fan on switch, Jake Brake,
439 Ignition wire

25ST0072-2
Rev. 04/4/00

DDC
responsibility
Engine sensors,
harness, &
connectors
Injector harness &
connectors
Injectors

13

25ST0072-2
Rev. 04/4/00

Schematic Diagram DDEC III / IV


Electronic
Control
Module
(ECM)

EEPROM

+
Battery

14

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

25ST0072-2
Rev. 04/4/00

15

25ST0072-2
Rev. 04/4/00

Power Supply DDEC III/ IV

16

25ST0072-2
Rev. 04/4/00

Power Supply DDEC III / IV

17

25ST0072-2
Rev. 04/4/00

Schematic Diagram DDEC III / IV


Electronic
Control
Module
(ECM)

EUI

EEPROM

+
Battery

18

25ST0072-2
Rev. 04/4/00

Electronic Unit Injectors

Series 71/92 EUI

Series 4000 Spray Nozzle

Series 149 EUI

Series 2000
EUP

Series 50/60 EUI

Series 53 EUI
19

Voltage in
Rocker Arm
Solenoid

Poppet
Valve

Cam

Plunger

Fuel out
Fuel in
Needle Valve

Series 50/60
Injector
Animation

Solenoid

Rocker Arm

filter

Fuel
Return

High
Pressure
Fuel

Needle
Valve

Nozzle

CAM

Series 4000
Nozzle
Animation

Rocker Arm
Solenoid

Fuel In
CAM

EUP

Cam
Spay
Nozzle

Series 2000
EUP
Animation

25ST0072-2
Rev. 04/4/00

Electronic Unit Pump

23

25ST0072-2
Rev. 04/4/00

Top Of Stroke
Fuel
In

Fuel
Out

Injector
Tip
24

25ST0072-2
Rev. 04/4/00

Start Of Injection
Fuel
In

Fuel
Out

Injector
Tip
25

25ST0072-2
Rev. 04/4/00

End Of Injection
Fuel
In

Fuel
Out

Injector
Tip
26

Injection Sequence
Fuel
In

Fuel
In
Fuel
Out

Fuel
Out

Injector
Tip

25ST0072-2
Rev. 04/4/00

Fuel
In
Fuel
Out

Injector
Tip

Injector
Tip

27

Injector Calibration Codes


DDEC II No Calibration Codes
DDEC III/ IV Calibration Codes From 00-99

25ST0072-2
Rev. 04/4/00

Part Number
Calibration Code
28

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

25ST0072-2
Rev. 04/4/00

29

25ST0072-2
Rev. 04/4/00

Injector Response Times

30

25ST0072-2
Rev. 04/4/00

Cylinder Cut-Out

31

25ST0072-2
Rev. 04/4/00

Injection Cycle
BAT
V_REG, 5V

0V

Voltage
(Inflection Point)

0A
Closed

Open

Current
Control Valve Lift

Injection Rate
IRT
BOE

PW
EOE EOI

BOI

Time
32

25ST0072-2
Rev. 04/4/00

Sensor Operations
Operates on 5 Volts for All D.C. Sensors
0 .25

Low Voltage

4.75

Normal
Operating
Range

High Voltage

34

25ST0072-2
Rev. 04/4/00

Sensor Wiring
Common Return Circuit. #452
Thermistor

Piezoresistive
Pressure sensor
Voltage is Proportional
to Pressure

35

25ST0072-2
Rev. 04/4/00

2-wire Sensors
5V Supply
Signal

Return
Sensor

ECM
Open
Short

=
=

HI VOLTAGE
LO VOLTAGE

36

25ST0072-2
Rev. 04/4/00

3-wire Sensors
ECM

Sensor
5V Supply
Signal
Return

Open Supply
Open Signal
Open Return
Supply short to Signal
Supply short to Return
Signal short to Return

=
=
=
=
=
=

LO VOLTAGE
LO VOLTAGE
HI VOLTAGE
HI VOLTAGE
LO VOLTAGE
LO VOLTAGE

37

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).

25ST0072-2
Rev. 04/4/00

38

25ST0072-2
Rev. 04/4/00

Schematic Diagram DDEC III / IV


Synch Reference
Timing Reference

Electronic
Control
Module
(ECM)

EUI

EEPROM

+
Battery

39

25ST0072-2
Rev. 04/4/00

Series 50/60
SRS/TRS Sensors

SRS/TRS
Bull Gear
DDEC III/ IV

Timing Wheel
DDEC III/ IV

41

Series 60
Sensor
Locations

Series 2000
SRS/TRS Sensors
SRS/TRS

Cam Gear/SRS

25ST0072-2
Rev. 04/4/00

TIMING
WHEEL

TIMING
WHEEL

43

Series 2000
Sensor
Locations

25ST0072-2
Rev. 04/4/00

Series 4000
SRS/TRS Sensors

SRS/TRS

Timing Wheels

Cam Gear/SRS

45

Series 4000
Sensor
Locations

Two Cycle
SRS/TRS with Timing Wheel
SRS/TRS
Sensor

SRS/TRS
Sensor

Timing Wheel
& Cam Pulley

25ST0072-2
Rev. 04/4/00

Timing Wheel
& Cam Pulley

Series 71

Series 92 / 6V, 8V, 12V-71


47

25ST0072-2
Rev. 04/4/00

Two Cycle
SRS/TRS with Timing Wheel

SRS/TRS
Sensors

SRS/TRS
Sensors

Timing
Wheels

Timing
Wheels

Series 92, 12V, 16V

Series 149
48

25ST0072-2
Rev. 04/4/00

Series 53
SRS/TRS with Timing Wheel
Timing
Wheel

SRS/TRS
Sensors

SRS PIN

49

25ST0072-2
Rev. 04/4/00

Schematic Diagram DDEC IV


Synch Reference
Timing Reference
Electronic Foot
Pedal Assembly

EUI

Electronic
Control
Module
(ECM)

EEPROM

Battery

50

25ST0072-2
Rev. 04/4/00

Throttle Position Sensor


Electronic 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
51

25ST0072-2
Rev. 04/4/00

Schematic Diagram DDEC IV


Synch Reference
Timing Reference
Electronic Foot
Pedal Assembly

Turbo Boost Pressure

EUI

Electronic
Control
Module
(ECM)

EEPROM

Battery

53

25ST0072-2
Rev. 04/4/00

Turbo Boost Sensor

Series 53
DDEC III Series 50/60/2-Cycle

Series 2000 / 4000

Series 50/60 DDEC IV


54

25ST0072-2
Rev. 04/4/00

Schematic Diagram DDEC III / IV


Synch Reference
Timing Reference
Electronic Foot
Pedal Assembly

Turbo Boost Pressure

Electronic
Control
Module
(ECM)

EUI

Fuel / Oil / Coolant/ Air


Temperature

EEPROM

+
Battery

55

25ST0072-2
Rev. 04/4/00

Temperature Sensors

Coolant Temperature Sensor


Series 50/60

Air Temperature Sensor


Series 50/60

Fuel/Oil/Coolant Temperature Sensor


Series 50/60/2-Cycle - Air Temp 53

Fuel/Oil/Coolant Temperature Sensor


Series 2000/4000

56

25ST0072-2
Rev. 04/4/00

Schematic Diagram DDEC III / IV


Synch Reference
Timing Reference
Electronic Foot
Pedal Assembly

Turbo Boost Pressure

Electronic
Control
Module
(ECM)

EUI

Fuel / Oil / Coolant


Temperature
Oil / Fuel Pressure

EEPROM

+
Battery

58

25ST0072-2
Rev. 04/4/00

Pressure Sensors
Coolant
Pressure

Oil / Fuel
Pressure

Series 50/60/2-Cycle

Series 2000/4000
Different Harness Connectors

Series 4000
High Pressure Fuel
Series 2000/4000

59

25ST0072-2
Rev. 04/4/00

Schematic Diagram DDEC III / IV


Synch Reference
Timing Reference
Electronic Foot
Pedal Assembly

Turbo Boost Pressure

Electronic
Control
Module
(ECM)

EUI

Fuel / Oil / Coolant


Temperature
Oil / Fuel Pressure

EEPROM
Oil level/Fuel Restriction

+
Battery

60

25ST0072-2
Rev. 04/4/00

On Engine Components
Oil Level Sensor
Mounts in Front Sump Nonmetal 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

61

25ST0072-2
Rev. 04/4/00

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

62

25ST0072-2
Rev. 04/4/00

Schematic Diagram DDEC III / IV


Synch Reference
Timing Reference
Electronic Foot
Pedal Assembly

Turbo Boost Pressure

Electronic
Control
Module
(ECM)

EUI

Fuel / Oil / Coolant


Temperature
Oil / Fuel Pressure

EEPROM
Oil level/Fuel Restriction

Coolant Level

+
Battery

63

25ST0072-2
Rev. 04/4/00

Coolant Level Sensor

DDEC II/ III Coolant Level Sensor


DDEC III or IV
Coolant Level Sensor

64

25ST0072-2
Rev. 04/4/00

Schematic Diagram DDEC III / IV


Synch Reference
Timing Reference
Electronic Foot
Pedal Assembly

Turbo Boost Pressure

Electronic
Control
Module
(ECM)

EUI

Fuel / Oil / Coolant


Temperature
Oil / Fuel Pressure

EEPROM
Oil level/Fuel Restriction

Coolant Level
VSG Control

+
Battery

65

VSG Control
Variable Speed Governor
Throttle Position Controls RPM

Droop

25ST0072-2
Rev. 04/4/00

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.

66

25ST0072-2
Rev. 04/4/00

Schematic Diagram DDEC III / IV


Synch Reference
Timing Reference
Electronic Foot
Pedal Assembly

Turbo Boost Pressure

Electronic
Control
Module
(ECM)

EUI

Fuel / Oil / Coolant


Temperature
Oil / Fuel Pressure

EEPROM
Oil level/Fuel Restriction

Coolant Level
VSG Control
Progressive Shift

+
Battery

67

Progressive Shift
Use Spec Manager to determine values to program for Progressive
Shift
Example

25ST0072-2
Rev. 04/4/00

Low Gear #1 off


Low Gear #1 limit
Low Gear #1 max
Low Gear #2 off
Low Gear #2 limit
Low Gear #2 max
High Gear on
High Gear max

12 Max MPH Limit


1400
1800
27 Max MPH Limit
1600
1800
50 Max MPH Limit
1700
68

25ST0072-2
Rev. 04/4/00

Progressive Shift

69

25ST0072-2
Rev. 04/4/00

Schematic Diagram DDEC III / IV


Synch Reference
Timing Reference
Electronic Foot
Pedal Assembly

Turbo Boost Pressure

Electronic
Control
Module
(ECM)

EUI

Fuel / Oil / Coolant


Temperature
Oil / Fuel Pressure

EEPROM
Oil level/Fuel Restriction

Coolant Level
VSG Control
Progressive Shift
Pressure Governor

+
Battery

70

25ST0072-2
Rev. 04/4/00

Pressure Governor
Fire Commander and Mastermind
use the same digital inputs and
outputs as cruise control

High Pressure
Sensor
Fire Commander
Mastermind
71

Electronic Fire Commander

Control Buttons
Engine Data

System Status

25ST0072-2
Rev. 04/4/00

Message Window

74

25ST0072-2
Rev. 04/4/00

Schematic Diagram DDEC III / IV


Synch Reference

Electronic
Control
Module
(ECM)

Timing Reference
Electronic Foot
Pedal Assembly

Turbo Boost Pressure

EUI

Fuel / Oil / Coolant


Temperature
Oil / Fuel Pressure

EEPROM
Oil level/Fuel Restriction

Coolant Level
VSG Control
Progressive Shift
Pressure Governor
Diagnostic
Request

+
Battery

Stop Engine
Override
75

25ST0072-2
Rev. 04/4/00

Diagnostic Request
or Stop Engine Override

76

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.

25ST0072-2
Rev. 04/4/00

78

25ST0072-2
Rev. 04/4/00

Schematic Diagram DDEC III / IV


Synch Reference

Electronic
Control
Module
(ECM)

Timing Reference
Electronic Foot
Pedal Assembly

Turbo Boost Pressure

EUI

Fuel / Oil / Coolant


Temperature
Oil / Fuel Pressure

EEPROM
Oil level/Fuel Restriction

Coolant Level
VSG Control

Engine Rating / Cruise Power / Switch Power

Progressive Shift
Pressure Governor
Diagnostic
Request

+
Battery

Stop Engine
Override
79

Multiple Horsepower Ratings


Three Independent Ratings
One Dependent Cruise Power Rating

Switch Power Options (C&I)

25ST0072-2
Rev. 04/4/00

Max. Power for Fully Loaded Engine


Min. Power for a Lightly Loaded Engine

80

25ST0072-2
Rev. 04/4/00

Schematic Diagram DDEC III / IV


Synch Reference

Electronic
Control
Module
(ECM)

Timing Reference
Electronic Foot
Pedal Assembly

Turbo Boost Pressure

EUI

Fuel / Oil / Coolant


Temperature
Oil / Fuel Pressure

EEPROM
Oil level/Fuel Restriction

Cruise Control Vehicle Speed Limiting


Vehicle Speed Sensor

Coolant Level
VSG Control

Engine Rating / Cruise Power / Switch Power

Progressive Shift
Pressure Governor
Diagnostic
Request

+
Battery

Stop Engine
Override
81

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.

25ST0072-2
Rev. 04/4/00

82

Vehicle Speed Sensor


Revs per Mile
High Gear Ratio
Rear End Ratio
Sensor 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

25ST0072-2
Rev. 04/4/00

Will not go above Idle


Code will be logged

83

25ST0072-2
Rev. 04/4/00

Cruise Control

84

25ST0072-2
Rev. 04/4/00

Schematic Diagram DDEC III / IV


Synch Reference

Electronic
Control
Module
(ECM)

Timing Reference
Electronic Foot
Pedal Assembly

Turbo Boost Pressure

EUI

Fuel / Oil / Coolant


Temperature
Oil / Fuel Pressure

EEPROM
Oil level/Fuel Restriction
Crankcase Pressure
Cruise Control Vehicle Speed Limiting
Vehicle Speed Sensor

Coolant Level
VSG Control

Engine Rating / Cruise Power / Switch Power

Progressive Shift
Pressure Governor
Diagnostic
Request

+
Battery

Stop Engine
Override
85

25ST0072-2
Rev. 04/4/00

Crankcase Pressure

Series 149 CCM

Series 4000 CCPS

Series 60 CCM

86

25ST0072-2
Rev. 04/4/00

Schematic Diagram DDEC III / IV


Synch Reference

Electronic
Control
Module
(ECM)

Timing Reference
Electronic Foot
Pedal Assembly

Turbo Boost Pressure


Fuel / Oil / Coolant
Temperature
Oil / Fuel Pressure

EEPROM

EUI

Stop
Engine
Check
Engine

Oil level/Fuel Restriction


Crankcase Pressure
Cruise Control Vehicle Speed Limiting
Vehicle Speed Sensor

Coolant Level
VSG Control

Engine Rating / Cruise Power / Switch Power

Progressive Shift
Pressure Governor
Diagnostic
Request

+
Battery

Stop Engine
Override
87

25ST0072-2
Rev. 04/4/00

Stop Engine / Check Engine Lights

88

25ST0072-2
Rev. 04/4/00

Schematic Diagram DDEC III / IV


Synch Reference

Electronic
Control
Module
(ECM)

Timing Reference
Electronic Foot
Pedal Assembly

Turbo Boost Pressure

EUI

PWM Ports
Stop
Engine

Fuel / Oil / Coolant


Temperature
Oil / Fuel Pressure

EEPROM

Check
Engine

Oil level/Fuel Restriction


Crankcase Pressure
Cruise Control Vehicle Speed Limiting
Vehicle Speed Sensor

Coolant Level
VSG Control

Engine Rating / Cruise Power / Switch Power

Progressive Shift
Pressure Governor
Diagnostic
Request

+
Battery

Stop Engine
Override
89

Pulse Width Modulated Outputs


Signals sent by the ECM to other microprocessor controlled
systems
Signal High
Signal Low

25ST0072-2
Rev. 04/4/00

20%
1 Hz

50%
1 Hz

80%
1 Hz

50 Hz duty cycle modulated


Four ports available-- circuits 908, 909, 910, 911
Factory programmed only

90

PWM

Circuit
No.
PWM #1 Output - VIH (Transmission)
908
PWM #2 Output - ESH (Throttle/GAS) 909
PWM #3 Output - ESH (Gas Valve/GAS) 910
PWM #4 Output - ESH (Fan Control)
911

Wire
Color
White
Lt. Green
Orange
Pink

ESH = Engine Sensor Harness


VIH = Vehicle Sensor Harness

25ST0072-2
Rev. 04/4/00

91

25ST0072-2
Rev. 04/4/00

Schematic Diagram DDEC III / IV


Synch Reference

Electronic
Control
Module
(ECM)

Timing Reference
Electronic Foot
Pedal Assembly

Turbo Boost Pressure

EUI

DDR Interface/ DDDL/ Reprogramming


PWM Ports
Stop
Engine

Fuel / Oil / Coolant


Temperature
Oil / Fuel Pressure

EEPROM

Check
Engine

Oil level/Fuel Restriction


Crankcase Pressure
Cruise Control Vehicle Speed Limiting
Vehicle Speed Sensor

Coolant Level
VSG Control

Engine Rating / Cruise Power / Switch Power

Progressive Shift
Pressure Governor
Diagnostic
Request

+
Battery

Stop Engine
Override
92

25ST0072-2
Rev. 04/4/00

DDR Interface with MPSI Printer

93

SAE Standards

25ST0072-2
Rev. 04/4/00

SAE Standards
MIDs
PIDs
FMIs
SIDs

95

SAE Code Format


PID - Parameter Identifier (can be measured)
SID - System Identifier (cannot be measured)
FMI - Failure Mode Identifier

25ST0072-2
Rev. 04/4/00

Example
PID 100
Oil Pressure

FMI

0 - Parameter High
1 - Parameter Low
3 - Circuit High (HI VOLT)
4 - Circuit Low (LO VOLT)
96

25ST0072-2
Rev. 04/4/00

Detroit Diesel
Diagnostic Link

97

DDDL Information

25ST0072-2
Rev. 04/4/00

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

98

25ST0072-2
Rev. 04/4/00

Detroit Diesel
Diagnostic Link

99

25ST0072-2
Rev. 04/4/00

Detroit Diesel
Diagnostic Link

100

25ST0072-2
Rev. 04/4/00

Detroit Diesel
Diagnostic Link

101

25ST0072-2
Rev. 04/4/00

DDR Communication- On Highway

DDEC II or III
12-Pin

DDEC III/ IV
6-Pin

102

25ST0072-2
Rev. 04/4/00

DDR Communication- On Highway

DDEC IV
9 Pin

103

DDEC II / III / IV
Reprogramming

25ST0072-2
Rev. 04/4/00

Reprogramming Station

105

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

25ST0072-2
Rev. 04/4/00

106

25ST0072-2
Rev. 04/4/00

Reprogramming Station
Windows Based for Download

107

25ST0072-2
Rev. 04/4/00

Reprogramming Station
Windows Based for Download

108

25ST0072-2
Rev. 04/4/00

Reprogramming Station
Windows Based for Download

109

25ST0072-2
Rev. 04/4/00

Schematic Diagram DDEC III / IV


Synch Reference

Electronic
Control
Module
(ECM)

Timing Reference
Electronic Foot
Pedal Assembly

Turbo Boost Pressure


Fuel / Oil / Coolant
Temperature

EUI

Communication
DDR Interface/ DDDL/ Reprogramming
PWM Ports

Oil / Fuel Pressure

EEPROM

Check
Engine

Stop
Engine

Oil level/Fuel Restriction


Crankcase Pressure
Cruise Control Vehicle Speed Limiting
Vehicle Speed Sensor

Coolant Level
VSG Control

Engine Rating / Cruise Power / Switch Power

Progressive Shift
Pressure Governor
Diagnostic
Request

+
Battery

Stop Engine
Override

112

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

25ST0072-2
Rev. 04/4/00

250k Baud Rate, controls Transmissions, braking


systems and retarders also used as the property data link
in multi ECM engines

113

25ST0072-2
Rev. 04/4/00

Schematic Diagram DDEC III / IV


Synch Reference

Electronic
Control
Module
(ECM)

Timing Reference
Electronic Foot
Pedal Assembly

Turbo Boost Pressure


Fuel / Oil / Coolant
Temperature

EUI

Idle Shut Down/Vehicle Power Down


Communication
DDR Interface/ DDDL/ Reprogramming
PWM Ports

Oil / Fuel Pressure

EEPROM

Check
Engine

Stop
Engine

Oil level/Fuel Restriction


Crankcase Pressure
Cruise Control Vehicle Speed Limiting
Vehicle Speed Sensor

Coolant Level
VSG Control

Engine Rating / Cruise Power / Switch Power

Progressive Shift
Pressure Governor
Diagnostic
Request

+
Battery

Stop Engine
Override

114

Idle Shut Down (ISD)/ Vehicle Power


Shutdown

25ST0072-2
Rev. 04/4/00

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

115

25ST0072-2
Rev. 04/4/00

Vehicle Power Shutdown


Idle
Ignition
Shutdown
On
Ignition switch
To Vehicle

ECM

116

25ST0072-2
Rev. 04/4/00

Schematic Diagram DDEC III / IV


Synch Reference

Electronic
Control
Module
(ECM)

Timing Reference
Electronic Foot
Pedal Assembly

Turbo Boost Pressure


Fuel / Oil / Coolant
Temperature

EUI
Engine Brake
Idle Shut Down/Vehicle Power Down
Communication
DDR Interface/ DDDL/ Reprogramming
PWM Ports

Oil / Fuel Pressure

EEPROM

Check
Engine

Stop
Engine

Oil level/Fuel Restriction


Crankcase Pressure
Cruise Control Vehicle Speed Limiting
Vehicle Speed Sensor

Coolant Level
VSG Control

Engine Rating / Cruise Power / Switch Power

Progressive Shift
Pressure Governor
Diagnostic
Request

+
Battery

Stop Engine
Override

117

25ST0072-2
Rev. 04/4/00

DDEC III/IV
Engine 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.

118

Engine Brakes
Must be at least 150 rpm above idle speed
Clutch Released input must be ON/GND
ECM must see 0% throttle
Range

Cruise Engine Brake


Yes/No
Engine Brake MPH
1-10
Engine Brake Increment
0-4
Engine Brake/Service Brake
Engine Brake Min MPH

25ST0072-2
Rev. 04/4/00

Yes/No
0-VSL

Example

Yes
3
2
Yes
35

120

DDEC Engine Brakes


#953 (Battery Negative)

T3

Low

S3

Med.

Brake Off
On
Med.
Low

ECM

HIGH
LO
MED

25ST0072-2
Rev. 04/4/00

Schematic Diagram DDEC III / IV


Synch Reference

Electronic
Control
Module
(ECM)

Timing Reference
Electronic Foot
Pedal Assembly

Turbo Boost Pressure


Fuel / Oil / Coolant
Temperature

EUI
Fan Controls
Engine Brake
Idle Shut Down/Vehicle Power Down
Communication
DDR Interface/ DDDL/ Reprogramming
PWM Ports

Oil / Fuel Pressure

EEPROM

Check
Engine

Stop
Engine

Oil level/Fuel Restriction


Crankcase Pressure
Cruise Control Vehicle Speed Limiting
Vehicle Speed Sensor

Coolant Level
VSG Control

Engine Rating / Cruise Power / Switch Power

Progressive Shift
Pressure Governor
Diagnostic
Request

+
Battery

Stop Engine
Override

122

25ST0072-2
Rev. 04/4/00

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

123

Fan Control
Conditions which activate the fan;

25ST0072-2
Rev. 04/4/00

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)

124

DDEC Fan Controls


Normal
Temperatures
Allow
High
Temperatures
Turn
FanFan
On Off

Air Supply

Temp sensor
Inputs
Optional Fan # 2

Output
Output
off
on
off

ECM

Ign. +

on
on
Fan off

Fan Override (Input Off)


#953 (-)
Aux. Fan Control (Input On)
Off)
Air Conditioning
Conditioning -- On
off
Air
(Fan on for at least 3 minutes)

25ST0072-2
Rev. 04/4/00

Schematic Diagram DDEC III / IV


Synch Reference

Electronic
Control
Module
(ECM)

Timing Reference
Electronic Foot
Pedal Assembly

Turbo Boost Pressure


Fuel / Oil / Coolant
Temperature

EUI

Optimized Idle
Fan Controls
Engine Brake

ISD / Vehicle
Power Down
Communication
DDR Interface/ DDDL/ Reprogramming
PWM Ports

Oil / Fuel Pressure

EEPROM

Check
Engine

Stop
Engine

Oil level/Fuel Restriction


Crankcase Pressure
Cruise Control Vehicle Speed Limiting
Vehicle Speed Sensor

Coolant Level
VSG Control

Engine Rating / Cruise Power / Switch Power

Progressive Shift
Pressure Governor
Diagnostic
Request

+
Battery

Stop Engine
Override

129

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

25ST0072-2
Rev. 04/4/00

130

25ST0072-2
Rev. 04/4/00

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 Switch
Under-hood Alarm
Start Relay
Overlay Relay
VSS Enabled
Optional Sleeper Thermostat

131

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.

25ST0072-2
Rev. 04/4/00

132

Optimized Idle Shutdown Sequence


With Battery Voltage above 12.2V, Oil Temp between
15C/60F and 40C/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.

25ST0072-2
Rev. 04/4/00

133

25ST0072-2
Rev. 04/4/00

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

134

25ST0072-2
Rev. 04/4/00

Schematic Diagram DDEC III / IV


Synch Reference

Electronic
Control
Module
(ECM)

Timing Reference
Electronic Foot
Pedal Assembly

Turbo Boost Pressure


Fuel / Oil / Coolant
Temperature
Oil / Fuel Pressure

EEPROM

EUI

Optimized Idle
Fan Controls
Engine Brake

ISD / Vehicle
Power Down
Communication
DDR Interface/ DDDL/ Reprogramming
PWM Ports
Check
Engine

Stop
Engine

Oil level/Fuel Restriction


Crankcase Pressure
Cruise Control
Vehicle Speed Limiting
Vehicle Speed Sensor

Coolant Level
VSG Control
Progressive Shift
Pressure Governor
Diagnostic
Request

Engine Rating / Cruise Power / Switch Power

+
Battery

Stop Engine
Override

137

Digital Inputs

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

25ST0072-2
Rev. 04/4/00

140

ECM

No Function
No Function
No Function
Cruise Enable
Fan Override

EEPROM

#150

#953

25ST0072-2
Rev. 04/4/00

DIGITAL INPUTS

+
Battery

141

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

25ST0072-2
Rev. 04/4/00

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

142

Digital Inputs (Contd)


Throttle Control

25ST0072-2
Rev. 04/4/00

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

143

Digital Outputs

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

25ST0072-2
Rev. 04/4/00

145

25ST0072-2
Rev. 04/4/00

OUTPUTS
SEL

ECM
To Jake brake

Ignition
#439

146

Digital Outputs

25ST0072-2
Rev. 04/4/00

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

147

Fuel Economy Incentive


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

25ST0072-2
Rev. 04/4/00

148

Fuel Economy Incentive


Parameter
Min MPG
Max MPH
Scaler MPH/MPG
Calc Type

Range
5-10 mpg
0-10 mph
0.1-20 mph/mpg
Filtered/Trip

Example
7.0
4
10.0
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 Data
Trip - Calculates using Trip Data

25ST0072-2
Rev. 04/4/00

149

PasSmart
Electronically Controlled Increased Passing Speed

25ST0072-2
Rev. 04/4/00

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.

150

Maintenance Alert System

25ST0072-2
Rev. 04/4/00

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

152

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

25ST0072-2
Rev. 04/4/00

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

153

25ST0072-2
Rev. 04/4/00

Maintenance Alert System

Oil Level Sensor

Fuel Restriction Sensor

Air Filter Restriction Sensor

2nd Coolant Level Sensor

Monitor Display Unit

154

DDC Installed Components


Includes Two Maintenance Alert System Sensors

25ST0072-2
Rev. 04/4/00

Oil Level Sensor (Requires Front Sump Non-metal Oil


Pan) Will not work on Rear Sump Applications
Fuel Restriction Sensor

155

25ST0072-2
Rev. 04/4/00

On Engine Components
Oil Level Sensor
Mounts in Front Sump Nonmetal 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

156

25ST0072-2
Rev. 04/4/00

On Engine Components
Fuel Restriction Sensor
Measures Fuel System
Restriction at Fuel Pump Inlet
Sensor Measures Actual Inlet
Restriction

157

Optional OEM Installed Components


OEMs Install These Components if Ordered by
Customer (Any Combination but Must Include On
Engine Components)

25ST0072-2
Rev. 04/4/00

2nd Coolant Level Sensor


Air Filter Restriction Sensor
Monitor Display Unit

158

25ST0072-2
Rev. 04/4/00

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

159

25ST0072-2
Rev. 04/4/00

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"

160

25ST0072-2
Rev. 04/4/00

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

161

Service Tools
Diagnostic Data Reader-(DDR) (Version 24.0 and higher
Detroit Diesel Diagnostic Link (DDDL) - Version 3.0

25ST0072-2
Rev. 04/4/00

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

162

Summary
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
Vehicle

Engine Only or Engine and Any Vehicle Sensors


Oil Level Requires Front Sump Plastic Plan
Display is Optional

25ST0072-2
Rev. 04/4/00

163

Construction & Industrial

Construction & Industrial

25ST0072-2
Rev. 04/4/00

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

165

Wire Crimping Exercise

25ST0072-2
Rev. 04/4/00

Wire Crimping Tools

167

25ST0072-2
Rev. 04/4/00

Wire Crimping Tools

168

25ST0072-2
Rev. 04/4/00

Wire Crimping Tools

169

25ST0072-2
Rev. 04/4/00

Wire Crimping Tools

170

25ST0072-2
Rev. 04/4/00

Wire Crimping

171

Wire Splicing

25ST0072-2
Rev. 04/4/00

Wire Splicing Tools

173

Series 71 & 92
SRS / TRS Adjustment

25ST0072-2
Rev. 04/4/00

Series 71/92 SRS/TRS Adjustment

175

Basic Electricity Wire Harness Exercise

25ST0072-2
Rev. 04/4/00

Sensor Operations
Operates on 5 Volts for All D.C. Sensors
0 .25

Low Voltage

4.75

Normal
Operating
Range

High Voltage

200

25ST0072-2
Rev. 04/4/00

Sensor Wiring
Common Return
Circuit. #452
Thermistor

Piezoresistive
Pressure sensor
Voltage is Proportional
to Pressure

201

25ST0072-2
Rev. 04/4/00

2-wire Sensors
5V Supply
Signal

Return
Sensor

ECM
Open
Short

=
=

HI VOLTAGE
LO VOLTAGE

202

25ST0072-2
Rev. 04/4/00

3-wire Sensors
ECM

Sensor
5V Supply
Signal
Return

Open Supply
Open Signal
Open Return
Supply short to Signal
Supply short to Return
Signal short to Return

=
=
=
=
=
=

LOW VOLTAGE
LOW VOLTAGE
HI VOLTAGE
HI VOLTAGE
LOW VOLTAGE
LOW VOLTAGE

203

25ST0072-2
Rev. 04/4/00

Electrical System
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.

452
120

Open
High voltage
code

204

Electrical System
452
432
416

Cavity A
Cavity B
Cavity C

Open
Low voltage code

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.

25ST0072-2
Rev. 04/4/00

205

Electrical System
452
432
416
Short

Cavity A
Cavity B
Cavity C

High Voltage Code

Definitions
Short Circuit

25ST0072-2
Rev. 04/4/00

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).

206

Electrical System
452
432
416
Ground

Cavity A
Cavity B
Cavity C

Low Voltage Code

Definitions
Grounded Circuit

25ST0072-2
Rev. 04/4/00

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.

207

Troubleshooting Tools

25ST0072-2
Rev. 04/4/00

Troubleshooting Tools
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.

Volt-Ohm Meter

209

25ST0072-2
Rev. 04/4/00

Troubleshooting Tools

Sensor Tester
J37164-A

Breakout Box (30 Pin)


J35634

DDEC III/IV Interface


J41005

210

25ST0072-2
Rev. 04/4/00

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

211