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Ddec master 2000 current4 6

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Ddec master 2000 current4 6

  1. 1. Detroit Diesel Electronic Controls DDEC DDEC DDEC DDEC DDEC IVIII
  2. 2. 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
  3. 3. 25ST0072-2 Rev. 04/4/00 4 DDEC History • DDEC I Introduced in 1985 on 92 Series • Series 60 Introduced in 1987 As the First Engine Ever Designed Exclusively for Electronic Controls • DDEC II Introduced in 1987 • DDEC III Introduced April, 1993 • DDEC III Full Production January, 1994 • DDEC IV Initial Release, August, 1997 • DDEC IV Full Production, January, 1998
  4. 4. 25ST0072-2 Rev. 04/4/00 5 What is DDEC? An advanced electronic fuel injection control system that can be integrated into many applications DDEC Consists of: • Sensors and switches • Conductors and connections • ECM (computer) – Hardware – Software • Injectors
  5. 5. 25ST0072-2 Rev. 04/4/00 7 Electronic Engine Advantages • Engine Protection • Engine Diagnostics • Reduced Maintenance • Improved Engine Governing • Fuel Economy Optimization • Enhanced Cold Starting • Smoke Control • Reduced Emission Levels
  6. 6. 25ST0072-2 Rev. 04/4/00 9 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
  7. 7. 25ST0072-2 Rev. 04/4/00 10 DDEC Necessities Ignition Electronic Control Module (ECM) EEPROM +- Battery Timing Reference Synch Reference EUI
  8. 8. 25ST0072-2 Rev. 04/4/00 11 Schematic Diagram DDEC III/ IV Electronic Control Module (ECM) EEPROM
  9. 9. 25ST0072-2 Rev. 04/4/00 12 Electronic Control Module
  10. 10. 25ST0072-2 Rev. 04/4/00 13 Electronic Control Module DDC responsibility Engine sensors, harness, & connectors Injector harness & connectors Injectors OEM responsibility Mandatory circuits Power and Ground J1922,J1939, Ignition Throttle position sensor Optional circuits Manual fan on switch, Jake Brake, 439 Ignition wire
  11. 11. 25ST0072-2 Rev. 04/4/00 14 Schematic Diagram DDEC III / IV Electronic Control Module (ECM) EEPROM +- Battery
  12. 12. 25ST0072-2 Rev. 04/4/00 15 Power Supply • DDEC II - 12 Volt • DDEC III - 12/24 Volt • DDEC IV- 12 or 24 Volt • Source must be Isolated from any other Vehicle Accessory • The ECM Power Source must be Fused with the Proper Amp • The ECM Must Be Incorporated with a 5 Amp Fuse on the 440 wire going into the 439 wire. • The ECM Case Must be Electrically Isolated from any Chassis Ground
  13. 13. 25ST0072-2 Rev. 04/4/00 16 Power Supply DDEC III/ IV
  14. 14. 25ST0072-2 Rev. 04/4/00 17 Power Supply DDEC III / IV
  15. 15. 25ST0072-2 Rev. 04/4/00 18 Schematic Diagram DDEC III / IV Electronic Control Module (ECM) EEPROM +- Battery EUI
  16. 16. 25ST0072-2 Rev. 04/4/00 19 Electronic Unit Injectors Series 71/92 EUI Series 149 EUI Series 50/60 EUI Series 4000 Spray Nozzle Series 2000 EUP Series 53 EUI
  17. 17. Series 50/60 Injector Animation Fuel out Fuel in Voltage in Solenoid Plunger Poppet Valve Needle Valve Rocker Arm Cam
  18. 18. Series 4000 Nozzle AnimationCAM Rocker ArmSolenoid filter Fuel Return High Pressure Fuel Needle Valve Nozzle
  19. 19. Series 2000 EUP Animation CAM Rocker Arm Solenoid EUP Cam Spay Nozzle Fuel In
  20. 20. 25ST0072-2 Rev. 04/4/00 23 Electronic Unit Pump
  21. 21. 25ST0072-2 Rev. 04/4/00 24 Top Of Stroke Injector Tip Fuel In Fuel Out
  22. 22. 25ST0072-2 Rev. 04/4/00 25 Start Of Injection Injector Tip Fuel In Fuel Out
  23. 23. 25ST0072-2 Rev. 04/4/00 26 End Of Injection Injector Tip Fuel In Fuel Out
  24. 24. 25ST0072-2 Rev. 04/4/00 27 Injection Sequence Injector Tip Fuel In Fuel Out Injector Tip Fuel In Fuel Out Injector Tip Fuel In Fuel Out
  25. 25. 25ST0072-2 Rev. 04/4/00 28 Injector Calibration Codes • DDEC II No Calibration Codes • DDEC III/ IV Calibration Codes From 00-99 Calibration Code Part Number
  26. 26. 25ST0072-2 Rev. 04/4/00 29 Injector Cycle Terminology IRT Injector Response Time - Length of Time (ms) required to close the Control Valve PW Pulse Width - Degrees of Crankshaft Rotation when Fuel is Injected
  27. 27. 25ST0072-2 Rev. 04/4/00 30 Injector Response Times
  28. 28. 25ST0072-2 Rev. 04/4/00 31 Cylinder Cut-Out
  29. 29. 25ST0072-2 Rev. 04/4/00 32 Injection Cycle BOE BOI EOE EOI IRT Time PW (Inflection Point) BAT Voltage 0V V_REG, 5V Current0A Closed Open Control Valve Lift Injection Rate
  30. 30. 25ST0072-2 Rev. 04/4/00 34 Sensor Operations Operates on 5 Volts for All D.C. Sensors .25 4.75 Normal Operating Range Low Voltage 0 5 High Voltage
  31. 31. 25ST0072-2 Rev. 04/4/00 35 Sensor Wiring • Common Return Circuit. #452 • Thermistor • Piezoresistive Pressure sensor • Voltage is Proportional to Pressure
  32. 32. 25ST0072-2 Rev. 04/4/00 36 2-wire Sensors 5V Supply Signal Return ECM Sensor Open = HI VOLTAGE Short = LO VOLTAGE
  33. 33. 25ST0072-2 Rev. 04/4/00 37 3-wire Sensors ECM Sensor 5V Supply Signal Return Open Supply = LO VOLTAGE Open Signal = LO VOLTAGE Open Return = HI VOLTAGE HI VOLTAGESupply short to Signal = Supply short to Return = LO VOLTAGE Signal short to Return = LO VOLTAGE
  34. 34. 25ST0072-2 Rev. 04/4/00 38 SRS/TRS Sensors • SRS/TRS: Magnetic pickup sensors generate alternating current (A.C.). The frequency will change dependent on the speed of the pulse wheel (RPM of engine).
  35. 35. 25ST0072-2 Rev. 04/4/00 39 Electronic Control Module (ECM) EEPROM +- Battery Timing Reference Synch Reference Schematic Diagram DDEC III / IV EUI
  36. 36. 25ST0072-2 Rev. 04/4/00 41 Series 50/60 SRS/TRS Sensors SRS/TRS Timing Wheel DDEC III/ IV Bull Gear DDEC III/ IV
  37. 37. Series 60 Sensor Locations
  38. 38. 25ST0072-2 Rev. 04/4/00 43 Series 2000 SRS/TRS Sensors SRS/TRS Cam Gear/SRS TIMING WHEEL TIMING WHEEL
  39. 39. Series 2000 Sensor Locations
  40. 40. 25ST0072-2 Rev. 04/4/00 45 Series 4000 SRS/TRS Sensors SRS/TRS Cam Gear/SRS Timing Wheels
  41. 41. Series 4000 Sensor Locations
  42. 42. 25ST0072-2 Rev. 04/4/00 47 Two Cycle SRS/TRS with Timing Wheel SRS/TRS Sensor Series 71 Series 92 / 6V, 8V, 12V-71 SRS/TRS Sensor Timing Wheel & Cam Pulley Timing Wheel & Cam Pulley
  43. 43. 25ST0072-2 Rev. 04/4/00 48 Two Cycle SRS/TRS with Timing Wheel SRS/TRS Sensors Timing Wheels Timing Wheels Series 92, 12V, 16V SRS/TRS Sensors Series 149
  44. 44. 25ST0072-2 Rev. 04/4/00 49 Series 53 SRS/TRS with Timing Wheel SRS/TRS Sensors Timing Wheel SRS PIN
  45. 45. 25ST0072-2 Rev. 04/4/00 50 Schematic Diagram DDEC IV Electronic Control Module (ECM) EEPROM Timing Reference Synch Reference Electronic Foot Pedal Assembly EUI +- Battery
  46. 46. 25ST0072-2 Rev. 04/4/00 51 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
  47. 47. 25ST0072-2 Rev. 04/4/00 53 Schematic Diagram DDEC IV Electronic Control Module (ECM) EEPROM Turbo Boost Pressure Timing Reference Synch Reference Electronic Foot Pedal Assembly EUI +- Battery
  48. 48. 25ST0072-2 Rev. 04/4/00 54 Turbo Boost Sensor DDEC III Series 50/60/2-Cycle Series 2000 / 4000 Series 50/60 DDEC IV Series 53
  49. 49. 25ST0072-2 Rev. 04/4/00 55 Schematic Diagram DDEC III / IV Electronic Control Module (ECM) EEPROM +- Battery Fuel / Oil / Coolant/ Air Temperature Turbo Boost Pressure Timing Reference Synch Reference Electronic Foot Pedal Assembly EUI
  50. 50. 25ST0072-2 Rev. 04/4/00 56 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
  51. 51. 25ST0072-2 Rev. 04/4/00 58 Schematic Diagram DDEC III / IV Electronic Control Module (ECM) EEPROM +- Battery Fuel / Oil / Coolant Temperature Turbo Boost Pressure Timing Reference Synch Reference Electronic Foot Pedal Assembly Oil / Fuel Pressure EUI
  52. 52. 25ST0072-2 Rev. 04/4/00 59 Pressure Sensors Series 50/60/2-Cycle Series 2000/4000 Series 2000/4000 Different Harness Connectors Coolant Pressure Oil / Fuel Pressure Series 4000 High Pressure Fuel
  53. 53. 25ST0072-2 Rev. 04/4/00 60 Schematic Diagram DDEC III / IV Electronic Control Module (ECM) EEPROM +- Battery Oil / Fuel Pressure Fuel / Oil / Coolant Temperature Turbo Boost Pressure Timing Reference Synch Reference Electronic Foot Pedal Assembly Oil level/Fuel Restriction EUI
  54. 54. 25ST0072-2 Rev. 04/4/00 61 On Engine Components • Oil Level Sensor – Mounts in Front Sump Non- metal Oil Pan – Utilizes Optical Technology to "See" Oil Level – Engine Must Be Off (Zero RPM ) for "X" Minutes (Based on Oil Temp.) to Drain Oil Back to the Pan – Switches at Four Quart Low Level – OEM Impact » Order Maintenance Alert System on the Engine
  55. 55. 25ST0072-2 Rev. 04/4/00 62 On Engine Components • Fuel Restriction Sensor – Measures Fuel System Restriction at Fuel Pump Inlet – Sensor Measures Actual Inlet Restriction – OEM Impact » Order Maintenance Alert System on the Engine
  56. 56. 25ST0072-2 Rev. 04/4/00 63 Schematic Diagram DDEC III / IV Electronic Control Module (ECM) EEPROM +- Battery Oil / Fuel Pressure Fuel / Oil / Coolant Temperature Turbo Boost Pressure Coolant Level Timing Reference Synch Reference Electronic Foot Pedal Assembly Oil level/Fuel Restriction EUI
  57. 57. 25ST0072-2 Rev. 04/4/00 64 Coolant Level Sensor DDEC III or IV Coolant Level Sensor DDEC II/ III Coolant Level Sensor
  58. 58. 25ST0072-2 Rev. 04/4/00 65 Schematic Diagram DDEC III / IV Electronic Control Module (ECM) EEPROM +- Battery Oil / Fuel Pressure Fuel / Oil / Coolant Temperature Turbo Boost Pressure Coolant Level Timing Reference Synch Reference VSG Control Electronic Foot Pedal Assembly Oil level/Fuel Restriction EUI
  59. 59. 25ST0072-2 Rev. 04/4/00 66 VSG Control • Variable Speed Governor – Throttle Position Controls RPM • Droop – Difference in RPM Between Full Load (Rated Speed) and Maximum Engine RPM (No Load) – Allows the engine to overrun the rated or governed engine speed.
  60. 60. 25ST0072-2 Rev. 04/4/00 67 Schematic Diagram DDEC III / IV Electronic Control Module (ECM) EEPROM +- Battery Oil / Fuel Pressure Fuel / Oil / Coolant Temperature Turbo Boost Pressure Coolant Level Timing Reference Synch Reference VSG Control Electronic Foot Pedal Assembly Progressive Shift Oil level/Fuel Restriction EUI
  61. 61. 25ST0072-2 Rev. 04/4/00 68 Progressive Shift • Use Spec Manager to determine values to program for Progressive Shift • Example Low Gear #1 off 12 Max MPH 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
  62. 62. 25ST0072-2 Rev. 04/4/00 69 Progressive Shift
  63. 63. 25ST0072-2 Rev. 04/4/00 70 Schematic Diagram DDEC III / IV Electronic Control Module (ECM) EEPROM +- Battery Oil / Fuel Pressure Fuel / Oil / Coolant Temperature Turbo Boost Pressure Coolant Level Timing Reference Synch Reference VSG Control Electronic Foot Pedal Assembly Progressive Shift Pressure Governor Oil level/Fuel Restriction EUI
  64. 64. 25ST0072-2 Rev. 04/4/00 71 Pressure Governor Mastermind Fire Commander High Pressure Sensor •Fire Commander and Mastermind use the same digital inputs and outputs as cruise control
  65. 65. 25ST0072-2 Rev. 04/4/00 74 Electronic Fire Commander Engine Data System Status Message Window Control Buttons
  66. 66. 25ST0072-2 Rev. 04/4/00 75 Schematic Diagram DDEC III / IV Electronic Control Module (ECM) EEPROM +- Battery Oil / Fuel Pressure Fuel / Oil / Coolant Temperature Turbo Boost Pressure Coolant Level Timing Reference Synch Reference VSG Control Electronic Foot Pedal Assembly Progressive Shift Pressure Governor Diagnostic Request Stop Engine Override Oil level/Fuel Restriction EUI
  67. 67. 25ST0072-2 Rev. 04/4/00 76 Diagnostic Request or Stop Engine Override
  68. 68. 25ST0072-2 Rev. 04/4/00 78 Engine Protection • Warning- Illumination of CEL,SEL only • Rampdown- Immediate reduction to 70% power, ramping down to 40% over 30 seconds and maintains 40% power. • Shutdown- Same as rampdown except engine is shutdown at the end of 30 seconds.
  69. 69. 25ST0072-2 Rev. 04/4/00 79 Schematic Diagram DDEC III / IV Electronic Control Module (ECM) EEPROM +- Battery Oil / Fuel Pressure Fuel / Oil / Coolant Temperature Turbo Boost Pressure Pressure Governor Coolant Level Timing Reference Synch Reference VSG Control Electronic Foot Pedal Assembly Progressive Shift Diagnostic Request Stop Engine Override Engine Rating / Cruise Power / Switch Power Oil level/Fuel Restriction EUI
  70. 70. 25ST0072-2 Rev. 04/4/00 80 Multiple Horsepower Ratings • Three Independent Ratings • One Dependent Cruise Power Rating • Switch Power Options (C&I) – Max. Power for Fully Loaded Engine – Min. Power for a Lightly Loaded Engine
  71. 71. 25ST0072-2 Rev. 04/4/00 81 Schematic Diagram DDEC III / IV Electronic Control Module (ECM) EEPROM +- Battery Cruise Control Vehicle Speed Limiting Vehicle Speed Sensor Oil / Fuel Pressure Fuel / Oil / Coolant Temperature Turbo Boost Pressure Pressure Governor Coolant Level Timing Reference Synch Reference VSG Control Electronic Foot Pedal Assembly Progressive Shift Diagnostic Request Stop Engine Override Engine Rating / Cruise Power / Switch Power Oil level/Fuel Restriction EUI
  72. 72. 25ST0072-2 Rev. 04/4/00 82 Cruise Control • Determined by vehicle speed (VSS) or engine speed (RPM) DDEC IV changed • Must be above 20 MPH or 1100 RPM to set • Cruise Power can provide higher HP while in cruise control by using the C. P. rating. • Uses up to 5 digital inputs and one digital output • VSG can be controlled by the cruise switch • Use cruise switches to set PTO high idle and lower high idle. You use a step up or step down & step up by pressing or toggling the resume switch.
  73. 73. 25ST0072-2 Rev. 04/4/00 83 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
  74. 74. 25ST0072-2 Rev. 04/4/00 84 Cruise Control
  75. 75. 25ST0072-2 Rev. 04/4/00 85 Schematic Diagram DDEC III / IV Electronic Control Module (ECM) EEPROM +- Battery Cruise Control Vehicle Speed Limiting Vehicle Speed Sensor Oil / Fuel Pressure Fuel / Oil / Coolant Temperature Turbo Boost Pressure Pressure Governor Coolant Level Timing Reference Synch Reference VSG Control Electronic Foot Pedal Assembly Progressive Shift Diagnostic Request Stop Engine Override Engine Rating / Cruise Power / Switch Power Oil level/Fuel Restriction EUI Crankcase Pressure
  76. 76. 25ST0072-2 Rev. 04/4/00 86 Crankcase Pressure Series 149 CCM Series 4000 CCPS Series 60 CCM
  77. 77. 25ST0072-2 Rev. 04/4/00 87 Schematic Diagram DDEC III / IV Electronic Control Module (ECM) EEPROM +- Battery Cruise Control Vehicle Speed Limiting Vehicle Speed Sensor Oil / Fuel Pressure Fuel / Oil / Coolant Temperature Turbo Boost Pressure Pressure Governor Coolant Level Timing Reference Synch Reference VSG Control Electronic Foot Pedal Assembly Progressive Shift Diagnostic Request Stop Engine Override Engine Rating / Cruise Power / Switch Power Oil level/Fuel Restriction Crankcase Pressure EUI Check Engine Stop Engine
  78. 78. 25ST0072-2 Rev. 04/4/00 88 Stop Engine / Check Engine Lights
  79. 79. 25ST0072-2 Rev. 04/4/00 89 Schematic Diagram DDEC III / IV Electronic Control Module (ECM) EEPROM +- Battery Stop Engine Check Engine Cruise Control Vehicle Speed Limiting Vehicle Speed Sensor Oil / Fuel Pressure Fuel / Oil / Coolant Temperature Turbo Boost Pressure Pressure Governor Coolant Level Timing Reference Synch Reference VSG Control Electronic Foot Pedal Assembly Progressive Shift Diagnostic Request Stop Engine Override Engine Rating / Cruise Power / Switch Power Oil level/Fuel Restriction Crankcase Pressure EUI PWM Ports
  80. 80. 25ST0072-2 Rev. 04/4/00 90 Pulse Width Modulated Outputs • 50 Hz duty cycle modulated • Four ports available-- circuits 908, 909, 910, 911 • Factory programmed only 1 Hz 50%20% 1 Hz 80% 1 Hz Signal Low Signal High • Signals sent by the ECM to other microprocessor controlled systems
  81. 81. 25ST0072-2 Rev. 04/4/00 91 PWM Circuit Wire No. Color • PWM #1 Output - VIH (Transmission) 908 White • PWM #2 Output - ESH (Throttle/GAS) 909 Lt. Green • PWM #3 Output - ESH (Gas Valve/GAS) 910 Orange • PWM #4 Output - ESH (Fan Control) 911 Pink • ESH = Engine Sensor Harness • VIH = Vehicle Sensor Harness
  82. 82. 25ST0072-2 Rev. 04/4/00 92 Schematic Diagram DDEC III / IV Electronic Control Module (ECM) EEPROM +- Battery Stop Engine Check Engine Cruise Control Vehicle Speed Limiting Vehicle Speed Sensor Oil / Fuel Pressure Fuel / Oil / Coolant Temperature Turbo Boost Pressure Pressure Governor Coolant Level Timing Reference Synch Reference VSG Control PWM Ports Electronic Foot Pedal Assembly Progressive Shift Diagnostic Request Stop Engine Override Engine Rating / Cruise Power / Switch Power Oil level/Fuel Restriction Crankcase Pressure EUI DDR Interface/ DDDL/ Reprogramming
  83. 83. 25ST0072-2 Rev. 04/4/00 93 DDR Interface with MPSI Printer
  84. 84. SAE Standards
  85. 85. 25ST0072-2 Rev. 04/4/00 95 SAE Standards •MIDs •PIDs •FMIs •SIDs
  86. 86. 25ST0072-2 Rev. 04/4/00 96 SAE Code Format • PID - Parameter Identifier (can be measured) • SID - System Identifier (cannot be measured) • FMI - Failure Mode Identifier Example PID 100 FMI 0 - Parameter High 1 - Parameter Low 3 - Circuit High (HI VOLT) 4 - Circuit Low (LO VOLT)Oil Pressure
  87. 87. 25ST0072-2 Rev. 04/4/00 97 Detroit Diesel Diagnostic Link
  88. 88. 25ST0072-2 Rev. 04/4/00 98 DDDL Information • New PC based DDEC service tool – Release 1.X » Windows 3.1 » PC-486, 33 MHz, 8MB RAM » Support Features up to DDEC III, R5.0 – Release 2.X » Windows 95 (98 2.11) » PC-486, 66MHz, 16MB RAM » Supports all DDEC Systems » Support Data Extractions & Trip Reporting Features – Release 3.X » Windows 95/98 » VGA color monitor » PC-486, 66MHz, 16MB RAM » Supports all DDEC Systems » Support Data Extractions & Trip Reporting Features
  89. 89. 25ST0072-2 Rev. 04/4/00 99 Detroit Diesel Diagnostic Link
  90. 90. 25ST0072-2 Rev. 04/4/00 100 Detroit Diesel Diagnostic Link
  91. 91. 25ST0072-2 Rev. 04/4/00 101 Detroit Diesel Diagnostic Link
  92. 92. 25ST0072-2 Rev. 04/4/00 102 DDR Communication- On Highway DDEC III/ IV 6-Pin DDEC II or III 12-Pin
  93. 93. 25ST0072-2 Rev. 04/4/00 103 DDR Communication- On Highway DDEC IV 9 Pin
  94. 94. DDEC II / III / IV Reprogramming
  95. 95. 25ST0072-2 Rev. 04/4/00 105 Reprogramming Station
  96. 96. 25ST0072-2 Rev. 04/4/00 106 Software • Software is programmable • Numbered like computer software – Major version changes number before dot ( X.00 ) – Minor version changes number after dot ( 9.XX ) • DDEC III software will be 19.XX or lower – Current DDEC III software is 9.00 • DDEC IV software will be 20.00 or higher – Current DDEC IV software is 28.00 • Software level can ONLY go UP, it can NEVER go back down
  97. 97. 25ST0072-2 Rev. 04/4/00 107 Reprogramming Station Windows Based for Download
  98. 98. 25ST0072-2 Rev. 04/4/00 108 Reprogramming Station Windows Based for Download
  99. 99. 25ST0072-2 Rev. 04/4/00 109 Reprogramming Station Windows Based for Download
  100. 100. 25ST0072-2 Rev. 04/4/00 112 Schematic Diagram DDEC III / IV Electronic Control Module (ECM) EEPROM +- Battery Stop Engine Check Engine Cruise Control Vehicle Speed Limiting Vehicle Speed Sensor Oil / Fuel Pressure Fuel / Oil / Coolant Temperature Turbo Boost Pressure Pressure Governor Coolant Level Timing Reference Synch Reference VSG Control PWM Ports Electronic Foot Pedal Assembly Progressive Shift Diagnostic Request Stop Engine Override Engine Rating / Cruise Power / Switch Power Oil level/Fuel Restriction Crankcase Pressure EUI DDR Interface/ DDDL/ Reprogramming Communication
  101. 101. 25ST0072-2 Rev. 04/4/00 113 Communication • J1587 – 9600 Baud Rate, used to transmit sensor and engine data (electronic dash display, vehicle management systems and electronic transmissions). MPSI readers, DDDL • J1922 – 9600 Baud Rate, controls Transmissions, braking systems and retarders • J1939 – 250k Baud Rate, controls Transmissions, braking systems and retarders also used as the property data link in multi ECM engines
  102. 102. 25ST0072-2 Rev. 04/4/00 114 Schematic Diagram DDEC III / IV Electronic Control Module (ECM) EEPROM +- Battery Stop Engine Check Engine Cruise Control Vehicle Speed Limiting Vehicle Speed Sensor Oil / Fuel Pressure Fuel / Oil / Coolant Temperature Turbo Boost Pressure Pressure Governor Coolant Level Timing Reference Synch Reference VSG Control PWM Ports Electronic Foot Pedal Assembly Progressive Shift Diagnostic Request Stop Engine Override Engine Rating / Cruise Power / Switch Power Idle Shut Down/Vehicle Power Down Oil level/Fuel Restriction Crankcase Pressure EUI DDR Interface/ DDDL/ Reprogramming Communication
  103. 103. 25ST0072-2 Rev. 04/4/00 115 Idle Shut Down (ISD)/ Vehicle Power Shutdown • Idle Shut Down (ISD): Turns engine off after programmed idle time has elapsed (optional “override” disables idle timer if the engine speed is increased by 100 during last 90 seconds of ISD sequence. The check engine light (CEL) will flash during this 90 seconds. • Vehicle Power Shutdown relay (optional/OEM) turns off electrical power to the vehicle as well as stopping the engine 2 - 100 Minutes
  104. 104. 25ST0072-2 Rev. 04/4/00 116 Vehicle Power Shutdown To Vehicle Ignition OnIdle Shutdown Ignition switch ECM
  105. 105. 25ST0072-2 Rev. 04/4/00 117 Schematic Diagram DDEC III / IV Electronic Control Module (ECM) EEPROM +- Battery Stop Engine Check Engine Cruise Control Vehicle Speed Limiting Vehicle Speed Sensor Oil / Fuel Pressure Fuel / Oil / Coolant Temperature Turbo Boost Pressure Pressure Governor Coolant Level Timing Reference Synch Reference VSG Control PWM Ports Electronic Foot Pedal Assembly Progressive Shift Diagnostic Request Stop Engine Override Engine Rating / Cruise Power / Switch Power Idle Shut Down/Vehicle Power Down Oil level/Fuel Restriction Crankcase Pressure EUI DDR Interface/ DDDL/ Reprogramming Communication Engine Brake
  106. 106. 25ST0072-2 Rev. 04/4/00 118 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.
  107. 107. 25ST0072-2 Rev. 04/4/00 120 Engine Brakes • Must be at least 150 rpm above idle speed Clutch Released input must be ON/GND ECM 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
  108. 108. DDEC Engine Brakes ECM S3 T3 #953 (Battery Negative) Brake Off LOOn Low Med. Low Med. MEDHIGH
  109. 109. 25ST0072-2 Rev. 04/4/00 122 Schematic Diagram DDEC III / IV Electronic Control Module (ECM) EEPROM +- Battery Stop Engine Check Engine Cruise Control Vehicle Speed Limiting Vehicle Speed Sensor Oil / Fuel Pressure Fuel / Oil / Coolant Temperature Turbo Boost Pressure Pressure Governor Coolant Level Timing Reference Synch Reference VSG Control PWM Ports Electronic Foot Pedal Assembly Progressive Shift Diagnostic Request Stop Engine Override Engine Rating / Cruise Power / Switch Power Idle Shut Down/Vehicle Power Down Oil level/Fuel Restriction Crankcase Pressure EUI DDR Interface/ DDDL/ Reprogramming Communication Engine Brake Fan Controls
  110. 110. 25ST0072-2 Rev. 04/4/00 123 Fan Control • Four fan configurations can be used – Single fan – Dual fans – Two speed fan – Variable speed fan (PWM) # 4 Hydraulically Operated (Bus) • Fan controlled by digital output(s) • “Fan override” & “air conditioning active” digital inputs can force the fan on • Series 4000 uses (PWM) #2 To Operate a Rockford Fan
  111. 111. 25ST0072-2 Rev. 04/4/00 124 Fan Control • Conditions which activate the fan; – High Oil, Coolant, or Air Temp – Circuit fault codes (HI VOLT, LO VOLT) on any of these three sensors – AC input – Fan Override input – Dynamic Braking (Fan is Activated During Engine Overspeed to Help Slow The Vehicle)
  112. 112. DDEC Fan Controls ECM Temp sensor Inputs Air Supply Ign. + Output “off” Fan “on” Optional Fan # 2 #953 (-) Fan Override (Input Off) Aux. Fan Control (Input On) Air Conditioning - off Temp sensor Inputs 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”
  113. 113. 25ST0072-2 Rev. 04/4/00 129 Schematic Diagram DDEC III / IV Electronic Control Module (ECM) EEPROM +- Battery Stop Engine Check Engine Cruise Control Vehicle Speed Limiting Vehicle Speed Sensor Oil / Fuel Pressure Fuel / Oil / Coolant Temperature Turbo Boost Pressure Pressure Governor Coolant Level Timing Reference Synch Reference VSG Control PWM Ports Electronic Foot Pedal Assembly Progressive Shift Diagnostic Request Stop Engine Override Engine Rating / Cruise Power / Switch Power Oil level/Fuel Restriction Crankcase Pressure EUI DDR Interface/ DDDL/ Reprogramming Communication ISD / Vehicle Power Down Engine Brake Fan Controls Optimized Idle
  114. 114. 25ST0072-2 Rev. 04/4/00 130 Optimized Idle • Automatic Starting and Stopping of the Engine • Maintains Engine Temperature and / or Battery Voltage • Optional Sleeper Thermostat • Truck Skin Temperature Sensor is used for continuous run • Saves Fuel by Running the Engine Only When Needed • Warm Engines Start Much Easier With Less Exhaust Emissions
  115. 115. 25ST0072-2 Rev. 04/4/00 131 Requirements for Optimized Idle  Cruise Enable Switch  Idle Shutdown Enabled  Vehicle Power Down Relay  Op Idle light on dash  Park Brake Switch  Transmission Neutral Switch (Some transmissions require high range in Neutral) Hood Switch Under-hood Alarm Start Relay Overlay Relay VSS Enabled Optional Sleeper Thermostat
  116. 116. 25ST0072-2 Rev. 04/4/00 132 Optimized Idle Shutdown Sequence  Park Brake set with hood closed and transmission in Neutral supplies ground to the Park Brake input and the Overlay Relay. Idle Timer starts and the Overlay Relay closes supplying power to the Start Relay.  Optimized Idle is activated by turning on the Cruise Enable Switch which supplies ground on the Cruise Enable input.  Optimized Idle Light flashes until the engine shuts down then remains on.
  117. 117. 25ST0072-2 Rev. 04/4/00 133 Optimized Idle Shutdown Sequence  With Battery Voltage above 12.2V, Oil Temp between 15ºC/60ºF and 40ºC/104F, and Sleeper Temp within limits, the Idle Timer shuts the engine down.  Vehicle Power Down Relay opens powering down the vehicle Ignition Circuit.  With Ignition key on, the ECM is still awake and it continuously monitors Battery Voltage, Oil Temperature and Sleeper Temperature.
  118. 118. 25ST0072-2 Rev. 04/4/00 134 Optimized Idle Start Sequence • With the hood closed, Transmission in Neutral, Park Brake set, and the Optimized Idle dash light ON,the ECM supplies ground on PWM #2, wire 909 which activates the under-hood alarm. • ECM then supplies ground on PWM #3, wire 910 which closes the Start Relay. • After the engine starts, the ECM supplies ground to the Vehicle Power Down relay which closes to supply Ignition power to the vehicle
  119. 119. 25ST0072-2 Rev. 04/4/00 137 Schematic Diagram DDEC III / IV Electronic Control Module (ECM) EEPROM +- Battery Engine Brake Stop Engine Check Engine Cruise Control Vehicle Speed Limiting Vehicle Speed Sensor Oil / Fuel Pressure Fuel / Oil / Coolant Temperature Turbo Boost Pressure Pressure Governor Coolant Level Timing Reference Synch Reference Fan Controls VSG Control PWM Ports Electronic Foot Pedal Assembly Progressive Shift Diagnostic Request Stop Engine Override ISD / Vehicle Power Down Engine Rating / Cruise Power / Switch Power Communication DDR Interface/ DDDL/ Reprogramming Optimized Idle EUI Oil level/Fuel Restriction Crankcase Pressure
  120. 120. Digital Inputs
  121. 121. 25ST0072-2 Rev. 04/4/00 140 Digital Input Functions • External switch requests function from the ECM • 31 options to choose from • 12 pins available on the 30 pin vehicle harness connector for input functions • Functions are assignable to any of these pins through the use of a “Reprogramming Station”
  122. 122. 25ST0072-2 Rev. 04/4/00 141 DIGITAL INPUTS Battery _ + #953 Cruise Enable Fan Override #150 No Function No Function No Function ECM EEPROM
  123. 123. 25ST0072-2 Rev. 04/4/00 142 Digital Inputs • Air Compressor Controls – Air Compressor Load Switch • Cruise Control (Uses Up to Five Inputs) – Cruise Enable – Clutch Released – Service Brake Released – Set/Coast On (Decrease) – Resume/Acceleration On (Increase) • Engine Brake – Engine Brake Disable – Engine Brake Low – Engine Brake Medium • Engine Protection – Auxiliary Input Protection #1 – Auxiliary Input Protection #2 – Diagnostic Request Switch – SEO/Diagnostic Request Switch • Engine Ratings – Limiting Torque Curve – Rating Switch #1 – Rating Switch #2 • Fan Control – Transmission Retarder Status (Release 2.00 or Later only) – Air Conditioner Status – Fan Control Override
  124. 124. 25ST0072-2 Rev. 04/4/00 143 Digital Inputs (Cont’d) • Throttle Control – Alternate Minimum VSG/Fast Idle (Release 2.00 or Later Only) – Dual Throttle (LSG) – Idle Validation Switch – Throttle Inhibit – VSG Station Change – VSG Station Complement • Pressure Governor System (PGS) (Uses Five Inputs) – Pressure Governor System Enable – Pressure/RPM Mode Switch – Set/Coast On (Decrease) – Resume/Acceleration On (Increase) • Additional Functions – Auxiliary Coolant Level Sensor – Parking Brake Interlock
  125. 125. Digital Outputs
  126. 126. 25ST0072-2 Rev. 04/4/00 145 Digital Output Functions • ECM commands (internal switches/grounds) action of some external device- fan control • 22 output options • 6 pins available, 3 on the 30 pin vehicle connector, 3 on the 30 pin engine harness connector (auxiliary outputs) • Configurable with the distributor or dealer reprogramming station
  127. 127. 25ST0072-2 Rev. 04/4/00 146 OUTPUTS ECM SEL To Jake brake Ignition #439
  128. 128. 25ST0072-2 Rev. 04/4/00 147 Digital Outputs • Coolant Level Low Light • Cruise Control Active Light (PGS Active Light) • Deceleration Light • Engine Brake Active • Fan Control #1 • Fan Control #2 • Low DDEC Voltage • Pressure Governor System Pressure Mode Light • Starter Lockout • Transmission Retarder • Vehicle Power Shutdown • VSG Active Indication • (Release 2.00 or Later only) – Low Oil Pressure Light – High Oil Temperature Light – High Coolant Temp. Light • (Release 3.00 or Later Only) – Ether Injection – Low Coolant Pressure Light – High Crankcase Pressure Light • (Release 4.00 or Later Only) – Optimized Idle Active light • Gas Solenoid Shutdown • Air Compressor Load Switch
  129. 129. 25ST0072-2 Rev. 04/4/00 148 • Encourages better driving habits by rewarding good fuel economy with extra road speed • If driver exceeds the target fuel economy extra road speed will automatically be added to his maximum vehicle speed Fuel Economy Incentive
  130. 130. 25ST0072-2 Rev. 04/4/00 149 Fuel Economy Incentive Parameter Range Example Min MPG 5-10 mpg 7.0 Max MPH 0-10 mph 4 Scaler MPH/MPG 0.1-20 mph/mpg 10.0 Calc 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 Data Trip - Calculates using Trip Data
  131. 131. 25ST0072-2 Rev. 04/4/00 150 PasSmart • Electronically Controlled Increased Passing Speed – PasSmart is an electronic feature that enables a fleet manager to enable a second Vehicle Speed Limit (VSL) to assist drivers during passing. – This second Vehicle Speed Limit (VSL) is programmed for a limited duration during a given period This feature is available with DDEC IV Software version R28.00. – As and example: If the fleet policy is 65 Miles Per Hour (MPH) the fleet manager can increase the Vehicle Speed Limit (VSL) an additional 5-20 MPH for 1- 255 minutes per day.
  132. 132. Maintenance Alert System
  133. 133. 25ST0072-2 Rev. 04/4/00 152 Maintenance Alert Sensors System • Designed to Provide Preventative Maintenance Information to Mechanics and Operators • Reduces Unexpected Downtime • Optimizes Normal Routine Service • Used on Highway Trucks only at this time
  134. 134. 25ST0072-2 Rev. 04/4/00 153 Maintenance Alert System • Overview – Based on Inputs from Customers, the Maintenance Alert System Provides Preventative Maintenance Information to Mechanics and Drivers to Reduce Unexpected Downtime and to Assist Normal Routine Service Scheduling • Features – Uses DDEC IV ECM – New DDEC Software Processes Information – Incorporates Four New Sensors (Both On and Off Engine) – Optional Remote Mounted Monitor Display Unit Available
  135. 135. 25ST0072-2 Rev. 04/4/00 154 Maintenance Alert System Oil Level Sensor Air Filter Restriction Sensor 2nd Coolant Level Sensor Fuel Restriction Sensor Monitor Display Unit
  136. 136. 25ST0072-2 Rev. 04/4/00 155 DDC Installed Components • Includes Two Maintenance Alert System Sensors – Oil Level Sensor (Requires Front Sump Non-metal Oil Pan) Will not work on Rear Sump Applications – Fuel Restriction Sensor
  137. 137. 25ST0072-2 Rev. 04/4/00 156 On Engine Components • Oil Level Sensor – Mounts in Front Sump Non- metal Oil Pan – Utilizes Optical Technology to "See" Oil Level – Engine Must Be Off (Zero RPM ) for "X" Minutes (Based on Oil Temp.) to Drain Oil Back to the Pan – Switches at Four Quart Low Level
  138. 138. 25ST0072-2 Rev. 04/4/00 157 On Engine Components • Fuel Restriction Sensor – Measures Fuel System Restriction at Fuel Pump Inlet – Sensor Measures Actual Inlet Restriction
  139. 139. 25ST0072-2 Rev. 04/4/00 158 Optional OEM Installed Components • OEMs Install These Components if Ordered by Customer (Any Combination but Must Include On Engine Components) – 2nd Coolant Level Sensor – Air Filter Restriction Sensor – Monitor Display Unit
  140. 140. 25ST0072-2 Rev. 04/4/00 159 OEM Installed Components • 2nd Coolant Level Sensor (CLS) – Separate Sensor from Current Primary CLS – Mounted in Coolant Surge Tank Above Primary CLS – Requires Interface Module – OEM Impact » Order Engine Mounted Sensors » Purchase CLS Sensor and Module from PDC » Mount Sensor in Surge Tank » Mount Interface Module » Provide Wiring Between the Sensor/Module/Engine Harness » Use VEPS( Vehicle Engine Program Station) to "Turn On” OEM Only
  141. 141. 25ST0072-2 Rev. 04/4/00 160 OEM Installed Components • Air Filter Restriction Sensor – Electronic Version of the Mechanical Filter Minder® – Switch Points at 15 and 20 Inches of Water – OEM Impact » Order Engine Mounted Sensors » Purchase Sensor from Engineered Products or PDC » Install into Turbo Inlet Tube » Provide Wiring from Sensor to Engine Harness Pigtail » Use VEPS to "Turn On"
  142. 142. 25ST0072-2 Rev. 04/4/00 161 OEM Installed Components • Monitor Display Unit – 2 Buttons and 8 LEDs (Green, Red, & Yellow) – Mounted in Cab – Reads Engine J1587 Data Link for Information – Can Access Maintenance Information with Ignition On or Up to 2 Hours After Ignition Off – Stores Status after 2 Hours for Later Display – OEM Impact » Order Engine Mounted Sensors » Purchase Display from PDC » Design and Install Display Bracket » Provide Wiring to Display
  143. 143. 25ST0072-2 Rev. 04/4/00 162 Service Tools • Diagnostic Data Reader-(DDR) (Version 24.0 and higher • Detroit Diesel Diagnostic Link (DDDL) - Version 3.0 and higher – Sensor Alerts Due to Failed Sensors – Quick Access Screen to Show Maintenance Alert System Alerts » Clear Maintenance Alert System (MAS) Filter Alerts – Maintenance Alert System sensors added to Data List – Warning Light Option Programming
  144. 144. 25ST0072-2 Rev. 04/4/00 163 Summary Engine Vehicle • Monitors and Displays Service Requirements – Oil Level – Fuel System Restriction – Air Filter Restriction – 2nd Coolant Level – Monitor Display Unit - in Cab – DDR and DDDL • Engine Only or Engine and Any Vehicle Sensors • Oil Level Requires Front Sump Plastic Plan • Display is Optional
  145. 145. Construction & Industrial
  146. 146. 25ST0072-2 Rev. 04/4/00 165 Construction & Industrial • Electronic Display Module (EDM) • Auxiliary Interface Module (AIM) • Air Comp Controls • Fuel Pressure Sensor (Low HP) • Nylon Vs. Plastic Harness • Multiple ECM • Optimized Idle • Switch Power • J1939
  147. 147. Wire Crimping Exercise
  148. 148. 25ST0072-2 Rev. 04/4/00 167 Wire Crimping Tools
  149. 149. 25ST0072-2 Rev. 04/4/00 168 Wire Crimping Tools
  150. 150. 25ST0072-2 Rev. 04/4/00 169 Wire Crimping Tools
  151. 151. 25ST0072-2 Rev. 04/4/00 170 Wire Crimping Tools
  152. 152. 25ST0072-2 Rev. 04/4/00 171 Wire Crimping
  153. 153. Wire Splicing
  154. 154. 25ST0072-2 Rev. 04/4/00 173 Wire Splicing Tools
  155. 155. Series 71 & 92 SRS / TRS Adjustment
  156. 156. 25ST0072-2 Rev. 04/4/00 175 Series 71/92 SRS/TRS Adjustment
  157. 157. Basic Electricity - Wire Harness Exercise
  158. 158. 25ST0072-2 Rev. 04/4/00 200 Sensor Operations Operates on 5 Volts for All D.C. Sensors .25 4.75 Normal Operating Range Low Voltage 0 5 High Voltage
  159. 159. 25ST0072-2 Rev. 04/4/00 201 Sensor Wiring • Common Return Circuit. #452 • Thermistor • Piezoresistive Pressure sensor • Voltage is Proportional to Pressure
  160. 160. 25ST0072-2 Rev. 04/4/00 202 2-wire Sensors 5V Supply Signal Return ECM Sensor Open = HI VOLTAGE Short = LO VOLTAGE
  161. 161. 25ST0072-2 Rev. 04/4/00 203 3-wire Sensors ECM Sensor 5V Supply Signal Return Open Supply = LOW VOLTAGE Open Signal = LOW VOLTAGE Open Return = HI VOLTAGE Supply short to Signal = HI VOLTAGE Supply short to Return = LOW VOLTAGE Signal short to Return = LOW VOLTAGE
  162. 162. 25ST0072-2 Rev. 04/4/00 204 Electrical System 452 Definitions • Open Circuit – An “open” describes a complete break in the path of current at some point in the circuit. The result of an “open” is that one or more loads in the circuit do not work. Open High voltage code 120
  163. 163. 25ST0072-2 Rev. 04/4/00 205 Electrical System 452 432 416 Cavity A Cavity B Cavity 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. Open Low voltage code
  164. 164. 25ST0072-2 Rev. 04/4/00 206 Electrical System 432 416 Cavity A Cavity B Cavity C Definitions • Short Circuit – A “short” occurs when a load in the circuit is accidentally bypassed. Electricity will always take the path of least resistance. The result of a “short” is that higher current flows, causing excessive heat or action from a device protecting the circuit (blown fuse or activated circuit breaker). Short High Voltage Code 452
  165. 165. 25ST0072-2 Rev. 04/4/00 207 Electrical System 452 432 416 Cavity A Cavity B Cavity C Definitions • Grounded Circuit – A “ground” is similar to a “short” because current accidentally bypasses a load in the circuit. The difference is that the bypass connects directly to the negative terminal of the power source by way of the chassis ground path. Ground Low Voltage Code
  166. 166. Troubleshooting Tools
  167. 167. 25ST0072-2 Rev. 04/4/00 209 Troubleshooting Tools Volt-Ohm Meter  To properly probe terminals use Kentmoore jumper wire kit number J39197. Within this kit the proper leads are provided.  The use of the lead ends of the volt ohm meter to probe the terminal ends will damage the DDEC connectors and will cause intermittent codes.
  168. 168. 25ST0072-2 Rev. 04/4/00 210 Troubleshooting Tools Sensor Tester J37164-A Breakout Box (30 Pin) J35634 DDEC III/IV Interface J41005
  169. 169. 25ST0072-2 Rev. 04/4/00 211 Troubleshooting Tools • NEW DDEC Engine Protection Test Kit Number 23526923 Purpose: To Reduce Diagnostic Troubleshooting time KIT INCLUDES 1. Coolant Level Low Simulator P/N 23524785 2. High Oil/Coolant Temperature P/N 23524787 3. Low Oil Pressure Simulator P/N 23524786

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