ddec master 2000 current4 6

Detroit DieselElectronic Controls

DDECDDECDDEC

DDECDDEC IVIII

25ST0072-2 Rev. 04/4/00 3

DDEC AGENDA

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

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DDEC History

• DDEC I Introduced in 1985 on 92 Series• Series 60 Introduced in 1987 As the First Engine

Ever Designed Exclusively for Electronic Controls• DDEC II Introduced in 1987• DDEC III Introduced April, 1993• DDEC III Full Production January, 1994• DDEC IV Initial Release, August, 1997• DDEC IV Full Production, January, 1998

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What is DDEC?

An advanced electronic fuel injection control system that can be integrated into many applications

DDEC Consists of:• Sensors and switches• Conductors and connections• ECM (computer)

– Hardware– Software

• Injectors

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Electronic Engine Advantages

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

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DDEC IV Features• Four New ECM’s

ECM DescriptionStandard Truck 6 Cylinder 12 VoltUniversal 8 Cylinder 12/24 VoltS4000 8 Cylinder 12/24 VoltNatural Gas 8 Cylinder 12/24 Volt

• Increased Memory - 57% Over DDEC III• Faster Processing Time - 50% Over DDEC III• J1939 Communication Link - Standard• Battery Backed Real Time Clock & Calendar• DDEC Data (Enhanced ECM Data Pages) -

Standard

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DDEC Necessities

Ignition

ElectronicControlModule(ECM)

EEPROM

+-Battery

Timing Reference

Synch Reference

EUI

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Schematic Diagram DDEC III/ IV


EEPROM

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Electronic Control Module

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Electronic Control Module

DDC responsibility

Engine sensors, harness, & connectors

Injector harness & connectorsInjectors

OEM responsibility

Mandatory circuits Power and Ground

J1922,J1939, Ignition

Throttle position sensorOptional circuits Manual fan on switch, Jake Brake, 439 Ignition wire

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Schematic Diagram DDEC III / IV


EEPROM

+-Battery

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Power Supply

• DDEC II - 12 Volt• DDEC III - 12/24 Volt• DDEC IV- 12 or 24 Volt• Source must be Isolated from any other Vehicle Accessory• The ECM Power Source must be Fused with the Proper Amp• The ECM Must Be Incorporated with a 5 Amp Fuse on the

440 wire going into the 439 wire.• The ECM Case Must be Electrically Isolated from any

Chassis Ground

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Power Supply DDEC III/ IV

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Power Supply DDEC III / IV

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EEPROM

+-Battery

EUI

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Electronic Unit Injectors

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

Series 4000 Spray Nozzle Series 2000 EUP

Series 53 EUI

Series 50/60 Injector

Animation

Fuel out

Fuel in

Voltage in

Solenoid

Plunger

Poppet Valve

Needle Valve

Rocker Arm

Cam

Series 4000 Nozzle

AnimationCAM

Rocker ArmSolenoid

filter

Fuel Return

High Pressure

Fuel

Needle Valve

Nozzle

Series 2000 EUP

AnimationCAM

Rocker ArmSolenoid

EUP

Cam

Spay Nozzle

Fuel In

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Electronic Unit Pump

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Top Of Stroke

InjectorTip

FuelIn

FuelOut

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Start Of Injection

InjectorTip

FuelIn

FuelOut

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End Of Injection

InjectorTip

FuelIn

FuelOut

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Injection Sequence

InjectorTip

FuelInFuelOut

InjectorTip

FuelIn

FuelOut

InjectorTip

FuelIn

FuelOut

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Injector Calibration Codes

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

Calibration Code

Part Number

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Injector Cycle Terminology

IRT Injector Response Time - Length of Time (ms) required to close the Control Valve

PW Pulse Width - Degrees of Crankshaft Rotation when Fuel is Injected

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Injector Response Times

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Cylinder Cut-Out

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Injection Cycle

BOE BOI EOE EOIIRT

Time

PW

(Inflection Point)

BAT

Voltage0V

V_REG, 5V

Current0A

ClosedOpenControl Valve Lift

Injection Rate

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Sensor Operations

Operates on 5 Volts for All D.C. Sensors

.25 4.75

NormalOperating

Range

Low Voltage

0 5

High Voltage

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Sensor Wiring

• Common Return Circuit. #452• Thermistor

• Piezoresistive Pressure sensor

• Voltage is Proportional to Pressure

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2-wire Sensors

5V Supply

Signal

Return

ECM SensorOpen = HI VOLTAGEShort = LO VOLTAGE

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3-wire Sensors

ECM Sensor5V Supply

Signal

Return

Open Supply = LO VOLTAGEOpen Signal = LO VOLTAGE Open Return = HI VOLTAGE

HI VOLTAGESupply short to Signal =Supply short to Return = LO VOLTAGESignal short to Return = LO VOLTAGE

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SRS/TRS Sensors

• SRS/TRS: Magnetic pickup sensors generate alternating current (A.C.). The frequency will change dependent on the speed of the pulse wheel (RPM of engine).

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EEPROM

+-Battery

Timing Reference

Synch Reference


EUI

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Series 50/60SRS/TRS Sensors

SRS/TRS

Timing WheelDDEC III/ IVBull Gear

DDEC III/ IV

Series 60 Sensor

Locations

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Series 2000SRS/TRS Sensors

SRS/TRS

Cam Gear/SRS

TIMING WHEEL

TIMING WHEEL

Series 2000 Sensor

Locations

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Series 4000SRS/TRS Sensors

SRS/TRS

Cam Gear/SRS

Timing Wheels

Series 4000 Sensor

Locations

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Two Cycle SRS/TRS with Timing Wheel

SRS/TRSSensor

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

SRS/TRSSensor

Timing Wheel& Cam Pulley

Timing Wheel& Cam Pulley

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Two Cycle SRS/TRS with Timing Wheel

SRS/TRSSensors

TimingWheels

TimingWheels

Series 92, 12V, 16V

SRS/TRSSensors

Series 149

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Series 53 SRS/TRS with Timing Wheel

SRS/TRSSensors

TimingWheel

SRS PIN

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Schematic Diagram DDEC IV


EEPROM

Timing Reference

Synch Reference

Electronic FootPedal Assembly

EUI

+-Battery

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Throttle Position SensorElectronic Foot Pedal Assembly

• 5 volt, three wire circuit

• Electronic Foot Pedal Assembly signals throttle position for the Limiting Speed Governor.

• Optional idle validation switch insures that the engine will remain at idle in the event of a TPS circuit failure

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Schematic Diagram DDEC IV


EEPROM

Turbo Boost Pressure

Timing Reference

Synch Reference


EUI

+-Battery

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Turbo Boost Sensor

DDEC III Series 50/60/2-Cycle

Series 2000 / 4000 Series 50/60 DDEC IV

Series 53

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EEPROM

+-Battery

Fuel / Oil / Coolant/ AirTemperature


Timing Reference

Synch Reference


EUI

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Temperature Sensors

Coolant Temperature SensorSeries 50/60

Air Temperature SensorSeries 50/60

Fuel/Oil/Coolant Temperature SensorSeries 50/60/2-Cycle - Air Temp 53

Fuel/Oil/Coolant Temperature SensorSeries 2000/4000

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EEPROM

+-Battery

Fuel / Oil / CoolantTemperature


Timing Reference

Synch Reference


Oil / Fuel Pressure

EUI

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Pressure Sensors

Series 50/60/2-Cycle

Series 2000/4000

Series 2000/4000Different Harness Connectors

CoolantPressure Oil / Fuel

Pressure

Series 4000 High Pressure Fuel

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EEPROM

+-Battery

Oil / Fuel Pressure



Timing Reference

Synch Reference


Oil level/Fuel Restriction

EUI

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On Engine Components

• Oil Level Sensor– Mounts in Front Sump Non-

metal Oil Pan– Utilizes Optical Technology to

"See" Oil Level– Engine Must Be Off (Zero

RPM ) for "X" Minutes (Based on Oil Temp.) to Drain Oil Back to the Pan

– Switches at Four Quart Low Level

– OEM Impact» Order Maintenance Alert

System on the Engine

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• Fuel Restriction Sensor– Measures Fuel System

Restriction at Fuel Pump Inlet– Sensor Measures Actual Inlet

Restriction – OEM Impact

» Order Maintenance Alert System on the Engine

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EEPROM

+-Battery

Oil / Fuel Pressure



Coolant Level

Timing Reference

Synch Reference



EUI

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Coolant Level Sensor

DDEC III or IVCoolant Level Sensor

DDEC II/ III Coolant Level Sensor

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EEPROM

+-Battery

Oil / Fuel Pressure



Coolant Level

Timing Reference

Synch Reference

VSG Control



EUI

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VSG Control

• Variable Speed Governor– Throttle Position Controls RPM

• Droop– Difference in RPM Between Full Load

(Rated Speed) and Maximum Engine RPM (No Load)

– Allows the engine to overrun the rated or governed engine speed.

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EEPROM

+-Battery

Oil / Fuel Pressure



Coolant Level

Timing Reference

Synch Reference

VSG Control


Progressive Shift


EUI

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Progressive Shift

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

• Example

Low Gear #1 off 12 Max MPH LimitLow Gear #1 limit 1400Low Gear #1 max 1800Low Gear #2 off 27 Max MPH LimitLow Gear #2 limit 1600Low Gear #2 max 1800High Gear on 50 Max MPH LimitHigh Gear max 1700

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Progressive Shift

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EEPROM

+-Battery

Oil / Fuel Pressure



Coolant Level

Timing Reference

Synch Reference

VSG Control


Progressive ShiftPressure Governor


EUI

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Pressure Governor

Mastermind

Fire Commander

High PressureSensor

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

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Electronic Fire Commander

Engine Data

System Status

Message Window

Control Buttons

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EEPROM

+-Battery

Oil / Fuel Pressure



Coolant Level

Timing Reference

Synch Reference

VSG Control


Progressive ShiftPressure Governor

DiagnosticRequest

Stop EngineOverride


EUI

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Diagnostic Requestor Stop Engine Override

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Engine Protection

• Warning- Illumination of CEL,SEL only

• Rampdown- Immediate reduction to 70% power, ramping down to 40% over 30 seconds and maintains 40% power.

• Shutdown- Same as rampdown except engine is shutdown at the end of 30 seconds.

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EEPROM

+-Battery

Oil / Fuel Pressure



Pressure Governor

Coolant Level

Timing Reference

Synch Reference

VSG Control


Progressive Shift

DiagnosticRequest

Stop EngineOverride

Engine Rating / Cruise Power / Switch Power


EUI

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Multiple Horsepower Ratings

• Three Independent Ratings• One Dependent Cruise Power Rating

• Switch Power Options (C&I)– Max. Power for Fully Loaded Engine– Min. Power for a Lightly Loaded Engine

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EEPROM

+-Battery

Cruise Control Vehicle Speed LimitingVehicle Speed Sensor

Oil / Fuel Pressure



Pressure Governor

Coolant Level

Timing Reference

Synch Reference

VSG Control


Progressive Shift

DiagnosticRequest

Stop EngineOverride



EUI

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Cruise Control

• Determined by vehicle speed (VSS) or engine speed (RPM) DDEC IV changed

• Must be above 20 MPH or 1100 RPM to set• Cruise Power can provide higher HP while in cruise

control by using the C. P. rating.• Uses up to 5 digital inputs and one digital output • VSG can be controlled by the cruise switch• Use cruise switches to set PTO high idle and lower

high idle. You use a step up or step down & step up by pressing or toggling the resume switch.

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Vehicle Speed Sensor• Revs per Mile

High Gear RatioRear End RatioSensor Type (Magnetic)# of teeth on Pulse Wheel

• Vehicle Speed Limit• Vehicle Overspeed with Fuel (typically set 3-4 mph above

road speed limit)• Vehicle Overspeed without Fuel (typically set 5-6 mph above

road speed limit)• VSS Antitamper

– Will not go above Idle– Code will be logged

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Cruise Control

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EEPROM

+-Battery


Oil / Fuel Pressure



Pressure Governor

Coolant Level

Timing Reference

Synch Reference

VSG Control


Progressive Shift

DiagnosticRequest

Stop EngineOverride



EUI

Crankcase Pressure

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Crankcase Pressure

Series 149 CCM Series 4000 CCPS Series 60 CCM

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EEPROM

+-Battery


Oil / Fuel Pressure



Pressure Governor

Coolant Level

Timing Reference

Synch Reference

VSG Control


Progressive Shift

DiagnosticRequest

Stop EngineOverride


Oil level/Fuel RestrictionCrankcase Pressure

EUI

CheckEngine

StopEngine

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Stop Engine / Check Engine Lights

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EEPROM

+-Battery

StopEngine

CheckEngine


Oil / Fuel Pressure



Pressure Governor

Coolant Level

Timing Reference

Synch Reference

VSG Control


Progressive Shift

DiagnosticRequest

Stop EngineOverride



EUI

PWM Ports

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Pulse Width Modulated Outputs

• 50 Hz duty cycle modulated• Four ports available-- circuits 908, 909, 910, 911• Factory programmed only

1 Hz

50%20%

1 Hz

80%

1 HzSignal LowSignal High

• Signals sent by the ECM to other microprocessor controlled systems

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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

25ST0072-2 Rev. 04/4/00 92



EEPROM

+-Battery

StopEngine

CheckEngine


Oil / Fuel Pressure



Pressure Governor

Coolant Level

Timing Reference

Synch Reference

VSG Control

PWM Ports


Progressive Shift

DiagnosticRequest

Stop EngineOverride



EUI

DDR Interface/ DDDL/ Reprogramming

25ST0072-2 Rev. 04/4/00 93

DDR Interface with MPSI Printer

SAE Standards

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SAE Standards

•MIDs

•PIDs

•FMIs

•SIDs

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SAE Code Format

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

Example

PID 100 FMI 0 - Parameter High 1 - Parameter Low3 - Circuit High (HI VOLT)4 - Circuit Low (LO VOLT)Oil Pressure

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Detroit Diesel Diagnostic Link

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DDDL Information

• New PC based DDEC service tool– Release 1.X

» Windows 3.1» PC-486, 33 MHz, 8MB RAM» Support Features up to DDEC III, R5.0

– Release 2.X» Windows 95 (98 2.11)» PC-486, 66MHz, 16MB RAM» Supports all DDEC Systems» Support Data Extractions & Trip Reporting Features

– Release 3.X» Windows 95/98» VGA color monitor» PC-486, 66MHz, 16MB RAM» Supports all DDEC Systems» Support Data Extractions & Trip Reporting Features

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DDR Communication- On Highway

DDEC III/ IV6-Pin

DDEC II or III12-Pin

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DDR Communication- On Highway

DDEC IV

9 Pin

DDEC II / III / IV Reprogramming

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Reprogramming Station

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Software

• Software is programmable• Numbered like computer software

– Major version changes number before dot ( X.00 )– Minor version changes number after dot ( 9.XX )

• DDEC III software will be 19.XX or lower– Current DDEC III software is 9.00

• DDEC IV software will be 20.00 or higher– Current DDEC IV software is 28.00

• Software level can ONLY go UP, it can NEVER go back down

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Reprogramming StationWindows Based for Download

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EEPROM

+-Battery

StopEngineCheck

Engine


Oil / Fuel Pressure



Pressure Governor

Coolant Level

Timing Reference

Synch Reference

VSG Control

PWM Ports


Progressive Shift

DiagnosticRequest

Stop EngineOverride



EUI

DDR Interface/ DDDL/ ReprogrammingCommunication

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Communication

• J1587– 9600 Baud Rate, used to transmit sensor and engine data

(electronic dash display, vehicle management systems and electronic transmissions). MPSI readers, DDDL

• J1922– 9600 Baud Rate, controls Transmissions, braking

systems and retarders • J1939

– 250k Baud Rate, controls Transmissions, braking systems and retarders also used as the property data link in multi ECM engines

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EEPROM

+-Battery

StopEngineCheck

Engine


Oil / Fuel Pressure



Pressure Governor

Coolant Level

Timing Reference

Synch Reference

VSG Control

PWM Ports


Progressive Shift

DiagnosticRequest

Stop EngineOverride


Idle Shut Down/Vehicle Power Down


EUI


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Idle Shut Down (ISD)/ Vehicle Power Shutdown

• Idle Shut Down (ISD): Turns engine off after programmed idle time has elapsed (optional “override” disables idle timer if the engine speed is increased by 100 during last 90 seconds of ISD sequence. The check engine light (CEL) will flash during this 90 seconds.

• Vehicle Power Shutdown relay (optional/OEM) turns off electrical power to the vehicle as well as stopping the engine

2 - 100 Minutes

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Vehicle Power Shutdown

To Vehicle

Ignition OnIdle ShutdownIgnition switch

ECM

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EEPROM

+-Battery

StopEngineCheck

Engine


Oil / Fuel Pressure



Pressure Governor

Coolant Level

Timing Reference

Synch Reference

VSG Control

PWM Ports


Progressive Shift

DiagnosticRequest

Stop EngineOverride




EUI


Engine Brake

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DDEC III/IVEngine Brakes

• DDEC III/IV controls engine brake operation• If configured for “cruise control engine brake”

the ECM will automatically turn on the brake if the set speed is exceeded.

• Two digital inputs and two ‘positive’ outputs are used to control the brake.

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Engine Brakes• Must be at least 150 rpm above idle speed

Clutch Released input must be ON/GNDECM must see 0% throttle

Range Example• Cruise Engine Brake Yes/No Yes

Engine Brake MPH 1-10 3 Engine Brake Increment 0-4 2

• Engine Brake/Service Brake Yes/No Yes• Engine Brake Min MPH 0-VSL 35

DDEC Engine Brakes

ECM

S3

T3

#953 (Battery Negative)

Brake Off LO On

Low

Med.

Low

Med.

MEDHIGH

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EEPROM

+-Battery

StopEngineCheck

Engine


Oil / Fuel Pressure



Pressure Governor

Coolant Level

Timing Reference

Synch Reference

VSG Control

PWM Ports


Progressive Shift

DiagnosticRequest

Stop EngineOverride




EUI


Engine BrakeFan Controls

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Fan Control

• Four fan configurations can be used– Single fan– Dual fans– Two speed fan– Variable speed fan (PWM) # 4 Hydraulically

Operated (Bus)• Fan controlled by digital output(s)• “Fan override” & “air conditioning active” digital

inputs can force the fan on • Series 4000 uses (PWM) #2 To Operate a Rockford Fan

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Fan Control

• Conditions which activate the fan;– High Oil, Coolant, or Air Temp– Circuit fault codes (HI VOLT, LO VOLT) on any of

these three sensors– AC input– Fan Override input– Dynamic Braking (Fan is Activated During Engine

Overspeed to Help Slow The Vehicle)

DDEC Fan Controls

ECM

Temp sensorInputs

Air Supply

Ign. +

Output“off”

Fan “on”

Optional Fan # 2

#953 (-)

Fan Override (Input Off)

Aux. Fan Control (Input On) Air Conditioning - off

Temp sensorInputs

High Temperatures Turn Fan OnNormal Temperatures Allow Fan Off

Output“on”

Fan “off”

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

Output“off”

“on”

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EEPROM

+-Battery

StopEngine

CheckEngine


Oil / Fuel Pressure



Pressure Governor

Coolant Level

Timing Reference

Synch Reference

VSG Control

PWM Ports


Progressive Shift

DiagnosticRequest

Stop EngineOverride



EUI


ISD / VehiclePower Down

Engine Brake

Fan ControlsOptimized Idle

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Optimized Idle

• Automatic Starting and Stopping of the Engine• Maintains Engine Temperature and / or Battery

Voltage• Optional Sleeper Thermostat• Truck Skin Temperature Sensor is used for

continuous run• Saves Fuel by Running the Engine Only When

Needed• Warm Engines Start Much Easier With Less Exhaust

Emissions

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Requirements for Optimized Idle Cruise Enable Switch Idle Shutdown Enabled Vehicle Power Down

Relay Op Idle light on dash Park Brake Switch Transmission Neutral

Switch (Some transmissions require high range in Neutral)

Hood SwitchUnder-hood AlarmStart RelayOverlay RelayVSS EnabledOptional Sleeper Thermostat

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Optimized Idle Shutdown Sequence Park Brake set with hood closed and transmission in Neutral

supplies ground to the Park Brake input and the Overlay Relay. Idle Timer starts and the Overlay Relay closes supplying power to the Start Relay.

Optimized Idle is activated by turning on the Cruise Enable Switch which supplies ground on the Cruise Enable input.

Optimized Idle Light flashes until the engine shuts down then remains on.

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Optimized Idle Shutdown Sequence With Battery Voltage above 12.2V, Oil Temp between

15ºC/60ºF and 40ºC/104F, and Sleeper Temp within limits, the Idle Timer shuts the engine down.

Vehicle Power Down Relay opens powering down the vehicle Ignition Circuit.

With Ignition key on, the ECM is still awake and it continuously monitors Battery Voltage, Oil Temperature and Sleeper Temperature.

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Optimized Idle Start Sequence • With the hood closed, Transmission in Neutral, Park Brake set, and the Optimized Idle dash light ON,the ECM supplies ground on PWM #2, wire 909 which activates the under-hood alarm. • ECM then supplies ground on PWM #3, wire 910

which closes the Start Relay. • After the engine starts, the ECM supplies ground to the Vehicle Power Down relay which closes to

supply Ignition power to the vehicle

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EEPROM

+-Battery

Engine Brake

StopEngineCheck

Engine

Cruise ControlVehicle Speed LimitingVehicle Speed Sensor

Oil / Fuel Pressure



Pressure Governor

Coolant Level

Timing Reference

Synch Reference

Fan Controls

VSG Control

PWM Ports


Progressive Shift

DiagnosticRequest

Stop EngineOverride

ISD / VehiclePower Down


CommunicationDDR Interface/ DDDL/ Reprogramming

Optimized IdleEUI


Digital Inputs

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Digital Input Functions

• External switch requests function from the ECM• 31 options to choose from• 12 pins available on the 30 pin vehicle harness

connector for input functions • Functions are assignable to any of these pins

through the use of a “Reprogramming Station”

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DIGITAL INPUTS

Battery

_+

#953

Cruise EnableFan Override

#150

No FunctionNo FunctionNo Function

ECM

EEPROM

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Digital Inputs

• Air Compressor Controls– Air Compressor Load Switch

• Cruise Control (Uses Up to Five Inputs)– Cruise Enable– Clutch Released– Service Brake Released– Set/Coast On (Decrease)– Resume/Acceleration On

(Increase)• Engine Brake

– Engine Brake Disable– Engine Brake Low– Engine Brake Medium

• Engine Protection– Auxiliary Input Protection #1– Auxiliary Input Protection #2– Diagnostic Request Switch– SEO/Diagnostic Request Switch

• Engine Ratings– Limiting Torque Curve– Rating Switch #1– Rating Switch #2

• Fan Control– Transmission Retarder Status

(Release 2.00 or Later only)– Air Conditioner Status– Fan Control Override

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Digital Inputs (Cont’d)

• Throttle Control– Alternate Minimum VSG/Fast

Idle (Release 2.00 or Later Only)

– Dual Throttle (LSG)– Idle Validation Switch– Throttle Inhibit– VSG Station Change– VSG Station Complement

• Pressure Governor System (PGS) (Uses Five Inputs)– Pressure Governor System

Enable– Pressure/RPM Mode Switch– Set/Coast On (Decrease)– Resume/Acceleration On

(Increase)

• Additional Functions– Auxiliary Coolant Level

Sensor– Parking Brake Interlock

Digital Outputs

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Digital Output Functions

• ECM commands (internal switches/grounds) action of some external device- fan control

• 22 output options• 6 pins available, 3 on the 30 pin vehicle connector, 3

on the 30 pin engine harness connector (auxiliary outputs)

• Configurable with the distributor or dealer reprogramming station

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OUTPUTS

ECM

SEL

To Jake brake

Ignition#439

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Digital Outputs

• Coolant Level Low Light• Cruise Control Active Light (PGS

Active Light)• Deceleration Light• Engine Brake Active• Fan Control #1• Fan Control #2• Low DDEC Voltage• Pressure Governor System

Pressure Mode Light• Starter Lockout• Transmission Retarder• Vehicle Power Shutdown

• VSG Active Indication• (Release 2.00 or Later only)

– Low Oil Pressure Light– High Oil Temperature Light– High Coolant Temp. Light

• (Release 3.00 or Later Only)– Ether Injection– Low Coolant Pressure Light– High Crankcase Pressure Light

• (Release 4.00 or Later Only)– Optimized Idle Active light

• Gas Solenoid Shutdown• Air Compressor Load Switch

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• Encourages better driving habits by rewarding good fuel economy with extra road speed

• If driver exceeds the target fuel economy extra road speed will automatically be added to his maximum vehicle speed

Fuel Economy Incentive

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Fuel Economy Incentive

Parameter Range ExampleMin MPG 5-10 mpg 7.0Max MPH 0-10 mph 4Scaler MPH/MPG 0.1-20 mph/mpg 10.0Calc Type Filtered/Trip Trip

If Scaler is set at:20.0 = 1 extra mph for every .05 mpg above target mpg 10.0 = 1 extra mph for every .1 mpg above target mpg 5.0 = 1 extra mph for every .2 mpg above target mpg 2.0 = 1 extra mph for every .5 mpg above target mpg 1.0 = 1 extra mph for every 1.0 mpg above target mpg

If Calc Type is set at:Filtered - Calculates using Total Engine DataTrip - Calculates using Trip Data

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PasSmart• Electronically Controlled Increased Passing Speed

– PasSmart is an electronic feature that enables a fleet manager to enable a second Vehicle Speed Limit (VSL) to assist drivers during passing.

– This second Vehicle Speed Limit (VSL) is programmed for a limited duration during a given period This feature is available with DDEC IV Software version R28.00.

– As and example: If the fleet policy is 65 Miles Per Hour (MPH) the fleet manager can increase the Vehicle Speed Limit (VSL) an additional 5-20 MPH for 1- 255 minutes per day.

Maintenance Alert System

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Maintenance Alert Sensors System

• Designed to Provide Preventative Maintenance Information to Mechanics and Operators

• Reduces Unexpected Downtime

• Optimizes Normal Routine Service

• Used on Highway Trucks only at this time

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• Overview– Based on Inputs from Customers, the Maintenance Alert

System Provides Preventative Maintenance Information to Mechanics and Drivers to Reduce Unexpected Downtime and to Assist Normal Routine Service Scheduling

• Features– Uses DDEC IV ECM– New DDEC Software Processes Information– Incorporates Four New Sensors (Both On and Off Engine)– Optional Remote Mounted Monitor Display Unit Available

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Oil Level Sensor Air Filter Restriction Sensor 2nd Coolant Level Sensor

Fuel Restriction Sensor Monitor Display Unit

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DDC Installed Components

• Includes Two Maintenance Alert System Sensors– Oil Level Sensor (Requires Front Sump Non-metal Oil

Pan) Will not work on Rear Sump Applications

– Fuel Restriction Sensor

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• Oil Level Sensor– Mounts in Front Sump Non-

metal Oil Pan– Utilizes Optical Technology to

"See" Oil Level– Engine Must Be Off (Zero

RPM ) for "X" Minutes (Based on Oil Temp.) to Drain Oil Back to the Pan

– Switches at Four Quart Low Level

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• Fuel Restriction Sensor– Measures Fuel System

Restriction at Fuel Pump Inlet– Sensor Measures Actual Inlet

Restriction

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Optional OEM Installed Components

• OEMs Install These Components if Ordered by Customer (Any Combination but Must Include On Engine Components)– 2nd Coolant Level Sensor – Air Filter Restriction Sensor – Monitor Display Unit

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OEM Installed Components• 2nd Coolant Level Sensor (CLS)

– Separate Sensor from Current Primary CLS

– Mounted in Coolant Surge Tank Above Primary CLS

– Requires Interface Module– OEM Impact

» Order Engine Mounted Sensors» Purchase CLS Sensor and Module

from PDC» Mount Sensor in Surge Tank» Mount Interface Module» Provide Wiring Between the

Sensor/Module/Engine Harness» Use VEPS( Vehicle Engine Program

Station) to "Turn On” OEM Only

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OEM Installed Components

• Air Filter Restriction Sensor– Electronic Version of the

Mechanical Filter Minder®– Switch Points at 15 and 20

Inches of Water– OEM Impact

» Order Engine Mounted Sensors» Purchase Sensor from

Engineered Products or PDC» Install into Turbo Inlet Tube» Provide Wiring from Sensor to

Engine Harness Pigtail» Use VEPS to "Turn On"

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OEM Installed Components

• Monitor Display Unit– 2 Buttons and 8 LEDs (Green, Red, &

Yellow)– Mounted in Cab– Reads Engine J1587 Data Link for

Information– Can Access Maintenance Information

with Ignition On or Up to 2 Hours After Ignition Off

– Stores Status after 2 Hours for Later Display

– OEM Impact» Order Engine Mounted Sensors» Purchase Display from PDC» Design and Install Display Bracket» Provide Wiring to Display

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Service Tools

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

and higher

– Sensor Alerts Due to Failed Sensors– Quick Access Screen to Show Maintenance Alert System

Alerts» Clear Maintenance Alert System (MAS) Filter Alerts

– Maintenance Alert System sensors added to Data List– Warning Light Option Programming

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Summary

Engine

Vehicle

• Monitors and Displays Service Requirements– Oil Level– Fuel System Restriction – Air Filter Restriction– 2nd Coolant Level– Monitor Display Unit - in Cab– DDR and DDDL

• Engine Only or Engine and Any Vehicle Sensors• Oil Level Requires Front Sump Plastic Plan• Display is Optional

Construction & Industrial

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Construction & Industrial

• Electronic Display Module (EDM) • Auxiliary Interface Module (AIM)• Air Comp Controls• Fuel Pressure Sensor (Low HP)• Nylon Vs. Plastic Harness• Multiple ECM• Optimized Idle• Switch Power• J1939

Wire Crimping Exercise

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Wire Crimping Tools

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Wire Crimping Tools

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Wire Crimping Tools

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Wire Crimping Tools

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Wire Crimping

Wire Splicing

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Wire Splicing Tools

Series 71 & 92 SRS / TRS Adjustment

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Series 71/92 SRS/TRS Adjustment

Basic Electricity -Wire Harness Exercise

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Sensor Operations

Operates on 5 Volts for All D.C. Sensors

.25 4.75

NormalOperating

Range

Low Voltage

0 5

High Voltage

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Sensor Wiring

• Common Return Circuit. #452

• Thermistor

• Piezoresistive Pressure sensor

• Voltage is Proportional to Pressure

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2-wire Sensors

5V Supply

Signal

Return

ECM SensorOpen = HI VOLTAGEShort = LO VOLTAGE

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3-wire Sensors

ECM Sensor5V Supply

Signal

Return

Open Supply = LOW VOLTAGEOpen Signal = LOW VOLTAGEOpen Return = HI VOLTAGESupply short to Signal = HI VOLTAGESupply short to Return = LOW VOLTAGESignal short to Return = LOW VOLTAGE

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Electrical System

452

Definitions• Open Circuit

– An “open” describes a complete break in the path of current at some point in the circuit. The result of an “open” is that one or more loads in the circuit do not work.

OpenHigh voltage

code

120

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Electrical System452432416

Cavity ACavity BCavity C

Definitions• Open Circuit

– An “open” describes a complete break in the path of current at some point in the circuit. The result of an “open” is that one or more loads in the circuit do not work.

OpenLow voltage code

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Electrical System

432416


Definitions• Short Circuit

– A “short” occurs when a load in the circuit is accidentally bypassed. Electricity will always take the path of least resistance. The result of a “short” is that higher current flows, causing excessive heat or action from a device protecting the circuit (blown fuse or activated circuit breaker).

Short High Voltage Code

452

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Electrical System452432416


Definitions• Grounded Circuit

– A “ground” is similar to a “short” because current accidentally bypasses a load in the circuit. The difference is that the bypass connects directly to the negative terminal of the power source by way of the chassis ground path.

Ground Low Voltage Code

Troubleshooting Tools

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Volt-Ohm Meter

To properly probe terminals use Kentmoore jumper wire kit number J39197. Within this kit the proper leads are provided.

The use of the lead ends of the volt ohm meter to probe the terminal ends will damage the DDEC connectors and will cause intermittent codes.

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Sensor TesterJ37164-A

Breakout Box (30 Pin)J35634

DDEC III/IV InterfaceJ41005

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• 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

ddec master 2000 current4 6

Education