Ddec Master 2000 Current4-6

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

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

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
Sensors
SRS/TRS
Sensors
Timing
Wheels
Timing
Wheels
Series 92, 12V, 16V
Series 149
48
25ST0072-2
Rev. 04/4/00
Series 53
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

Synch Reference
Timing Reference
Electronic Foot
Pedal Assembly
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

Synch Reference
Timing Reference
Electronic Foot
Pedal Assembly
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

Synch Reference
Timing Reference
Electronic Foot
Pedal Assembly
Electronic
Control
Module
(ECM)
EUI

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
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

Synch Reference
Timing Reference
Electronic Foot
Pedal Assembly
Electronic
Control
Module
(ECM)
EUI

Temperature
Oil / Fuel Pressure
EEPROM
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

Synch Reference
Timing Reference
Electronic Foot
Pedal Assembly
Electronic
Control
Module
(ECM)
EUI

Temperature
Oil / Fuel Pressure
EEPROM
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

Synch Reference
Timing Reference
Electronic Foot
Pedal Assembly
Electronic
Control
Module
(ECM)
EUI

Temperature
Oil / Fuel Pressure
EEPROM
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

Synch Reference
Timing Reference
Electronic Foot
Pedal Assembly
Electronic
Control
Module
(ECM)
EUI

Temperature
Oil / Fuel Pressure
EEPROM
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

Synch Reference
Electronic
Control
Module
(ECM)
Timing Reference
Electronic Foot
Pedal Assembly
EUI

Temperature
Oil / Fuel Pressure
EEPROM
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

Synch Reference
Electronic
Control
Module
(ECM)
Timing Reference
Electronic Foot
Pedal Assembly
EUI

Temperature
Oil / Fuel Pressure
EEPROM
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

Synch Reference
Electronic
Control
Module
(ECM)
Timing Reference
Electronic Foot
Pedal Assembly
EUI

Temperature
Oil / Fuel Pressure
EEPROM
Cruise Control Vehicle Speed Limiting

Vehicle Speed Sensor
Coolant Level
VSG Control
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

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

Synch Reference
Electronic
Control
Module
(ECM)
Timing Reference
Electronic Foot
Pedal Assembly
EUI

Temperature
Oil / Fuel Pressure
EEPROM
Crankcase Pressure
Coolant Level
VSG Control
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

Synch Reference
Electronic
Control
Module
(ECM)
Timing Reference
Electronic Foot
Pedal Assembly

Temperature
Oil / Fuel Pressure
EEPROM
EUI
Stop
Engine
Check
Engine

Crankcase Pressure
Coolant Level
VSG Control
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

Synch Reference
Electronic
Control
Module
(ECM)
Timing Reference
Electronic Foot
Pedal Assembly
EUI
PWM Ports
Stop
Engine

Temperature
Oil / Fuel Pressure
EEPROM
Check
Engine

Crankcase Pressure
Coolant Level
VSG Control
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

Synch Reference
Electronic
Control
Module
(ECM)
Timing Reference
Electronic Foot
Pedal Assembly
EUI
DDR Interface/ DDDL/ Reprogramming

PWM Ports
Stop
Engine

Temperature
Oil / Fuel Pressure
EEPROM
Check
Engine

Crankcase Pressure
Coolant Level
VSG Control
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
Windows Based for Download
107
25ST0072-2
Rev. 04/4/00
108
25ST0072-2
Rev. 04/4/00
109
25ST0072-2
Rev. 04/4/00

Synch Reference
Electronic
Control
Module
(ECM)
Timing Reference
Electronic Foot
Pedal Assembly

Temperature
EUI
Communication
PWM Ports
Oil / Fuel Pressure
EEPROM
Check
Engine
Stop
Engine

Crankcase Pressure
Coolant Level
VSG Control
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

Synch Reference
Electronic
Control
Module
(ECM)
Timing Reference
Electronic Foot
Pedal Assembly

Temperature
EUI
Idle Shut Down/Vehicle Power Down

Communication
PWM Ports
Oil / Fuel Pressure
EEPROM
Check
Engine
Stop
Engine

Crankcase Pressure
Coolant Level
VSG Control
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

Synch Reference
Electronic
Control
Module
(ECM)
Timing Reference
Electronic Foot
Pedal Assembly

Temperature
EUI
Engine Brake
Communication
PWM Ports
Oil / Fuel Pressure
EEPROM
Check
Engine
Stop
Engine

Crankcase Pressure
Coolant Level
VSG Control
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

Synch Reference
Electronic
Control
Module
(ECM)
Timing Reference
Electronic Foot
Pedal Assembly

Temperature
EUI
Fan Controls
Engine Brake
Communication
PWM Ports
Oil / Fuel Pressure
EEPROM
Check
Engine
Stop
Engine

Crankcase Pressure
Coolant Level
VSG Control
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

Synch Reference
Electronic
Control
Module
(ECM)
Timing Reference
Electronic Foot
Pedal Assembly

Temperature
EUI
Optimized Idle
Fan Controls
Engine Brake
ISD / Vehicle
Power Down
Communication
PWM Ports
Oil / Fuel Pressure
EEPROM
Check
Engine
Stop
Engine

Crankcase Pressure
Coolant Level
VSG Control
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

Synch Reference
Electronic
Control
Module
(ECM)
Timing Reference
Electronic Foot
Pedal Assembly

Temperature
Oil / Fuel Pressure
EEPROM
EUI
Optimized Idle
Fan Controls
Engine Brake
ISD / Vehicle
Power Down
Communication
PWM Ports
Check
Engine
Stop
Engine

Crankcase Pressure
Cruise Control
Vehicle Speed Limiting
Coolant Level
VSG Control
Progressive Shift
Pressure Governor
Diagnostic
Request
+
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)
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 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
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

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
Oil Level 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
155
25ST0072-2
Rev. 04/4/00
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
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

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

Electronic Version of the
Mechanical Filter Minder
Switch Points at 15 and 20
Inches of Water
OEM Impact
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

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
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
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
Sensor Tester
J37164-A
Breakout Box (30 Pin)

J35634
DDEC III/IV Interface

J41005
210
25ST0072-2
Rev. 04/4/00
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

Ddec Master 2000 Current4-6

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Ddec Master 2000 Current4-6

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Formats disponibles

DDEC

DDEC Consists of:

Electronic Engine Advantages

Increased Memory - 57% Over DDEC III

Schematic Diagram DDEC III/ IV

Electronic Control Module

Electronic Control Module

Schematic Diagram DDEC III / IV

Power Supply DDEC III/ IV

Power Supply DDEC III / IV

Schematic Diagram DDEC III / IV

Electronic Unit Injectors

Series 71/92 EUI

Series 4000 Spray Nozzle

Series 149 EUI

Series 50/60 EUI

Electronic Unit Pump

Injector Calibration Codes

Injector Cycle Terminology

IRT Injector Response Time - Length of Time (ms)

Injector Response Times

Schematic Diagram DDEC III / IV

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

Series 92, 12V, 16V

Schematic Diagram DDEC IV

Throttle Position Sensor

Schematic Diagram DDEC IV

Turbo Boost Pressure

Turbo Boost Sensor

Series 2000 / 4000

Series 50/60 DDEC IV

Schematic Diagram DDEC III / IV

Turbo Boost Pressure

Fuel / Oil / Coolant/ Air

Coolant Temperature Sensor

Air Temperature Sensor

Fuel/Oil/Coolant Temperature Sensor

Fuel/Oil/Coolant Temperature Sensor

Schematic Diagram DDEC III / IV

Turbo Boost Pressure

Fuel / Oil / Coolant

Schematic Diagram DDEC III / IV

Turbo Boost Pressure

Fuel / Oil / Coolant

Schematic Diagram DDEC III / IV

Turbo Boost Pressure

Fuel / Oil / Coolant

Coolant Level Sensor

DDEC II/ III Coolant Level Sensor

Schematic Diagram DDEC III / IV

Turbo Boost Pressure

Fuel / Oil / Coolant

Difference in RPM Between Full Load

Schematic Diagram DDEC III / IV

Turbo Boost Pressure

Fuel / Oil / Coolant

Low Gear #1 off

12 Max MPH Limit

Schematic Diagram DDEC III / IV

Turbo Boost Pressure

Fuel / Oil / Coolant

Electronic Fire Commander

Schematic Diagram DDEC III / IV

Turbo Boost Pressure