1.diagnostico y Reparacion Del Sistema de Combustible Motor Ism Vol I

DDEC
DDEC
DDEC
DDEC
III DDEC IV
Detroit Diesel
Electronic Controls
DDEC AGENDA
• Pre-Test
• Objectives
• Review Manuals
• Features & Components
• System Hardware
• Repair Tools
• Basic Electricity
• Trouble Shooting
• DDEC Reprogramming
• Post-Test, Evaluations
ST0072-2
ev. 04/4/00 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
ST0072-2
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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
ST0072-2
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Electronic Engine Advantages
• Engine Protection
• Engine Diagnostics
• Reduced Maintenance
• Improved Engine Governing
• Fuel Economy Optimization
• Enhanced Cold Starting
• Smoke Control
• Reduced Emission Levels
ST0072-2
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DDEC IV Features
• Four New ECM’s
ECM Description
Standard Truck 6 Cylinder 12 Volt
Universal 8 Cylinder 12/24 Volt
S4000 8 Cylinder 12/24 Volt
Natural 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
ST0072-2
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DDEC Necessities
Ignition
Electronic
EUI
Control
Module
(ECM)
Synch Reference
Timing Reference
EEPROM
- +
Battery
ST0072-2
ev. 04/4/00 8
Schematic Diagram DDEC III/ IV
Electronic
Control
Module
(ECM)
EEPROM
ST0072-2
ev. 04/4/00 9
Electronic Control Module
ST0072-2
ev. 04/4/00 1
Electronic Control Module
OEM responsibility DDC

responsibility
Mandatory circuits Power
and Ground Engine sensors,
harness, &
connectors
J1922,J1939, Ignition
Injector harness &
Throttle position sensor connectors
Optional circuits Manual Injectors
fan on switch, Jake Brake,
439 Ignition wire
ST0072-2
ev. 04/4/00 1
Schematic Diagram DDEC III / IV
Electronic
Control
Module
(ECM)
EEPROM
- +
Battery
ST0072-2
ev. 04/4/00 1
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
ST0072-2
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Power Supply DDEC III/ IV
ST0072-2
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Power Supply DDEC III / IV
ST0072-2
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EUI
Electronic
Control
Module
(ECM)
EEPROM
- +
Battery
ST0072-2
ev. 04/4/00 1
Electronic Unit Injectors
Series 71/92 EUI Series 149 EUI Series 50/60 EUI
Series 4000 Spray Nozzle Series 53 EUI

Series 2000 EUP
ST0072-2
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Voltage in Series 50/60
Rocker Arm Injector
Solenoid Animation
Cam
Poppet
Valve
Plunger
Fuel out
Fuel in
Needle Valve
Series 4000
Solenoid Rocker Arm
Nozzle
filter CAM Animation
Fuel High
Return Pressure
Fuel
Needle Nozzle
Valve
Series 2000
EUP
Rocker Arm
Solenoid Fuel In
Animation
CAM
EUP
Cam
Spay
Nozzle
Electronic Unit Pump
ST0072-2
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Top Of Stroke
Fuel
In
Fuel
Out
Injector
Tip
ST0072-2
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Start Of Injection
Fuel
In
Fuel
Out
Injector
Tip
ST0072-2
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End Of Injection
Fuel
In
Fuel
Out
Injector
Tip
ST0072-2
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Injection Sequence
Fuel Fuel Fuel

In In In
Fuel Fuel Fuel
Out Out Out
Injector Injector Injector

Tip Tip Tip
ST0072-2
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Injector Calibration Codes
• DDEC II No Calibration Codes

• DDEC III/ IV Calibration Codes From 00-99
Part Number
Calibration Code
ST0072-2
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Injector Cycle Terminology
zIRT Injector Response Time - Length of Time (ms)

required to close the Control Valve
zPW Pulse Width - Degrees of Crankshaft Rotation

when Fuel is Injected
ST0072-2
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Injector Response Times
ST0072-2
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Cylinder Cut-Out
ST0072-2
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Injection Cycle
BAT
V_REG, 5V
0V
Voltage
(Inflection Point)
0A Current
Control Valve Lift
Closed
Open
Injection Rate
IRT PW
BOE BOI EOE EOI
Time
ST0072-2
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Sensor Operations
Operates on 5 Volts for All D.C. Sensors
0 .25 4.75 5
Low Voltage Normal High Voltage

Operating
Range
ST0072-2
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Sensor Wiring
• Common Return
Circuit. #452
• Thermistor
• Piezoresistive
Pressure sensor
• Voltage is Proportional
to Pressure
ST0072-2
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2-wire Sensors
5V Supply
Signal
Return
ECM Sensor
Open = HI VOLTAGE
Short = LO VOLTAGE
ST0072-2
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3-wire Sensors
ECM Sensor
5V Supply
Signal
Return
Open Supply = LO VOLTAGE

Open Signal = LO VOLTAGE
Open Return = HI VOLTAGE
Supply short to Signal = HI VOLTAGE
Supply short to Return = LO VOLTAGE
Signal short to Return = LO VOLTAGE
ST0072-2
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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).
ST0072-2
ev. 04/4/00 3
Synch Reference
EUI
Timing Reference Electronic
Control
Module
(ECM)
EEPROM
- +
Battery
ST0072-2
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Series 50/60
SRS/TRS Sensors
SRS/TRS
Timing Wheel
Bull Gear
DDEC III/ IV
DDEC III/ IV
ST0072-2
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Series 60
Sensor
Locations
Series 2000
SRS/TRS Sensors
SRS/TRS TIMING
WHEEL
TIMING
WHEEL
Cam Gear/SRS
ST0072-2
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Series 2000
Sensor
Locations
Series 4000
SRS/TRS Sensors
SRS/TRS
Timing Wheels
Cam Gear/SRS
ST0072-2
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Series 4000
Sensor
Locations
Two Cycle
SRS/TRS with Timing Wheel
SRS/TRS SRS/TRS
Sensor Sensor
Timing Wheel Timing Wheel

& Cam Pulley & Cam Pulley
Series 71 Series 92 / 6V, 8V, 12V-71

ST0072-2
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Two Cycle
SRS/TRS SRS/TRS
Sensors Sensors
Timing Timing
Wheels Wheels
Series 149
Series 92, 12V, 16V
ST0072-2
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Series 53
Timing
Wheel SRS/TRS
Sensors
SRS PIN
ST0072-2
ev. 04/4/00 4
Schematic Diagram DDEC IV
Synch Reference
EUI
Timing Reference Electronic
Electronic Foot
Pedal Assembly
Control
Module
(ECM)
EEPROM
- +
Battery
ST0072-2
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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
ST0072-2
failure
ev. 04/4/00 4
Schematic Diagram DDEC IV
Synch Reference
EUI
Timing Reference
Electronic Foot
Electronic
Pedal Assembly Control
Module
Turbo Boost Pressure
(ECM)
EEPROM
- +
Battery
ST0072-2
ev. 04/4/00 4
Turbo Boost Sensor
Series 53
DDEC III Series 50/60/2-Cycle
Series 2000 / 4000 Series 50/60 DDEC IV
ST0072-2
ev. 04/4/00 4
Synch Reference
EUI
Timing Reference
Electronic Foot
Electronic
Module
(ECM)
Fuel / Oil / Coolant/ Air
Temperature
EEPROM
- +
Battery
ST0072-2
ev. 04/4/00 5
Temperature Sensors
Coolant Temperature Sensor Air Temperature Sensor

Series 50/60 Series 50/60
Fuel/Oil/Coolant Temperature Sensor Fuel/Oil/Coolant Temperature Sensor

Series 50/60/2-Cycle - Air Temp 53 Series 2000/4000
ST0072-2
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Synch Reference
EUI
Timing Reference
Electronic Foot
Electronic
Module
(ECM)
Fuel / Oil / Coolant
Temperature
Oil / Fuel Pressure

EEPROM
- +
Battery
ST0072-2
ev. 04/4/00 5
Pressure Sensors
Coolant
Oil / Fuel
Pressure
Pressure
Series 50/60/2-Cycle
Series 2000/4000
Different Harness Connectors
Series 4000
High Pressure Fuel
Series 2000/4000
ST0072-2
ev. 04/4/00 5
Synch Reference
EUI
Timing Reference
Electronic Foot
Electronic
Module
(ECM)
Temperature
Oil / Fuel Pressure
EEPROM
Oil level/Fuel Restriction
- +
Battery
ST0072-2
ev. 04/4/00 5
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
ST0072-2
ev. 04/4/00 5
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
ST0072-2
ev. 04/4/00 5
Synch Reference
EUI
Timing Reference
Electronic Foot
Electronic
Module
(ECM)
Temperature
Oil / Fuel Pressure
EEPROM
Coolant Level
- +
Battery
ST0072-2
ev. 04/4/00 5
Coolant Level Sensor
DDEC II/ III Coolant Level Sensor
DDEC III or IV
Coolant Level Sensor
ST0072-2
ev. 04/4/00 5
Synch Reference
EUI
Timing Reference
Electronic Foot
Electronic
Module
(ECM)
Temperature
Oil / Fuel Pressure
EEPROM
Coolant Level
VSG Control
- +
Battery
ST0072-2
ev. 04/4/00 5
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.
ST0072-2
ev. 04/4/00 6
Synch Reference
EUI
Timing Reference
Electronic Foot
Electronic
Module
(ECM)
Temperature
Oil / Fuel Pressure
EEPROM
Coolant Level
VSG Control
Progressive Shift - +
Battery
ST0072-2
ev. 04/4/00 6
Progressive Shift
• Use Spec Manager to determine values to program for

Progressive Shift
• Example
Low Gear #1 off 12 Max MPH Limit

Low Gear #1 limit 1400
Low Gear #1 max 1800
Low Gear #2 off 27 Max MPH Limit
Low Gear #2 limit 1600
Low Gear #2 max 1800
High Gear on 50 Max MPH Limit
High Gear max 1700
ST0072-2
ev. 04/4/00 6
Progressive Shift
ST0072-2
ev. 04/4/00 6
Synch Reference
EUI
Timing Reference
Electronic Foot
Electronic
Module
(ECM)
Temperature
Oil / Fuel Pressure
EEPROM
Coolant Level
VSG Control
Pressure Governor Battery
ST0072-2
ev. 04/4/00 6
Pressure Governor
•Fire Commander and Mastermind

use the same digital inputs and
outputs as cruise control
High Pressure
Sensor
Fire Commander
Mastermind
ST0072-2
ev. 04/4/00 6
Electronic Fire Commander
Control Buttons
Engine Data
System Status
Message Window
ST0072-2
ev. 04/4/00 6
Synch Reference
EUI
Timing Reference
Electronic Foot
Electronic
Module
(ECM)
Temperature
Oil / Fuel Pressure
EEPROM
Coolant Level
VSG Control
Diagnostic Stop Engine
Request Override
ST0072-2
ev. 04/4/00 6
Diagnostic Request
or Stop Engine Override
ST0072-2
ev. 04/4/00 6
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.
ST0072-2
ev. 04/4/00 6
Synch Reference
EUI
Timing Reference
Electronic Foot
Electronic
Module
(ECM)
Temperature
Oil / Fuel Pressure

EEPROM
Coolant Level
VSG Control Engine Rating / Cruise Power / Switch Power
Request Override
ST0072-2
ev. 04/4/00 7
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
ST0072-2
ev. 04/4/00 7
Synch Reference
EUI
Timing Reference
Electronic Foot
Electronic
Module
(ECM)
Temperature
Oil / Fuel Pressure

EEPROM
Cruise Control Vehicle Speed Limiting

Coolant Level Vehicle Speed Sensor
Request Override
ST0072-2
ev. 04/4/00 7
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.
ST0072-2
ev. 04/4/00 7
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
– Will not go above Idle
– Code will be logged
ST0072-2
ev. 04/4/00 7
Cruise Control
ST0072-2
ev. 04/4/00 7
Synch Reference
EUI
Timing Reference
Electronic Foot
Electronic
Module
(ECM)
Temperature
Oil / Fuel Pressure

EEPROM
Crankcase Pressure

Request Override
ST0072-2
ev. 04/4/00 7
Crankcase Pressure
Series 149 CCM Series 4000 CCPS Series 60 CCM
ST0072-2
ev. 04/4/00 7
Synch Reference
EUI
Timing Reference
Electronic Foot
Electronic
Module
(ECM)
Stop
Fuel / Oil / Coolant Engine
Temperature
Oil / Fuel Pressure

Check
EEPROM Engine

Crankcase Pressure

Request Override
ST0072-2
ev. 04/4/00 7
Stop Engine / Check Engine Lights
ST0072-2
ev. 04/4/00 7
Synch Reference
EUI
Timing Reference
Electronic Foot
Electronic
Module
(ECM) PWM Ports
Fuel / Oil / Coolant Stop

Temperature Engine
Oil / Fuel Pressure

Check
EEPROM Engine

Crankcase Pressure

Request Override
ST0072-2
ev. 04/4/00 8
Pulse Width Modulated Outputs
• Signals sent by the ECM to other microprocessor controlled
systems
20% 50% 80%

Signal High
Signal Low
1 Hz 1 Hz 1 Hz
• 50 Hz duty cycle modulated

• Four ports available-- circuits 908, 909, 910, 911
• Factory programmed only
ST0072-2
ev. 04/4/00 8
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
ST0072-2
ev. 04/4/00 8
Synch Reference
EUI
Timing Reference
Electronic Foot
Electronic
Module DDR Interface/ DDDL/ Reprogramming
(ECM) PWM Ports
Fuel / Oil / Coolant Stop

Temperature Engine
Oil / Fuel Pressure

Check
EEPROM Engine

Crankcase Pressure

Request Override
ST0072-2
ev. 04/4/00 8
DDR Interface with MPSI Printer
ST0072-2
ev. 04/4/00 8
DDR Interface with MPSI Printer
ST0072-2
ev. 04/4/00 8
Detroit Diesel
Diagnostic Link
ST0072-2
ev. 04/4/00 8
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
ST0072-2
ev. 04/4/00 8
Detroit Diesel
Diagnostic Link
ST0072-2
ev. 04/4/00 8
Detroit Diesel
Diagnostic Link
ST0072-2
ev. 04/4/00 8
Detroit Diesel
Diagnostic Link
ST0072-2
ev. 04/4/00 9
DDR Communication- On Highway
DDEC II or III
DDEC III/ IV
12-Pin
6-Pin
ST0072-2
ev. 04/4/00 9
DDR Communication- On Highway
DDEC IV
9 Pin
ST0072-2
ev. 04/4/00 9
Troubleshooting Tools
h To properly probe terminals use

Kentmoore jumper wire kit number J39197.
Within this kit the proper leads are provided.
h 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
ST0072-2
ev. 04/4/00 9
Sensor Tester Breakout Box (30 Pin) DDEC III/IV Interface

J37164-A J35634 J41005
ST0072-2
ev. 04/4/00 9
DDEC II / III / IV
Reprogramming
Reprogramming Station
ST0072-2
ev. 04/4/00 9
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
ST0072-2
ev. 04/4/00 9
Windows Based for Download
ST0072-2
ev. 04/4/00 9
ST0072-2
ev. 04/4/00 10
ST0072-2
ev. 04/4/00 10
Wire Crimping Exercise
Wire Crimping Tools
ST0072-2
ev. 04/4/00 10
Wire Crimping Tools
ST0072-2
ev. 04/4/00 10
Wire Crimping Tools
ST0072-2
ev. 04/4/00 10
Wire Crimping Tools
ST0072-2
ev. 04/4/00 10
Wire Crimping
ST0072-2
ev. 04/4/00 10
Wire Splicing
Wire Splicing Tools
ST0072-2
ev. 04/4/00 10
Series 71 & 92
SRS / TRS Adjustment
Series 71/92 SRS/TRS Adjustment
ST0072-2
ev. 04/4/00 11
Synch Reference
EUI
Timing Reference
Electronic Foot
Electronic
Module
Turbo Boost Pressure Communication
(ECM) DDR Interface/ DDDL/ Reprogramming
Temperature PWM Ports
Oil / Fuel Pressure Stop

Check
Engine Engine
EEPROM
Crankcase Pressure

Request Override
ST0072-2
ev. 04/4/00 11

1.diagnostico y Reparacion Del Sistema de Combustible Motor Ism Vol I

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1.diagnostico y Reparacion Del Sistema de Combustible Motor Ism Vol I

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Droits d'auteur :

Formats disponibles

DDEC

• DDEC I Introduced in 1985 on 92 Series

An advanced electronic fuel injection control system

DDEC Consists of:

• Increased Memory - 57% Over DDEC III

OEM responsibility DDC

Series 71/92 EUI Series 149 EUI Series 50/60 EUI

Series 4000 Spray Nozzle Series 53 EUI

Fuel Fuel Fuel

Injector Injector Injector

• DDEC II No Calibration Codes

zIRT Injector Response Time - Length of Time (ms)

zPW Pulse Width - Degrees of Crankshaft Rotation

Operates on 5 Volts for All D.C. Sensors

Low Voltage Normal High Voltage

Open Supply = LO VOLTAGE

• SRS/TRS: Magnetic pickup sensors generate

Timing Wheel Timing Wheel

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

• Electronic Foot Pedal

• Optional idle validation

Series 2000 / 4000 Series 50/60 DDEC IV

Coolant Temperature Sensor Air Temperature Sensor

Fuel/Oil/Coolant Temperature Sensor Fuel/Oil/Coolant Temperature Sensor

Oil / Fuel Pressure

• Oil Level Sensor

• Fuel Restriction Sensor

DDEC II/ III Coolant Level Sensor

• Variable Speed Governor

• Use Spec Manager to determine values to program for

Low Gear #1 off 12 Max MPH Limit

•Fire Commander and Mastermind

• Warning- Illumination of CEL,SEL only

• Rampdown- Immediate reduction to 70% power,

• Shutdown- Same as rampdown except engine is

Oil / Fuel Pressure

VSG Control Engine Rating / Cruise Power / Switch Power

• Three Independent Ratings

• Switch Power Options (C&I)

Oil / Fuel Pressure

Cruise Control Vehicle Speed Limiting

• Determined by vehicle speed (VSS) or engine speed

• Vehicle Speed Limit

Oil / Fuel Pressure

Cruise Control Vehicle Speed Limiting

Series 149 CCM Series 4000 CCPS Series 60 CCM

Oil / Fuel Pressure

Oil level/Fuel Restriction

Cruise Control Vehicle Speed Limiting

Fuel / Oil / Coolant Stop

Oil / Fuel Pressure

Oil level/Fuel Restriction

Cruise Control Vehicle Speed Limiting

20% 50% 80%

• 50 Hz duty cycle modulated

• ESH = Engine Sensor Harness

Fuel / Oil / Coolant Stop

Oil / Fuel Pressure

Oil level/Fuel Restriction

Cruise Control Vehicle Speed Limiting

h To properly probe terminals use

h The use of the lead ends of the volt ohm

Sensor Tester Breakout Box (30 Pin) DDEC III/IV Interface