Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
DDEC
DDEC
DDEC
DDEC
DDEC
Detroit Diesel
Electronic Controls
WITH EXHAUST GAS RECIRCULATION
DDEC AGENDA
• Pre-Test
• Objectives
• Review Manuals
• Features & Components
• System Hardware
• Repair Tools
• Basic Electricity
• System Operation
• Trouble Shooting
• DDEC Reprogramming
• Post-Test, Evaluations
25ST0072-2
Rev. 04/4/00 2
What is DDEC?
25ST0072-2
Rev. 04/4/00 3
DDEC History
25ST0072-2
Rev. 04/4/00 4
Electronic Engine Advantages
• Engine Protection
• Engine Diagnostics
• Reduced Maintenance
• Improved Engine Governing
• Fuel Economy Optimization
• Enhanced Cold Starting
• Smoke Control
• Reduced Emission Levels
25ST0072-2
Rev. 04/4/00 5
DDEC IV Features
Ignition
Electronic
EUI
Control
Module
(ECM)
Synch Reference
Timing Reference
EEPROM
- +
Battery
25ST0072-2
Rev. 04/4/00 7
Electronic Control Module
25ST0072-2
Rev. 04/4/00 8
Electronic Control Module
25ST0072-2
Rev. 04/4/00 9
Schematic Diagram DDEC III / IV
Electronic
Control
Module
(ECM)
EEPROM
- +
Battery
25ST0072-2
Rev. 04/4/00 10
Power Supply
• DDEC II - 12 Volt
• DDEC III – 12 / 24 Volt
• DDEC IV- 12 or 24 Volt
• Source must be Isolated from any other Vehicle Accessory
• The ECM Power Source must be Fused with the Proper Amp
• The ECM Must Be Incorporated with a 5 Amp Fuse on the
440 wire going into the 439 wire.
• The ECM Case Must be Electrically Isolated from any
Chassis Ground
25ST0072-2
Rev. 04/4/00 11
Power Supply DDEC III / IV with or without EGR
25ST0072-2
Rev. 04/4/00 12
Schematic Diagram DDEC III / IV
EUI
Electronic
Control
Module
(ECM)
EEPROM
- +
Battery
25ST0072-2
Rev. 04/4/00 13
Electronic Unit Injectors
25ST0072-2
Rev. 04/4/00 14
Voltage in Series 50/60
Rocker Arm Injector
Solenoid Animation
Cam
Poppet
Valve
Plunger
Fuel out
Fuel in
Needle Valve
Top Of Stroke
Fuel
In
Fuel
Out
Injector
Tip
25ST0072-2
Rev. 04/4/00 16
Start Of Injection
Fuel
In
Fuel
Out
Injector
Tip
25ST0072-2
Rev. 04/4/00 17
End Of Injection
Fuel
In
Fuel
Out
Injector
Tip
25ST0072-2
Rev. 04/4/00 18
Injection Sequence
25ST0072-2
Rev. 04/4/00 19
Injector Calibration Codes
Part Number
Calibration Code
25ST0072-2
Rev. 04/4/00 20
Injector Cycle Terminology
25ST0072-2
Rev. 04/4/00 21
Injector Response Times
25ST0072-2
Rev. 04/4/00 22
Cylinder Cut-Out
25ST0072-2
Rev. 04/4/00 23
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
25ST0072-2
Rev. 04/4/00 24
Typical EUI Fuel Injection Systems
2200 bar
Peak Pressure
Injection Injection
Begins 345 bar Ends
25ST0072-2
Rev. 04/4/00 26
5 Volt Sensor Operation
25ST0072-2
Rev. 04/4/00 27
2-wire Sensors
5V Supply
Signal
Return
ECM Sensor
Open = HIGH VOLTAGE
Short = LOW VOLTAGE
25ST0072-2
Rev. 04/4/00 28
3-wire Sensors
ECM Sensor
5V Supply
Signal
Return
25ST0072-2
Rev. 04/4/00 29
Electrical System
Definitions
• Open Circuit
– An “open” describes a complete break in the
path of current at some point in the circuit.
The result of an “open” is that one or more
loads in the circuit do not work.
452
120 Open
High voltage
code
25ST0072-2
Rev. 04/4/00 30
Electrical System
452 Cavity A
432 Cavity B
416 Cavity C
Open
Low voltage code
Definitions
• Open Circuit
– An “open” describes a complete break in the path of
current at some point in the circuit. The result of an
“open” is that one or more loads in the circuit do not
work.
25ST0072-2
Rev. 04/4/00 31
Electrical System
452 Cavity A
432 Cavity B
416 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).
25ST0072-2
Rev. 04/4/00 32
Electrical System
452 Cavity A
432 Cavity B
416 Cavity C
Ground
Low Voltage Code
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.
25ST0072-2
Rev. 04/4/00 33
SRS/TRS Sensors
25ST0072-2
Rev. 04/4/00 34
Schematic Diagram DDEC III / IV
Synch Reference
EUI
Timing Reference Electronic
Control
Module
(ECM)
EEPROM
- +
Battery
25ST0072-2
Rev. 04/4/00 35
Series 50/60
SRS/TRS Sensors
SRS/TRS
Timing Wheel
DDEC II
25ST0072-2
Rev. 04/4/00 36
Series 50/60
SRS/TRS Sensors
SRS/TRS
Timing Wheel
Bull Gear
DDEC III/ IV
DDEC III/ IV
25ST0072-2
Rev. 04/4/00 37
Series 60
Sensor
Locations
Schematic Diagram DDEC IV
Synch Reference
EUI
Timing Reference Electronic
Electronic Foot
Pedal Assembly
Control
Module
(ECM)
EEPROM
- +
Battery
25ST0072-2
Rev. 04/4/00 39
Schematic Diagram DDEC IV
Synch Reference
EUI
Timing Reference
Electronic Foot
Electronic
Pedal Assembly Control
Module
Turbo Boost Pressure
(ECM)
EEPROM
- +
Battery
25ST0072-2
Rev. 04/4/00 40
Turbo Boost Sensor
Series 50/60
DDEC IV V
W/EGR
25ST0072-2
Rev. 04/4/00 41
Schematic Diagram DDEC III / IV
Synch Reference
EUI
Timing Reference
Electronic Foot
Electronic
Pedal Assembly Control
Module
Turbo Boost Pressure
(ECM)
Fuel / Oil / Coolant/ Air
Temperature
EEPROM
- +
Battery
25ST0072-2
Rev. 04/4/00 42
Temperature Sensors
25ST0072-2
Rev. 04/4/00 43
Schematic Diagram DDEC III / IV
Synch Reference
EUI
Timing Reference
Electronic Foot
Electronic
Pedal Assembly Control
Module
Turbo Boost Pressure
(ECM)
Fuel / Oil / Coolant
Temperature
- +
Battery
25ST0072-2
Rev. 04/4/00 44
Pressure Sensors
Series 50/60
Oil Pressure
25ST0072-2
Rev. 04/4/00 45
Schematic Diagram DDEC III / IV
Synch Reference
EUI
Timing Reference
Electronic Foot
Electronic
Pedal Assembly Control
Module
Turbo Boost Pressure
(ECM)
Fuel / Oil / Coolant
Temperature
Oil / Fuel Pressure
EEPROM
Oil level/Fuel Restriction
- +
Battery
25ST0072-2
Rev. 04/4/00 46
Schematic Diagram DDEC III / IV non EGR
Synch Reference
EUI
Timing Reference
Electronic Foot
Electronic Optimized Idle
Pedal Assembly Control Fan Controls
Engine Brake
Module ISD / Vehicle
Turbo Boost Pressure Power Down
(ECM) Communication
Fuel / Oil / Coolant DDR Interface/ DDDL/ Reprogramming
Temperature PWM Ports
Oil / Fuel Pressure Check Stop
Engine Engine
MASS EEPROM
Oil level/Fuel Restriction
Crankcase Pressure
Cruise Control
Coolant Level Vehicle Speed Limiting
Vehicle Speed Sensor
VSG Control Engine Rating / Cruise Power / Switch Power
Progressive Shift - +
Pressure Governor Battery
Diagnostic Stop Engine
Request Override
25ST0072-2
Rev. 04/4/00 47
DDR Communication- On Highway
DDEC II or III
DDEC III/ IV
12-Pin
6-Pin
25ST0072-2
Rev. 04/4/00 48
DDR Communication- On Highway
DDEC IV
9 Pin
25ST0072-2
Rev. 04/4/00 49
Diagnostic Socket
25ST0072-2
Rev. 04/4/00 51
Diagnostics
Flash Codes
25ST0072-2
Rev. 04/4/00 53
Troubleshooting Tools
25ST0072-2
Rev. 04/4/00 54
Troubleshooting Tools
25ST0072-2
Rev. 04/4/00 55
Diagnostic Tools
Pro-Link Suite 8
Detroit Diesel Diagnostic Link 6.2
25ST0072-2
Rev. 04/4/00 56
Detroit Diesel Diagnostic Link
25ST0072-2
Rev. 04/4/00 57
DDDL Information
25ST0072-2
Rev. 04/4/00 58
Detroit Diesel
Diagnostic Link
25ST0072-2
Rev. 04/4/00 59
Detroit Diesel
Diagnostic Link
25ST0072-2
Rev. 04/4/00 60
Detroit Diesel
Diagnostic Link
25ST0072-2
Rev. 04/4/00 61
• Volts
• Amps
• Ohms
• Shorts
• Open
• Grounds
• Resistance
• DVOM
• Soldering
• Shrink Tube
• Wiring Schematics
25ST0072-2
Rev. 04/4/00 62
Wire Crimping Exercise
Wire Crimping Tools
25ST0072-2
Rev. 04/4/00 64
Wire Crimping Tools
25ST0072-2
Rev. 04/4/00 65
Wire Crimping Tools
25ST0072-2
Rev. 04/4/00 66
Wire Crimping Tools
25ST0072-2
Rev. 04/4/00 67
Wire Crimping
25ST0072-2
Rev. 04/4/00 68
Wire Splicing
Wire Splicing Tools
25ST0072-2
Rev. 04/4/00 70
DDEC IV
Additional EGR Sensors and Circuits
DDEC IV EGR Electronics
25ST0072-2
Rev. 04/4/00 72
Series 60 EGR
EGR System Sensors
• New Sensors
– Barometric Pressure
– Turbo Compressor Inlet
Temperature & Relative
Humidity
– EGR Differential
Pressure/Delta
– Turbo Compressor Outlet
Temperature
– Turbocharger Speed
– EGR Temperature
• New Software
– AECD Controls
– Diagnostics DDEC IV System
25ST0072-2
Rev. 04/4/00
Series 50 EGR Sensors 73
Right Side View
Oil Temp Sensor
25ST0072-2
Rev. 04/4/00 74
Auxiliary Emission
Control Device
AECD Function
25ST0072-2
Rev. 04/4/00 76
Schematic Diagram DDEC III / IV
Additional EGR Sensors and Circuits
AECD
RH / TCITS
Electronic OEM
Turbo
(ECM) Connector
Speed EGR
Temperature
EGR Delta
EEPROM
Barometric
Pressure
TCOTS
12-24 Volt
VPODS
EGR VNT
25ST0072-2
Rev. 04/4/00 77
Schematic Diagram DDEC III / IV with EGR
EUI RH / TCITS
Timing Reference
Electronic Foot
Electronic Optimized Idle OEM
Pedal Assembly Control Fan Controls
Engine Brake
Module ISD / Vehicle
Turbo Boost Pressure Power Down 10 Pin
Turbo
(ECM) Communication Connector
Progressive Shift - +
Pressure Governor Battery 12-24 Volt
VPODS
Diagnostic Stop Engine
Request Override EGR VNT
25ST0072-2
Rev. 04/4/00 78
Schematic Diagram DDEC III / IV with EGR
Synch Reference
EEPROM
25ST0072-2
Rev. 04/4/00 79
Series 60 EGR Cam Gear
25ST0072-2
Rev. 04/4/00 80
Series 60 EGR SRS Sensor
25ST0072-2
Rev. 04/4/00 81
Schematic Diagram DDEC III - IV with EGR
Synch Reference
EEPROM
25ST0072-2
Rev. 04/4/00 82
Schematic Diagram DDEC III / IV w/EGR
Synch Reference
Timing Reference
Electronic Foot
Electronic
Pedal Assembly Control
Module
Turbo Boost Pressure
(ECM)
EEPROM
25ST0072-2
Rev. 04/4/00 83
Schematic Diagram DDEC III / IV with EGR
Synch Reference
Timing Reference
Electronic Foot
Electronic
Pedal Assembly Control
Module
Turbo Boost Pressure
Turbo
(ECM)
Speed
EEPROM
25ST0072-2
Rev. 04/4/00 84
TSS
25ST0072-2
Rev. 04/4/00 85
Turbo Speed Sensor
25ST0072-2
Rev. 04/4/00 86
Variable Nozzle Turbocharger
• Turbo Speed Sensor Spacer
• Flat on Shaft Generates Pulse
• DDEC Limits Turbo Speed
• 98k @ Sea Level
25ST0072-2
Rev. 04/4/00 87
Schematic Diagram DDEC III / IV with EGR
Synch Reference
Timing Reference
Electronic Foot
Electronic
Pedal Assembly Control
Module
Turbo Boost Pressure
Turbo
(ECM)
Speed Fuel / Oil / Coolant / EGR
Temperature
EEPROM
25ST0072-2
Rev. 04/4/00 88
EGR Temperature Sensor
25ST0072-2
Rev. 04/4/00 89
Schematic Diagram DDEC III / IV with EGR
Synch Reference
Timing Reference
Electronic Foot
Electronic
Pedal Assembly Control
Module
Turbo Boost Pressure
Turbo
(ECM)
Speed Fuel / Oil / Coolant / EGR
Temperature
EGR Delta
EEPROM
25ST0072-2
Rev. 04/4/00 90
EGR Delta Pressure Sensor
25ST0072-2
Rev. 04/4/00 91
Delta Pressure Sensor
25ST0072-2
Rev. 04/4/00 92
Delta P Sensor
25ST0072-2
Rev. 04/4/00 93
Schematic Diagram DDEC III / IV with EGR
Synch Reference
Timing Reference
Electronic Foot
Electronic
Pedal Assembly Control
Module
Turbo Boost Pressure
Turbo
(ECM)
Speed Fuel / Oil / Coolant / EGR
Temperature
EGR Delta Oil / Fuel Pressure
EEPROM
Barometric
Pressure
25ST0072-2
Rev. 04/4/00 94
Barometric Pressure Sensor
25ST0072-2
Rev. 04/4/00 95
BARO
25ST0072-2
Rev. 04/4/00 96
Schematic Diagram DDEC III / IV with EGR
Synch Reference
Timing Reference
Electronic Foot
Electronic
Pedal Assembly Control
Module
Turbo Boost Pressure
Turbo
(ECM)
Speed Fuel / Oil / Coolant / EGR
Temperature
EGR Delta Oil / Fuel Pressure
MASS EEPROM
Oil level/Fuel Restriction
Barometric
Pressure
TCOTS
25ST0072-2
Rev. 04/4/00 97
Turbo Compressor Outlet Temp Sensor
• CAC Protection
25ST0072-2
Rev. 04/4/00 98
Turbo Compressor Outlet Temperature Sensor
• TCOTS
• Protects Charge Air Cooler
• Located in Turbo Compressor Outlet Housing
• Used for AECD Controls
25ST0072-2
Rev. 04/4/00 99
Schematic Diagram DDEC III / IV with EGR
Synch Reference
Timing Reference
Electronic Foot
Electronic
Pedal Assembly Control
Module
Turbo Boost Pressure
Turbo
(ECM)
Speed Fuel / Oil / Coolant / EGR
Temperature
EGR Delta Oil / Fuel Pressure
MASS EEPROM
Oil level/Fuel Restriction
Barometric
Pressure
Coolant Level
TCOTS
VSG Control
Progressive Shift - +
Pressure Governor Battery 12 or 24 Volt
VPODS
Diagnostic Stop Engine
Request Override EGR VNT
25ST0072-2
Rev. 04/4/00 100
Variable Pressure Operating Device
• VPOD
• VPOD Signal is PWM Output from DDEC
• Electric Proportional Solenoid Valve
• 12V and 24V Options
• Modulates Air Pressure to VNT and EGR Valve
• VPODS Regulate EGR Valve and VNT Positions
• VPODS are Slewable
25ST0072-2
Rev. 04/4/00 101
VPOD
25ST0072-2
Rev. 04/4/00 102
Series 60 EGR Components
Variable Nozzle Turbocharger
25ST0072-2
Rev. 04/4/00 103
Series 60 EGR
Variable Nozzle Turbocharger
25ST0072-2
Rev. 04/4/00 104
Series 60 EGR
Variable Nozzle Turbocharger
• Garrett GT 42
25ST0072-2
Rev. 04/4/00 105
Variable Nozzle Turbocharger
Unison Ring
25ST0072-2
Rev. 04/4/00 106
EGR Valve & Actuator
25ST0072-2
Rev. 04/4/00 107
Series 60 EGR Components
EGR Hot pipe
25ST0072-2
Rev. 04/4/00 108
Series 60 EGR Components
EGR Butterfly Valve
Valve Actuator
25ST0072-2
Rev. 04/4/00 109
Schematic Diagram DDEC III / IV with EGR
Synch Reference
Timing Reference
Electronic Foot
Electronic
Pedal Assembly Control
Module
Turbo Boost Pressure
Turbo
(ECM)
Speed Fuel / Oil / Coolant / EGR
Temperature
EGR Delta Oil / Fuel Pressure
MASS EEPROM
Oil level/Fuel Restriction
Crankcase Pressure
Barometric
Pressure Cruise Control
Coolant Level Vehicle Speed Limiting
TCOTS Vehicle Speed Sensor
VSG Control Engine Rating / Cruise Power / Switch Power
Progressive Shift - +
Pressure Governor Battery 12-24 Volt
VPODS
Diagnostic Stop Engine
Request Override EGR VNT
25ST0072-2
Rev. 04/4/00 110
Crankcase Pressure
Series 60 CCM
25ST0072-2
Rev. 04/4/00 111
Schematic Diagram DDEC III / IV with EGR
Synch Reference
RH / TCITS
Timing Reference
Electronic Foot
Electronic OEM
Pedal Assembly Control
Module
Turbo Boost Pressure 10 Pin
Turbo
(ECM) Communication Connector
Progressive Shift - +
Pressure Governor Battery 12-24 Volt
VPODS
Diagnostic Stop Engine
Request Override EGR VNT
25ST0072-2
Rev. 04/4/00 112
Relative Humidity and
Compressor Inlet Temperature Sensor
• Reports Humidity and Compressor Inlet Temperature for
AECD Controls
• OEM Installed in Air Intake System
•Connects to Ten Pin Engine Sensor Harness Pigtail for OEM
Interface
25ST0072-2
Rev. 04/4/00 113
Schematic Diagram DDEC III / IV with EGR
Synch Reference
RH / TCITS
Timing Reference
Electronic Foot
Electronic OEM
Pedal Assembly Control Engine Brake
Module ISD / Vehicle
Turbo Boost Pressure Power Down 10 Pin
Turbo
(ECM) Communication Connector
Progressive Shift - +
Pressure Governor Battery 12-24 Volt
VPODS
Diagnostic Stop Engine
Request Override EGR VNT
25ST0072-2
Rev. 04/4/00 114
DDEC III/IV Engine Brakes (NON EGR)
Turbo
(ECM) Communication Connector
Progressive Shift - +
Pressure Governor Battery 12-24 Volt
VPODS
Diagnostic Stop Engine
Request Override EGR VNT
25ST0072-2
Rev. 04/4/00 116
Schematic Diagram DDEC III / IV with EGR
Synch Reference AECD
EUI RH / TCITS
Timing Reference
Electronic Foot
Electronic Optimized Idle OEM
Pedal Assembly Control Fan Controls
Engine Brake
Module ISD / Vehicle
Turbo Boost Pressure Power Down 10 Pin
Turbo
(ECM) Communication Connector
Progressive Shift - +
Pressure Governor Battery 12-24 Volt
VPODS
Diagnostic Stop Engine
Request Override EGR VNT
25ST0072-2
Rev. 04/4/00 117
Maintenance Alert Sensors System
25ST0072-2
Rev. 04/4/00 118
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
25ST0072-2
Rev. 04/4/00 119
Maintenance Alert System
Oil Level Sensor Air Filter Restriction Sensor 2nd Coolant Level Sensor
25ST0072-2
Rev. 04/4/00 120
On Engine Components
25ST0072-2
Rev. 04/4/00 121
On Engine Components
25ST0072-2
Rev. 04/4/00 122
DDC Installed Components
25ST0072-2
Rev. 04/4/00 123
OEM Installed Components
25ST0072-2
Rev. 04/4/00 124
OEM Installed Components
25ST0072-2
Rev. 04/4/00 125
OEM Installed Components
25ST0072-2
Rev. 04/4/00 126
Service Tools
25ST0072-2
Rev. 04/4/00 127
Summary
25ST0072-2
Rev. 04/4/00 128
Schematic Diagram DDEC III / IV with EGR
Synch Reference
Timing Reference
Electronic Foot
Electronic
Pedal Assembly Control
Module
Turbo Boost Pressure
Turbo
(ECM)
Speed Fuel / Oil / Coolant / EGR
Temperature
EGR Delta Oil / Fuel Pressure
MASS EEPROM
Oil level/Fuel Restriction
Barometric
Pressure
Coolant Level
TCOTS
25ST0072-2
Rev. 04/4/00 129
Coolant Level Sensor
DDEC III-IV-V
Coolant Level Sensor
25ST0072-2
Rev. 04/4/00 130
Schematic Diagram DDEC III / IV with EGR
Synch Reference
Timing Reference
Electronic Foot
Electronic
Pedal Assembly Control
Module
Turbo Boost Pressure
Turbo
(ECM)
Speed Fuel / Oil / Coolant / EGR
Temperature
EGR Delta Oil / Fuel Pressure
MASS EEPROM
Oil level/Fuel Restriction
Barometric
Pressure
Coolant Level
TCOTS
VSG Control
25ST0072-2
Rev. 04/4/00 131
Progressive Shift
25ST0072-2
Rev. 04/4/00 132
VSG Control
25ST0072-2
Rev. 04/4/00 133
Pressure Governor
High Pressure
Sensor
Fire Commander
Mastermind
25ST0072-2
Rev. 04/4/00 134
Electronic Fire Commander
Control Buttons
Engine Data
System Status
Message Window
25ST0072-2
Rev. 04/4/00 135
Diagnostic Request
and Stop Engine Override
25ST0072-2
Rev. 04/4/00 136
Schematic Diagram DDEC III / IV with EGR
Synch Reference
Timing Reference
Electronic Foot
Electronic
Pedal Assembly Control
Module
Turbo Boost Pressure
Turbo
(ECM)
Speed Fuel / Oil / Coolant / EGR
Temperature
EGR Delta Oil / Fuel Pressure
MASS EEPROM
Oil level/Fuel Restriction
Barometric
Pressure
Coolant Level
TCOTS
VSG Control
Progressive Shift - +
Pressure Governor Battery
Diagnostic Stop Engine
Request Override
25ST0072-2
Rev. 04/4/00 137
Power Supply
• DDEC II - 12 Volt
• DDEC III - 12/24 Volt
• DDEC IV- 12 or 24 Volt
• Source must be Isolated from any other Vehicle Accessory
• The ECM Power Source must be Fused with the Proper Amp
• The ECM Must Be Incorporated with a 5 Amp Fuse on the
440 wire going into the 439 wire.
• The ECM Case Must be Electrically Isolated from any
Chassis Ground
25ST0072-2
Rev. 04/4/00 138
Power Supply DDEC III / IV with or without EGR
25ST0072-2
Rev. 04/4/00 139
Multiple Horsepower Ratings
25ST0072-2
Rev. 04/4/00 140
Cruise Control
25ST0072-2
Rev. 04/4/00 141
Vehicle Speed Sensor
25ST0072-2
Rev. 04/4/00 142
Diagnostic Request
and Stop Engine Override
25ST0072-2
Rev. 04/4/00 143
Check Engine / Stop Engine Lights
25ST0072-2
Rev. 04/4/00 144
Engine Protection
25ST0072-2
Rev. 04/4/00 145
Pulse Width Modulated Outputs
25ST0072-2
Rev. 04/4/00 146
NON EGR PWM CIRCUTS
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
25ST0072-2
Rev. 04/4/00 147
EGR PWM CIRCUTS
Circuit Wire
No. Color
• PWM #1 Output - VIH (Transmission) 908 White
• PWM #2 Output - ESH (EGR Control) 909 Lt. Green
• PWM #3 Output - ESH (OI STARTER) 910 Orange
• PWM #4 Output - ESH (VNT Control) 911 Pink
25ST0072-2
Rev. 04/4/00 148
DDEC III / IV / V
Reprogramming
Reprogramming Station
25ST0072-2
Rev. 04/4/00 150
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 36.00
• Software level can ONLY go UP, it can NEVER go
back down
25ST0072-2
Rev. 04/4/00 151
Reprogramming Station
Windows Based for Download
25ST0072-2
Rev. 04/4/00 152
Reprogramming Station
Windows Based for Download
25ST0072-2
Rev. 04/4/00 153
Reprogramming Station
Windows Based for Download
25ST0072-2
Rev. 04/4/00 154
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
25ST0072-2
2 - 100 Minutes
Rev. 04/4/00 155
Fan Control
25ST0072-2
Rev. 04/4/00 156
Fan Control
25ST0072-2
Rev. 04/4/00 157
DDEC Fan Controls
Normal
High Temperatures
Temperatures Allow
Turn FanFan
On Off
Air Supply
Temp sensor
Inputs
Optional Fan # 2
Output
Output
“off”
“on”
“off”
ECM Ign. + “on”
“on”
Fan “off”
#953 (-)
25ST0072-2
Rev. 04/4/00 159
Requirements for Optimized Idle
25ST0072-2
Rev. 04/4/00 160
Optimized Idle Shutdown Sequence
25ST0072-2
Rev. 04/4/00 161
Optimized Idle Shutdown Sequence
25ST0072-2
Rev. 04/4/00 162
Optimized Idle Start Sequence
• 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 proprietary data
link in multi ECM engines
25ST0072-2
Rev. 04/4/00 164
Infrared Information System
Infrared Information System
25ST0072-2
Rev. 04/4/00 166
Schematic Diagram DDEC III / IV
Synch Reference
EUI
Timing Reference
Electronic Foot
Electronic
Pedal Assembly Control
Module
Turbo Boost Pressure Communication
(ECM) DDR Interface/ DDDL/ Reprogramming
Fuel / Oil / Coolant
Temperature PWM Ports
Progressive Shift - +
Pressure Governor Battery
Diagnostic Stop Engine
Request Override
25ST0072-2
Rev. 04/4/00 167
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
25ST0072-2
Rev. 04/4/00 168
Schematic Diagram DDEC III / IV
Synch Reference
EUI
Timing Reference
Electronic Foot
Electronic
Pedal Assembly Control
Module Idle Shut Down/Vehicle Power Down
Turbo Boost Pressure Communication
(ECM) DDR Interface/ DDDL/ Reprogramming
Fuel / Oil / Coolant
Temperature PWM Ports
Progressive Shift - +
Pressure Governor Battery
Diagnostic Stop Engine
Request Override
25ST0072-2
Rev. 04/4/00 169
Schematic Diagram DDEC III / IV
Synch Reference
EUI
Timing Reference
Electronic Foot
Electronic
Pedal Assembly Control Engine Brake
Progressive Shift - +
Pressure Governor Battery
Diagnostic Stop Engine
Request Override
25ST0072-2
Rev. 04/4/00 170
Schematic Diagram DDEC III / IV
Synch Reference
EUI
Timing Reference
Electronic Foot
Electronic Optimized Idle
Pedal Assembly Control Fan Controls
Engine Brake
Module ISD / Vehicle
Turbo Boost Pressure Power Down
(ECM) Communication
Fuel / Oil / Coolant DDR Interface/ DDDL/ Reprogramming
Temperature PWM Ports
Oil / Fuel Pressure Check Stop
Engine Engine
EEPROM
Oil level/Fuel Restriction
Crankcase Pressure
Cruise Control
Coolant Level Vehicle Speed Limiting
Vehicle Speed Sensor
VSG Control Engine Rating / Cruise Power / Switch Power
Progressive Shift - +
Pressure Governor Battery
Diagnostic Stop Engine
Request Override
25ST0072-2
Rev. 04/4/00 171
Digital Inputs
Digital Input Functions
25ST0072-2
Rev. 04/4/00 173
DDEC III – IV Digital Inputs
No Function
ECM No Function
No Function
Cruise Enable
Fan Override
#953
EEPROM
#150
_
+
Battery
25ST0072-2
Rev. 04/4/00 174
DDEC III – IV Digital Inputs
25ST0072-2
Rev. 04/4/00 175
DDEC III – IV Digital Inputs (Cont’d)
25ST0072-2
Rev. 04/4/00 176
Digital Outputs
DDEC III – IV Digital Output Functions
25ST0072-2
Rev. 04/4/00 178
Outputs
SEL
ECM
To Jake brake
Ignition
#439
25ST0072-2
Rev. 04/4/00 179
DDEC III – IV – Digital Outputs
25ST0072-2
Rev. 04/4/00 180
DDEC –III – IV Digital Outputs (Cont’d)
25ST0072-2
Rev. 04/4/00 181
Fuel Economy Incentive
25ST0072-2
Rev. 04/4/00 182
Fuel Economy Incentive
25ST0072-2
Rev. 04/4/00 183
PasSmart
25ST0072-2
Rev. 04/4/00 184
Series 60 EGR
Electrical Schematic
25ST0072-2
Rev. 04/4/00 185
DDEC V
History of DDEC V
25ST0072-2
Rev. 04/4/00 187
DDEC V Features
25ST0072-2
Rev. 04/4/00 188
DDEC V Improvements Over DDEC IV
25ST0072-2
Rev. 04/4/00 189
DDEC V Improvements over DDEC IV (cont.)
• Memory:
– DDEC IV: 512 kB Flash, 66 kB RAM, 32 kB EEPROM
– DDEC V: 2496 kB Flash, 282 kB RAM, No EEPROM
• High Speed Programming
– New DDEC Multilink Translator (J1708, CAN & J1939)
» Uses Same J1708 Cables as DDC RP1202 Translator
» Translator Now Available: P/N 23528022
25ST0072-2
Rev. 04/4/00 190
DDEC V ECU
25ST0072-2
Rev. 04/4/00 191
DDEC V ECU
25ST0072-2
Rev. 04/4/00 192
DDEC V – Hardware changes
• Stud thread is M6 x
1, stud height above
the shroud will be
about 12 mm
• Corrosion resistant,
plated, nylon insert
or prevailing torque
lock-nuts are
recommended
25ST0072-2
Rev. 04/4/00 193
DDEC V Electronics
25ST0072-2
Rev. 04/4/00 194
DDEC V ECU Connectors
25ST0072-2
Rev. 04/4/00 196
DDEC V – Software changes
• Fan control
– The fan control outputs will stay on when the ignition is
turned off until the engine speed is zero
– Requirement for FL – must wire the fan controls to +12V
for feature to work
» If switched +12V is used, fan will turn off with ignition and
freewheel
25ST0072-2
Rev. 04/4/00 197
DDEC V A&I Manual
25ST0072-2
Rev. 04/4/00 198
DDEC V Codes
Sensor Function
Barometric Pressure Senses barometric pressure.
Sensor (Baro Sensor)
25ST0072-2
Rev. 04/4/00 199
DDEC V Codes (cont.)
Sensor Function
Engine Oil Pressure Senses gallery oil pressure for functions such as
Sensor (EOP Sensor) engine protection.
Intake Air Temperature Senses air temperature for functions such as fan
Sensor (IAT Sensor) control and engine fueling.
25ST0072-2
Rev. 04/4/00 200
DDEC V Codes (cont.)
Sensor Function
Supply Fuel Senses fuel temperature for functions such as engine
Temperature Sensor fueling.
(SFT Sensor)
Turbo Compressor Senses turbo out air temperature.
Temperature Out
Sensor
Turbo Speed Sensor Senses turbo speed for over-speed conditions.
(TSS)
25ST0072-2
Rev. 04/4/00 201
Schematic Diagram DDEC V
Synch Reference
EUI TCITS OEM
Timing Reference
Electronic Foot
Electronic Optimized Idle
Pedal Assembly Control Fan Controls
Engine Brake
Module ISD / Vehicle
Turbo Boost Pressure Power Down
Turbo
(ECM) Communication
Speed Fuel / Oil / Coolant / EGR (ECU) DDR Interface/ DDDL/ Reprogramming
Temperature PWM Ports
EGR Delta Oil / Fuel Pressure V Check Stop
Engine
Engine
MASS
Oil level/Fuel Restriction
Crankcase Pressure
Barometric
Pressure Cruise Control
Coolant Level Vehicle Speed Limiting
TCOTS Vehicle Speed Sensor
VSG Control Engine Rating / Cruise Power / Switch Power
Progressive Shift - +
Pressure Governor Battery 12-24 Volt VPOD
Diagnostic Stop Engine
Request Override Hydraulic EGR VNT
25ST0072-2
Rev. 04/4/00
Valve 202
Schematic Diagram DDEC V
Synch Reference
Timing Reference
Electronic Foot
Electronic
Pedal Assembly Control
Module
Turbo Boost Pressure
Turbo
(ECM)
Speed Fuel / Oil / Coolant / EGR (ECU)
Temperature
EGR Delta Oil / Fuel Pressure V
MASS
Oil level/Fuel Restriction
Barometric
Pressure
Coolant Level
TCOTS
VSG Control
Progressive Shift - +
Pressure Governor Battery 12-24 Volt VPOD
Diagnostic Stop Engine
Request Override Hydraulic EGR VNT
25ST0072-2
Rev. 04/4/00
Valve 203
DDEC V Hydraulic EGR Valve
25ST0072-2
Rev. 04/4/00 204
EGR Valve & Actuator
December 2004
Hydraulic Actuator & Control Valve
25ST0072-2
Rev. 04/4/00 205
Series 60 ‘04 EGR
25ST0072-2
Rev. 04/4/00 206
EGR Valve Assy.
Supply Port
Return Port
25ST0072-2
Rev. 04/4/00 207
Series 60 2004 DDEC V
Reprogramming Station
Factory/Distributor Tools DDEC V
25ST0072-2
Rev. 04/4/00 209
Distributor Reprogramming DDEC V
25ST0072-2
Rev. 04/4/00 210
Schematic Diagram DDEC V
Synch Reference
EUI TCITS OEM
Timing Reference
Electronic Foot
Electronic Optimized Idle
Pedal Assembly Control Fan Controls
Engine Brake
Module ISD / Vehicle
Turbo Boost Pressure Power Down
Turbo
(ECM) Communication
Speed Fuel / Oil / Coolant / EGR (ECU) DDR Interface/ DDDL/ Reprogramming
Temperature PWM Ports
EGR Delta Oil / Fuel Pressure V Check Stop
Engine
Engine
MASS
Oil level/Fuel Restriction
Crankcase Pressure
Barometric
Pressure Cruise Control
Coolant Level Vehicle Speed Limiting
TCOTS Vehicle Speed Sensor
VSG Control Engine Rating / Cruise Power / Switch Power
Progressive Shift - +
Pressure Governor Battery 12-24 Volt VPOD
Diagnostic Stop Engine
Request Override Hydraulic EGR VNT
25ST0072-2
Rev. 04/4/00
Valve 211
Bosch N-3 Fuel Injector
25ST0072-2
Rev. 04/4/00 212
Bosch N3
25ST0072-2
Rev. 04/4/00 214
Bosch N-3 Injector
25ST0072-2
Rev. 04/4/00 215
N3 Advantages over S60 N2
Reliability
40% Improved Strength
•
• Reduced External Leakage
Potential
• Improved Nut Design
Performance
• Reduced Trapped Volume
•Faster Response Time
•Improved End of Injection
Behavior
• Reduced Weight (~15 lb. per
engine)
25ST0072-2
Rev. 04/4/00 216
DDEC V
Sensor Wiring
DDEC V ESH Schematic
25ST0072-2
Rev. 04/4/00 218
DDEC V TRS/SRS Sensor
ECU
E-17 TRS - 1
E-18 TRS + 2
E-20 SRS - 1
E-19 SRS + 2
EHC
25ST0072-2
Rev. 04/4/00 219
DDEC V On-Highway Governors
ECU
TPS
Signal
V-13/14 A
V-11 5 Volt B
V-60 Return C
D
V-16 IVS, Closed @ Idle E .
V-59 Return
F .
VHC
13: ALSG
14: VSG
25ST0072-2
Rev. 04/4/00 220
DDEC V Turbo Speed Sensor
ECU
E-35 TSS - 1
E-34 TSS + 2
EHC
25ST0072-2
Rev. 04/4/00 221
DDEC V Temperature Sensor
ECU
E-15 Return 1
XX Signal 2
XX is
CTS: E-5
2 seconds to set a high temp. code
OTS: E-7
EHC
EGR: E-10
25ST0072-2
Rev. 04/4/00 222
DDEC V Three Wire Engine Sensors
ECU
Return
E-15 1
Signal
XX 2
5 Volt
E-12 3
XX is
OPS: E-31 7 seconds to set a low pressure code
EHC BPS: E-37
TBS: E-39
25ST0072-2
Rev. 04/4/00 223
DDEC V Coolant Level Sensors
ECU
Signal
V-37/38 A
V-60 Return B
25ST0072-2
Rev. 04/4/00 224
DDEC V Three Wire Vehicle Sensor
ECU
V-60 Return A
Pressure Governor
VHC
25ST0072-2
Rev. 04/4/00 225
Diagnostic Test Mode/Stop Engine Override
DDEC V Switch - DTM/SEO
ECU
Diag. Request
V-24
V-59 Return
VHC
25ST0072-2
Rev. 04/4/00 226
DDEC V Diagnostic Connector
ECU
Ground A
Power B D
V-43 J1939 + C E
J1939 - C
V-58 D
J1939 Shield F A B
V-44 E
V-56 J1587 + F J
J1587 - G G
V-57 H
Plug H
Plug J
VHC
J 1587 & 1939
25ST0072-2
Rev. 04/4/00 227
DDEC V Power, Ground, and Ignition
ECU
V-15 . . 10 Amp
V-61
V-62
V-65
V-66
30 Amp .Pos.
Batt.
V-63
V-64
V-67
.
Neg.
V-68
VHC
25ST0072-2
Rev. 04/4/00 228
DDEC V VNT VPOD
ECU
EHC
25ST0072-2
Rev. 04/4/00 229
DDEC V Cruise Control
ECU
Input, Cruise On/Off
V-9
Input, Set/Coast
V-47
Input, Resume/Accel
V-8
Input, Clutch Released
V-10
Input, Service Brake Released
V-3
Sensor Return
V-59
Low Output, Cruise Light Ignition
V-XX
V-17 VSS +
V-18 VSS -
VHC
25ST0072-2
Rev. 04/4/00 230
DDEC V Warning Lights
ECU
CEL/AWL Ignition
V-1
SEL/RSL Ignition
V-2
Indicator Ignition
V-X
To Veh. Systems
Ign. Sw
Low Output, VPS
V-7
VHC
25ST0072-2
Rev. 04/4/00 232
DDEC V Jakes
ECU
Analog Input, Brake Low
V-39
Analog Input, Brake Med
V-51
Sensor return
V-59
Digital Output, High Side. Low/High Brake
E-49
Digital Output, High Side. Med/High Brakes
E-48
EHC/VHC
25ST0072-2
Rev. 04/4/00 233
DDEC V Series 60 Injector Wiring
ECU
E-63
1
E-65
Bank 1 Return 2
E-61
E-64
3
E-68
4
E-66
Bank 2 Return 5
E-62
E-67
EHC 6
25ST0072-2
Rev. 04/4/00 234
DDEC V VIH Schematic
25ST0072-2
Rev. 04/4/00 235
DDEC V
Service Tools
Service Tools
Test Sensors